Schwing SPB 28 Operation Manual Download Page 25

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Safety

S 39/41 SX Operation Manual

Safety Manual .................................................27

How to Order Additional Safety Manuals .......27
Schwing phone numbers ...............................27

Warning Labels (Decals) ................................27

Safety

Summary of Contents for SPB 28

Page 1: ...Operation Manual SPB Separate Placing Boom Part 98370060 Revision 1 2 Date 10 28 20 5900 Centerville Road St Paul MN 55127 1 888 SCHWING 724 9464 www schwing com...

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Page 5: ...ol Panel 37 Cable Radio Remote Box 38 Status LCD Display 39 Joystick Configuration 39 Radio Cable Remote Buttons Switches 40 Status Lights 41 Pairing Transmitter to Receiver 42 Setting Joystick Min Ma...

Page 6: ...Components 81 Warning and instruction decals on tower 81 Controllers 82 Climbing 82 Climbing 85 After Climbing 88 Maintenance and Troubleshooting 89 Emergency operation control 89 Maintenance 93 Pres...

Page 7: ...pections 105 Inspect boom and structural support 105 Changing boom pipe 106 Time related Maintenance 106 Periodic structural inspection 106 Hydraulic Oil Viscosity Chart 109 Torque Specifications for...

Page 8: ...8 Table of Contents SPB Operation Manual...

Page 9: ...er s Statement 11 Safety Alert Symbols 12 How to reach us 13 ID Tags 13 Boom ID and Pipeline tag 13 Power Pack Lifting Weight tag 13 Power pack ID tag 13 How to order missing tags 14 Expected Service...

Page 10: ......

Page 11: ...ecessary for the setup operation mainte nance and servicing of your concrete pump All opera tors should become familiar with the information in this manual as it will promote safety efficiency of oper...

Page 12: ...The signal word CAUTION used without the safe ty alert symbol means the hazard COULD cause damage to equipment or property The keywords listed above will be displayed throughout the text of this manu...

Page 13: ...of the MAKE UP PIPES See parts book for standard lengths LARGO de las TUBER AS NECESARIAS Consulte el libro de repuestos para ver los largos est ndar Pipeline wears with each pump stroke Check pipewa...

Page 14: ...ft Maximum weight of boom pipeline WITHOUT CONCRETE is El peso m ximo de la tuber a de la pluma SIN CONCRETO es de Maximum weight of boom pipeline INCLUDING CONCRETE is El peso m ximo de la tuber a d...

Page 15: ...humidity of 75 Hydraulic pressure 60 of Pmax Maximum hydraulic pump setting of 280 horse power Maximum temperature of 60 F for fresh con crete Maximum concrete throughput of 40 000 cubic yards per yea...

Page 16: ...16 Introduction SPB Operation Manual...

Page 17: ...tions SPB Operation Manual SPB 28 Specifications 19 SPB 28 Working Range Diagram 20 SPB 35 Specifications 21 SPB 35 Working Range Diagram 22 SPB 37 Specifications 23 Working Range Diagram SPB 37 24 Sp...

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Page 19: ...Super 2000 Schwing Raised Boom Pipeline Elbows Quantity Radius Wall thickness 10 90 degrees 2 45 degrees 10 8 in centerline Twin Wall Super 2000 Boom End Hose Material Rated burst pressure Maximum le...

Page 20: ...20 Specifications SPB Operation Manual SPB 28 Working Range Diagram SPB 28 End Hose 12 20 10 93 80 70 60 50 10 93 30 40 23 1 23 1 25 11 80 70 60 50 10 30 20 40...

Page 21: ...n Wall Super 2000 Schwing Raised Boom Pipeline Elbows Quantity Radius Wall thickness 10 90 4 45 2 32 5 10 8 in centerline Twin Wall Super 2000 Boom End Hose Material Rated burst pressure Maximum lengt...

Page 22: ...22 Specifications SPB Operation Manual SPB 35 Working Range Diagram SPB 35 235...

Page 23: ...3000 Schwing Raised Boom Pipeline Elbows Quantity Radius Wall thickness 10 90 4 45 2 32 5 9 8 in centerline Twin Wall Super 3000 Boom End Hose Material Rated burst pressure Maximum length Rubber 4 ply...

Page 24: ...24 Specifications SPB Operation Manual Working Range Diagram SPB 37 SPB 37 235...

Page 25: ...25 Safety S 39 41 SX Operation Manual Safety Manual 27 How to Order Additional Safety Manuals 27 Schwing phone numbers 27 Warning Labels Decals 27 Safety...

Page 26: ......

Page 27: ...of the following manuals free of charge for each unit that is listed with its serial number and current location Manual Part Number Safety Manual English 30327535 Safety Manual Spanish 30381024 Co wor...

Page 28: ...28 Safety S 39 41 SX Operation Manual...

Page 29: ...here is always the unex pected Please understand that there is no substitute for common sense and dedication to the idea that you are responsible for your own safety and affect the safety of those aro...

Page 30: ...Rules For Pump Operators 33 IV Cleaning The Pump And System 45 9 Safety Rules For Cleaning The Boom 45 10 Safety Rules For Cleaning The Concrete Valve And Hopper 45 11 Safety Rules For Cleaning The W...

Page 31: ...Separate Pipeline 28 III Concrete Pump Operation 33 8 Safety Rules For Pump Operators 33 IV Cleaning The Pump And System 45 9 Safety Rules For Cleaning The Boom 45 10 Safety Rules For Cleaning The Con...

Page 32: ...tion which if not avoided COULD result in minor to moderate injury The signal word CAUTION used in a yellow box but without the safety alert symbol means the point addresses a hazard which if not avoi...

Page 33: ...the pump breathing mask when mixing slurry or whenever there is cement or other toxic dust in the air rubber gloves during clean out rubber boots anytime you have to stand in concrete 2 4 Jewelry athl...

Page 34: ...ption medications or over the counter drugs many of which have spe cific warnings about operating machinery after taking the medication Figure 3 2 7 Don t bring your personal problems to work with you...

Page 35: ...om or system pipeline BE SURE that you have the proper training equipment and attachments to do this procedure safely Proper attachments include A blowout head with properly sized air discharge regula...

Page 36: ...in good condition If found to be missing incomplete or damaged work must not begin until the situation has been made safe 3 9 Inspect the tires and brakes on the truck Never drive a truck with bald or...

Page 37: ...ans loose tools etc that could interfere with the operation of the vehicle 3 16 Be sure that all road related safety devices warning signs flares fire extin guisher etc are present and secured for tra...

Page 38: ...can be damaged by the bouncing motion that occurs while driving but this damage is easily avoided by using the strap Figure 7 3 22 Be certain that all loose items on the unit are secured for travel be...

Page 39: ...ng on bridge or elevated roadways be sure that they can support the weight of the vehicle Figure 9 4 4 Collision hazard Before driving under ANY structure BE SURE that the machine will clear Figure 9...

Page 40: ...es required by heavy vehicles 4 12 Be familiar with your emergency equipment Know how to light a flare etc 4 13 Drive defensively You are at a distinct disadvantage when it comes to maneuverability an...

Page 41: ...ng 5 6 Always use safety chains and break away protection when tow ing a trailer 5 7 Be aware of local or state regulations regarding mirrors lights and maximum speed when towing a trailer 5 8 When to...

Page 42: ...ll boom positions needed to do the job Figure 13 Never decrease the safety distance to reach an unsafe area with the boom 6 4 When power lines are in the area where the boom will be moving to complete...

Page 43: ...ain 20 or 50 feet of clearance Mechanical or hydraulic malfunction may cause the boom to move down Figure 15 DANGER Slewing Radius of the Boom Slab to be Poured High Voltage Power Lines Minimum of 20...

Page 44: ...lines at all times See Figure 16 DANGER shckbhnd eps Slewing Radius of the Boom Slab to be Poured High Voltage Power Lines Minimum of 20 foot clearance from wires 50 foot above 350 Kv Extremely hazard...

Page 45: ...res You can t tell from here Get the best possible vantage point sptpostn eps dpthprct eps From the vantage point of this operator it would be extremely difficult to tell if the end of the boom will c...

Page 46: ...as cranes scaffolding and buildings Figure 19 6 12 Place wheel chocks under the tires on sloping terrain Release the brakes and allow the machine to settle against the chocks then reapply the brakes...

Page 47: ...its or check with the manufacturer Never exceed the recommended weight or structural damage could occur 6 16 Possible structural damage If you remove the supplied tip hose and replace it with a combin...

Page 48: ...able to have an end hose as the last piece of delivery system If you will be swinging the full boom over workers or property you must be able to plug the delivery system See the instructions for plugg...

Page 49: ...areas are documented on safety decals and in operation manuals see Figure 24 Be aware of these areas if they apply to your unit and set up the pump taking these areas into consideration 6 20 Collisio...

Page 50: ...known that under certain circumstances shortrigging is unavoidable see Figure 25 If no alternatives are practical and you must shortrig for a particular job keep these points in mind Unless otherwise...

Page 51: ...ly allowed by the manufacturer The inner and outer outrigger box reinforcements will not align in intermediate positions Figure 26 Figure 26 Partial extension Fulcrum 2 Outrigger fully extended Lever...

Page 52: ...or any excavation The rule of thumb is for every foot of drop stay back from the base edge at least 1 foot the one to one rule See Fig ure 28 Note that the forces on the outriggers are transferred to...

Page 53: ...to 1 ratio with the outrigger this cliff could collapse Outrigger force is transmitted at a 45 degree angle and there is no material to support the force at point X WARNING Base edge 1to145 2 eps Figu...

Page 54: ...ad contacts all pieces of cribbing Run cribbing in the opposite direction if needed D 6 30 Tipping hazard See Figure 33 Regardless of whether you know the load bearing capacity of the soil or not you...

Page 55: ...positioned correctly close all outrigger hydraulic shutoff valves if your machine is so equipped 6 32 Do not unfold or operate the placing boom when lightning is present in the immediate area If you a...

Page 56: ...onents is affected by pumping pressure concrete composition pipeline material velocity of moving concrete and other factors The use of ultrasonic equipment for determining pipe wall thickness of singl...

Page 57: ...is ready to work secure it against unau thorized use Either stay with the unit or make sure no one can start it without you This could be accomplished for example by activating the emergency stop swit...

Page 58: ...If they are frayed or have open spots in the insulation or if the connectors are worn or loose have repairs made by a licensed electrician 7 6 Consider the safe approach and departure of the ready mix...

Page 59: ...ions of pipe nearest the pump are subjected to the high est pressure and the greatest wear Because of this increase of pressure near the pump you should install only thick walled pipe in like new cond...

Page 60: ...r radio communications a system of visual or auditory signals lights or bells or a sig nalperson Figure 39 If a signalperson is used agree on hand signals before beginning the pour ACPA recommended ha...

Page 61: ...ust fit into the pipeline tight enough that air cannot escape ahead of it A ball or go devil catcher that will catch the go devil or ball or some other method of controlling the discharge while the li...

Page 62: ...mpressed air is relieved Catcher type 2 is long enough that the compressed air escapes behind the go devil Note This would happen with either catcher when used with a ball instead of a go devil The ad...

Page 63: ...ators are responsible for the safe operation of the machines it is crucial that they understand the proper operation of the machine and the safety rules that apply to the job at hand so the course of...

Page 64: ...void hazardous proximity or contact with power lines under all circumstances Be sure that you maintain 20 feet 6 meters of clearance The 20 feet 50 feet above 350 Kv allows room for the movement of th...

Page 65: ...live power line is always dangerous to anyone and everyone electrically connected to the machine Figure 46 Use extreme caution near power lines 8 11 Do not rely on depth perception when working near...

Page 66: ...will conduct enough current to kill you if you contact the 8000 volts to ground that is normally found on residential power lines in the United States Figure 48 Voltage may be higher than 8000 especi...

Page 67: ...a hoist or crane Figure 50 8 17 Explosion hazard Never remove the fuel cap or refuel the unit near hot surfaces sparks or open flames Never smoke while refueling CAUTION WEAR HEARING PROTECTION PERMI...

Page 68: ...amount left in the pipeline 3 Persons standing at the discharge end or near the delivery line must be warned to move away until all of the air has been purged see Figure 51 Personnel should move a pru...

Page 69: ...lied may not be a pump able mix for example there may be too much sand or too little cement There may be bleeding or segregation Some admixtures adversely affect pumpability e g too much air entrainme...

Page 70: ...force of the pump The concrete becomes segregated in the hopper a If the concrete is too wet the cement and fine material get washed from the stone and coarse sand This mix will not pump It is for th...

Page 71: ...spot of the plug because the jammed material will keep the pipeline from vibrating This method won t find a plug in a hose To find a plug in a hose with the pressure relieved tap or step on the hose t...

Page 72: ...n air compressor If the pump pressure can t move it air pressure won t either 8 31 Crushing amputation hazard Do not remove the water box covers or grates when the machine is stroking Figure 56 If you...

Page 73: ...a Whenever you are connecting or disconnecting the remote cable push in the emergency stop switch 8 34 Crushing amputation hazard Never put your hands feet or any other body part into the water box co...

Page 74: ...be moved extensively arrange for a workman to stay with the pump and put yourself in a position to see the end of the boom Figure 58 8 37 Always block the discharge end when you must swing a full boo...

Page 75: ...f the ball or go devil doesn t come out of the delivery system after applying compressed air you must relieve the pipe of air pressure before opening it If the bleed off valve plugs when you are drain...

Page 76: ...stop system relieving the accumulator pressure and or a lockout tagout process with the ignition key If the hopper grate was removed or raised return to its secured operational position before restart...

Page 77: ...necessary to bend over the water box for cleaning Be sure boom is stowed and outriggers are secured for travel before moving the unit 11 3 Falling hazard Be sure of your footing when cleaning the wate...

Page 78: ...ected to the end of the pipeline during the blowout process unless there is a pre planned clean out station erected to route the discharge into the ready mix truck The point of discharge must be contr...

Page 79: ...other tool that will assure a safe distance from clamps to avoid concrete blowing in your eyes Do not use compressed air to blow out concrete delivery hose single pipe sections and short pipelines up...

Page 80: ...ble of handling the maximum con crete pressure of the pump and of course must be installed before the pour begins Several different styles are available ranging from a manually operated flat gate that...

Page 81: ...ersion valve 5 Install the ball s in the pipeline secure the blowout head and hook up the air compressor Do not apply the air yet Item 2 Figure 67 6 If you will be diverting the discharge to a clean o...

Page 82: ...Do not allow the concrete to accelerate Item 5 Figure 67 11 When concrete starts to accelerate shut off the air supply from the com pressor and open the air regulator to bleed air from the line Rapid...

Page 83: ...immediately Contact the manufacturer of your unit to obtain replacements 13 5 If safety devices or guards are removed for inspection pur poses they must be replaced before someone uses the machine 13...

Page 84: ...eat it lightly Do not fudge results The lives of the operator oiler and workers on the job are depending on it 14 2 Keep the machine clean Oil spills grease loose tools and dis placed accessories are...

Page 85: ...by a welder certified to the manufacturer s specifica tions 14 13 Welding on any structural member must be done according to the manufacturer s specifications 14 14 Never allow welding current to trav...

Page 86: ...a minimum clearance of 20 feet 6 meters between the power line and any part of the unit 50 feet 15 meters for lines above 350 Kv See Figure 71 15 6 Falling hazard If you cannot work at ground level yo...

Page 87: ...rules are one simple Lockout Tagout procedure A procedure may also be provided in the operation manual for the unit and there may be state or local regulations that require a more advanced or stringen...

Page 88: ...ggers tower etc the repair must be inspected by qualified personnel before use 15 20 Always use the correct tools for the job Tools should be kept clean and in good condition 15 21 If you see a cowork...

Page 89: ...tting any solid object in hopper WARNING DANGER Stay clear Contact will result in death or serious injury if the unit becomes electrically charged WARNING Keep hands out of hopper and valve assembly S...

Page 90: ...om comes within 20 feet 50 feet above 350 Kv of power lines The spotter must understand the responsibilities assigned and must be able to judge a 20 or 50 foot distance Use visual aids such as cones t...

Page 91: ...ump Do not attempt to remove the material from the hopper or grate while the hydraulic system is ready to work See point 16 19 on page 64 If necessary push the emergency stop switch E stop to stop the...

Page 92: ...elivery system These procedures include pumping in reverse for a couple of strokes 3 Persons standing at the discharge end or near the delivery line must be warned to move away until all of the air ha...

Page 93: ...n taken apart or opened for any reason 16 15 Never use compressed air to clear a blockage The operator is responsible for knowing the safe blockage removal procedures It is unsafe and unnecessary to u...

Page 94: ...andling pipeline or any other heavy object Learn how to lift without using your back Get assistance if needed 16 19 Crushing amputation hazard Never put your hands feet or any other body part into the...

Page 95: ...not remove the water box cover to add water for example until the operator has disabled the machine Replace the covers before the operator restarts the pump 16 22 Keep unauthorized personnel off of t...

Page 96: ...Electrocution hazard If the pump or boom becomes energized with high voltage and you are in contact with any part of it you are at risk of elec trocution You should monitor the movement of the boom an...

Page 97: ...ng any obstruction or hazard Where jobsite safety is concerned two sets of eyes and ears are better than one 17 4 Never use compressed air to clear a blockage It is unsafe and unnecessary If the pump...

Page 98: ...ly If the operator tells you that air is coming in the delivery system pro ceed as follows Get to ground level if in a high place and remain well away from the dis charge or at least take cover Stay a...

Page 99: ...yes 17 11 After removing pipe sections you must reassemble using gas kets and clamps Pipelines assembled without gaskets will leak cement and water which can cause a blockage 17 12 Concrete is being m...

Page 100: ...tioned between the boom or boom hose and any fixed object like a wall or column Figure 93 17 16 Do not kink the end hose Kinking will cause the pump to cre ate maximum concrete pressure The pump may u...

Page 101: ...istance if needed 17 20 Crushing hazard Never position your hands or any body part between the end of the delivery system and a fixed object e g between the tip hose and the concrete form Figure 95 Wa...

Page 102: ...nfusion and conflicting signals only one person should act as a signalperson give operational signals to the pump operator However the operator is trained to obey a stop signal from anyone and everyon...

Page 103: ...to find the Minimum Pipe wall Thickness chart Due to expanding graphics that chart has moved to a later page in this book You will always find it in the Appendix section of the Safety Manual VII Weld...

Page 104: ...e of the weight savings compared with other styles 2 Heavy Duty couplings are designed for pres sures up to 2250 PSI 2 1 They have 20 more contact area than metric couplings and a tapered face that dr...

Page 105: ...ssure calculations ONLY There is no allowance for mechanical forces other than pressure and thicker walls may be needed for mechanical strength because of support or restraint considerations 6 The cha...

Page 106: ...In all cases blockages create a hazard by causing high concrete pressure combined with the sometimes uncoordinated efforts of untrained workmen to remedy the problem Bulk Density The mass of a substan...

Page 107: ...exposure to sound at different volume lev els The chart can be found on page 37 of this Safety Manual Drive Engine The primary source of power for a hydraulic system Typically the word engine denotes...

Page 108: ...ated personnel Maintenance All procedures for service inspection and repair of concrete pumps and related equipment Maintenance and inspection are methods of maintaining the desired state of the equip...

Page 109: ...ed Person As used in this Safety Manual a qualified person is defined as a person who by possession of a recognized degree of certificate of professional standing or who by extensive knowledge train i...

Page 110: ...nually or hydraulically operated valve that will prevent the flow of concrete in either direction The shutoff valve must be able to withstand the maximum pressure on the con crete of which the pump is...

Page 111: ...eration of the boom could be operation by a passer by unauthorized repairs to the boom could be repairs designed without the manufacturer s knowledge Unintentional Movement Movement of the pump boom o...

Page 112: ...ociation The MANUAL and ADVISORY SAFETY CODE of PRACTICE for CONCRETE PUMPING British Concrete Pumping Association Material Placement Systems B30 27 an American National Standard ASME Additional techn...

Page 113: ...402indexcov eps ALPHABETICAL INDEX 700indxcov fm PAGE 83 SAFETY MANUAL Alphabetical Index...

Page 114: ...ete 39 unpumpable mix 39 blowing out See cleaning out with compressed air blowout head See clean out accessories blowout head boom See placing boom boom watching 67 brakes worn 6 bulk density defined...

Page 115: ...accumulator 76 agitator 76 ASME B30 27 76 blanking plate 76 blockage 76 bulk density 76 caution 2 certified operator 76 concrete delivery hose 18 76 concrete pressure 77 conductors 77 danger 2 decibel...

Page 116: ...irt removal 16 support capacity See soil support capacity diversion valve use 52 drive engine defined 77 driving cautions 10 safety devices 7 10 11 selecting route 8 9 stopping distance 10 windshield...

Page 117: ...system 64 71 notifying operator 61 personal protective equipment 59 licensed electrician defined 78 lights 7 lockout tagout 44 57 loose items securing for travel 7 8 M maintenance changing maximum pre...

Page 118: ...7 pipe ends 54 inspection 5 opening when pressurized 41 49 63 69 pre dispatch 6 wall thickness chart 75 weld on ends 74 pipeline weight per foot 55 pipe wall thickness chart 75 placing boom as hoist...

Page 119: ...uirements 50 when to open 52 signal word defined 2 signalperson defined 80 use 26 30 44 72 signalperson how many may become 72 sleep importance of 2 snow removal 16 soil support capacity 22 soil press...

Page 120: ...67 water box checking while pumping 42 danger 43 47 64 water jet defined 81 weather conditions considerations 6 lightning 25 maximum wind speed 25 weight knowledge of 9 knowledge responsibility 9 weig...

Page 121: ...Safety guards 33 Warning Horn 33 Holding Valves 33 Fuses and circuit breakers 34 Power Pack 35 Boom Handvalve 36 Operator Control Panel 37 Cable Radio Remote Box 38 Status LCD Display 39 Joystick Con...

Page 122: ...30 Overview S 39 41 SX Operation Manual...

Page 123: ...re Owner Distributor Operator circle which applies Safety decals refer to decal sheet Tools spare parts refer to tool sheet Visual inspection of paint job Holding valve on boom All boom pin retainers...

Page 124: ...ic circuit turn the E Stop button counter clockwise on the Radio Re mote E Stop Figure 1 The Emergency Stop Switch Pressure Relief Valves Pressure relief valves are the safeguards which lim it maximum...

Page 125: ...he hydraulic cylinder to pre vent it from creeping or moving until pressure is applied If hydraulic pressure is lost for any reason for example if a hydraulic hose or fitting blows holding valves will...

Page 126: ...itive goes to negative without resistance Component malfunction a coil that has to move a sticky valve Mechanical interference a shovel handle stuck through the oil cooler fan blade To maintain this s...

Page 127: ...w Drive D Electric Motor E Hydraulic Filter F Hydraulic Quick Disconnects G Receiver Enclosure H Hydraulic Pump I Hydraulic Level Temperature Gauge J Support Legs K Turret Adapter L Electrical Sockets...

Page 128: ...l Boom Handvalve A Boom 1 Extend Retract Handle B Boom 2 Extend Retract Handle C Boom 3 Extend Retract Handle D Boom 4 Extend Retract Handle E Boom Slewing Handle F Boom Enable Handle G Mast Lower Rai...

Page 129: ...my Plug WARNING ADVERTENCIA Do not touch hydraulic oil leaks Get immediate medical attention if oil penetrates skin No toque las fugas de aceite hidr ulico Obtenga atenci n m dica inmediata si el acei...

Page 130: ...t Stop Switch D Air Cuff Closed Optional E Browse LCD Button F Horn Switch G Boom Speed Selector Switch H N A I LED Antenna Light J Emergency Stop Button E Stop K LED Power Battery Indicator Light L N...

Page 131: ...h Statues Machine Status RPMs Strokes per minute Machine Status Hydraulic Oil Temperature Concrete Pump Pressure Start 0 0 0 0 0 0 C 0 Left Joystick 2 Boom Up 2 Boom Down 2 Boom Not Used Tip Retract T...

Page 132: ...peed of each boom section Use the fast speed rabbit when folding and unfolding or when fast boom movements are appropriate for the job conditions Use the slow speed turtle when job conditions require...

Page 133: ...unctions actuated Transmitter transfers control data red on green on Transmitter on but no connection to the receiver red flashing red on Transmitter on and active Issue of command blocked by safety f...

Page 134: ...osition Stroke Limiter Dial must be turned to 1 Figure 2 E Stop Power Button Power LED Stroke Limiter Snail Rabbit Switch Figure 2 Transmitter switches and buttons 5 Open the control panel door Press...

Page 135: ...so beep indicat ing the current PO number selected and flash the antenna LED Description PO Number Notes Not Used Po 00 Direction not used Po 01 Inverts the direction of a function 00 Normal 01 Flippe...

Page 136: ...10004659 0035 2 FITTING GAUGE COUPLING 10018990 0036 2 HOSE TEST 12 X 24 WHIP DN2 400 bars 10018991 0047 1 Kit ROCK VALVE TOOLBOX TRUCK TRAILER 98362524 0061 1 Hose 5 Pulsor 200 x 12 metric ends 3036...

Page 137: ...Cross Frame Installation 51 Freestanding Mast on Cross Frame 52 Recommended Tools 52 Assembling Mast Sections 52 Self Climbing Mast 55 Installation of Boom and Column 55 Assembly of ladder and back re...

Page 138: ...ather pumping tips 74 Preheating the hydraulic oil 75 Preheating the boom pipeline 75 Cleanout 76 Cleaning out the boom 76 Cleaning the vertical pipeline 77 Folding up the clean boom 78 Emergency Proc...

Page 139: ...se the following checklist to determine your equip ment needs Pipe sections Adapter pipes If all pipe ends are not identical see the information on Weld on End Coupling Comparison in the Appendix of t...

Page 140: ...lic reservoir each week Open the ball valve under the hydraulic reservoir Fig ure 3 and allow the fluid to run into a pan until it chang es from water to oil Water is heavier than oil so it sits on th...

Page 141: ...a molybdenum disulphide grease Bolts securing the mast can one be used once New hardware must be used with each setup 10 9 Figure 4 Bolts connecting the mast Proper pipe clamps are to be used to attac...

Page 142: ...as sembled to provide safe working space The area must be secured with barriers or roped off 2 Cast into the slab eight 1 1 2 8 UNC X 6 mm threaded rods attached to the anchor bolt channel to secure...

Page 143: ...rument to ensure that the frame is level Use steel shims or packers to level the cross frame 6 Once the cross frame is centered and levelled the lifting gear is removed 7 Secure the frame in place usi...

Page 144: ...the boom to mast connection or the boom arm to turret connection hydraulic torque wrench to torque the bolts hold ing the flanges of the mast sections paint brush for applying grease to connection pi...

Page 145: ...ns are assembled 12 The mast sections should be raised at one end to allow the fitting of the head section and working platform A support is then placed under the mast Figure 14 Assemble head section...

Page 146: ...the mast assembly to ensure that the pipeline on the column is able to connect to the delivery pipeline from the concrete pump 21 The flange connections are secured per step 10 22 The rigger climbs th...

Page 147: ...e with each other 5 The edges of the openings must be solid and must be held in place by approved metal wedges The floor frames are kept in place by metal wedges that are held in frames and jammed aga...

Page 148: ...ust be removed to fit the mast on floor frames between floors The lad ders only need to be fitted where there is no other access to the working platform 12 A suitable back propping scheme must be empl...

Page 149: ...bolts A pry bar over 3 feet long A wood block 6 to 8 inches high no longer than the width of the boom cradle A tag rope at least 20 feet long two would be better Removing boom from truck When removing...

Page 150: ...fting Power Pack And Boom Assembly MASS 8532 kg 18810 lbs SPB 35 MASS 8600 kg 18960 lbs SPB 37 Use This Configuration When Lifting Turret And Boom Assembly MASS 5829 kg 12850 lbs SPB 35 MASS 5897 kg 1...

Page 151: ...guide it slowly away from the truck Movement should be slow and straight back being careful to clear the tower with the low er boom and hydraulic hoses Also watch the tip hose bracket on the bottom o...

Page 152: ...Manual Dummy plug Self Climber Remote Socket SPB Remote Socket Main Power Inlet Figure 28 Boom tower and oor frames 14 Attach the power and remote cables Figure 28 15 Position pipeline gasket and con...

Page 153: ...Gray A1ZC3 K N A T k n a T Rod Side Red Blue B1ZC3 4 D Z 1 A e d i S n o t s i P K N A T k n a T 4 D Z 1 B e d i S d o R Piston Side Orange Yellow A1ZE5 K N A T k n a T Rod Side Orange Red B1ZE5 Air L...

Page 154: ...62 Operation SPB Operation Manual Lifting Instructions 1 of 3...

Page 155: ...63 Operation SPB Operation Manual Lifting Instructions 2 of 3...

Page 156: ...64 Operation SPB Operation Manual Lifting Instructions 3 of 3...

Page 157: ...e the thickest pipe wall because it is the closest to the pump All sections of the baseline should be connected by two bolt clamps and the pipeline should be anchored solidly Two Bolt Clamp Figure 31...

Page 158: ...887 Start Button Local Off Remote Switch Power Socket Cable Dummy Plug Socket Power Disconnect Handle Figure 33 Electrical Panel Ensure motor is spining in the clock wise direction after starting From...

Page 159: ...Disconnect Handle in the Off position E Stop Button Motor On Off Switch WARNING ADVERTENCIA Do not touch hydraulic oil leaks Get immediate medical attention if oil penetrates skin No toque las fugas d...

Page 160: ...hose if either of the raised ends are worn or if the rubber is movable inside of the steel sleeve Because this tip hose may see the max imum possible concrete pressure that the pump can generate it i...

Page 161: ...ply steel reinforced Heavy Duty raised end Weight of hose 77 pounds Weight of concrete in the hose 156 pounds Figure 37 Examplesof adapter reducer hose combinations Never use grooved or victaulic pip...

Page 162: ...opper Remind the pump operator to not let the concrete level in the hopper become low If air is sucked into the ma terial cylinders the pump will compress the air Com pressed air always poses a hazard...

Page 163: ...as an unsuitable resonant frequency for a certain application after the fact but predicting it in the design stage is nearly impossible Severe boom bounce is caused by taking the natural stiffening an...

Page 164: ...s a thin tick sound be cause the forces on the steel do not allow the pipe to vibrate Consider tapping your pipeline in each of these configurations when there is no blockage just to become familiar w...

Page 165: ...ted it is best to not pump on very cold days Stop the dripping concrete while moving When you need to swing a full boom over personnel a finished slab or equipment it is your responsibility to protect...

Page 166: ...ordered by the con tractor until the last minute It usually happens late in the day so typically 4 of the 5 ready mix drivers that you were seeing all day have gone home and the same man that brought...

Page 167: ...rior to going out again If cold weather operation is expected regularly you should have an air dryer installed on the truck air system 5 If you are expecting cold weather for extended pe riods of time...

Page 168: ...ng out of the end hose walk to the end of the boom with the sponge ball Remove from the end of the boom any reducers hose or pipes which are smaller than 6 inches 150 mm Place the clean out sponge bal...

Page 169: ...vered to prevent the spray of concrete to the surrounding area There are two types of catch baskets One is shorter than the go devil and one is longer Each type has advantages and disadvantages Figure...

Page 170: ...g for obstructions rotate the boom into the storage position There are arrows welded to the turret and tower on the passenger side of the unit that will line up when the boom is rotated to the correct...

Page 171: ...100 bar 1450 psi Minimum permissible spraying distance 12 If the high pressure washer used generates a high er water pressure the spraying distance must be in creased accordingly Use of Cleaning Agen...

Page 172: ...the nished oors Item 2 to guide the boom tower Item 3 The climbing oor frames transfer the occurring forces to the structure and carry the hydraulic cylinders Item 4 Figure 32 used for raising the boo...

Page 173: ...ylinder with hydraulic lines 6 lifting arms 7 lifting pin 8 guide roller 9 Supporting pin The components of the climbing equipment must be moved from oor to oor when the maximum lifting height of the...

Page 174: ...rol Valve Figure 47 Emergency control valve Climbing The placing boom ready for operation is anchored via the boom tower and the base cross on the foundation base slab During the climbing operations t...

Page 175: ...for leaks Check screws for wear Check cables and connectors of the remote con trol for damage If you detect damage or excessive wear have the con cerned parts inspected by the Schwing after sales ser...

Page 176: ...er to the lowermost climbing oor frame Make sure the hoses and lines are not kinked They must hang freely and also be protected against kinking during the climbing operations 8 Empty the concrete pum...

Page 177: ...rs with the momentary contact switch Item 3 Figure 43 of the cable re mote control repeatedly into the limit stop posi tions Check the hydraulic connections for leaks and remove if any 3 2 1 Figure 54...

Page 178: ...move the lifting pins 5 Remove the lifting pins and insert into the next hole Figure 46 6 The next lifting procedure can now be started 7 Repeat these steps until the boom tower has reached the desire...

Page 179: ...d eight wedges into the guides of the lower frame arrows Figure 49 Wedges should never be driven in more than two oor frames Remember that A minimum distance between oor frames is required Due to the...

Page 180: ...30355887 Start Switch Stop Switch Local Remote Switch Main Power Switch Figure 62 Main switch key switch and electric motor start switch 2 Set the main switch Item 1 Figure 51 to 0 3 Disconnect the c...

Page 181: ...ced stability and load bearing capaci ty It will also void the Schwing warranty Troubleshooting When a hydraulic line has broken 1 Depress the EMERGENCY STOP button on the cable remote control Item 1...

Page 182: ...e Switch Main Power Switch Figure 66 Drive motor of hydraulic unit Item 3 and Key switch Item 4 3 Move lever upwards boom tower is raised Item 1 Figure 56 or 1 Move lever downwards boom tower is lower...

Page 183: ...95 Hydraulic Oil Recommendations 96 Biodegradable Hydraulic Oils 96 Maintenance Checklist 97 Scheduled Maintenance 97 Pressure settings 97 Daily Maintenance 98 Visually Inspect the Machine 98 Check H...

Page 184: ...oil for temperature reasons 102 Changing oil boom slewing gearcase 102 Hydraulic Boom Filter 103 Yearly Maintenance 103 Change the hydraulic oil 103 Unscheduled maintenance 104 Pipewall thickness 104...

Page 185: ...to lower rated hoses or ttings Schwing uses metric ttings and hoses with metric threads on the couplings There are six sizes of tubes and ttings and six sizes of hoses all measured by di ameter All b...

Page 186: ...the exposed tab with the hole positioned at nine o clock 2 Pull the tab from the handle to expose the slot 3 Insert padlock through the slot and lock it Line up handle with hole Pull on tap to expose...

Page 187: ...national Standards Organization ISO has developed a meth od of grading hydraulic oils for viscosity For summer in northern North America we recommend ISO VG 46 weight oil while in the winter we recomm...

Page 188: ...ellus T 46 TEXACO Rando HD 32 HDZ 32 HD 46 HDZ 46 HD 68 HDZ 68 WINTERSHALL Wiolan HS 32 HV 32 HS 46 HV 46 HS 68 HV 68 Biodegradable Hydraulic Oils ESSO Univis WEPG 32 Univis WEPG 46 Univis HEES 46 Typ...

Page 189: ...Check End Hose Check slewing brake function Check auto greaser reservoir Drain water from hydraulic tank Grease boom and turret Check slewing gear oil Grease slew drive gears Check slewing gear hardwa...

Page 190: ...problem If you need ideas about where to look for the source of water contamination call Schwing America s Service Department at 651 429 0999 or 800 328 9635 Oil Level Indicator Filler Neck Filler Ven...

Page 191: ...throttle is preset at the factory and should not be readjusted unless you rst consult the Service Department at Schwing America Brake Valve Manifold Multiple disk brake system Figure 6 Slew drive with...

Page 192: ...ease pump reservoir as necessary and to check each tting to be certain that it is allowing grease to pass freely There are many grease ttings on the boom and each of them should be pumped full of grea...

Page 193: ...er will work Never use gasoline 2 Replace the dipstick plug the breather cap and the pinion gear cover 3 Restart the unit Slew the boom left and right sev eral times shut off the truck engine and put...

Page 194: ...om slewing gearcase Do this procedure when the oil is warm When the oil is cold it does not drain easily and it does not rinse dirt and contamination off the gears You must however be sure that the oi...

Page 195: ...ply to lling the tank after draining and cleaning To change the oil 1 Shut off the motor and apply Lock out Tag out procedures 2 For safety the oil should be cool Do not change oil that is above 120 F...

Page 196: ...e testers are available from suppliers of quality control and testing equipment CAL ON OFF Figure 16 Ultrasonic tester Main areas of wear Delivery pipeline tends to wear about 4 inches beyond the ange...

Page 197: ...Remote control boxes and cables for proper op eration exposed wires broken controls missing control guards or broken plugs Boom and outrigger structures for visible defor mations cracks and damage Boo...

Page 198: ...g the proper tools Always install new or like new pipeline on the boom Use new gaskets and pins in the clamps Clean and check the clamps carefully and grease them before re installing The clamps and g...

Page 199: ...ilver Chromated 112 Recommended Emergency Hose Kit 113 Fitting Wrench Sizes 113 Straight fittings 113 Banjo fittings 114 End Cap Separate from Stem 114 End Cap Part of Stem 114 Weld on Ends Coupling C...

Page 200: ......

Page 201: ...perature at which the oil will still be thick enough to provide lubrication and sealing If it were warmer the components would have metal to metal contact thermal break down The optimum operating visc...

Page 202: ...to be torqued to a 200 pound re quirement must be within the range of 208 192 foot pounds for a dial scale torque wrench Schwing equipment uses two different types of bolts one has a black or silver f...

Page 203: ...a l C y t r e p o r P 8 8 10 9 12 9 8 8 10 9 12 9 Thread Designation N m ft lb N m ft lb N m ft lb Thread Designation N m ft lb N m ft lb N m ft lb M 4 X 0 7 2 2 1 6 3 2 2 4 3 8 2 8 20 15 28 21 33 24...

Page 204: ...6 3 24 18 35 26 41 30 M 5 X 0 8 5 3 4 7 8 6 9 7 50 37 70 52 85 63 M 6 X 1 8 6 13 5 10 16 2 12 46 34 65 48 80 59 M 8 X 1 25 22 16 32 24 38 28 83 61 120 89 145 107 M 10 X 1 5 44 32 64 47 75 55 80 59 115...

Page 205: ...clean will cause a variety of problems in the operation of the unit Diameter Length Part Number 8 6400mm 30314105 13 6400mm 30314106 16 1350mm 10049948 20 1000mm 10049959 25 2100mm 30347677 32 1100mm...

Page 206: ...16 7 8 3 4 12 R 1 4 in 22 22 19 7 8 7 8 3 4 12 R 3 8 in 22 27 22 7 8 1 1 16 7 8 12 R 1 2 in 22 30 24 7 8 1 3 16 15 16 16 mm 30 32 27 1 3 16 1 1 4 1 1 16 20 mm 36 41 32 1 7 16 1 5 8 1 1 4 25 mm 46 50 4...

Page 207: ...ring assembly Both the ends and clamps weigh more than metric style and therefore should not be used on booms without consulting the manufacturer 3 Metric couplings are designed for pressures up to 14...

Page 208: ...ical strength because of support or restraint considerations 6 The chart does not take into account metal fatigue caused by pressure cycles 7 The chart does not apply to the system at the back end of...

Page 209: ...IA 9 D CF DN125 85BAR 1233WP 4 9 DIA 20 30mm D1 D1A Measuring points on Weld end Measure multiple points circumferential in the weld end groove as illustrated in D2 and D2A Measurements should be done...

Page 210: ...ic 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 Association There are severa...

Page 211: ...e hopper Examples of foreign material include small animals hammers ready mix truck fins unmixed clumps of cement hardened con crete that breaks away from ready mix truck fins and soft drink cans Many...

Page 212: ...e may have other values in different countries Murphy s Law An old adage that says Anything that can go wrong will go wrong and at the worst possible moment Operational Area The area around a working...

Page 213: ...stance 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 particles past the rocks compounding the p...

Page 214: ...ations See the safety rules regarding this subject in section 4 of this Safety Manual Transport Position Transport Position refers to the position of the boom during transport For transport the boom i...

Page 215: ...amps off on OPERATOR S PANEL Remote box power Box to truck communications Emergency stop status OMNEX REMOTE BOXES ONLY OUTRIGGERS REMOTE CONTROL BOX Boom 2 speed control slow medium fast Truck engine...

Page 216: ...124 Appendix SPB Operation Manual...

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