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OPERATION MANUAL ORIGINAL INSTRUCTIONS FOR CONCRETE LINE PUMPS

All SP “Rock Valve” Models

Part Number 30100750

Line Pump Division 5900 Centerville Rd White Bear, MN. 55127 1-888-SCHWING (724-9464) www.schwing.com

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CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Version 3.0.8 Revision date 05/14

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ORIGINAL OPERATING INSTRUCTIONS FOR ALL SP Ò ROCK VALVE ” MODELS

swg99a001.eps

Part Number 30100750 Version 3.0.8 Copyright © 2014, Schwing All rights reserved

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Table of Contents

Introduction Manufacturer’s Statement........................................................................... 8 Safety alert symbol and signal word explanation ................................. 8 How to reach us .................................................................................... 9 How to order parts ................................................................................ 9 Model Number:........................................................................................... 9 Serial Number:............................................................................................ 9 ID Tag Location........................................................................................ 10 ID Tag ....................................................................................................... 11 If your ID tag is missing ..................................................................... 11

Specifications Unit Specifications.................................................................................... 14 Hydraulic Pressure Specifications ............................................................ 16 Concrete Pump.................................................................... bar (PSI) 16 Noise emission levels............................................................Decibels 16

Safety How to Order Additional Safety Manuals ................................................ 18

Product Overview First Commissioning................................................................................. 22 Installation of your new unit ............................................................... 22 Machine Description................................................................................. 23 Emergency Stop switches ................................................................... 23 Concrete pump hydraulic pumps ........................................................ 24 Concrete Pump Circuit........................................................................ 24 SP Circuit Diagram................................................................................... 28 Phase A ............................................................................................... 28 Phase B................................................................................................ 30 Phase C................................................................................................ 32 Phase D ............................................................................................... 34 SP 2000 Circuit Diagram.......................................................................... 36 Phase A ............................................................................................... 36 Phase B................................................................................................ 38 Phase C................................................................................................ 40 Phase D ............................................................................................... 42 Phase E................................................................................................ 44 Phase F ................................................................................................ 46 Phase G ............................................................................................... 48 Phase H ............................................................................................... 50 Phase I................................................................................................. 52 Phase J................................................................................................. 54 Phase K ............................................................................................... 56 Component Locations ............................................................................... 58 Hopper Area........................................................................................ 63

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Table of Contents Safety Devices ......................................................................................... Emergency Stop Switches.................................................................. Automatic Shut-off Circuit Agitator.................................................. Safety Valves (Pressure relief valves) ............................................... Safety Guards..................................................................................... Fuses .................................................................................................. Warning Labels..................................................................................

66 66 66 66 66 66 67

Operation Preparation ............................................................................................... Arrive to work on time, with a clear head. ........................................ Have the right machine for the job. ................................................... Have the equipment that you will need for the job............................ Have the right personal protective equipment for the job.................. Check the equipment before leaving the yard.................................... Towing the unit ........................................................................................ Licensing............................................................................................ Backing up. ........................................................................................ Changing lanes................................................................................... Loading the unit for shipment............................................................ Unit Setup ................................................................................................ Selecting the proper set up location on the job site. .......................... Laying out the pipeline ...................................................................... Setting the Stabilizers ........................................................................ Operating the Pump ................................................................................. Basic Troubleshooting .......................................................................

70 70 70 70 72 73 74 74 74 74 74 75 75 75 76 76 77

Before the first truck backs up to your hopper .................................. Lubricate your pipeline. ..................................................................... To control the speed of the unit ......................................................... Pump the job ...................................................................................... Time Constraints................................................................................ To disable the entire unit in an emergency ........................................ Delays ................................................................................................ Keep the waterbox full....................................................................... Use of the vibrator ............................................................................. Blockages........................................................................................... Clean-out............................................................................................ Disposing of excess concrete ............................................................. Clean the hopper ................................................................................ Clean the rock valve and material cylinders...................................... Be careful with acid ........................................................................... Clean the waterbox ............................................................................

78 81 83 84 85 86 86 86 86 87 87 88 88 92 93 94

Preparation for travel ......................................................................... Special Pumping Situations ..................................................................... Rod side to piston side pumping (SP 2000)....................................... Quick Clean-out................................................................................. Cold weather pumping....................................................................... Preheating the hydraulic oil ...............................................................

95 95 95 96 96 97

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Table of Contents

Maintenance Filtration.................................................................................................. 100 General Information.......................................................................... 100 Specific Information ......................................................................... 100 Hydraulic Oils......................................................................................... 102 General Information.......................................................................... 102 Specific information.......................................................................... 102 Pressure, Hoses and Fittings ................................................................... 102 General Information.......................................................................... 102 Specific Information ......................................................................... 103 General Maintenance Tips ...................................................................... 104 Torque Specifications ....................................................................... 104 Adjusting relief valves. ..................................................................... 104 Removal of safety devices. ............................................................... 104 Preventative Maintenance....................................................................... 105 Daily Maintenance............................................................................ 105 Weekly Maintenance ........................................................................ 106 Monthly maintenance........................................................................ 107 Quarterly Maintenance...................................................................... 109 Semiannual maintenance .................................................................. 110 Annual maintenance.......................................................................... 114 Scheduled maintenance checklist ........................................................... 115 Unscheduled maintenance ...................................................................... 116 Inspecting hydraulic hoses................................................................ 116 Changing rams .................................................................................. 116 Preparation for long term storage ..................................................... 116 Restarting unit after long term storage.............................................. 116 Tier IV engine Regeneration Control Logic ..................................... 121 Regeneration Monitoring and Warning Levels................................. 122

Appendix Hydraulic Oil Viscosity Chart ................................................................ 126 Torque Specifications for Metric Bolts................................................... 127 Recommended Emergency Hose Kit ...................................................... 128 Fitting Wrench Sizes............................................................................... 129 Straight Fittings................................................................................. 129 Banjo Fittings.................................................................................... 129 Maintenance checklist............................................................................. 130 Output charts........................................................................................... 131 Using the chart. ................................................................................. 132 Nomograph ............................................................................................. 137 Using a Nomograph.......................................................................... 137 Weld On Ends / Coupling Comparison .................................................. 145 MInimum Pipe Wall Thickness .............................................................. 146 Glossary of Terms................................................................................... 147 Additional Reading Material................................................................... 152 List of Lubricants and Nitrogen .............................................................. 153

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Table of Contents End of Life Protocol............................................................................... 156

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Table of Contents

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Introduction

swg99a001.eps

INTRODUCTION Manufacturer’s Statement......................................................................... 8 Model Number: .......................................................................................... 9 Serial Number:............................................................................................ 9 ID Tag Location ......................................................................................... 10 ID Tag........................................................................................................ 11

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Introduction

Introduction This operation manual contains unit specifications, product overview information, the safety manual, operation information, and maintenance information for your concrete pump unit.

Safety alert symbol and signal

word

explanation The triangle with the exclamation point inside is used to alert you to an important safety point and is called a safety alert symbol. One of the following signal words will appear after the safety alert symbol:

Manufacturer’s Statement WARNING Improper setup / operation creates hazards. Do not operate this machine without training. Understand the warnings in safety manuals and on decals.

Technical modifications that are made to units will be documented in each new edition of the operation manual.

Danger s

p e . 9 9 0 0 0 0

The information contained in the operation manual is absolutely necessary for the safety, proper setup, operation, maintenance, and servicing of your concrete pump. By learning this information and practicing it every day, you can expect that your concrete pump unit will give you efficient and reliable service year after year. For your own benefit and safety, read the information in this manual, and follow the instructions to the letter.

Warning Caution

•

Before you operate your concrete pump for the first time, you should read the operating instructions several times through. We recommend that you keep a copy with the concrete pump for quick reference while on the job site. The general knowledge must be in place before you arrive on the job site. Any and all persons who operate a concrete pump must be familiar with the operating instructions. Even a temporary operator (for example, if the normal operator is ill or on vacation) must be familiar with the operation instructions. It stands to reason that a person who has not operated a particular concrete pump before will not know how to safely operate that concrete pump. The machine is built to the latest technology and safety regulations, but it may still be dangerous to people and property if it is operated, maintained, repaired, or used incorrectly.

•

•

•

If the safety alert symbol is followed by the signal word DANGER, it indicates a hazardous situation which, if not avoided, WILL lead to death or serious injury. If the safety alert symbol is followed by the signal word WARNING, it indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury. If the safety alert symbol is followed by the signal word CAUTION, it indicates a potentially hazardous situation which, if not avoided, MAY result in minor to moderate injury. The signal word CAUTION used without the safety alert symbol means the point addresses a hazard which COULD cause damage to equipment or property.

The illustrations contained in this manual are intended to clarify text passages. They may look slightly different from your unit, but this has only been allowed if it does not fundamentally change the factual information.

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Introduction Warnings have been placed in the text where needed. Additional information used with the signal words is printed in decal format, as shown below, to explain the specific hazard. Occasionally bold text is used in addition to the decal for emphasis. All persons working near the concrete pump unit must be able to recognize hazardous situations. They must know how to avoid these situations and how to react quickly and appropriately whenever hazardous situations arise.

Heed the warnings shown on the decals!

DANGER Hazard and consequence will be shown in this space.

s

p .e 4 5 0 0 0 0

WARNING Hazard and consequence will be shown in this space.

s

p e . 7 5 0 0 0 0

If you encounter a circumstance that is not covered by this manual, Schwing America’s Service Department will be more than happy to assist you with all of your parts and service needs. Call us at either of these #’s: • Minnesota (main office) (651) 429 - 0999 • Call Center 1- 888-SCHWING (724-9464)

How to order parts To place an order for spare parts, you can order on line at schwingparts.com , or you can call our toll free parts line from anywhere in the continental United States, except Minnesota. Parts department hours are Monday through Friday, 6:00 AM to 6:00 PM (central time). Orders will also be accepted via fax, 24 hours/day. • Spare Parts 1- 888-SCHWING (724-9464) • Spare Parts (fax) (651) 429 - 2112 Whenever you call the factory for spare parts or service, have the model number handy. You can find the model and serial number on the ID tag that is mounted to the subframe of the unit. For future reference, the model number and serial number of your machine can be found on this page.

NOTE!

CAUTION Hazard and consequence will be shown in this space.

How to reach us

When replacing parts always use original Schwing replacement parts s

p .e 6 3 0 0 0 0

Model Number:

Serial Number:



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Introduction

ID Tag Location The ID tag for this machine is located on the right hand side of the tongue on the passenger side as shown in Figure 1.

SWG99a002.eps

Figure 1 Location of ID tag and serial number

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Introduction

ID Tag

SUBSIDIARY OF SUBSIDIARIA DE

5900 Centerville Rd White Bear, MN 55127 Phone: 651-429-0999 www.schwing.com This product is covered by one or more U.S. patents - see patent decal

MODEL MODELO WEIGHT

LBS.

TONGUE WEIGHT

PESO

MAX. HYD. PRESSURE PRESIÓN. HID. MAX.

###

LBS.

SPM

PESO DE ENGANCHE

###

Sys. 1

3 7 6 0 0 1 0 3

Este producto está cu bierto por una o más patentes de Estados Unidos – vea la etiqueta

SERIAL # # DE SERIE 123456789

SP ????? ###

GmbH.

Herne / Germany Phone: (02325) 8771 www.schwing.de

###

Sys. 2

###

YEAR AÑO 200? MAX.

MATERIAL PRESSURE

CPM

###

Sys. 3

###

PSI

PRESIÓN MATERIAL

###

Sys. 4

###

Sys. 5 newSPIDtag.eps

Figure 2 ID Tag and serial number The ID Tag provides information about the entire unit the pumpkit, the hydraulic systems, and the year of manufacture. The unit serial number is on the tag and also stamped into the subframe directly below the ID tag, as shown in Figure 2.

NOTE!

All numbers used on ID t ag illustrations in this book are for reference only and sho uld not be used in any calculations regarding your unit. For information specific to your unit, check the ID t ag and serial number affixed to the unit itself as shown in Figure 1.

If your ID tag is missing If the tag has been removed from the unit and you need information about your concrete pump unit, read the unit serial number that is stamped into the steel subframe. The unit serial number is located on the tongue directly below the ID tag as shown in Figure 2. When you locate the number, call the Schwing Service Department for the information. The unit files are arranged by this serial number and the service personnel can find out anything about the unit from the file that corresponds to this number. New ID tags are available from the Service Department when you provide the unit serial number.



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Introduction

NOTES

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swg99a001.eps

SPECIFICATIONS Unit Specifications ................................................................................... 14 Hydraulic Pressure Specifications ............................................................ 16


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Specifications

Specifications Unit Specifications MODEL

SP

CONCRETE PUMP KIT

1250

80/55 x 1400:180

SP 1000 HP

SP

90/50x1000:150

1000

90/50x1000:1

80

Piston side

Piston side

Piston side

34 95 yd3/hr

26 35 yd3/hr

35 70 yd3/hr

C6.6TA-ECU (Tier3) 129.5Kw (173 Hp)

C4.4TA-ECU (Tier3) 104 Kw (139 Hp)

C4.4TA-ECU (Tier3) 104 Kw (139 Hp)

Strokes/minute (max.) Max. Output

Power Power (Current Electric Motor) Power (hyd. pumps) Output (hyd. pumps) Req’d. Speed (hyd. pumps)

NA

75Kw(100Hp)

100 Kw 284L/min (70gpm)

Diesel

2200 rpm

Electric

1800 rpm

Pressure (max. hyd.)

75Kw(100Hp)

80 Kw

80 Kw

1 81 L/min (48 g pm)

246 L/min (65 gpm)

2200 rpm 1

2200 rpm

800 rpm

1

800 rpm

330 bar (4785 psi)

278 bar (4050 psi)

300 b ar (4350 psi)

Theoretical Concrete Output

95 yd3/hr

35 yd3/hr

70 yd3/hr

Max. Pressure on Concrete

64.9 bar (942 psi)

100 b ar (1450 psi)

Max. Horizontal Pumping Distance

297.8m (977 ft.)

463.3 m (1520 ft.)

Max. Vertical Pumping Distance

86.9 m (285ft.)

146.3m(4

Max. Aggregate Size

38.1mm(1.5in.)

Min. Concrete Slump

0mm(0in.)

80ft.)

12.7mm(0.5in.)

177.8m m(7in.)

152.4mm(6in.)

1397 mm (55 in.)

990.6 mm (39 in.)

Differential Cylinder Diameter

79.8 mm (3.14 in.)

Fuel Tank Capacity

1

89.9 mm (3.54 in.)

LongRock

HP ShortRock

1295.4 mm (51 in.)

1295.4 mm (51 in.)

189.3 L (50 gal.)

113.6L(30g

al.)

Gross Weight

4182 kg (9200 lbs.)

Length

5486.4 mm (216 in.)

Width

1930.4 mm (76 in.)

1651 mm (65 in.)

Height

2209.8 mm (87in.)

1 879.6mm(74in.)

Remote Control Cable Length

14

30.5m(100ft.)

8.1 mm (1.5 in.)

0mm(0in.)

Stroke Length

Charging Hopper Height

100.6m(330ft.) 3

0mm(0in.)

Pumping Cylinder Diameter

Concrete Valve

75.8 bar (1100 psi) 353.6 m (1160 ft.)

3295kg (7250lb s.) 4165.6 mm (164 in.)

30.5m(100ft.)


80mm (7 in.)

990.6 mm (39 in.) 89.9 mm (3.54 in.) LongRock 1295.4 mm (51 in.) 113.6L(30g

al.)

3295kg (7250lb s.) 4165.6 mm (164 in.) 1651 mm (65 in.) 1 879.6 mm (74 in.) 30.5m(100ft.)

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Specifications

MODEL CONCRETE PUMP KIT Strokes/minute (max.) Max. Output

Power (Tier3/Stage 3 A engine) Power (Tier4 engine)

SP 750-18

SP 750-15

90/50 x 1000:180

80/50 x 1000:150

120/ 80 X 1600:200

Piston side

Piston side

Piston/Rod side

Power (hyd. pumps)

Speed (hyd. pumps)

Diesel

Pressure (max. hyd.) Theoretical Concrete Output Max. Pressure on Concrete

500

35

30/24

50 yd3/hr

91 yd3/hr/118 yd3/hr

45 yd3/hr

C4.4T (Tier3) 75 Kw (100Hp)

C4.4T (Tier3) 75 Kw (100Hp)

C6.6TA-ECU (Tier3) 129.5 Kw (173 Hp)

C4.4T (Tier3) 60 Kw (80 Hp)

NA

C3.4T4F/IV

56 Kw (75 Hp)

C3.4T4i/IIIB 56 Kw (75 Hp)

2200rpm* 1800 rpm

113 Kw (150 Hp)

52 Kw

240 L/min (65 gpm) 209 L/min (54 gpm)

electric

SP

80/50 x 1000:150

35

60 Kw

Output (hyd. pumps) Req’d.

2000

70 yd3/hr

C3.4T4i/IIIB

Power (Current Electric Motor)

SP

2200rpm* 1

800 rpm

32.5 @ 2500 RPM

56 Kw (75 Hp)

122 Kw

41 Kw

430 L/min (114 gpm)

193 L/min (50 gpm)

2300rpm* 1

2200RPM*

800 rpm

300 bar (4350 psi)

266.7 b ar (3867 psi)

300b ar (4350 psi)

266b ar (3867 psi)

70 yd3/hr

50 yd3/hr

118 yd3/hr

45 yd3/hr

108 bar (1566 psi)/60 bar (870 psi)

76 bar (1100 psi)

75.8 bar (1100 psi)

75.8 bar (1100 psi)

Max. Horizontal Pumping Distance

353.6 m (1160 ft.)

353.6 m (1160 ft.)

457 m (1500 ft.)

Max. Vertical Pumping Distance

100.6 m (330 ft.)

100.6 m (330 ft.)

121 m (400 ft.)

Max. Aggregate Size

38.1 mm (1.5 in.)

3 8.1 mm (1.5 in.)

Min. Concrete Slump

0mm(0in.)

0mm(0in.)

63 mm (2.5 in.) 0mm(0in.)

353.6 m (1160 ft.) 100.6 m (330 ft.) 38.1 mm (1.5 in.)

0 mm (0 in.) 152.4

Pumping Cylinder Diameter

177.8 m m (7 in.)

152.4 mm (6 in.)

200 mm ( 8 in.)

Stroke Length

990.6 mm (39 in.)

990.6 mm (39 in.)

1600 mm (63 in.)

mm (39 in.) 79.8

Differential Cylinder Diameter

89.9 mm (3.54 in.)

79.9 mm (3.14 in.)

120 mm (4.75 in.)

mm (3.14 in.) Short

Concrete Valve

LongRock

Charging Hopper Height

1295.4 mm (51 in.)

Fuel Tank Capacity

LongRock 1295.4 mm (51 in.)

MRock 1373 mm (54 in.)

mm (6 in.) 990.6

Rock 1219.2 mm (48 in.) 75.7 L (20

113.6 L (30 gal.)

75.7 L (20 g al.)

189 L (50 gal.)

gal.)

Gross Weight

3357 kg (7400 lbs.)

2994 kg (6600 lb s.)

5724 kg 12,620 (lbs.)

2948 kg (6500 lbs.)

Length

4165.6 mm (164 in.) 4165.6 mm (164 in.)

Width

1651 mm (65 in.)

1651 mm (65 in.)

Height

1879.6 mm (74 in.)

1 879.6 mm (74 in.)

Remote Control Cable Length

30.5 m (100 ft.)

30.5 m (100 ft.)

5 816 mm (229 in.) 1930 mm (76 in.)

431 8 mm (170 in.) 1676.4 mm (66 in.)

2373 mm (93.4 in.)

1 879.6 mm (74 in.)

30.5 m (100 ft.)

30.5 m (100 ft.)

* Max RPM of the hydraulic pumps is calculated while the pump is under a full load. Depending on theunit, it is acceptable for the max RPM to vary slightly from the published estimate.


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Specifications

Hydraulic Pressure Specifications Oil should be at 40° to 50° Celsius before testing.

ConcrePtu e mp

b(aPr

SP-1250 SP-1000HP SP-1000 SP-750-18 SP-750-15 500SP SP-2000 Agitator Accumulator dump valve Accumulator secondary relief Soft switch relief Stroke limiter circuit

(47 330 85) 280 (4050) 300 (4350) 300 (4350) 266 (3 867) (3 266 867) 300 (4350) (1 125 812) 200 (2900) 220 (3200) 100 (1450) 0-25 (0-363)

Nitrogen pressure

(1450) 100

Noise emission levels 500SP 750SP 1000 SP 1250 SP 2000 SP

16

SI)

Decibels dB107 dB110 dB113 dB113 dB113

OperationManual-All

SP Rock Valve Models

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swg99a001.eps

SAFETY How to Order Additional Safety Manuals .................................................. 18 Safety Manual (Separate Document) ...........Immediately following page 20

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Safety

Safety

Schwing phone numbers

The information contained in this section of the operation manual is absolutely necessary for the safe setup, operation, maintenance, and servicing of your concrete pump and placing boom.

• • • •

Spare Parts . . . . . . . . . . . . . . . . . (888) SCHWING Spare Parts (fax) . . . . . . . . . . . . . .(651) 429 - 2112 Spare Parts (toll free fax) . . . . . . .(877) 554 - 5119 In Minnesota, or outside of continental U.S. . . . .(651) 429 - 0999

The Safety Manual is a separate document from the rest of this manual. Because it is a separate document, the page numbering and formatting will be different than the rest of your manual. This was done to allow

To order manuals, copy the order form shown on page 20, and Fax it to Schwing at one of the above numbers, or mail it to:

the Safety Manual to be inserted in many different publications while appearing exactly the same in all places. The Safety Manual has its own alphabetical index, which is found at the end of the Safety Manual.

Schwing Spare Parts Department 5900 Centerville Rd St. Paul, MN, 55127

NOTE!

How to Order Additional Safety Manuals To place an order for additional Safety Manuals (or any other manual), you can call our toll free parts line from anywhere in the continental United States except Minnesota, where you must use the main Schwing office number. Schwing Spare Parts Department hours are Monday through Friday, 6:00 AM - 6:00 PM (Central Time). Orders will also be accepted via fax, 24 hours/day. We will ship one set of each of the following manuals free of charge for each unit that is listed with its serial number and current location: Safety Manual, • English: . . . . . . . . . . . . . . . . . . . . . . . . . .30327535 • Spanish: . . . . . . . . . . . . . . . . . . . . . . . . .30381024 Co-worker Safety Rules, laminated, • English: . . . . . . . . . . . . . . . . . . . . . . . . . .30381022 • Spanish: . . . . . . . . . . . . . . . . . . . . . . . . .30381027 Co-worker Safety Rules, unlaminated, • English: . . . . . . . . . . . . . . . . . . . . . . . . . .30381023 • Spanish: . . . . . . . . . . . . . . . . . . . . . . . . .30381028 Small line Safety Manual, • English: . . . . . . . . . . . . . . . . . . . . . . . . . .30381680 • Spanish: . . . . . . . . . . . . . . . . . . . . . . . . .30381841

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Safety

August 29, 2008 Safety/Service Bulletin 1023-08 Subject: Release of Safety Manual version 6.x.1

Dear Schwing Customer, The Safety Manual has been updated to version 6.0.1 and has several changes, most of which pertain to the more common incidents currently being reported in the concrete pumping industry (hose whipping, tip overs and electrocution). One notable pagination change occurred. The pipewall thickness chart, which has always appeared on page 73 of the Safety Manual, has been pushed back to page 75. In the past, releases such as this would include the complete paperback manual and a non-laminated version of the updated Co-worker Safety Rules. In an effort to “Go Green”, we have decided to ship a CD containing six PDF files: Version 6.0.1 of Safety Manual (English & Spanish), version 6.0.1 of the Co-worker Safety Manual (English & Spanish), and version 6.0.1 of the Line Pump Safety Manual (English & Spanish). This package, as in the past, also includes an order form for hard copies of any of those documents. Just fill out the attached form(s) and fax it to us at the number listed. We will ship one set of manuals free of charge for each unit that is listed with its serial number and current location. Additional manuals are available at a nominal fee. The Co-worker Safety Rules are available as laminated books intended to be kept on the pump for easy reference. Please instruct your operators to make the co-worker information available to the placing crew and laborers, and to read the information to the workers if they believe the workers wouldn’t understand the printed text. If you are planning any safety Safety Rules training forversion your customers, theofCo-worker also available inversion, a non- the laminated at a fraction the cost. If you choose booklet to orderisthe un-laminated part numbers are 30381023 for English and 30381028 for Spanish. You could also print them yourself from the file on the enclosed disc. Of course, the non-laminated version is not intended to be kept on the pump. It is our objective to get a copy of each of these publications into the hands of every operator and the workers around the pump. Please help us make the Safety Manual effective for jobsite safety by obtaining a copy for each of your operators, and encourage them to read and understand the rules. Older versions of the manual should be discarded when the new version is in hand.

Thank you in advance for your consideration in this matter. Best Regards,

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

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Safety a

Safety Manual v 6.0.1 Order Form Please complete this form and mail to: Or send via fax to:

Fax # (651) 429 - 8261 (publications dept.)

5900 Centerville Road White Bear, Mn. 55127 Telephone (651) 429-0999 Attention: Publications

Company: Street Address: We cannot ship manuals to a P.O. box

City, State, Zip: Phone (

Attention:

)

Manual part number:____________________

Model number:


Serial number:


Model number:


Serial number:


Model number:


Serial number:


Model number:


Serial number:


Model number:


Serial number:

Safety Manual, Bound, English v 6.0.1 .................................................................................. Safety Manual, Bound, Spanish v 6.1.1 .................................................................................. Co-worker, Bound & Laminated, English v 6.0.1 .................................................................... Co-worker, Bound & Laminated, Spanish v 6.1.1 .................................................................. Line Pump, Bound, English v 6.0.1 .........................................................................................

Part #30327535 Part #30381024 Part #30352799 Part #30381027 Part #30381680

Line Pump, Bound, Spanish v 6.1.1 .......................................................................................

Part #30381841

Feel free to copy or otherwise reproduce this form if more copies are needed.

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Overview

swg99a001.eps

OVERVIEW First Commissioning ................................................................................. 22 Machine Description ................................................................................. 23 SP Circuit Diagram ................................................................................... 28 SP 2000 Circuit Diagram .......................................................................... 36 Component Locations............................................................................... 58 Safety Devices .......................................................................................... 66

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Overview

Product Overview First Commissioning

Installation of your new unit When your new Schwing was delivered, it was accompanied by several documents in addition to this operation manual. One of those important documents is called the “DELIVERY INSPECTION REPORT”. Each of the applicable 35 items listed should be checked before your new pump is sent to the first job.

Operational

Repair Required

Comments* (If repair is required)

1. Engine Coolant 2. Engine oil level 3.Transmission oil level 4. Oil level system l and ll 5. Oil level system lll 6. Transfer case or FTD oil level 7. Oil in gear compartment of Hyd. Pump 1 8. Oil level in dist. gear box (banana pumps) 9. Oil level in agitator gear box 10. Flushing oil level (gate valve system) 11. Oil level in compressor 12. Agitator greased 13. Rock valve greased (if equipped) 14. Drive line greased 15. Outriggers & boom greased 16. Manual & remote throttles set to proper RPM ( RPM) 17. Setting of relief valve system l 18. Setting of relief valve system ll 19. Setting of relief valve system lll 20. Pressure gauges work system l&ll&lll 21. Hydraulic lines checked for leakage (heat oil to 80˚ c) 22. Hydraulic oil cooler checked for leakage and proper air flow 23. Water pump 24. Agitator 25. Forward-reverse for pumpkit 26. Outriggers 27. Remote control (boom) functions 28. Manual check of all hand valves 29. Holding valves on boom 30. All boom pin retainers in place 31. End hose cable hook installed 32. Tail light and clearance 33. Safety decals (see decallights sheet) 34. Tools/Spare Parts (see tool check list) 35. Visual inspection of paint job * Please note any other comments on back of white copy

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Machine Description It is recommended that you read this section of the manual while you are near the concrete pump so that you can identify the components that are discussed.

The Schwing trailer-mounted concrete pump is mounted on a trailer chassis. The pump is hydraulically or electrically driven.

Emergency Stop switches Pressing one of the RED EMERGENCY PUSH STOP switches (Figure 3) will stop the engine.

SWG98n135.eps

Figure 3 Emergency Stop Switches (4)



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Overview Concrete pump hydraulic pumps

Concrete Pump Circuit

The hydraulic pumps for the concrete pump circuit are variable displacement piston pumps. They are horsepower controlled, which means that as pressure rises, the flow decreases, so the power consumption remains constant. We use this type of pump so the engine will not bog down under hard pumping conditions. The pumps also accept external signals for control of the output. At Schwing, we route signals to the pump from the hydraulic stroke limiter. The net effect is to tell the pump to put out less oil per revolution, as required by the pump operator (Figure 4).

The method of getting the hydraulic cylinders to change direction at the appropriate times is the subject of several paragraphs on the following pages. The hydraulic pumps that supply oil to the concrete pump kit are made to be able to adjust the amount of oil they deliver both by internal pressure sensing devices and by adjustment of external valves (the stroke limiter). This Operation Manual will deal with a rock type of concrete valve. Contact Schwing Service Department at 1 - (888) SCHWING for questions regarding flat gates. Shown in Figure 5 are the components of the concrete pump control system.

4_Pumps.t iff

Figure 4 Main Hydraulic Pump and External Connections

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5

20 6 S3 boom

16

13 9A

18

14 15

17

9B 21 10A 10B 11 S2 7 S1 4 25 3

10C

23

12

22 10D

24 8A

1

2

19

8B

hiflopmk.eps

1. Hydraulic oil reservoir 2. Main hydraulic pumps 3. Main pressure relief valve 4. Directional control valve S1 5. Rock Valve slewingcylinder 6. Directional control valve S3 7. Directional control valve S2 8A - 8B. Differential hydraulic cylinders 9A - 9B. Reversing valves (MPS) 10A - 10D. Check valves 11. Main shutoff valve (Ball cock) 12. Hydraulic return filter with bypass valve

14. Pilot to close accumulator dump valve 15. Manual accumulator dump valve 16. Acc umulator pressure maintenance check valve Acc 17. umulator relief valve 1 8. Accumulator pressure gauge Acc 19. umulator hydraulic pump Acc 20. umulator redundant relief, E-stop manifold 21. NG 10 valve for forward/reverse 22. Soft switch relief valve 23. Soft switch shutoff valve 24. Soft switch reversing valve 25. M ain flow poppet valve

13. Accumulator

Figure 5 The fully hydraulic pump control system (for hi-flo pumpkit) Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame


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Figure 6 The rock valve slewing cylinders (shown as item 5 in Figure 3)

Figure 7 “S” valve diagram explanation for S2 and S3 valves (shown as items 6 and 7 in Figure 3) The term “differential cylinder” refers to the fact that each of the hydraulic cylinders that push the concrete have an area difference (referred to as an “area differential”) between the two sides of the piston. This area differential is due to the fact that the rod extends only from one side of the piston, and not the other. The rock slewing cylinders on this model are single acting. They have no piston, other than a false piston to prevent the rod from coming out of the cylinder.

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Figure 8 Differential hydraulic cylinder diagram explanation (shown as items 8A and 8B in Figure 3) The switching valves have a logic function, in that they sense multiple pressures simultaneously and will route oil from the poppet end port to the output port ONLY if the pressure from the poppet end port exceeds the pressure at the spring end port by more than 2:1.

Figure 9 Switching valve diagram explanation



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SP Circuit Diagram

•

High pressure oil (red) flows from the main hydraulic pump (2) through the parallel position of the S2 valve (7) into the piston side of the left hand differential cylinder (8A). The cylinder extends, pushing concrete out of the material cylinder, through the rock valve, and into the pipeline. (This is called the pressure stroke.)

•

The oil that is forced out of the rod side of the right differential cylinder (8A) flows through hoses into the rod side of the right differential cylinder (item 8B). This oil is called rocking oil (orange).

•

The rocking oil forces the right side differential cylinder (8B) to retract, which creates a vacuum in the material cylinder. The right side material cylinder fills with concrete. (This is called the suction stroke.)

•

The oil from the piston side of the right differential cylinder (8B) is routed back to the tank.

•

The oil shown as blue, such as the oil in the reservoir, is at rest, or pressureless.

The following diagrams A through D show the switching functions of the fully hydraulic pump control system plumbed on PISTON SIDE with simplified schematics. The agitator circuits are not shown.

Phase A Please note that right and left refer to the orientation you would have if you were looking from the trailer hitch towards the front of the unit. •

•

As soon as you start the engine, the accumulator hydraulic pump (19) begins pumping high pressure oil (red) to charge the accumulators.(13). Shown in the beginning position in phase A schematic. High pressure oil (red) continues to flow into the accumulator circuit until the accumulators (13) are charged to the pressure cut-off point of the accumulator hydraulic pump (19). When the cut-off point is reached, the accumulator pump reduces the hydraulic oil flow until there is just enough to maintain the cut-off pressure.

•

The high pressure oil (red) from the accumulator circuit flows through the S3 directional control valve (6), which is in the parallel position, into the right-hand rock slewing cylinder port(5).

•

The rod of the rock slewing cylinder (5) fully extends to the right, if not already extended.

•

The S1 directional control valve (4), which controls whether the unit pumps in forward, neutral, or reverse, is put into the forward position by energizing one of the coils on the solenoid valve(20).

•

A pilot signal (high pressure oil) is routed from the accumulator circuit to the end cap of the S2 directional control valve (7), which moves into the parallel position.

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Overview

A Hi-Flo

Phase

5

KEY

High Pressure 6.75 mm

6.75 mm

Rocking Oil Pressure Low Pressure Soft Switch Pressure Zero Pressure (Tank, or oil at rest) Nitrogen pressure set at 100 bar (1450 PSI)

A3

B3

13

S3 XA1

XB1

11

6

Psp

2.4 mm

16

14 15

17

2.0 mm

2.4 mm

Mp T

10C X3

A

Mp1

300 bar

P

10A

10B 12

XA

B XB

9A ZS1

ZS2 1.3

1.0

9B

8A

ZK1

8B

ZK2 1.3

1.0 SP

10D

T

A

XA

1.7 mm

B

A1 1.7 mm

B1

S2

XB

PR

7

4

S1 XR

XP

P2

P1

MP T2

T1 1.2

3

310 bar

18 MX

1.4

X1

23

100 bar 1.1 mm

X3 T

22

20 bar

1.1

2

19

24

20 1



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Overview Phase B

•

Please note that right and left refer to the orientation you would have if you were looking from the trailer hitch towards the front of the unit. •

The right side differential cylinder (8B) reaches top dead center. If there is extra rocking oil in the loop that the right side differential cylinder (8A) cannot retract to the bottom dead center position, then oil is

As the rock slewing cylinder (5) retracts, pressure in the accumulator circuit falls. When it drops below the set point of the accumulator hydraulic pump cut-off pressure, the accumulator hydraulic pump (19) increases the flow of hydraulic oil to charge the accumulator circuit (13).

removed now through check valve 10D. •

The right side differential cylinder (8A) reaches bottom dead center. As the piston reaches the guide bushing, it exposes a port to the end cap of the switching valve (9A), which becomes connected to high pressure oil (red). The left end cap of the switching valve (9A) is connected to low pressure oil (orange), so the switching valve slides into the parallel position, sending high pressure oil (red) toward the end cap of the S3 valve (6).

•

The pressure signal reaches the S3 valve end cap (6), pushing the valve into the cross-over position.

•

The oil on the right end cap of the S3 valve (6) flows back to tank (1).

•

In the cross-over position, the S3 valve (6) routes oil from the accumulator to the port on the right-hand rock valve slewing cylinder (5). The cylinder begins to extend.

•

The oil from the left hand side of the rock valve slewing cylinder (5) is routed back to tank (1).

•

Shown in beginning position in phase B schematic. A pilot signal (high pressure oil) is routed from the accumulator circuit to the left side end cap of the S2 directional control valve (7). The S2 valve slides into the cross-over position.

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Phase

5

KEY

Ba Hi-Flo


6.75 mm


A3

B3

S3 XA1

XB1

11

6

13 Psp

2.4 mm

16

14 15

17

2.0 mm

2.4 mm

Mp T

10C X3

A

Mp1

300 bar

P

10A

10B 12

XA

B XB

9A ZS1

ZS2 1.3

1.0

9B

8A

ZK1

8B

ZK2 1.3

1.0 SP

10D

T

A

XA

1.7 mm

B

A1 1.7 mm

B1

S2

XB

PR

7

4

S1 XR

XP

P2

P1

MP T2

T1 1.2

3

310 bar

18 MX

1.4

X1

23

100 bar 1.1 mm

X3 T

22

20 bar

1.1

2

19

24

20 1



WPhifloB.eps

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Overview Phase C Please note that right and left refer to the orientation you would have if you were looking from the trailer hitch towards the front of the unit. •

The rock valve slewing cylinder (5) has fully extended

•

High pressure oil (red) continues to flow into the accumulator circuit until the accumulator (13) is charged to the pressure cut-off point of the accumulator hydraulic pump (19). When the cut-off point is reached, the accumulator pump reduces the hydraulic oil flow until there is just enough to maintain the cut-off pressure.

•

The S2 valve (7) has finished sliding. Oil is now routed from the main hydraulic pump (2) to the piston side of the right hand differential cylinder (8B).

•

As the right hand differential cylinder (8B) moves, rocking oil (orange) reaches the left end cap of the switching valve (9A). The valve closes by the pressure applied and the force of the return spring. This removes the pilot signal to the left side of the S3 directional control valve (6).

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•

As the right side differential cylinder (8B) extends, the concrete in the material cylinders from stage A is forced out into the delivery pipeline. (Pressure stroke.)

•

The oil from the rod side of the right side differential cylinder (8B) travels through the hoses to the rod side of the right hand differential cylinder (8A), forcing it to retract which it creates a void in the material cylinder and concrete begins to flow in to fill that void. (Suction stroke.)

•

The oil from the piston side of the left hand differential cylinder (8A) is routed through the S2 valve (7), and back to tank (1).


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C Hi-Flo

Phase

5

KEY


6.75 mm


A3

B3

13

S3 XA1

XB1

11

6

Psp

2.4 mm

16

14 15

17

2.0 mm

2.4 mm

Mp T

10C X3 A

Mp1

300 bar

P

10A

10B 12

XA

B XB

9A ZS1

ZS2 1.3

1.0

9B

8A

ZK1

8B

ZK2 1.3

1.0 SP

10D

T

A

XA

1.7 mm

B

A1 1.7 mm

B1

S2

XB

PR

7

4

S1 XR

XP

P2

P1

MP T2

T1 1.2

3

310 bar

18 MX

1.4

X1

23

100 bar 1.1 mm

X3 T

22

20 bar

1.1

2

19

24

20 1



WPhifloC.eps

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Overview Phase D

•

Please note that right and left refer to the orientation you would have if you were looking from the trailer hitch towards the front of the unit. •

The right side differential cylinder (8B) extends to top dead center. The right side differential cylinder (8A) approaches bottom dead center.

•

If there is not enough rocking oil to completely extend cylinder 8A, rocking oil will now be added through check valve 10C.

•

When the left side differential cylinder is in the top dead center position, pressure is applied to the right end cap of the switching valve (9B). The left end cap of the switching valve is connected to low pressure, so the valve slides into the parallel position. The switching valve routes the pilot signal to the right side end cap of the S3 valve (6).

•

The S3 valve (6) moves to the parallel position in response to the pilot signal. The oil in the left side end cap of the S3 valve (6) escapes to

At the same time that the rock valve cylinder is extending, a high pressure pilot signal is sent to the right end port of the S2 spool. It slides into the parallel position. When it has completed the travel, oil is routed from the main pump (2) to the rod side of the right hand differential cylinder (8A).

This brings us back to phase A. The machine has made one complete cycle, which consists of two suction strokes and two pressure strokes.

tank. •

High pressure oil (red) is routed from the accumulator circuit through the S3 valve (6) to the extend port of the rock valve slewing cylinder (5).

•

The rock valve slewing cylinder (5) extends to the right, sending the retract side oil back to tank (1) through the S3 valve (6).

•

As the rock slewing cylinder (5) extends, pressure in the accumulator circuit falls. When it drops below the set point of the accumulator hydraulic pump cut-off pressure, the accumulator hydraulic pump (19) increases the flow of hydraulic oil to charge the accumulator circuit (13).

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Phase

5

Hi-Flo

KEY High Pressure 6.75 mm

6.75 mm


A3

B3

S3 XA1

XB1

11

6

13 Psp

2.4 mm

16

14 15

17

2.0 mm

2.4 mm

Mp1

300 bar

Mp T

10C X3

P

10A

A

10B 12

XA

B XB

9A ZS1

ZS2 1.3

1.0

9B

8A

ZK1

8B

ZK2 1.0

1.3 SP

10D

T

A

XA

1.7 mm

B

A1 1.7 mm

B1

S2

XB

PR

7

4

S1 XR

XP

P2

P1

MP T2

T1 1.2

3

310 bar

18 MX

1.4

X1

23

100 bar 1.1 mm

X3 T

22

20 bar

1.1

19

2

24

20 1



WPhifloD.eps

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SP 2000 Circuit Diagram Phase A With S1 valve (1) in the forward position, and the S2 valve (2) in the left position oil flows to the right hand differential acting on the rod side. Oil from the piston side of the right hand differential oil is passed to the piston side of the left hand differential and the rod side oil of the left hand differential is directed back to tank via valves S2 and S1 and through the filter (7). Oil directed through the S3 has the rock valve shift cylinder held in the retracted (right) position so that concrete from the left hand material cylinder is being pushed into the delivery pipe line. Concrete from the hopper is being sucked into the right hand material cylinder.

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4

12.5mm

12.5mm

KEY High Pressure Rocking Oil 12

Low Pressure

18

13

Zero Pressure (Tank, or oil at rest)

3

S3

1.5 mm hole drilled through spool

S1

1 2

To Agitator

S2 10

15 14

To Fwd/Rev Handvalve 8 16

D

5 20

7 6 17



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Overview Phase B The differential cylinders have reached the end of their stroke position*. Switching valve (5) is sending a high pressure signal to the left hand end cap of S3 valve (3). Oil from the right hand end cap of the S3 valve (3) is relieved via check valve (15), the S2 valve (2), S1 valve (1), filter (7) and back to the hydraulic tank.

NOTE! If the left hand differential has not fully extended at this point due to not enough loop oil, high pressure oil will continue to flow through check valve (17) on the right hand differential until the left hand differential is fully extended.

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4

12.5mm

12.5mm


Low Pressure

18

13


3

S3


S1 1

2

To Agitator

S2 10

15 14


D

5 20

7 6 17



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Overview Phase C High pressure oil from switching valve (5) has now shifted the S3 valve (3) fully to the right hand position. At this point the pressure oil to the rock valve shift cylinder (4) is changed and the right hand side of the cylinder is getting oil so that the cylinder will extend. Oil from the left hand side of the rock valve shift cylinder is routed to tank via valves (3, 1) and filter (7).

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4

12.5mm

12.5mm


Low Pressure

18

13


3

S3


S1

1 2

To Agitator

S2 10

15 14


D

5 20

7 6 17



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Overview Phase D The rock valve shift cylinder (4) has now fully extended. At this point a signal is sent to the left hand end cap of the S2 valve (2) from a signal port on the rock valve shift cylinder (4). As the S2 valve (2) shifts to the right oil from the right hand end cap of the S2 valve (2) is routed to the hydraulic tank via check valve (13), valves (3, 1) and the filter (7).

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4

12.5mm

12.5mm


Low Pressure

18

13


3

S3


S1 1

2

To Agitator

S2 10

15 14


D

5 20

7 6 17



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Overview Phase E With the S2 valve (2) fully shifted and held in the right hand position, pressure oil is routed through the S1 valve (1) and the S2 valve (2) to the rod side of the left hand differential cylinder. Please note that while the left hand differential cylinder is starting to retract, check valve (17) must close otherwise the right hand differential cylinder will not extend.

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4

12.5mm

12.5mm


Low Pressure

18

13


3

S3


S1 1

2

To Agitator

S2 10

15 14


D

5 20

7 6 17 Note: Check Valve Must Close



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Overview Phase F Pressure oil is being routed through the S1 valve (1) and S2 valve (2) to the rod side of the left hand differential cylinder causing it to retract. Oil from the piston side of the left hand differential cylinder is passed to the piston side of the right hand differential via the loop hose. The oil on the rod side of the right hand differential is going through valves (2 and 1), filter (7) and back to the tank. Oil directed through the S3 valve has the rock valve shift cylinder held in the extended position so that concrete from the right hand material cylinder is being pushed into the delivery pipe line and concrete from the hopper is being sucked into the left hand material cylinder.

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4

12.5mm

12.5mm


Low Pressure

18

13


3

S3


S1 1

2

To Agitator

S2 10

15 14


D

5 20

7 6 17



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Overview Phase G The left hand differential cylinder has now fully retracted*. Switching valve (6) is sending a high pressure signal to the right hand end cap of the S3 valve (3). Oil from the left hand end cap of the S3 valve (3) is relieved via check valve (14), the S2 valve (2), S1 valve (1), filter (7) and back to the hydraulic tank.

NOTE! If the left hand differential cylinder h as not fully retracted at this point because of to much loop oil, high pressure oil will continue to flow thro ugh check valve (16) and b ack to the hy draulic tank until the left hand differential cylinder is fully retracted.

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4

12.5mm

12.5mm


Low Pressure

18

13


3

S3


S1 1

2

To Agitator

S2 10

15 14


D

5 20

7 6 17



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Overview Phase H High pressure oil from the switching valve (6) has not shifted the S3 valve (3) fully to the left hand position. At this point the pressure oil to the rock valve shift cylinder (4) is changed and the left hand side of the cylinder is getting oil so that the cylinder will retract. Oil from the right hand side of the rock valve shift cylinder (4) is being routed to tank via valves (3, 1) and filter (7).

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4

12.5mm

12.5mm


Low Pressure

18

13


3

S3


S1 1

2

To Agitator

S2 10

15 14


D

5 20

7 6 17



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Overview Phase I The rock valve shift cylinder (4) has now fully retracted. At this point a signal is sent to the right hand end cap of the S2 valve (2) from a signal port on the on the rock valve shift cylinder (4). As the S2 valve (2) shifts to the left oil from the right hand end cap of the S2 valve (2) is routed to the hydraulic tank via check valve (12), valves (3, 1) and filter (7).

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4

12.5mm

12.5mm


Low Pressure

18

13


3

S3


S1 1

2

To Agitator

S2 10

15 14


D

5 20

7 6 17



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Overview Phase J With the S2 valve (2) fully shifted and held in the left position, pressure oil is routed through the S1 valve (1) and the S2 valve (2) to the rod side of the right hand differential cylinder. Please note that check valve (16) must close otherwise the right hand differential cylinder will not retract.

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4

12.5mm

12.5mm


Low Pressure

18

13


3

S3


S1 1

2

To Agitator

S2 10

15 14


D

5 20

7 6 17



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Overview Phase K Refer to diagram 1 for explanation of first working stroke.

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4

12.5mm

12.5mm


Low Pressure

18

13


3

S3


S1 1

2

To Agitator

S2 10

15 14


D

5 20

7 6 17



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Component Locations The control panel (Figure 10) contains: • Emergency stop button (also known as an Estop switch). This is a standard, red-faced push button. Pushing it disables all the circuits on the unit, including the accumulator circuit, by stopping the diesel engine. The engine stops because the E-stop switch also disables the diesel engine fuel shutoff valve. The E-stop switch must be turned and pulled to reset, and

•

•

•

•

•

• •

•

58

it must be out to start the engine. The emergency stop switches on the driver side of the pump and on the remote control have identical functionality and are wired in series with the emergency stop on the control panel. Diesel glow plug lamp - Lamp will illuminate until the glow plug is warm enough to start the diesel engine. Engine oil pressure indictor lamp - This lamp illuminates only when there is no engine oil pressure, so it is normal for it to light when the key switch is on but the engine is not running. It is not normal for it to light when the engine is running; if that happens, you should stop the engine immediately. Engine coolant temperature indicator lamp This lamp illuminates whenever the engine oil becomes too hot. Hot oil is a sign of a loose, worn, or broken V-belt or of oil that is so old that the viscosity properties have broken down. Charging system lamp - This should illuminate if the key switch is in the on position, but the engine is not running. It should also illuminate if the engine is running but the V-belt breaks or the alternator stops working. Hour meter - This meter keeps track of the number of hours on the diesel engine and hydraulic pumps. Use it to keep track of hours for maintenance purposes. Engine RPM gauge - Supplies information about engine speed. Electronic throttle control switch (optional)This switch is only utilized when it has been included as an option on the unit. Pump Off switch - Controls the concrete pump on and off function.

•

Concrete pump forward - off - reverse switch When the local - off - remote switch is in the local position, then the forward - off - reverse switch is active for controlling pump forward and reverse functions. This switch does nothing when the local - off - remote switch is set to remote. • Key switch - Starts and stops the diesel engine, and supplies power to the rest of the electrical system. • Concrete pump local - off - remote switch Selects between local control concrete pump on, concrete pump off and remote control. When remote control is selected, the pump on off function is transferred to the remote control box. When you select the off position, the hydraulic pump maintains a standby pressure of 300 PSI. • Remote control cable receptacle - This is where you plug in the remote control box cable. The plug is covered with a weather proof cap which must be removed to plug in the remote cable. • Oil cooler switch - Allows the operator to activate the oil cooler when the oil begins to heat up too much. • Agitator On-Off switch - Allows the o perator to control the movement of the agitator. • Vibrator Auto-Off-Manual switch - Allows the operator to utilize the vibrator in any of the three modes available. a. When in the Auto position, the vibrator will run any time the pump is activated. b. When Off, the vibrator will not run at all. c. When the Manual position is selected the vibrator will run continuously.


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Emergency stop switch

Vibrator -Auto-Off_ -Manualswitch

Diesel Engine Engine glow plug oil pressure coolent temp. lamp lamp lamp Charging system lamp

c o n t r o lp n l. e p s

Hour meter 20

RPM

30

X 1000

40

Hobbs QUARTZ

10 0

000000

I HOURS

Engine RPM gauge Agitator On-Off_ switch

Optional electronic throttle control

Pump Off switch

Oil cooler switch Dummy Plug

Pump -Local-Off-Remoteswitch

Pump -Forward-Reverseswitch Key switch

98347087

Figure 10 Components of the Main Control panels for SP 305, 500, 750 and (top), and SP 1000, 1250, and 2000 (bottom) Emergency stop switch Vibrator -Auto-Off_ -Manualswitch

LCD Info

MURPHY

Optional electronic throttle control

Agitator On-Off_ switch

Pump Off switch

Oil cooler switch Dummy Plug Pump -Local-Off-Remoteswitch Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame

Pump -Forward-Reverseswitch Key switch

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Overview •

Your pump is designed with a soft switch system that reduces main system pressure during the shifting of the Rock Valve. In the event of a failure in the soft switch system, it is possible that your main system pumping pressure could be reduced to the continuous pressure of the soft switch system (100 bar). In an emergency, it is possible to disable the soft switch function by turning the soft switch shutoff valve 90˚ (Figure 11).

Cl o s e d

Safety relief cartridge

NOTE! The stroke limiter must be turned down to 60% or less before disabling the soft switch function to prevent damaging the hydraulic system. This procedure causes an extreme pressure spike of on the system with each stroke. Have the system repaired, and enable the soft switch as soon as possible.

O p en Soft switch relief cartridge

s p .e 6 7 2 0 0 0

Figure 11 The Soft Switch Valve found on the Brain

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Overview •

The tool components (Figure 12). There is a storage compartment on the drivers side; however, all accessories are shipped in a crate.

1

2 5

3 4

Figure Acce12ssories Supplied

The supplies accessories include the following: 1. Remote control with 30 meters of cable 2. Rock valve cover alignment bolts 3. Clean-out rake 4. Tool box complete with tools 5. Box containing parts books, operator manuals, and other literature



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Overview •

Battery Compartment (Figure 13).

Figure 13 Engine Battery •

Emergency Stop Switch (Figure 14). Pushing this switch shuts off the engine and dumps all hydraulic oil circuits to the reservoir, thereby preventing machine movement.

Figure 14 Emergency Stop Switch

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Overview Hopper Area Hopper grate interlock switch

Vibrator

Grease bar

Grease zerk Tension nut locking bolt Tension nut

Outlet pipe

SWG98n164.eps

Agitator motor

Clean-out door

Figure 15 Components of the Hopper Area •

Agitator motor (Figure 16) is a hy draulically driven motor that is directly coupled to the agitator shaft.

Figure 16 Agitator Motor



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Overview •

Rock valve grease manifold (Figure 17). From this manifold, you can grease all points on the rock valve assembly that would normally not be easily accessible to a grease gun. There are

other points on the rock valve assembly that must be greased, but they are in accessible locations.

Figure 17 Grease Manifold •

Rock valve assembly (Figure 18). Maintenance of the rock valve components are covered in detail in Section 6 of this manual. Here we will just note some of the external component names and locations.

5 2 1 3 4 1 Tension Nut Locking Bolt 2 Tension Nut 3 Outlet Pipe 4 Clean-out Cover 5 Grease Zerk

SWG98n167.eps

Figure 18 Components of the Rock Valve Area

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Overview •

Optional electric vibrator (Figure 19). This device is an electric motor that has eccentric weights attached to a shaft at each end. When the motor spins, the weights shake the unit, and whatever is attached to it (the hopper grate or hopper, in our case). The purpose of this

device is to assist low slump concrete in falling through the grate, and into the concrete cylinders. If your use of this machine includes pumping of low slump concrete, you will find this option invaluable.

Figure 19 Vibrator mounted on the hopper grate •

Hopper grate interlock safety switch. Hopper grate must be completely down to close safety switch or pump will not operate.

hoppergratelock.eps

SP hopper grate interlock switch

Figure 20 Hopper grate interlock switch SP units



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Overview

Safety Devices The following is a separate grouping of just the safety devices found on the pump. The items listed here MUST be kept in good working condition, or injury may result. Bypassing a safety device for servicing or emergency fold-up or clean-out should only be done by persons that know what systems are disabled by the bypass procedure, and must be set back to the srcinal position upon completion of the service or emergency procedure.

pressures may be “tweaked” to accomplish certain things, but they must only be done with the advice and step by step instructions of an authorized Schwing representative familiar with the system and safety devices, such as a serviceman. Under no circumstances should you raise pressures arbitrarily, or because you “think it might help”. Conversely, lowering pressure settings may cause poor machine performance, heat and its related premature component degradation, and in some extreme cases, could cause dangerous operation.

Emergency Stop Switches

Safety

In addition to the emergency stop switch on the main control panel, there is an emergency stop switch on the opposite side of the hopper and at the top side of the waterbox. If you are operating from the remote control box, you will find another emergency stop switch there. All emergency stop switches are wired in series, so they do the exact same thing. The emergency stop switch on the remote control box will not work if it is not plugged in, because the remote control box is electrically removed from the system at this time. The emergency stop switches cut off electricity to the concrete pump forward/reverse/pilot valve. In addition, they stop the electricity path to the normally open bypass valve (dump valve).

In addition to the aforementioned safety devices, there are guards placed over moving parts. Following is a list of the guards: • waterbox grate and covers • hopper grate • slewing cylinder cover

Guards

These were placed for YOUR protection. Don’t operate the machine without all safety guards in place. If they become damaged, lost, stolen or inoperable because of any other circumstances, they must be replaced before operation continues.

Fuses Fuses are devices that are intended to protect against

Shut-off Circuit Agitator Automatic The agitator hydraulic circuit runs through a separate dump valve that routes oil directly from the pump back to tank if the following safety conditions are compromised: • electricity is lost on the unit • the hopper grate is raised • the hopper grate is removed In spite of this safety device it is important to remember that it is made of machine parts which, according to Murphy’s law, will fail at the worst possible moment. Never put your hands, arms, legs or any other body part into the hopper while the hydraulic system is ready to operate.

Safety Valves (Pressure

relief valves)

complete system failure, fire, and dangerous operation. They do so by melting when the current in an electrical circuit becomes higher than it is allowed to get. Here are a couple of examples of causes of over current: • Short circuits (positive 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). In order to maintain this safety device, you simply replace a blown fuse with the correct size and type fuse, and NEVER bypass a fuse. A very good rule of thumb for fuses is this: If it blows once, replace it. If it blows again, there is something very wrong. Find the cause of the problem and repair it before activating the circuit again.

The pressures listed onare hydraulic schematics in manuals and literature not nominal figures.and They are the pressures that the machine was designed to work with, and that the components were designed to accommodate. There are a very few instances where

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Overview Warning Labels Each machine is equipped with a set of warning labels that are installed based on model and installed options. These labels will fade in time from ultraviolet radiation, rain, steam cleaning, etc. It is very important that the machine has a complete and readable set of the warning labels at all times. To address the problem of fading labels, Schwing has made the decision to supply warning labels at cost for as long as the machine is in service. To get replacement labels, identify which label(s) you need from the decal location guide shown in your parts book, get the serial number of the unit off the serial number plate and call our Spare Parts Department at 1 (888) SCHWING. The person taking the order will make a note of the serial number of the unit for our files, and send you the labels that you need. Complete sets or single labels may be ordered. If the serial number plate is missing or unreadable, the number is stamped into the subframe just below the normal location of the serial number plate



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Overview

NOTES

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Operation

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OPERATION Preparation ............................................................................................... 70 Towing theunit.......................................................................................... 74 Unit Set-Up ............................................................................................... 75 Operating the Pump.................................................................................. 76 Special Pumping Situations ...................................................................... 95

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Operation

Operation

Have the right machine for the job.

Preparation Before you pump the first job with this machine, you must know what you are doing. If you have never pumped concrete before, become familiar with this entire manual, the safety rules for pumping concrete as described in the Schwing Safety Manual (included as Section 3 of this manual), the features of the machine, and the procedures for pumping concrete. It would be a very good idea to set up the machine in a safe location and practice with the pump controls before you ever put concrete in the machine. Once you are on a job site with the machine, you will have the safety of many other people in your hands and it will be inappropriate and unsafe to make mistakes. Only experience in running the unit will give you the confidence and fine control that your coworkers expect and deserve. If you are an experienced pump operator already, read this manual cover to cover anyway, to be sure you understand the particulars of your new machine. Set up the unit for a trial run before you take it to a job. You will not regret knowing the location of the controls and devices. This manual will discuss specific setup, cleanout, maintenance, and operation techniques ONLY as they relate to this particular machine. It is not the intention of this manual to teach you how to be an expert concrete pump operator. For that, you will need the information from this manual, plus information from several other sources (listed under the heading of “Additional Reading Material” in the Appendix section of this manual, starting on page 7-40) and extensive on the job experience.

Arrive to work on time, with a clear head. A professional pump operator knows that the day will go better if you have time to do the pre-checks outlined in the following paragraphs. If you skip them because you are late for work, you are setting yourself up for at least a bad day, and perhaps an accident. Wandering around the shop in a stupor because of a hangover or lack of sleep is no better than showing up late. Either way, you will not be certain that the machine is in tip top shape and all necessary equipment and accessories are present and in good working order until it’s too late to do anything about it.

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Concrete pumps are limited in what jobs they can do. Be sure you have the appropriate pump for your particular job. Schwing’s Sales and Service Department can assist you with pump application questions.

Have the equipment that you will need for the job. Will you need extra pipe sections to make the pour? Use the following checklist for pipeline needs: • Pipe sections • Adapter pipes, if all pipe ends are not identical (see the pipe end comparison in the Appendix section of this manual, beginning on page 7-32). • End hoses • Reducers • Clamps for all pipe end styles and sizes • Clamp Pins Have all pipe and pipe accessories inspected for condition, loaded, and secured for travel before moving the unit. Keep in mind the pressure rating of your unit when you inspect the condition of pipe accessories see the chart regarding pipewall thickness versus pressure section of this manual, beginningin on the pageAppendix 7-33. You will also need normal everyday pumping accessories. Use the following list as a minimum for normal pumping requirements: • Shovel • Barrel for mixing slurry, if required. It is recommended that the barrel remain with the unit if you ever use it, even if you don’t need it for today’s job. • Pipeline lubrication mixes, enough for the day’s job. Either commercial lubricating powder or portland cement for mixing slurry. NOTE! This is not always required, in some cases slurry will be delivered to you, in other cases the portland cement will be supplied at the job site. In all cases, you must know how

•

your lubrication will be accomplished before you leave the yard. Grease gun and grease tubes


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Operation •

• •

Spray can filled with form oil (not necessary, but very helpful) Clean-out balls Water hose and nozzle Clean-out rake Working lamps for night work An approved air blow-out cap (see the Safety Manual for blow out cap requirements) 5 gallon bucket Hand tools

•

Hammer

• • • • •

Of all of the above mentioned items, the hammer is the tool that you will need the most often. It can be used for pipeline setup and removal. It can be used to tap pipe to locate blockages (follow the safety instructions found in the Safety Manual portion of this Operation Manual for this procedure). It makes a good persuasion device for rusted nuts and bolts, and for knocking out concrete that has set up in clamps and hoppers. Many pumpers take the head off of the wooden handle and have it installed on a steel pipe. This makes it perfect for pipeline installation, because the handle can be used to pry clamp handles up or down. Experienced pump operators never walk from the pump to the pipeline without a hammer. A four or five pound sledge works best. Last, but not least, you will need the things required by law for operation of a motor vehicle, things related to safety of the motor vehicle, and paperwork needed for the job, such as: • Valid driver’s license • Fuel permit • Cab card • Registration • Insurance card • First aid kit • Flares • Reflector signs • Fire extinguisher • Job ticket • Map(s) • Job site phone number and contact person



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Operation Have the right personal protective equipment for the job. •

•

•

Concrete is made from lime, which is very alkaline. If it stays on your skin long enough, it will cause severe burns, and in extreme cases the affected skin will simply fall off. Because of this, always wear water resistant work boots and gloves, and if you will be working IN the concrete, wear water PROOF gloves and boots. In either case, the boots should have steel toes. There are boots made especially for concrete work that will protect your feet from lime and accidental impact (Figure 21). Falling objects on a job site are not uncommon. Hard hats were made to protect you from this hazard, but they only work if you wear them.

• •

•

•

Safety goggles may very well keep you from getting splashed concrete in your eyes. Snug fitting work clothes will help prevent accidents involving moving parts. Concrete pumps may generate higher sound pressure levels than O.S.H.A. allows for constant exposure. You can protect yourself by wearing hearing protection when on or near the machine. When mixing your grout in the morning, or anytime that there will be airborne cement or other fine powder nearby, wear breathing protection. Anytime that there is danger of ricocheted rocks or sand (when shotcreting, for example), wear a full face shield.

HARD HAT SAFETY GOGGLES

HEARING PROTECTION

BREATHING MASK SAFETY VEST

SNUG FITTING CLOTHES

GLOVES

STEEL TOED SHOES SafegearWvest.eps

Figure 21 Wear personal protective equipment

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Operation Check the equipment before leaving the yard. Check the following items each day before the pump is taken from the yard. It is easier to remedy a problem in the yard then at a work site.

On The Towing Truck • • •

Truck engine oil level and condition. Antifreeze / co olant level in the radiator. Battery fluid level and condition.

• •

Tire condition and proper air pressure. Brake system air pressure and condition (bleed water from air tanks). Clean the windows of ice, frost, mud, etc. Clean the mirrors of ice, frost and mud, and properly align for clear vision. Keep the cab free of debris, especially on the floor. Accidents can happen when foreign objects get stuck between the clutch or brake pedal and the fire wall.

• • •

•

On The Pump • • • • • • • • • • •

Check diesel fuel level in all tanks. Verify diesel engine oil level. Radiator coolant level should be full. Check that battery and battery cable connections are clean and tight. Check condition of belts and hoses. Replace as necessary. Verify all safety guards are in place. Grease Agitator bearings. Grease Rock Valve lubrication points. Clean any dirt or debris from engine air intake. Check condition of tires and air pressure. Structural integrity of the unit. Give the unit a visual inspection. Look for cracks, chipped paint, rust (especially rust under the paint), and missing parts. Clean and repaint areas that have chipped paint to avoid damage to structural steel. Replace missing parts before using the unit. Report any structural abnormalities to the Schwing Engineering Department before using the unit. If the engineers determine that repair is necessary for safe operation, DO NOT OPERATE THE UNIT UNTIL REPAIRS ARE COMPLETED.


•

•

•

Pipeline must be complete and free of dents, cracks and holes. Pipe must have sufficient wall thickness to handle the maximum pressure of the pump. (Inspect weekly with an ultrasonic thickness tester. See Maintenance section of this manual, beginning on page 6-10.) All safety guards must be in place and secure for travel. Hydraulic oil level and condition. The oil should be clear and clean looking. ‘Milky’ looking oil, or oil with a lot of air bubbles entrained is oil that needs replacement before the next job begins. (NOTE! Oil that is holding air bubbles overnight should be replaced, but it is not an oil problem if it is becoming bubbly on the job. In that cases, it will be a problem with the integrity of the hydraulic seals somewhere in the system.) Top up oil levels ONLY with the same type of oil that is in the reservoir. Do not mix name brands, even if they have the same viscosity. Each oil manufacturer uses different additive packages to accomplish anti-foaming, silt settling, anti-wear, etc. The mixing of these different chemical additive packages may render them useless. Drain water from the hydraulic reservoir each morning. This is done by removing the pipe plug and opening the drain valve located under the hydraulic reservoir, and allowing the fluid to run into a pan until it changes from water to oil. (Water is heavier than oil, so it sits on the bottom of the tank, and therefore drains out first.) Visually check the unit for hydraulic leaks, and repair any leaks before operating the machine. Lost hydraulic oil harms the environment, and it is expensive to clean up and replace the lost oil. Be sure that everything on the unit is ready for road travel. This includes securing all accessories and miscellaneous equipment.


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Operation

Towing the unit

Changing lanes.

Many accidents involving concrete pumps are traffic accidents. To avoid accidents, you must remember this one point...you are not driving a c ar. You know those yellow caution signs posted on the roads? The ones that say 50 M.P.H. under the symbol for a curve in the road? Those signs are meant for you, when you are towing a pump. Most people ignore those signs when they are in their car, because the car they drive feels safe going around that curve at 60 M.P.H. When towing

When towing a pump, you will have blind spots to your right and left sides. Unfortunately, many drivers are unaware of these spots, and will travel in them for extended time periods. These spots are avoidable with the use of convex mirrors, which attach on or below the rear view mirrors. Before changing lanes, check these convex mirrors for other drivers who may be ‘hiding’ there. Signaling well in advance will warn other drivers of your intentions.

a trailer-mounted concrete pump, this is NOT the case. All caution signs will apply to you when you are towing a pump. Slippery when wet, bridge out ahead, and all the rest. Trailer-mounted concrete pumps are heavy, which results in longer stopping distances. They are top heavy, which can lead to rollovers at speeds that would be no problem for a car. You can’t see directly behind you, so backing up becomes dangerous, etc. You know the rules of the road for trucks, or you wouldn’t have passed the commercial driver’s license exam. This section of the manual deals with the specifics that they can’t include in the driver’s manual...the way a trailer-mounted concrete pump acts under various driving conditions.

Loading the unit for shipment.

Licensing.

If the unit will be transported (such as by railroad or ship), care must be taken to see that people and property are protected during the loading process. In these cases, remember the following points:

For Ramp Loading •

• •

If you don’t have a valid commercial driver’s license, DO NOT TOW THIS UNIT.

•

Backing up. You will be able to see the road behind you on the left and right sides, but YOU WILL NOT BE ABLE TO SEE DIRECTLY BEHIND YOU. If you must back up, and there is any chance at all that there may be traffic or pedestrians behind you, you must use a guide. A guide is a person that watches for traffic, pedestrians, and other obstructions, and stands in such a position that you can see him (her) giving you instructions. Installing a back up warning device such as a horn or bell will give you some measure of safety, but you can’t rely on it. For example, a child walking behind your unit when you begin to back up may become frightened by the back up warning sound and freeze where they stand. If you are in an isolated area where there will not be traffic or pedestrians, you can get out of the cab and look for obstructions before beginning to back up.

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Use only ramps that provide adequate and stable support for loading purposes. Ensure that no one would be hurt if the unit were to tip or slip off of the ramps. Be sure that the ramps will not cause the unit to pivot beyond the ability of the hitch. If you are using guides to provide instructions, they must not remain in the driving zone. Secure the machine on or the transport against rolling, slipping tipping over.vehicle

For Crane Or Forklift Loading/unloading •

If lifting the unit with a forklift, be sure that the forks do not damage any components that sit below the bottom of the subframe.

NOTE! Do not attem pt to lift the unit with a forklift unless the unit is equipped with fork channels. •

•

Concrete pumps may only be moved by crane if they have been equipped with slinging rings that were designed for that purpose. Slinging rings that were designed for this purpose can be ordered from Schwing for installation on new units, or for field retrofits. Never hook lifting devices to standard pump parts, like the concrete valve, hopper, or anything else. These parts were definitely NOT designed to support the entire unit load.


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•

•

Check the load bearing capacity of any slings, cables or other lifting devices that will be used to lift the machine. Never exceed the rated working capacity of the lifting device. No one is allowed to walk, stand, or work under suspended loads. Keep the area free of personnel.

Unit Set-Up Selecting job site. the proper set up location on the Sometimes, the person in charge of the pour will have a spot ready for you. If he is experienced, he will pick an appropriate spot that will allow a safe and efficient pour. Other times, the person in charge will only tell you what is to be poured, and it will be up to you to select the set-up location. In still other cases, the person in charge will have picked a totally inappropriate spot for you. In these cases, your ability to be an effective diplomat may dictate how the day is going to go for you. If it is not already so, you will have to make the location safe and efficient on your own. In all cases, the set-up point MUST allow at least one ready-mix truck to get safely to and from your hopper and if you are pumping in an area where exhaust fumes may linger or be confined, proper ventilation must be assured. In addition to the above mentioned requirements, it is desirable that the set-up point also have these features: • Able to handle the safe arrival and departure of 2 or more ready-mix trucks. This means obeying the 1 to 1 rule by staying at least one foot back from excavations or cliffs for every one foot of distance to the base edge. • Out of the way of major traffic flow patterns for the job site. If no one can move on the site because of your setup position, you will have to move anyway...you might as well plan for it at the start. • If your unit has hydraulic stabilizers, jack them down only until they feel the weight of the unit. Always leave the tires in contact with the • •

Laying out the pipeline We will not cover the do’s and don’ts of pipeline layout in this manual. If you don’t know how to correctly lay out a pipeline, read and understand the chapters on concrete pipeline in one of the books about pumping concrete. Several of these books are listed under the heading “Additional Reading Material”, found on page 7-42 in the Appendix section of this manual. We will, however, cover of few specific points that are common to pumping jobs in North America. Start at the point of discharge and work your way back to the pump. In the majority of cases, you will need rubber hose at the point of discharge, and usually the placing crew will prefer 3" or 4" rubber hose to 5". This means that you will need a reducer at the discharge end. If you will have to reduce to smaller diameter pipe or hose for the placing crew, always make the long part of the run with the larger diameter, and reduce as close as possible to the point of discharge. There is one instance where it may be desirable to run the entire distance with the smaller size, and that is if you will be pumping very, very slowly on a hot day. In that case, the concrete may start to set before it reaches the point of discharge, and it will resist the change of size that is required inside of a reducer. If you suspect that you may have a job like this booked, call the Schwing Service Department for advice before you set up the job. Use as few hoses as possible. Hoses have more resistance to flow than pipe does, therefore it will take higher pressure to push through hoses than pipe. Use the largest diameter hose that the crew will let you use. The diameter of the hose directly affects the largest size stone that you will be able to pump. If you will be pumping stone larger than 1", you will not be able to use 3" or smaller hose. To attempt to do so will result in blockages. Do not use hose for changing pipeline direction. Pipe elbows are available with many different degrees of bend, and they will require less pumping pressure than hose.

ground. The area to be utilized must be as level as possible. If the workplace has inadequate lighting, don’t begin the pour until proper lighting is provided

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Operation Setting the Stabilizers •

•

•

Position the dunnage pads (use scrap plywood, 2x4’s, etc.) on the ground where the stabilizer will be positioned after extension. Drop each stabilizer to its pad and insert the locking pin. Jack the front of the unit using the tongue jack until the weight of the unit is on both stabilizers.

If the unit has hydraulic stabilizers, you must be sure the faucet valves (Figure 22) are open to supply hydraulic fluid to the system and activate the stabilizer hand valves to the extend position until the unit is supported properly. Generally, that means each stabilizer must begin to feel the weight of the unit. Then close the valves.

NOTE! W d anhen d leuvnit el is thestabilize wheels should remain in contact with the ground to lessen any possible movement of the machine while pumping

Figure 22 Optional hydraulic outrigger controls shown here on the SP 500

Outrigger activation handles

50 0H ydO utr igg er.e ps

Operating the Pump •

Connect remote panel. control cable or dummy plug into the the control

NOTE! The pump will not function without one of these plugged in. • • • •

Turn the Pump Switches to the OFF position. Place Pump shift lever into the NEUTRAL position. Make sure all Emergency Switches are in the RUN positions. If using the optional radio (cordless) remote, Engine won't start unless radio remote and receiver are linked. Turn the radio on by using the following sequence: 1. Turn the ignition key to the ON position which supplies power to the receiver. 2. Engage the E-stop on the radio remote. 3. Press power button on radio remote, light will flash. 4. Disengage E-stop on radio remote, light will be solid.

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Outrigger faucet valves

•

Wait 10 seconds before turning ignition key to engage the starter.

•

For cold weather starts use the following procedure: a. Move the throttle lever to the low idle position before you start the engine.

NOTE! If necessary, increase the throttle slightly so the en gine will start in cold con ditions. The engine should not exceed 1500 RPM until the oil pressure has increased. b. Turn the engine start switch two clicks, which should illuminate the glow plug lamp, and hold in that position for at least 6 seconds. This will activate the glow plug and aid in the starting of the engine.

NOTE! Do not operate the glow plugs for more than at aurtime. 30lugsecon s occ Damage to the glow s coudld . p

c. After 6 to 10 seconds, turn the engine start switch to the START position and crank the engine.


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Operation d. Release key when engine starts. e. Slowly return the throttle to idle

NOTE! If the glow plug indicator light flashes rapidly for two to three secon ds, or if the light f ails to illuminate, a m alfunction exists in the cold st art system. Do not use ether or other starting fluids to start the engine. f. If the engine does not start, release the key and allow the electric starter motor to cool, then repeat steps b through e. g. Turn the engine start switch to the off position in order to stop the engine.

NOTE! Most of our pumps have Turbo-Charged Diesel engines. To avoid damage to the turbo when starting, do not run the engine to high speed immediately from a cold start.

Bearing damage will result due to insufficient lube oil supply. Let the engine warm up for at least 30 seconds before going to full speed. Failure can also occur when shutting down the engine under full load. The oil in the supply tube can burn and plug the line. Let the en gine idle for 2 minutes before shutdown. •

Set throttle to 1800 RPM’s. (2500 RPM Maximum)

CAUTION

On the SP1000, 1250 and 2000 units, if

OIL PRESSURE, ALTERNATOR CURRENT, or COOLANT LEVEL is not what it should be when the engine is started, you will be notified by a fault warning in the LCD window (Figure 23). To correct a fault shown in the window, See the HMI User’s Guide included with other documentation. Do not operate until situation is corrected.

Figure 23 HMI display

hmidisplay.eps

Basic Troubleshooting

•

Engine won’t start: •

• • •

Radio remote transmitter is not linked with the receiver. Activate the remote by following the sequence shown under Operating the Pump above. No fuel. Emergency stop switch in OFF position. Dead battery.

Engine running but pump won’t operate: •

Turn stroke limiter knob out fully.

•

Verify switch hopperis grate is completely down and safety activated. Check fuse for pump circuit.

•

Engine quit running: •

Check fuse for fuel shut-off / E-stop switch circuit (See schematic).

Agitator won’t operate: •

Check fuse for agitator bypass circuit (See schematic).

Hourmeter not operating: •

Check hourmeter fuse inside (See schematic).

Dead Battery •

Possible problem with the alternator indicator light connection on the control panel.

•

When the key switch is turned clockwise one click, the indicator light for the alternator (found on control panel) will illuminate and will not go out until the engine starts.

Check diesel fuel level.



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Operation •

•

•

•

If the light does not come on when the key is turned one click clockwise, the engine may not charge the battery. The first step should to be to check the LED. If it is bad, be sure to replace it. The second step would be to check the connection and receptacle internally and externally. Look for green evidence of corrosion. Remember that the only time the LED is illuminated is when engine is off with the key switch on. If the light does not go out after the engine starts the alternator has a fault. If corrosion exists, the receptacle should be replaced. When the circuit is not able to be completed properly as a result of corrosion the alternator is not receiving a signal and the engine may not charge the battery when started. If an oversized light bulb is used during replacement, the alternator may overcharge the battery causing premature battery failure.

Before the first truck backs up to your hopper If you have completed setup before the first ready mix truck is due to arrive on the job (a highly recommended practice), this is a good time to get some things ready for the day. • Find out who will be giving you signals throughout the day. There must be only one person that gives you signals, so as to avoid conflicts in instructions. Talk to the person about the signals that you will use, and come to an agreement before you start pumping. The American Concrete Pumping Association has standardized hand signals for concrete pumping that are shown on decals on the unit. This decal is also shown in the Appendix section of the Safety Manual, which is included as one chapter of this Operation Manual. In many cases, the job site management will give you a walkie-talkie that is on their own frequency so that you may speak directly to your signal man. Be aware that in some cases, this walkie-talkie may cause interference with the Schwing radio remote control system. Check it out before the pour begins.

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•

•

•

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Talk to the foreman of the placing crew. Be sure that the crew is aware of the safety rules for the placing crew as described in the Safety Manual. If they are not familiar with the rules, show them the rules that apply to them from the quick index that was supplied with your unit. Make sure they understand about not kinking the tip hose. Go over the safety rules with any oilers or laborers that have been assigned to work with you at the pump. Show them the emergency stop switches. If they will be backing readymix trucks to your hopper, explain about the danger of putting themselves between the pump and the ready-mix truck. Position your remote box and cable in a place that you won’t trip over the cable, but you will be able to move around at will once the pour begins. It is critical to be able to see the point of discharge once the pour begins. If this is not possible, arrange for a spotter NOW. Get your breathing mask ready for mixing the slurry. Have all of your personal protective devices on or nearby. Fill your waterbox with water, if it is not already full (Figure 24).

NOTE! MUST BE SHUT OFF ANYTIME THE PUMP YOU COVER OR REMOVE THE WATERBOX GRATE. Secure the controls so th at no one

can turn it on without your knowledge.

Figure 24 Be sure the waterbox is full of water


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Put a couple of shovelfuls of sand or dirt in the bottom of the rock valve housing, above the clean-out door. This will prevent concrete from filling the door area and setting during the course of the day. (Figure 25). Be sure the clean-out door is closed tightly and locked by tapping on the end of the “T” handle with your hammer (Figure 26).

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If you will be using portland cement and water to make your lubricating slurry, prepare for it now (Figure 27). Position your barrel, shovel, and sack of portland cement on the ground behind your hopper. Fill your barrel with about 25 or 30 gallons of water. (Of course, this step can be skipped if slurry is to be delivered to you from the ready mix company, or if you are using powdered slurry mix.) Get your clean-out rake in a p osition that you will not trip on it, but you will be able to grab it when you begin clean-out. Many times, cleaning the pump is done when you are in a hurry, because concrete is setting, that is no time to have to look for the rake or, worse yet, to use your hands to pull loose material out of the pump because you don’t have time to look for it.

NOTE! NEVER use your hands for a clean-out rake.

WARNING Figure 25 Put a couple of shovelfuls of sand in the bottom of the hopper, over the clean-out door.

Amputation hazard. Stop pump before cleaning the Rock Valve and hopper.

s p .e 5 1 0 0 0 0

closedoor.eps

Figure 26 Tapping on “T” handle to lock the clean out door

Figure 27 Spray 25 to 30 gallons of water

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Operation because where the grease comes out concrete will be able to go in. Once concrete makes it inside of the grease cone, you will quickly wear out the bearings. When re-greasing after the hopper is full of concrete and you can no longer see the cones, just give the zerks a couple of squirts. This is one of the few times when it is better to under grease than to over grease.

Grease your agitator bearings (Figure 28). There is one zerk on each side of the hopper. Re-grease every two or three hours, as the pour allows.

NOTE! You don’t grease agitator be arings like you grease most other bearings. That is, if you normally pump in grease until you see it squirting out somewhere, you will ruin your agitator seals. When you grease the agitator bearings, watch the rubber grease cones that are located inside the hopper. You want the cones to bulge out slightly because they are full of grease, but you don’t want to have the grease come out around the shaft,

Grease the rock valve lubrication points before the pour begins (Figure 28). Once started, grease them every couple of hours. There are 4 zerks to grease for the rock valve, plus the two for the agitator.

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Figure 28 Showing the location of the grea se points

You can keep your hopper and splash guard looking better, and help yourself at clean-out time by spraying them with form oil before the pour begins. This oil is specifically formulated to prevent concrete from sticking to forms, and it works just as well at preventing concrete from sticking to your unit. It doesn’t hurt to spray it on the other areas that are likely to get splashed by concrete, either.

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Operation Lubricate your pipeline. Once the ready mix truck(s) arrive on the job, you can lubricate your pipeline. Schwing highly recommends that you pre-lubricate the separately laid pipeline each time you must pump into dry pipe. In some parts of the United States and Canada, the concrete is so rich with cement fines that operators do not pre-lubricate to begin pumping operations. This practice is NOT recommended. The amount of time saved by not pre-lubricating cannot begin to make up for the hassle of having to remove pipe sections from a separately laid pipeline. Most importantly, the blockages caused by failure to lubricate can be dangerous (see the section on blockages in the Safety Manual section of this Operation Manual). There are commercially available products that will lubricate a pipeline with much less volume (meaning much less weight) than portland cement and water. These products usually come in sandwich sized plastic bags, and lubricate about 100 feet of 5" pipe per bag. Instructions for mixing vary by the different manufacturers. These products are less expensive than portland cement, and do not set like cement. If you use these products, pay close attention to the instructions and warnings on the package. If you only have portland cement for lubricating your pipeline, you will have to wrestle with the weight. Choose one ofBefore the methods shown below, based on job situation. you begin to mix the slurry, putthe on your breathing mask and the rest of your personal protection equipment. If you have help in the form of a laborer assigned to work at the pump, or an oiler or other handy guy, you can mix the best slurry in a barrel. By mixing it on the ground in a barrel, you can get good consistency and break up clumps of cement that tend to form, not unlike lumps in mashed potatoes. However, this method has the disadvantage of having to lift the barrel and pour the slurry into the hopper, which is why you will need help. To use this method, lay a sack of portland on top of the barrel which has been filled with about 25 gallons of water. Take a shovel and break open the sack with the blade, allowing the cement to fall into the barrel. When the bag is empty, set it off to the side and

cylinders, but for now, don’t worry about it. Make one barrel of mix for each 100 feet of laid pipeline that the concrete will see, but if you will be going through more than 200 feet of pipe, you, your boss, or the concrete superintendent on the job site should have arranged to have a grout mixture brought to you by the ready mix plant. Unless you have at least a half a yard of slurry delivered to the pump, do not try to pump this mix yet. Using the barrel method, you can add a little sand, if needed, to stretch the amount of slurry mixed. This would be helpful if you have to pump through 300 feet of line, but only have 2 sacks of cement available. If you are alone at the pump, you will not be able to lift the barrel to pour the slurry into the hopper (it will weigh 250 to 300 pounds...not many people would be able to lift it alone). In this case, lay the sack of cement on the hopper grate, and break it open.

NOTE! Do not stand on the ho pper grate for this, or any other, procedure. The “NO POINT RULE” applies to the hopper grate. Get a water hose and direct the spray into the hopper, aiming at the edge of the pile of cement. This will wash the cement into the bottom of the valve housing, mixing as you go. Try to break up clumps of cement with the spray, but do not put your hands or any other body part into the hopper. Mix more slurry as needed for the length of the pipeline, as described above. When the cement has all been washed to the bottom, you can cycle the rock valve back and forth a few times to agitate the mix a little more. Do not try to pump this mix until you can back it up with concrete immediately.

NOTE! When initially starting the pump, or when restarting for any reason, personnel should stay a reasonable and prudent distance beyond the reach of the discharge hose until the concrete runs steadily and the line is free of compressed air. Air will be in the line when first starting, restarting, or after the line has been taken apart or opened for any reason. Compressed air can cause the hose to whip violently. For more detailed information see the Safety Manual.

mix any the cement water with blade. Break up cementand clumps that the areshovel encountered and continue mixing until the mixture is smooth and creamy. Get your helper and pour the mixture into the hopper. It will not cover the openings to the material Startup 250:Users:Danny:Desktop:Operationmanuals:line pumps:All SP Rock Valve models:Frame files:operation.fm


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Figure 29 Mixing the slurry in a barrel

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After the correct amount of slurry has been placed in the hopper, back up the first ready mix truck to your hopper.

NOTE! DO NOT stand between the ready mix truck and the pump. If the driver’s foot would slip off of the clutch while he was backing, you could be crushed between the two m achines. Look at the concrete before putting it into your hopper. If the mixing fins of the truck are badly worn, the mix will not be homogenous (that is, the rock, sand, cement and water will not be properly mixed). Do not allow a chute full of grey colored rocks to be put into your hopper...it is almost a certainty that you will plug the line before you get concrete out of the pipe. If this is the case, have the driver dump the first chute off to the side, and then display the next chuteful. In most cases, the mix will look a lot better after the first chuteful is dumped. If not, dump the next chute to the side also. You will learn by experience what mixes can and can’t be pumped and how the two look. Once the mix looks good, turn on the pump in the ‘forward’ mode, and have the driver fill the hopper. Pump slowly and watch the concrete pump circuit pressure gauge until the slurry starts to escape from the pipe and/or hose. If the pressure approaches the relief valve setting of 300 bar, immediately switch the pump to ‘reverse’ mode, and notify the ready mix driver to stop dumping. Give the unit one or 2 strokes in reverse, then go back to ‘forward’. If the concrete continues to slide without high pressure, then you’re OK. If pressure again rises towards the relief setting, repeat the reverse cycle. In many cases you can prevent a blockage by “rocking” it back and forth. In fewer cases, the plug will not cooperate and you will need to find the source of the blockage and remove it manually. Startup 250:Users:Danny:Desktop:Operationmanuals:line pumps:All SP Rock Valve models:Frame files:operation.fm

NOTE! You must not open a blocked pipeline without first sucking the concrete back into the hopper! the act of putting the pump into reverse for several strokes will release the pressure on the blockage. Cover the hopper before reversing pump and understand the safety rules for opening a blocked pipe as shown in the Safety Manual section of this Operation Manual. With an accumulator, speed control is available as soon as the engine is started. You do not have to wait for a steady hydraulic pressure in the concrete pump circuit before you can use the stroke limiter to change the strokes per minute of the pump. Once concrete has emerged the point discharge, stop pumping. If youfrom are pumping into ofa pipeline, wait for the start signal before you begin to pour.

To control the speed of the unit There are two ways to control the speed on this unit: by the stroke limiter by the engine throttle. The stroke limiter is a hydraulic device that can be adjusted at the operator’s panel. Its function is to raise and lower the output of the hydraulic pumps that operate only the concrete pump. This has the advantage of allowing the engine to remain at higher RPM, where horsepower is at the maximum. With an accumulator, there is pressure in the system as soon as the engine is started, and therefore you can use the stroke limiter immediately to control the speed. Basically, it will work whenever there is 50 bar or more showing on the concrete pump circuit pressure gauge. It has an adjustment range of 100%. That is, it can go from zero strokes per minute to maximum strokes per minute. Beware...because it can go to zero strokes per minute,


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Operation it is possible to stop pumping altogether by adjusting this valve. That means that when the differential cylinders are stopped at the end of the stroke and the rock valve is moving, the pumps return to maximum output until the rock valve cylinder has completed its

travel. This interruption of the stroke limiter signal is known as ‘fast switch’. It is recommended that all output control be done by the stroke limiter and not the engine throttle (Figure 30).

Less strokes

More strokes volumeknob.eps

Volume control knob (stroke limiter)

Figure 30 Showing adjustment of the manual stroke limiter To control the speed of the unit by the engine throttle, simply speed up or slow down the engine. This has the effect of turning the hydraulic pumps slower, which results in less hydraulic fluid output. This method of

expulsion of concrete on the next stroke as the now compressed air escapes. This could be dangerous, so be sure that the ready mix driver understands the situation. If you have taken air in to the material cylinders, you

speed control is primarily used when you want to limit ALL of the hydraulic circuits...agitator, concrete pump, etc. It has the disadvantage of lowering the horsepower output of the engine. It is possible to kill the engine with the hydraulics of the unit, if you lower the RPM too much.

can cushion the expulsion by stopping the concrete pump and filling the hopper with concrete before the next stroke. The mass of the concrete will prevent the compressed air from pushing anything out of the hopper. Once the hopper is full, it is safe to resume pumping. Even with the hopper full of concrete, some compressed air will be introduced into the delivery pipeline. When it reaches the discharge point, the air will cause a sudden expulsion of concrete. If the hose person is walking a wall or column, or is otherwise in a precarious position when this expulsion happens, it could cause an accident. Best is to avoid ever sucking air into the material cylinders, but if it does happen, YOU MUST WARN THE HOSE PERSON.

Try to match your pumping speed to the needs of the placement crew and with the supply of concrete. It doesn’t do any good to bury the crew with concrete, then wait for half an hour for the next truckload of concrete to arrive.

Pump the job If you are not able to see the point of discharge from where you must operate the unit, be sure your spotter is in position before starting the pump. Oncealert youthe getready the start the pump in forward, and mixsignal, driver put to start dumping. Concrete must always cover the openings of the material cylinders or you will suck air into the material cylinders. If this happens, there will be a sudden

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NOTE! Keep an eye on the oil tem perature during the pour. If it gets over 80˚ C (176˚ F) you must be sure the oil cooler fan is running. If that isn’t enough to keep the oil below 80˚, refill the waterbox with fresh water and run water over the oil tank to help with cooling. If th at doesn’t work, shut the pump down and find the source of the overheating.


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Operation Point out the emergency stop switches to the driver if you will be standing somewhere other than at the operator’s panel. That way, the driver could warn you or stop the machine if he sees a dangerous situation develop. Always keep an eye on the point of discharge, or your spotter. If the hose man is giving you signals, he will have his hands full and will not be able to jump up and

down or wave his hands to get your attention. On a typical job site, it is doubtful that you could hear him yelling. As the day progresses and the crew removes pipe sections from the end of the slickline, wash the pipes, clamps and gaskets with water (Figure 31). If you don’t wash them until the pour is finished, you will not be able to get the hardened concrete out of them. This job can be done between loads of concrete, or by an oiler or laborer at almost any time.

Figure 31 Wash slickline as pour it is removed from the

Time Constraints Remember, if anything goes wrong on the unit while it is pumping, you only have 15 to 30 minutes to solve it before the concrete sets (less with old concrete on a hot day, more with fresh concrete on a cool, cloudy day). If you know that it will take longer than that to fix, clean out before you begin repairs. If concrete is beginning to set, you will have to clean out in a very quick and efficient manner. There are special instructions for quick clean-out, which you will find in this section (Section 5), starting on page 96. If you keep your head and keep moving, you can usually avoid the dreaded “pipe party”, even with unfavorable pumping circumstances. Old concrete and hot days make up the worst case scenario. Under certain hot weather and old concrete circumstances, the concrete may go from being pumpable to setting very, very quickly. This is


called “flashing”, and if it happens to you, you may lose some pipe. See also the section on delays described in Item on page 86. If you are pumping in very cold conditions (below +10° F.) the concrete could freeze. In this case, the machine will act like the concrete has set, but all is not lost. As long as the concrete is frozen, it cannot continue to set. If this happens to you, you are done pumping for the day. You will not be able to clean out at the job, unless they have a heated area where you could move the pump for clean-out. If not, inform site management and your company, load the pipe and hose, gather up your things and find a heated area for clean-out. Further information can be found in the chapter entitled, “Cold weather pumping” beginning on page 96.


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Operation To disable the entire unit in an emergency If an emergency arises that requires that the hydraulic system be disabled completely, for example if a hose or fitting broke, you must stop the engine. If you are faced with this, do not hesitate or investigate first. Shut off the engine, then investigate. It is recommended that a long length hose of each of the possible 4 diameters be kept with the unit for such emergencies. See page 4 of the Appendix (Section 7), for a list of the 4 hose diameters, and the recommended length of each for emergency use. If you lose electricity on the unit for any reason, the dump valve will open. This will route oil from the hydraulic pump directly back to the tank. This is also what happens when any emergency stop button is pushed. To continue pumping, you will have to find out what happened and fix it. If you cannot find out what has happened within 10 minutes or so, you will have to take action to prevent the concrete from setting up or freezing. For information on where to look and what to do if you lose electricity on the unit, contact the Schwing Service Department at (651) 429-0999.

Delays There will be delays. Sometimes you will have to wait for concrete, sometimes the workers will be scrambling to finish the next form to be pumped, sometimes a form will through nocan fault of your or this halfidle a dozen otherfail reasons. You make goodown, use of time by washing pipe, clamps and gaskets that have been removed from the delivery system, washing splashed concrete from your hopper area, eating lunch or whatever. The important thing to remember is that concrete begins to set as soon as it becomes motionless. Every 5 minutes or so, give the pump a stroke, which will make the concrete in the elbows and reducers change their shape, thus breaking the set. If you have to wait more than one or two 5 minute periods, you will have to continue differently for different situations. In either case, remember this: Concrete setting in the pipe acts like a blockage. Blockages can be dangerous, because the pump will create maximum pressure on the concrete. If you are waiting for concrete to arrive, Do not let the alfhopper the hopp become lesswater thantohthe full. If concrete is er getting stiff, add while you are waiting. A word of warning regarding this procedure...The concrete will eventually set up anyway. If you have to wait so long that the concrete is

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setting, it would be better to clean out and start over when the fresh concrete has arrived. This has the added advantage of making Murphy’s Law work for you...as soon as you begin to clean out, the concrete will arrive. If you are waiting for a form to be finished or repaired, or anytime that the delay has nothing to do with waiting for concrete, you can give the pump one or two strokes in 5 minute intervals for a longer time, because the ready mix truck will be able to refill your hopper. Be careful about where the concrete is going when you are giving the machine these one or two stroke cycles. If the form is broken, you will be complicating matters by putting more concrete in there. Eventually, you have to make the call...once concrete begins to set while it is being pumped, you have only minutes to get the machine cleaned out. For this procedure, see the chapter on clean-out. Another thing to consider is the condition of the concrete in the ready mix trucks. If you have 3 or 4 trucks lined up behind the pump and they have been waiting with you, their concrete is also setting. Let’s say you have been waiting for 45 minutes while a form is being repaired. The ready mix plant is 25 minutes away from the job, and the driver was waiting to get to your pump for 35 minutes before the form broke. His concrete is now an hour and 45 minutes old. If it is a hot day, you are risking a “pipe party” by pumping his concrete. You are the one that has to make the call. Hey, nobody said the job would be easy, did they?

Keep the waterbox full Don’t forget to check the water in the waterbox regularly (and don’t forget to stop the pump before you open the waterbox covers). The water is very important for cooling the differential cylinders, and lubrication of the rubber rams.

Use of the vibrator If you are pouring very stiff concrete and it isn’t flowing well through the hopper grate, turn on your vibrator. If you didn’t buy a vibrator with the unit, they are available for field retrofit. Under no circumstances should you remove the hopper grate while the machine is operating, nor should the machine be operated when the grate is not in place. You wouldn’t believe some of the stuff that comes out of ready mix trucks. Mixer fins, clumps of unmixed cement, cats, dogs, rebar, golf clubs (you have to assume someone had a very bad round), tools of all sorts, etc. Your grate will catch it before it goes into the hopper (providing it is in place).


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Operation If any of the listed items made it into your hopper, they would probably cause a blockage, which is always dangerous. Worse would be if you fell into the hopper. In any case, it is dangerous to operate without the grate over the hopper.

Blockages If you have a blockage in your pipeline that you cannot remove by the backward / forward rocking motion described on page 83, you will have to disassemble the pipeline to find it. Before you disassemble the pipeline, you MUST relieve the pressure by pumping in reverse for several strokes. You must not forget this step! • When you go to the pipeline to find the blockage, take your hammer with you. Wear ALL of your personal protective devices for this procedure. 99.9% of the time, you will find the blockage in a reducer, hose or elbow. The act of reversing the pump will make the pipeline sound differently, when tapped with a hammer, than if it were pressurized. ‘Tapped’ is a key word here. You can damage the pipe by striking it hard. You should be able to hear the difference. An empty pipe has a definite reverberating “tong” sound. A relieved pipe will have a meaty “thak” sound, and a pressurized pipe will have a thin “tik” sound because the forces on the steel will not allow it

•

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they will hang overhead. Return to the pump and start pumping in forward again, slowly at first, until you are sure that there are no more blockages. If another blockage is encountered, remember to relieve the pressure again by pumping in reverse for several strokes, before finding the remaining blockages. Do not use compressed air to remove a blockage. Your concrete pump has at least 6 times more pressure available than an air compressor. If the pump won’t push the plug, air certainly won’t. In addition, air that is compressed builds a reservoir of pressure that will continue to be dangerous even when the compressor is shut off.

Clean-out It is an unfortunate truth, in many cases, that you will have to wait for the “balance load” of concrete. This is usually 1 or 2 yards that weren’t ordered by the contractor 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 the next to the last load will have to go and get the balance load. This gives you time to get ready for clean-out and to stow pipeline, clamps, etc., but it has the disadvantage that the concrete in your machine will be old by the time he returns. This is the

to vibrate. Once you have located the blockage, CAREFULLY remove the clamp(s) from the blocked piece(s). If you are not wearing a full face shield, turn away from the clamp as you pull the handle. Providing you have relieved pressure by stroking in reverse, you should be OK, but sometimes a blockage will store pressure because there is another blockage up or down stream. It’s better to be safe than sorry. Once the clamps are removed, the danger is past. Displace the blocked piece enough that you can push a piece of rebar or other long poking device into it. If the blockage is in a hose, it will help to hit the outside of the hose with the hammer. Again, do not damage the hose by hitting it so hard that the steel braids inside get permanently

most dangerous time for setting in the machine. Be aware of it, and take any steps necessary to keep the concrete alive. Clean out if you have to, but if the balance load is very small, refilling the hopper, material cylinders and pipeline may use up the entire balance load without ever delivering concrete to the form. In that case, they would have to order another balance load, and no one is going to be happy about it. When the balance load arrives, it is usually fresh concrete. That means that if you pump at least 1/2 yard, your machine will be filled with fresh concrete for clean-out, which is to your advantage. The worst thing that can happen is: On a hot day, the balance load is only 1 wheel barrow full. You will not be able to get fresh concrete all the way through the pipe when you pump the balance load, so the concrete that is in the end of the pipe for cleaning is as old as the next to the

disfigured. Once the blockage is removed, clean up the clamp, gasket, and pipe end with a rag or, in a pinch, wipe the concrete off with your hands. Reassemble the pieces, and pin the clamp(s) if

last load. BE With old concrete upon it is imperative that CAREFUL! the pipe is cleaned immediately finishing the pour.


Check Your Water Supply! You Will Need Water For Clean-out.


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Operation If you will be cleaning the pipeline by pressing a sponge ball through the line with air or water, you should wet the ball first. A lot of operators simply fill their 5 gallon bucket with water and throw the ball in to soak when there’s about a half hour of pumping left. Other operators start soaking the ball first thing in the morning, but the ball won’t last as long if it is always in water.

WARNING Hose whip hazard! Never use compressed air to clean out rubber hose. The result could be a violent whip of the hose as the air is released. If water must be conserved, dump the hoses manually and rinse them with the water nozzle.

difficult to obey the three point rule, which then creates a falling hazard. Plus, the hose is very likely to kink because of the rapid change in direction from the ground up to the hopper and back down into the drum. If it kinks while your holding it, you could be thrown to the ground or struck by the hose. And finally, the pump hopper almost never holds enough water to push out the entire line, so if you're holding the hose as the hopper goes empty, the line will now have compressed air being pushed through, creating the risk of a hose whip as it is released into the drum.

Clean the hopper s p e . rn a w p i h w e s o h

Disposing of excess concrete If you can’t dump extra concrete on the ground and don’t have an eco pan on the job, you may be able to spread a plastic sheet under the pump and drop it on that to be picked up after it sets. If you choose to pump the concrete from the hose out into the ready-mix truck, use a candy cane or goose neck to secure the delivery line to the hopper. Never climb ladder holding thehopper hose on shoulder or hang itthe over the edge of the foryour several reasons. Climbing the ladder with the hose makes it very

Tap on the “T” handle that opens the clean-out door on the bottom of the hopper with your hammer (Figure 32). When the door opens, the concrete at the bottom of the hopper should fall out. If it doesn’t, put the pump in “REVERSE” mode for a couple of strokes. If that doesn’t work, turn the pump to the “NEUTRAL”, or “OFF” position. WARNING! Do not do the following procedure while the pump is engaged in either ‘forward’ or ‘reverse’. The pump must be “OFF”. Aim your hammer upwards and pound any material that is lodged in the clean-out door. More than likely, a couple of taps will free the material. If not, you will have to keep tapping until it is free. This procedure can be minimized or eliminated by putting sand in the bottom of the rock valve housing before you begin pumping, as documented on page 79.

Figure 32 Open the clean-out door

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Operation Be sure of your footing and keep the hopper grate in place for the following procedure. Spray water into the hopper from above (Figure 33). Keep the agitator turning until you have sprayed the blades clean. Wash the material from the hopper out of the clean-out door on the bottom.

SWG98n186.eps

Figure 33 Clean the agitator and hopper through the grate with water



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Operation Stop the agitator from turning by placing the agitator switch on the control panel in the “OFF” position. Do not proceed to the next step until this is done. You will be able to visually confirm that the agitator has stopped by looking in the hopper (Figure 34).

NOTE! This switch will only work while the unit is in “Local” control. The best way to confirm that the agitator is stopped is use the manual control lever. It can be found on the curb side of the unit.

Agitator On-Off switch

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Figure 34 Stop the agitator by placing the switch on the control panel in the “OFF” position.

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Operation Poke any material that has set in the corners of your hopper with a piece of rebar or other stiff, long bar (Figure 35). Do not remove the hopper grate for this, or any other clean-out procedure. This procedure can, and must be done with the hopper grate in place. Don’t spend too much time on this procedure, or the concrete will have time to set up in the rock valve and material cylinders.

If concrete in the hopper has completely set, you will need to use a chipping hammer or other power tool to clean it. The grate is removable for this purpose, but the hydraulic system must first be disabled by stopping the engine and removing the key. For safety reasons, it is recommended that you return to your shop before removing any concrete that has completely set. Once the concrete has set, there is no advantage to chipping it away at the job site.

Figure 35 Remove built up concrete from the hopper with a piece of rebar or similar device



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Operation Clean the rock valve and material cylinders

Figure 36 Use the rake to remove material from the rock valve and material cylinders

Figure 37 Never put your hands in the concrete valve Once the hopper is clean, you should clean out the rock valve and material cylinders. Before you begin this

thereby eliminating the need to pull material from deep inside the cylinder. Be sure that the concrete pump is

step, bring the engine speed to an idle. Stroke the concrete pump one complete stroke in “REVERSE”, until the rock valve shifts across, then stop the pump. This step assures that the material cylinder that is exposed will have the rubber ram extended to the end,

turned to the “OFF” position before proceeding. Get your clean-out rake, and pull any material from the exposed material cylinder, the rock valve, and the outlet pipe (Figure 36).

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Operation NOTE!

WARNING Amputation hazard. Stop pump before cleaning the Rock Valve and hopper.

DO NOT PUT YOUR HANDS INTO THE VALVE HOUSING AT ANY TIME (Figure 37)! s p e . 5 1 0 0 0 0

Figure 38 Spray out the rock valve and material cylinder Spray water into the opening, washing the end of the rubber ram, the material cylinder, the rock valve and the outlet pipe. Continue washing until the water that leaves the valve is clear and clean. Visually inspect that no rocks, sand or clumps of concrete remain. If there is still material, continue spraying (Figure 38). Be sure that your rake, and everything else is out of the valve area, then cycle the machine in reverse for one more stroke. This will expose the opposite material cylinder, and completely extend its rubber ram. Pull any loose material out with the clean-out rake, then spray out the material cylinder as in the previous step.

Be careful with acid

CAUTION Chrome and rubber seal damage. Be very careful when using aggressive cleaners around chrome and rubber seals.

s p .e n io t u a C

Many aggressive cleaning compounds can do damage to chrome and rubber seals. Always follow directions very carefully when using such cleansers.

By putting the pump in the “REVERSE” mode, you are sucking from the pipeline (which is not connected during the clean-out procedure) and pumping into the hopper. Because of this, you may find that you now have some material in the bottom of the hopper again. You should now wash this material out. Spray off the clamps, gaskets and wedges. Close the hopper clean-out door, and reattach the bungy cord, if used. Startup 250:Users:Danny:Desktop:Operationmanuals:line pumps:All SP Rock Valve models:Frame files:operation.fm


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Operation Clean the waterbox NOTE! The waterbox is an integral part of the pump kit and provides lubrication and cooling to the pumping cylinders and hydraulic system. The waterbox needs to be cleaned and flushed daily. Dirty water will not have the same flushing or cooling effect as clean water. Hydraulic oil expands up to 5% when heated. It is for this re ason the waterbox has d afterupevery to be ditraine job. dAs the oil cools, shrinks in the ifferenti al cylinders, and can actually pull water in over the rod packings.

To clean the waterbox, start by lowering the engine RPM to an idle. Leave the waterbox cover in place, for now. Open the drain and allow the existing water to flow out the bottom. When water stops flowing, give the unit a stroke or two in either forward or reverse. This will force the water in the extended cylinder back into the waterbox, and therefore out of the drain. The

waterbox is empty when no more water flows out of the drain, even after the unit is cycled. STOP THE PUMP and secure it against unintentional starting by pushing the emergency stop button. Be sure of your footing. Remove the waterbox covers, and spray the waterbox and cylinders until all cement fines and grout are loose (Figure 39). If you will not be filling the waterbox again until just before the next pour (a highly recommended practice), then you should do the following procedure: • •

•

Replace the waterbox cover. Put the pump into “FORWARD” or “REVERSE” for 1 or 2 strokes, to force the clean water out of the drain. Close the drain.

If you need to refill the waterbox immediately, simply close the drain, and finish filling the waterbox. Don’t forget to replace the waterbox cover before restarting the unit.

IMPORTANT! If the machine will be transported or stored in below freezing temperatures, you must drain all the water out of the waterbox. See the section on cold weather operation for further details.

Figure 39 Stopfooting, sure out the pump, of your thenbe spray the waterbox.

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Operation Preparation for travel Store your clean-out rake, sponge ball, grease gun, hammer, shovel, and all other accessories securely for travel. If the job was set up that you were keeping track of the concrete delivery tickets, you should turn them over to the concrete supervisor when you have him sign your job ticket. Before you get into the cab to drive, take a walk around the trailer. Look for items that you may be forgetting, look under the unit for personnel and obstructions, and check for air pressure, tire pressure and wear, etc. Many driving accidents happen on the way back to the shop after a job, or on the way to a second job. Think about your route, bearing in mind the time of day, road construction, etc. As hard as it may be, you want to begin driving with a fresh attitude and clear head.

When configured on the PISTON SIDE, the hydraulic oil is routed from the S2 valve to the differential cylinders at the port that is on the piston end (the end away from where the rod protrudes). The rocking oil loop is connected from one cylinder to the other on the rod end. Note that the rods are moving the same direction in both examples shown, whether they are configured for rod side or piston side pumping. This is accomplished by crossing the lines from the S2 valve as shown, and is necessary for the purpose of maintaining the proper sequence of action so the concrete valve is timed with the movement of the differential cylinders.

NOTE! If your unit is equipped with hydraulic stabilizers, be sure the faucet valves are closed prior to leaving the job.

Special Pumping Situations Rod side to piston side pumping (SP 2000) The hydraulic system for the 900 and 1200 series pistonsidehoses.eps

concrete pump can be configured for ROD SIDE or PISTON SIDE pumping, as shown in Figure 40. Rod side pumping allows maximum yards per hour output, while piston side pumping allows maximum pressure to be exerted on the concrete. (See specific instructions for pumping on piston side in the Operation section of this manual). Piston side operation dramatically raises the maximum pressure on the concrete. For this reason it is crucial that your entire material delivery system be rated to handle the available pressure and kept in “like new” condition. Remember that pipe wears with each yard pumped. Inspect the wall thickness regularly. The maximum material pressure available on piston side depends on which differential and material cylinders you purchased with your unit and is stamped into the main ID tag.

Figure 40 Hose configuration for rod side pumping with a SP 2000

When configured on ROD SIDE, the hydraulic oil is routed from the S2 valve to the differential cylinders at the port on the rod end (the end from which the rod protrudes). The rocking oil loop hose is connected from one cylinder to the other on the piston end. Startup 250:Users:Danny:Desktop:Operationmanuals:line pumps:All SP Rock Valve models:Frame files:operation.fm


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Operation Quick Clean-out

•

If concrete is setting up in the machine, you will have to clean out in a hurry. It is important that you remember the safety rules when cleaning a setting machine. Accidents happen when you panic. Stay calm and work as fast as you can without skipping any safety rules.

• • • •

You should prioritize the order of clean-out with regards to the extent of the setting action. Basically, you should keep in mind the amount of time and money involved to replace any components that are ruined by failure to clean before the concrete completely sets. To help you make this decision, we have included the following list which is arranged in order from most expensive and difficult to replace, to easiest and cheapest to replace. We are not suggesting that you clean out in the same order, but it may help in determining where you want to start. • Rock valve cast housing • Rock valve • Material cylinders • Hopper • Pipeline In practice, an experienced operator will dump the hopper and material cylinders, and rake out the bulk of the material from the valve in just a couple of minutes, moving immediately to the pipeline. The rest of the material in the hopper and valve can be chipped out if it won’t wash clean. Be sure to disable the hydraulic system on the unit by stopping the engine, putting the key in your pocket, and putting a “DO NOT OPERATE” tag on the ignition switch before entering the valve/hopper area for chipping. When cleaning a setting machine, don’t worry about getting each part perfectly clean before moving on to the next part. Once you have used water to remove the bulk of the concrete from a component, it will be thinned enough to not completely set until you can get back to it.

•

•

Water in waterbox freezes while you are driving to the job. Hydraulics are slow and sluggish. If it’s very cold, concrete can freeze in the pipeline while you are pumping. Concrete freezes in the hopper. The concrete will be loaded with calcium chloride or an equivalent to allow the concrete to set before it freezes. This will accelerate setting, in much the same manner as a hot day accelerates setting. Anything you wash with water becomes coated with ice, which will not melt and evaporate until the temperature raises above freezing. Machine parts that you touch become very slippery if they contact any water.

Some of these potential problems can be solved or tolerated, others cannot. A majority of the time the concrete will be mixed using very hot water, to keep the concrete from freezing during the delivery and waiting period. Some tips for cold weather pumping: Store the machine indoors in locations that have cold winters, like the northern U.S. and Canada. If you don’t have a heated shop for the winter, consider renting one. Do not put water in the water tank or the waterbox before driving to the job. If possible, contact the ready mix company and arrange for the first driver to be loaded with hot water to fill your waterbox and to mix your slurry. Arrange for the last driver to be full with hot water and prepared to let you clean out using this water.

NOTE! Your Schwing unit was delivered with Mobil Univis N46 hydraulic oil. This m ulti viscosity oil should work nicely for any temperature between -20˚ F and 100˚ F. If you have chosen to change to a regular viscosity oil, pay close attention to the following paragraphs.

Cold weather pumping It is possible (and routine in some parts of the world) to pump concrete with outside temperatures as low as -10° Fahrenheit, even colder under certain circumstances. Thisand can present a variety of problems compared with pumping in moderate temperatures, such as:

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Operation If you are expecting cold weather for extended periods of time, such as winter in the northern United States and Canada, you should change your oil to a thinner viscosity type, such as an ISO VG 32, which will give you a lower pour point. Be aware, however, that this oil cannot protect the components to as high a temperature as the standard oil shipped with your unit (DTE 15).

Agitator quarter turn shutoff valve (open position)

000174.eps

result in a blockage. To clear the line, all normal blockage steps should be taken and additionally, you have to work fast enough that the concrete doesn’t freeze before you get it moving. If the concrete freezes in the pipeline, you are done pumping until you have warmed up the machine. The good news is: the concrete will stop setting when it has frozen. Once you bring the machine into a warm place, you will be able to clean it. If the concrete freezes in the hopper, you are done pumping. a warm place to bring the machine and clean it as Find it melts.

Motor

Figure 41 Quarter turn valve installed in the agitator circuit.

Preheating the hydraulic oil Another option is to preheat the oil before beginning the pour. This will require that you order a hydraulic shut-off valve, and install it as shown in Figure 41. The part number of this valve is 10004680. You will have to arrive at the job early enough to do the procedure.

If the concrete is loaded with calcium chloride, you will have to keep the concrete alive using the same techniques used for pumping on hot days. The calcium chloride accelerates setting, but if it does freeze, the setting stops. When you do begin to thaw the machine, the concrete will begin to set again, even more quickly than on the job, because you are now in a warm area. Do not waste time when cleaning a machine under these circumstances. Be very careful of ice when pumping in cold conditions. Ice can form on all objects and surfaces.

Allow about 10 or 15 extra minutes. To preheat the oil: • Start the motor, but do NOT rev the engine to full RPM until the hydraulic oil is warm (at least 20° Centigrade). If you do, the hydraulic pumps will not be able to suck the thick oil as fast as they are turning, resulting in pump cavitation and damage to the pumps. Leave the engine at an idle. • Close the quarter turn valve. • Let the machine idle until the oil is at 20° Centigrade, then rev the engine to half throttle. • Continue heating the oil to 50° or 60° Centigrade. • Open the quarter turn valve. There’s nothing you can do about a separately laid pipeline. In most cases, pours that require a separate pipeline will cancel if it is very cold. If they don’t cancel, there is a good chance that you will not be able to get concrete through the line because the slurry will freeze against the walls of the pipe, then the concrete will have to be pushed through the pipe dry. This could



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NOTES!

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Maintenance

swg99a001.eps

MAINTENANCE Filtration ............................................................................................... 100 Hydraulic Oils....................................................................................... 102 Pressure, Hoses and Fittings............................................................... 102 General Maintenance Tips................................................................... 104 Preventative Maintenance ................................................................... 105 Scheduled maintenance checklist ....................................................... 115 Unscheduled maintenance .................................................................. 116

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Maintenance

Maintenance Maintenance is what you do to the machine to keep it in good working condition. There are two kinds of maintenance, preventative and repairs. Preventative maintenance is important to avoid unnecessary repairs, but eventually even well maintained machine parts will wear out and require repair or replacement. Some maintenance needs to be done daily, some weekly, some monthly, some quarterly, some semiannually and some annually. It is a good idea to make a checklist that will tell you what maintenance is due, and when it is due. A checklist is included in the Appendix section of this manual. Keep accurate records of maintenance performed, and when the work was completed. In this way, you will know that all necessary work has been completed on time. Complete maintenance records could also make the machine worth more money when it comes time to sell or trade it. There are certain things you should know about the maintenance of your machine that will not come up on a timetable of things to do. We begin the section with some general information regarding some of these items.

Filtration General Information Filtration is the single most important method of keeping your unit’s hydraulic system operational. Particles that could damage the components are introduced into the oil by the differential cylinders and the valves, through the reservoir breather tube, and by internal wear in the components themselves. Additionally, when you change hydraulic oil the new oil is not clean enough to be used in a concrete pump without being pre-filtered. In fact, new hydraulic oil is only filtered at the refinery to 40µ (40 microns). The oil in a Schwing needs to be filtered to a MINIMUM of 25µ, and preferably finer than that. Filters are rated by: • the size of particles they trap, and whether that size is nominal, or absolute • •

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the dirt holding capacity, in grams the clean element pressure drop for a given flow rate (in PSI and gallons per minute or bar and liters per minute), and

•

the ratio of particles of a given size encountered versus particles passed (referred to as the beta ratio). An example of a beta ratio would be β25 = 200 (pronounced beta twenty five equals two hundred). This means that for every 200 particles of 25 microns or larger that hit the filter media, one makes it through. A finer filter would be, for example, β12 = 200. A courser filter example would be β25 = 75. For concrete pumps, medium to fine filtration is required.

NOTE! It is recommended that after an initial 100 hour break in period, both the hydraulic oil and filter and motor oil and filter be replaced. Check with Schwing service for the correct lubricants and filter to use in your climate.

Specific Information Here are some facts regarding filtration as they relate to your pump: As delivered from the factory, each Schwing is equipped with a return filter that is rated at 12 micron (shown as 12µ) absolute. The beta ratio is β12 = 200. In our case, the beta ratio means that for every 200 particles of dirt that hit the filter media that are 12 micron or larger in size, 1 will make it through. Although we are not happy about the one particle that is allowed through, we do not use finer filtration because A) the components don’t require it, and B) a finer filter would plug up with dirt too often, resulting in high maintenance costs to you. We have settled on a compromise that should afford long service life and minimum maintenance costs. Don’t be fooled by the one particle that gets through, this is an extremely high quality element with very good trapping characteristics. The clean element pressure drop is about 6 PSI at 200 liters per minute (element only) + 2 PSI for the housing, for a total of 8 PSI ∆P when the element is clean. The pressure drop varies with the viscosity of the oil, which is why you can ignore the delta P pop out indicator until the oil is heated to normal operating temperatures. It will hold 75 of and200 80 l/m. grams dirt,rate when operating at between a flow rate Theofflow is important, because the filter would hold more if you


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Maintenance operated at a lower flow rate. Good filtration is not cheap, but it will save you thousands of dollars by preventing component failure. The return filter is equipped with an integral bypass check valve, with a spring force of 50 pounds. That means that when the filter is clogged with dirt and oil is having a hard time making it through, the pressure difference between the filter inlet and the tank raises. This pressure difference (commonly referred to as a pressure differential) is called delta P, and is shown as ∆P. When the ∆P reaches 50 PSI, the check valve opens and the oil returns to the tank unfiltered. If the filter did not have the bypass check valve, it would simply break apart when it was clogged. That would put all of the dirt that it ever trapped directly into the system, plus the element itself would become a contaminant. The pumps are equipped with a medium pressure filter assembly that has been manufactured especially for us (Figure 42). It is equipped with an integral bypass check valve, set at 50 PSI. The bypass valve protects

the filter element from damage due to running with a clogged filter or cold starts. The assembly is equipped with an anti-back flow check valve, which prevents oil from draining out of the tank while you are changing elements. There is a delta P indicator to tell you when the element is dirty (set at 35 PSI). You should replace the element whenever the indicator pops out and the oil is above 20 degrees Celsius. Under normal circumstances, the element will need replacement about every 6 months. The element has been designed to remove all particles large enough to cause undue wear and job site breakdowns (beta 12 = 200). You can keep the hydraulic system running year after year by replacing the element when replacement is due. Do not substitute “will fit” elements in this housing. To change the element: a. Make sure the engine is shut off. b. Position a pan or bucket under the filter housing to catch drips. c. Use a filter wrench to remove the old filter.

oilfilter.eps

Figure 42 The main return filter The typeofofexperience filters installed on your are the result of years and testing. Weunit recommend that you DO NOT change the housing or element to some other type. You may learn that, in the long run, sometimes cheaper is more expensive. Startup 250:Users:Danny:Desktop:Operationmanuals:line pumps:All SP Rock Valve models:Frame files:Maintenance.fm


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Maintenance

Hydraulic Oils General Information Hydraulic oils are rated for viscosity, heat dissipation, foaming characteristics, pour point, antiwear additives, anticorrosive additives, lubricating qualities, compressibility, temperature range, temperature stability, and other functions. Although many different brands of oil meet these specifications, they may use different chemical additive packages to achieve the end result. For this reason, you should not mix two different brands of oil. The additive package from one brand may be incompatible with the additive package from the other, rendering both packages useless. Recently, a few manufacturers have introduced biodegradable hydraulic oils onto the market. These oils are based on vegetable extracts instead of mineral extracts. They are considered safer for the environment in the event of a spill, although the additive packages are not inert. None of them has yet been accepted for use in Schwing pumps, but are under consideration and testing. These oils must not be mixed with mineral-based hydraulic oils, even in very small amounts. If you will be pumping a job in an environmentally sensitive location and want to use this type of hydraulic oil, please contact the Schwing Service Department at (651) 429-0999 for instructions on making the biodegradable.

change

from

mineral

oil

to

Viscosity of hydraulic oil is similar in concept to the different weights of motor oil. For example, in the winter you may run 5W-30 in your car, while in the summer you run 10W-40. The same is true for hydraulic systems. If you live in a climate where the weather is changing from extremely hot conditions to extremely cold conditions, and you no longer use our Mobil Univis oil, you should consider changing the weight of the hydraulic oil that you use, by the season. The International Standards Organization (ISO) has developed a method of grading hydraulic oils for viscosity. For summer in northern North America, we recommend ISO VG 46 weight oil, while in the winter we recommend ISO VG 32 or even VG 22, depending on how cold it gets in your area. For southern North America and Central 46 for the winter andAmerica, ISO VGwe 68recommend or VG 100ISO for VG the summer, depending on how hot it gets. The lower the ISO VG number, the thinner the oil is and the lower the pour point of the oil is. On the other hand, the thinner

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the oil is, the lower the temperature will have to be before it breaks down the lubricating film that protects your components. See the chart in the back of the Appendix section of this manual for help in selecting the proper oil for your requirements. The quality of the oil needed for use in a Schwing machine is rated in the DIN system. The ratings have to do with the chemical additive package that is introduced into the oil. Both the DIN rating HLP and HV qualities are approved for use in our machines.

Specific information All machines leave the Schwing factory filled with Mobil UNIVIS N46 hydraulic oil unless otherwise requested by the customer. The multi viscosity nature of this oil should work nicely for any temperature between -20˚ F and 100˚ F. If you want your new machine filled with a different brand or different viscosity oil, you should specify when ordering. Many other brands of oil have been approved for use in Schwing machines, including: • Mobil DTE 25 • Shell Tellus oil • BP Energol • Aral Vitam • Esso Nuto • Esso Univis • Total Azolla • Wintershall Wiolan The brands listed have been approved; however, any oil that meets the quality and viscosity standards described above can be used.

When to change your hydraulic oil You should change your hydraulic oil at least once per year. If you use good filters and change them when they are dirty then the oil will be clean, even after a year, but the chemical additive packages that give the oil its properties will break down with time, and no amount of filtration will bring them back.

Pressure, Hoses and Fittings General Information Most concrete pump hydraulic systems run with fairly high pressures, in the 2000 to 5000 PSI range. The maximum pressure is determined by adjustment of the


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Maintenance main relief valve, and the machines are designed to handle this pressure safely. Concrete pressure is just a ratio of the hydraulic pressure.

job. The hydraulic pump can’t withstand 4900 PSI for more than a few minutes and it breaks. You now have to replace a pump before you can make another pour.

If you lower the pressure at which the system runs, you can harm the system. For example, you ask the machine to develop 3000 PSI hydraulic pressure to push the concrete where you want it to go. You want to replace a hydraulic hose with a less expensive, lower pressure hose, so you lower the relief valve setting from 4350 PSI to 2500 PSI. What is the result? The concrete still requires 3000 PSI to get where you want it, but your relief valve opens at 2500. Now the oil that should be pushing the concrete is traveling back to tank instead. All of the horsepower that it took to send the oil out of the pumps at 2500 PSI is turned to heat, which will boil the oil. The oil (in this example) loses its lubricating qualities at 80° Centigrade, so components begin to wear, sending debris down stream, which adds to the wear. The system would be destroyed in minutes if it continued to operate under these conditions.

If you leave the machine at the factory specification, you DO NOT harm the system. It gives you years of dependable service. This means you should only use fittings and hoses that have a sufficient WORKING PRESSURE to handle the system requirements and if you take a job that needs more pressure than your machine is capable of, you should buy or rent a higher pressure machine.

If you raise the pressure at which the system runs, you can harm the system. Using a new example, the concrete requires that the machine develop 4900 PSI hydraulic pressure to push it where you need it. Your machine is factory set to run at a maximum of 4350 PSI, so you raise the setting of the main relief to do the

Specific Information Schwing uses high pressure fittings and hoses on all circuits, even if the relief valve for that circuit is set to low or medium pressure. The fittings and hoses are rated at a minimum of 5000 PSI working pressure, and in the case of some fittings, up to 15,000 PSI. We advise against changing any circuit to lower rated hoses or fittings. We use metric fittings and hoses, with metric threads on the couplings. There are four diameter sizes of tubes and fittings used on this unit, and four diameter sizes of hoses. The chart below tells you what the sizes are, and what they will attach to. All block threads are metric or BSPP. Instructions for setting the relief functions are shown in the preventative Maintenance section of this manual. hose/fittings chart.eps

Hose Size


Connects with Fitting and Tube Size

8

8

12

13

13

16

16

16

20

20

20

25

25

25

30

32

32

38

Tube and Fitting Size

Figure 43 Showing hose, fitting and tube sizes and equal connection sizes.

Hose ID (mm)

Tube and Tube and Fitting OD Connects with Fitting ID (mm) Hose Size (mm)

12

12

8

8

16

16

13

13

20 25

20 25

16 20

16 20

30

30

25

25

38

38

32

32


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Maintenance

General Maintenance Tips

SWG98n175.eps

Showing the effects ofFigure proper44prestressing of a bolt.

Torque Specifications

Removal of safety devices.

When performing maintenance that requires removal and replacement of bolts, it is very important to adhere to the torque specifications that apply to that bolt (Figure 44).

Sometimes you will have to remove a safety guard or other safety device in order to perform maintenance. For these situations, you must take extra care to be sure of your own safety, and that of your co-workers. If you have to put your hands, feet or any other body part into a part of the machine that would normally be guarded, be sure that the machine is turned off and that the key is in your pocket. If there is more than one key in existence, you should also put a “DO NOT OPERATE” sign on the controls or over the start switch. Lock out tags were provided with you pump when it was delivered (Figure 45).

The graphs in Figure 44 demonstrate what happens to a bolt if it is not properly torqued. The dashed line represents the prestress on the bolt. As the device that uses the bolt goes through its normal functions, the bolt in example “A” gets stretched and relaxed with every duty cycle, because the bolt is prestressed under the maximum force of the cycle. In example “B”, the prestress of the bolt has been raised to more than the maximum force of the duty cycle, so the bolt doesn’t ever feel the cycle. In this example, bolt “B” would last MUCH longer than bolt “A”. The torque specifications for bolts used on Schwing equipment are found in the Appendix section of this manual.

Adjusting relief valves. While adjusting a relief valve is not normally a dangerous procedure, you should remember that it has the potential to cause trouble. The main thing to watch out for is this: Sometimes people that don’t know better will have a problem with a machine and begin trouble shooting by raising the relief valve setting. When that doesn’t help, they forget to lower it back down. Now when you check the pressure by creating a hydraulic dead block, the pressure is set too high. In extreme cases, this can cause hoses or fittings to burst, or other component failure. To be safe, you should begin the adjustment procedure by turning the adjustment device to the lowest possible setting, then bring the device back up to the proper setting.

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Front

Back

DANGER

DANGER

LOCKED OUT

This unit has been LOCK OUT

DO NOT OPERATE This lock/tag may only be removed by: Name ________________ Dept. _________________ Expected Completion_____

Only the individual who signed the reverse side may remove this lock/tag. Remarks: ________________ ________________________ ________________________ ________________________ ________________________ ________________________

XYZ Company No. 12 345 lockout .eps

Figure 45 Lockout/Tagout provided with unit Before restarting the machine after performing maintenance, be sure to put away all tools, parts and supplies, and clear the area of personnel. If your company has a “lock out - tag out” policy in place, abide by it. Concrete pumps are big enough to hide a man. Be sure to yell “clear” before starting the unit at any time, and allow time for response before proceeding.


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Maintenance

Preventative Maintenance

reservoir (Figure 47). Place a drain pan under the outlet hose, open the valve, and watch the liquid as it leaves the hose. When the liquid changes from water to oil, close the valve. Because of condensation, which is aggravated by large heating and cooling cycles, it is normal that there will be a small amount of water in the tank every day, but it should settle to the bottom of the tank overnight. The water that is drained should be clear, and the oil that follows it should also be clear, not milky.

NOTE! There is a s ample m aintenance chart shown in the Appendix of this m anual, beginning on page 130.

Daily Maintenance •

•

•

•

Check the levels and condition of the lubricants and coolant in the towing truck. Follow the manufacturers recommendations for quantity and type. Bleed the moisture out of the truck air system by opening the pet cocks located on the bottom of the air tanks. This is especially important if there is a chance that the moisture will freeze. Check the condition of the tires on both the towing truck and the trailer. Do not drive the unit with bald, cracked or damaged tires. Check the wheel hubs on the trailer for lubricant. Fill the hubs halfway with 90 wt. gear lube, if fluid is below that point. Check the level and condition of the hydraulic oil (Figure 46). Top up, if necessary, with the same brand and type of oil. If you have a filter buggy to pump oil into the tank, use it. Replace milky looking oil, which is a sign of water contamination. Try to determine the source of the water, if possible. If the oil has turned milky quickly, like from one day to the next, then just replacing the oil will not solve your problem, and 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 the Schwing Service Department at (651) 429-0999. OilLEV.eps

•

Check the differential cylinder rod packings. Note! In order to conform to new European regulations, beginning after 4th quarter of 1995 the waterbox will be fitted with a bolt down grate under the waterbox covers. This will make manually checking the rod packings each day, like we have instructed you to do in the past, impractical. To check for rod packing wear, fill the waterbox with water above the level of the differential cylinder rods (if no grate is installed), or above the bolt down grates (if installed). Let it sit for a few minutes. If oil begins to float to the top of the water, it is an indication that the rod packings are worn (oil is lighter than water, and will float). Don’t forget to let the water out after the check, especially if freezing temperatures are expected. Failure to replace the rod packings when they need it will result in contaminates from the waterbox, including water, entering the hydraulic oil at the packings and wearing on the rods, cylinder tubes, guide bushings, pistons and the piston rings. The material that gets worn off of the above mentioned items also becomes contamination, accelerating the wear. Left unchecked, this wear will totally destroy a differential cylinder. Normally, you will be due for new packings after 1 to 2 years. 2Koildrn.eps

Oil Level Indicator

Figure 46 indicator. The hydraulic oil level •

Bleed the water out of the bottom of the hydraulic oil reservoir, by opening the drain cock or faucet located at the bottom of the


Figure 47 The drain cock used to drain water from the reservoir.


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Maintenance •

•

•

•

• •

Each day you should visually inspect the bolts on the rock valve and the rubber rams. Notice if there is any play. If you see something suspicious, shut off the engine, put the key in your pocket and remove the hopper grate or waterbox covers and inspect with a wrench. If you find that they are loose, tighten with a torque wrench to the torque specifications found on page 127 of the Appendix section of this manual. Don’t forget to replace the hopper grate and/or waterbox covers before using the

NOT put a wrench on the tension nut to get it to go to a new hole. Overtightening the tension nut will cause premature wear on the kidney seal. The tension nut adjusts the free play of the rock valve on the kidney seal end. Wear on the cutting ring end is compensated for automatically by the pressure spring. Replace and tighten the keeper bolt. You do NOT have to tighten the keeper bolt according to the torque specifications that normally are used for that bolt size. Just be sure the bolt is

machine. Grease the rock valve and agitator bearings. This can be done on the job as described in the Operation section of this manual beginning on page 80, providing you have remembered to bring your grease gun and grease tubes. Visually inspect the unit for damage or leaks each day. Repairs should be made before the unit is operated. Once a day you should check your maintenance checklist to see if any weekly, monthly, semiannual or annual maintenance is due. Check daily, the fluid level in the radiator. Add 50% water and 50% ethylene glycol if needed. A heavy duty, dry air cleaner filters all of the air entering the engine. Excessive restriction of the air intake system reduces the flow of air to the engine affecting horsepower output, fuel consumption and engine life. An air restriction indicator is installed in the air intake manifold. Visually inspect the restriction indicator daily to assure the filter is not restricted. Service the air filter when the red diaphragm is exposed. Press the reset button on the restriction indicator after servicing the air filter.

tight enough that it won’t fall out.

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Keeper Bolt Tension Nut SWG98n245.eps

Cover Bolts (7)

Figure 48 Rock valve tension nut assembly and housing cover bolts. •

Weekly Maintenance •

Spacer

Check the rock valve tension nut for play once each week (Figure 48). To check this nut, remove the 16mm keeper bolt, grasp the tension nut by hand and turn clockwise. There are many holes for the keeper bolt on the spacer behind the tension nut. The object is to place the keeper bolt in the furthest hole that you can reach when you turn the tension nut BY HAND. If the tension nut will only turn enough to get part way to a new bolt hole, then turn the it BACK to the previous hole. DO

Check the hopper grate interlock switch to be sure it is secure. Never put your hands, arms, legs or any other body part into the hopper while the hydraulic system is ready to operate or without verifying zero pressure on the accumulator. It is important that the switch be checked on a regular basis to be sure that it is functioning properly and that are all ever mounting screws are secure. If the screws found to be loose, they should be removed and replaced using Loctite or other similar product to assure they remain secure.


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Maintenance •

Rotate the cutting ring. Actually, this is more dependent on the type of concrete and the number of cubic yards pumped than on a time schedule, but you should check it for wear at least once per week, and rotate it as needed. To rotate: a. First shut off the engine and put the key in your pocket b. Raise hopper grate and secure with “T” bolt. c. Loosen the tension nut Figure 48. d. Loosen theremove 8 coverthebolts a couple of threads, but do not bolts. e. Loosen the 12 x 35 bolt on the end of the rock shaft by the slewing lever. f. The rock valve will slide far enough out for you to rotate the cutting ring 90 °. g. Remove the hopper grate. h. From inside of the hopper, tap the cutting ring forward, towards the spectacle plate. The ring should pop loose (if not, loosen the cover bolts a little more, then gently pry the rock valve rearwards a little more). Rotate the ring 90 ° clockwise. It doesn’t really matter which way you rotate, but to keep from forgetting which way you went last time, we recommend going clockwise each time. That way the rotation will always bring up a new side. i. Be sure that the ring is centered in the rock valve. Tighten the cover bolts slightly, if needed, to be sure that the ring isn’t cocked one way or the other. j. Be s ure there is no debris between the b ack cover and the rock valve housing (if so, clean it out). Tighten the cover bolts just enough to bring the back plate up against the rock housing. Then tighten each bolt equally, using a torque wrench. Alternate which bolts you tighten, like you would when tightening a wheel on a car. The torque specs for these bolts (M20 x 65, 8.8 hardness) is 300 foot/lbs. k. Lower the hopper grate and secure it with the grate lock. l. Tighten the tension nut according to the instructions in 5.2-1. Tighten the keeper bolt.

•

Drain the moisture from the fuel filter at least once per week. On the bottom of the fuel filter is a drain cock, drain until moisture ceases to come out. Also drain the water out of the bottom of the fuel tanks. Using the drain cocks on the bottom of the fuel tanks.

Monthly maintenance •

Check the mounting hardware of the subframe, the oil tank, the pump kit, the differential cylinders, and the material cylinders. Check for bolt tightness, cracks and other abnormalities. • Check all hydraulic pressures. The specifications for each circuit are shown below, and on the hydraulic schematic that applies to that circuit. The schematics are all contained in the Appendix section of this manual. Changes in pressures may indicate trouble in one or more components, and will serve as early warning indicators IF you check them on a regular basis. PRESSURE SETTINGS MUST BE MADE WITH THE OIL AT NORMAL OPERATING TEMPERATURES (40° to 60° C). To heat the oil to operating temperature: a. When the oil is very cold (at or below the pour point of your hydraulic oil), • •

Bring engine RPM to an idle. Let the engine idle until the temp. gauge on the operator’s panel reads 20°.

b. When the oil is warm (above the pour point of your hydraulic oil), follow instructions a. through g below. Shut off the concrete pump when the oil shows 40 ° C on the temperature gauge of the operator’s panel.

Lubricate mechanical moving parts with oil, or a WD-40 type of lubricant.



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Maintenance Setting the concrete pump pressure

Concrete pump shutoff (Shown in open position)

Soft switch relief valve

Close

Closed

Safety relief cartridge s p e . 6 7 2 0 0 0

Open Soft switch relief cartridge

ng 20 .ep s

Soft switch shutoff

Figure 49 The main relief valve, concrete pump circuit. The Schwing concrete pump circuit on the WP Series pumps are designed to be operated at a maximum pressure of 330 bar (4785 PSI). It is controlled by a pressure compensated pump. To check the main system pressure see Figure 49: a. Be sure that the waterbox covers are installed on the waterbox. We do not recommend using the remote control box for the following procedure. b. Wear safety glasses when setting pressures. c. Start the engine. d. Close the quarter turn shut-off valves shown in Figure 49. e. Put the operator’s panel switch “remote / local” into the “local” position. f. Using the throttle control near the operator’s panel, rev the engine up to full RPM. g. Using the concrete pump “forward / neutral / reverse” switch, put the concrete pump into the “FORWARD” position. The unit will stroke no more than once, then the rock cylinder will retract. Oil will have nowhere to go except over the main relief valve.

750-15 and the BPA 450 and 500. Return the pump to “neutral” whether in needs adjustment or not. i. Put the concrete pump into the “FORWARD” position again. The machine will not stroke this time, but will again develop maximum pressure. Read the pressure on the gauge. If more adjustment is needed, return the pump to “NEUTRAL”, then repeat the steps until you achieve the desired pressure.

NOTE! If you cannot achieve the desired pressure, you have a problem. In this case, unscrew the adjustment knob by several turns so that your pressure isn’t too high once the problem is found. Contact the Schwing Service Department for advice on how to continue. j. Return the pump to the “NEUTRAL” position. k. Open the quarter turn valve. l. Return the RPM to an idle and go on to the other pressure settings, as required.

h. Read the pressure on the gauge, as shown. It should read 330 bar for the WP 1250, 300 for the WP 1000 and the 750-18, or 286 for the

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Maintenance Setting the agitator pressure

Allen screw 4mm

Relief valve Jam nut 13mm

SWG98n198.eps

Figure 50 Showing the agitator hand valve and gauge port.

The agitator circuit has a maximum pressure of 125 bar (1812 PSI), limited by the relief valve located in the agitator hand valve (Figure 50). There is a gauge port for checking or setting the pressure in this circuit. The port is located on the agitator hand valve.

To set the circuit pressure: a. Stop the unit, and put the key in your pocket. b. Remove one of the hoses from the agitator motor and plug both the hose and the fitting with high pressure hydraulic plugs (this step can be skipped if you have installed a quarter turn valve as shown in Figure 41 on page 97. In that case, simply close the quarter turn valve). c. Install the 0-300 bar gauge on the hose. d. Locate the relief valve on the agitator hand valve. e. Be sure that any personnel are clear. f. Restart the engine and bring it to full RPM. g. Activate the agitator hand valve. This will send the oil against the high pressure plug. The oil will have nowhere to go, so it will return to the tank over the relief valve in the hand valve. The pressure at which it relieves can be seen on the gauge. It should read 125 bar. h. To adjust the pressure, use a 13mm wrench to loosen the jam nut and a 4mm allen wrench to turn the relief valve. Turn it clockwise to


increase pressure, or counter clockwise to decrease pressure, until 125 bar is showing on the gauge. i. Return the agitator hand valve to the neutral position. j. Stop the engine and put the key in your pocket. k. Remove the high pressure plugs and fittings from the agitator hose and reinstall the hose on the agitator motor. l. Remove the pressure gauge. Replace the gauge port cover. m. The unit can now be restarted, if necessary. Don’t forget to put the key back in the engine before you go home.

Clean the oil cooler fin s Spray out the coils of the oil cooler with a high velocity water nozzle, or pressure washer. If you use a pressure washer, be careful not to get so close that you damage the electric motor or bend the cooler fins.

Quarterly Maintenance Change the engine oil, oil filter, fuel filter and check the air breather element after the first 100 hours of operation. Schwing recommends changing the oil and filters every 500 hours or once a year, which ever comes first. Schwing uses Mobile 10W-30 in all engines. For specific grades of motor oil and general maintenance of your engine, refer to your Duetz operation manual.


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Maintenance Semiannual maintenance Change hydraulic oil for temperature reasons

NOTE! Your Schwing unit was delivered with Mobil Univis N46 hydraulic oil. This multi viscosity oil should work nicely for any temperature between -20˚ F and 100˚ F. If you have chosen to change to a regular viscosity oil, pay close attention to the paragraph below. Change hydraulic oil, if you live in a geographical location where the weather changes the temperature range drastically. If you save the oil in clean barrels and properly store the barrels, you can reinstall this oil when the weather changes back. You can use the oil for a maximum of 2 six month seasons. Contact your hydraulic oil dealer to obtain clean barrels and the proper storage procedures. CAUTION

buggy for oil transfer, consider buying one, or at least rent one for the occasions when you change your hydraulic oil.

Charging the Accumulator Charge the accumulator every six months or 1000 hours. a. Before you begin, you will need a charging kit (Figure 51). Do not attempt to charge the accumulator without one. You can order the kit from Schwing, using part number 30390139. b. The nitrogen bottle should only be used with a high pressure regulator. If it was not supplied with the bottle, order one before proceeding with this job. c. You cannot charge the accumulator with the engine running. The key switch must be in the “OFF” position. Put a “DO NOT OPERATE” tag over the key switch, and put the key in your pocket so that no one can start the unit.

If you ignore proper storage procedures, the oil will become so contaminated that reuse will become destructive to the machine. If you don’t own a filter

Tank Regulated Pressure Pressure

High pressure gas regulator is not included with the kit. These are available from the nitrogen supplier.

Figure 51 Showing the charging kit for the accumulator and a high pressure gas

Nitrogen Bottle

regulator. charge valve assy 10 0

15 0

1500 2000 1000

2500

200

50 500

3000

hose

3500

0

250

30355456

BPL HYDAC bladder Accumulator

ACCUMULATOR CHARGING KIT (Includes hose and charge valve assy) SCHWING PART NUMBER: 30355436 chargkit.eps

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Maintenance d. Remove the valve guard and gas valve cap from the accumulator (Figure 52). Valve Protection Cap

Valve Seal Cap

Figure 52 Showing the accumulator gas valve cap and valve guard

Valve Stem O-ring

HYDAC bladder Accumulator accum closeup

e. Back the T handle of the gas chuck all the way out (counter clockwise) before attaching the charging assembly to the accumulator gas valve. f. Close the bleed valve and disconnect the hose from the valve body. This will insure that the initial pressure reading is accurate, and prevent the pressure from escaping out of the filling hose. g. Screw the swivel nut to the gas valve of the accumulator and tighten to 10 to 15 inch/ pounds. h. Grasp the T handle on the gas chuck and turn it clockwise all the way down. This will press a pin into the gas valve, opening it. Read the pressure before you even hook up the nitrogen bottle. This prevents you from trying to add gas to an already overcharged accumulator. If the pressure is at or above the desired setting of 1450 PSI, skip to point l. If the pressure is low, continue to the next step. i. Make sure that the nitrogen supply is shut off. Attach the regulator assembly to the nitrogen bottle. Attach the hose to the high pressure regulator and to the gas valve on the charge valve assembly. j. Back off the high pressure regulator adjustment handle by turning counter clockwise. k. Crack open the nitrogen valve (on the nitrogen bottle), raise the pressure of the regulator adjustment handle, and SLOWLY fill the accumulator. Shut off the supply when the Startup 250:Users:Danny:Desktop:Operationmanuals:line pumps:All SP Rock Valve models:Frame files:Maintenance.fm

gauge indicates the desired nitrogen pre-charged pressure. NOTE! If the nitrogen bottle doesn't have at least 1450 PSI pressure, you will not be able to charge the accumulator to 1450 PSI. l. If the desired pre-charge is exceeded, close the nitrogen bottle valve, then SLOWLY open the bleed valve. Close the bleed valve when the desired pressure is reached.

NOTE! Never Let Nitrogen Out Of The Accumulator By Pressing The Gas Valve Pin W A Forei n Object. The Maith y Rup turegThe Valve Se at! High Pressure

m. Let the pre-charge sit for 10 or 15 minutes. This allows the gas temperature to stabilize. n. Recheck the gauge pressure. Add or release nitrogen until the pre-charge is correct. Be sure that the bleed valve is closed before adding pressure. o. When finished pre-charging, screw the T handle of the gas chuck all the way out, then open the bleed valve. p. Hold the gas valve on the accumulator, and unscrew the swivel nut. Remove the assembly. q. Mix some soap and water to make a bubbly mixture. Spread it around the gas valve cap to check for leaks. If a leak is found, replace the accumulator, or have it repaired by qualified personnel. Do not attempt the repair yourself. r. Replace the gas valve cap (tighten to 10-15 inch/pounds). Replace the valve guard. The job is complete.


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Maintenance

BLADDER ACCUMULATOR Cross Section of the Accumulator

1. Steel Shell 2. Bladder 3. Bladder Stem 4. Port Assemblies 5. Fluid Ports 6. Gas Valve

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Maintenance Stages of Bladder Accumulator Operation 1. Without Nitrogen Charge

2. With Nitrogen Charged to pressure P1

3. Influx of hydraulic oil for storage

4. Fluid charged to maximum working pressure P3

5. Discharge of hydraulic oil

6. Fluid discharged down to minimum working pressure p2



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Maintenance Annual maintenance Change hydraulic oil for age reasons Change hydraulic oil, if you haven’t already done it because of the weather. The same filling rules that apply to adding hydraulic oil apply to filling the tank after draining and cleaning. To change the oil: a. The engine must be shut off. Put the key in your pocket.

b. The oil should be cool. This is for safety reasons. Do not change oil that is above 120° F (50° C). c. Drain the old oil into barrels or another waste oil receptacle. The oil can be pumped out of the inspection cover on the top of the tank, or drained out of the bottom of the tank (Figure 53 ).

2Koildrn.eps

Figure 53 Change hydraulic oil

d. Once the oil is drained, clean the tank through the inspection covers using cleaning solvent and lint free rags. DO NOT USE GASOLINE! Remove all of the silt from the bottom of the tank. e. Close the drain, if open. Refill by pumping new oil out of the barrels with a filter cart. If no cart is available, rent one. REMEMBER! NEW OIL IS NOT CLEAN ENOUGH TO INSTALL IN YOUR UNIT. If you ignore this step you may begin having trouble with pumps and valves immediately, or within the first few days. See the information at the beginning of this chapter for specific information about hydraulic oils that are approved for use in Schwing machines. f. Change the main return filter before restarting the unit.

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Maintenance

Scheduled maintenance checklist The following is the normal recommended maintenance schedules (after the break in period).

Task

y l

ai

D

y l k ee

W

ly h t n o M

ly l

a u

n n -a i m e S

y ll

a u

n n A

d e d e

e N s A

re b m u N e

ga

P

Check Engine Fluid Levels

√

105

Check Tires

√

105

Check Hydraulic Oil

√

105

Bleed Moisture From Hydraulic Tank

√

105

Check Differential Cylinder Rod Packings

√

105

Inspect Bolts On Rams

√

106

Grease Rock Valve and Agitator Bearings

√

106

Inspect For Damage and Leaks

√

106

Check If Maintenance Is Due

√

106

Check Rock Valve Tension Nut

√

106

Inspect Cutting Ring/Rotate If Needed

√ √

107

Lubricate Mechanical Moving Parts

107

Check Unit Mounting Hardware

√

107

Check Hydraulic Pressures

√

107

Set Concrete Pump Pressure

√

108

Set Agitator Pressure

√

109

Clean Hydraulic Oil Cooler Fins

√

109

Change Hydraulic Oil For Temperature Reasons

√

110

Check the Pre-Charge Of The Accumulator

√

110

Change Hydraulic Oil For Age Reasons Change Hydraulic Oil Return Filter



√

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√

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Maintenance

Unscheduled maintenance The following items will have to be maintained on your pump. The time of service that you get from these parts varies dramatically from unit to unit because of the wide range of applications to which these machines are subjected. Differences in concrete and pressure play a major role in the wear of these components.

Inspecting hydraulic hoses Hydraulic hoses should be checked during routine inspections. Check for damage to the outer layer or fittings. For example; Wire reinforcement is exposed, separation from the fitting, chafing, cuts, cracks, brittle outer layer or any other type of deformation like layer separation, blistering, crushing, corrosion, or kinking. In addition check for leaking fittings or improper fit.

NOTE! Hydraulic hoses should be replaced every six years to avoid the possibility of accidental rupture and possible personal injury. The date of manufacture of a hydraulic hose can be found stamped into the hose fittin g.

Changing rams When you begin to see not just cement dust in your waterbox at the end of the day, but also small bits of sand or even pebbles, it is time to change the rams.

•

•

•

you are alone, so your attention will not become divided. If someone comes up, stop working until they leave. Reduce engine r.p.m. to absolute minimum, and adjust the stroke limiter to minimum strokes. The slower the hydraulic pumps are turning, the slower the differential cylinder rods will move. This buys extra time in case the unexpected happens. Where possible, use a nylon strap or towel to remove and replace the dogbone and ram. This will help to keep your hands out of the waterbox as much as possible. Please do not skip any of the above steps. If you leave the engine running, you are already skipping the one step that makes an accident impossible.

Preparation for long term storage If the unit will be stored for long periods of time the following precautions must be taken: • Fully retract both differential rod cylinders • Fill hydraulic reservoir to the base of the filler neck • Drain fuel tanks • Disconnect the battery • Coat Rock Valve components with light weight oil

NOTE! NOTE!

When ch anging rams, you will h ave to put your hands in the waterbox on several occasions. In the past, we instructed you to stop the engine each and every time before putting your hands into the waterbox, and we still highly recommend the practice.

However, If You Insist On Changing Rams With The Motor Running, You Must Take The Following Precautions To Avoid Amputation Of Hands, Arms And Fingers: •

Do Not Use The Remote Control For This Procedure! Unplug It And Store It.

•

Do Not Allow Anyone Else At The Passenger Side Controls When You Are Changing Rams. The chances of accidental amputation are greatly increased if more than one person is around. There are also less distractions when

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Contact Schwing service for instructions

Restarting unit after long term storage When the unit is being removed from long term storage, precautions must be taken before restarting using the following steps: • Restore differential cylinders to operating position • Drain condensation from the hydraulic reservoir • Be sure the level of hydraulic oil is at appropriate level • Perform a complete visual inspection of entire unit • Add fuel and reconnect the battery • Start engine and run at low RPM until unit reaches operating temperature and cycle pump.


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Maintenance To remove the old rams Close the shut-off valve (Figure 54). This gives you control over the direction of travel of the differential cylinders.

SWG98n197.eps

Figure 54 Showing the concrete pump shut-off valve (dump

valve). Drain the waterbox. Remove the waterbox cover, and the bolt down grate. Retract the left side differential rod almost all the way into the waterbox (Figure 55). Leave about 1.5 inches of travel, which will allow you to remove the spacer coupling (dogbone).

Push the emergency stop button on the operator’s panel. Stop the engine and put the key in your pocket (stopping the engine before putting your hands in the waterbox is mentioned at every appropriate spot).

Figure 55 Retract the left side rod into the waterbox all but about an inch and a half



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Maintenance A 55 mm open end wrench and a 24 - 30 mm box end wrench were supplied with the unit. You will need them for this step. Locate the 55 mm wrench on the dog bone to hold the assembly from turning. You can

rest the handle against the side of the waterbox as shown in Figure 56. Unscrew the 4 M20 bolts that hold the assembly together.

Figure 56 Remove the bolts from the dog bone Be sure all personnel and tools are out of the waterbox, then start the engine. Release the emergency stop button. Finish retracting the left side rod into the waterbox. The dogbone will fall out.

Push the emergency stop button on the operator’s panel. Stop the engine and put the key in your pocket. Remove the dogbone from the waterbox as shown in Figure 57.

Figure 57 Remove the dogbone Start the engine. Release the emergency stop button. Slowly extend the cylinder rod until it just contacts the rubber ram flange. Be Careful Not To Drive The Rubber Ram Into The Material Cylinder.

of the unit. Call the Schwing Service Department at (651) 429-0999 for instructions on this procedure.

NOTE! If it happens that you accidentally knock the ram into the m aterial cylinder so far that you can’t reach it, you will have to remove it by knocking it out from the rock valve end

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Maintenance

Figure 58 Showing the removal bolt grooves on the flanges Push the emergency stop button on the operator’s panel. Stop the engine and put the key in your pocket. There is a groove in the ram flange that will line up with a groove in the cylinder flange. A 1/2 inch x 2 1/2 inch bolt with nut will drop into this groove and allow you to pull the ram out (Figure 58). The fit should be snug, but there’s no need to tighten the nut with tools,

and note that the ram flange and cylinder flange are shown outside of the waterbox for clarity of the illustration. Start the engine. Release the emergency stop button, and slowly retract the cylinder rod until the ram is clear of the material cylinder (Figure 59).

Figure 59 Slowly bring the ram into the waterbox Push the emergency stop button on the operator’s panel. Stop the engine and put the key in your pocket. Remove the nut and bolt, and the ram will be free to come out of the waterbox. Clean and inspect the bolts and cone washers, the dog bone, and the cylinder flange. Replace any damaged or worn parts with new ones.



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Maintenance To install the new rams Apply Loctite primer (or equivalent) to the M20 bolts. Allow the primer to dry. While the primer is drying, apply a liberal coat of clean grease to the new rams. There is no such thing as too much grease here, because the excess will be wiped off by the material cylinders during installation.

With the engine still stopped, hold the new ram up to the cylinder flange. Line up the grooves, and drop your nut and bolt into place to hold the assembly together. Again, you should only tighten the nut finger tight. Start the engine. Release the emergency stop button. Slowly extend the cylinder until the ram is installed in the material cylinder, but the mounting flange is still exposed enough to remove the nut and bolt (Figure 60).

SWG98n214.eps

Figure 60 Slowly push the new ram into the material cylinder It is important to install the dog bone against the new ram first, not the cylinder flange. This gives you an extra 6 to 8 inches of safety margin when you extend the cylinder to meet the dog bone. If you attach to the cylinder flange first, chances are good that you will accidentally knock the new

Push the emergency stop button on the operator’s panel. Stop the engine and put the key in your pocket. Remove the nut and bolt. Start the engine. Release the emergency stop button. Slowly retract the rod again, until there is room to install the dog bone. Push the emergency stop button on the operator’s panel. Stop the engine and put the key in your pocket. Apply Loctite 242 or equivalent to 2 of the M20 bolts. Place the dog bone up against the flange of the new ram. Install 2 of the M20 bolts (with Loctite) And The Cone Washer Sets. At this time finger tighten only.

ateri at ram into the l acylin far thfor yo be am ble to are ch it.der Seesopoint u won’t information on this problem.

Start the engine. Release the emergency stop button. Slowly move the cylinder down to where it’s flange butts up to the dogbone. Be careful not to go too far (Figure 61)!

NOTE!

Figure 61 Slowly move the cylinder to meet the dog bone

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Maintenance Push the emergency stop button on the operator’s panel. Stop the engine and put the key in your pocket. You may have to slightly rotate the dog bone to align the bolt holes with the cylinder flange. When aligned, coat the 2 remaining M20 bolts with Loctite and install, including the cone washer sets. Once all 4 bolts are started, you may tighten the bolts to the torque spec for M20 10.9 bolts (420 ft/lbs). Repeat the previous steps for the right side ram. Open the shut-off valve. Note that the unit will not cycle with this valve closed.

Changing the Material Cylinders. The material cylinders eventually wear out. They are considered worn out when the chrome starts to wear off the barrel. Normally, the end attached to the Rock Valve wears out first, because it sees the most concrete. The waterbox end may be in like-new condition, because that end never experiences concrete. For this reason, the material cylinders were designed to be able to flip end 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 cylinders before they get too thin or break through in one or more spots. Once that happens, you cannot flip them, because they will be structurally too weak to hold the pressure forces at the waterbox end. The procedure for changing and aligning the material cylinders is the subject of Service Bulletin G-102/88. Contact the Schwing Service Department at (651) 429-0999 or 678-560-9801 if you need a copy of the bulletin.

Tier IV engine Regeneration Control Logic Regeneration Operation: The following section explains how the engine control system monitors and manages the exhaust after treatment system. Primarily the system works passively, using the Diesel Oxidations Catalyst (DOC) to reduce particulates and promote the production of NO 2, which is used for oxidations of Particulate Matter (PM) in the Diesel Particulate Filter (DPF). These chemical reactions will occur when the gas temperature into the DOC is greater than 250°C. This chemical process is known as ‘Passive Regeneration’. The engine control system will monitor the exhaust system temperature and engine duty to predict the amount of soot accumulating (if any) in the particulate Startup 250:Users:Danny:Desktop:Operationmanuals:line pumps:All SP Rock Valve models:Frame files:Maintenance.fm

filter. The engine control system will elevate exhaust system temperatures to initiate ‘Active Regeneration’ if there is insufficient passive regeneration or if the maximum time between active regenerations has been reached. When triggered the engine control system will elevate the exhaust system temperature to increase the DOC temperature. Once the target DOC temperature is reached the control system will introduce hydrocarbons into the exhaust gas stream. The hydrocarbons will oxidize across the DOC, for thermal oxidation of the particulates in the filter.

Regeneration Normal Operation States State 1 - Primary Operation.

The system is designed to passively regenerate during engine operation. A typical machine duty cycle should be sufficient to promote good levels of passive regeneration. The solid line in Figure 63, State 1, shows the level of soot rising and falling over time. The system passively regenerates at different levels dependant on machine duty and DOC temperature, the soot level always staying below 90% soot loading. State 2 - Active Regeneration

The engine control system predicts the level of soot accumulation in the particulate filter. If the engine duty cycle does not allow sufficient exhaust temperature for passive regeneration, soot accumulation will continue to rise. When optimum soot loading is reached, between 90%130% and all of the preconditions are met, an active regeneration will start. Active regeneration will reduce soot loading to approximately 20% at which point active regeneration will stop. During automatic active regeneration normal operation of the machine can be continued. State 2 shown in Figure 64 shows an accumulation of soot above 90%. The conditions for automatic regeneration are met at point A ‘Regeneration Active Lamp’ is illuminated, soot is reduced to 20%.Active regeneration will be triggered 20 engine hours from the last active regeneration if the soot model has not triggered sooner. If regeneration is required and the engine speed is above 1200rpm automatic regeneration will start. Once started the engine speed may fall below 1200rpm, however the speed must not fall below 950rpm.The low idle speed will be temporarily modified to 950rpm during regeneration if it is normally below this threshold.


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Maintenance Regeneration Monitoring and Warning Levels State 3 – DPF Elevated Soot Loading

If an active regeneration does not occur between 90%130% the DPF warning lamp will illuminate at 130% (Figure 64 Point C). This may occur due to conditions for active regeneration not being met or if the operator has disabled the active regeneration. The DPF lamp is used to indicate that regeneration of the DPF is required. It is recommended that if applicable the DPF regeneration disable switch be deactivated. If the system has not been disabled then a manual regeneration should be performed using the switch on the control panel (Figure 62). If the DPF lamp is on for one of the above reasons, then it will remain on until regeneration has been completed.

DUMMY PLUG OR REMOTE MUST BE PLUGGED IN TO OPERATE.

State 4 (D) –DPF Excessive Soot Loading

If the DPF Regeneration disable switch continues to be activated or a manual regeneration has not been performed then the soot load will continue to increase to 170% (Figure 64 Point D) at this point the warning lamp will illuminate and the DPF lamp will remain illuminated. The engine control system will invoke a 25% derate. At this point automatic regeneration is disabled by the engine ECM, only a manual regeneration can be completed. State 4 (E) – DPF Non Recoverable

If soot is allowed to accumulate to 230% the engine should be stopped, the shutdown lamp will illuminate. If the engine monitoring system is configured to shutdown the engine will shutdown automatically. The engine may be restarted but will shutdown after 30 seconds of operation.

98351115 02 spcontrolpanel.eps

Manual Regeneration Switch

Figure 62 Switch on panel for manual regeneration

normalregen.eps

130

J1939 SPN 3701 - 001

AUTOMATIC ACTIVE REGENERATION

% G N I D90 A PASSIVE REGENERATION O L T O O S

A

J1939 SPN 3701 - 000

State 5 – DPF Delta Pressure Monitoring (Wall Flow

STATE 1

Only)

STATE 2

The pressure differential measured across the DPF is used as an input to a flow resistance model. This model allows a comparison of the DPF soot load against the primary soot load estimation model. Under normal operating conditions the delta pressure based model will predict soot load below the engine software model. Active regeneration can be triggered from the flow resistance model if the DPF is becoming blocked at a higher rate than expected (according to the soot load estimation model) (Figure 64 Point F).

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TIME

Figure 63 Normal regeneration


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Maintenance

DPF NON RECOVERABLE – REPLACE DPF

! 230 AUTOMA TIC ACTIVE REGENERATION DISABL ED

E

! J1939 SPN 3701 - 011

OR MANUAL REGENERATION ONLY

! % G N I 170 D A O L T O O S 130

D J1939 SPN 3701 - 010

AUTOMA TIC OR MANUAL ACTIVE REGENERATION

C

F J1939 SPN 3701 - 001

AUTOMA TIC ACTIVE REGENERATION

90

J1939 SPN 3701 - 000

PASSIVE REGENERATION

STATE 3 STATE 4 STATE 5

TIME

Figure 64 Monitoring and warning levels



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Maintenance

NOTES!

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Appendix

swg99a001.eps

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

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Appendix

Appendix

•

The Appendix contains the technical documentation of your machine and its systems. This documentation is correct for your machine when it left the factory, but it may need to be updated from time to time.

•

Hydraulic Oil Viscosity Chart NOTE! aslic delioil. veredThis Y ouvrisSchwin nit with Mobil Uni N46 g uhy multi drw au viscosity oil should work nicely for any temperature between -20˚ F and 100˚ F. If you have chosen to change to a regular viscosity oil, pay close attention to the following. The chart below shows the relationship between the oil temperature and its viscosity. As you can see, the oil gets thicker when the temperature is low, and thinner as the temperature rises.

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•

The cold start limit represents the coldest temperature at which the oil is thin enough to flow into the hydraulic pumps. Anything colder, and the pumps would not be able to suck the oil (cavitation). The minimum permissible viscosity represents the warmest temperature at which the oil will still be thick enough to provide lubrication and sealing. Anything warmer, and the components will have metal to metal contact (thermal breakdown). The optimum operating viscosity is the range of oil thickness where the oil will work the best (thin enough to flow easily, thick enough to protect the system components).

For an example of how to read the chart, look at the range for VG-46 oil below. The chart shows the cold start limit as -8° C (18° F), and the minimum permissible viscosity as 90° C (194° F). The optimum range is at about 50° C to 76° C.


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Appendix

Torque Specifications for Metric Bolts The following charts show the tightening torques specified for the bolts used on Schwing equipment. The charts are to be followed unless there is different torque spec. indicated for a particular procedure. Torque specifications are very important for proper machine function. For further information on this subject, see the section on bolt tightening in the

.

Maintenance section of this manual. 1. Nuts and Bolts as per DIN 912 – 931 – 933 – 934 – 6914 - 6915 Applicable to: 1. Geomet/Dacromet 500 coating.

2. Black and silver-chromated nuts and bolts fitted with mounting paste such as Cu or MOS 2.

Assuming a friction coefficient of µ = 0.1.

Coarse-Pitch Thread n o ti a n ig s e D

Nm

M 4 X 0.7

2.2

M 5 X 0.8

4.3

M 6X1

7.5

d a re h T

Fine-Pitch Thread

* Fitting Tightening Torque (Nm, ft lb)

Bolt Size

Bolt Size

Grade

8.8

10.9 ft

12.9 ft lb

n o ti a n ig s e D

* Fitting Tightening Torque (Nm, ft lb) Grade

8.8

10.9

1.6

3.2

2.4

3.8

2.8

M 8X1

20

15

28

21

33

3.2

6.4

4.7

7.5

5.5

M 10 X 1

40

29

57

42

68

5.5

10.8

8

12.6

9.3

37

lb

27

Nm

55 100

f t lb

12.9

ft lb

M 10 X 1.25

Nm

ft

Nm

lb

Nm

d a e r h T

41

Nm

64

f t lb 24 50 47

M 8 X 1.25

18

13

27

20

31

23

M 12 X 1.25

67

49

74

115

M 10 X 1.5

36

27

53

39

62

46

M 12 X 1.5

65

48

95

70

110

81

M 12 X 1.75

62

46

90

66

108

80

M 14 X 1.5

105

77

155

114

180

133

85

M 14 X 2

100

74

140

103

170

125

M 16 X 1.5

160

118

235

173

280

206

M 16 X 2

150

111

225

166

260

192

M 18 X 1.5

240

177

345

254

400

295

M 18 X 2.5

220

162

310

228

365

269

M 20 X 1.5

335

247

475

350

590

435

M 20 X 2.5

300

221

440

324

510

376

M 20 X 2

560

413

M 22 X 2.5

420

310

590

435

700

516

M 22 X 1.5

460

339

650

479

750

553

M 24 X 3

530

391

750

553

880

649

M 24 X 2

560

413

810

597

940

780

575

1300

958

M 27 X 3 M 30 X 3.5 M 36 X 4

*

1080 796 -

-

1120 1530

826 1128

**2000 **1475

1750 1290 -

M 27 X 2 M 30 X 2

820

604 1170

862

1390

1170 862 1660 1224 1930

693 1025 1423

-

The fitting tightening torque corresponds to the axial force in the bolt at which the limit of elasticty of the latter is ut ilised 90 % by tension and torsion.

12_09

** only Octagonal column



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Appendix

GENERAL SAE BOLT TORQUE SPECIFICATION TABLE Use the values listed unless special torques are specified. Values are for UNC and UNF thread fasteners. Values do not apply if graphite, moly-disulphide or other extreme pressure lubricant is used.

SAE Grade Number

5

8

Bolt head identification marks. See Note below. BoltSize 1/4” 5/16” 3/8” 7/16” 1/2” 9/16” 5/8” 3/4” 7/8” 1” 1-1/8” 1-1/4” 1-3/8” 1-1/2”

l b.-ft 9-11 17-20.5 35-42 54-64 80-96 110-132 150-180 270-324 400-480 580-696 800-880 1120-1240 1460-1680 1940-2200

N•m

lb.-ft

12-15 23-28 48-57 73-87 109-130 149-179 203-244 366-439 542-651 787-944 1085-1193 1519-1681 1980-2278 2631-2983

12-15 24-29 45-54 70-84 110-132 160-192 220-264 380-456 600-720 900-1080 1280-1440 1820-2000 2380-2720 3160-3560

N•m 16-20 33-39 61-73 95 -114 149-179 217-260 298-358 515-618 814-976 1220-1464 1736-1953 2468-2712 3227-3688 4285-4827

NOTE: Bolt head identification marks are shown as per grade. Manufacturerís marks may vary.

Recommended Emergency Hose Kit We recommend that you carry one of each of the following hoses on the unit for use if you would blow a hose on the job. Each size listed represents the longest

hose of each diameter that is installed on the unit in the factory. Keep the inside of the hoses clean until needed by capping the ends and taping the cap into place. Dirt introduced into your hydraulic system by installing a hose that was not kept clean will cause a variety of problems in the operation of the unit.

WPhose lengths.eps

128

Diameter

Length

Part Num ber

8 13 16 20 25

1000mm 1200mm 800mm 1250mm 1100mm

10050174 10049906 10049943 10049962 30347674


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Fitting Wrench Sizes This chart is provided as an aid to selecting the proper wrench to hold or tighten the hydraulic fittings found on Schwing equipment. Sizes may change, use only as a guide.

Straight Fittings

Banjo Fittings



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Appendix

Maintenance checklist The following is the normal recommended maintenance schedules (after the break in period).

Task

y l

ai

D

y l k ee

W

ly h t n o M

ly l

a u

n n -a i m e S

a u

n n A

d e d e

e N s A

re b m u N e

ga

P

Check Engine Fluid Levels

√

105

Check Tires

√

105

Check Hydraulic Oil

√

105

Bleed Moisture From Hydraulic Tank

√

105

Check Differential Cylinder Rod Packings

√

105

Inspect Bolts On Rams

√

106

Grease Rock Valve and Agitator Bearings

√

106

Inspect For Damage and Leaks

√

106

Check If Maintenance Is Due

√

106

Check Rock Valve Tension Nut

√

106

Inspect Cutting Ring/Rotate If Needed

√ √

107

Lubricate Mechanical Moving Parts

107

Check Unit Mounting Hardware

√

107

Check Hydraulic Pressures

√

107

Set Concrete Pump Pressure

√

108

Set Agitator Pressure

√

109

Clean Hydraulic Oil Cooler Fins

√

109

Change Hydraulic Oil For Temperature Reasons

√

110

Check the Pre-Charge Of The Accumulator

√

110

Change Hydraulic Oil For Age Reasons Change Hydraulic Oil Return Filter

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Appendix

Output charts

•

The hydraulic pumps that drive your concrete pump are horsepower controlled. That means that when pressure rises past a certain point (known as the breakpoint), the pumps will change their displacement per revolution resulting in less flow and less strokes per minute. The reason for this is so the pumps will not stall your engine by drawing too much horsepower. Output charts show the horsepower curve (in kilowatts, or KW) of the concrete pump hydraulic circuit. From them, you

•

can determine: • the maximum concrete pressure of the pump kit model. • the maximum output (in cubic yards per hour) of the pump kit model.


• • •

the maximum strokes per minute of your pump kit model. the maximum output (in liters per minute) of your hydraulic pumps. the output that can be expected at various pumping pressures. the condition of your hydraulic pumps (when used in conjunction with a flow meter). the break point of your hydraulic system.

An explanation of an output chart is shown in the chart following, by some examples of chart usage. The output chart of the pump kit shipped with this manual is shown in the Appendix. .


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Appendix Using the chart. Example 1, checking flow at a given pressure: Your unit is configured on the rod side (standard from the factory). You notice that your machine is not getting as many strokes per minute as you are used to seeing. You count the strokes and see that you are getting about 21 1 /2 per minute. You check your pressure gauge and see that the hydraulic oil pressure is at 220 bar.

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To determine if your unit is acting normally: Locate the 220 bar oil pressure marking on the rod side scale (item A in the example below). Next, you draw a line straight across the page until you intersect with the horsepower curve (item B in the example below). Draw a straight line down from the intersection point until you pass through the rod side number of strokes scale, and read the strokes per minute. At 220 bar you should be getting a little more than 21 strokes per minute. Your unit is fine.


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Appendix Example 2, checking your hydraulic pumps. To determine if your pumps are still in good working condition, you use the output chart and a flow meter. You test one pump at a time, multiply the readings by 2, and chart the result. You multiply the readings because the chart is based on the output of two pumps, but we are only testing one at a time. To test your pumps: • Be sure that you are using the chart that applies to your unit. • Be sure to set the RPM to the correct setting. Even a few RPM difference will give you a bad reading. Check it with a digital tach, if one is available.

•

•

Be sure that you know how to use your flow meter. Read the instructions that came with it. Flow meters must be calibrated periodically. Make 2 copies of the output chart, so you don’t ruin your srcinal. You need one chart for each pump tested.

Read the flow at 0 bar, 100 bar, 150 OR 200 bar, 250 bar, and 300 bar. You also document the breakpoint. The breakpoint is where the flow drops off rapidly. You will be able to notice it on the flow meter. If you think it would be helpful, copy the chart below. Check which reading (150 or 200 bar) you used. The breakpoint will be very close to either 150 or 200 bar, so it’s not necessary to take them both. The breakpoint specification is shown on each output chart.

As an example, we’ll pretend that we have just taken these readings:



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Appendix The next step would be to plot the readings on the output chart. Take one of your clean out put chart copies and proceed as follows: • Lay a straight edge (a ruler or similar device) horizontally across the page, at the pressure point that you are plotting. Make a light line across the chart. In the example below we are using the rod side scales and curve (you could use the piston side scale and curve instead). The ruler is shown ready to draw a line at 250 bar hydraulic pressure.

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•

• •

Turn the ruler sideways and draw a lig ht line up the page from the liters/minute reading you took at that pressure (don’t forget to multiply the reading by 2). In our example, we measured 276 liters at 250 bar. At the point where the two lines intersect, put a dot. Do the same thing with each pressure reading. You should end up with 6 dots.


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Appendix Next, connect the dots. If your plotted line reasonably matches the specification plot on the chart, the pump is OK. If your line is to the lower left of the spec, the pump is getting weak. If your line is to the upper right

of the spec, you’ve done the test incorrectly, or you are using the wrong chart. In our example, the pump is OK (see the plot below).

Next we need to check the 2nd pump. We hook up the flow meter just as when we checked the first pump. Again, be sure that you have the correct speed, gear, chart, etc. This time our example will have worse results.



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Appendix Again, plot the results on a clean copy of the flowchart. As we plot this pump, we can see that the dots are moving quite a bit to the inside of the flow specification (see the chart below).

When you connect the dots, the line is completely below the specifications. This pump is very weak, and will completely stop pumping oil soon. You may notice high heat with this unit, if you are pumping at high oil pressures. NOTE! Never try to make up for this weak pump by increasing the speed of the engine. As the pump turns faster than specification, it will not be able to suck oil as fast as it is turning (it is called “cavitation” if this happens), and immediate failure could result.

material cylinders, or hydraulic pumps, because you may need a different output chart than the one that was srcinally shipped with the unit.

If the plotted curve matches the spec for a while, but the breakpoint is too high or too low, it is possible to make an adjustment. Contact the Schwing Service Department for the procedure. There are many different possible pump kits and power settings for each unit. If you accidentally destroy your srcinal output chart, please have your serial number handy when you call to get a replacement. Also, please advise us if you have changed differential cylinders,

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Appendix

Nomograph Using a Nomograph General Information Concrete pumps are limited in what jobs they can do by 3 things: 1. The amount of power available, 2. The maximum concrete output available, and 3. The maximum concrete pressure available. To determine the suitability of a particular pump for a particular job, a tool is needed to estimate the power required by the job. The nomograph is this tool. In the case of a concrete pump that is driven by it’s own prime mover, such as a trailer mounted concrete pump, or a truck mounted pump with separate drive engine, the power rating (in Kw) is shown for the engine or electric motor. In the case of a truck mounted pump that uses a PTO from the truck engine, the power rating reflects the power output of the hydraulic pumps only (all the power from the truck engine is normally not available to the concrete pump and should not be used for power calculations).

Assuming that you know the required output for the job, the nomograph will help you to calculate the required pressure. With known output and pressure, the power requirement can be found. The nomograph was developed by extensive trial and error testing and has proven to be accurate to within ±10% in nearly all pumping applications. The srcinal nomographs used “spread measure” of fresh concrete instead of slump and the two are not directly interchangeable. In translating the charts from spread measure to slump some approximations are used, but the ±10% accuracy will still apply. In all cases it is assumed that you will receive fresh, quality concrete on your job, and that the concrete will be plastic enough to flow into the material cylinders. If you know that the concrete will be hard to feed into the cylinders you should adjust the output requirement to compensate for incomplete filling. For example, if you will need 50 cubic yards per hour into the form but the concrete is so stiff that it will only provide 80% filling of the cylinders, then you should multiply the output required by 1.25.

The nomograph is divided into 4 quadrant s.

Figure 65 Quadrants



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Appendix The upper left quadrant is the beginning and end point of the graph, and shows maximum output, pressure and power for a specific machine. The upper right quadrant accounts for the relationship between output of concrete and pipeline diameters. The lower right quadrant accounts for the resistance to flow of the entire pipeline system, and the lower left quadrant accounts for the pumpability of the concrete. To use the nomograph, you begin at output required and move in a clockwise direction until you encounter the lines that represent your job situation. Each time you meet the line that applies, you make a 90° turn until you come to a point on the bottom of the upper left quadrant that shows pressure required (Figure 66).

•

We will need an average output of 45 cubic yards/hr, but we will be pumping only 75% of the time. The rest of the time will be spent moving hose, removing pipe lengths, waiting for concrete trucks, etc. This means that when we are actually pumping, we will need an

• •

output rate of 45 ÷ .75 = 60 yd3/hr. We will use 5" diameter pipeline for our job. We will have the following pipeline lengths: 30 ft. horizontal, 1 long sweep elbow, 250 ft.

•

vertical, sweep elbows, horizontal,2 40long feet of 5" rubber hose. 150 feet We will specify a slump of 3-4", and use the 3" line on the chart.

To illustrate the use of a nomograph, we will use a hypothetical job situation with the following specifications:

Figure 66 Moving around a nomograph •

In addition, when we add the pressure for the vertical run we will have to add 1.1 times 250 ft. = 275 PSI.

All of these criteria willquadrants. be explained in detail as we go through the individual

138

A Description of the Quadrants a. The upper left quadrant describes the power curve of a given Kw rating, and the maximum flow and maximum pressure of a particular concrete pump.


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Appendix

Figure 67 Upper left quadrant Any concrete pump selected for a certain job must meet 3 technical parameters: 1. The TK number of the pump must be equal to or greater than the TK number of the job, 2. the maximum output required by the job must be available from the pump, and 3. the maximum pressure required by the job must be available from the pump. It is important to notice the pump max. pressure and max. output even if the TK of the pump is larger than the job requirement. An example of the reason for this is illustrated in point #3 below. These parameters are decided during the design stage of the unit and cannot be adjusted on the job. If the unit has the ability to go from rod side to piston side, maximum pressure and output can be exchanged, that is you can decrease one while increasing the other an equivalent amount. 1. The Technical Identification Number (abbreviated as TK) is the Kw multiplied by 25, and the number 25 is a constant that has several efficiency factors figured in. When using a metric nomograph (pressure in bar and flow in cubic meters per hour), the pressure multiplied by the flow will always directly Startup 250:Users:Danny:Desktop:Operationmanuals:line pumps:All SP Rock Valve models:Frame files:Appendix.fm

relate to the TK. For example, if you needed 50 cubic meters/hour and determined that this will require 60 bar you can multiply 50 x 60, which equals 3000. Any pump you select must have a TK of 3000 or greater. If you are using a nomograph that has been converted to American units of measure (pressure in PSI and flow in cubic yards/hour) you can still multiply the pressure times the flow, but you must divide the answer by the conversion factor between metric and US units of measure to get the TK. The conversion factor for yards 3 to meters3 and bar to PSI is 18.966. For all practical purposes you can use 19. For example, if you need 60 cubic yards/hour and determine that your job set-up will require 950 PSI, you can multiply 60 x 950, which equals 57,000. Divide this by 19 and you find that your TK requirement is 3000. Again, any pump you select should have a TK of 3000 or greater. 2. The Maximum Output (abbreviated as max Q) is determined by the size of the hydraulic pumps, the number of strokes per minute and the size of the differential and


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Appendix material cylinders. Usually, the unit is designed so maximum output can be achieved only at less than maximum pressure. 3. Maximum Pressure (abbreviated as max P) is determined by the size of the differential and material cylinders and the setting of the main relief valve. To be sure that the unit will handle the job be careful to notice max P and max Q. Here is an example of why that is important. You only need 20 yards/hour, but you calculate that you will need 1900 PSI pressure. The TK of this job is 2000. The pump has a TK of 2775, so there is enough power available, BUT... the maximum pressure available from the pump is only 1570 PSI. This pump wouldn’t do the job. b. Follow the chart in a straight line from required output into the upper right quadrant until you come to the size of the pipeline that you will use. A good rule of thumb for sizing pipeline is to use the largest diameter pipeline that you can. It takes less force to move concrete through a 6" pipeline than, for example, a 4" pipeline. When pressure is exerted on concrete in a pipeline, a paste of water and cement fines coats the inside of the pipeline and forms a slippery layer on which

the bulk of the concrete slides. While it is true that a 6" pipeline has more surface area to coat than a 4" pipeline (49% more), the volume of concrete that can move on the layer is increased by 125% which results in lower velocity of the concrete (in feet per second), lower friction, and therefore lower pressure. A pump that may not be capable of completing a difficult job through 4" or 5" pipe may very well be able to do it through 6" pipe.

NOTE! Experience has taught us that 5" is the optimum pipeline size for lengthy vertical runs such as those found on a high rise building. It is large enough for most aggregate, but small enough that you minimize backers when the concrete valve cycles. You must also consider the men at the point of placement. There are very few, if any, hose men that can move 6" hose on a slab all day. There is no provision in the nomograph for mixing pipeline sizes. For example, if you will be reducing from 5" to 4" pipe you should calculate the ch art as if you were using 4" pipe for the entire distance. This will not be com pletely accurate, but you will be safe in your pressure calculation. In our example, we will use 5" pipeline (Figure 68).

Figure- 68 Upper right quadrant Pipeline diameter

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Appendix When the output line intersects the pipeline diameter that corresponds to your job, you should draw a line straight down into the lower right quadrant, as shown in Figure 68. c. The lower right quadrant refers to the proportional value of your pipeline. It is a way of taking into account not only the length of the pipeline, but also the amount of bends, the increased resistance of flow in rubber hose, etc. It is more a measure of the resistance to flow than a length measurement. To calculate the proportional value of your pipeline, the following criteria will apply: • each 90° bend with a radius of 250 mm (boom elbow) = 3.5 feet

• • •

•

each 90° bend with a radius of 1 meter (long sweep) = 10. feet each 30° or 45° bend with a radius of 1 meter or 250 mm = 3 feet each section of rubber hose causes 3 times as much resistance as the same length of steel pipe (e.g. 12 feet of rubber hose has the same resistance as 36 feet of pipeline). all distances should be fig ured equally whether they are horizontal and vertical. The increased pressure required to push concrete vertically is accounted for by adding pressure, not distance. Our example pipeline is shown below (Figure 69).

.

Figure 69 Calculating Proportional Values Startup 250:Users:Danny:Desktop:Operationmanuals:line pumps:All SP Rock Valve models:Frame files:Appendix.fm


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Appendix Once you have calculated the proportional value of your pipeline, you can extend your line down from the upper right quadrant until it intersects with the line that represents your pipeline. When you reach the

intersection, make a 90° turn clockwise, into the lower left quadrant. As noted above, we will use 600 feet as our proportional value (Figure 70).

Figure 70 Lower right quadrant Proportional Value of Pipeline d. The lower left quadrant refers to the pumpability of the concrete. If the concrete specifications allow a range in slump (for example 3 - 4"), you should always use the lower end to be safe. In our example, we use 3"

slump. You extend the line from the lower right quadrant until it intersects with the 3" slump line, then make a 90° turn clockwise, which will lead you back into the upper left quadrant through the pressure scale (Figure 71).

Figure 71 Lower left quadrant - Pumpability of the Concrete

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Appendix As you can see by the chart in Figure 71, we are reentering the upper left quadrant through the pressure scale at about 650 PSI. Remember, we now have to add the head pressure for our vertical rise. At 1.1 PSI per foot of level difference, and our 250 foot vertical run, we must now add 1.1 x 250 = 275 PSI to the 650 PSI from the chart.

downhill the operator will need special knowledge, but you don’t need to add any head pressure to the nomograph.

The nomograph is now complete. The TK of our job can be calculated like this:

TK = (PSI x yd3/hr) ÷ 19

650 PSI+ 275 PSI = 925 PSI

We need a unit that is capable of 925 PSI, and 60 yd 3/ hr. The TK of this job is:

NOTE!

TK = (925 x 60) ÷ 19

When calculating the head pressure from vertical runs, it doesn’t matter if the pipeline runs straight up and down, or if it runs uphill at an angle. Only the level difference in feet is needed for the pressure calculation. If the pipeline is running

TK TK = 55,500 = 2921÷ 19 The unit must have a TK of over 2921 and it must be able to pump 60 yd 3/hr and 925 PSI Simultaneously. Look at the pump shown in our sample nomograph (Figure 72).

Figure 72 Is this unit sufficient for the job? • • •

Can the unit pump at 925 PSI - YES Can the unit pump 60 yd3/hr? - YES Can the unit pump both simultaneously? - NO! This unit will not do the job.

The engine is a little bit too small. The intersection of 3

60 yards /hr and plotted forthat visual representation, but925 youPSI canhas seebeen immediately the TK of the job (2921) is bigger than the TK of the unit (2775). The curved black line represents the TK of the unit. If the unit is going to be able to handle the job, the Startup 250:Users:Danny:Desktop:Operationmanuals:line pumps:All SP Rock Valve models:Frame files:Appendix.fm

intersection of pressure and yds 3/hr will be to the right and down from the curved line. Anything to the left or above the line is beyond the power of the engine. What if we could order this same unit with a slightly bigger engine? The TK of the bigger engine is 3300. This should work. Plotting the intersection of our hypothetical job again, you can see that it falls within the power zone of the engine (Figure 73).


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Appendix

Figure 73 Same model pump with a bigger engine. Bearing in mind that the nomograph should only be considered accurate to within ± 10%, you should always calculate conservatively, and allow for the graph tolerance. In the case of the pump in Figure 73, we should still be safe even if the pressure required were 10% greater (1017 PSI). What if you already own the pump shown in Figure 72? Is there anything that can be done to the job specifications to make the pump with the smaller engine work? You could use the smaller TK unit shown if Figure 72 if you can get an OK to do any of the following things: • •

•

Pump the top of the building at 50 yd 3/hr instead of 60 yd3/hr. Pump the top of the building at a 4" slump instead of 3" (this would still be within specifications). Remove some of the rubber hose at the end of

the horizontal run. With job circumstances that did not require a substantial vertical run, you could also use 6" instead of 5" diameter pipeline.

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Appendix

Weld On Ends / Coupling Comparison Shown is a comparison among commonly used ends/couplings. No two ends shown can be joined without the use of an adapter pipe or a special adapter clamp. Clamps and pipe strength must also be considered when determining proper system requirements. The ratios shown in the text below represent the safety factor from burst : working 1. Male / female o-ring type couplings have the

Male / Female O-Ring (shown with clamp)

highest pressure ratingThey of the ends commonly for concrete pumping. can withstand 4350used PSI @ a 2:1 safety factor. They are self aligning and waterproof when used with o-rings in good condition. Typically not used on booms because of their weight. Pipes equipped with this style coupling cannot be swapped end-for-end. 2. Heavy-Duty couplings are designed for pressures up to 2250 PSI @ 2:1. They have 20% more contact area than metric couplings, and a tapered face that draws the pipe sections together during assembly. Both the ends and clamps weigh more than metric style, and therefore should not be used on booms without consulting the manufacturer. 3. Metric couplings are designed for pressures up to 1400 PSI @ 2:1. They have 85% more contact area than grooved couplings. The face is flat and will not draw pipe together. Although they have a raised edge, they are not compatible with Heavy Duty couplings unless a special clamp or an adapter pipe is used to change from one style to the other. Metric connections are standard equipment on booms because of the weight savings compared with other styles. 4. Grooved couplings (lip height of 0.15” or less) are designed for pressures only up to 750 PSI @ 2:1. The recessed groove is hard to clean when changing pipe on a job. The weld-on end fails before the pipe because the groove is cut into the pipe thickness, making it the weakest spot. Grooved couplings are not recommended for concrete pumping applications.

Heavy Duty

Metric

≤ 0.15"

Grooved (Victaulic)

weldends4.eps

NOTE: All pressure ratings listed refer to 5 inch (125mm) diameters in like-new condition. Other pressures would apply to other sizes.



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Appendix

MInimum Pipe Wall Thickness Minimum Pipe Wall Thickness As a Function of Pressure 11 gauge

9 gauge

gauge 7

SCHEDULE 40 (1/4 wall)

3/16”

300 4200 4000

290 280 270

3800 3600

4

260

“

H

T A E

T

E R

.4 4

T A

”

E H

T A

T

R

250 4.8

240 3400

D E

220

3000

210

”

&

E

D

“ .9 4

5

230

3200

T A E

E H

T A

R T

E

E T A

E R T “

H

D

E T A

D

6

“

E H

T A

E T A E R T

D

s sy 0“ 4.

m te

EAT

4.9

4 4.

“s

ys

m te

) m m m te 25 (1 m ys s te m “ 4.8 yste 5“ sys )s e ug ga m 11 ste 9, sy 7, 6“ ( “

200 2800

190

E2600 R U S2400 S E R P2200 L A I 2000 R E T A1800 M

180

1600

110

1400

100

170 160 150 140 130 120

s p e . 2 s s re P s v l a w e ip p

90 1200 1000 800

80 70 60 50

600

40

400

30 20

200 0

PSI

” 0 2 1 .

10

0

” 0 5 1 . 0

” 7 7 1 . 0

” 8 8 1 .

” 0 5 2 .

0

0

0 BAR

0

.heattreated

.025"

.050"

.075"

.standard

.100"

.125"

.150"

.175"

.200"

.225"

.250"

.275"

.300"

.325"

.350"

.375"

PIPE WALL THICKNESS

1. 2. 3. 4. 5.

This chart assumes a safety factor of 2:1. Higher safety factors may be required in some circumstances. Wear reduces wall thickness. Thickness must be checked on a regular basis. Pressures may be limited even more by clamp style or pipe endused. The chart is based on 62,000 PSI tensile strength. Heat-treated calculations are based on 120,000 PSI tensile strength. The chart is for pressure calculations ONLY. There is no allowance for mechanical forces other than press ure, and thicker walls may be needed for mechanical strength because of support or restraint considerations. 6. The chart does not take into account metal fatigue caused by pressure cycles.

Note! This chart is intended as a guide for concrete pumping applications and is subject to the notes, assumptions, and conditions listed above. Any other use of this chart is not recommended. This chart does not apply to dou ble-wall pipe. Double wall pipe canbe checkedby inspecting the inside of the pipe. If the inser t is intact, the pipe is okay. If the insert is worn through, the pipe mustbe replaced. Contact your pipe supplier for the pressure capacity of your double-wall pipe.

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Appendix

Glossary of Terms The following is a list with descriptions of some of the terms used in this manual (this includes the glossary of terms found in the Safety Manual Appendix section):

Accumulator A hydraulic device that stores fluid power energy in much the same way that a capacitor stores electrical energy. Because an accumulator will store energy, it MUST be drained and depressurized before work begins on an accumulator equipped actuator or hydraulic system.

Agitator A device set in the concrete hopper to keep concrete moving, which prevents it from setting. It is typically a rotating shaft to which several paddles have been mounted. See Also: Hopper Grate

AWS D1.1 The code for structural welding with steel as defined by the American Welding Society. Sections 3, 5, and paragraph 9.25 of Section 9 apply. See Also: Certified Welder and EN 287-1

Blanking Plate Also known as a blanking plug or end cap. its purpose is to prevent material from falling out of the delivery system (typically the end hose) when moving a full boom over personnel or property.

Blockage Simply put, if the pump is pushing and concrete fails to come out at the point of discharge, it is called a blockage. The causes of blockages are detailed in Section 6 of this manual. In all cases, blockages can create a dangerous situation by causing high concrete pressure, combined with the sometimes uncoordinated efforts of untrained workmen to remedy the problem.

Bulk DensityThe mass of a substance per volume. For example, 1 cubic foot of air weighs much less than 1 cubic foot of water. 1 cubic foot of lightweight concrete Startup 250:Users:Danny:Desktop:Operationmanuals:line pumps:All SP Rock Valve models:Frame files:Appendix.fm

weighs less than 1 cubic foot of steel entrained concrete. We could say that steel entrained concrete has a higher bulk density than lightweight concrete. All calculations for the Operation Manuals and specifications of concrete pumps are based upon 150 pounds per cubic foot, which is the approximate mass of hard rock (normal) concrete.

Certified Operator An operator that has been issued a certification card by the American Concrete Pumping Association. There are several classes of certification, each relating to a different category of pump. Foran operator to become certified, he (she) must pass the tests given regarding operation, set up, and clean-out for each category of pump, plus pass the safety rules test which is common to all certification categories, plus meet the experience requirements set forth for each category, plus maintain a safe and clean driving record. Certified operators are considered qualified operators (in regards to their categories). See Also: Expert, Qualified Operator

Certified Welder

As it relates to concrete pumping and this Safety Manual, a Certified Welder is a person that has applied for, taken and passed the American Welding Society (AWS) or the European Normal (EN) test for structural steel welding. Anyone welding on a concrete pump placing boom, outriggers, towers, etc. must be certified to AWS D1.1 Sections 3, 5, and paragraph 9.25 of Section 9 AND/OR EN287-1/ PREN288-3.

Concrete Pressure The force per square area that is exerted on the concrete. The concrete pressure will always be a ratio in direct proportion to the hydraulic oil pressure on the concrete pump circuit. See also: Maximum Pressure


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Appendix Conductors

EN 287-1 / PREN 288-3 Materials that will conduct electricity. Copper, silver, aluminum, gold, steel, and water are considered GOOD conductors of electricity. Air, fiberglass, rubber, ceramics and glass are considered POOR conductors. All of these conductors have a resistance to the flow of electricity that can be measured in terms of ohms per linear foot. As voltage gets higher, more current flows through the same resistance. In the case of high voltage electric wires (8000 volts, for example) even the poor conductors will carry enough current through your body to ground that you could be killed (as little as 35 milliamps will cause cardiac arrest). Some conductors, like air, resist electricity very well, but if the voltage gets high enough, current will flow (lightning is a good example of this). See Also: Electrocution

The code for structural welding with steel as defined by the European Norm. See also: Certified Welder

Expert As used in this Safety Manual, an expert is defined as: persons that, on the basis of their specialized training and experience, have developed a high degree of knowledge and skill in the areas of concrete pumps, concrete pumping, clean-out procedures, generally accepted engineering norms, and safety regulations to the point that they are able to evaluate equipment and processes as they relate to job safety. They would demonstrate their knowledge and abilities by passing the certification testing and experience requirements of the American Concrete Pumping Association. Other experts may include master mechanics and after-sales service technicians of the manufacturer. See Also: Certified Operator

Decibels One tenth of a bel. Abbreviated dB. It is a measurement of volume. As it applies to concrete pumps, it is a measurement of the sound pressure level one meter away from a noise source. Because constant exposure to loud sound can cause permanent hearing loss, O.S.H.A. has developed guidelines for time limits on exposure to sound at different volume levels. The chart can be found in Section 6 of this manual.

Drive Engine The primary source of power for a hydraulic system. Typically, the word “engine” denotes an internal combustion device, where as the word “motor” denotes an electrical device. See also: Prime Mover

Foreign Material Material that was never intended to be pumped, which ends up in the concrete hopper. Examples of foreign material include small animals, hammers, ready mix truck fins, unmixed clumps of cement, hardened concrete that breaks away from ready mix truck fins, soda pop cans, etc. Many of these items can create a blockage if pumped.

Go Devil A plug made from a rubber composite, usually with several fins that expand to seal when pressure is applied. They are intended to be inserted in a steel delivery pipeline and pushed with water or compressed air for the purpose of cleaning the pipe. Not to be used with rubber hose or short sections of pipe. See Also: Sponge Ball

Electrocution Made from the words “Electric” + “Execution”. It means death by electricity. See also: Conductors

Guide An assistant brought in to help in backing up a truck or trailer, or other circumstances where the driver cannot

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Appendix see enough to assure safety. See also: Spotter

High Voltage For the purposes of this manual, anything over 120 volts AC will be considered high voltage. In the U.S., electrically driven concrete pumps normally operate the motors at 480 volts AC (high voltage) and the controls at 24 volt DC (low voltage). When dealing with electric wires in residential or industrial areas the voltage will be approx. 8000 volts to ground, or 13,800 volts from phase to phase (distribution voltage). When dealing with electric wires that are mounted on steel towers, high above the ground, the voltage will range from 100,000 to 1,000,000 volts (transmission voltage).

Hopper Grate A meshwork placed over the concrete hopper, typically made from steel bars. It serves the functions of keeping human body parts away from the agitator (when left in its proper position), and keeping large foreign objects from falling into the hopper, which could cause blockages if they were pumped. The hopper grate MUST be secured into position to be effective.

Jacking the Outriggers Adjustment of the outriggers in the vertical direction. With boom mounted concrete pumps you should strive to make the adjustments so that the unit sits within 3° of level.

Licensed Electrician A qualified electrician licensed by the state, county or municipality where the connections are to be made. In some locations electricians are not required to be licensed, and in these cases the work should still be carried out by competent professionals. Under no circumstances should high voltage connections be made by a concrete pump operator or related personnel.

Maintenance All procedures for servicing, inspection and repair of concrete pumps and related equipment and devices. Maintenance and inspection are methods of MAINTAINING the desired state of the equipment. Repair is the method of RESTORING the desired state of the equipment.

Maximum Pressure When talking about a hydraulic system, maximum pressure refers to the highest pressure that can be achieved with the settings of the circuit relief valves. When discussing concrete output, maximum pressure refers to the pressure that will be developed if the hydraulic system pressure reaches the relief valve setting. Concrete pressure is always the force at which the differential cylinders are moving, divided by the cross sectional area of the concrete cylinder. Maximum concrete pressure, then, is developed when the differential cylinders are moving with maximum force, which is determined by the hydraulic system relief valve setting. During norm al pumping, the resistance of moving the concrete through the pipe or boom creates the pressure needed by the pump, and is well under the maximum pressure. See Also: Concrete Pressure

Minimum Safety Distance In this manual, the term “minimum safety distance” refers to the closest distance that you are allowed to approach an object, electrical wires, etc. and still leave room for errors in human judgement or machine malfunction. With electrical wires under 350 Kv in the U.S., this distance is 20 feet, as recommended by the American Concrete Pumping Association. This distance may have other values in different countries. An old saying that goes like this: “AnyMurphy’s Law thing that can go wrong, will go wrong, and at the worst possible moment”.



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Appendix Operational Area

PTO

The area around a working piece of equipment or point of discharge where dangers can be encountered due to the nature of the machinery or process in use. Do not allow unauthorized presence in this area for safety reasons.

O.S.H.A. Occupational Safety and Health Administration. A branch of the United States federal government that deals with job safety. They establish and enforce safety regulations for industry and business. Among the areas over which they have authority are construction job sites and work shops.

Personal Protective Apparel Things you can wear to protect yourself from potential dangers in a concrete placing environment. Examples are: • Snug fitting work clothes • Steel Toed work boots • Lime re sistant gloves • Safety glasses • Ear muffs or ear plugs • Rubber boots when you have to stand in concrete • Hard hat

Point of Discharge The location of concrete expulsion from a delivery system. This can be the point of placement (the actual form that is being filled with concrete) or the clean-out area after completion of the job.

Pour Used by the concrete pumping industry and in this manual as a noun. It is the specific job for the pump during any given time period. E.g. “We’ll grab lunch right after the pour”.

Prime Mover The primary powerThe source a hydraulic system. termfor “prime mover” is generic in that is denotes neither an internal combustion engine nor an electric motor.

150

Power Take Off. A switchable output from the transmission or an intermediate gearcase. On a concrete pump it is used to divert the power from the engine and drive train to turn the hydraulic pumps.

Qualified Operator An individual that has: • reached the age of 18 years, and • is physically and mentally capable, and • has been trained in the proper operation and maintenance of the pump and placing boom (if applicable), and • has demonstrated their capabilities to their company in respect to the operation and maintenance of the pump and placing boom, and • can be expected to perform these duties, as assigned, in a reliable manner.

Qualified Personnel A generic term used to describe a person that is qualified in the area of application. For example, having your boom repairs inspected by “qualified personnel” before use would refer to inspection by a certified welder or certified welding inspector. Having repairs to your hydraulic system done by “qualified personnel” would refer to repairs made by qualified workshop personnel.

Qualified Workshop Personnel An individual that: • has reached the age of 18 years, and • is physically and mentally capable, and • has been trained in proper repair, maintenance, and inspection procedures plus the pertinent safety rules for concrete pumps and related equipment, and • has demonstrated their ties to their company in capabiliregards to the above mentioned procedures and rules, and • can be expected to perform these


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Appendix duties, as assigned, in a reliable manner.

Sponge Ball A medium to hard sponge formed into a sphere and used to clean the inside of delivery pipelines. See Also: Go Devil

Rock Jam A specific type of blockage caused when the cement and fines of the concrete are not present in sufficient quantity to fully coat the larger aggregates and the walls of the delivery system. In these cases, the rock (larger aggregates of the mix) will form a wedge inside of the pipe. Resistance

Spotter A spotter is a person that stands at a vantage point where he (she) can see both the point of discharge and the operator of the pump. The spotter would then direct the operator to operate the unit as required by the job circumstances with 2 way radios or hand signals. A spotter can be anyone that is familiar with the safety rules for the pump and workers, and is equipped with a radio or knows the appropriate hand signals. A spotter is needed whenever the operator cannot safely see the point of placement or the distance between the unit and an unsafe area. See Also: Guide

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 problem. In some cases the wedge can be broken up by alternately pumping in forward and then reverse. See also: Blockage

Separate Pipeline A pipeline that is laid between the concrete pump and the point of discharge, other than the placing boom pipeline.

Shut-Off Valve In hydraulics: a valve with the ability to stop the flow or pressure of hydraulic oil. Must be able to withstand the maximum pressure of the hydraulic circuit that it controls. In concrete: A manually or hydraulically operated valve that will prevent the flow of concrete in either direction. Some concrete shut-off valves also have the ability to divert the flow of concrete to a different pipeline, for example, to a discharge point for clean-out. The shut-off valve must be able to withstand the maximum pressure on the concrete of which the pump is capable.

Soil Pressure The force per square area that is exerted on the ground by the outrigger legs. The amount of pressure that the soil will support varies with the composition and compaction of the soil. To make a determination on the stability of the soil, see the chart in Section 5 of this manual.


Sucking

Back The act of putting the concrete pump into the reverse mode for any of several reasons. Some examples of reasons to suck back: • To relieve pressure in the delivery system before opening when a blockage has occurred. • To clean the boom with a sponge ball upon completion of the pour. • To remove concrete from the boom for the purpose of folding the boom for moving.

Thrust Block Also known as a “dead man”. This is a large block of poured concrete, usually with one or more sweep elbows cast inside, placed at the bottom of a vertical run for the purpose of supporting the weight of the vertical run, and lateral stabilization of the pipeline. It stabilizes and supports the vertical run by virtue of its enormous mass (normally one cubic yard or larger). In this manual, “Towing Vehicle” Towing Vehicle applies only to trailer mounted concrete pumps. It is the vehicle that you will use to tow the trailer on the road,


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Appendix job site, or in the yard. Size and condition of the towing vehicle is extremely important in these applications. See the safety rules regarding this subject in Section 4 of the Safety section.

Transport Position This relates to the position of the boom. Boom is completely folded and lowered into the rests. For traveling, the boom straps must be secured. When stowing in the traveling position because of a thunderstorm, for example, but no travel is imminent, the boom straps need not be secured.

Unauthorized Without authority, without permission. Examples: Unauthorized operation of the boom could be operation by a passing teenager, unauthorized repairs to the boom could be repairs made without the manufacturers permission.

the water system that needs to go into the hopper, concrete valve, or waterbox for cleaning.

Additional Reading Material This is a partial listing of the books that have been written on the subject of concrete pumping. Books that were omitted were done so unintentionally. • “Pumping Concrete and Concrete Pumps” by Karl Ernst v. Eckardstein, published by F. W. •

•

Schwing GmbH “Pumping Concrete - Techniques and Applications” by Robert Allen Crepas, published by the Aberdeen Group “Nomographs - A guide to usage” by Robert Edwards, © 1992, Schwing America, Inc.

Unintentional Movement Movement of the pump, boom or related equipment without a specific intentional command by the operator. An example of an unintentional movement would be if an operator fell while walking with the remote control box and accidentally hit a joystick, which caused a boom movement. Unintentional movement can be avoided by disabling the hydraulic system with the emergency stop devices when not in immediate use.

Vertical Run Sections of concrete delivery pipeline that are running in an up (or down) direction. Vertical runs have very specific procedures and rules for installation, support, cle aning, and inspection. Concrete pumping personnel should, therefore, have specific training in these procedures and rules before attempting to use them in a job setting.

Water Jet

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The actual stream of water that comes out of the end of a water hose or pressure washer. This is the only part of


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Appendix

List of Lubricants and Nitrogen This list describes the materials that were installed in your concrete pump unit when it left the factory. Other brands of lubricants and their usage are described in the following lists.

Hydraulic oil

Mobile UNIVIS N46

Gearcase oil

HD 80w-90

Truck fluid levels

See owners manual for your specific truck

Compressor oil

Mobil Rarus 427 or 429

Grease for spline and couplers

Optimoly Paste White T - 250 grams

Grease for autogreaser

EP2/NLGI No. 2

Dry nitrogen

Any brand of dry nitrogen is suitable for recharging accumulators 000566.eps

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Appendix

Hydraulic Oils other than Mobil UNIVIS ISO viscosity VG 32 = winter in northern US and Canada ISO viscosity VG 46 = summer in northern US and Canada ISO viscosity VG 68 = Tropical areas, desert summers; indoor uses.

Brand

Viscosity / DIN quality designation VG 32 / HLP

VG 46 / HLP

VG 68 / HLP

HD 32 HDZ 32

HD 46 HDZ 46

HD 68 HDZ 68

DTE 3224 GF 32 HLP 32 H 32 ZS 32 HS 32

DTE 4625 GF 46 HLP 46 H 46 ZS 46 HS 46

DTE 6826 GF 68 HLP 68 H 68 ZS 68 HS 68

Texaco Rando HD Texaco Rando HDZ Mobil DTE Shell Tellus Aral Vitam BP - Energol Esso - Nuto Total - Azolla Wintershall - Wiolan •

The order of the list is meaningless. Any oil that meets the HLP quality designation and ISO viscosity specification may be used.

•

Mixing oils by different manufacturers is not recommended. The additive packages of the manufacturers may be incompatible. Contact the oil manufacturers for information before mixing.

•

New hydraulic oil is not clean enough for use in a Schwing concrete pump or placing boom and should be installed in the machine through a filter. The filtering should be done at β 25 = 200 or finer.

•

The following table shows the characteristics of Mobil UNIVIS N46. You may use this information for comparison with other brands. ISO Viscosity Viscosity Viscosity cST @ cST @ Viscosity Class 40° C 100° C Index VG 32

•

32

6.39

151

Flash point °F 208

Pour point °F -48

VG46

46

8.19

152

216

-48

VG68

68

11.0

151

222

-42

Some oil manufacturers offer vegetable based hydraulic oils which are considered environmentally friendly (the additive packages are not inert, however). These vegetable based oils must NEVER be mixed with mineral based oils. A complete flush of the hydraulic system must be performed when changing to this type of fluid. If you’re considering using biodegradable oils, please contact Schwing Service Department for advice about which might be acceptable for use in your Schwing.

OM14

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Appendix

Gearcase Oils A) for distribution gearcases

Brand

Viscosity / DIN quality designation VG 220 / CLP

Texaco Mobil Shell Aral

Meropa 220 Mobilgear 630 Omala Oil 220 Degol BG 220, Degol BMB 220

BP Esso Wintershall

Energol 220 SpartanGR-XP - EP 220 Wiolan - IT 220

B) for motor vehicle gearcases

Brand

Viscosity / Mil-L quality designation 90 (85w-90) / 2105 B

Texaco Mobil Shell Aral BP Esso Wintershall

Geartex EP-C Mobilube HD Spirax HD, Spirax MB Gearbox Oil HYP Energear Hypo 90, Hypogear 90 EP Gear Oil GX-D, Gear Oil GX Wiolan Hypoid Gearbox Oil 90

•

The order of the list is meaningless. Any oil that meets the DINquality designation and ISO viscosity specification may beused.

•

The lubricants listed above are suitable for continuous ambient temperatures of -10 C (14 F) to +40 C (104 F). For conditions outside of this range, contact the oil manufacturer for recommendations.

•

Viscosity class 220 roughly corresponds to SAE 90.

Compressor Oils •

Use VG 100 oil when ambient temperature is 0 to 10 C (32 to 50 F).

•

Use VG 150 oil when ambient temperature is above 10 C (50 F).

Brand

ISO Viscosity / DIN quality desi gnation

Texaco Mobil Shell Aral BP Wintershall


VG 100 / VDL

VG 150 / VDL

Compressor Oil - EP 100 Rarus 427 Corena - H 100 Motanol - HE 100 Energol - RC 100 Wiolan - CD 100

Compressor Oil - EP 150 Rarus 429 Corena - H 150 Motanol - HE 150 Energol - RC 150 Wiolan - CD 150


5 1 M O

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Appendix

Grease A) For filling the automatic greasers

Brand

Viscosity / DIN quality desi gnation EP 2 / CLP

Texaco Mobil Shell

Starplex 2 Mobilgrease HP Alvania EP - 2

•

Shell Alvania is installed in new machines at the Schwing factory.

•

Any equivalent grease may be used.

B) For all other bearings

Brand

Viscosity / Pressure rating

Texaco Mobil Shell Aral BP Esso Optimal

Multifak EP-2 Mobilith AW 2 Alvania grease R 2 HLP 2 Energrease LS2 Multipurpose grease Beacon 2 Olitsta longtime 3 EP

2 / EP

•

The order of the lists is meaningless. Any grease that meets the quality designation and viscosity specification may beused. OM19A

End of Life Protocol Schwing is committed to preserving the earth in a usable state for generations to come through proper recycling. When your concrete pump reaches the end of its life cycle and is no longer usable, it is very important to dispose of it properly. The most practical method of doing so would be to ship it back to Schwing. If you choose to dispose of it yourself, you must be sure to separate all electronic and hydraulic components, and break them down to remove all precious metals and hazardous materials which must be disposed of individually.

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Alphabetical Index

swg99a001.eps

ALPHABETICAL INDEX

Operation Manual - Line pumps

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Alphabetical Index

A accessories for driving checklist for pumping checklist supplied . accidents traffic . . appendix

. . . . . . . . . . . . .71 . . . . . . . . . . . . .70 . . . . . . . . . . . . .61 . . . . . . . . . . . . .74

additional reading material . . . fitting/wrench sizes . . . . . . glossary of terms . . . . . . . hydraulic oil viscosity chart . . . minimum pipe wall thickness chart nomographs . . . . . . . . . using the graph . . . . . . output chart . . . . . . . . . recommended emergency hose kit scheduled maintenance checklist . torque specifications . . . . . attitude arriving on time . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

152 129 147 126 146 137 137 131 128 130 127

. . . .70

B backing up (driving) . . . . . balance loads . . . . . . . . blockages . . . . . . . . . reversing the pump . . . . boom pipeline minimum wall thickness

. . . .

. . . .

. . . .

. . . .

. . . .

.74 .87 .87 .87

. . . . . 146

C caution . . . . . . . . . . . . . . . . 8 changing lanes (driving) . . . . . . . . .74 clamps washing . . . . . . . . . . . . . .85 cleanout . . . . . . . . . . . . . . . .87 cleaning the hopper and valve housing . .88 cleaning the rock valve and material cylinders 92 cleaning the waterbox . . . . . removing set material from hopper cold weather pumping . . . . . . preheating the hydraulic oil . . . time constraints . . . . . . .

158

. . . . .

. . . . .

. .94 . .91 85, 96 . .97 . .85

concrete from worn out mixers . . inspecting before dumping minimum hopper level . . time constraints . . . . . very cold weather . . . . control system, hydraulic . . couplings comparison . . . . . . grooved type . . . . . . heavy-duty type . . . . male/female o-ring type metric type . . . . . victaulic type . . . . . cylinder differential . . . . . . rock valve slewing . .

. . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

83 83 84 85 85 25

. . . . . . 145 . . . . . . 145 . . . .

. . . .

. . . .

. . . .

. . . .

. 145 . 145 . 145 . 145

. . . . . . . 27 . . . . . . . 26

D danger . . . . . . . . . . delays and blockages . . . . . balance load . . . . . . hot weather . . . . . . keeping the concrete alive . very cold weather . . . .

. . . . . . . 8 . . . . .

delivery system pipe end comparison . . . . diagram explanation s valve . . . . . . . . . diagrams hydraulic control system . . rod side-piston side pumping differential cylinder diagram explanation . . . . driving backing up . . . . . . . . changing lanes . . . . . . license requirements . . . . safety rules . . . . . . . see also, safety manual

. . . . .

. . . . .

. . . . .

. . 86 . 86, 87 . . 86 . . 86 . . 86

. . . . . 145 . . . . . 26 . . . . . 25 . . . . . 95 . . . . . 27 . . . .

. . . .

. . . .

. . . .

. . . .

74 74 74 74

E emergency stopping procedure . . . . . . . . . 23 emergency hose kit . . . . . . . . . . . 128


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Alphabetical Index emergency procedures disabling the entire machine emergency stop switch . . . . hopper area . . . . . . . operator’s panel . . . . . equipment pre-checks on pump . . . . . . . . on truck . . . . . . . .

. . . .

. . . .

. . . .

. . . .

. . . .

86 66 66 23

. . . . . . . . . .

73 73

F

lubricate . . . . . . . . . lubricate . . . . . . . . . lubrication quantity of slurry needed . slickline . . . . . . . . slurry mixing . . . . . . . pumping it through . . with commercial lubricant with portland cement . . .

fitting/wrench size chart . . . . . . . . . 129 fuses . . . . . . . . . . . . . . . . 66

. . . . . . 81 . . . . . . 81 . . . .

. . . .

. . . .

. . . .

. . . .

. . . .

81 83 81 81

with ready mix grout . . . . . . . . . 81 without slurry . . . . . . . . . . . 81

M

G glossary of terms, alphabetical grease points rock valve . . . . . . . greasing agitator bearings . . . . list of lubricants . . . . rock valve . . . . . . . guards . . . . . . . . . .

. . . . . . 147 . . . . . . . . . .

. . . .

. . . .

. . . .

. . . .

64

. 80 . 153 . 80 . 66

H

maintenance . . . . . . . . . . . hydraulic oil specific information . . . . . preventive maintenance scheduled maintenance checklist manufacturer’s statement . . . . . . missing id tag . . . . . . . . . . .

. . 99 . . 102 . . 130 . . .8 . . 11

N new id tags . . . . . . . . . . . . . . 11 nomographs

hopper cleaning the hopper . . . . . removing set material . . . . spraying with form oil . . . . how to reach us . . . . . . . . . hydraulic control system, diagram . hydraulic pumps main . . . . . . . . . . . hydraulic system pressure specifications . . . .

. . . . . . . . . . . .

88 91 80

. . . . . 9 . . . . 25 . . . .

24

. . . .

16

I id tag . . . . . . . . . . . . . . . 10, 11 id tag location . . . . . . . . . . . . . 10

L laborers and oilers safety rules . . . . . . . license required to drive . . . . list of additional reading material list of lubricants and nitrogen . Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame files:AllSPRockvalveIOM.fm

. . . . . . 81 . . . . . . 81

. . . .

. . . .

. . . .

. . . .

. 78 . 74 . 152 . 153

explanation 137 using the graph. .. .. .. .. .. .. .. .. .. .. .. 137

O oilers and laborers safety rules . . . . . . . . . output chart checking your hydraulic pumps . explanation . . . . . . . . . overview fuses . . . . . . . . . . . . main hydraulic pumps . . . . . pressure relief valves . . . . . . rock valve components . . . . . rock valve slewing cylinder . . . rod side-piston side configurations

. . . 78 . . . 133 . . . 131 . . . . . .

. . . . . .

. . . . . .

66 24 66 64 26 95

safety devices . . . . . . . . . . . 66 vibrator (optional) . . . . . . . . . . 65 warning labels . . . . . . . . . . . 67


159

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Alphabetical Index

P parts, see spare parts personal protective devices breathing mask . . . . . . . . . . . .78 list of . . . . . . . . . . . . . . .72 personal protective equipment, see personal protective devices pipe weld on ends . . . . . . . . . . . 145 pipeline (separate), see slickline piston side pumping diagram . . . . . . . . through the boom . . . . . placing crew safety rules . . . . . . . pre-checks danger of skipping . . . . on pump . . . . . . . . on truck . . . . . . . . preparation for pumping prechecks . . . . . . rock valve . . . . . . selecting a set-up location spraying the hopper . . tools and accessories . .

. . . . . .95 . . . . . .95 . . . . . .78 . . . . . .70 . . . . . .73 . . . . . .73

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

.73 .79 .75 .80 .70

for travel after cleanout . . . . . . . . . . .95 pressure specifications . . . . . . . . . . . .16

R rock valve cleaning . . . . . . component identification preparation for concrete slewing cylinders . . . rod side pumping diagram .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

88, 92 . .64 . .79 . .26 . .95

S s valve diagram explanation . . . . safety alert symbol and signal words arranging for a spotter . . . blockages . . . . . . . . devices . . . . . . . . .

160

. . . . . .26 . . . .

. . . .

. . . .

. . . .

. . . .

. 8 .78 .87 .66

agitator shut-off . . . . bypassing the dump valve emergency stop switch . fuses . . . . . . . . pressure relief valves . . warning labels . . . . . disabling the entire machine . driving . . . . . . . . . backing up . . . . . . changing lanes . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

66 86 66 66 66 67 86 74 74 74

minimum hopper level . . . . personal protective devices . . breathing mask . . . . . rules for oilers and laborers . . rules for the placing crew . . . selection of set-up location . . . . . . separately laid pipeline, see slickline serial number this unit . . . . . . . . . . service telephone numbers . . . . . service department . . . . . . . slickline checklist . . . . . . . . . minimum wall thickness chart .

. . . . .

. . . . .

. . . . .

. . . . .

84 72 78 78 78

washing . . . . . . . . . slurry if it plugs . . . . . . . . pumping it through . . . . spare parts hours . . . . . . . . . . telephone numbers . . . . special pumping situations cold weather pumping . . . specifications 1200 pumpkit . . . . . . 900 pumpkit . . . . . . . concrete pump . . . . . . hydraulic pumps . . . . . pressure of hydraulic circuits pressure of pumpkit . . . .

. . . . 75

. . . . .9 . . . . .9 . . . . .9 . . . . 70 . . . . 146

. . . . . 85 . . . . . 83 . . . . . 83 . . . . . .9 . . . . 8, 18 . . . . . 96 . . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

14 14 14 14 16 14

torque . . . . . . . . . . . . . . 127 spotter arranging for . . . . . . . . . . . . 78 switch emergency stop . . . . . . . . . . 23, 66


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Alphabetical Index

T time constraints . . . . . . . . troubleshooting checking your hydraulic pumps loss of boom and outriggers . . loss of electricity . . . . . . procedures . . . . . . . . time constraints . . . . . .

. . . . . . . . .

. . . . .

. . . . .

85

. 133 . 86 . 86 . 77 . 85

V version number operation manual . . . . . . . . . . . iii vibrator . . . . . . . . . . . . . . . 65

W walk around hopper area . . warning . . . . . warning labels . . waterbox cleaning . . . filling with water keeping it full .

. . . . . . . . . . 63 . . . . . . . . . . . 8 . . . . . . . . . . 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame files:AllSPRockvalveIOM.fm

94 78 86


161

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162


revDate

SERVICE REPAIR INSTRUCTIONS FOR

THE " SMALL ROCK" VALVE

DOCUMENT #98330783

5900 Centerville Road St.Paul, MN 55127 Tel 651-429-0999 Fax 651-429-3464 www.schwing.com

REV. 05/20/14

Small Rock Valve

Small Rock Valve Safety Instruction When performing maintenance on Schwing Equipment, the safety regulations must be followed. The observation of these regulations is the responsibility of the maintenance personnel. The following are some supplementary recommendations.

WARNING

READ FIRST! 1. WARNING! Read and understand the operation manual of the machine before attempting any repairs. If in doubt, call the manufacturer. Incorrectly done repairs endanger operational safety of the machine. 2. WARNING! Burning hazard! Never work on a hydraulic system with hot oil. 3. WARNING! Falling hazard! If you cannot work at ground level, you must use a suitable work platform. 4. WARNING! If maintenance work requires that you use a crane, hoist, fork truck, etc., you must read and understand the safety regulations for that equipment. 5. WARNING! If working the machine requires that it be operated, and you are not qualified as an operator, you must get someone who is qualified to assist you. 6. WARNING! If you will be working in a hidden area inside the machine, protect yourself by taking the key from the ignition and putting a “DO NOT OPERATE” sign on the controls. In the case of electrically driven units, disconnect the main circuit breaker and lock it in the disconnected position. 7. WARNING! Never activate the system hydraulics without checking if another workman is in a hidden position. Always yell “CLEAR”, and allow time for response, before starting the prime mover. 8. WARNING! Never use gasoline or diesel fuel as a cleaning solvent. This is critical to remember when cleaning hydraulic oil reservoirs, because gas and diesel fuels are highly explosive, and gasoline or diesel fuel traces left in the oil may ignite when compressed. 9. WARNING! Always use the correct tools for the job. Tools should be kept clean, and in good condition. 10. If you see a co-worker engaging in an unsafe practice, explain the dangers. Safety is always in the hands of those on the job. 11. WARNING! Never work on a pressurized hydraulic system. Stop the prime mover and relieve the accumulator circuit (if so equipped) before you open the hydraulic system.

Service Manual

1

Small Rock Valve

Rock Valve Parts Identification and Clearance Specifications Rock Housing

Spectacle or Inlet Plate

Cutting Ring Rock Valve

Bushing Seal Cover

Kidney Seal Kidney or Outlet Plate Pressure Spring Setting Disc Tension Nut Cording must be to outside when installed

Locking Washer Locking Bolt

Lubrication grooves MUST face out from Rock Valve Centering Screw

Outlet Flange

1.5 - .2.0mm (.060 - .080")

Dimensions shown are with all new wear parts.

2

Service Manual

A

Small Rock Valve

Small Rock Valve Lubrication Points Use a grease gun with the recommended grease listed in the chart below. Locate the grease points, clean the grease fitting before filling it, and inject grease until you see old grease displaced by the new grease. Lubricate the grease points at 8 hour intervals and whenever the machine work is completed for the day.

Grease Points Grease Points

Minimum Specifications for grease. Lithium base high-pressure grease KP 2 K per DIN 51502. BP

Energrease LS2

MOBIL

Mobilith AW 2

SHELL

Alvania grease R2

TEXACO

Multifak 20

ARAL

HLP 2

ESSO

Beacon 2

OPTIMAL

Olitsa longtme 2EP

Service Manual

3

Small Rock Valve

Lengthening the Service Life of the Spectacle Plate and Cutting Ring Conditioned by outside influences (material variations), as well as by differing work strains on partial sections, the cutting ring and the housing lining wear out unequally.

Friction

Friction and stone crushing

Spectacle or Inlet Plate

Friction

Friction and stone crushing

Cutting Ring

The grooves resulting from operation are irrelevant as long as the armouring is not worn out completely. To ensure uniform wear and, thus, considerably longer service lives, we recommend the following: 1. Move the Rock Valve to the left and right end position once a week after thorough cleaning, and check the condition of both the Cutting Ring and the Housing Lining. 2. Turn the Cutting Ring 90 degrees when there is a clearance greater than 1.5mm-2.0mm (.0590”-.0590”) between the Cutting Ring and the Housing Lining. The Cutting Ring typically wears at the 3 and 9 o’clock position. Turning the Cutting Ring 90° will ensure uniform wear and lengthen the service life.

max 1.5mm 0.590"

Cutting Ring

Cutting Ring max 1.5mm 0.590"

4

Housing Lining

Housing Lining

Service Manual

Small Rock Valve Check for the gap at several points along the Cutting Ring circumference, and always turn the Cutting Ring in the same direction. It is only necessary to loosen the Securing Bolts of the Housing Cover approximately 10mm (.3937”) in order to release the Pressure Spring and turn the Cutting Ring.

Rotate the Cutting Ring 90˚ clockwise

Securing Bolts

3. Check the distance between the Cutting Ring and the Rock after each turn of the Cutting Inlet Housing Lining Cutting Ring

B

Rock Valve Pressure Spring

Service Manual

Ring. If it exceeds 8mm (.315”), the pretension of the Pressure Spring is not enough to correctly press the worn cutting ring up against the Spectacle Plate. In this case, the Cutting Ring has to be replaced

5

Small Rock Valve Rebuilding the Rock Valve 1.

Remove the Locking Bolt from the Tension Nut.

Locking Bolt

2. Loosen the Tension Nut.

NOTE: It’s ok to remove the Tension Nut with a wrench, but it must never be tightened more than hand tight

Tension Nut

3. Remove the Tension Nut. 4. Remove the Setting Disc Tension Nut

Setting Disc

6

Service Manual

Small Rock Valve 5. Install the alignment rods • SAI Part #30309007

Alignment Rod

6. Slide the rear housing cover back slightly. C L

7. Center Rock Valve using a pry bar, so the lever is straight up. 8. Remove the Locking Bolt for the Cylinder Pin on the Slewing Yoke 9. Using a drift punch, drive pin out of the hole. 10. Pull yoke up and out of the slew lever. Move out of the way and tie up.

Locking Bolt Stop Washer

Service Manual

7

Small Rock Valve 11. Remove 12mm bolt and lever disk from Rock shaft 12. Remove slew lever. 12 x 30 Bolt Disk

Slew Lever

13. Using a lifting device, slide Rock Valve out of bushing and place on a work surface. 14. Remove Kidney Seal an d Pressure Spring. Clean both ends of the Rock Valve, removing all concrete debris.

Pressure Spring

Kidney Seal

8

Service Manual

Small Rock Valve 15. Remove the Seal Cover from the Rock Slewing Shaft and remove the O-ring. Seal Cover

O-Ring 70x8

16. Remove the O-ring from the groove of the Rock shaft bushing on the Rear Cover Housing. 17. Clean the O-ring groove removing all concrete debris, paying special attention to the grease journals are clean. NOTE: Check that grease will come through from the zerk.

O-ring 65x8

18. Using the correct size bushing driver, drive the old Rock shaft bushing out of the front cover of the Rock housing.

Bushing Driver

19. Using the correct size bushing driver, drive the old Rock Shaft Bushing out of the Rear Cover Housing.

Bushing Driver

Hammer Rear Cover Housing

Service Manual

9

Small Rock Valve 20. Remove the two bolts attaching the Spectacle Plate to the Front Cover. Counter Sunk Bolts

21. Carefully remove the Spectacle Plate from the Rock Housing.

Spectacle Plate

22. Remove the four, 20 mm bolts from the outlect delivery pipe. 23. Remove the four bolts from the rear cover that attach the Kidney Plate to the rear cover. 24. Remove the Kidney Plate. NOTE: The Kidney Plate should have a smooth, mirror-like finish, free of any scratches, gouges, or wear grooves. NOTE: Before reassembly, make sure that a ll components are thoroughly cleaned.

10

Service Manual

Small Rock Valve 25. Reassemble the Rock Valve assembly in the reverse order that it was disassembled. Slide the cover back in place. NOTE: Upon reassembly, generously grease the Kidney Seal, Kidney Plate, Cutting Ring and the Spectacle Plate. This is important, because after you have assembled the Rock and done some necessary adjustment, you are going to have to shift the Rock several times before making the final adjustments.

26. Adjust the Tension Nut, which is tightened only hand tight. If the Locking Bolt shown can be installed in the Setting Disc freely, then do so. If the hole in the Tension Nut does not align with the thread hole in the Setting Disc, loosen the Tension Nut to the previous hole, and install the Locking Bolt.

NOTE: Check to make sure that the proper clearance is obtained between the Rock Valve and the Cutting Ring and between the Rock Valve and the Kidney Plate. If the Rock components are worn, the dimensions may be larger that specified.

Locking Bolt

If the dimensions are too small, loosen the Adjusting Nut and pry the Rock Valve in the direction needed. Stroke the unit several times, and recheck the dimensions. If the dimensions are correct, reinstall the Tension Nut and re-adjust. IMPORTANT! At no time should you operate the Rock Valve without first lubricating the outlet wear plate. Spraying the plate with water or oil will usually be adequate prior to start-up for pumping. Moving the kidney seal against a

dry plate will cause excessive wear and premature failure.

Service Manual

11

Small Rock Valve Mounting a New Pressure Spring If the Pressure Spring has to be replaced, remove the old spring and clean the vacant area thoroughly to clear it of concrete residue. If dust and residue is ignored, the new spring cannot be installed correctly, and the flow of concrete could pull it out of the groove. Furthermore, the high pretension resulting from reassembling with concrete residue in the area of the spring leads to premature wear of the Cutting Ring and Housing

Inlet Housing Lining Cutting Ring

B

Rock Valve Pressure Spring

Lining.

NOTE: Slightly grease the new Pressure Spring when installing it. The same applies to Put seam on top

the Kidney Seal. Do not use too much grease, because grease accumulating in the spring chamber operates as a spacer, increasing the spring pretension. Although these components will withstand a great deal of hard usa ge, the Pressure Spring and Kidney Seal should be inspected whenever the Cutting Ring is replaced.

Cording MUST be to outside when installed

12

Service Manual

Small Rock Valve

Determining Wear on the Kidney Seal & Housing Lining - Outlet Side

2

2

Spring installed

M d

1

mm

Replace the kidney seal if any of the following conditions exist: • A considerable formation of cracks are found in the areas marked by arrows. This problem is very rare. • The lip is completely worn to the point that the pressure relief grooves are no longer recognizable. • The distance indicated by “M” of the released kidney seal does not exceed 30mm (1.1875").

Figure 1

Replace the outlet housing lining (kidney plate) only if scores deeper than 1.5mm are found in the area that contacts the kidney seal. You can measure this by placing a steel ruler across the kidney plate in several places and using a depth gauge to determine the gap.

Figure 2

NOTE: Outside of the area that contacts the Kidney Seal, you may detect scores that are due to aggregate particles stuck between the Rock Valve and the Kidney Plate. (See fig. 2 and fig. 3) THESE SCORES DO NOT MATTER IN THE LEAST!

Figure 3

Service Manual

13

Small Rock Valve

Replacement of Cutting ring and Kidney seal

Locking Bolt

CAUTION! Under no circumstances should you allow the kidney seal to be run with a dry hopper. This will destroy the kidney seal and is the primary cause of premature wear encountered at the outlet side of the Rock Valve. If you will be repairing the Rock or troubleshooting a problem, always fill the hopper with water to the top of the

Rock Valve before switching. 1. Remove the Locking Bolt from the Tension Nut. 2. Loosen the Tension Nut. NOTE: It’s ok to remove the Tension Nut with a wrench, but it must never be tightened more than hand tight. Tension Nut

3. Remove the Tension Nut. 4. Remove the Setting Disc. •

Tension Nut

Setting Disc

14

Service Manual

Small Rock Valve 5. Install the Alignment Rods • SAI Part #30309007.

Alignment Rod

6. Slide the rear housing cover back slightly. 7. Remove the Kidney Seal for inspection, and replace it if necessary. See the previous section of this manual entitled Determining Wear on the Kidney Seal and Housing Lining--Outlet Side for reference. 8. Loosen the bolt that holds the slew lever on the Rock shaft, but do not remove

Kidney Seal

Service Manual

15

Small Rock Valve 9. Slide the Rock Valve back about 1.5 inches, and carefully remove the cutting ring. NOTE: If you are going to turn the Cutting Ring, you only have to move the Rock back far enough to allow you to loosen the ring and turn it 90 degrees. To determine if your Cutting Ring needs to be turned, refer to the previous section of this manual entitled

Lengthening the Service Life of the Spectacle Plate & Cutting Ring. Cutting ring eing removed

10. Make sure that all parts are tho roughly cleaned, and reassemble in reverse order. Slide the Rock cover back into place, and secure it with bolts.

11. Adjust the Tension Nut, which is tightened only hand tight. If the Locking Bolt shown can be installed in the Setting Disc freely, then do so. If the hole in the Tension Nut does not align with the thread hole in the Setting Disc, loosen the Tension Nut to the previous hole, and install the Locking Bolt.

Locking Bolt

16

Service Manual

Small Rock Valve

1.5 - .2.0mm (.060 - .080")

A

NOTE: Check to make sure that the proper clearance is obta ined between the Rock Valve and the Cutting Ring and between the Rock Valve and the Kidney Plate. If the Rock components are worn, the dimensions may be larger that specified. If the dimensions are too small, loosen the Adjusting Nut and pry the Rock Valve in the direction needed. Stroke the unit several times, and recheck the dimensions. If the dimensions are correct, reinstall the Tension Nut and re-adjust.

Dimensions shown are with all new wear parts.

IMPORTANT! At no time should you operate the Rock Valve without first lubricating the

outlet wear plate. Spraying the plate with water or oil will usually be adequate prior to start-up for pumping. Moving the kidney seal against a dry plate will cause excessive wear and premature failure.

Service Manual

17

Small Rock Valve These units were designed to have no adjustment. Before assembling slew lever, use a wire brush to clean splines on shaft and lever. Use grease or anti-seize to lubricate splines during assembly. If you do notice that the Rock is missing the material cylinder openings, you must check to see where the problem may be (i.e., articulated bearings, shifting cylinder (internal), or Rock slewing lever may need adjustment).

Level C L

Please call the Schwing Service Department at (651) 429-0999 with any questions regarding this matter. Slewing Yoke Timing

(Viewed From Cylinder End) The slewing yoke is installed properly when the center line of the hydraulic cylinder rod is in line with the center line of both the slewing shaft and the inlet or cutting ring. Rock is hanging freely and the lever is flat on top. A torpedo level will be centered.

18

Service Manual

C L

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SP 500 / 750-15D Spare Part s L ist

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Ordering Inform ati on Document# 98323807 Revi si on : May, 2015 When o rdering parts pl ease specify: • Model and Serial number • Quantity • Part number and Description

Schwi ng Call Center (P arts & Serv ice) 1-888-SCHWING (724-9464) FAX: (651) 429-2112 24 Hours - Monday thru Saturday www.schwingparts.com

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Torque Tables Nuts and Bolts as per DIN 912 - 9 31 - 933 - 934 - 6914 - 6915 Applicable to: Geomet 500 and Dacromet 500 coating. Black and silver-chromated nuts and bolts ftted with mounting paste such as Cu or MOS2

Assuming a friction coefcient of µ = 0.1.

Applicable to: Black and silver chromated nuts andbolts.

Assuming a friction coefcient of µ = 0.14.

*The tting tightening torque corresponds to the axial force in the bolt at which the limit of elasticty of the latter is utilised 90% by tension and torsion. ** SPB - Octagonal Mast

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MACHINE CHARACTERISTICS The code designation of the concrete pumps can be broken down as follows: Mechanical pump, trailer serial number explanation Model Plate SP

500

001

Stationary Pump

Model

Unit#

The Model Plate is located on the righthand side of the machine. The Serial No. additionally is punched into the machine frame just below the Model plate. Schwing America 5900 Centerville Rd

Schwing Gmbh Heerstrasse 9-27

SUBSIDIARY OF SUBSIDIARIA DE

White Bear, MN 55127 Phone: 651-429-0999 www.schwing.com

2 0 7 8 5 0 8 3 8 9

D-44653 Herne / Germany Phone +49-2325-987-0 www.schwing.de

This product is covered by one or more U.S. patents - see patent decal /Este producto está cubierto por una o más patentes de Estados Unidos-vea la etiqueta SERIAL # # DE SERIE

MODEL MODELO

YEAR ANO

MAX SPM

HP kW

WEIGHTS/LOADS/PESO/CARGA Total Weight Peso Total

LBS N

LBS N

Tongue Weight Lengua De Peso

Allowable Vertical Tongue Load Carga Vertical Permisible

HYDRUALICPRESSURES/PRESIONESHIDRAULICAS Concrete Pump / Bomba De Concreto

P.S.I. bar

Agitator El Agitador

Please note the Model # and Serial # of your machine.

P.S.I. bar

LBS N

Allowable Horizontal Tongue Load Carga Horizontal Permisible

LBS N

MATERIALPRESSURE/PRESIONES Accumulator El Acumulador

P.S.I. Auxiliary bar Auxiliar

P.S.I. bar

Material

RS

PS

RS

PS

P.S.I. bar

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Table of Contents - SP500/750-15 1.0 Sub A ss emb ly ............................................................. 1 Axle Assembly..................................................................................................................... 2 Axle Placement ...................................................................................................................3 Chassis Assembly (1 of 2)...................................................................................................4 Chassis Assembly (2 of 2)...................................................................................................5 CAT C4 4T 80 HP Engine Assembly (1 of 3).......................................................................6 CAT C4 4T 80 HP Engine Assembly (2 of 3).......................................................................7 CAT C4 4T 80 HP Engine Assembly (3 of 3).......................................................................8 Air Intake Extensions .......................................................................................................... 9 Fuel Separator / Bafe Installation ....................................................................................10 Heat Shield Installation .................................................................................................... 11 1015-80/50 Pump kit Assembly......................................................................................... 12 10040856 - Differential Cylinder Assembly ..................................................................13 Differential Cylinder Plumbing ...........................................................................................14 10192655 - MPS Valve ................................................................................................15 1015 (6”) - Ram with Connector & Adapter .......................................................................16 Long Rock - Housing Assembly ........................................................................................17 Long Rock Valve Assembly ............................................................................................... 18 Long Rock - Slewing Cylinders/Agitator ............................................................................ 19 30390238 - Slewing Cylinder Assembly ......................................................................20 Long Rock Valve Greaser Assembly .................................................................................21 Hydraulic Tank Assembly (1 of 2) ......................................................................................22 Hydraulic Tank Assembly (2 of 2) ......................................................................................23 98350314 - Hydraulic Oil Cooler Assembly ................................................................. 24 Controller Assembly (1 of 2) ..............................................................................................25 Controller Assembly (2 of 2) ..............................................................................................26 10192654 - Control Block Assembly ............................................................................ 27 10188446 - Control Unit S1-S2....................................................................................28 98352331 / 98352332 - Solenoid Valve DS3-S2 .........................................................29 10183940 - NG 25 Poppet Valve Insert .......................................................................30

2.0 Main Assemb ly .......................................................... 31 Pumpkit Installation ...........................................................................................................32

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Table of Contents Hydraulic Controller - Tube Rack ......................................................................................33 Tube Rack Hydraulic Hoses (1 of 2) ................................................................................. 34 Tube Rack Hydraulic Hoses (2 of 2) ................................................................................. 35 Hopper Assembly ..............................................................................................................36 Engine Installation .............................................................................................................37 Fuel Tank Installation ........................................................................................................ 38 Fuel Lines Installation - SP500 .........................................................................................39 Fuel Lines Installation - SP750 .........................................................................................40 Hydraulic Pump Connections ............................................................................................41 Hydraulic Tank / Accumulator Installation.......................................................................... 42 10304502 - E-Stop Assembly ...................................................................................... 43 Hydraulic Tank Connections ..............................................................................................44 Hydraulic Cooler Installation .............................................................................................45 MPS Valve Plumbing .........................................................................................................46 Emergency Stop Manifold Plumbing .................................................................................47 10201988 / 10201989 Emergency Stop Manifold ............................................................. 48 Operator Controls Installation ...........................................................................................49 98347086 - Control Panel Assembly ...........................................................................50

3.0 Fi nal Ass emb ly .......................................................... 51 Shroud Installation ............................................................................................................52 Exhaust Installation ...........................................................................................................53 Exhaust Installation with Catalytic Convertor ....................................................................54 98365128-Assy. Exhaust Mufer System CAT C4.4 .........................................................55 Miscellaneous ................................................................................................................... 56

4.0 Sch emat ics ................................................................ 57 98378929 - Hydraulic Schematic ...................................................................................... 59 98380853 - Electrical Schematic....................................................................................... 61

5.0 Shipping ..................................................................... 63 Spare Parts and Accesories ..............................................................................................64 98347141 - Cable Remote ................................................................................................ 65 98392576 Decal Kit (1 of 4) ..............................................................................................66

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Table of Contents 98392576 Decal Kit (2 of 4) ..............................................................................................67 98392576 Decal Kit (3 of 4) ..............................................................................................68 98392576 Decal Kit (4 of 4) .............................................................................................. 69

6.0 Opt ions ...................................................................... 71 98347792 - Radio Remote Kit ........................................................................................... 72 Radio Remote Installation .................................................................................................73 Hydraulic Outrigger Assembly (1 of 3) .............................................................................. 74 Hydraulic Outrigger Assembly (2 of 3) .............................................................................. 75 Hydraulic Outrigger Assembly (3 of 3) .............................................................................. 76 Dual Axle Assembly........................................................................................................... 77 Dual Axle Fenders ............................................................................................................. 78 Dual Axle Fenders - w/Lifting Frame .................................................................................79 Dual Axle Fenders - Accumulator Installation....................................................................80 Vibrator Assembly .............................................................................................................81 Water Pump Assembly ......................................................................................................82 98348884 - Water Pump Unit ............................................................................................ 83 Water Pump Installation (1 of 2) ........................................................................................ 84 Water Pump Installation (2 of 2) ........................................................................................ 85 Water Pump Installation w/Agitator ................................................................................... 86 Auxiliary Valve Installation.................................................................................................87 Auxiliary Circuit Gear Pump Assembly.............................................................................. 88 Auxiliary Circuit Installation ...............................................................................................89 Dual Stroke Counter Installation .......................................................................................90 Auto Greaser Pump/Feeder Block Install .......................................................................... 91 Auto Greaser Feeder Valve Plumbing...............................................................................92 Electric Throttle .................................................................................................................93 Lifting Frame ..................................................................................................................... 94 Reector Locations ...........................................................................................................95

Appendix A ...................................................................... 97 Hayes Coupling Installation...............................................................................................98

Appendix B ...................................................................... 99 Hydraulic Fittings Tightening Procedure ......................................................................... 100

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1.0 Sub A ss emb ly Axle Assembly.......................................................................................................................... 2 Axle Placement ........................................................................................................................ 3 Chassis Assembly (1 of 2)........................................................................................................ 4 Chassis Assembly (2 of 2)........................................................................................................ 5 CAT C4 4T 80 HP Engine Assembly (1 of 3)............................................................................ 6 CAT C4 4T 80 HP Engine Assembly (2 of 3)............................................................................ 7 CAT C4 4T 80 HP Engine Assembly (3 of 3)............................................................................ 8 Air Intake Extensions ............................................................................................................... 9 Fuel Separator / Bafe Installation ......................................................................................... 10 Heat Shield Installation ..........................................................................................................11 1015-80/50 Pump kit Assembly.............................................................................................. 12 10040856 - Differential Cylinder Assembly ....................................................................... 13 Differential Cylinder Plumbing ................................................................................................ 14 10192655 - MPS Valve ..................................................................................................... 15 1015 (6”) - Ram with Connector & Adapter ............................................................................ 16 Long Rock - Housing Assembly ............................................................................................. 17 Long Rock Valve Assembly .................................................................................................... 18 Long Rock - Slewing Cylinders/Agitator ................................................................................. 19 30390238 - Slewing Cylinder Assembly ........................................................................... 20 Long Rock Valve Greaser Assembly ...................................................................................... 21 Hydraulic Tank Assembly (1 of 2) ........................................................................................... 22 Hydraulic Tank Assembly (2 of 2) ........................................................................................... 23 98350314 - Hydraulic Oil Cooler Assembly ...................................................................... 24 Controller Assembly (1 of 2) ................................................................................................... 25 Controller Assembly (2 of 2) ................................................................................................... 26 10192654 - Control Block Assembly ................................................................................. 27 10188446 - Control Unit S1-S2......................................................................................... 28 98352331 / 98352332 - Solenoid Valve DS3-S2 .............................................................. 29 10183940 - NG 25 Poppet Valve Insert ............................................................................ 30

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Axle Assembly

30391431 HARNESS WIRE AXLE

30390508 TUBE 3/4 OD.X 5/8 ID X 30" (WELD) HEAT SHRINK EACH WIRE AND AL L TOGETHER TO WIRING HARNESS

10009876 NUT M6 NYLOCK

30392733 AXLE 7000 8 LUG ELECT

30391602 LOOM CLAMP 3/8" 10001764 SCREW M6X20

GREASE CAP 98350966 BUTT SPLICE AND GROUND BOTH SIDES

Trailer Align ement Inspection The alignment inspection is required on all trailer pumps from P88 to SP’s. The alignment needs to checked prior to tire assembly. With a calibrated tape, measure from one end of the axle to the tongue centerline, Record the measurement and repeat the same Procedure to the opposite side of the axle. Both sides of the trailer must be equal. (Within 1/4” Of Each Ofter, If Greater Than 1/4” Realign Axle And Repeat Procedure) For tandem axle trailer, measure rear axle the same way. Axles should be equal distance apart. TRAILER ALIGNMENT

BA D

GOOD

Wheel

Wheel

b

b Tongue

Centerline

Coupler

a Ax le Wheel

Coupler

a c a--- tr ail er axle b --- measu remen t c --- measu remen t

Ax le Wheel

Isosc eles Triangle --- Two si des equ al

1-2

Tongue

Centerline

SP 500/750-15

c

Straight Tongue Trailer Shown App li es to A --- fram e to ngu es al so

May, 2015

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Axle Placement

May, 2015

1

2

3 4 5

6

7

Dual Axl e CAT

1

2

3 4 5

6

7

Single Ax le CAT

1

2

3 4 5

6

7

Single Axle Ele ctr ic

SP 500/750-15

3 - 1

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Chassi s Assembl y (1 of 2) 30358402 (4) 5/8” x 2-1/2” GR8

30391349* ASSY JACK SIDE WIND

30397304 OPTIONAL

30392299 (4) M16X40

30391038 (4) 5/8” FLAT

10009875 (4) M8 NYLOCK

30391038 (4) 5/8” FLAT SAE

10010371 (4) M8 FLAT 30391038 (4) 5/8” FLAT

30396181 TOW EYE HITCH

10001106 (2) M12X70

1001286 (4) M16 NYLOCK

10001280 (2) M12 NYLOCK

30396433 (4) 5/8” x 3” GR8 30394086 U-BOLT 3/8" SAFETY CHAIN

30390193 WMT CHASSIS SP500/450

30394087 SAFETY CHAIN 3/8" X 4'

30392300 (4) M20X60 120 FT LBS.

48” Each Minimum Including hook

30330552 CLEVIS HOOK W/LATCH

30392698 CLAMP HYD HS167

30391038 (4) 5/8” FLAT 30391368 (4) 5/8” NYLOCK

98344168 Standard Handle 98344172 Jack Leg

98380857 Handle with optional water pump

10001808 SCREW (4) M8X25

98344169 Plate

*30391349 - Jack As sembl y

30394263 ASSY AXLE 7000# 8-LUG

30394115 -- STEEL 98352725 -- ALUMINUM AIR PRESSURE 80 PSI 30391360 (4) 3/4” FLAT WASHER

30373530 -- STEEL 30396337 -- CHROME 95 FT-LB NEVER SEIZE

30392112 (4) M20 CROWN

98333188 -- CHROME

1-4

SP 500/750-15

May, 2015

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Chassi s Assembl y (2 of 2) 30391374 1/4” NYLOCK 30303735 1/4″ FLAT

30303275 BREAK AWAY SWITCH W/CABLE 2009

HARDWARE FOR BOX 30373841 - 1/4 ” X 3/4” 30373852- /4” LOCK WASHER TAILIGHT HARNESS

7 POLE PLUG BLUE

WHITE/BLACK 6

BROWN

30391417 SCREW 1/4 X 1”

RED

4

GREEN

3

GREEN

YELLOW

2 1

30396184 30303719 ADAPTER ENCLOSURE 7 POLE VEHICLE 30395669 JUNCTIION BOX CONNECTOR HARNESS MALE 7 POLE

BROWN

BLACK BLACK

30392973 CABLE HARNESS TAILLIGHT

BREAK-AWAY SWITCH

30373847 (16) 1/2” NYLOCK 30391335 (16) 1/2” FLAT

30337904 (16) SCREW 1/2” X2”

30397359 (SET) 30393671 HITCH PIN #8

30337904 (16) SCREW 1/2” X2” 30373838 LOCK WASHER 5/8

30397331-LH 30397330-RH 30330542 SLEEVE ASSEMBLY 30394743 PIN WITH CHAIN

30397393 LIGHT LICENSE BRCKT PLASTIC

30330541 OUTRIGGER LEG WMT

May, 2015

BLUE

5

SP 500/750-15

5 - 1

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CAT C4 4T 80 HP Eng in e As sem bl y (1 of 3)

30330521 BALL JOINT/ FOR CABLE 30304506

SP500 98354109-US 98354110-CE 98354111-LRC SP750-15 98354112-US 98354113-CE 98354114-LRC

30391509 CABLE ASSY

10011106 M6 FLAT

10134153 M6 SKM

30392236 SCREW 1/4-28

98348306 THROTTLE CABLE BRKT

10129842 SKM 8

30304506

10001796 SCREW 8X16

30396953 SERRATED FLANGE NUT M6 30349654 WASHER LOCK M6 30394438 HORN 12V

30390331 COUPLER SAE 10 COUPLING GREASE

10001114 (4) M12X80 GR 8.8 30391335 1/2” FLAT 98348977 WASHER 1/2" ID 10001256 SCREW 8X70 10010371 8 FLAT WASHER 98345629 ISOLATOR MOUNTS

FOR COUPLING INSTALLATION SEE APPENDIX A 10136867 (8) M10 SKZ 98351382(8) SCREW 3/8" X 1"

10129841(12) SKM 10 30391605 PUMP MNTG PLATE

10001861(12) SCREW M 10X30

98350965 WMT MOTOR MOUNT

30373462 WASHER 5/8 10010371 8 FLAT 10009875 M8 NYLOCK

1-6

30391335 1/2” FLAT 10009876 NUT M12

SP 500/750-15

May, 2015

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CAT C4 4T 80 HP Eng in e As sem bl y (2 of 3) 10018570 EWSD 12 L

*30395278 - ACCUMULATOR MANIFOLD 30395769 O-Ring

10144059 SNV 12 L

10114516 GES 12 LR-WD

10008054 TS 12 L

30392102 SHCS M6X110

30395471 Motor

10095632 8 X 550

10114516 GES 12 LR-WD

Hydraulic Tank

30395470 30395472

10144059 SNV 12 L

10018570 EWSD 12 L 10052338 8 X 350

30395473

10008083 GS 12-L

10114516 GES 12 LR

MOUNTING ORIENTATION

*98354016 - J & G 10019730 ETSD 12 L

10025113 8 X 500

98354084 1 1/4" X 25MM 98354086 1" X 16MM

10018850 EWSD 20 S 10184637 GES 20 SR-WD

30393409 BRACKET 10011106 M6 FLAT

10011985 M6 NYLOCK

10001323 (4) M16 X 50 SHC

30392879 10001191 (4) M12 X 40

30390206 PUMP HYDRAULIC

30393781 VARIABLE

10138330 (4) M12 SKZ

30390706 ADAPTER 30390506 3-1/4” X1/8”

10161984 GES 12 L/R 1/4

10018417 EWSD 25 S

30393965 FIXED

10184638 GES 25 SR-WD 10018570 30390381 EWSD 12 L PUMP FLANGE 30390499 O-RING 30301940 33 X 3 GES 12

10032145 (4) M20 SKZ 30308465 (4) 3/4” X 2”

98354082 98354083 1" X 20MM 3/4" X 12MM

30390028 COUPLING M26 X 3/4"

10008087 WS 16-S

30395497 O-RING 2 X 84

30350471 10065682 FLANGE EWSD 30 S CONN 1"

30391365 (4) 3/8” X1-1/4” 10136867 (4) M10 SKZ 30394524 HYDRAULIC PUMP

30390057 G25 1-5/16 98324565 10009260 PUMP GES 16-S X 7/8" COUPLER 10001021 10019122 ORING EWSD 16-S 3 X 84

30394073 10018570 10139855 (4) 10164227 3"SAE/3" EWSD 12 L M16 SKZ SNV 16-S BARB 10161984 30390262 GES 12 L/R 1/4-WD 10150334 MNTG SET 10018570 GES FLANGE EWSD 12 L 16-SR X 1/2 10001143 (2) 30329777 10020459 ADAPT GE M10 FLAT 30395278* COUPLING 10001695 (2) 10150334 M10X25 10050169 GES 10008142 10136867(4) 8 X 550 16 SR-WD 10192344 MAS 12 LR M10 SKZ GES 20 10144059 *98354016 - J & G 10018570 SNV 12 L EWSD 12 L 10114516 30394127 - BARNES NOTE: LARGE PORTS GES 12 LR-WD ON TOP 10018570 EWSD 12 L 10136867 (4) 10019121 M10 SKZ ELSD 12 L 10000971 (2) 10030252 M10X25 SHC 12 L/R 1/2” GES

May, 2015

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7 - 1

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CAT C4 4T 80 HP Eng in e As sem bl y (3 of 3) 98347948 ALTERNATOR

Main Power Relay to Start Solenoid Vibrator Power Relay to Intake Heater

4 0 2 0

0 4

Tach Sender

0 2

Engine-Start/Stop 4 0 2 0

Battery to Fuse Holder

0 4 0 2

Intake Heater

10001237 Nut M5

grey - Tach Signal black/white - Alt. D

30349653 Lock M5

98349607 40A

30396953 Nut M6

98349605 20A

red - Battery to Alt.

red 4 0 2 0

30396953 NUT M6

0 4

Re l ay red

0 2

red 3 0 6 0

0 3 0 6

to

Ba

St

t te

ar t

So

l en

oid Fu Ba s eH tte ry old to er Al t . ry

to

30392857 - 40” 750-18 30392858 - 16” 750-15 98349606 30A 98349609 60A

98351361 RELAY MOUNT

98354014 M6 X1 X 90

98349610 FUSE HOLDER

10011106 M6 DISC

10011985 NUT M6 98354169 SPACER

4 0 2 0

0 4 0 2

10011106 M6 DISC 98349610 FUSE HOLDER

4 0

10011985 M6 NYLOCK

2 0

98353481 ELEC COVER

10129840 SKM 12 10001528 12 x 45 (Blue Loctite) Main Groun d

0 4 0 2

30396506 CABLE 2/0 GA 10129841 M10 SKM 10001855 M10x20

1-8

Note: Vertically mou nt relay from t he X-2 harne ss

SP 500/750-15

Ground To Frame

May, 2015

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Air Intake Ext ensions

98353337 SP500 RAIN CAP

98353341 SP750-15 RAIN CA P

98349677 SP500

98351830 SP750-15

98351383 T-BOLT 3.75"-4.06" SS

98351383 T-BOLT 3.75"-4.06" SS

SP750 98356219 - PRIMARY AIR FILTER 98356221 - SECONDARYAIR FILTER SP500 98356217 - PRIMARY AIR FILTER 98356218 - SECONDARYAIR FILTER

May, 2015

SP 500/750-15

9 - 1

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Fuel Separator / Bafe Installation 30373514 (6) HOSE CLAMP

10001796 BOLT 8X16 10129842 SKM 8

15”

12”

30373514 (6) HOSE CLAMP

20”

10001796 BOLT 8X16 10129842 SKM 8

30391110 5/16” FUEL LINE 98347956 FUEL SEPERATOR

98349676 (SP500)

98349676 (SP500)

10001283 10MM NUT 98348969 5/16" BARB X 1/2" MALE

98347955 Oil Filter

98348917 BAR

10129840 SKM 12

10011143 10 FLAT WASHER

10001513 12X25 98348969 5/16" B ARB X 1/2" MALE

100301862 SCREW 10X35

1 - 10

98347961 Secondary Fuel Filter

98357977 ASSY

30373514 (6) HOSE CLAMP

SP 500/750-15

May, 2015

30392690 5/16” BARBED

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Heat Shield Installation

10001575 (2) SCREW M6 x 20 10011985 (2) M6 NYLOCK

98349347 SHROUD SUPPORT 10011985 (2) M6 NYLOCK 30387022 TUBE CAB FLOOR SPACER

98349346 STROKE LIMIT HEAT SHIELD

10129841 SKM 10 10001307 SCREW M10X45 98349348 HEAT SHIELD ELECTRICAL 10138330 SKZ 12 10001508 12X20

May, 2015

SP 500/750-15

11 - 1

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1015-80/50 Pump ki t As semb ly 30329763 COVER WATERBOX

10040856 80/50X1000

10001209 NUT M16

CLOSED POSITION HANDLE TO THE OUTSIDE SP500

10001512 M16 FLAT

CLOSED POSITION HANDLE TO THE REAR SP750

10001512 M16 FLAT

10027758 M16X75 (ANTI-SEIZE)

30390914 DRAIN HANDLE (ANTI-SEIZE)

30391227 WMT WATERBOX 6" W / DRAIN

10000458 O-RING 150X4

30391572 5/16-18 STAINLESS (ANTI-SEIZE) 30391241 ROD THREADED 6"

30391573 3/8-16 STAINLESS

30391240 BRCKT GUIDE 6"

30391037 PLUG SUPPORT

10207022 M20X140 (ANTI-SEIZE) 10001509 M20 FLAT

10000478 O-RING 160X3 10004174 SPLIT RING

30390838 URETHANE DISC 30390853 SPACER

30391574 M6X12 A-2 (LOCTITE)

30391573 3/8-16 STAINLESS

30313571 FLANGE 10001509 M20 FLAT 10001438 M20X90 230 FT-LB MIN (ANTI-SEIZE)

98356325 GORTEX

30373731 CYLINDER 30313571 FLANGE 10004174 SPLIT RING

30390338 WATERBOX 30390872 ELBOW 2" 90 DRAIN 30390871 NIPPLE

10000470 O-RING 158X5 10104113 TRANSITION PIECE FROM 10000470 O-RING ROCK VALVE 158X5 ASSEMBLY

30373425 DRAIN PLUG

1 - 12

SP 500/750-15

May, 2015

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10040856 - Differential Cylinder Assembly 10000458 10001056

10027753

10160565 98321191 10047860

10003414

10130304 (2) Screw Plug G 1 VS-WD

98321190 10027756 10027757

10040859

10013030 10000703

10040857

10016238 10000933

10027750

10040858

10040859 Cylinder Blo ck 80/5 0

98321189

10027757 (3) Screw M12 X 80

10040858 Hydraulic Piston B 80X 50/50-25

10047860 Guide Bushing

10013030 Rectangular ring 80.0/ 73.0 x 3.0 (4)

10040857 Disc 77x10 10003414 Sealing Gland set

10000703 O-Ring 48x4 NBR

10027753 Back-Up Ring Unslotted

10027750 Piston Rod 50x116mm

10040859 Cylinder Block 80/50

10000933 O-Ring 72x4

10130304 Screw plug G 1 VS-WD

10016238 Backup Ring 10001209 (4) Nut M16

10040859 Cylinder block 80/ 50 10000458 O-Ring 150x4

10160565 Guide Strip ID

10001056 O-Ring 100x3

98321191 Rod Sealing 50x65 10001512 (8) Washer 98321189 Tension Ring 80/50

10027758 (4) Screw M16x75

10027756 (8) Screw M12x40 98321190 Scraper 50x60x9

May, 2015

SP 500/750-15

13- 1

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Diffe rential Cylinder Plumbi

ng

10050168 8X450 10018570 EWSD 12 L 10144059 SNV 12 L

10018570 EWSD 12 L

10008084 WS 12 L 10050174 8X1000

10172599 GES 12 L/R 1/2-WD 10018570 EWSD 12 L

10050168 8X450 10018570 EWSD 12 L 10114516 10144059 GES SNV 12 L

10192655 CONTROL BLOCK 10009876 (4) M12 NYLOCK 25 FT-LB MAX 30373843 (4) 1/2” FLAT SAE

12 LR-WD

30394771 BRACKET MPS 10129842 (2) M8 LOCK

* 3 1/4” 10008084 WS 12 L

10001808 (2) M8X25

* 3 1/4” FROM END OF DIFFERENTIAL TO MPS MOUNTING PLATE

10050174 8X1000

10030475 TUBE SUPPORT 114.3 10184638 GES 25 SR

10018481 20X700 10184665 RSWS 25 SR 1”

10050168 8X450

10114518 RSWS 12 LR-WD

10184638 GES 25 SR 10018481 20X700

30392906 M12 10018570 EWSD 12 L

10172599 GES 12 L/R 1/2 10114518 RSWS 12 LR-WD 10018570 EWSD 12 L

30313717 TUBE 12 MM X 5 3/8" 30333032 30333030 CART. W/SEALS CHECKVALVE

10050174 8X1000 10114518 RSWS 12 L/R 3/8 A

30313715 TUBE 12MM X 4 7/8"

10172599 GES 12 L/R 1/2 10018570

10172599 GES 12 L/R 1/2

EWSD 12 L 30313717 TUBE 12MM X 5 3/8"

10114518 RSWS 12 LR-WD 10018570 EWSD 12 L

30333032 30333030 CART. CHECKVALVE W/SEALS 10172599 GES 12 L/R 1/2

1 - 14

10184665 RSWS 25 SR 1”

10114518 RSWS 12 LR-WD 10050174 8X1000

30313714 TUBE 12MM X 3 7/8"

SP 500/750-15

May, 2015

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10192655 - MPS Valve

10199494 "W" 2.4 MM 10165394 VALVE CARTRIDGE 9612 10J G01 10006658 SCREW PLUG R 1/4 -WD

10077825 1.0mm “ B”

10199494 "W" 2.4 MM 10204122 CONNECTION PIECE12 L

10171647 PISTON MPS NO. 1

10213188 VALVE HOUSING VBL-MPS

10072866 PRESSURE SPRING

10204122 CONNECTION PIECE12 L 10077825 1.0mm “ B”

May, 2015

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15- 1

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1015 (6” ) - Ram wi th Connector & Adapter

10033751 COUPLING FLANGE 30411614 DOGBONE W/HARDWARE 10209273 - SPARE PARTS # 98356271 - PRODUCTION # ONLY 10001896 M12 FLAT 10187342 BUSHING H

10001106 M12X70 LOCTITE

10001834 M20X75 LOCTITE

10001834 M20X75 LOCTITE 10187342 BUSHING H

10161863 PUMPING PISTON

1 - 16

SP 500/750-15

May, 2015

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Long Rock - Housing Assembly

10008400 (2) M30 (SPECIAL) GASKET SEALANT

10067810 Bearing bushing D 70/85 x 57

10017436 O-RING 10066146 70 X 8 SEALING COVER

30394279 (2)

10011143 (3) M30X70 SPECIAL ANTI-SEIZE SHAFT M10 FLAT LOCTITE THREADS 10001861 (3) 150 FT-LB MIN SCREW M10X30 30391048 200 FT-LB MAX PLATE 10002404 WEAR SPRING STRAIGHT PIN

30390527 HOUSING W/BRK

10033969 - LONG ROCK

LONGROCK

SHORTROCK

10032145 (10) M20 SCHNOOR

200 FT-LB MIN ANTI-SEIZE AL L BOLTS

30390185 M20X45 SHC

200 FT-LB MIN ANTI-SEIZE ALL BOLTS

30390185 M20X45 SHC 10004643 M20X65 SHC

10004643 M20X65 SHC

10001420 M20X65

10001438 M20X90

30390185 M20X45 SHC

10001420 M20X65 10001420 M20X65

May, 2015

10032145 (10) M20 SCHNOOR

10004643 M20X65

30390185 M20X45 SHC

10001438 M20X90 10001438 M20X90

SHC

SP 500/750-15

10004643 M20X65 SHC

17- 1

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Lon g Rock V alve Ass embly

30391049

OUTLETS

10001283 (1) M10 NYLOCK 10011143 (1) M10 FLAT

SILICONE 10035783 SEALING RING

30390339 5” HD

SPRING

10067965 ROCK DN 165/135 L

30390588 TUBE 16MM X 2.5MM

30392534 5" HD 8 deg angle

30392904 125mm Short

CUTTING RING 10064473 PRESS

10080782 LOCKING COVER

10001512 M16 FLAT (1)

30391394 125mm Lon g

10001896 M12 FLAT (1) 10032789 CLAMPING PIECE LH

10001875 M10X50 (1) 10032788

10032182 SEAL KIDNEY

CLAMPING PIECE RH 10139855 (4) M16 SKZ 10025851 HOUSING LINNING

Cordin g MUST be to outside when installed

10001671 (4) M16X70 SHC

10025626 BUSHING 10000455 D 2.563" X 2.559" O-RING 148 X 5 10004677 O-RING 10017396 65 X 8 SETTING DISC

10043980 TENSION NUT 10139855 M16 SKZ

30329750 ROCK VALVE COVER

10001596 M16X30

Lubrication gro oves MUS T face out from rock valve ANTI-SEIZE ALL BOLTS

1 - 18

10032145 M20 SCHNOOR 10001420 M20X65 230 FT-LB MIN

10006723 M16 SCHNOOR

10030909 WEARING TUBE 10032815 O-RING 150 x 3 10001347 M16X50 HHCS 120 FT-LB MIN

SP 500/750-15

10001509 M20 FLAT 30390976 M20X70

SEE CHART

May, 2015

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Long Rock - S lewing Cylind ers/ Agitator 10018417 EWSD 25 S

10001517 SCREW M12X30

10001503 M12X16 (LOCTITE)

30373371 GREASE FIT 1/8"

30357989 (0.2660 IN) 98337382 STOP WASHER 10032193 (ANTI-SEIZE)

10018617 M12 SCHNOOR 10066066 DISC E 15 X 77 10018417 EWSD 25 S 30357989 (0.2660 IN)

30390238 HYD CYL SINGLE ACTION

10000203 O-RING 12X3.5

10008083 GS 12 L

30392208 HYD TUBE 12 MM X 3-3/4

30327966 SLEWING LEVER WP DUAL

10018570 EWSD 12 L

30373371 GREASE FIT 1/8"

30329777 ADAPT 12PL7/8

10000985 M10X40 SHC 10136867 SKZ 10

30390238 HYD CYL SINGLE ACTION

10039180 HYDRAULIC MOTOR

10061076 SEALING CONE

10001517 M12X30

10061077 BUSHING

10018617 LOCK S 12

10061074 BEARING 30317544 GREASE FIT 90 DEG 30390253 (ANTI-SEIZE)

98337382 STOP WASHER 10011747 FLANGE SUPPORT 10129841 SKM 10

10007772 BUSHING

10061076 SEALING CONE

30390592 1/2”X2-3/4” (SPECIAL)

10001861 SCREW M10X30

Comes w/motor

30317544 GREASE FIT 90 DEG

10065383 SPRING-TYPE STRAIGHT PIN

10042338 AGITATOR SHAFT

30391038 FLAT, 5/8" 10000627 O-RING 35X3

10000765 O-RING 60X5 10064515 BUSHING

May, 2015

10001503 M12X16 (LOCTITE)

SP 500/750-15

19- 1

10000765 O-RING 60X5 10064514 MOTOR BUSHING

30373847 NYLOCK 1/2” NUT

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30390238 - Slewi ng Cyl in der Ass embl y

30373371 GREASE FITING 1/8”

30397473 - CYLINDER ROD/PISTION (INCLUDES GREASE ZERKS AND BEARING) 30390324 - PACKING KIT (ALL SEALS AND WIPER)

30390027 BEARING SLEWING CYLINDER 30373371 GREASE FITING 1/8”

30390238 CYLINDER SLEWING SINGLE ACTION

30390027 BEARING SLEWING CYLINDER

1 - 20

SP 500/750-15

May, 2015

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Lon g Rock Valve G reaser Assemb ly 10007886 CONE LUB. NIPPLE 30305039 CAP PLUG # GC-5 red

30391390 (WELD)

” 27

98387637 GREASE LINE, L. ROCK , SP 500

” 27

” 37

10200242 SCREW JOINT M10 X 1K

98387636 GREASE LINE 37" 98387634 GREASE LINE 27"

10207031 SCREW JOINT M10 X 1 VS 10200242 SCREW JOINT M10 X 1K

10007886 CONE LUB. NIPPLE

30316515 LUB ADAPTER

98363492 GREASE NIPPLE 45° M10 98363492 GREASE NIPPLE 45° M10

May, 2015

SP 500/750-15

21- 1

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Hydrauli c Tank Assembl y (1 of 2) 10160659 SCREW FOR CLEANING COV. 30303273 SEAL RING M16 NYLON 10006836 COVER 10000616 O-RING 214 x 5

30373903 (2) 5/16-18X1”

98373554 CAP FILLER BREATHER

LOCKTITE 30373859 (2) 5/16” LOCK

10006835 CROSS NUT

10184638 GES 25 SR

30302128 (2) 5/16” FLAT

30390535 (ELECTRIC) PIPE 30394096 PLUG 3/4" WMT HYDR. TANK (STANDARD) 98346395 WMT HYDR. TANK

10049957 20X650

T OU

30395423 HEAD BPA/WP PUMPS

IN

30393809 FILTER GAUGE

10184638 GES 25 SR 30394990 OIL LVL INDICATE W. THERMOMETER

10018417 EWSD 25 S

10018417 EWSD 25 S

30390081 GAUGE NUT 1/2"

30390440 3/8”X1-3/4” LOCKTITE

30394213 FILTER

10184639 GES 30-SR X 1 1/4 10184638 GES 25-SR X 1 10001505 RED-R R 3/4(25/20) 30393615 MAGNET 4" X 1/2" X 1/8"

10184637 GES 20-SR X 3/4"

30393615 (BELOW INLET)

10184638 GES 25-SR X 1

) (25 ) (12

30308097 WATER PIPE PLUG 1/2" 30393219 NIPPLE CLOSE 1/2" 30326818 BALL VALVE 1/2" L OW PRES. 30390720 BUSHING 3/4MX1/2F

30334927 ELBOW STR 3/4"

) (16 ) (20

10150334 GES 16-SR X 1/2"

) (12 ) (25

10172599 GES 12-LR X 1/2

10184637 GES 20-SR X 3/4"

) (12 (25

10114516 GES 12-LR X 3/8

)

10184638 10114516 GES 12-LR X 3/8

GES 25-SR X 1

10184638 GES 25-SR X 1

1 - 22

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May, 2015

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Hydrauli c Tank Assembl y (2 of 2)

10018570 EWSD 12-L

10050168 8 X 450

30390975 G12/34-16 30390167 HAND VALVE SINGLE 30397142 5/16″ X1-3/4″ SHC 10018570 EWSD 12-L

30390975 G12/34-16UNF 10025113 8 X 500

30390975 G12/34-16UNF 10008132 GS 16-S X 12-L

30305039 (3) CAP PLUG # GC-5 red

30391390 10184664 (WELD) RSWS 20-S R3/4"

10007886 (3) CONE LUB. NIPPLE 30307281 HYD TUBE 16 MM X 20 1/2" 30307546 STAUFF 5/8” 10002481 COVER PLATE 10001771 M6 X 35 30301345

10018483 8 X 900

10052338 8 X 350 10172599 GES 12-LR X 1/2

10200242 (3) SCREW JOINT M10 X 1K 10172599 GES 30396066 12-LR X 1/2 VALVE 12V AGIT 10018570 EWSD 12-L

10144059 SNV 12-L

10018570 EWSD 12-L 10019730 ETSD 12-L

10008132 GS 16-S X 12-L

COMPLETE

10172599 GES 12-LR X 1/2 10052338 8 X 350

10025113 8 X 500

10019121 ELSD 12-L 10018570 EWSD 12-L

May, 2015

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23- 1

10018483 8 X 900

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98350314 - Hydraulic Oil Cooler Assembly

10117711 SCREW M8x12 10129842 SKM 8

98350468 RUBBER BUFFER

10184638 GES 25 SR-WD

98350320 COOLER SUPPORT

98350314 - 12V * 98350315 - 24V 98350321 SP COOLER SUPPORT

10129842 (10) SKM 8

10001796 (4) Screw 8x16

10129842 (10) SKM 8 10010699 (6) Screw 8x12

98350467 SHROUD SP COOLER

*

98350314 - 12V 98350315 - 24V

98352861 ASA FITTING PORT SP TORQUE BOLTS 12NM 9 LB./FT

10134153 (4) SKM 6

10000633 0-RING 35x3

10001756 (4) Screw 6x10

10203753 - 12V FAN 10190119 - 24V FAN 10000633 O-RING 35 x 3 98352861 ASA FITTING PORT SP 98352858 RADIATOR CORE

1 - 24

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98352862 FITTING KIT (2) 98352861 (1) PLUG

May, 2015

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Controller Assembly

(1 of 2)

10018417 EWSD 25-S

10008149 GS 25-S 10018417 EWSD 25-S

10008087 WS 16-S

10184638 GES 25-SR X 1" 30305600

10164227 30397382 GES 25 X 1 1/4”

10001492 1 1/4” X1

10150334 GES 16-SR X 1/2"

10001541 1 1/2” X1

10212924 -- 12V 10217064 -- 24V

10000328 RED R1"-WDxR1/2"

10018417 EWSD 25-S

10192654

10184638 GES 25-SR X 1" 10184638 GES 25-SR X 1"

10114516 GES 12-LR X 3/8"

10025113 8X500

10018570 EWSD 12-L

10114516 GES 12-LR X 3/8"

10114516 GES 12-LR X 3/8"

30397316

10129840 (2) M12

10184638 GES 25-SR X 1" 10018570 10018417 EWSD 12-L EWSD 25-S

10001513 (2) M12X25

10201988 - 12V 10201989 - 24V

30397317 10001517 12X30 10129840 SKM 12

10129841 (2) M10

10049944 16X1000

10001859 (2) M10x25

10172599

10184637

10062202 13X800

30395547 16SR 3/4”

May, 2015

SP 500/750-15

10019122 EWSD 16-S

25- 1

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Controller Assembly

10018570 EWSD 12-L

10020459 MEASURING COUPLING

(2 of 2)

10018570 EWSD 12-L 30306479 HYD TUBE 12 X 2 X 30 10028506 (TIGHTEN HANDLE)

30390400 1.1MM 10018570 EWSD 12-L 10019122 EWSD 16-S

10150334 GES 16-SR X 1/2"

10114516 GES 12 LR-WD

10018570 EWSD 12-L

10045794 8X300

30390041 1.3MM 10018570 EWSD 12-L

10172599 GES 12-LR X 1/2"

10114516 GES 12-LR X 3/8"-WD

10018570 EWSD 12-L

10018570 EWSD 12-L 10172599 GES 12-LR X 1/2"

10045794 8X300

10045794 8X300 30390041 1.3MM NOTE: TIGHTEN AT ASSEMBLY

10184638 GES 25-SR X 1"

10018417 EWSD 25-S

1018481 20 x 700

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10192654 - Contro l Blo ck As sembl y 10188446 CONTROL UNIT SVE-DA-MO20

10175450 VALVE CARTRIDGE VDP 06/42

10154892 VALVE CARTRIDGE 9612 07J G01

10183517 VALVE HOUSING F. S1-2 MO20


10183940 BUILT-IN TWO-WAY VALVE 10187626 SPRING DISH

10184051 PISTON S1 MO20

10028653 PRESS SPRING 3.6 X 30.0 X 72.5 10184050 TOP COVER S1 MO20 10187644 O-RING 53.57 X 3.53 10001203 M12 X 70 10106481 O-RING 44.04 x 3.53

10012242 GROOVED RING SEALING SET 10184052 PISTON S2 MO20 10186693 TOP COVER S2/S3 MO20 10184690 10001196 JUNCTION PLATE SCREW M12 x 55 10044494 SCREW PLUG G 1/2 VS-WD 10215082 VALVE HOUSING S3 MO20

10183793 SQUARE RING 26.57 X 3.40

10184300 PISTON S3 MO20 10186693 TOP COVER S2/S3 MO20

10012242 GROOVED RING SEALING SET

May, 2015

SP 500/750-15

10106481 O-RING 44.04 x 3.53

27- 1

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10188446 - Control Unit S1-S2

10165396 BALLCOCK MNTG KIT 10121917 SCREW PLUG G 1/8 VS-WD 10077807 NOZZLE 1.1 MM "H" 10188315 VALVE HOUSING



10175450 VALVE CARTRIDGE VDP 06/42

10121917 SCREW PLUG G 1/8 VS-WD 10006658 SCREW PLUG VS-R 1/4 -WD

10077794 NOZZLE 1.4 MM "P"

98352397 - 12V SOLENOIDS 98352399 - 24V SOLENOIDS

NOT INCLUDED WITH 10188446 98352332 - 12V PILOT VAL VE ASSY, W/SOLENOIDS 98352331 - 24V PILOT VAL VE ASSY, W/SOLENOIDS

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May, 2015

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98352331 / 98352332 - Sol eno id Valv e DS3-S2

98352332 - Solenoid valve DS3-S2/11N-D12 98352331 - Solenoid valve DS3-S2/11N-D24

98359075 Cap DS3-S2

98352397 - Coil 12V DC 98352399 - Coil 24V DC

98352442 Knurled nut

98352440 Solenoid tube

98359074 Gearshift lever

98352443 Bellows

T

T

P A

10000419 22 x 2

10014618 10014618 15.6 x 15.6 x 1.78 1.78

10139808 21.95 x 1.78

10067834 9.25 x 1.78

B

10067834 9.25 x 1.78

10191675 36 x 1.5

98352390 Sealing set

May, 2015

SP 500/750-15

29- 1

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10183940 - NG 25 Pop pet Valv e Ins ert

10183940 - CONTROL SPOOL 10173757 - SEALING SET

1 - 30

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May, 2015

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2.0 Main As semb ly Pumpkit Installation ....................................................................................................................32 Hydraulic Controller - Tube Rack ...............................................................................................33 Tube Rack Hydraulic Hoses (1 of 2) ..........................................................................................34 Tube Rack Hydraulic Hoses (2 of 2) ..........................................................................................35 Hopper Assembly .......................................................................................................................36 Engine Installation ......................................................................................................................37 Fuel Tank Installation .................................................................................................................38 Fuel Lines Installation - SP500 ..................................................................................................39 Fuel Lines Installation - SP750 ..................................................................................................40 Hydraulic Pump Connections .....................................................................................................41 Hydraulic Tank / Accumulator Installation...................................................................................42 10304502 - E-Stop Assembly ...............................................................................................43 Hydraulic Tank Connections.......................................................................................................44 Hydraulic Cooler Installation ......................................................................................................45 MPS Valve Plumbing..................................................................................................................46 Emergency Stop Manifold Plumbing ..........................................................................................47 10201988 / 10201989 Emergency Stop Manifold ......................................................................48 Operator Controls Installation ....................................................................................................49 98347086 - Control Panel Assembly ....................................................................................50

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Pumpkit Installation

30392906 (2) U-BOLT 12 X 100MM

10001347 (4) SCREW M16X50

30390046 (2) CYLINDER HEAD HOLDER

30373843 (4) 1/2” FLAT 10001280 (4) M12 NYLOCK 25 FT-LB MAX

30391038 (4) 5/8” FLAT 10001286 (4) M16 NYLOCK

2 - 32

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May, 2015

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Hydrauli c Cont rol ler - Tube Ra ck

10008083 GS 12-L

10008083 GS 12-L 10” 5”

30390943 TUBE 12MM X 21" 5”

2 1/2”

30304436 TUBE

6 1/2”

12 MM X 44.00

30303823 (12) SCREW M6 X 55

10008083 GS 12-L

10002483 (6)

30307545 (24) STAUFF PLASTIC 1/2" 10008122 GSS 25-S

LOCTITE

30392687 TUBE 12MM X 52 30373824 (8) 1/2” X1-1/2”

10002474 (2) WELD-ON PLATE

10008083 GS 12-L

10008122 GSS 25-S LOCTITE

98387716 TUBE 25MM X 60.5"

30373843 (8) 1/2” FLAT 30373847 (8) 1/2” NYLOCK

May, 2015

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2 - 33

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Tub e Rack Hyd raul ic Hoses (1 of 2)

10049958 20X900

10018481 20X700

10079398 20X800

10049955 20X500

10018481 20X700

10049955 20X500

10050172 8X800

10018483 8X900

10018484 8X700 10018483 8X900

2 - 34

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May, 2015

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Tub e Rack Hyd raul ic Hoses (2 of 2)

10050171 8X750

10018483 8X900

10050174 8X1000 10025656 8X600

May, 2015

10050169 8X550

SP 500/750-15

2 - 35

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Hoppe r As sembly 10001859 SCREW M10X25

30394960 BUSHING SET COLLA R 30391539 PLT FASTNER 10001283 M10 NYLOCK

30394047--STANDARD 30391115--SHOTCRETE (CE)

10001808 (1) SCREW M8X25 10010371 (1) M8 FLAT WASHER

30389195 (1) 3/8” NYLOCK 30391603 NOTE: SLOTTED HOLE

98375573 PARTS 1” HOLE SEAL

10010371 (1) M8 FLAT 10009875 (1) M8 NYLOCK

30373893 (2) 3/8” PLAIN 30373882 T BOLT

30391011 COVER 30391010 CAM HOPPER SWITCH 98360418 SPACER

30391369 1/4” FLAT

10162488 30396679 (4) 10000203 PESTLE USE BLUE O-RING 30390155 LOCTITE 12 X 3.5 M5X50 SHC 60083318 (4) SCHNORR WASHER 10162469 LIMIT SWITCH 10183457 REDUCING M 20/M 16 RING 10183656 SCREW JOINT M16x1.5

30391451 PLATE BLOCK HOPPER LIMIT

10001517 (8) SCREW M12X30

30391439 HOPPER SP750

10001896 (8) WASHER M12 FLAT

30353473 (Spare Parts ) Gasket 1" X 1/2" X 196" 98376324 (Production) Seal Gasket

ATTACH GREASE BRACKET AFTER HOPPER INSTAL LATION

2 - 36

SP 500/750-15

May, 2015

30303962 SCREW 1/4”X1/2”

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Engine Installation

30389195 (2) 3/8″ NYLOCK 30390221

10008524 Battery 12V

30391246 (4) 1/2” X3” 10008617 (4) SKZ 12

30391335 (4) 1/2” FLAT

30390195 - BATTERY BRACKET

98339285 - ROD

3/8” NUT 30302135 98339284 - PL ATE

Part# 98347952 98347961 98347964 98347967 98347970 98347955 98356217 98356218 98356219 98356221

May, 2015

Description BELT - FRONT CAT C4.4 FILTER - FUEL SECONDARY CAT C4.4T 80HP & 100HP STARTER - CAT C4.4 GASKET - WATER PUMP CAT C4.4T 80HP & 100HP PUMP - WATER W/GASKET CAT C4.4T 80HP & 100HP98347971 FILTER - OIL CAT C4.4 Filt er - A IR PRIMARY CAT C4.4 SP 500 Filt er - A IR SECONDARY CAT C4.4 SP500 Filt er - A IR PRIMARY CAT C4.4 SP 750 Filt er - A IR SECONDARY CAT C4.4 SP750

SP 500/750-15

2 - 37

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Fuel Tank Inst allation

30373488 FUEL CAP NEW TYPE W / GAUGE

30373496 GAS TANK PAD P88 & BPA & SP 98354522 WMT FUEL TANK SP500/750 CAT ENGINE

30391433 5/16" BARB STRAIGHT

98337425 2pcs - 28”

30397343 FUEL STRAP SUPT FUEL TANK

30373894 3/8” FLAT(4)

30373491 PET-COCK FUEL TANK

2 - 38

30302568 (4) LOCK WASHER 30391500 (4) 3/8”X1-1/2”

SP 500/750-15

May, 2015

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Fuel L ines Installatio n - SP5 00

62”

41”

May, 2015

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2 - 39

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Fuel L ines Installatio n - SP7 50

72”

40”

2 - 40

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May, 2015

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Hydra ulic Pump Conne ction s

10049943 16 X 800 10050170 8 X 650 10062202 13 X 800

10049976 25 X 750 10018480 13 X 900

10018481 20 X 700

10049955 20 X 500

May, 2015

10049957 20 X 650

SP 500/750-15

2 - 41

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Hydraulic Tank / Accumul ator Insta llation

30373824 (6) 1/2” X1-1/2”

30396565 M4 X 16 SHC

10129840 (6) SKM 12

10308274 PLUG

98374537 ACCUMULATOR BLACK CAP

10000660 40 x 3

30392693 OR 30392370

10304502

10018481 20X700

10008133 K-REDS 30-S X 25-S

LOCTITE (BLUE) 10184639 GES 30-SR X 1 1/4"

2 - 42

SP 500/750-15

10065682 EWSD 30-S

May, 2015

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10304502 - E-Stop Assembly

10303897 10304502

10305847

10303897

10303912

10196274

10305847

10180689

10303910

May, 2015

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Hydraulic Tank Connections

10050170 8 X 650

10018483 8 X 900

30339910 20-1/2” 10177485

10177485 10049939 16 X 400

10050167 8 X 400 10025113 20X500

2 - 44

SP 500/750-15

May, 2015

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Hydra ulic Coole r Insta llation

10049909 13X1700

10008121 K-REDS 25-S X 16-L

10049962 20X1250

30337904 (2) 1/2” x2” 30373843 (2) 1/2” FLAT WASHER

30391246 (4) 1/2” x 3” 10018617 (4) SKZ M12 30391335 (4) 1/2” GRD 8 FLAT WASHER

98352541

30391345 (2) 1/2” FLAT WASHER 1/2 SAE

30373847 (2) 1/2” NYLOCK

May, 2015

SP 500/750-15

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MPS Valve Plu mb in g TANK

P

T

MPS “T” MPS “SP”

10050180 8X1700

TANK

10050180 8X1700

10018483 8X900

2 - 46

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May, 2015

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Emerge ncy Stop Ma nifol d Plumbin g

10184664 RSWS 20-S R3/4"

10062202 13 x 800 10029729 16 x 900

X1

10025113 8 x 500

May, 2015

SP 500/750-15

2 - 47

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10201988 / 10201989 Emergency Stop Manifold

10201988 - 12V COMPLETE 10201989 - 24V COMPLETE 10020459

10006658 PLUG 1/4”

10201994

10006658 PLUG 1/4”

10068021 PLUG 3/8” 10201996 - CARTRIDGE 10172462 - SEAL KIT

10201999 - CARTRIDGE 10300873 - SEAL KIT

10020459

10141166 - 12V COIL 10141167 - 24V COIL 10141166 - 12V COIL 10141167 - 24V COIL

2 - 48

SP 500/750-15

May, 2015

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Operator Contro ls Insta llation

30373894 30391355 10018990 30340489 30397413

98324094

10001764 (4) M6X20

98325260-CE 10004662-US 10004662

10134153 (8) SKM 6 30391509

30391549 30391509 THROTTLE CABLE ASSEMBLY 30330520 - HEAD ASSEMBLY CABL E CRAFT 30396210 - HEAD ASSEMBLY MORSE

98347086

98349602 - Assy h arness power SP500 X-1 98380851 - Assy h arness SP500 X-2 CAT w/pump

May, 2015

SP 500/750-15

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98347086 - Contr ol Panel As semb ly 98348894 - Connector 98346126 - Cable harness pin 30338952 - CONNECTOR PIN 12-14 AWG 30303041 30341452 - SEAL

98345493 - Connector 98346126 - Cable harness pin 30363093

98355029

98348891 (4) LED Lamp

30302179 Hour Meter

98348893 - Seal 98333325 - Nut 98333327 - Was her 30346014 CORROSION INHIBITOR

30324217 30341452 - SEAL

30340911 30341452 - SEAL

98348895 Key Switch w/Key 98362034 Spare Key

30373456 30341452 - SEAL

98348896 Seal

98345495-Connector 98347087

98348899 - Fuse LED back plate

30324217 98348892 - Seal 30341452 - SEAL 98347087 - Nut 98333326 - Wash er

98347087 Face Plate

30350907 30341452 - SEAL

30369481 (1) 20 AMP FUSE 20 10

30334013 (8) 10 AMP FUSE

10 10 10

30334014 (1) 15 AMP FUSE

10

30347715

30347720

10 15 10 10

98354095 Relay 12V

30365156 (10) FUSE HOLDER

98355020 Relay Kit

10047757 Relay Base K1

10044213 Relay

K2 K3 K5 K9 K10

98348897

2 - 50

SP 500/750-15

98348904 relay base

98348905 micro relay

May, 2015

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3.0 Fin al A ss emb ly Shroud Installation .....................................................................................................................52 Exhaust Installation ....................................................................................................................53 Exhaust Installation with Catalytic Convertor .............................................................................54 98365128-Assy. Exhaust Mufer System CAT C4.4 ..................................................................55 Miscellaneous ............................................................................................................................56

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Shroud Insta llation 30373841 1/4”X3/4”

98341953 WMT RADIATOR INTAKE 30337703 Flat 1/4”

30394628 30373233

30391549 3/8 - 16 X 1"

30396202 30396139

30373894 3/8”FLAT

30373852 1/4 LOCK

98349390 TRAILER SHROUD 30396281 (2) 1/2" REC. BUMPER

30373841 1/4”X3/4”

30396501 30396138 KIT 30390273

30389195 3/8” Nylock 3/830391549 - 16 X 1"

30373894 3/8”FLAT WASHER

30373894 3/8” FLAT

30337703 Flat 1/4” 30337703 Flat 1/4”

30391374 Nylock 1/4”

30373894 3/8” FLAT 30389195 LOCK NUT 98346881 SUPPORT LEG HOOD LH

98346882 SUPPORT LEG HOOD RH

30391500 3/8”X1-1/2” 30373894 3/8” FLAT

30373894 3/8” FLAT 30389195 LOCK NUT 98381753 ASSY PLATE CYL SHROUD SP500 98380885 (2) HHCS CAPTIVE M10 X 20 10001896 (2) 98380886 (2) M13 WASHER CAPTIVE M10 WASHER

98374362 CAPTIVE M12 98354868 WMT CYL SHROUD 98382087 ASSY TOP CYL SHROUD

3 - 52

98354855 FRT SHIFT CYL SHROUD SP 500

SP 500/750-15

May, 2015

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Exhaust Installation

Work Instructions

30395660 ENGINE SILENCER 3.5 DIA.

30392468 RAIN CAP 3-1/2"

30396009 CLAMP DOUBLE SADDLE 3.5"

98392890 WMT -3.5" EXHAUST ELBOW T3

98346736 EXHAUST ASSY CATERPILLAR C4.4

10001513 SCREW M12 X 25

NOTE: ADD EXHAUST SEALA NT 98385774 98355557 CLAMP BAND 3.5" 10001004 SCREW M8X25

10001894 FLAT WASHER

10001572 M8 LOCK WASHER

98346739 ADAPTER EXHAUST

98354029 EXHAUST GASKET

10001894 FLAT WASHER 10009876 NYLOCK M12

May, 2015

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Exha ust Installation w ith Catalytic Conve rtor

30395660

30392468

30396009

98346738

NOTE: ADD EXHAUST SEALA NT 98385774 98355557 CLAMP BAND 3.5" 30395797 10001513 Screw M 12 x 25

98348797

NOTE: ADD EXHAUST SEALA NT 98385774


98355557 CLAMP BAND 3.5"

10007599 Rubber Buffer DN75

98348798

10001004 M8X25 10001572 M8 LOCK

98354029 EXHAUST GASKET


10009876 Nylock M 12

3 - 54

SP 500/750-15

May, 2015

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98365128-Assy. Exhaust Mufer System CAT C4.4

98365442 CAP STACK DON. P270535 98365439 MUFFLER DON. M065142

98365444 (2) CLAMP BAND

10001513 SCREW M12 X 25

NOTE: ADD EXHAUST SEALA NT 98385774


98365128 EXHAUST ASSY CAT C4.4

98365443 CLAMP BAND 2.5" 98365441 TUBE ADAPTER 10001004 SCREW M8 X 25 10001572 M8 LOCK WASHER 98354029 EXHAUST GASKET

10001894 FLAT WASHER 10009876 NYLOCK M 12

May, 2015

SP 500/750-15

3 - 55

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Miscellaneous

98323606 10081307 3/16” RIVET 30391024 (4) M6X16 FHS 30390987 30393418

30389195 (8) 3/8” NYLOCK 30373894 (16) FLAT 3/8” 30396825 (8) 3/8” X3”

3 - 56

SP 500/750-15

May, 2015

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4.0 Schemati cs 98378929 - Hydraulic Schematic ...............................................................................................59 98380853 - Electrical Schematic................................................................................................61

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98378929 - Hydraulic Schematic

May, 2015

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SP 500/750-15

4 - 59

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98380853 - Electrical Schematic

May, 2015

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SP 500/750-15

4 - 61

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5.0 Shi pp in g Spare Parts and Accesories .......................................................................................................64 98347141 - Cable Remote .........................................................................................................65 98392576 Decal Kit (1 of 4) .......................................................................................................66 98392576 Decal Kit (2 of 4) .......................................................................................................67 98392576 Decal Kit (3 of 4) .......................................................................................................68 98392576 Decal Kit (4 of 4) .......................................................................................................69

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Spare Part s and Ac cesori es

ENGINE MANUAL PARTS BOOK SAFETY MANUAL SAFETY MANUAL QUICK INDEX s 5E L i 30 r t s 5/ a 30 e P SP p ar S

30396184

t

30390831 30374173 - REDUCER 3” X 2” X 36” HEVI-DUTY END 30372216 - PIPE - COUPLING, SNAP 3” 30374147 - PIPE - ELB OW, REDUCING 90 DEGREE 30372220 - CLAMP - SNAP COUPLING

TOOL BOX, COMPLETE

30397522 Description Tool Box Hammer, 3 Lb Grease Gun Screwdriver, 10 Hose, Grease Gun Cartridge, Grease Gun Wrench, Double Open End, 10 X 11 Wrench, Double Open End, 12 X 13 Wrench, Double Open End, 14 X 17 Wrench, Double Open End, 19 X 22 Wrench, Double Open End, 24 X 27 Wrench, Double Open End, 24 X 30 Wrench, Double Box End, 24 X 30 Wrench, Double Open End, 30 X 32 Wrench, Double Open End, 36 X 41 Wrench, Single Open End, 46 Wrench, Single Open End, 50 Wrench, Single Open End, 55 Wrench, Service, 2” Key Hex, M--4, Din 911 Key Hex, M--5, Din 911 Key Hex, M--6, Din 911 Key Hex, M--8, Din 911 Key Hex, M--10, Din 911 Key Hex, M--12, Din 911 Key Hex, M--14, Din 911 Key Hex, M--17, Din 911 Key Hex, M--19, Din 911 Key Hex, 2.5MM Allen Balldriver Key, 3MM

5 - 64

SP 500/750-15

Part # 30302926 30302927 30302928 30302929 30302930 30314685 30304288 30302933 30302934 30302935 30302936 30302937 30313643 30302938 30302939 30302940 30302941 30302942 30331222 30302945 30302946 30302947 30302948 30302949 30302950 30302951 30302952 30302953 30304923 30325908

May, 2015

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98347141 - Cable Remote

98347141

30391554

30337546-SOCKET 98354521-CONNECTOR 30363096

98355213

98355212 LED 98349424

30356355

98354999

May, 2015

98355000

SP 500/750-15

5 - 65

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98392576 Decal Ki t (1 o f 4) WARNING WARNING D o n o t p a in t o v e r t h i s la b e /lN o p in ta r e n c im a d e é s ta e ti q u e ta

WARNING Stored hydraulic energy. Releaseall hydraulic pressure and verif y zero pressureongauge bef oreservici ng.

Stopagitatorbef oreputting any solid object in hopper.

D o n o t p a in t o v e r th is la b e l/ N o p in ta r e n c im a d e é s ta tie q u e ta

HYDRAULIC OIL ONLY ACEITE HIDRAULICO SOLAMENTE

ADVERTENCIA Detengaelagitadorantes decolocar un objeto sólido en latolva.

30354742

30334976C

30334976 30362340

30335000B

30335000

B 2 6 1 0 9 3 0 3

CUIDADO WARNING

D o n o t p a i n t o ver t h i s l a b el /No p i n t a r en c i m a d eést a et i q u et a

ADVERTENCIA No useesta maquinaria sin estar capacitado. Entiendalas advertencias delos manuales de seguridad y delas calcomanías.

30392275

3035474201

ADVERTENCIA Energíahidráulic aalmacenada. Aliviar toda lap resión hidrául icay verif ica rque elmanómetroindique presión cero antes derealizar el mantenimiento.

Do not operatethis machinewithout training. Understand thewarnings in safety manuals and on decals.

30390178 30390538

30390162 30312146

30336983 Donotpa intoverthis la bel/Nopinta rencima deésta etiqueta

WARNING Air pumpe d thro ug h t he machine co uld injure the ho se pe rso n. If air is suc ke d into the pump, sig nal o pe rato r to sto p. If that fails, activate E-sto p.

ADVERTENCIA Aire bo mbe ado e n la máquina pue de lastimar al o pe rado r de mang ue ra. Si e ntra aire a la bo mba,indique al o pe rado r que pare . Si no lo hace , active parada 98336365

98336365

30302078

B 0 3 7 9 6 3 0 3

Certified Co m pliancewith ASME B30.27Safety Standard

9 3 0 0

30369730

30336985 30381848 WARNING Keep hands away f rom hydraulic cylinder. Stop pump when greasing.

WARNING

ADVERTENCIA Mantengalas manos alejadas delcilindrohidráulico. Detenga labombacuando engrase. Do no t paint o ver this label/No pintar encim adeés taetiqueta

30364521A

30364521

D o n o t p a in t o v e r th is l a b e l/ N o p i n ta r e n c im a d e é s ta e t iq u e ta

Stand clear of outriggers whenactivating.

WARNING

SAFETY INSTRUCTIONS (Coupling)

30349283

•Ins pect co uplings befo reeach us e. •Wo rking pres s urem arked is fo r new and pro perly s ecured co upling. •External m echanical lo ading will reducethewo rking pres s ure. •Do no t us es nap co uplings when theline m ay bedragged o r pulled aro und rebar,o bs tructio ns ,o r cables . •Snap co uplings m us t bem aintained and adjus ted pro perly. •Us egas ket ins ide co upling to prevent co ncretefro m bleeding liquid and caus ing lineblo ckages . •Self- lo cking co uplings lo ck when clo s ed. •Ins tall retaining pin in s nap co uplings t o prevent inadvertent o pening.

ADVERTENCIA Apartase del os soportes cuando actuando.

INSTRUCCIONES DE SEGURIDAD (Acoplamient o) 30364520

30364520

Stay clear o f pressurized co ncreteplaci ng system.

ADVERTENCIA Permanezcaalejado del sistemadedistribu ció n deco ncreto presurizado

•Ins peccio neel aco plam iento antes decadaus o . •Lapres ió n de trabajo m arcadaes paraaco plam iento s nuevo sy co rrectam entefijado s . •Las cargas m ecánicas externas reducirán lapres ió n detrabajo . •No us eaco plam iento s defijació n apres ió n cuandoes po s ibleques earras treo tire delalínea alrededo r devarillas derefuerz o ,o bs truccio nes o cables . •Sedeben m antener y ajus tar co rrectam entelo s aco plam iento s defijació n a pres ió n. •Us euna juntadentro del aco plam iento paraevitar queel co ncreto pierdalíquido y caus eo bs truccio nes en lalínea. •Lo s aco plam iento s detrabado auto m ático s etr aban al cerrars e. •Ins talepas ado res deretenció n en lo s aco plam iento s defijació n apres ió n paraevitar ques eabran inadvertidam ente.

30308020

Do n o t p a in t o ve r th is la b e l/No p in ta r e n cima d e é sta e tiq u e ta

30370516

WARNING This machine is remote controlled and may start at anyunit. time. Stop engine before servicing

30306123 WARNING Bef oreopening ablocked pipeline, relievepress ureby reversingpump. Seemanual.

ADVERTENCIA Esta máquina funciona a control remoto y puede ponerse en marcha en cualquier momento. Apagar el motor antes de realizar el mantenimiento. Do notpa intoverthisla bel/No pinta rencima

30332668

deésta etiqueta

30309999

ADVERTENCIA Alivie lapr esión antes de destapar unatuberíabloqueada,invirtien do paraello labomba. Veael manual.

INSTRUCCIONESDE SEGURIDAD

SAFETYINSTRUCTIONS

Recommended hand signals Señales demano recomendadas

D o no t paint o ver this label/No pintar enc im adeésta etiqueta

(2go lpecit o s) (2t aps)

30319867 1.

AGITATOR

2. STARTPUMP SPEEDUP

1.

SLOW PUMP DOWN 2.

PR EN D ER L A BAJARVELOCIDAD BO MBA AC EL ER AR A LA BOMBA

2 3 6 3 6 3 0 3

3. 4. STOP PUMP LITTLE BIT

5. 6. 7. RELIEVE ADDWATER ALL DONE PRESSURE 4-GALLONS CLEANUP

3. PARARLA BOMBA

5. ALIVIARLA PRESIÓN

4. UNPOCO

6.

7.

AÑ AD IR AG U A TERMINADO 4 - G AL O N ES LIMPIAR

30365188

30363632

WARNING WARNI NG

Burn hazard . Do not touch hot engine or exhaust parts.

Burnhaz ard.Donottouchhot engineorexhaustparts.

AD VE RTE NCI A Peligro de quem aduras.No toqueelm otor nipiez as del escape calientes. Do not paint ov er t his label/ N o pint ar encim adeéstaet iquet a

ADVERTENCIA Peligro de quemaduras. No toque el motor ni piezas del escape calientes. D o n o t p a i n t o ve r th i s l a b e l /N o p i n ta r e n ci m a d e é sta e ti q u e ta

30364523

WARNING D o n o t p a i n t o v e r th is la b e l/ N o p in ta r e n c im a d e é s ta e itq u e ta

30363822 Do not put solid objects in waterboxcleanout holes.

ADVERTENCIA No inserte objetos sólidos en los agujeros de limpieza de la caja de agua. 3035513701

30355137

5 - 66

98326986

NO!

2 0 7 8 5 0 8 3 8 9

WARNING Keep hands out of waterbox. Stop motor if access is required. Keep guards in place.

ADVERTENCIA Nometalasmanosala cajadeagua. Pareel motor si necesitatener acceso. Mantengalas cubiertas cerradas. D o n o t p a i n t o ver t h i s l a b el /No p i n t a r en c i m a d eést a et i q u et a

30319872E

30319872

SP 500/750-15

30390770

98380587

May, 2015

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98392576 Decal Ki t (2 o f 4) ATTENTION

ATENCIÓN

WARNING

C h an g e al l fi l ter el emen ts i f th e d i rty fi l t er l amp C amb i ar l o s el emen to s d el fi l tro si l al ámp arad e avi so i l l u mi n ates wh en o i l i s ab o ve 20 d eg rees C .If u n i t i l u mi n ac u an d oelac ei teestaso b r e20C .Si l au n i d adn o ti en el ámp ar ad eavi so ,c amb i el o s el emen to s c ad a10,000 d o es n o t h ave el ec tri c al fi l ter l amp ,c h an g e th e metro sc ú b i c o soc ad a6meses,o l oq u eo c u rrap ri mero . el emen tsevery13,000 yd s3 o r every 6 mo n th s, wh i c h ever o c c u rs fi rst. D ATEO FLASTC H AN GE

D ATEO FLASTC H AN GE



FEC H AD ELÚ LTIM O C AM BIO FEC H AD ELÚ LTIM O C AM BIO FEC H AD ELÚ LTIM O C AM BIO FEC H AD ELÚ LTIM O C AM BIO

Do no t paint over this label/No pintar encimadeéstaetiqueta

D o n o t p a in t o v e r th i s la b e l/ N o p in ta r e n c i m a d e é s ta e ti q u e t a

30307386E

30307386 IMPORTANT T hehy draulic oil filters on this unit aredisposable. Cleaning and re- useis not possible. It is time to replacethe filter if the oil is at normal operating temperatureand the "dirty filter" indicator light is illuminated. Normal operating temperature is needed because, on somemachines, when the oil is cold the"dirty filter" lamp may illuminateeven if thefilter is clean.

30390207

Do not touch hydraulic oil leaks. Get immediate medical attention if oil penetrate sski n.

ADVERTENCIA No toque las fugas de aceitehidráulico. Obtengaatención médica inmediata si el aceite penetra en la piel.

IMPORTANTE Los filtros deaceitehidráulicos deesta unidad son desechables. No sepueden limpiar ni volver ausar.Es tiempo de reemplazar el filtro si el aceiteestáauna temperaturadeoperación normal y laluzindicadorade “filtro sucio” est á encen dida. Senecesitauna tempe ratur a de operación normal debido aqu e en algunas máquinas, cua ndo el ace ite estáfrío, la luz indicadorade “filtro suc io” puedeencenderse aunqueel filtro estélimpio.

30344840

WARNING

This machine is remote controlled and may start at any time. Stop engine before servicing unit.

WARNING

ADVERTENCIA Esta máquina funciona a control remoto y puede ponerse en marcha en cualquier momento. Apagar el motor antes de realizar el mantenimiento.

Do not paint over this label/No pintar en cimade éstaetiqueta

30301858

B 2 6 1 0 9 3 0 3

30390162

EMERGENCY STOP PARO DE EMERGENCIA ARRÉT D'URGENCE

Don o tp a in to ve rth is

la b e l/Nop in ta re n cima d e é sta e tiq u e ta

30340149

30309999D

30309999

30390178

D o n o t p a in t o v e r th is la b e /lN o p i n ta r e n c im a d e é s ta e itq u e t a

Stop agitator bef oreputting any solid object in hopper.

ADVERTENCIA Detengael agitador antes decolocar un objeto sólido en latolva.

30390538

30354742

98326985

30336985 98326987 WARNING D o n o t p a in t o v e r th is la b e l/ N o p i n ta r e n c i m a d e é s t a e t iq u e ta

WARNING Keep hands away from hydraulic cylinder. Stop pump when greasing.

ADVERTENCIA Mantengalasmanos alejadas del cilindro hidráulico.Detenga labomba cuando engrase .

WARNING Explosion hazard. Do not charge accumulator with oxygen or compressed air. Chargewith dry nitrogenonly.

ADVERTENCIA Apartase de los soportescuando actuando.

30364520

Peligro deexplosión. No cargar el acumulador con oxígeno ni airecomprimido. Cargar con nitrógeno seco solamente. Donotpaintoverthis

label/Nopintarencimadeéstaetiqueta

3036452201

30364522

ADVERTENCIA Peligro de quemaduras. No toque el motor ni piezas del escape calientes.

30364521A

30364521

ADVERTENCIA

WARNING Burn hazard. Do not touch hot engine or exhaust parts.

Do n o t p a i n t o ve r th i s l a b e l /No p i n ta r e n ci m a d e é sta e ti q u e ta

Do no t paint o ver this label/Nopintar encim adeésta etiqueta

Stand clear of outriggers when activating.

Place on Accumulator Bottle

30364523 30332668 WARNING Stored hydraulic energy. Releaseall hydraulic pressureand verif y zero pressureon gaugebef o reservicing.

ADVERTENCIA Energíahidráuli caalmacenada. Aliviar toda lapr esión hidráulica y verif icar queel manómetro indique presión cero antes derealizar el mantenimiento. D o n o t p a i n t o ver t h i s l a b el /N o p i n t a r en c i m a d eést a et i q u et a

30334976 WARNING

Explosion hazard. Do not charge accumulator with oxygen or compressed air. Chargewith dry nitrogen only.

ADVERTENCIA Peligro deexplosión. No carger el acumulador con oxígeno ni aire comprimido. Cargar con nitrógeno seco solamente. D o n o t p a i n t o ver t h i s l a b el /N o p i n t a r en c i m a d eést a et i q u et a

30324599

Water Box 30363822

WARNING WARNING D o n o t p a i n t o v e r

NO! D o n o t p a in t o v e r th i s la b e l/ N o p i n ta r e n c im a d e é s ta e t iq u e ta

th is la b e l/ N o p in t a r

n e c im a d e é s ta e t iq u e ta

Do not put solid objects in waterbox cleanout holes.

ADVERTENCIA No inserte objetos sólidos en los agujeros de limpieza de la caja de agua.

NO!

Do not put solid objects in waterbox cleanout holes.

ADVERTENCIA No inserte objetos sólidos en los agujeros de limpieza de la caja de agua.

3035513701

30355137

3035513701

30355137 WARNING

WARNING

Keep hands out of waterbox. Stop motor if access is required. Keep guards in place.

Keep hands out of waterbox. Stop motor if access is required. Keep guards in place.

ADVERTENCIA

ADVERTENCIA

No metalas manos alacajade agua. Pareel motor si necesitatener acceso. Mantengalas cubiertas cerradas. D o n o t p a i n t o ver t h i sl a b el /N o p i n t a r en c i m a d eést a

et i q u et a

No metalas manos alacajade agua. Pareel motor si necesitatener acceso. Mantengalas cubiertas cerradas.

30319872E

D o n o t p a i n t o ver t h i s l a b el /N op i n t a r en c i m a d eést a

30319872

May, 2015

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30319872E

30319872

SP 500/750-15

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98392576 Decal Ki t (3 o f 4) WARNING

WARNING This machine is remote controlled and may start at any time. Stop engine before servicing unit.

D o n o t p ia n t o ve r th is l a b e l /N o p in t a r e n c im a d e é s t a e ti q u e ta

ADVERTENCIA Esta máquina funciona a control remoto y puede ponerse en marcha en cualquier momento. Apagar el motor antes de realizar el mantenimiento. Do not paint over this label/No pintar encimadeéstaetiqueta

30309999D

30309999

Stay off hopper grates.

ADVERTENCIA Manténgase alejado de la rejilla que cubren la tolva.

30309998

30355887

98336366

WARNING D o n to a p in to v e r th is la b e l /N o p in ta r e n ci m a

30390179

d e é ts a e itq u e ta

St op agit at or bef oreput t ing any solid object in hopper.

ADVERTENCIA Det engael agit ador ant es decolocar un objet o sólido en lat olva.

30354742

30307689 WARNING

D o n o t p a i n t o v re th is la b e l/N o p in ta r e n c i m a d e sé ta e ti q u e ta

Keep hands out of hopper and valveassem bly. Seeoperat io n manual if access is required.

ADVERTENCIA No met alas manos alat olvao válvula. Consult e el manual de operación si necesit a t ener acceso.

30332962

30332963

30319869

30363739

. avl ot al ner buc e u q al l i j er al ed odaj el a esa g nét na M

AI CNET REVDA

a t e u iq te a ts

. s et ar g r e p p o h ff o y at Sdeé

a im c n e r ta n i p o N l/e b la is h t r e v o t in a p t o n

30392272 98382635

98382635

o D

GNI NRA W at e u qit e at sé e d a m i c ne r at ni p o N

. g

G sin N I is Nm R dis A ar Wgu ty e f a S

1 0

A I 040 C37330 N E T R E V D A

o n d a d i r u g e s e r. d ta l a i fa rd r a tá u s G e

30309998

30350290

l e bal si ht r e vo t ni a p t o n o D

30337004

10 9 8990303

. avl ot al ner bu c euq allij er al ed o daj el a e sagn ét na M

AI CNET REVDA

a t e u itq

. s et ar g r ep po hf f o yat S tase

é e d a m ic n e rt a in p o /N l e b la s i th rv e to in a p to n o D

98382635

GN I NRA W

at eu iqt e at sé ed a imcne rat in p o N

A I C N E T R E V D A

1 0 .g 4 o 0 0 n n 7 i 3 s 3 d 0 s a 3 i i m d r is u g e rd a s e r. u d a g a lt a f ty id e r r f a tá a s S u G e l eb la si th re vo t ni a pt on o D

G IN N R A W

at e uqi t e at s é ed a m i c ne r at ni p o N/l e bal si ht r ev o t ni a pt on o D

3 0 3 5 4 7 4 2 0 1

e d D n e e l c te a o n to o l g lv c a a a e . ru la n g o ita b je d o to r s a n ó te li s d o

A D V E R T E N C I A

a n y s o li d o b je c t in h o p p e r.

S to p a g it a to r b e fo re p u tt in g

W A R N I N G

ae t utiqetaé sedaimn cea rn tp i o/Ne l blaisthe r vtoinatponD o

3 0 3 5 7 4 4 2 1 0

e n d eD e la o c te t lo n g lvo ca a a . ru e la n itg o a d jb o te o ra sn t ló id e s o

A D V E R T E N C IA

aS t yn o so p a lid itg oa t jb ro ce tb e f in o r he op p p tu e in .r g

W A R IN N G

30354742

at eu iqt e at sé ed a imcne rat in p o N

. g

G sin IN is Nm Rs A

o n d a d ir

1 IA0400 C337 N03 E T R E V D A

u i g e d r s . a u e rta g d l ia a ty d rf e r f a á t a s S u G e l eb la si th re vo t ni a pt on o D

W

WARNING D o n o t ip a tn o v e r th is la b e l/N o p in t a r e n c im a d e é tsa e tiq u e ta

EMERG ENCYSTO P PARO DEEMERG ENCIA ARRÉT D'URG ENCE

Sta yo ffh o p p e rg r a te s.

ADVERTENCIA Manténgasealejado rejillaq uecubren

WAR N IN G

dela latolva.

Exp l o si o n re a n d fi h a za rd .St op engine b eof re ren gfu. e l i

3030999801

AD VER T EN C IA Pei gl ro de e xp l o si ó n i n ce nod.Pa i ree lm oot r a net sd eca rg a r co m b ubsti le . D onotpaintovert hisl abel/Npinotarencim adeést aetqueta3

at e u qi t e at sé e d a m i c n e r at ni p o N

WARNING

. g

. g

D o n o t p a in t o v re t ih s l a b e l/ N o p i tn a r e n icm a d e é st a e t iq u e ta

G nis is IN m N R is A ard Wug

at e u qi t e at sé e d a m i c n e r at ni p o N

G isn N I is Nm R sdi A ra Wug y t fe a S

o n d a d ir u g e s . e r d a lt a i fa d r r a á u ts G e

1 0 4 0 0 7 3 3 0 3

A I C N E T R E V D A

ty fe a S

l e bal si ht r ev o t ni a p t o n o D

ADVERTENCIA

30337004

. g

G nis is IN m N R is A ard Wug ty fe a S

o n d a d ri u g e s . e r d a lt ia fa d r r a á u ts G e

l e bal si ht r e v o t ni a p t o n o D

30337004

l e bal si ht r ev o t ni a p t o n o D

Stay off hopper grates.

y

0354738A

at eu qit e at sé e d a m i c ne r at ni p o N

0 IA7004 C33 N30 E T R E V D A 1

o n d a ird u g e s . e r d a lt ia fa d r r a á u ts G e

EMERGENCYST OP PARO DE EMERGENCIA ARRÉT D'URGENCE

IA C N E T R E V D A

WARNING Explosion and f ire hazard. Stop engine bef oreref uel ing.

ADVERTENCIA Peligro deexplosión y incendio.Pareelmotor antes decargar combustible. D o n o t p a i n t o ver t h i s l a b el /N o p i n t a r en c i m a d eést a et i q u et a

30354738

30340149

Manténgase alejado de la rejilla que cubren la tolva.

30309998

5 - 68

30350290

SP 500/750-15

May, 2015

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98392576 Decal Ki t (4 o f 4)

Lifting Frame

Lift here. l e b la e c e r d n i e p s a p e N

N e p a s p e in d re c e la b e l

Soulevez ici. 3031794001

30317940

OUTRIGGER estabilizador

98351269 01

98351269

30363630 02

30363630

WATER PUMP bomba de agua

30363633 A

30363633

May, 2015

SP 500/750-15

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6.0 Opt io ns 98347792 - Radio Remote Kit ....................................................................................................72 Radio Remote Installation ..........................................................................................................73 Hydraulic Outrigger Assembly (1 of 3) .......................................................................................74 Hydraulic Outrigger Assembly (2 of 3) .......................................................................................75 Hydraulic Outrigger Assembly (3 of 3) .......................................................................................76 Dual Axle Assembly....................................................................................................................77 Dual Axle Fenders......................................................................................................................78 Dual Axle Fenders - w/Lifting Frame ..........................................................................................79 Dual Axle Fenders - Accumulator Installation.............................................................................80 Vibrator Assembly ......................................................................................................................81 Water Pump Assembly ...............................................................................................................82 98348884 - Water Pump Unit .....................................................................................................83 Water Pump Installation (1 of 2) .................................................................................................84 Water Pump Installation (2 of 2) .................................................................................................85 Water Pump Installation w/Agitator ............................................................................................86 Auxiliary Valve Installation..........................................................................................................87 Auxiliary Circuit Gear Pump Assembly.......................................................................................88 Auxiliary Circuit Installation ........................................................................................................89 Dual Stroke Counter Installation ................................................................................................90 Auto Greaser Pump/Feeder Block Install ...................................................................................91 Auto Greaser Feeder Valve Plumbing........................................................................................92 Electric Throttle ..........................................................................................................................93 Lifting Frame ..............................................................................................................................94 Reector Locations ....................................................................................................................95

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98347792 - Radio Remot e Ki t

98349672 RECEIVER 98349674 ANTENNA KIT

CO

SN Par t#

98349671 TRANSMITTER

Mo NTROLSYS T de l: R EMS INC. 160

ESTO P

RUN

E-S TO P E-S TO PF ault

ESTO FU P NCT FAUION LT

FU NC TIO N/F No Fault AU LT Sh Ovor to Gr ert cu rrenound t / Shor t to Supp ly No Fu nc tions ON

LIN K STAT US

LIN K Lin No

k Lin k

STA TU S

OK

Fault Low BAT T. Fuse Blo wn Sy Incstem orr Po ectlywe red

30396631 LEATHER POUCH

30396635 NiCad 1.2V AA(4)

98349673 CABLE

A

R

B

98339848 CHARGER

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Radio Remot e Inst allation

To Control Panel

CO

SN

Par t#

Mo NTROLSY ST de l: R EMS INC. 160

ESTO P

ESTO P FUNC FAUTION LT

RUN

E-ST OP E-ST OP

Fau lt

FU NC TIO N/ F No Fau AU lt LT Sho Overt t oG r cur roun rent d/ Sho rt t oSu ppl y No Fun ctio nsO N

LIN K

STAT US

LIN K Link No

Link

STAT US

OK

Fau lt

98349674 ANTENNA KIT

Low

BA TT.

Fus eB low Sys n Incotem r rectPow ly ered

From Antenna

10001768 (2) M6 x 30

10011106 (10) M 6 FLAT

98349672 RECEIVER

May, 2015

10011985 (6) M6 Nut

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Hydra ulic Outri gger Assembly (1 of 3)

SHORT SIDE TO FRONT

PORTS TO BACK

10001280 (4) M12 NYLOCK 30391927 (4) M12X50 30367910 (PAIR)

30390991 (PAIR)

30390885

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Hydra ulic Outri gger Assembly (2 of 3) 10019122 EWSD 16-S 10050169 8X550

30390975 G12/34-16 30301940 GES 12x9/16" 10144059

30397143 5/16” x 2-1/4" 7”

10018570 EWSD 12-L 10050176 8X1250

1 1/4”

30391428 98353571

10008084 WS 12-L

30301940 GES 12x9/16" 10144059

30390975 G12/34-16

10018570 EWSD 12-L 10058430 8X1800

10025113 8X500

10008084 WS 12-L To Agitator

30341778 8X1650

10010371 FLAT 10138329 SKZ 8 30394810 REPLACEMENT HANDLE

30307534 PLATE

8 x10001010 30-8.8-A2C

30307547 STAUFF 30307547 STAUFF

To Outrigger

30309815 6 x 70

10144059 30307547 STAUFF 30307534 PLATE 1001779 BOLT 6X40

30301940 GES 12x9/16"

10008084 WS 12-L

10018570 EWSD 12-L

10307753 8X2000

10058430 8X1800

NOTE: ADDED AT MAIN ASSEMBLY

To Outrigger

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Hydra ulic Outri gger Assembly (3 of 3)

10050176 8X1250

30390400 1.1MM

10018570 EWSD 12-L

10114516 GES 12x3/8"

10161984 GES 12-LR 1/4-WD

10144059 SNV 12-L 10018570 EWSD 12-L 30390400 1.1MM

10004685 10018570 EWSD 12-L

10161984 GES 12-LR 1/4-WD 10018570 EWSD 12-L 10114516 GES 12x3/8"

10004685 10144059 10018570 EWSD 12-L

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Dual Ax le Assembly

30392300 (8) M20X60 120 FT LBS. 30392300 (8) M20X60 120 FT LBS.

30395174

30391216 AIR PRESSURE 65 PSI 30373530 -- STEEL 30396337 -- CHROME 95 FT-LB NEVER SEIZE

30391360 (8) 3/4” FLAT

30395174

30392112 (4) M20 CROWN 115 --30391360 (4) 3/4” FLAT 30392112 (4) M20 CROWN 98333188 -- CHROME

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Dual A xl e Fenders

30389195 (12) NUT HEX 3/8”NYLOCK 30373894 (24) FLAT 3/8" WASHER

30389195 (12) NUT HEX 3/8”NYLOCK 30373894 (24) FLAT 3/8" WASHER

30358387 (12) SCREW 3/8" X 2-1/4" 30373894 (24) FLAT 3/8" WASHER

98392397-RH Fender 98392395-LH Fender (Shown )

98353794 WMT END 30373894 (24) FLAT 3/8" WASHER 30389195 (12) NUT HEX 3/8”NYLOCK

FENDER SUPT 98353795 WMT CENTER FENDER SUPT

30373894 (24) FLAT 3/8" WASHER 30358387 (12) SCREW 30373894 (24) 3/8" X 2-1/4" FLAT 3/8" WASHER 30358387 (12) SCREW 3/8" X 2-1/4"

98353794 WMT END FENDER SUPT

30373894 (24) FLAT 3/8" WASHER 30358387 (12) SCREW 3/8" X 2-1/4" 48.75” 25.75” 7.25”

Tap these two holes

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Dual Axl e Fenders - w/Lift ing Frame

10009875 (12) NUT M8 10129842 (24) SKM 8

10009875 (12) NUT M8 10129842 (24) SKM 8

10001825 (12) SCREW M8 X 50 10129842 (24) SKM 8

98392397-RH Fender 98392395-LH Fender (Shown )

98353794 WMT END

10129842 (24) SKM 8 10009875 (12) NUT M8

FENDER SUPT 98353795 WMT CENTER FENDER SUPT

10129842 (24) SKM 8 10001825 (12) SCREW 10129842 (24) M8 X 50 SKM 8 10001825 (12) SCREW M8 X 50

98353794 WMT END FENDER SUPT

10129842 (24) SKM 8 10001825 (12) SCREW M8 X 50

48.75” 25.75” 7.25”

Tap these two holes

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Dual Ax le Fe nders - Acc umul ator Installation

8 1/2” 4”

5/16” 16” 10”

10009875 M8 NYLOCK

10001376 M8 FLAT

10010371 M8 FLAT 30373824 (6) 1/2”X1-1/2”

10001808 M8X25

10001106 (1) M12X70

30391345 (6) 1/2” FLAT SAE

10184639 GES 30-SR X 1 1/4 30392693 OR 30392370

10065682 EWSD 30-S 30392698 10001280 (1) M12 NYLOCK 10008133 K-REDS 30-S X 25-S

10018481 20X700

30373843 (6) 1/2” FLAT 30373847 (6) 1/2” NYLOCK

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Vibrator As sembly Standard 2 3/8” Gap Stitch Weld 1.5” X 1.5” 1.5” X 1.5”

European Center on Grate

30394047 - Standard Gr ate 30391115 - Europ ean Grat e

1 3/4”

NOTE: USE M10 X 55 1001139 FOR HOPPER MOUNT VIBRATOR 10072108 - 12V 10072107 - 24V

10001875 (4) M10 X 50 10011143 (8) DIN 125

20-1/2”

30392127

9-5/8”

10” Cut 1” Hole

15-3/8”

10011143 (8) DIN 125 10001283 (4) DIN 985 M 10

C L

C L

Change plates to 4/3 configuration when mounted on grate

May, 2015

Leave plates to 6/1 configuration when mounted on hopper

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Water Pump As sembly

30309420

WATER OUT

30303372 10012265

30301976 30302117 30390519

9-1/4” LENGTH

30309420

10000995 M8 X 16 SHC

30301987

WATER IN

10138329 SKZ 8

30390519 30396547

10192670 M10 X 120

30301976

30373453* 30394058*

98348884 10001251

30373453*

M10 10030252 30396471* 30305093

10138329 M8LOCK

* KEEPFILL ITEMS

10184637 10126649 5/16-18X1-1/4” SHC

10008084

10018849

10019122

30302673 GARDENSPRAYNOZZLE 30301987 50′ GARDENHOSE 3/4″ 300PSI

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98348884 - Water Pum p Uni t

98348884

10000995 M8X16 SHC 10138329 M8 LOCK

30302837 10170889 10164399 - Water Pum p 10170884 - Repair Ki t 10050289 10011759 10174462

98347768 10138329 M8 LOCK

10001251 M10

10192670 M10X120

10126649 5/16-18X1-1/4 SHC 10170890

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Water Pump Inst allation (1 of 2) 10001822 (3) SCREW M8 X 40 10010371 M8 FLAT WASHER

10001822 (3) SCREW M8 X 40 10010371 M8 FLAT WASHER 10002374 SCREW M8 X 60 10010371 M8 FLAT WASHER

10049904 13 X 700 30355125 M6 X 30 10002507

10050171 8 X 750

30307545 10008083 GS 12-L 1” 3039268 Tube 12 mm x 52"7

10008088 GS 16-S

30306562 TUBE 16 MM X 43 3/8"

10001771 M6 X 35 10002481 30307546 30397071

10010371 M8 FLAT WASHER 10009875 M8 NYLOCK

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Water Pump Inst allation (2 of 2)

30390167 HAND VALVE SINGLE

30397142 5/16″ X 1-3/4″ SHC 10001748 UNION NUT M 12 L 10006804 WIPER RING 10000151 O-RING 8.73 X 1.78

30390975 G12/34-16UNF

10018570 EWSD 12

10049905 13x1000 10008087 WS 16

10008083 GS 12-L

10050175 8X1200

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Water Pump Inst allation w /Agitator 10018570 EWSD 12-L 30390975 G12/34-16UNF 10012513 8X500

98381529 VALVE - MAN 2 SEC 3 POS & 2 POS 10180936 RELIEFALVE DBV-JG3 30397143 5/16”x 2-1/4” SHC

30390975 G12/34-16UNF

NOTE: PLUG ON GES 12 WITH CAP PLUG.

10001748 UNION NUT M 12 L 10006804 WIPER RING 10090541 GES 12-L X 9/16" 10144059 12-L SNV

10000151 O-RING 8.73 x 1.78 10008084 WS 12-L

10018570 EWSD 12-L 10008132 GS 16-S X 12-L 10030252 GES 12-LR X 1/2" 10019730 ETSD 12-L 30307281 TUBE 16 MM X 20 1/2" 30307546 10215931 12V 10215932 24V

10002481

10018570 EWSD 12-L

30396066 w12V coil

10001771

10144059 SNV 12-L 10030252 GES 12-LR X 1/2"

30301345 COMPLETE

10018483 8x900

10030252 GES 12 L/R 1/2

10019121 ELSD 12 L

10012513 8X500

10052338 8X350

10008088 GS 16-L 10049905 13X1000

10008132 GS 16-S X 12-L

10018570 EWSD 12-L

10008083 GS 12-L

10050175 8X1200

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Auxiliary Valve Ins tallati on 10018570

30390975 30392057 10052338 8X350

30397143 5/16″ X2-1/4″ SHC

10023648

30390975

10023647

30301940

10052338 8X350 30303431 10050167 8X400

10023647

10023648

10008132 30301940

10018570

10030252 10019121 10018570 10144059 10030252 30396066 30301345 10025656 8X600

30307281 10052338 8X350

10030252

10019121

10050167 8X400

10050167 8X400

10019729

10008087

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Auxiliary Circuit Gear Pu mp Assembly

10001779 SCREW M6 X 40 30307534 COVER PLATE 30307548 STAUFF 1" (25MM)

10011143 WASHER M10 10136867 SKZ 10 10000976 SCREW M10 X 30

98355073 WMT TUBE SUPT

30329777 GE 12PL7/8 14UNF 98347085 PTO ADAPTER CAT 4.4 98364618 GEAR PUMP 10192344 GES 20 S 10008086 REDSD 20/25 S

10019122 EWSD 16 S

SHORT END

98355074 TUBE 25MM X 23" LG. BEND 10008149 GS 25 S

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Auxiliary Circuit Installati on

10018417 EWSD 25S

10019121 ELSD 12

10184638 GES 25 SR-WD

10018570 EWSD 12

10050168 8 X 450

10018570 EWSD 12

30390975 G12/34 16UNF 98381527 2 Position 30390975 G12/34 16UNF 10050169 8 X 500

10018481 20 X 700

10016804 10000151 10001748 30397142 SHCS 5/16” -18 X 1-3/4"

30390975 G12/34 16UNF 10183548 13 X 600

10019122 EWSD 16 S

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Dual Strok e Counter Installatio n

ON

ECE

DIP SWITCHES 1234

30391203 STROKE COUNTER

BLACK 1 9-28 V DC

BLUE Power In 4

3

E CE

2

1

PWR COMMON

A

30391203 STROKE COUNTER

BLACK 2

BLACK 1

BROWN Common

BROWN Proximity

GREEN / YELLOW

30391644

3

ECE

NO

BLACK 2

9-28 V DC

4

2

1

PWR COMMON

A

BLUE Proximity

NO

BLACK

10001861 10x30

30392078

10011143 M10 Flat 10001283 M10 Nylock

SET BRACKET AS SHOWN AND SLIDE TOWARDS OPERATOR’S SIDE UNTIL STOP BLOCKS L OCATE. DRILL HOLE THROUGH PLATE FOR 3/8” BOLT. INSTALL PROXIMITY SWITCH A ND WIRE COUNTER. ADJ UST DISTANCE OF PROXIMITY SWITCH TO SLEWING CYLINDER PIN UNTIL CLOSE ENOUGH FOR SIGNAL TO REGISTER ON COUNTER. (APPROXIMATELY 1/8” )

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Auto Greaser Pump/Feeder Block Install

30359045 Grease Pump w/Harness 30353879

10026589 EWSD 10-L

98351705 Grease Pump

30316516 10 X 3/8" FNPT 30316517 SLEEVE 10MM 10001808 (3) DIN 933 M8 X 25

30316216 (75” )

10129842 (3) SKM 8

30353879 HARNESS

7” 9” 30325767 FEEDER VALVE VPKM 4 10134153 SKM 6

T2 T1 T3 T3

MK PV

30347231 CABLE SEAL GREY 30342974 TERMINAL 30342977 MALE 2-MALE PIN

MK PV MK PV MK PV

10001779 SCREW M6 X 40

RED/BLACK -A BROWN - B

1”

May, 2015

1/2 ”

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Auto Gr easer Feeder Valve Plumbing H

G

31”

49”

30325767

VP VP VP

10200243 (8)

VP

F

2T

KM KM

3T KM 3T KM

10134153 SKM 6

A

88”

1T

E

66”

10001779 BOLT M6 X 40

32”

30316516

B

C

44” 30316517

60”

75” To Grease Pump

D

55”

A

H 10200243 10207031 (8) 30355384 30316515 (5)

G C B

E

D F

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Electric Throttl e

30330521

SP500

30304506

98354109-US 98354110-CE 98354111-LRC 98348306

SP750-15

10011106 M6 FLAT

98354112-US 98354113-CE 98354114-LRC

30304506 30373852 1/4 LOCK 10129842 SKM 8 30392236 1/4-28

10001796 8X16

30396953 (1) M6 30349654 COUPLING WASHER LOCK M6 GREASE

10001796 M8 X 16

30394438 30390331 10001360 SERRATED LOCK 10129840 LOCK WASHER M12 10001513 M12x25

30303962 HCS 1/4x1/2 10134153 SKM 6

FOR COUPLING INSTALLATION SEE APPENDIX A

10129841(12) SKM 10

30302568(8) 3/8”L OCK

98367173 ACTUATOR MNT SP ELEC THROTTLE

98351382(8) 3/8" X 1"

30339188 ACTUATION CONTROL 12 V with Cable

30391605

SP500/SP750-15

MOTOR GREEN A - WHITE/BL ACK B - WHITE/RED

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SP750-18

MOTOR GREEN A - WHITE/RED B - WHITE/BLACK

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10001861(12) M 10X30

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Lifti ng Fra me

30391038 5/8” FLAT 30396529 HHCS 5/8” x 3 1/2”

30391368 5/8” NYLOCK 30391038 5/8” FLAT

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Reector Locations

30390772 AMBER REFLECTOR TYPICAL OPPOSITE SIDE 30390771 RED REFLECTOR TYPICAL OPPOSITE SIDE

SP 500

30390772 RED REFLECTOR TYPICAL OPPOSITE SIDE

3035474201

30390771 RED REFLECTOR

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Appendix A Hayes Coupling Installation........................................................................................................98

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Hayes Coupling Installation Hayes Coupling 40 lb.-ft.

1. Install Hayes coupling to engine flywheel. Torque bolts to 40 lb.-ft. 2. Install pump mounting plate to engine bellhousing. Torque bolts to 40 lb.-ft.

40 lb.-ft. Pump Mounting Plate

Dial Indicator 3 Locate dial indicator magnet on face of Hayes coupling. Zero Position

4. Locate dial indicator on pump mounting plate. Set the dial indicator to the 0 degree position.. Once the dial indicator is touching the pump mounting plate, move dial indicator towards pump mounting plate until the needle makes one full revolution in the negative direction Lock dial indicator in place.

0˚ 270˚

90˚

180˚

5. Zero dial indicator by turning face plate until needle points to zero. Dial Indicator Magnet

Positive

6. Rotate engine crankshaft, recording run-out measurements at 90 degree intervals. Be sure to record whether the needle moves in the positive or negative direction.

0

5

10

5

.0005in

10

7. If all measurements are less than 0.009", proceed with assembly. Grease pump shaft and inside of coupling with grease supplied with coupling. If grease is not supplied with

15

coupling use Texaco Coupling Grease, SAI p/n 30365450.

Negative

7 - 98

8. If measurements exceed 0.009", contact SAI Quality department or SAI Engineering department.

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Appendix B Hydraulic Fittings Tightening Procedure ..................................................................................100

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Hydra ulic Fittings Tight ening Procedure 1. Set the fitting to desired direction and tighten the nut by hand. It is important to hold the fitting body firmly in place.

2. Using the proper wrench, tighten nut, when you feel a noticeable increase in force - tighten nut another 1/3 of a turn. CAUTION!

Not following the above steps can cause leakages or slipping of the fitting.

3. After the fitting has been tightened according to this procedure, mark the fitting with a “/”.

4. If a fitting or fastener has been tightened to a specific torque, mark the fitting/fasterner with an “X”. Be sure to mark the fitting/fasterner AFTER and NOT BEFORE it has been tightened. IMPORTANT

Torque bolt to spec.

8 - 100

Mark bolt with ”\”

Recheck torque

Mark bolt with ”X”

Iy you do not know if the fitting/fasterner has been properly tightened, please ask your supervisor.

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SCHWING AMERICA INC. PRODUCT WARRANTY Schwing America, Inc. (“Schwing”) warrants its new equipment against defects in material and workmanship under normal use and service, and which shall not have been subject to misuse, negligence or accident, for a period of one year from the date of purchase Schwing will, at its option, replace or repair free of charge, FOB Schwing warehouse such part or parts thereof as in its reasonable judgement shall be deemed defective. Your Schwing equipment is designed to operate with only Schwing OEM products. Use of other products may void the warranty and may not be covered by the Schwing warranty. This warranty does not obligate Schwing to bear the cost of transportation of such parts to or from Schwing warehouse. This warranty shall not apply to any equipment manufactured by Schwing which shall have been loaded or operated beyond its rated capacity as specified by Schwing. Damage resulting from improper installations, alterations or neglect of recommended maintenance will be considered as misuse and not as a defect. Certain parts of the equipment, such as but not limited to, the pumping cylinders, pumping rams, concrete pump systems, mixer drums, chutes, etc., are subject to normal wear. This normal wear is not covered under this warranty. On boom units, structural components such as weldments provided by Schwing are warranted on a limited, prorated basis for a period of ten years provided current structural inspections have been conducted and necessary repairs have been made in accordance with the American National Standard, ASME 830.27, Material Placement Systems. All warranties must be submitted within sixty days of the invoice. Exceptions will be made for stock parts orders. Spare parts are warranted for a period of six-months and subject to the same limitations as new equipment. No labor will be granted for equipment out of the warranty period. SCHWING SHALL HAVE NO LAIBILITY TO THE BUYER OF SUCH EQUIPMENT OR OTHER PERSON FOR INCIDENTAL DAMAGES, SPECIAL DAMAGES, CONSEQUENTIAL DAMAGES OR OTHER DAMAGES OF ANY KIND OR NATURE WHATSOEVER, WHETHER ARISING OUT OF BREACH OF WARRANTY OR OTHER BREACH OF CONTRACT, NEGLIGENCE OR OTHER TORT, OR OTHERWISE, EVEN IF SCHWING SHALL HAVE BEEN ADVISED OF THE POSSIBILITY OR LIKELIHOOD OF SUCH POTENTIAL LOSS OR DAMAGE.For all other purposes hereof, the term “consequential damages” shall include lost profits, penalties, delay damages, liquidated damages or other damages and liabilities which the buyer shall be obligated to pay or which the buyer may incur based upon, related to or arising out of its contracts with its customers or other third parties. In no event shall Schwing be liable for any amount of damages in excess of the amounts paid by the buyer for goods or services as to which a breach of contract has been determined to exist. The parties expressly agree that the price for the goods and the services was determined in consideration of the limitation on damages set forth herein and such limitation has been specifically bargained for and constitutes an agreed allocation of risk which shall survive the determination of any court of competent jurisdiction that any remedy herein fails of its essential purpose. Schwing reserves the right to make changes and improvements in its product without incurring any obligation to install any such changes or improvements in its products previously manufactured. Schwing makes no warranty of its outside purchased components or accessory equipment such as, but not limited to, truck chassis, engines, transmissions, gear cases, tires, wheels, tools, etc., the same being subject to the warranties of their respective manufacturers. Without limiting the generalities of the foregoing THERE IS NO OTHER REPRESENTATION OR WARRANTY, EXPRESS OR IMPLIED, WITH RESPECT TO NEW CONCRETE EQUIPMENT AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. 1075153.2

2021 SA REV.F/8/07

SCHWING AMERICA, INC

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Metr ic Hydraulic Fitti ngs Part Number: 98324024 Revision Date: 05/01/15

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Ordering Inform ati on Doc um ent # 98324024 Revi sio n Level:01 Revision Date: 04/23/15 When ord ering parts p lease specify: • Model and Serial number • Quantity • Part number and Description

Schwi ng Call Center (P arts & Servic e) 1-888-SCHWING (724-9464) FAX: (651) 429-2112 24 Hours - Monday thru Saturday www.schwingparts.com

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Table of Con tents

Cap Nut ..............................................................................................................5 Ferr ule ...............................................................................................................9 EGESD ..............................................................................................................11 ELSD .................................................................................................................13 ETSD .................................................................................................................15 EWSD ................................................................................................................17 GAS ...................................................................................................................19 GES ...................................................................................................................21 GFS ...................................................................................................................25 GS .....................................................................................................................27 GSS ...................................................................................................................29 MAS...................................................................................................................31 RED ...................................................................................................................33 RSWS ................................................................................................................37 S ........................................................................................................................39 SNV ...................................................................................................................41 TS ......................................................................................................................43 VS ......................................................................................................................45 VSD ...................................................................................................................47 WFS...................................................................................................................49 WS .....................................................................................................................51 WSS ..................................................................................................................53 Hose 6...............................................................................................................55 Hose 8...............................................................................................................57 Hose 10.............................................................................................................63 Hose 12.............................................................................................................67 Hose 16.............................................................................................................75 Hose 20 ............................................................................................................83 Hose 25.............................................................................................................89 Hose 31.............................................................................................................99 Hose 32............................................................................................................101 Torque Wrench Settings for Coated Fittings ...............................................107 Bu lk head Fit ti ng Ins tal lat io n .........................................................................107 Wren ch and Cou pl in g fo r Fit ti ng s .................................................................108 Fitting Assembly Instruction NS Style Prole - Dull Green Colored .........109

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CapNut

Ferrules

EGESD

ELSD

ETSD

EWSD

GAS

GES

GFS

GS

GSS

MAS

RED

RSWS

S

SNV

TS

VS

WFS

WS

WSS

Hose 6

Hose 8

Hose 10

Hose 12

Hose13

Hose16

Hose20

Hose25

Hose32

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Cap Nut Material Description Union nut LL DIN 4 3870


Union DIN L nut 63870

10032481

Union DIN L nut 63870

60090806

Union nut LL DIN 6 3870 Union DIN S nut 63870 L Union 6M nut Union nut L-1.4571 6 M LL Union 6M nut S Union 6M nut Union nut S-1.4571 6 M Union DIN L nut 83870 Union DIN S nut 83870

60085290 60074913 10001760 10193304 10001763 10067354 10193298 60084481 60090804

L Union 8M nut

10001755

L Union 8M nut

10043790

Union nut L-1.4571 8 M LL Union 8M nut S Union 8M nut Union nut DIN 10 L 3870 Union L10 M nut Union nut M 10 L-1.4571 Union S10 M nut Union nut DIN 12 L 3870

10193540 10008617 10008618 60076423 10008616 10194757 10067355 60090803

Union nut DIN 12 S 3870

60090802

Union nut B-M L12

10018569

Union L12 M nut

10001748

Union nut M 12 L-1.4571

10068026

Union S12 M nut Union nut M 12 S-1.4571

10067356 10069436

Union S14 M nut

10034741

Union 1.5 x14 nut M

10034679

Union nut 15 L (butt joint ftting)

60090753

5

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Cap Nut Material Description Union nut DIN 15 L3870 Union nut 15 DIN L 3872 Union L15 M nut

10011244 10085721


60090800

Union nut B-M S16

10019759

Union S16 M nut Union nut M 16 S-1.4571 Union nut DIN 18 L3870

10001743 10068056 60083918

Union L18 Nut M

10000316

Union L18 M nut

10043789

Union nut M 18 L-1.4571 Union nut DIN 20 S 3870 Union nut B-M S20 Union S20 M nut Union nut M 20 S-1.4571 Union nut DIN 22 L3870

10194861 60077707 10019762 10001741 10068055 60090799

Union L22 M nut

10000321

Union 1.5 x22 nut M

10015468

Union nut M 22 1.5 black x-

10214316


60090798

Union nut B-M S25

10019765

Union S25 M nut Union nut M 25 S-1.4571 Union 1.5 x26 nut M Union nut DIN 28 L3870 Union L28 M nut Union nut M 28 L-1.4571 Union nut DIN 30 S 3870 Union S30 M nut Union nut DIN 35 L3870 Union L35 M nut

6


10001738 10068073 10201825 60079964 10000326 10171981 60090797 10001720 60074139 10067352

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Cap Nut Material Description Union nut M 35 L-1.4571 Union S38 M nut Union nut M 38 S-1.4571 Union L42 M nut Union nut M 42 L-1.4571 2Union x55 nut M

Part Number 10193301 10001722 10163898 10067353 10193920 10121816

7

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Ferrule Material Description Cutting ring LL 4DIN 3861


Cutting ring DIN S6 3861

60074912

Cutting ring L/S CR 6

10001726

Cutting ring CR L/S-1.4571 6 Cutting ring LL CR 6

10193309 10001724

Cutting 6ring L

10032482

TAPER BUSH DIN 3861L /6

60090821

Cutting ring L/S CR 8

10001728

Cutting ring CR L-1.4571 8 Cutting ring LL CR 8 Cutting S 8ring D Taper bush DIN 3861 8S Cutting ring CR 10 L/S Cutting ring CR 10 L/S-1.4571 TAPER BUSH DIN 3861L 10 /

10193563 10008615 10043793 60090819 10009296 10194752 60076422

Profled ring 10 L/S P-R

60090818

Cutting ring 12 DIN S 3861

60090816

Cutting ring CR 12 L/S

10001730

Cutting ring CR 12 L-1.4571 TAPER BUSH DIN 3861L 12 / Cutting ring CR S 14 Cutting ring 15 DIN L 3861

10068027 60090817 10034742 60090814

Cutting ring CR L 15

10085720

Cutting ring CR S 16

10001732

Cutting ring CR 16 S-1.4571

10068058

Taper bush DIN 3861 16 S

60090813

Cutting ring 18 DIN L 3861 Cutting ring CR L 18

60083916 10000117

Cutting ring CR 18 L-1.4571 Cutting L ring 18 D Cutting ring CR S 20

10194859 10043794 10001733

9

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Ferrule Material Description Cutting ring CR 20 S-1.4571 Taper bush DIN 3861S 20

Part Number 10068057 60077708

Cutting ring CR L 22

10000119

Taper bush DIN 3861 22 L

60090812

Cutting ring CR S 25

10001734

Cutting ring CR 25 S-1.4571 Taper bush DIN 3861 25 S Cutting ring 28 DIN L 3861 Cutting ring CR L 28 Cutting ring CR 28 L-1.4571 Cutting ring CR S 30 Taper bush DIN 3861S 30 Cutting ring 35 DIN L 3861 Cutting ring CR L 35 Cutting ring CR 35 L-1.4571 Cutting ring CR S 38 Cutting ring CR 38 S-1.4571 Taper bush DIN 3861S 38 Cutting ring CR L 42 Cutting ring CR 42 L-1.4571

10

10068074 60090811 60090810 10000212 10171977 10001735 60090809 60074138 10067350 10193310 10001736 10192765 60090808 10067351 10193924

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EGESD Description Material Screw joint EGESD SR-WD 6

Number Part 10000336

Screw joint EGESD LM-WD 8

10190220

Screw joint EGESD SR-WD 8

10010634

FITTING-LUB,COUPLINGEGESD10LM-WD

30343116

Screw joint EGESD 12 L/3/8 NPT

10089005

Screw joint EGESD 12 L/R 1/2-WD

10067361

Screw joint EGESD 12 L/R 1/4-WD

10018571

ScrewjointEGESD12L/R1/4-WD-1.4571

10159548

Screw joint EGESD 12 LM-WD

98323222

Screw joint EGESD 12 LR-WD

10018568

ScrewjointEGESD12LR-WD1.4571 -

10169105

Screw joint EGESD 12 S/R 1/2-WD

10120694

Screw joint EGESD 12 SR-WD

10096963

ScrewjointEGESD12-LX9/16"-18UNF ScrewingEGESD12LM18x1.5-WD Studstandpipeadapt.EGESD-12S/R1/2"-WD Screw joint EGESD 15 LR-WD

30317534 98327701 60107359 10130325


10020109

ScrewjointEGESD16SR-WD1.4571 -

10192763

ScrewjointEGESD16-SX11/16"-12UN

30332799

ScrewjointEGESD16-SX15/16"-12UN

30333434

ScrewjointEGESD16-SX3/4"-16UNF(

30314195

ScrewjointEGESD16-SX3/4"-16UNF(

30354458

ScrewjointP-EGES16S1/2NPT-SV

30301939

Screw joint EGESD 18 LM-WD

10000858


10067362

Studstandpipeadapt.EGESD-18L/R1/2"-WD Screw joint EGESD 20 SR-WD

60107361 10019728

ScrewjointEGESD20SR-WD-1.4571 ScrewjointEGESD20-SX11/16"-12UN ScrewjointEGESD20-SX3/4"NPT

10131498 30340607 30312044

11

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EGESD Description Material

Number Part


10000335


10015029

ScrewjointEGESD25SR-WD-1.4571 ScrewjointEGESD25-SX11/16"-12UN ScrewjointEGESD25-SX15/16"-12UN ScrewjointEGESD25-SX15/8"-12UN

10193402 30313266 30313962 30321115

ScrewjointEGESD25-SX15/8"-12UNF

30333735


10067363

ScrewjointEGESD28LR-WD1.4571 Screw joint EGESD 30 S/1 1/4 NPT

10193294 10017023

Screw joint EGESD 30 SM-WD

10067366


10067368

ScrewjointEGESD30SR-WD1.4571 Screw joint EGESD 35 L/1 1/4 NPT Screw joint EGESD 35 LR-WD ScrewjointEGESD38 11/2 S/ NPT

10194720 10015246 10067364 10017024


10006780

ScrewjointEGESD38SR-WD1.4571 -

10193296

ScrewjointEGESD38-SX11/2"NPT

30312278

ScrewjointEGESD38-SX11/4"NPT

30312546

Screw joint EGESD 42 L/1 1/2 NPT

10015245


10067365

ScrewjointEGESD42LR-WD1.4571 -

10194731

12

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ELSD Description Material Fitting body ELSD L6 Fitting body ELSD L-1.4571 6 Fitting body ELSD L8 Fitting body ELSD L-1.4571 8 Fitting body ELSD S8

Number Part 10067388 10193311 10067389 10194749 98319687

Fitting body ELSD 10 L

10009275

Fitting body ELSD 10 S

10067394


10019121


10096961

Fitting body ELSD 12 L-1.4571 Fitting body ELSD 12 S-1.4571 Fitting body ELSD 12 L

10097072 10193561 30373606


10118164


10018848

Fitting body ELSD 16 S-1.4571

10131501


10067390


10008033


10008034


10008035

Fitting body ELSD 25 S-1.4571 Fitting body ELSD 28 L Fitting body ELSD 28 L-1.4571 Fitting body ELSD 30 S Fitting body TEE ELSD 30-S S.S. Fitting body ELSD 35 L

10170782 10100551 10193312 10080061 30396397 10100550

Fitting body ELSD 35 L-1.4571

10193431

Fitting body ELSD 38 S Fitting body ELSD 38 S-1.4571

10008036 10193313


10067393


10106304

Fitting body ELSD 42 L-1.4571

10193922

13

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ETSD Description Material Fitting body ETSD L6 Fitting body ETSD L-1.4571 6 Fitting body ETSD L8 Fitting body ETSD L-1.4571 8 Fitting body ETSD 10 L Fitting body ETSD 10 L-1.4571 Fitting body ETSD 12 L Fitting body ETSD 12 L-1.4571 Fitting body ETSD 12 S-1.4571

Number Part 10067396 10193344 10008038 10194746 10188680 10194748 10019730 10146631 10193581

Fitting body ETSD 15 L

10154620

Fitting body ETSD 16 S

10008040

Fitting body ETSD 16 S-1.4571

10193426


10067397


10008041


10008044


10008046

Fitting body ETSD 25 S-1.4571 Fitting body ETSD 28 L Fitting body ETSD 28 L-1.4571 Fitting body ETSD 30 S Fitting body ETSD 30-S

10193343 10067398 10193345 10067404 30391370


10067401


10008037


10067403

Fitting body ETSD 42 L-1.4571

10193921

15

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EWSD Material Description Fitting body EWSD L6 Fitting body EWSD L-1.4571 6 Screw joint EWSD A4 -L6 Fitting body EWSD L8 Fitting body EWSD L-1.4571 8

Part Number 10008042 10193346 10207443 10008043 10193359

Fitting body EWSD S8

98319688

Fitting body EWSD 10 L

10026589


10018570

Fitting body EWSD 12 L-1.4571

10068051


10093240

Fitting body EWSD 16 S

10019122

Fitting body EWSD 16 S-1.4571 Fitting body EWSD 18 L Fitting body EWSD 18 L-1.4571 Fitting body EWSD 20 S Fitting body EWSD 20 S-1.4571

10131502 10067405 10193361 10018850 10068050


10008049


10018417

Fitting body EWSD 25 S-1.4571 Fitting body EWSD 28 L Fitting body EWSD 28 L-1.4571

10170678 10012953 10193362


10065682


10067406

Fitting body EWSD 35 L-1.4571 Fitting body EWSD 38 S Fitting EWSD 38 S-1.4571 Fitting body EWSD 42 L Fitting body EWSD 42 L-1.4571

10193363 10018530 10163906 10067407 10195063

17

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GAS Material Description

Part Number

Fitting body GAS LM 6

10184098

Fitting body GAS LR 8

10008057

Fitting body GAS 10 SR

10069376

Fitting body GAS 12 L/R 1/4

10009267


10069380

Fitting body GAS 12 L/M 10x1

10208965

Fitting body GAS 15 LR

10035477


10045915


10106761


10012225


10009269


10067408

Fitting body GAS 25 SR-1.4571

10193314


10087501


10086878


10067409

Fitting body GAS 38 SR-1.4571 Fitting body GAS 42 LR

10194732 10086877

19

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GES Material Description Fitting body GES L/ 61/8 NPT Fitting body GES L/R 6 1/4 K Fitting body GES L/R 6 1/4-WD FittingbodyGES6L/R1/4-WD-1.4571

Part Number 10194223 10184099 10203630 10193315

Fitting body GES LLM 6

10029402

Fitting body GES LLR 6

10008090

Fitting body GES LR-WD 6 FittingbodyGES6LR-WD-1.4571

10203920 10207442

Fitting body GES SR-WD 6

10184634

FittingbodyGES8L/7/16-20UNF

10090540

FittingbodyGES8L/7/16-20UNF-

10193632

FittingbodyGES8L/M22x1,5-WD Fitting body GES LLM 8 Fitting body GES8 LM 14x1.5-WD Fitting body GES LM-WD 8 FittingbodyGES8LM-WD-1.4571 Fitting body GES LR-WD 8 FittingbodyGES8LR-WD-1.4571 Fitting body GES SM-WD 8 Fitting body GES SR-WD 8 Fitting body GES 10 L/M 10x1 K

10009276 10009284 10008061 10067421 10194774 10170592 10193322 10074107 10012224 10124472

FittingbodyGES10L/M16x1.5-WD

10008075

FittingbodyGES10L/R1/2-WD-1.4571

10196137

Fitting body GES 10 LM-WD Fitting body GES 10 LR/3/8-WD

10196421 98320294

Fitting body GES 10 LR-WD

10153998

FittingbodyGES10LR-WD-1.4571 Fitting body GES 10 SR-WD

10195205 10184635

Fitting body GES 12 L/ 1/2 NPT FittingbodyGES12L/ 3/4-16UNF FittingbodyGES12L/7/16-20UNF

10107415 10067410 10015242

21

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GES Material Description

Part Number

FittingbodyGES12L/9/16-18UNF

10090541

Fitting body GES 12 L/M 14x1,5

60103675

FittingbodyGES12L/M18x1.5-WD

10008071

FittingbodyGES12L/M12x1,5-WD

10308516


10308514

FittingbodyGES12L/M22x1,5-WD Fitting body GES 12 L/R 1/2-WD FittingbodyGES12L/R1/2-WD-1.4571 Fitting body GES 12 L/R 1/4 K Fitting body GES 12 L/R 1/4 WD Fitting body GES 12 L/R 1/4-WD

10009262 10172599 10193440 10185104 10210593 10161984

FittingbodyGES12L/R1/4-WD-1.4571

10193436

FittingbodyGES12L/R1/4-WD-short

98369981

FittingbodyGES12L/R1/4-WD-So

10187888

Fitting body GES 12 LM-WD

10214676


10114516

FittingbodyGES12LR-WD-1.4571 Fitting body GES 12 S/ 1/2 NPT Fitting body GES 12 S/R 1/2-WD Fitting body GES 12 SR-WD Fitting body GES 12-L X 3/8 NPT FittingbodyGES12-LRX0.8(0.8MMOR Fitting body GES 12-LR 3x Fitting body GES 14 SM-WD

10195219 10095283 10186991 10184636 30325817 30392717 30357958 10034740


10300525

FittingbodyGES15L/M22x1.,5-WD

10181681

Fitting body GES 15 LR-WD Fitting body GES 16 S/ 1/2 NPT FittingbodyGES16S/7/8-14UNF Fitting body GES 16 S/M27x2-WD FittingbodyGES16S/M27x2-WD-1.4571

22

10114515 10009264 10009260 10016112 10192764

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Part Number

Fitting body GES 16 S/R 3/8-WD

98325308

Fitting body GES 16 SM-WD

10190489

Fitting body GES 16 SR-WD

10150334

FittingbodyGES16SR-WD-1.4571 FittingbodyGES16S/3/4"-16UNF Fitting body GES 18 L/ 1/2 NPT FittingbodyGES18L/3/4-16UNF FittingbodyGES18L/3/4-16UNF-1.4571 FittingbodyGES18L/7/8-14UNFFittingbodyGES18L/7/8-14UNF FittingbodyGES18L/M18x1,5-WD Fitting body GES 18 LM-WD FittingbodyGES18LM-WD-1.4571 Fitting body GES 18 LR 34-WD

10193317 98373410 98393852 10090542 10193634 10193633 10152315 10034056 10189947 10194753 98386337

Fitting body GES 18 L/R 3/8-WD

98391407


10126327

FittingbodyGES18LR-WD-1.4571 FittingbodyGES20S/11/16-12UN Fitting body GES 20 S/R 1/2-WD Fitting body GES 20 S/R 1-WD Fitting body GES 20 SM-WD Fitting body GES 20 SR-WD

10193320 10192344 98326832 98340659 10191796 10184637

FittingbodyGES20-S 3/4 / 16UNF -

30381982

Fitting body GES 20-S X 3/4" NPT

30303164

FittingbodyGES20SR-WD-1.4571 FittingbodyGES22L/11/16-12UN Fitting body GES 22 L/ 3/4-NPT FittingbodyGES22L/M22x1,5-WD

10068038 10090545 98329521 10209794


10067060


10153999

Fitting body GES25 S/R 1 1/4-WD

10202558

23

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Part Number


10205277


10008079


10184638

FittingbodyGES25SR-WD-1.4571 Fitting body GES 25 SR-WD-7,2 FittingbodyGES28L/15/16-12UN

10193316 98316312 10090546

Fitting body GES 28 L/R 1 1/2-WD

10205280

Fitting body GES 28 L/R 1 1/4-WD

10205279

Fitting body GES 28 LM-WD FittingbodyGES28LM-WD-1.4571 Fitting body GES 28 LR-WD FittingbodyGES28LR-WD-1.4571 FittingbodyGES28LR-WD-FPM-1.4571 FittingbodyGES28L/M26x1,5-WD Fitting body GES 30 S/R 1-WD

10186004 10194747 10154000 10193319 10178310 10209793 98340660


98350985


10214625


10184639

FittingbodyGES30SR-WD-1.4571 FittingbodyGES35L/11/16-20UN

10194721 10090649


10147924


10154001

FittingbodyGES35LR-WD-1.4571 Fitting body GES 38 S/R1 1/4-WD Fitting body GES 38 SR-WD FittingbodyGES38SR-WD-1.4571 Fitting body GES 38-SM-WD Fitting body GES 42 LR-WD FittingbodyGES42LR-WD-1.4571

24

10193318 98359148 10008120 10192787 10067415 10169427 10193923

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GFS Material Description Fitting body GFS 12 L-35


Fitting body GFS 12

80000456

Fitting body GFS 15 L-40

10120527

Fitting body GFS 16 S-35

10008004

Fitting body GFS 16

80000457


10130077


10204934


10009274


98355595


10200486

25

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GS Material Description Fitting body LGS 6 Fitting body LL GS 6 Fitting body LGS 68/ Fitting body LGS 8 Fitting body GS L 10 Fitting body GS L 12 Fitting body GS 12/ L8 Fitting body GS 12/10 L Fitting body GS 12 L-1.4571 Fitting body GS 12 L, MPS Fitting body GS 12 S-1.4571 Fitting body GS 12/ L6 Fitting body GS 15/12 L Fitting body GS L 15 Fitting body GS 15/10 L

Part Number 10008064 10137903 10008123 10008074 10008078 10008083 10008129 10048107 10068025 10173849 10194836 10209220 10008131 10085719 10207483

Fitting body GS S 16

10008088

Fitting body GS 16 S/12 L

10008132

Fitting body GS 16 S-1.4571

10138385

Fitting body GS L 18

10067416


10008093

Fitting body GS 20/16 S Fitting body GS 20 S-1.4571 Fitting body GS 20 S-1.4571

10029946 10068046 10146632


10105453


10008149


10009294

Fitting body GS 25/20 S Fitting body GS S 25

10024716 10129200

Fitting body GS 25-S DEMO

30328409


98367253


10067417

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GS Material Description

Part Number


10008098


10067418


10008101

Fitting body GS 38/25 S

10009280

Fitting body GS 38 S-1.4571

10163899

Fitting body GS 38-S DEMO

30328405

Fitting body GS L 42 Fitting body GS 42 L-1.4571 Fitting body GS 42/28 L

28

10067419 10194739 98348916

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GSS Material Description Fitting body GSS L-m.S 6 Fitting body GSS L-m.S 8 Fitting body GSS 10 L Fitting body GSS 10 S-m.S Fitting body GSS 12 L Fitting body GSS 12 L Fitting body GSS SO 12 -L

Part Number 10067420 10067091 10008105 10067424 10008109 10068053 98393586

Fitting body GSS 12 S

10085038


10008112

Fitting body GSS 16 S-1.4571

10163902

Fitting body GSS 18 L

10067422


10008001


10068052

Fitting body GSS 22 L-m.S Fitting body GSS 25 S FittingbodyGSS25S-m.S-1.4571 Fitting body GSS 28 L-m.S FittingbodyGSS28L-m.S-1.4571 Fitting body GSS 30 S Fitting body GSS 35 L-m.S Fitting body GSS 38 S FittingbodyGSS38S-m.S-1.4571 Fitting body GSS 42 L-m.S

10067423 10008122 10193399 10105977 10193396 10008125 10090648 10008127 10163903 10086082

29

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MAS Material Description

Part Number

Fitting body MAS LR 6

10037355

Fitting body MAS SR 6

10067425

Fitting body MAS LR-1.4571 6

10193395

Fitting body MAS LR 8

10008147

Fitting body MAS SR 8

10067426

Fitting body MAS 12 LR

10008142

Fitting body MAS 12 L/R 1/2

10008144

Fitting body MAS 12 SR

10067429

Fitting body MAS 12 LR-1.4571 Fitting body MAS 12 L/R 1/2

10068043 10195262

31

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RED Material Description Fitting body REDSD8/12 L-VA


Fitting body REDSD 8/6 L

10008145


10024587


10067430

Fitting body REDSDN 10/8 L A3L

10008059

Fitting body REDS 12-L X 6-L

30364237

Fitting body REDSD 12 L/16 S

10214689

Fitting body REDSD 12 S/12 L

10305243

Fitting body REDSD 12/6 L-VA

10194879

Fitting body REDSD 12/6 S

10158825


10008062

Fitting body REDSD 12/10 L-VA Fitting body REDSDN 12/6 L A3L

10159545 10037354

Fitting body REDSDN 12/10 L

10309615

Fitting body REDSDN 12/10 L A3L

10071747

Fitting body REDSDN 12/15 L Fitting body REDSD 15/8 L Fitting body REDSDN 15/12 L A3L Fitting body REDSD 16 S/8 L FittingbodyREDSD16S/12L A3L

10217594 10009277 10008065 10178576 10019729

Fitting body REDSD 16 S/12 L-VA

10129201


10067440


10028338


10067441


10008070


10214690

Fitting body REDSD 18/6 L Fitting body REDSD 18/8 L

10067431 10008073


98325123


10067432

Fitting body REDS 20 S/12 L-VA

10068054

33

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RED Material Description Fitting body REDS 20/16 S-VA



10008080


10160854


10018849


10008086

Fitting body REDSDN 20/6 S

10067442

Fitting body REDSDN 20/12 S A3L

98333018


10009285


10008092


10067433


10008089


10067434


10122121


10008111


10008119


10008094


10067443

Fitting body REDSD 25/12 S-VA

10193413

Fitting body REDSD 25/16 S-VA

10170680

Fitting body REDSD 25/20 S-VA Fitting body REDSD 25/25 S Fitting body REDSD 25/25 S-VA Fitting body REDSD 25/30 S

10129199 10008126 10170683 10008128


10008121


10008124


10129984

Fitting body REDSD 28/12 L Fitting body REDSD 28/15 L

10067435 10118163


10159485


10122122

Fitting body REDSD 28L/25S

34

98349065

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RED Material Description

Part Number


10025179


98316321


10067444


10067445


10008133


98327222


10067450


10008130


10067436


10190329


10160853


10067437


10193562


10008135


10138918


10067451


10008139

Fitting body REDSD 38/25 A3L S

10008140

Fitting body REDSD 38/25 S-VA Fitting body REDSD 38/30 S Fitting body REDSD 38/30 S-VA

10193408 10095380 10194719


10008137


10070607


10102714


10194828


10067439

Fitting body REDSD 42/28 L-VA Fitting body REDSD 42/35 L

10194736 10067438

35

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RSWS Material Description Fitting body RSWS L/R 6 1/4-WD


Fitting body RSWS LLM 6

10029401

Fitting body RSWS LLR 6

10132784

Fitting body RSWS LR-WD 6

10072771

Fitting body RSWS SR-WD 6

10184646

FittingbodyRSWS6SR-WD-1.4571 Fitting body RSWS-6-LLR FittingbodyRSWS8L/M14x1,5-WD Fitting body RSWS LLM 8

10193405 10146945 10008009 10008008

Fitting body RSWS LM-WD 8

10008007

Fitting body RSWS LR-WD 8

10008018

Fitting body RSWS SM-WD 8

10074106

Fitting body RSWS SR-WD 8

10184647

Fitting body RSWS 10 L/R 3/8-WD

10008020

Fitting body RSWS 10 LM-WD

10188678

FittingbodyRSWS10LM-WD-1.4571

10194751

Fitting body RSWS 10 LR-WD

10184640

Fitting body RSWS 10 SR-WD

10184648

FittingbodyRSWS12L/M18x1,5-WD Fitting body RSWS 12 L/M-WD FittingbodyRSWS12L/M-WD-1.4571 Fitting body RSWS 12 L/R 1/4-WD FittingbodyRSWS12L/R1/4-WD-1.4571 Fitting body RSWS 12 LR-WD FittingbodyRSWS12LR-WD-1.4571 Fitting body RSWS 12 SR-WD FittingbodyRSWS12SR-WD-1.4571 FittingbodyRSWS15L/M22x1,5-WD

10008012 10008011 10192772 10209519 10168965 10114518 10192773 10184649 10170810 10181682


10207452


10114517

Fitting body RSWS 16 SM-WD

10008013

37

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Fittings Book

RSWS Material Description Fitting body RSWS 16 SR-WD FittingbodyRSWS16SR-WD-1.4571

Part Number 10130323 10101623


98350565


10126382


10008014


10184664

FittingbodyRSWS20SR-WD-1.4571

10170682


10008015


10008027


10008016

Fitting body RSWS 25 SR-HD-WD Fitting body RSWS 25 SR-WD FittingbodyRSWS25SR-WD-1.4571

10307542 10184665 10194878


10184641


10008017


10184666


10184643


10067386


10184667


10184645

38

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S Material Description Fitting body KS L 12 Fitting body KS 12 L-1.4571

Part Number 10008136 10159551

Fitting body KS S 16

10012226


10008138

Fitting body KS L 22

10008141


10025175


10008143

39

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SNV Material Description

Part Number

Screw joint SNV L8

10189299

Screw joint SNV S8

98319692

Screw joint SNV L 10 Screw joint SNV L612 /

10189300 10194222

Screw joint SNV L 12

10144059

Screw joint SNV 12 1.4571 -L

10169106

Screw joint SNV 12 L-drilled up Screw joint SNV L 15

10307554 60107156

Screw joint SNV S 16

10164227

Screw joint SNV 16 1.4571 -S

10170679

Screw joint SNV L 18 Screw joint SNV 18 L/ 16 S Screw joint SNV S 20

10170700 10308718 10163822

Screw joint SNV 20 S/ 16 S

98372317

Screw joint SNV 20 S/ 18 L

98389940

Screw joint SNV 20-S Screw joint SNV L 22 Screw joint SNV 22 L/ 20 S Screw joint SNV 22L/20S

30395583 10089099 10308717 60107401


10155397


10170701


10089098

Screw joint SNV L 28 Screw joint SNV 28 L/ 25 S Screw joint SNV S 30 Screw joint SNV 30-S Screw joint SNV L 35 Screw joint SNV 35 L/ 30 S

10185996 10306617 10159466 30349738 10087500 10195989


10018529


98382837


10194831

41

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SNV Material Description Screw joint SNV 38/30 S Screw joint SNVRS 38 S Screw joint SNV L 42

Part Number 10184149 10010016 10086083


10173405

Screw joint SNV 42 1.4571 -L

10194832

Screw joint SNV 42 L/ 38 S

42

98323477

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TS Material Description Fitting body LTS 6 Fitting body TS L-1.4571 8 Fitting body LTS 8 Fitting body TS L 12 Fitting body TS 12 L-1.4571 Fitting body TS S 16

Part Number 10008050 10194750 10008052 10008054 10159550 10008056

Fitting body TS 16 S-1.4571

10160776

Fitting body TS 16/16/12 S

10021957

Fitting body TS L 18

10067454

Fitting body TS S 20

10008058

Fitting body TS 20 S-1.4571

10068047


10008060


10008063

Fitting body TS 25 S-1.4571 Fitting body TS L 28 Fitting body TS 28 L-1.4571

10194738 10067455 10194255


10025173


10067456

Fitting body TS 35 L-1.4571 Fitting body TS S 38 Fitting body TS 38 S-1.4571 Fitting body TS L 42 Fitting body TS 42 L-1.4571

10193416 10008067 10193417 10067457 10194829

43

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VS Material Description FITTING HYD, - PLUG VS L/S 8 FITTING HYD, - PLUG VS 10 L/S LockingplugVS12L/S1.4571stainless FITTING HYD, - PLUG VS 12 L/S LockingplugVS16S-1.4571stainless

Part Number 10016806 10016805 10195353 10016804 10193421

FITTING HYD, - PLUG VS 16 S

10016803


10016789


10016790


10016801


10016791

45

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VSD Material Description

Part Number

LOCKING PLUG VSD L/S 6 M.MB.

10016807

LOCKING PLUG VSD L/S 8 M.MB.

10016806

LOCKING PLUG VSD 10 L/S M.MB.

10016805

Blanking plug VSD 12 L/S M.MB.

10016804

LOCKINGPLUGVSD12L/SM.MB.Blanking plug VSD 16 M.MB. S

10192777 10016803

LOCKING PLUG VSD 18 L M.MB.

10067357

Blanking plug VSD 20 M.MB. S

10016789

Blanking plug VSD 22 L (M.MB.) Blanking plug VSD 25 M.MB. S LOCKING PLUG VSD 25 S M.MB.Blanking plug VSD 28 L (M.MB.) Blanking plug VSD 30 S

10016802 10016790 10192778 10067358 10016801


10067359

LOCKING PLUG VSD 38 M.MB. S

10016791


10067360

47

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WFS Material Description

Part Number

Fitting body WFS 12 L-35

10023589


10009271


98340673

Fitting body WFS 16 S-35

10008072


10130078


98355267


10009272

Fitting body WFS20 S-55-1.4571

10146628


10008076


10012216

Fitting body WFS 28 -40 L

98327539


10164630


98315295


10091297

49

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WS Material Description

Part Number

Fitting body LWS 6

10067458

Fitting body LWS 8

10067459

Fitting body WS L 10

10067460


10008084

Fitting body WS 12 L-1.4571

10097071


10118165

Fitting body WS S 16

10008087

Fitting body WS 16 S-1.4571

10163900


10067461


10008091


10008096


10008099


10170681


10067462


10067465


10163901


10067463


10015214


10067464

Fitting body WS 42 L-1.4571

10194835

51

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WSS Material Description Fitting body WSS S-m.S 6 Fitting body WSS S8

Part Number 10105457 10008104

Fitting body WSS 10 L

10008106


10060879


10103148

Fitting body WSS 16 S

10031363

Fitting body WSS 16 S-1.4571

10163905


10306348

Fitting body WSS 20 S

10008107

Fitting body WSS 22 L-m.S Fitting body WSS 25 S FittingbodyWSS25S-m.S-1.4571 Fitting body WSS 30 S Fitting body WSS 35 L-m.S Fitting body WSS 38 S FittingbodyWSS38S-m.S-1.4571 Fitting body WSS 42 L FittingbodyWSS42L-m.S-1.4571

98342570 10008114 10194834 10009278 10174667 10155037 10194833 10155444 10194730

53

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Hose 6 MaterialDescription Hose 2TP DN06 300 x

End1

Hydraulichose350barDN6/2STx360 Hose 2TP DN06 365 x Hose 2TP DN06 520 x HydraulichoseDN6/2STx550 Hydraulichose350barDN6/2STx570 Hose 2TP DN06 620 x

End2 Degree

STR

Part#

10203921 STR

STR

10148833

90°

10309162

90°

STR

STR STR 90°

98339059

90°

10162725

STR

10120862

90°

10309592

Hydraulichose350barDN6/2STx670

STR

STR

10136776


STR

STR

10123137


STR

STR

Hose 2TP DN06 770 x Hydraulichose350barDN6/2STx800

90° STR

Hose 2TP DN06 810 x

90°

HydraulichoseDN6/2STx900

STR

10309147

STR 90°

STR

STR

Hydraulichose400barDN6/2SNx1000

STR

STR

90°

90°

STR

STR


10118117 0°

90°


Hose 2TP DN06 x1150

10123138

90°

Hydraulichose350barDN6/2X1200

10308608 10162682 10013203 10128797

90°

98350127 10186703 30353941


STR

90°

10162721


STR

90°

10162726


STR

90°

HydraulichoseDN 6/2ST x1400

STR

10162680 10162683


30353946


STR

STR

98339456


STR

STR

10186702

Hydraulichose400barDN6/2SNx1500 Hydraulichose350barDN6/2X1500

STR

STR

10309778 30353947


STR

45°

10162673


STR

90°

10162676

Hydraulichose350barDN6/1x1600

30353948

55

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Hose 6 MaterialDescription Hydraulichose400barDN6/2SNx1700 HydraulichoseDN6/2STx1800 Hydraulichose400barDN6/2SNx1900 Hydraulichose400barDN6/2SNx2100 HydraulichoseDN6/2STx2200

End1 STR STR STR STR STR

End2 Degree STR 90° STR STR 90°

Part# 10306558 10162681 10178786 10306559 10162706


STR

STR

10178435

Hydraulichose120barDN6/2TEx2900

STR

STR

10015238


STR

STR

10182899


STR

STR

10182903


STR

STR

10024583


10101876


10097667


10101520


STR

STR

10182904


STR

STR

10178442


STR

STR

10178443


STR

STR

Hydraulic hose 310bar DN 6 X 6500

56

10178444 10200239

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Hose 8 MaterialDescription

End1

End2 Degree

Part#

Hydraulic hose DN X 34' 8LG

30323985

Hydraulic hose DN MM 8 X 47' LG

30326092

Hydraulic hose DN MM 8 X 48' LG

30326093

Hydraulichose350barDN 8/2SCx 300

STR

STR


STR

STR

10045794 10052338


30325047


STR

STR

10050167


90°

STR

98364397

Hydraulichose350barDN 8/2STx 400

STR

STR

10188695


STR

STR

10192786

HydraulichoseDN 8/2SCx 400-MSHA+

STR

STR

98377745


90°

STR


STR

STR

10050168


90°

STR

98388417


90°

STR


STR

STR

Hydraulichose350barDN8/2ST-FLHx450

STR

STR

98393338

75°

98393346 10192780 10034573


STR

STR

10025113


STR

45°

10209534


90°

STR

98393353


STR

Hydraulichose350barLOBADN 8/2ST-FLHx 500 Hydraulichose350barDN 8/2SCx 550

STR STR

STR STR STR

10195220 10147966 10050169


STR

STR

10188697


STR

45°

10196156

HydraulichoseDN 8/2SCx 550-MSHA+

STR

STR 90° STR

98377746

Hydraulichose350barDN 8/2SCx 550 Hydraulichose350barDN 8/2SCx 600

STR STR

98364403 10025656

Hydraulichose350barDN 8/2SC x600

STR

90°

98391649

Hydraulichose350barDN8/2SCx620

45°

STR

98388418


STR

STR

10050170

57

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Hose 8 MaterialDescription Hydraulichose350barDN 8/2SCx 650 Hydraulichose350barDN8/2ST-FLHx 650

End1 90° STR

End2 Degree STR STR

Part# 98355101 10018533


STR

STR

10018484


90°

STR

98354544

Hydraulichose350barDN8/2ST-FLHx700 HydraulichoseDN 8/2SCx 700-MSHA+ Hydraulichose350barDN 8/2SCx 750 Hydraulichose350barDN 8/2STx 750 HydraulichoseDN 8/2SCx 750-MSHA+ Hydraulichose350barDN 8/2SCx 800 Hydraulichose350barDN8/2ST-FLHx800 HydraulichoseDN 8/2SCx 800-MSHA+

STR STR STR STR STR STR STR STR

STR STR STR STR STR STR STR STR

10017616 98377717 10050171 10192781 98377753 10050172 10037383 98377720


STR

STR

10095632


STR

STR

10018483

Hydraulichose350barDN8/2ST-FLHx900 HydraulichoseDN 8/2SCx 900-MSHA+ Hydraulichose 350barDN 8/2SCx 920DKO-L/DKO-L

STR STR STR

STR STR STR

10041629 98377721 98322970


STR

STR

10050173

Hydraulichose350barDN 8/2SCx1000

STR

STR

10050174

Hydraulichose350barsLOBADN8/2ST-FLHX1000 HydraulichoseDN 8/2SCx1000-MSHA+

10077469 STR

STR

98377755


STR

STR

10025658


STR

45°

10190491


90°

STR

98355057

Hydraulichose350barDN8/2ST-FLHx1100 HydraulichoseDN 8/2SCx1100-MSHA+ Hydraulichose350barDN 8/2SCx1200 Hydraulichose350barDN 8/2SCx1200 HydraulichoseDN 8/2SCx1200-MSHA+

10016765 STR STR 45° STR

STR STR STR STR

98377747 10050175 98392969 98383461


STR

STR

10050176


STR

STR

10050177

58

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Hose 8 MaterialDescription HydraulichoseDN 8/2SCx1300-MSHA+ Hydraulichose350barDN8/2SCx1350

End1 STR 90°

End2 Degree

STR STR


Part# 98377714 98388540 30341777


STR

STR

10095631


STR

STR

10050178


STR

STR

10050179


45°

STR

98388420

Hydraulichose350barDN 8/2STx1500 HydraulichoseDN 8/2SCx1500-MSHA+

STR STR

STR STR


STR

STR


STR

STR

HydraulichoseDN 8/2SCx1600-MSHA+ Hydraulichose350barDN 8/2SCx1650

STR STR

STR STR

HydraulichoseDN8/2X1650350 - BAR

10192779 98377718 98327662 10018482 98377719 98322640 30341778


STR

STR

10050180


45°

STR

98388419


90°

STR

98388541


STR

STR

HydraulichoseDN 8/2SCx1800-MSHA+

STR

STR

10058430 98377722


STR

STR


STR

STR

10307753


STR

90°

98324390

HydraulichoseDN 8/2SCx2000-MSHA+

STR

STR

10197123

98377723


STR

STR

10050181


STR

STR

98339515


STR

STR

10050182

Hydraulichose350barDN 8/2SCx2400 Hydraulichose350barDN 8/2SCx2500

STR STR

STR STR

10059237 10309361


STR

STR

10093579


90°

STR

98392950


STR

STR

10189279

59

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Hose 8 MaterialDescription Hydraulichose350barDN 8/2SCx2800 Hydraulichose350barDN 8/2STx2800

End1 STR STR

End2 Degree STR STR

Hydraulic hose x 2 DN 8/2TP x 2900

Part# 10199552 10171584

10128163


STR

STR

10189281


STR

STR

10087069

Hydraulichose350barDN8/2STx3000 Hydraulichose350barLOBADN8/2ST-FLH-X3000

STR STR

STR STR

Hydraulic hose DN 3100 X 8 STR

STR


STR

STR


Hydraulichose350barDN 8/2STx3500

10128602 30365915



10160272

10050183 10182898 30355602

STR STR

STR STR


10189407 10171583 30355603


STR

STR


STR

STR


98340663 10134099 30355605


30358414


STR

STR

10133620


STR

STR

98393775


STR

STR


10179079 30358415


30355606


STR

STR

98339410


STR

STR

98367273


STR

STR

10207510

Hydraulichose350barDN 8/2SCx4700 Hydraulichose350barDN8/2X4700

STR

STR

98376038 30355607


STR

STR

10303855


STR

STR

98376037


STR

STR

10018485

60

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End1

End2 Degree


Part#

30341031


STR

STR

10190841


STR

STR

98315344


STR

STR

10056385


STR

STR

10185302


STR

STR

10193051


STR

STR


98384977 30314105


30328412


STR

STR

10190522


STR

STR

10303854


STR

STR

98339411


STR

STR

10303852


STR

STR

10217433


STR

STR

98315347


STR

STR

10185304


STR

STR

10217434


STR

STR

10303851


STR

STR

98315345


10068024

61

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End1

End2 Degree

Hydraulichose330barsDN10/2SNx 250

STR

STR

Hydraulichose350barsDN10/2TPx 300

STR

90°


90°

45°


STR

10209812 0°

90°

Hose 2TP DN10 x 355

90°

90°

Hose 2TP DN10 x375

STR

90°

Part# 10096681

10206527 10209821 10309551 10308610

Hose 2TP DN10 390 x

10308609

Hose 2TP DN10 390 x

10309146

Hose 2TP DN10 x 390 Hose 2TP DN10 x390

STR

STR

90°

90°

Hose 2TP DN10 x 390

STR

90°

Hose 2TP DN10 x 400

90°

STR

10309151 90°

10309161 98321682 10309621


STR

90°

10306520


STR

90°

10209820


STR

90°

10162699

Hose 2TP DN10 410 x

98325474

Hose 2TP DN10 460 x

98325510

Hose 2TP DN10 460 x Hydraulichose350barsDN10/2TPx 470 Hydraulichose350barsDN10/2TPx 470

98325513 90° 90°

90°

325°

90°

35°

Hydraulichose330barDN10/2SNx 500

STR

90°

Hydraulichose100barDN10/TPSx 500

45°

90°


90°

0°

HydraulichoseDN10/2STx500 Hydraulichose350barsDN10/2TPx 550 HydraulichoseDN10/2STx550 Hydraulichose330barsDN10/2SNx 600 Hydraulichose350barDN10/2SCx 600

STR STR STR STR 90°

STR 90° 90°

10209827 10209829 10215792

0°

10206530 10207665 10162703 10209816 10162715

90° STR

10306543 98355102


90°

0°

10207656


STR

STR

10207671


STR

90°

10209815

63

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Hose 10 MaterialDescription HydraulichoseDN10/2STx600 Hose 2TP DN10 x 635 Hydraulichose330barDN10/2SNx 650

End1 STR STR

End2 Degree 90°

90°

STR


98315767 90°

90° STR

STR


STR

90°

Hydraulichose350barsDN10/2TPx 800 HydraulichoseDN10/2STx800

90°

Hose 2TP DN10 x 890 Hydraulichose100barDN10/TPSx900

90°

STR STR


90°

10162713 270°

10206526 10209811

90°

10162714

90°

10306519

90°

90°

10207655 10162705

90°

STR STR

10215793

90°



Part# 10162707

98315774

0°

10207648


STR

45°

10207941


STR

90°

10209825


STR

90°


STR

STR

10162698


STR

45°

10162704

Hose 2TP DN10 x950

90°

90°

Hose 2TP DN10 950 x

10162675

90°

98315800 98315816


STR

180°

10306545


STR

45°

10207940

Hose 2TP DN10 1000 x

90°

STR

98323590

Hydraulichose330barsDN10/2SNx1000

STR

STR

10128799


STR

90°

10306550

Hydraulichose350barsDN10/2TPx1000

STR

45°

10208281


STR

90°

10209824

Hydraulichose100barDN10/TPSx1050 Hydraulichose100barDN10/TPSx1050 Hose 2TP DN10 1100 x

90° 90° 90°

0° 0° 90°

98353391

Hydraulichose350barsDN10/2TPx1100 Hydraulichose350barsDN10/2TPx1100

64

10207667 10207668

10206531 STR

STR

10207666

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End1


End2 Degree

STR

45°

Part# 10208280


STR

90°

10162702


STR

STR

10152039


STR

90°

10162719

Hydraulichose350barsDN10/2TPx1300 HydraulichoseDN10/2STx1300

STR STR

90° STR

Hose 2TP DN10 1400 x

98350360


STR

Hydraulichose350barsDN10/2TPx1400 Hose 2TP DN10 1450 x

98324573 10162716

90°

STR 90°

90° 90°

10306544 10209835 98315789


STR

STR

10207938


STR

45°

10209831


STR

45°

10209833


STR

90°

10309775


STR

180°

Hydraulichose350barsDN10/2TPx1800 HydraulichoseDN10/2STx1800

10306499 98316572

STR

90°

10162700


STR

90°

10209832


STR

90°

10209834


STR

STR


90°

0°


90°

0°


STR

STR

10162717 10207642 10207643 10162697


90°

0°

10207644


90°

0°

10207645


STR

90°

10207939

HydraulichoseDN10/2STx2800 HydraulichoseDN10/2STx3000

STR STR

HydraulichoseDN10/2STx3000 HydraulichoseDN10/2STx3000 Hydraulichose350barsDN10/2TPx3200

STR 90°

10162695 10162701

STR

90°

10162720

STR

STR

10162723

STR

0°

10207649

65

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End1

End2 Degree

Part#


90°

0°

10207935


90°

0°

10207934


90°

0°

10211676


STR

90°

10162722

Hydraulichose350barDN10/2TPx4700

STR

90°


90°

STR

10210579


90°

0°

10207669


STR

STR

10210580

10162724


STR

90°


STR

90°

98319811


STR

STR

60106919


STR

90°

98339553


STR

90°

98339554


STR

STR

60107666


STR

STR

60107667


STR

STR

10179082


STR

STR

98315343

66

98319810

Home

Print Fittings Book


End1

Hydraulichose415barDN12/4SPx300

STR

Hydraulichose415barDN12/4SPx350 Hydraulichose415barDN12/4SPx350

End2 Degree

Part#

STR

10200316

STR

90°

10165526

STR

STR

10193955


STR

STR

10049900


STR

90°

10206585


90°

90°


STR

STR

98355040


90°

STR

98394100

Hydraulichose415barDN12/TPxx430

STR


90°

Hydraulichose470barDN12/3SCx 440

90°

90°

STR

STR

45°


STR

STR

90°

STR

10306500

10209802

STR



90°

98318187 85°

98393348 10200317 98368643

85°

98393350


STR

STR

98355041


90°

STR

98393351

Hydraulichose470barDN12/3SCx 480 Hydraulichose415barDN12/TPxx480

90° STR

STR 90°

98393352 10209809


STR

STR

10049901


90°

STR

98394104

Hydraulichose415barLOBADN12/4SP-FLH-x500 Hydraulichose425barDN12/4SPx500

STR

STR

10147912

STR

90°

10306503


90°

STR

98354542


STR

STR

98355053


STR

STR

10049902


STR

STR

10192782


STR STR

STR 90°

10037385 10306462


45°

STR

98355042


90°

STR

98355047


90°

STR

98355048

67

Home

Print Fittings Book


End1

End2 Degree

Part#


90°

STR

98393354


STR

STR

10183548


STR

STR

10199665


STR

90°

10309774


STR

90°

10309779


90°

STR

98355043


90°

STR

98355046


90°

STR

98355049

HydraulichoseDN12/4SPx600-MSHA+

STR

STR

98377725


STR

90°

10306512


90°

STR

10210581


STR

STR

10049903

Hydraulichose415barLOBADN12/4SP-FLHx650

STR

STR

10038223


STR

90°

10306505


90°

STR

98354539


90°

STR


STR

98354543

90°

10209804


STR

90°

98393806


STR

STR

10174118


90°

45°


STR

STR

10049904


STR

45°

10307826


STR

90°

98364447


90°

STR

98354675


90°

STR

98355050


STR

STR

98368267


STR STR

90° STR

10306518 10308136

Hydraulichose415barDN12/4SPx 750

STR

90°


45°

45°

STR

STR


68

75°

10206532

98393693 90°

10308792 10062202

Home

Print Fittings Book


End1

End2 Degree

Part#


STR

STR

10192783


90°

STR

98364389


90°

STR

98364858


STR

90°

10306514


90°

STR


STR

98354672

STR

98377751


STR

90°

10306481


STR

45°

10207942


STR

STR

98327841


90°

STR

98369455


STR

90°

10309772


90°

STR

10309614


STR

45°

10208282


STR

STR

10018480


STR 90°

STR 90°

10018534 90°

10306474


STR

90°

98367608


STR

90°

98367608


STR

90°

98318106


STR

STR


STR

90°

98393690


STR


STR

STR

98355052


90°

STR

98318168


STR

45°

10208285


STR

90°

10210577


STR 90°

STR STR

10049905 98391596


90°

STR

98354676


90°

STR

98358800


STR

90°

98370923 85°

STR

10306542

98377752

69

Home

Print Fittings Book


End1

End2 Degree


STR

90°


90°

STR


Part# 10309766 98330010

98354674


90°

STR


STR

90°

98354677 98319766


90°

0°

10206534


STR

STR

10024672


STR

90°

10215801


STR

45°

98393702


STR

STR

10049906


STR

STR

10090416


STR

45°

98367046


90°

STR

98380483


STR

90°

10309773


STR

90°

10162718


STR

STR

98336138


90°

STR

98355055


STR

STR

10049907


STR

STR

98328184


90°

STR

Hydraulichose415barDN12/4SPx1400 Hydraulichose415barDN12/TPxx1400

98388543 98386856

STR

STR

10216425


STR

90°

98319744


STR

90°

10209795


STR

STR

10044561


STR

STR

10049908

Hydraulichose415barDN12/4SPx1550 Hydraulichose310barDN12/2TPx1600

STR STR

STR 90°

98377924 10210578


90°

STR

98386282


STR

90°

98352335


STR

STR

98370924

70

Home

Print Fittings Book

Hose 12 MaterialDescription Hydraulichose415barDN12/4SPx1700

End1

End2 Degree

Part#

STR

STR

10049909


90°

STR

98393742


STR

STR

10049910


STR

45°

98393696


STR

STR

98339512


STR

STR

10049911


STR

90°

98324620


STR

90°

10306555


STR

STR

10049912


STR

90°

10306551


STR

STR

98339513


STR

STR

10216426


STR

STR

10162791


STR

STR

10309360


STR

45°

98393699


STR

STR

10049913


STR

STR

10199553


STR

STR

10309359


STR

STR

10059239


STR

STR

10189284


STR

STR

10162790


STR

STR

10189285


STR

STR

10207657


STR

90°

10210585


STR

STR

98319527


STR

90°

98324389

HydraulichoseDN12/4SPx3000DKO-S Hydraulichose415barDN12/4SPx3100

STR

STR

10059240 98319530


90°

STR

10207932


STR

STR

10081340

Hydraulichose415barLOBADN12/4SP-FLH-x3200

STR

STR

10128603

71

Home

Print Fittings Book


End1


STR

Hydraulichose310barDN12/2TPx3350 Hydraulichose415barDN12/4SPx3400

End2 Degree

Part#

STR

98369380

STR

90°

10207654

STR

STR

98319531


STR

STR

10189406


90°

0°

10207933


STR

STR

10064293


STR

STR

98318383


STR

STR

98339510


STR

STR

98339511


STR

STR

10133622


STR

STR

10185297


STR

STR

98375940


STR

STR

98320778


STR

STR

98352731


STR

STR

98375941


STR

STR

10185298


STR

STR

98367271


STR

STR

98367270


STR

STR

98382802


90°

STR

10207670


STR

STR

98339412


STR

STR

98367269


STR

STR

98375631


STR

STR

10063503


STR

STR

10190840


STR STR

STR STR

98319865 10036328


STR

STR

10185299


STR

STR

10198530


STR

STR

98339413

Hose DN12 3500 x

72

98317293

Home

Print Fittings Book


End1

End2 Degree

Part#


STR

STR

10190521


90°

STR

98361419


90°

STR

98378192


STR

STR

98339450


90°

STR

98378193


90°

STR

98378194


STR

STR

10063940


STR

STR

10214500

73

Home

Print

Home

Print Fittings Book

Hose 16 MaterialDescription Hydraulichose350barDN16/4SPx 200

End1 STR

End2 Degree 90°

Part# 10163823


90°

STR

98394044


STR

STR

10154055


STR

STR

Hydraulichose350barDN16/TPXx300

90°

45°

180°

10049938


90°

45°

180°

10210584 10206528


STR

45°

10163825


STR

STR

10176374


STR

STR

10176375

Hydraulichose350barDN16/4SPx 380 Hydraulichose250barDN16/2STx400

STR STR

90°

10078489

45°

10191606


STR

STR

10199661


STR

STR

10049939


STR

90°

10160745


STR

45°

10198777


STR

45°

98393514


STR

STR

10152296


STR

90°

10163824


STR

45°

10180536


STR

STR

10171562


STR

45°

10193580


STR

90°

98318105


STR

STR

10155019


STR

45°

10163826


STR

90°

10165729


STR

STR

10167882

Hydraulichose270barDN16/2STx500 Hydraulichose350barDN16/4SPx500

STR STR

STR STR

10155020 10049940


STR

45°

10190249


STR

90°

10215049


45°

90°

115°

10209803

75

Home

Print Fittings Book


End1

End2 Degree

Part#


STR

STR

98355069


STR

STR

10094172


STR

STR

10155021


90°

STR

10207662


STR

45°

10165728


STR

45°

10195310


STR

STR

98344486


STR

STR

10153644


STR

STR

10049941


STR

STR

10147910


STR

45°

10190447


STR

90°

10155482


STR

STR

10171225


STR

45°

10180748


STR

STR

10049942


STR

45°


STR

90°


90°

90°


STR

90°

98367643

Hydraulichose400barDN16/4SPx6 00

STR

STR

10306515


STR

STR

HydraulichoseDN16/4SPx 600-MSHA+

STR

STR

10190449 10209375 90°

98364398

10306480 98377729

Hydraulichose150barDN16/1TPx 650

90°

STR

10207651

Hydraulichose250barDN16/2STx 650

STR

STR

98327274


STR

90°

10158254


STR

45°

10180749

Hydraulichose250barDN16/2STx 650 Hydraulichose250barDN16/2STx 650

STR STR

45° 45°

10193565 10195328


STR

STR

10025659


STR

90°

98321760

Hydraulichose350barDN16/TPXx 650

STR

STR

10210583

76

Home

Print Fittings Book

Hose 16 MaterialDescription Hydraulichose350barLOBADN16/4SP-FLH-x 650 HydraulichoseDN16/4SPx 650-MSHA+

End1 STR STR

End2 Degree STR

Part# 10036729

STR

98377761


30380085


30301357

HydraulichoseDN16/4X680350 - BAR Hydraulichose130barDN16/1SNx 700 Hydraulichose225barDN16/2STx 700 Hydraulichose250barDN16/2STx 700

30302328 STR 90°

STR 45°

10129564 180°

10160746

STR

90°


STR

STR

10173828


STR

45°

10180750


STR

STR

10193566


STR

STR

10019736


STR

STR

Hydraulichose350barDN16/TPXx700 Hydraulichose350barLOBADN16/4SP-FLH-x 700 Hydraulichose400barDN16/4SPx 700

STR STR

10164704

10072695 10206529

STR

10016764

STR

STR


STR

STR

10160763


STR

45°

10209374


STR

90°

98370115


STR

STR

98365097


STR

90°

98364448


90°

STR


STR

STR

10309765

98355067 98388304


STR

90°

10158251


STR

STR

10160765


STR

STR

10193567

Hydraulichose250barDN16/2STx 800 Hydraulichose350barDN16/4SPx 800

STR STR

45° STR

10215246 10049943


STR

90°

10215802


STR

90°

98380043


STR

STR

98377765

77

Home

Print Fittings Book


End1


STR

Hydraulichose250barDN16/2STx 850 Hydraulichose250barDN16/2STx 850 Hydraulichose350barDN16/4SPx 850 Hydraulichose130barDN16/1SCx 900

End2 Degree

Part#

90°

10155483

STR

45°

10160766

STR

STR

10197805

STR STR

90° 90°

98318111 98393724


STR

STR


STR

STR

10160785


45°

45°

10165460


STR

90°

10167252


STR

45°

10180751


STR

45°

10193564


STR

STR


STR

STR

10153288

10029729 98377757


STR

45°


STR

90°

98370116


STR

45°

10215099


STR

STR

98370933


STR

45°

10184563


STR

STR

98321755


90°

0°

10180865

10206533


STR

STR

10153289


STR

90°

10165452


STR

STR

10143967


STR

STR


STR

STR

10049944 98377759


STR

45°

98321758

Hydraulichose130barDN16/1SCx1100 Hydraulichose250barDN16/2STx1100

STR STR

90° 45°

98375342 10184564


STR

STR

10209373


STR

STR

10049945


STR

90°

98321761

78

Home

Print Fittings Book

Hose 16 MaterialDescription Hydraulichose400barDN16/4SPx1100 HydraulichoseDN16/4SPx1100-MSHA+

End1 90° STR

End2 Degree 90° STR 45°

0°

Part# 10215803 98377760


STR


90°


STR

STR

10155805


STR

90°

10162946


STR

STR

10209415


STR

STR

10049946

STR

Hydraulichose350barDN16/TPXx1200 Hydraulichose350barLOBADN16/4SP-FLH-x1200

STR

Hydraulichose250barDN16/2STx1300 Hydraulichose350barDN16/4SPx1300 Hydraulichose350barDN16/4SPx1300

Hydraulichose130barDN16/1SCx1350 Hydraulichose350barDN16/4SPx1350 Hydraulichose250barDN16/2STx1400 Hydraulichose350barDN16/4SPx1400 Hydraulichose350barDN16/TPXx1400 Hydraulichose150barDN16/1TPx1450

10207650

10208283 STR



98393730

STR

10147963

STR

10167627

STR

45°

10183218

STR

STR

10049947

STR

90°

98380439

STR STR STR STR STR STR STR

45° 90° STR STR STR STR STR


98382809 98393725 10049948 98339803 98373570 10216255 10207326 98386754


STR

STR


STR

STR

10049949


STR

90°

98318104


STR

STR

98370927

Hydraulichose130barDN16/1SCx1600 Hydraulichose150barDN16/1TPx1600

90°

0°

98373572

98386753 10207647


STR

STR

10049950


STR

90°

98382751


STR

90°

98375363

79

Home

Print Fittings Book

Hose 16 MaterialDescription Hydraulichose250barDN16/2STx1650 Hydraulichose350barDN16/4SPx1650

End1 STR STR

End2 Degree STR STR

Part# 10209416 98370925


STR

90°

98386750


STR

STR

98345462


STR

STR


STR

STR


STR


STR

Hydraulichose130barDN16/1SCx1900 Hydraulichose250barDN16/2STx1900 Hydraulichose350barDN16/4SPx1900

STR

10024682 98377762

STR

98383587

STR

90°

98386751

STR

STR

98345461

STR

90°

Hydraulic hose DN 16/2SN 1980 Hydraulichose130barDN16/1SCx2000

10049951

98386701 80200091

STR

STR

98388482


STR

STR

10049952


STR

STR

98384368


STR

STR


STR

STR

10065126 98383588


STR

90°

98367165


STR

STR

10169184


STR

STR

98377766


STR

STR

98381269

Hydraulichose250barDN16/2STx2300 Hydraulichose350barDN16/4SPx2300 HydraulichoseDN16/4SPx2300-MSHA+ Hydraulichose130barDN16/1SCx2400

STR STR STR STR

STR STR STR 45°


STR

90°

HydraulichoseDN16/4X2400-350BAR Hydraulichose350barDN16/4SPx2500

STR

STR

Hydraulichose350barDN16/4SPx2600 Hydraulichose350barDN16/4SPx2700 HydraulichoseDN16/4SPx2700-MSHA+

80

STR STR STR

STR STR STR

98345460 10196164 98383463 98393726 98367166 30302244 10199554 10189289 10160954 98383464

Home

Print Fittings Book

Hose 16 MaterialDescription Hydraulichose130barDN16/1SCx2800

End1 STR

End2 Degree 45°

Part# 98392304


STR

STR

98361560


STR

STR

10216256


STR

STR

10189290


STR

STR

HydraulichoseDN16/4X3200350 - BAR Hydraulichose350barDN16/4SPx3400 Hydraulichose130barDN16/1SCx3600

10193824 30319319

STR STR

STR STR

10064294 98393767


STR

STR

10192832


STR

STR

10309910


STR

STR

60107208


STR

STR


STR

STR

10196590 98393727


STR

STR

98352734


STR

STR

10025190


STR

STR

10049953


STR

STR

98352750


STR

STR

98376032


STR

STR

10185300


STR

STR

10197825


STR

STR

10195024


STR

STR


10196163 30322610


STR

STR

10198531


STR

STR

98383679


STR

STR

10214501

81

Home

Print

Home

Print Fittings Book


End1

End2 Degree

Hydraulic hose DN 20 X 34' LG

Part#

30323984

Hydraulic hose DN 20 X 44' LG

30323983

Hydraulic hose DN 20 MM X 47' LG

30326094

HydraulichosePRESSUREDN20MMX48'LG Hydraulic hose DN 20/4 DN 20/4X 250 DKO-S/DKO-S 90

30326095 STR

90°

10086131


STR

90°

10083314


STR

STR

10184074


STR

STR

10193572


STR

STR

10049954


STR

STR

10193568


STR

45°

10304498


STR

STR

10193415


STR

90°

10165730


STR

STR

10189896


STR

STR

10196328


STR

90°

10166350


STR

STR

HOSE SILVER DN 500 20 X Hydraulichose215barDN20/2SCx 500

10167671 10012525

STR

45°

180°

10215805


STR

STR

10153645


STR

45°

10202091


STR

STR

10049955


STR

45°

10215050


45°

STR

10215806


STR

STR

10158250


STR

STR

10049956

Hydraulichose350barDN20/4SPx 550 Hydraulichose375barDN20/3SCx 550

STR STR

45° 90°

10194788 98355071

Hydraulichose420barDN20/4Shx 550

STR

90°

10306510


STR

STR

10198070


STR

STR

98326063

83

Home

Print Fittings Book

Hose 20 MaterialDescription Hydraulichose350barDN20/4SPx 600

End1

End2 Degree

Part#

STR

45°

10194923


STR

STR

98368588


STR

90°

10165447


STR

STR

10212781


STR

STR

10049957


STR

90°

10198909

Hydraulichose350barDN20/4SPX650 Hydraulichose350barLOBADN20/4SP-FLH-x 650 Hydraulichose215barDN20/2STx 700

98379738 STR

STR

10036721

STR

STR

90°

90°

STR

STR


STR

STR

10192785


STR

90°

10198912

Hydraulichose350barDN20/4SHx 700 Hydraulichose350barDN20/4SPx 700

Hydraulichose350barLOBADN20/4SP-FLH-x 700 HydraulichoseDN20/4SPx 700-MSHA+

STR STR

STR STR

10155806 90°

10205298 10018481

10014481 98383465


STR

STR

10306482


STR

90°

10164625


STR

STR

10169188


STR

45°

10194787


STR

STR

Hydraulichose380barDN20/4SPx750 HydraulichoseDN20/1STx750

10160760 98355173

STR

90°

10162686


STR

90°

98393735


STR

90°

10164705


STR

STR

10169189


STR

STR

10079398

Hydraulichose350barDN20/4SPx 800 Hydraulichose350barDN20/4SPx 800

STR STR

45° 90°

10215247 10215248


STR

STR

98387500


STR

90°

98393736


STR

STR

10159101

84

Home

Print Fittings Book


End1


STR

Hydraulichose350barDN20/4SPx 850 Hydraulichose215barDN20/2STx 900

End2 Degree

Part#

STR

10165727

STR

45°

10186989

STR

STR

10189802


STR

STR

10049958


STR

45°

10186992


STR

90°

10215101


STR

90°

10309752

Hydraulichose350barLOBADN20/4SP-FHL-x 900 HydraulichoseDN20/4SPx 900-MSHA+

STR STR

STR

10016767

STR

98377730


STR

STR

98321494


STR

90°

10160761


STR

STR

98321762


STR

STR

10128802


STR

STR

10165444


45°

45°


STR

STR

10049959


STR

45°

10194474


STR

STR

98377935


STR

STR

98326268

STR

STR

Hydraulichose350barDN20/4X1100 Hydraulichose350barDN20/4SPx1100

98367041

30380090


STR

45°


90°

STR


90°

STR

STR

10049960 98393741 10208284 98377756


STR

90°

98321763


STR

STR

98383042

Hydraulichose105barDN20/1SCx1200 Hydraulichose150barDN20/1TPx1200

STR 90°

45° STR

98375340 10207372


STR

STR

10049961


STR

STR

10195314


STR

45°

10209376

85

Home

Print Fittings Book


End1

End2 Degree

Part#


STR

90°

10210582


STR

90°

98322680


STR

45°

98382813

Hydraulichose420barDN20/4Shx1200

STR

90°

10306477


STR

90°

98318103


STR

90°


90°

45°


STR

STR

10049962


STR

STR

10164333


STR

90°

10164336


STR

STR

10019735


STR

STR

10307498


STR

90°

10306556


STR

STR

10049963


90°

STR

98316557


STR

STR

98321737


STR

STR

98322686


STR

100°

10309776

Hydraulichose420barDN20/4Shx1400

STR

90°

10309764


STR

90°

98375362


STR

STR

98377951


STR

STR


45°

45°


STR

STR

10049964


STR

STR

10192784


STR

90°

10306557

Hydraulichose150barDN20/1TPx1550 Hydraulichose350barDN20/4SPx1600

90° STR

45° STR


STR

90°

10162677


STR

100°

10309777


STR

STR

10049967

86

98393737 0°

10207325

98326267 90°

0°

98370043

10211373 10049965

Home

Print Fittings Book


End1


90°

Hydraulichose105barDN20/1SCx1800 Hydraulichose215barDN20/2STx1800

End2 Degree

Part#

STR

98316569

STR

90°

98386749

STR

STR

98384366


STR

STR

98384366


STR

STR

10049968


STR

STR

Hydraulichose350barDN20/4SPx2000 Hydraulichose350barDN20/4SPx2000 HydraulichoseDN20/1STx2000 Hydraulichose350barDN20/4SPx2100

STR STR STR

STR 90° STR

HydraulichoseDN20/4X2100DEMO Hydraulichose350barDN20/4SPx2200

10194115 10025088 98345464 10162679 10090410 30328408

STR

STR


10194116 10025089


STR

45°

98393738


STR

STR

10037453


STR

STR

10186576


STR

STR

98330012


STR

STR

98338986


STR

STR

10059241

Hydraulichose350barLOBADN20/4SP-FLH-x3000

STR

STR

10128604


STR

STR

10193825


STR

STR

10194117


STR

STR

10193573


STR

STR

10185301


STR

STR

98393747


STR

STR

10188448

Hydraulichose350barDN20/4SPx4400 Hydraulichose375barDN20/3SCx4600

STR 45°

STR STR

98339514 98352735


STR

STR

98375939


STR

STR

98315674


STR

STR

98315676

87

Home

Print Fittings Book

Hose 20 MaterialDescription Hose DN20-20m

88

End1

End2 Degree

Part# 98322234

Home

Print Fittings Book

Hose 25 MaterialDescription Hydraulichose165barDN25/2SNx275 Hydraulichose210barDN25/2TPx330

End1 90° 90°

End2 Degree 90° STR

350 HOSE X6DN X 25 Hydraulichose88barDN25/1SNx360 Hydraulichose25barDN25x370

270°

Part# 10309770 98316554

10011156 STR

90°

STR

STR

Hydraulichose25barDN25x400

90°

90°

Hydraulichose380barDN25/4SHx400

STR

STR

10207840 98343083 270°

98353011 10198069


30393961


STR

90°

10207658


STR

STR

98365089


STR

90°


STR

STR

10190313


STR

45°

10190314


STR

10162060

90°

500 HOSE X6DN X 25

98317636 10011158


STR

STR

10167883


STR

45°

10190042


STR

90°

10209372


90°

STR

98318188

Hydraulichose25barDN25x500 Hydraulichose380barDN25/4SHx500 Hydraulichose380barLOBADN25/4SH-FLH-x500

STR STR STR

90°

10308579

STR

10049974

STR

90°


STR

45°

98322597


STR

STR

10182390


STR

45°

98336381

Hydraulichose25barDN25x550 Hydraulichose380barDN25/4SHx550

STR STR

Hydraulichose385barDN25/4SHx550 Hydraulichose88barDN25/1SCx550 HydraulichoseDN25/4X550350 - BAR

90° STR

90°

10037387


180°

98317638

90° STR 90° STR

98337689 10302784 180°

98325505 98385333

30380086

89

Home

Print Fittings Book

Hose 25 MaterialDescription Hydraulichose280barDN25/TPx570

End1 45°

End2 Degree 45°

600 HOSE X6DN X 25

Part# 10209801

10011160


STR

Hydraulichose165barDN25/2STx600 Hydraulichose165barDN25/2STx600 Hydraulichose25barDN25x600

180°

90°

10306507

STR

45°

10196329

STR

STR

STR

10197723

90°

98316309


STR

STR

10199555


STR

45°

10208690

HydraulichoseDN25/4X600350 - BAR Hydraulichose165barDN25/2SNx650 Hydraulichose165barDN25/2SNx650

30380087 90° 90°

45°

180°

STR


STR

STR


90°

90°


STR

STR


10309771 98355077 10209371

350°

10207659 10309900

STR

STR


90°

90°


STR

STR

10171566


STR

45°

10215100

700 HOSE X6DN X 25

98341397 180°

98356715

10027923


180°

STR

10205328


STR

45°

10306509


STR

90°

10308580


STR

STR

10049975


STR

90°

10309767


STR

90°

10215807


STR

90°

98325504

STR STR

STR 90°

98377754 98319735

HydraulichoseDN25/4SHx700-MSHA+ Hydraulichose110barDN25/1TPx750 Hydraulichose165barDN25/2STx750

STR

45°

10196330


STR

STR

10196639


90

STR

90°

98317199

Home

Print Fittings Book

Hose 25 MaterialDescription Hydraulichose25barDN25x750

End1 90°

End2 Degree 90°

0°

Part# 98330640

Hydraulichose380barDN25/4SHx 750

STR

45°

98388544


STR

STR

10049976


STR

45°

98375360


STR

90°

98375361


STR

45°

98319734


STR

90°

10207841


90°

90°

180°

10205326


STR

STR

10168730


STR

45°

10198908


STR

STR

98343082


STR

90°

98356716


STR

STR

10171564

HydraulichoseDN25/4X800350 - BAR HydraulichoseDN25/4SHx800-MSHA+

30380088 STR

STR

98377732


STR

45°

98388546

Hydraulichose 88barDN25/1SCx 850

STR

90°

98390410


STR

45°

10196640


STR

STR

98340716

Hydraulichose165barDN25/2STx850 Hydraulichose25barDN25x850 Hydraulichose380barDN25/4SHx 850 Hydraulichose110barDN25/1TPx870 Hydraulichose25barDN25x875

45° 90° STR STR 90°

45° 90° STR

90°

90°

90°

Hydraulichose165barDN25/2STx900 Hydraulichose25barDN25x900

STR STR

STR 90°

STR

STR


10308791 0°

98317809

10011162



98352487 98319764 98393743

90°

900 HOSE X6DN X 25


180° 180°

STR STR

180°

98326700 10173829 10207370 98356513 10025172

STR

10049977

91

Home

Print Fittings Book

Hose 25 MaterialDescription Hydraulichose88barDN25/1STx900 HydraulichoseDN25/4SHx900-MSHA+ Hydraulichose110barDN25/1TPx910 Hydraulichose25barDN25x930

End1 STR STR STR STR

End2 Degree 90°

STR

98377748

45°

98352336

90°

950 HOSE X6DN X 25

Part# 10162684

10308578 10011163

Hydraulichose 88barDN25/1SCx 950

STR

90°

98390411


STR

45°

10162947


STR

45°

10195308


STR

STR

98384361


STR

STR


90°

90°

98384361 90°

98336244


STR

45°

98390505


STR

STR

98382833


STR

90°

10308790


STR

90°


STR

45°


STR

STR

10307236 10182391 10143968


STR

STR

98340266


STR

STR

98365087


10025170


STR

90°

98380467


90°

STR

10205299


STR

STR

10303076


STR

STR

98382015


STR

90°

10162670

HydraulichoseDN25/4x1000350 - bar

30393716

Hydraulic hose DN 25/4 x 1000 DKS HydraulichoseDN25/4SHx1000-MSHA+

STR


STR

STR

10037654 98377749 10306910


STR

45°

10207324


STR

45°

10209532

92

Home

Print Fittings Book


End1 90°


90°


STR

End2 Degree 90°

180°

Part# 98331746

90°

10309901 10207323


STR

STR

10173830


STR

45°

10215837


STR

90°

98318102


STR

STR

10181824


STR

90°

98382826


STR

45°

10309611


STR

45°

10162953

HydraulichoseDN25/4X1100-350BAR

Hydraulichose165barDN25/2STx1150 Hydraulichose25barDN25x1150

30347674

STR STR

45°

10195566

90°

98316311


STR

STR


45°

90°

100°


90°

90°

180°


STR

98340661

45° 45°

10309613 10211371 10211372


90°


STR

90°

160°

10205297

98319763


STR

STR

10189895


STR

45°

10209617


90°

STR

98318116


STR

STR

10207661


STR

STR

10062367


90°

STR

10205300


STR

45°

98382836

Hydraulic hose DN 25/4 x 1200 SAE Hydraulichose380barDN25/4SHx1220

90°

90°


STR

90°


45°

45°


STR

STR

230°

10025182 98316556 98322326

90°

98370044 98317202

93

Home

Print Fittings Book


End1

STR

90°

90°

Hydraulichose25barDN25x1250 HOSE LINE DN 25 1280 x

End2 Degree

STR

Part# 98317810

180°

STR

98341348 10199867


STR

STR


45°

90°

10308788


45°

STR

98319762


STR

STR

10153292


STR

STR

98364401


STR

45°

98375339


STR

STR

10°

98382016

HydraulichoseDN25/4X1300350 - BAR Hydraulichose25barDN25x1340

10309612

30347675 STR

60°

10300953

Hydraulichose 88barDN25/1SCx1350

STR

STR

98390412


STR

45°

10180864


STR

STR


90°

90°

STR

STR


10177020 180°

98326699 10154906


90°

STR

10214457


STR

90°

10308577


STR


STR

STR

10194996

90°

98393745

HydraulichoseDN25/4X1400-350BAR

30349285


STR

90°


90°

90°

HOSE LINE DN 25 1450 x

STR

98319736 10°

98324070 10199863


STR

45°

10191407


STR 90°

STR STR

98316310 10309844


90°

45°

160°

98343750


90°

90°

98352337


STR

45°

10209533

94

Home

Print Fittings Book


End1

End2 Degree

Part#


STR

STR

10140372


STR

STR

98383585


STR

STR

10118160


STR

45°

10195309


STR

STR

98366903

Hydraulichose 88barDN25/1SCx1600

STR

STR

98386855


45°

STR

98343749


STR

STR

10167628


90°

STR

10217421


STR

STR

10193332


STR

90°

10215808

STR

45°

HydraulichoseDN25/4X1600-350BAR Hydraulichose165barDN25/2STx1650

30358675


90°


STR

Hydraulichose110barDN25/1TPx1680 Hydraulichose25barDN25x1700

90° STR

90°

10209618 0°

90° 90° 90°

10307072 98375336

10°

98319761 98317200


STR

STR

10124716


STR

STR

98326266


STR

STR

98339580


STR

90°

98380705

STR

STR

HydraulichoseDN25/4X1800-350BAR Hydraulichose165barDN25/2STx1900

30349287 10303251


90°

STR

10207660


STR

90°

98317640


STR

STR

10199556

Hydraulichose88barDN25/1STx1900 Hydraulichose165barDN25/2STx2000

STR STR

90° STR

10162674 98353995


STR

STR

98317203


STR

STR

10195131


STR

STR

98386748

95

Home

Print Fittings Book


End1

End2 Degree


STR

STR


STR

STR

10197290

HydraulichoseDN25/4X2100-350BAR Hydraulichose25barDN25x2150 Hydraulichose165barDN25/2STx2200 Hydraulichose25barDN25x2200 Hydraulichose380barDN25/4SHx2200 Hydraulichose380barDN25/4SHx2300 Hydraulichose25barDN25x2350

Part# 98344033

30347677 90° STR STR STR STR STR

90°

0°

STR

10306479 98326265

90°

10209792

STR

98386466

STR

98382844

90°


STR

STR


90°

90°

98335364 98319825 90°

98385456


STR

STR

98318189


STR

STR

98345458


STR STR

STR STR

98365084 98319465


STR

STR

98328008


STR

45°

98364820

Hydraulichose380barDN25/4SHx2800 Hydraulichose17barDN25/1SPx3000 Hydraulichose380barDN25/4SHx3000

STR STR STR


STR

Hydraulichose25barDN25x3200 Hydraulichose25barDN25x3200 HydraulichoseDN25/4SHx3200

STR

STR STR STR

98393744 10143264 98339480

180°

98356785

STR

90°

10309708

STR

STR

98356714 10081241

3400 Hose xDN 25

98317287


STR

STR

10309709

Hydraulichose25barDN25x3900 Hydraulichose25barDN25x4000

STR STR

90° 90°

98318583 98319492


STR


STR


STR

96

STR 180°

98389281 98328009 10025192

Home

Print Fittings Book


End1


STR

Hydraulichose25barDN25x4800 Hydraulichose25barDN25x5200

End2 Degree

98324080

STR

90°

98324048

STR

STR

98359798

STR

STR

550 HOSE X6DN X 25 Hydraulichose25barDN25x5800

10011159

Hydraulichose350barDN25/4SHx6000 Hydraulichose380barDN25/4SHx12000 Hydraulichose88barDN25/1SCa=3.7m

Part#

STR

98318584 10025195

STR

STR

10214502 98383996

97

Home

Print

Home

Print Fittings Book

Hose 31 MaterialDescription Hydraulichose 45barDN31/3TEx 750

End1 STR

End2 Degree 180°

Part# 98388283


STR

90°

98392205


STR

90°

98389993

99

Home

Print

Home

Print Fittings Book


End1

End2 Degree

Part#

HOSEHIGHPRESSUREDN32MMX36'LG

30326096

HOSEHIGHPRESSUREDN32X44'LG

30323982

HOSEHIGHPRESSUREDN32MMX48'LG

30326097


STR

90°

200 HOSE X6DN X 32 Hydraulichose350barDN32/4SHx2200

90°

STR

300 HOSE X3DN X 32 Hydraulichose350barDN32/4SHx 340

10160808 10021822 113°

98393511

10027619 STR

STR

400 HOSE X6DN X 32

98393340 10025092

Hydraulichose350barDN32/4SHx4 00

STR

STR

98390345


STR

STR

10000191

Hydraulichose350barsDN32/4SHx 425

90°

STR

10310017


STR

STR

10200946


STR

STR

98316690


STR

STR

10000194


90°

STR


90°

90°

98351546 0°

10306495


STR

45°

10160807


STR

45°

10197722


STR

90°

10197724


0°

90°

98344488


STR

STR

10000195


STR

45°

10198913


STR

STR

98355063

Hydraulichose350barsDN32/4SHx600

98325396


STR

STR

98382857

Hydraulichose350barsDN32/4SHx 620 Hydraulichose325barDN32/4SHx 650

90° STR

90° 45°


STR

STR

10000197


STR

STR

98328517


STR

STR

98390345

0°

10306494 10196638

101

Home

Print Fittings Book


End1

End2 Degree


Part#

30380089


STR

45°

10211137


STR

STR

10000202


STR

90°

90°

10306496


STR

45°

10186988


STR

STR

10000207


90°

STR


90°

90°

STR

STR

90°

90°

STR

STR

Hydraulichose350barDN32/4SHx 780 Hydraulichose125barDN32/2SNx 800 Hydraulichose350barDN32/4SHx 800 Hydraulichose350barsDN32/4SHx 800

STR

90°

98316551 0°

10001128 90°

10215814 10000213

90°

Hydraulichose350barsDN32/4SHx800 HydraulichoseDN32/4SHx 800-MSHA+

10306456

10306498 98325398

STR

STR

98377763


STR

45°

98318100


STR

STR

98383683


STR

90°

10215809


STR

STR

98383683


STR

STR

10001131


STR

90°

90°

10309768

Hydraulichose125barDN32/2SNx 900

STR

90°

10210576


STR

STR

10176003


STR

STR

10000217


STR

90°

10205293


45°

STR

10205301

Hydraulichose350barLOBADN32/4SH-FLH-x 9 00 HydraulichoseDN32/4SHx 900-MSHA+ Hydraulichose350barDN32/4SHx 920

STR

STR

10036732

STR STR

STR 90°

98377764 10215810


STR

STR

10000220


STR

90°

10215811


90°

90°

102

0°

10215812

Home

Print Fittings Book

Hose 32 MaterialDescription Hydraulichose350barsDN32/4SHx 980 Hydraulichose350barsDN32/4SHx 990 Hydraulichose350barsDN32/4SHx 990

End1 STR 90°

End2 Degree 90°

90°

90°

210°

Part# 10309769 98316550

STR

45°

98318101


90°

STR

10205323


STR

STR

10143969


STR

45°

10201897


STR

STR

HydraulichoseDN32/4SHx1000-MSHA+

STR

10000226

STR

98383467


STR

45°

98344031


STR

STR

10165866


STR

45°

10184096


STR

STR

10000230


STR

90°

10215813


STR

STR

98382290


90°


STR

Hydraulichose325barDN32/4SHx1200 HydraulichoseDN32/4SHx1200-MSHA+ Hydraulichose350barDN32/4SHx1200

STR STR STR

STR

98292965

STR

10168193

45°

10183219

STR

98387499

STR

10000231


90°


STR

45°

98321262


STR

STR

98339506


STR

90°

10306460


STR

45°

10184097


45°

45°


STR

STR

10195313

Hydraulichose350barDN32/4SHx1300 Hydraulichose350barDN32/4SHx1300

STR STR

90° STR

10205294 98364461

HydraulichoseDN32/4SHx1300-MSHA+

STR

STR

STR

98392963

0°

10215853

98383468


STR

STR

10000232


STR

90°

10165867

103

Home

Print Fittings Book


End1

End2 Degree

Part#


90°

90°

10207843


STR

STR

98350899


90°

90°

10306547


STR

45°

10195312


STR

45°

10213684


STR

STR

10000233


STR

90°

98347356


STR

STR

10000234


STR

90°

HydraulichoseDN32/4X1500DEMO -

98347357 30328404


STR

STR

98378861


STR

45°

98384978


STR

STR

10000236

Hydraulichose350barLOBADN32/4SH-FLH-x1600

STR

STR

10037388


STR

90°

10307951


STR

45°

10209377


STR

STR

98378854


STR

45°

10215838


STR

STR

98339457


STR

90°

98343036


STR

STR

10308433


STR

STR

98324632


STR

STR

10154054


STR

90°

98347355


90°

STR

98318255


STR

90°

98343037

Hydraulichose350barDN32/4SHx2000 Hydraulichose350barDN32/4SHx2060

STR STR

STR 45°

10077214 98382819


STR

STR

10302761


STR

STR

98324633


STR

90°

10306461

104

Home

Print Fittings Book

Hose 32 MaterialDescription Hydraulichose350barDN32/4SHx2200

End1

End2 Degree

Part#

STR

STR

STR

STR

10306985


90°

STR

98330009


STR

STR

98318186


STR

STR

98345459


STR

STR

98326263


STR

STR

98382374


STR

STR

2300 xHose 2DN x32 Hydraulichose350barDN32/4SHx2300

10306090

HOSE 3000 X6DN X 32 Hydraulichose350barDN32/4SHx3000

98326264

98380872 10127165

STR

STR

HOSE 3500 X6DN X 32

10151306 10127166


STR

STR

10169630


STR

STR

98349932


STR

STR

10214499

105

Home

Print

Print

Home

Fittings Book

Torq ue Wrench Settings for Coated Fitting s Wrench Head Hose to fitng Fitng to Fitng Fitng to Block Banjo Size Nm / Ft Lbs Nm / Ft Lbs Nm / Ft Lbs Nm / Ft Lbs 1 7 mm

21 0 /5

1 9 mm

-

22 mm

430 /0

2 7 mm

-

30 mm

705 /2

640 /4 -

850 /9

12 08 /9

10 0/74 1 60/11 8

26 0/19 2

5 0 mm

2 10/15 5

40 0/29 5

19 0/14 0

3 00/22 1

-

L = 90 / 66 1 11/1 50 S = 115 / 85

4 6 mm

6 0 mm

-

755 /5

3 6 mm

5 5 mm

L = 35 / 26 S = 55 / 41

53 0 /7

-

-

-

-

45 0/33 2

-

395/84 0

-

44 0/32 5

-

Bulkhead Fitting Installation 1. 2. 3. 4. 5.

6.

Unscrew the nut. Apply Red Loctite 371 as described below. Insert the bulkhead lead-in into the hole. Manually screw on the lock nut. You can install the lock nut with a suitable torque wrench and the assembling torque applying to the respective union system. (see table) Install tting into the pipe joint and properly torque. Apply Red Loctite 271on front surfaces

Apply only a(one verydrop) smallon amount threadof adhesive

Fitting torque for bul Siz e

khead gl ands [ Nm]

Ser ie s [Nm] / [Ft lb s] Siz e Ser ie s [Nm] / [Ft lb s]

6

18/25

6

26/35

8

30/40

8

41/55

10

37 50 /

10

52 70 /

12

52 70 /

12

63 85 /

66 90 /

14

15 18

L

115 85 /

16

110 81 /

S

120 89 /

22

210 155 /

20

200 148 /

28

310 229 /

25

340 251 /

35

500 369 /

30

480 354 /

42

600 443 /

38

850 627 /

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Wrench and Coupling

for Fittings Table 1:Straight Fittings

Fitting/Tube Size 8mm 12mm 16mm 20mm 25mm 38mm

Capnut

Coupling Body 17mm 19mm 27mm 32mm 41mm 55mm

17mm 22mm 30mm 36mm 46mm 60mm

Am erican Cap Nut 11/16” 7/8” 3/16” 1 7/16” 1 13/16” 1 3/8” 2

American Coupl in g Body 11/16” 3/4” 1/16” 1 1/4” 1 5/8” 1 3/16” 2

Table 2:Banjo Fittings Fitting/Tube Size 8mm 12R-1/4mm 12R-1/4mm 16mm 20mm

Capnut

25mm 38mm

46mm 60mm

17mm 22mm 22mm 30mm 36mm

Couplin g End Cap Body 17mm 19mm 19mm 19mm 27mm 22mm 32mm 27mm 41mm 32mm 55mm --

41mm 55mm

Am eri can Cap Nut 11/16” 7/8” 7/8” 1-3/16” 1-7/16”

Am erican Coupl in g End Cap Body 11/16” 3/4” 3/4” 3/4” 1-1/16” 7/8” 1-1/4” 1-1/16” 1-5/8” 1-1/4”

113/16” 3/8” 2

2” --

Table 3: Fit tin g Size / Hose Size Fitting/TubeSize

HoseSize

8mm 10mm 12mm 16mm 20mm 22mm

6 8 8 13 16 16

25mm 30mm 38mm

20 25 32

1-5/8” 2-3/16”

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Fitting Assembly Instruction NS Style Prole - Dull Green Colored NOTE! The prole ring ttings are coated with a clear sliding agent which reduces friction and avoids the need to additionally oil the ttings components. In order to ensure positive assembly, ttings should always be pre-assembled using a spare mating tting. After pre-assembly, discharge the spare tting. In case of repair, direct assembly in the pre-assembly adapter is also possible

Direct Assembly 1.

Saw off the tube at right angles and debur it. Do not use a tube cutter, but a sawing machine, if possible. Lightly debur tube ends at inside and outside.

6990 01. ai

2.

Place the nut and prole ring on the tube as shown.

6990 02. ai

3.

Press tube into tting body up to tube abutment. tighten nut by hand.

6990 03. ai

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Fittings Book

4.

Tighten nut until ferrule grips tube which is felt by a noticeable increase in torque. Controlled Final Assembly Using MEG-R3 Tube OD

Series

Assembly Torque

[mm]

[mm]

6 8 10 12 15 18 22 28 35 42

6x1 8x1 10x1 12x1.5 15x1.5 18x1.5 22x2 28x2 35x3 42x3

50 / 37 7052 / 90 / 66 115 / 85 210 / 155 310 / 229 500/369 600 / 443

6x2 8x1.5 10x1.5 12x1.5 14x2 16x1.5 20x2 25x2.5 30x3 38x4

35 26 / 55 41 / 7052 / 8563 / 110 81 / 120 / 89 200/148 340 / 251 480/354 850/627

6 8 10 12 14 16 20 25 30 38

5.

Min. tube wall thickness

L

S

Pre-Assy. Force

[Nm] / [ft lb] (30º)

[kN]

25 / 18 40 30 /

1)

17 22 30 40 44 46 77 77 100 125 23 40 37 40 46 46 77 95 120 145

Final assembly by 1 turn. Important: Hold tting body rmly by means of a spanner. Application o f deviating numbers of tight ening turns reduces the nominal pressure rating and the life of the tting which causes leakages or displacement of the tube.

6990 05. ai

6.

Check penetration of cutting edge. A visible ring of material should ll the space in front of the prole ring end face. Prole ring may turn tube but should not be capable of axial displacement.

6990 03. ai

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STANDARD NEW PRODUCT WARRANTY Schwing America, Inc. (“Schwing”) warrants its new equipment against defects in material and workmanship under normal use and service, provided such equipment shall not have been subject to misuse, negligence or accident, for a period of twelve months from the date of purchase, or 2000 hours of use, whichever shall occur first. Schwing warrants new spare parts against defects in material and workmanship for a period of six months from the date of purchase. This warranty shall not apply to any equipment or spare parts which shall have been loaded or operated beyond their rated capacity as specified bySchwing. Damage resulting from improper installations, alterations or neglect of recommended maintenance will be considered as misuse andnot as a defect. Certain parts of the equipment, such as, butnot limited to, the pumping cylinders, pumping rams, concrete pump systems, mixer drums and chutes, are subject to normal wear. Normal wear is not covered under this warranty. Your Schwing equipment is designed tooperate with only Schwing OEM products.Use of nonSchwing OEM products voids any warranties provided by Schwing. Buyer’s SOLE AND EXCLUSIVE REMEDYfor breach of this warranty shall be replacement or repair, free of charge, of such part or parts as are determined to be defective, or repayment of the purchase price paid by Buyer, whichever such remedy Schwing shall select. To make a claim under this warranty, Buyer must, within ninety (90) days of discovery of the defect in material or workmanship, give written notice of the defect to Schwing and, if requested by Schwing, promptly deliver the equipment to Schwing, FOB Schwing warehouse. On boom units, structural components such as weldments provided by Schwing are warranted against defects in materials and workmanship for aperiod of ten years from the date of purchase, provided structural inspections have been conducted and necessary repairs have been made in accordance with the American National Standard, ASME 830.27, Material Placement Systems, and such inspections and repairs have been properly documented. If such inspections have not been conducted and necessary repairs made,this warranty is void. Buyer’sSOLE AND EXCLUSIVEREMEDY for breach of this warranty shall be repair or replacement of any components found to be defective, whichever such remedy Schwing should select, but Buyer shall be responsible for the cost of any replaced components at Schwing’s current published list prices and for the labor charged by a Schwing authorized servicer to repair or replace the components, based upon a fraction, the numerator of which is the number of years since the date of purchase of the equipment, and the denominator of which is ten (10). SCHWING SHALL HAVE NO LIABILITY TO THE BUYER OF SUCH EQUIPMENT OR SPARE PARTS OR OTHER PERSON FOR INCIDENTAL DAMAGES, SPECIAL DAMAGES, CONSEQUENTIAL DAMAGES OR OTHER DAMAGES OF ANY KIND OR NATURE WHATSOEVER, WHETHER ARISING OUT OF BREACH OF WARRANTY OR OTHER BREACH OF CONTRACT, NEGLIGENCE, STRICT LIABILITY OR OTHER TORT, OR OTHERWISE, EVEN IF SCHWING SHALL HAVE BEEN ADVISED OF THE POSSIBILITY OR LIKELIHOOD OF SUCH POTENTIAL LOSS OR DAMAGE.For purposes hereof, the term “consequential damages” shall include lost profits,

penalties, delay damages, liquidated damages or other damages and liabilities which the Buyer shall be obligated to pay or wh ich the Buyer may incur based upon, related to or arising out of its contracts with its customers or other third parties. In no event shall Schwing be liable for any amount of damages in excess of the amounts paid by the Buyer for goods or services as to which a breach of warranty or contract has been determined to exist. The parties expressly agree that the price for goods and the services was determined in consideration of the limitation on damages set forth herein and such limitation has been specifically bargained for and constitutes an agreed allocation of risk which shall survive the determination of any court of competent jurisdiction that any remedy herein fails of its essential purpose. Schwing reserves the right to make changes and improvements in its product without incurring any obligation to install any such changes or improvements in its products previously manufactured. Schwing makes no warranty of components or accessory equipment purchased by Schwing from third parties, such as, but not limited to, truck chassis, engines, transmissions, gear cases, tires, wheels and tools, the same being subject to the warranties of their respective manufacturers. Except as provided herein, and in Schwing’s General Terms and Conditions of Sale, which are incorporated herein by reference, SCHWING MAKES NO OTHER REPRESENTATIONS OR WARRANTIES, EXPRESS OR IMPLIED, WITH RESPECT TO NEW EQUIPMENT OR SPARE PARTS, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. 4968873v3 11/201

SCHWING AMERICA, INC

SCHWING-CONCRETE-PUMP-MANUALS.pdf

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