SCHWING TrainingManual

SERVICE TRAINING

TRAINING MANUAL

Copyright All rights reserved. The information and drawings contained herein must not be duplicated, used improperly, or communicated to third parties without the consent of Schwing America Inc. All Information is subject to revision 5900 Centerville Road White Bear, MN 55127 TEL 651-429-0999 FAX 651-429-2112 www.schwing.com

SCHWING SERVICE DEPARTMENT (651) 429-0999 OR

1-888-292-0262 OR

FAX (651) 429-2112 8:00 A.M. TO 5:00 P.M. (Central Time) (MONDAY THROUGH FRIDAY)

SCHWING PARTS DEPARTMENT 1-800-328-9635 OR

FAX (651) 429-2112 6:00 A.M. - 9:00 P.M. (Central Time) (MONDAY THROUGH FRIDAY)

24 Hour Service Hotline 1-888-292-0262 (MONDAY THROUGH SATURDAY)

Branches Florida............................................................. 1-813-985-8311 Northern California........................................ 1-925-371-8595 Southern California ....................................... 1-562-493-1012 Georgia ........................................................... 1-678-560-9801 Texas .............................................................. 1-972-245-5166

SERVICE TRAINING

Table of Contents

Typical Twin Circuit ........................ 1

Typical Boom Circuit .................... 16

PTO Switch/Air Valve ..................................................1 PTO ...............................................................................2 Continuous Duty Solenoid ............................................2 CPC/CPCII Controller ..................................................3 Hydraulic Pumps ...........................................................3 Fixed Displacement ......................................................4 Variable Displacement ..................................................4 Main Control Block “Brain” .........................................4 Concrete Pump Forward/Reverse Valve .......................5 Main Control Block - S1/S2 Spool ...............................5 Main Relief Valve .........................................................6 Differential Cylinders ...................................................6 Material Cylinders ........................................................7 Differential Cylinder - Bottomed Out ...........................7 MPS Valve ....................................................................8 S3/Accumulator Control Block .....................................8 Accumulator Theory .....................................................9 Rock Valve Slewing Cylinder ......................................9 Soft Switch Relief Valve ............................................10 Main Control Block - S2 Spool ..................................10 Differential Cylinder - Beginning of stroke ................11 MPS ............................................................................11 Differential Cylinder - Bottomed Out .........................12 MPS ............................................................................12 S3/Accumulator Control Block ...................................13 Rock Valve Slewing Cylinder ....................................13 Soft Switch Relief Valve ............................................14 Main Control Block - S2 Spool ..................................14 Differential Cylinders .................................................15

Boom Pump ................................................................16 E-Stop Manifold .........................................................17 Poppet Valve Theory ..................................................17 E-Stop - Override .......................................................18 Boom Handvalve - No functions activated ................18 Boom Handvalve - Outrigger enabled ........................19 Outrigger Handvalve ..................................................19 Boom Handvalve - Boom Function Activated ...........20 Pulsar Coil Theory ......................................................20 Boom Holding Valves ................................................21 Manual Controls and Overrides ..................................21

Training Manual

Table of Contents

SERVICE TRAINING

Service Manual

SERVICE TRAINING

Typical Twin Circuit Main Control Block Main Relief/Soft Switch

MPS Valve

Differential Cylinders S3/Accumulator Valve Rock Valve Slewing Cylinder

Accumulator Pump Boom Pump

Rock Valve

PTO Material Cylinders

Hydraulic Pumps

PTO Switch/Air Valve Air Pressure Switch

Air Pressure Switch (Energized) To:PTO

• Switch pushed “in”, air supply blocked by spool. • Switch pulled “out” , opening is created allowing air pressure to energize the air pressure switch. • A passage way is created allowing air pressure to be sent to the PTO.

Air blocked by spool PULL TO APPLY

PARKING BRAKE PUSH TO RELEASE

QUARTZ 00000.1

1 HOURS

From:Truck Air Supply

PTO switch Must be pulled

Training Manual

Power to fuse

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SERVICE TRAINING

PTO • Air is routed to the small cylinder mounted in the distribution gear case (PTO). • When the cylinder is pushed “in” the PTO is in the pumping position. • When the cylinder is pushed “out” the PTO is in the travel position. Air Supply Block

To:12v Controller

PTO.eps

Fork

All hydraulic pumps for the concrete pump, placing boom, agitator, etc. are mounted on a distribution gearcase. When you are driving the truck, the power of the truck engine is transmitted through the truck transmission, through a propeller shaft, through the bottom of the distribution gearcase, through another propeller shaft, and into the rear end(s) of the truck. When you are operating the unit, the distribution gearcase interrupts the power to the rear ends, and transmits it to internal gears that turn the hydraulic pumps. Changing between travel and pumping modes is accomplished by means of an air switch in the truck cab.

Continuous Duty Solenoid • Electric signal from Air Switch enters Continuous Duty Solenoid

CPC/CPC II Style (Not used on Vector units)

• The signal energizes the magnetic coil in the Continuous Duty Solenoid • The energized magnetic coil, pulls the plunger “down” To: Controller

• A connection is established between the 12 volt power supply and CPC Controller

Plunger

Magnetic Coil

From: 12v Power Supply

Cont_Solenoid.eps

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SERVICE TRAINING

CPC/CPCII Controller The CPC/CPC II provides a proportional signal to each of the boom functions and the concrete pump output. It also controls all on/off functions on the unit. The CPC/CPC II receives power via the PTO switch through the Continuos duty solenoid and into the “Power” connector.

CPC/CPC II POWER REAR CTR UMB CTR RADIO CTR ID LINK ALARM E-STOP

WHEN WELDING ANYWHERE ON UNIT POWER CABLE MUST BE DISCONNECTED

L1357-01

Vector Controller

“Power” Connector

The Vector control system is a completely digital control system, which means that the function movements are converted to numbers (0’s and 1’s). The numbers are sent to the controller where they are analyzed, converted back to analog (voltage or current), and sent to the valves and indication devices.

Vector

1

OK

2

OFF

x1000 3 0 PTO 1500 rpm 62˚C

Menu: [ENTER]=ON

HOME

+

HELP

START

CLEAR

-

ENTER

QUIT

X12 Connector (Behind)

Hydraulic Pumps Typical Gearbox To: Main Control Block

To: Boom Control Block

Pumpkit Pumps

s .ep ps um licP u dra To: Hy

The hydraulic pumps for the concrete pump circuit are bent axis, variable displacement piston pumps. They are horsepower controlled, which means that as pressure rises towards maximum, the flow can decrease, so the power consumption remains constant. We use this type of pump so the truck 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 of these devices is to tell the pump to put out less oil per revolution, as required by the pump operator.

To: S3 Accumulator Agitator To: Oil Cooler

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SERVICE TRAINING

Fixed Displacement Puts out a set amount of oil, that can only be changed by increasing/decreasing the RPMs. Fixed Dispalcement Bent Axis

Variable Displacement Variable or Positive displacement pumps deliver to the system, a variable amount of oil according to the angle for the rotary group or swash plate.

min

max

min

Variable Displacement Bent Axis

max

Variable Displacement Swash Plate PumpCutaways.eps

Main Control Block “Brain” • Oil from hydraulic pumps enter the “P1” and “P2” ports of the Main Control Block. • S1 spool is in the neutral position From: Pumps

• Hydraulic oil will flow through the Main Control Block and go back to the hydraulic tank.

To: Tank

To: Tank

S1 Spool

From: Pump From: Pump S2 Spool

HiFlowBrain.eps

S1 - Neutral Position, pathway block

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Training Manual

SERVICE TRAINING

Concrete Pump Forward/Reverse Valve

A

B

To: Main Control Block/MPS Valve “P2” Vent T

Blocked pathway (Neutral)

A B

From: Pump

• In the “forward” position, a passage way is created between the pressure port and the “A” port, through grooves in the spool.

P

• Oil is sent to the “XP” port of the Main Hydraulic Control Block and the “XB” port of the MPS valve.

To: Main Control Block (XP port) and MPS Valve (XB port) A

The Concrete Pump Forward/Reversing valve is a simple control device, containing a 3 position, 6 way spool attached to a handle. The valve receives hydraulic oil from the Accumulator pump. • In the neutral position, the passage way for the hydraulic oil is blocked and will return to tank.

B

• This valve also plugs the vent line, which allows pressure to build in the system

Passageway created (Forward position)

Main Control Block - S1/S2 Spool • With hydraulic pressure on the “XP” side of the spool and no pressure on the “XR” side, the S1 spool will move into the “Forward” position.

S1 - Forward Position, pathway to S2 spool created

• Passage way created for the hydraulic oil from the Main Hydraulic Pumps to move past the S1 spool and unto the S2 spool. • Passage way created for the hydraulic oil moving past the S2 spool and unto the Differential Cylinder.

S1 Spool

“XP”

“XR”

From: CP Forward/Reverse Valve From: Pump

S2 Spool

From: Pump

HiFlowBrain_S1.eps

Pathway to Differential cylinder To: Differential Cylinder

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SERVICE TRAINING

Main Relief Valve The main relief valve protects the hydraulic circuit, by relieving pressure before it reaches 350 bar or greater. • Pressure exceeds 350 bar and presses against the 350 bar main relief valve plunger.

80 bar 350 bar

• The 350 bar relief valve spring will collapse, creating a passage way for the oil to bleed to tank. This creates a pressure drop in the poppet spring chamber. Less than relief pressure

Over relief pressure

• Pressure is greater on the piston side of the poppet than the spring side. This will collapse the poppet spring allowing the poppet to open. • With the poppet opened, a passage way is created, allowing oil to escape to tank until 350 bar pressure or lower is achieved.

Poppet opens

Excess oil drained to tank

Differential Cylinders

Loop Oil

To:MPS ZK2 To:MPS ZK1 High pressure oil

The term differential cylinder means that each hydraulic cylinder that pushes the concrete has an area difference (referred to as an “area differential”) between the two sides of the piston. This area differential exists because the rod extends only from one side of the piston. This is in contrast to the rock valve slewing cylinder, for example, which has a rod extending from both ends of the piston and therefore has the same area on both sides of the piston (it is a nondifferential cylinder). • Hydraulic oil from the Main Control Block flows to the rod side of the left hand differential cylinder. • The pressure from the hydraulic oil extends the rod of the left hand differential cylinder.

From: Pumps To:MPS ZS1 To:MPS ZS2 From: Pumps

6

DiffCylinders.eps

• Loop oil on the piston side of the left hand differential cylinder crosses over to piston side of the right hand differential cylinder, causing that rod to retract.

Training Manual

SERVICE TRAINING

Material Cylinders The material cylinders contain rubber rams that are connected to the differential cylinder rods. One side will push the concrete through the Rock valve while the opposite side will suck concrete from the hopper. Concrete “pushed” through Rock Valve

Concrete “sucked in” from hopper

MatCylinders.e

Differential Cylinder - Bottomed Out • Left-hand differential cylinder bottoms out. • Signal lines connected to the “ZK1”,“ZK2”, “ZS1” and “ZS2” ports of the MPS valve.

To:MPS ZK2 To:MPS ZK1

From: Pumps To:MPS ZS1 To:MPS ZS2 From: Pumps

DiffCylinders_Bottom.ep

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SERVICE TRAINING

MPS Valve

X3

To: Soft Switch Reversing Valve To: S3 Spool

A

B

XB

XA

ZS1

ZS2

ZK1

ZK2

The MPS system consists of three small directional control valves. The main pressure that is supplied to these directional control valve is supplied by the accumulator. • A high pressure signal line from the Differential Cylinder enters the MPS valve through the “ZK2” port. • This moves the NG 6 directional valve over creating a passage way for the Accumulator oil to flow through MPS valve and out the “A” and “X3” port. From: Differential Cyl.

From: Differential Cylinder

T

SP

Passage way created To:S3 Spool From: Accumulator Pump

From: Differential Cyl. From: Accumulator Pump

S3/Accumulator Control Block • Hydraulic oil from the MPS valve “A” port enters the “XA” port of the S3/Accumulator Control Block. To: Rock valve slewing cylinder and S2 spool

• The S3 spool moves to the “left”.

From: MPS valve "B" port

• A passage way is created for accumulator oil to travel to the Rock valve Slewing Cylinder and S2 spool in the Main Control Block.

From: MPS valve "A" port To: Rock valve slewing cylinder To: S2 spool Manual Bleed

S3_Block02.eps From: Accumulator Pump From: Accumulator Pump

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SERVICE TRAINING

Accumulator Theory

Without Nitrogen Charge

With nitrogen charged to pressure P1

Influx of hydraulic oil for storage

The accumulator can be considered an energy storage device for hydraulics, similar to the function of a battery in an electrical circuit. The accumulator stores the oil flow of a small hydraulic pump until it is time to shift the Rock Valve. When needed all of the oil that as been stored in the accumulator is quickly released. This has the following benefits: • Lower power requirements for switching the RockValve (less horsepower taken from the engine). • Simpler switching to begin the next stroke (the differential cylinders get the signal to change direction as soon as the S3 spool moves, regardless if the Rock Valve has moved or not).

Fluid charged to maximum working pressure P3

Discharge of hydraulic oil

Fluid discharged down to minimum working pressure P2 AccumulatorTheory.eps

Rock Valve Slewing Cylinder From: S3/Accumulator Control Block

From: S3/Accumulator Control Block

The rock valve slewing cylinder is a nondifferential cylinder (see Differential Cylinder). The switching grooves are used in single-circuit machines, but not in twin-circuit machines. • A working line from the “A” port of the S3/ Accumulator Control Block enters the rear of the Rock Valve Slewing cylinder • This pushes the rod over, thus “switching” the rock valve.

RockSlewingCylinder.eps

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SERVICE TRAINING

Soft Switch Relief Valve Signal from MPS Valve X3

X3

80 bar

80 bar

350 bar

350 bar

When the Rock Valve is shifting, a signal line enters the “X3” port of the Main Control Block • The Soft Switch Reversing Valve is opened, creating a passageway to the 80 bar relief valve. • Pressure exceeds 80 bar and presses against the 80 bar Soft Switch relief valve plunger. • The 80 bar relief valve spring will collapse, creating a passage way for the oil to bleed to tank. This creates a pressure drop in the poppet spring chamber.

X3

X3

80 bar

80 bar

350 bar

350 bar


Path open to tank

Main Control Block - S2 Spool • Signal line from the MPS valve enters the “XB” port of the Main Control Block • S2 spool moves to the ‘right” • A passage way is created for oil to travel to the Differential Cylinder. From: CP Forward/Reverse Valve S1 Spool

From: Pump

From: Pump S2 Spool

“XB”

“XA”

From: Accumulator Control Block

HiFlowBrain_S2.eps

Pathway to Differential cylinder

10

Training Manual

To: Differential Cylinder

SERVICE TRAINING

Differential Cylinder - Beginning of stroke Loop Oil

• Hydraulic oil from the Main Control Block flows to the rod side of the right-hand differential cylinder. • The pressure from the hydraulic oil extends the rod of the right-hand differential cylinder.

pressure oil

To:MPS ZK2

• Loop oil on the piston side of the right-hand differential cylinder crosses over to piston side of the left hand differential cylinder, causing that rod to retract.

To:MPS ZK1

From Pumps To:MPS ZS1 To:MPS ZS2 DiffCylinders_NewStroke.eps

From Pumps

MPS

X3

• A high pressure signal line from the Differential Cylinder is sent to the “ZK1” port of the MPS valve.

B

• Pressure is greater on the “ZK1” side of the NG 6 spool than the “ZK2” side.

Signal lost

A

• The NG 6 spool will move to the “right” closing the passage way for high pressure accumulator oil.

XB

XA

ZS1

ZS2

ZK1

ZK2

SP

From: Differential Cyl.

T

Passage way closed

From: Differential Cyl. From: Accumulator Pump

From: Accumulator Pump

Training Manual

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SERVICE TRAINING

Differential Cylinder - Bottomed Out • The Differential cylinder has reached the bottom of the last stroke. • High pressure signal line are sent to the “ZK1”, “ZK2”, “ZS1” and “ZS2” ports of the MPS valve.

To:MPS ZK2 To:MPS ZK1

From Pumps To:MPS ZS1 To:MPS ZS2 DiffCylinders_03.eps

From Pumps

MPS X3

To: Soft Switch Reversing Valve B

A

To: S3 Spool

XB

XA

ZS1

ZS2

• A high pressure signal line from the Differential Cylinder enters the MPS valve through the “ZS2” port. • This moves the NG 6 directional valve over creating a passage way for the Accumulator oil to flow through MPS valve and out the “B” port and unto the S3 spool. • Accumulator oil also travels out the “X3” port and unto the Soft Switch Reversing Valve.

From: Differential Cylinder To:Soft Switch Reversing Valve To:S3 Spool

ZK2

ZK1

From:Differential Cylinder

SP

T

Passage way created


From:Differential Cylinder


12

Training Manual

SERVICE TRAINING

S3/Accumulator Control Block To: Rock valve slewing cylinder and Main Control Block From: MPS valve "A" port

• Hydraulic oil from the MPS valve “B” port enters the “XB” port of the S3/Accumulator Control Block. • The S3 spool moves to the “left”.

A

• A passage way is created for accumulator oil to travel to the Rock valve Slewing Cylinder and S2 spool in the Main Control Block.

B

S3_Block.eps

To: Rock valve slewing cylinder Manual Bleed

To: S2 spool From: MPS valve "A" port



Rock Valve Slewing Cylinder • A working line from the “B” port of the S3/ Accumulator Control Block enters the front of the Rock Valve Slewing cylinder

From: S3/Accumulator Control Block

• This pushes the rod over, thus “switching” the rock valve. From: S3/Accumulator Control Block

Training Manual

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SERVICE TRAINING

Soft Switch Relief Valve Signal from MPS Valve X3

X3

80 bar

80 bar

350 bar

350 bar

When the Rock Valve is shifting, a signal line enters the “X3” port of the Main Control Block • The Soft Switch Reversing Valve is opened, creating a passageway to the 80 bar relief valve. • Pressure exceeds 80 bar and presses against the 80 bar Soft Switch relief valve plunger. • The 80 bar relief valve spring will collapse, creating a passage way for the oil to bleed to tank. This creates a pressure drop in the poppet spring chamber.

X3

X3

80 bar

80 bar

350 bar

350 bar


Path open to tank

Main Control Block - S2 Spool • Signal line from the MPS valve enters the “XA” port of the Main Control Block • S2 spool moves to the “left” • A passage way is created for oil to travel to the Differential Cylinder.

S1 Spool

From: CP Forward/Reverse Valve From: Pump

From: Pump

S2 Spool

To: Differential Cylinder

HiFlowBrain_S2.eps

From: Accumulator Control Block

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Training Manual

SERVICE TRAINING

Differential Cylinders • Hydraulic oil from the Main Control Block flows to the rod side of the left hand differential cylinder. • The pressure from the hydraulic oil extends the rod of the left hand differential cylinder. • Loop oil on the piston side of the left hand differential cylinder crosses over to piston side of the right hand differential cylinder, causing that rod to retract.

From Pumps

From Pumps

DiffCylinders_04.eps

Training Manual

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SERVICE TRAINING

Typical Boom Circuit Boom Cylinder

To:Outrigger Function Outrigger Handvalve

Boom Pump

1 PM

P1

P4

T

T

M

P3 P2

Boom Handvalve Estop Manifold

Boom Pump To: Boom Control Block

To: Main Control Block

The hydraulic pump for the placing boom is a variable displacement, bent axis, axial piston pump. It feeds all of the following components: • the hydraulic cylinders on the boom sections • the hydraulic cylinders on the outriggers • the hydraulic motor for the boom slewing gear

Boom Pump

• the hydraulic motor for the water pump • the hydraulic motor of the compressor (optional equipment)

dra Hy

s .ep 02 s_ mp u P ulic

To: S3 Accumulator

To: Agitator To: Oil Cooler

Training Manual

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SERVICE TRAINING

E-Stop Manifold • Hydraulic oil from the boom pump enters the E-stop Manifold from the “P1” port.

P2 T

T P4

P3

Equal Pressure Poppet Closed

P1

Energized Solenoid

• If the solenoid is not energized, a passage way will be created for the signal line to go to tank.

Signal Line from P1 port

• This will create a pressure drop on the spring side of the poppet valve.

P2 T

T P3

• With the solenoid energized, a signal line from the “P1” port enters the spring side of the poppet valve. This will equalize the pressure on both sides of the poppet. The pressure plus spring tension will hold the poppet closed.

Greater Pressure Poppet Opened

P4 P1

De-energized Solenoid

• Pressure from the P1 port will overtake the spring tension, allowing the poppet to open. • A passage way is created for the oil from the “P1” port to escape to tank.

Passage way to tank

Poppet Valve Theory 1

Pressure “A” = “B”

2

Pressure “A”

Pressure “A”

Pressure “B” + Spring

3

Pressure “A” > “B”

Pressure “A” > “B”


4

1. Pressure “A” and “B” are equal. With ‘B” pressure, plus the spring, Pressure “A” is not great enough to open the poppet. 2. If pressure “A” is greater than pressure “B” plus the spring tension, pressure “A” will collapse the spring, lower the poppet. 3. With the poppet lowered, a path for excess pressure is created and flows back to tank. 4. When pressure ‘B” is greater or equal to pressure “A” the spring will expand, closing the pathway to tank.

Pressure “A” = “B”

Housing

Pressure “A” Poppet Pathway to Tank (open)


Pathway to Tank (closed)

Spring


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SERVICE TRAINING

E-Stop - Override Concrete pump, agitator, accumulator dump valve

Override buttons MP

S

Boom/outrigger circuit dump valve

T MP

S

P3

P2

Agitator system plumbing

P4

P1

Concrete pump system plumbing

• Turn the bypass key switch to “Bypass” position. If control is not restored, there probably a hydraulic problem; Proceed to the next step. • To manually bypass each system, the inlet plumbing to the nonworking system must be plumbed out of the manifold. • With the engine stopped, disconnect the plumbing for the nonworking system at the appropriate fitting

Boom/outrigger system plumbing

Accumulator system plumbing

BY-PASS NORM. BY-PASS

by-pass2.eps

Boom Handvalve - No functions activated • Oil enters the Boom Handvalve from the “P” port.

Blocked passage way

C2

C1

Apitech_Side_03.eps

From: Pump

From: Boom Pump

18

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SERVICE TRAINING

Boom Handvalve - Outrigger enabled • Outrigger push button is depressed • Pulsar coil is activated • Spool moves, creating a passage way for the oil to exit out of the “C2” port and unto the outrigger hand valve.

To: Outrigger Handvalve To: Outrigger Handvalve

Apitech_Side_02.eps

Solenoid Energized Passage open

From: Boom Pump

Outrigger Handvalve

A

B

The Outrigger hand valve is a simple control device, containing four - 3 position, 6 way spools attached to handles. The valve receives hydraulic oil from the Boom Handvalve. • In the neutral position, the passage way for the hydraulic oil is blocked • In the “extend” position, a passage way is created between the pressure port and the “A” port of the Outrigger hand valve.

To: Outrigger Function

A

• This will send oil to whatever outrigger function has been activated. Example “Outrigger Extend”.

B

Training Manual

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SERVICE TRAINING

Boom Handvalve - Boom Function Activated • Either the pulsar coil or handle are activated • A passage way is created for the oil to be sent to whatever boom function has been activated.

Blocked passage way

To: Boom Function From: Pump

Passage open

Apitech_Side_01.eps

From: Boom Pump

Pulsar Coil Theory Coil Control Oil to Spool

Control Disk

As the control disk pulses “on” and “off”, pretension oil is allowed to flow from the pressure passage to the tank passage. Since the top orifice is larger than the bottom orifice, eventually more oil will be in the tank passage than can leave through the 0.024 orifice. At this point, pressure will build in the main spool control port and move the main spool. The longer the “on” time, the greater the pressure in the control port, and the further the main spool is moved, causing the boom to go faster.

0.040 Orifice Pilot Pressure

20

Training Manual

SERVICE TRAINING

Boom Holding Valves Passage way for rod side oil (to tank)

Passage way for piston side oil

Two hydraulically unlockable check valves (H.E.R. valves, or holding valves) on each boom cylinder prevent the boom from coming down unintentionally

LINE B LINE A

From:Boom Handvalve

Passage way closed. Oil trapped, cylinder held in place

LINE B LINE A

Manual Controls and Overrides 000419.eps

1

2

3

4

5

6

7

10 11

AGITATOR

CONCRETE PUMP

Boom 1

Boom 2

Boom 3

Boom 4

Boom 1 Telescope

Slewing Boom / Outrigger

Water / Compressor

10189517

DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).

1

3

4

WARNING Do not operate this machine without training. Understand the warnings in safety manuals and on decals.

2

WARNING Clear area before activating outriggers

REAR EXTEND

REAR JACKING

FRONT JACKING

FRONT EXTEND

8 12

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

E-stop Boom #1 Control Handle Boom #2 Control Handle Boom #3 Control Handle Boom #4 Control Handle Boom Telescope Handle Boom Slewing Control Handle Water Pump/Air Compressor Handle Water Pump System Change-Over Valve Concrete Pump Handle Agitator Handle Two Position Boom/Outrigger Handle.

9

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SERVICE TRAINING

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Training Manual

SERVICE TRAINING The Schwing Group ............................................................ 1 Schwing America, Inc. ................................................. 1

Hydraulic Training General Principles ............................................................... 3 Mechanical Versus Hydraulic ............................................. 7 Transfer of Energy .............................................................. 7 Hydraulic Jack ..................................................................... 8 Linear & Rotary Actuators .................................................. 8 Basic Hydraulic Components .............................................. 9 Check Valve Comparison ................................................. 10 Shuttle Valve ..................................................................... 11 Throttle Check Valve ........................................................ 12 Switching Valves .............................................................. 13 Hydraulic Pumps ............................................................... 14 Placing boom hydraulic pumps .................................. 14 Concrete pump hydraulic pumps ............................... 14 Fixed Displacement Pump ................................................ 15 Rexroth A2F20 ........................................................... 15 Variable Displacement Pump ............................................ 15 Rexroth A7VO ........................................................... 15 Variable Displacement Axial Piston Pump ....................... 16 RexrothA10VO .......................................................... 16 RexrothA11VO .......................................................... 16 Rexroth A11VO Adjustments .................................... 17 Transfer Cases ................................................................... 18 Relief Valves ..................................................................... 19 Safety Relief Valves .......................................................... 20 Pressure Relief Valve Type DB ................................. 20 Pressure Relief Valves Type DBW ............................ 20 Hydraulic Symbols ............................................................ 21 Hydraulic Symbols (Cont.) ............................................... 22 Hydraulic Symbols (Cont.) ............................................... 23 Hydraulic Symbols (Cont.) ............................................... 24 Hydraulic Symbols (Cont.) ............................................... 25 Hydraulic Symbols (Cont.) ............................................... 26 Hydraulic Symbols (Cont.) ............................................... 27 Formulas ............................................................................ 28

Pumpkits 800 Gate Valve .................................................................. 30 801 Gate Valve .................................................................. 31 801 Pumpkit Schematic ............................................. 32 Concrete Pump Control Block ................................... 33 Stroke Limiter ............................................................ 34

Table of Contents

494 Block ....................................................................34 Hydraulically Unlockable CheckValve ......................35 Gate Valve ..................................................................35 900-1200 Single Circuit .....................................................37 900-1200 Single Circuit Schematic ............................38 Concrete Pump Control Block ....................................39 Stroke Limiter .............................................................40 494 Block ....................................................................40 Switching Valve .........................................................41 A7VO .........................................................................41 Rock Valve .................................................................42 Phase A .......................................................................44 Phase B .......................................................................45 Phase C .......................................................................46 Phase D .......................................................................47 Phase E .......................................................................48 Phase F ........................................................................49 Phase G .......................................................................50 Phase H .......................................................................51 Phase I ........................................................................52 Phase J ........................................................................53 Phase K .......................................................................54 Troubleshooting .................................................................55 High-Flow Single Circuit 2020/2023 ................................61 High-Flow Single Circuit Schematic ..........................62 Concrete Pump Control Block ....................................63 Switching Manifold ....................................................64 Stroke Limiter with Fast Switch/Dampner .................64 Phase A .......................................................................66 Phase B .......................................................................68 Phase C .......................................................................70 Phase D .......................................................................72 Twin Circuits .....................................................................74 1200 Twin Circuit with Switching Valves ........................75 Twin Circuit Schematic w/Soft Switch ......................76 Concrete Pump Control Block ....................................77 S3 Control Block ........................................................77 Soft Switch .................................................................78 Accumulator Unloader Valve .....................................78 Accumulator Control Block/Dump Valve ..................79 Phase A .......................................................................80 Phase B .......................................................................82 Phase C .......................................................................84 Phase D .......................................................................86 1200 Twin Circuit with MPS .............................................89 Twin Circuit with MPS/Soft Switch ...........................90 Concrete Pump Control Block ....................................91 S3 Control Block ........................................................91 MPS ............................................................................92 Accumulator Control Block/Dump Valve ..................93 Soft Switch .................................................................94 Phase A .......................................................................96

Training Manual

Table of Contents Phase B .......................................................................98 Phase C .....................................................................100 Phase D .....................................................................102 Twin Circuit with Variable displacement accumulator pump Schematic 104 Model Number Nomenclature .........................................105 Hi-Flow Pumpkits (2023-2525) ......................................106 Hi-Flow Pumpkits (2525H) .............................................107 Hi-Flow Pumpkits Schematic ...................................108 Concrete Pump Control Block .................................109 Main Relief/Soft Switch Block ................................110 MPS ..........................................................................111 S3 Control Block - Machined ...................................112 S3 Control Block - Cast ...........................................113 2023 Circuit diagram ................................................114 Phase A .....................................................................114 Phase B .....................................................................116 Phase C .....................................................................118 Phase D .....................................................................120

Booms Black & White .................................................................123 Electric/Air/Oil .........................................................123 Electric/Oil/Oil .........................................................123 Proportional .....................................................................125 Boom Holding Valves .....................................................126 28X B&W Boom .............................................................127 Load Sense Hydraulic Circuits ........................................131 Overview ..................................................................131 Components ..............................................................132 Basic Principles - Simple Circuit .............................133 Basic Principles - Orifice .........................................134 Basic Principles - Without Relief Valve ..................135 Basic Principles - With Relief Valve .......................136 Basic Principles - Delta-P ........................................137 Basic Principles - Delta-P ........................................138 Basic Principles - Pressure Cut-Off .........................139 Basic Principles - Shuttle Valves .............................140 Basic Principles - Pressure Regulator ......................141 A7 Variable Displacement Hydraulic Pump Training ....142 All Functions in Neutral ...........................................142 Cylinder Extend Function Initiated ..........................144 Hydraulic Cylinder Extending .................................146 Hydraulic Cylinder Fully Extended Pump ...............148 Fixed Displacement Pump Training ................................150 All Function in Neutral ............................................150 Boom Function Activated ........................................151 Cylinder Pressurized at the End of Stroke ...............152 Output Charts ...................................................................153 Using the Chart ................................................................154

Using a Nomograph ........................................................ 159 General information ................................................. 159 The quadrants ........................................................... 161 Minimum Pipe Wall Thickness ....................................... 167 Preventative Maintenance ............................................... 168 Scheduled Maintenance ........................................... 168 Filtration .......................................................................... 170 General information ................................................. 170 Specific information ................................................. 170 Changing hydraulic oil filters .................................. 170 Changing high pressure water filter ......................... 171 Hydraulic Oils ................................................................. 171 General information ................................................. 171 Specific information ................................................. 172 When to change your hydraulic oil .......................... 172

Electrical Introduction ..................................................................... 173 What is Electricity? ......................................................... 173 Amperage ........................................................................ 176 Voltage ............................................................................ 177 Resistance ........................................................................ 177 Basic Circuits .................................................................. 179 Schematics ...................................................................... 181 Circuit Types ................................................................... 181 Ohm’s Law ...................................................................... 183 Series Circuit Laws ......................................................... 185 Parallel Circuit Laws ....................................................... 186 Series – Parallel Circuits ................................................. 188 Circuit Faults ................................................................... 189 Using Test Equipment ..................................................... 190 The Troubleshooting Process ................................... 195 Electrical Symbols .......................................................... 196 Electrical Symbols .......................................................... 197 Electrical Symbols .......................................................... 198 Controller Systems .......................................................... 199 Analog ...................................................................... 199 Digi-Prop (Microwave) ............................................ 199 Comfort Control ....................................................... 199 C32 ........................................................................... 200 CPC .......................................................................... 200 CPC II ...................................................................... 200 Vector - Current Production ..................................... 201 28X Truck and Pumpkit Circuit ...................................... 203 28X Boom Circuit ........................................................... 204

Training Manual

SERVICE TRAINING

Misc Procedures Material Cylinder Alignment .......................................... 205 Pumping on piston side ................................................... 207 (Available on some units only) ................................ 207 Shimming the Differential Cylinders .............................. 208 Determining the proper shimm size ......................... 208 Dimension A ............................................................ 208 Dimension B ............................................................ 208 Formula .................................................................... 209 Apitech Control Chamber Air Bleed Procedure ............. 210 Hydraulic Pump Adjustments ......................................... 213 Main System Pumps A11VO ................................... 213 Setting the Flow Rate ............................................... 213 Horsepower Setting .................................................. 214 Q-min Output Flow .................................................. 214 Check all hydraulic pressures. ................................. 215 Setting pressures on Hi-flo -6 pumpkits .................. 215 Pressure setting procedure: ...................................... 216 Setting the soft switch relief pressure ...................... 217 Accumulator Bypass Retrofit .......................................... 219 Service Bulletin 1001-03 ......................................... 219 Trouble Shooting Kit ...................................................... 220

Training Manual

Table of Contents

Table of Contents

Training Manual

SERVICE TRAINING

The Schwing Group

Schwing America, Inc.

Schwing America, Inc. is a wholly owned subsidiary of the Schwing GmbH located in Herne, Germany. Schwing was founded in Germany in 1934, it has always been a family owned company and is currently managed by Gerhard Schwing. The Schwing Group has grown steadily since its inception over sixty years. The company is known for its innovation and worldwide operations. The Groups primary products are concrete pumps, ready mix trucks and batch plants. Pumping and boom technologies are applied to other products as opportunities arise. Currently the Schwing Group has factories located around the world at: • Schwing GmbH, Herne, Germany • Schwing GmbH, Memmingen, Germany • Schwing America, Inc., White Bear, USA • Schwing GmbH, St. Stefan, Austria • Schwing SIWA, Sao Paulo, Brazil • Schwing Shanghai, China • Schwing India The Schwing group also has numerous sales and service locations around the world.

SAI was started in 1974, located in a small office on Pierce Butler Road. At this time SAI was primarily a sales, service and parts facility, with the assembly and some manufacturing subbed out to Telelect. This arrangement continued until October 1978. Telelect suffered a prolonged strike, which really hurt SAI. It was at this time that the Schwing company purchased the property here at 5900 Centerville Road. This facility was previously a distribution center for Arctic Cat snowmobiles, and consisted of 114,000 sq. ft., which included a couple pole barns on 16 acres of land. In 1983, we added 20,000 sq. ft. of production space and then in 1986 we added 28,000 sq. ft. to this space introducing our paint facility and testing facility. Then in 1989, an additional 29 acres of land was purchased to the North, and our 20,000 sq. ft. weld shop was constructed. We also worked over one of the pole barns for our fab facility and trailer assembly plant. These additions have proven to be a major break through to make us a complete manufacturing facility. In 1993 we started on our 28,000 sq. ft. office facility. In 1995 we completed construction of a 62,000 sq. ft. state of the art Weld Shop. In addition, in 1996 we added the 15,000 sq. ft.

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SERVICE TRAINING

machining center, which is home of the new Forrest Line machining Center. For the year 2000, Schwing America, Inc. has added a 75,000 sq. ft paint booth. This state-of-the-art behemoth is the largest building in the surrounding communities. Dubbed the “Super Booth” by industry insiders. This is the largest facility for painting concrete pumps in the world. The six-story structure combines with retractable roof panels to accommodate unfolded booms. Painters will use catwalks to cover

every surface with high quality acrylic urethane in an endless array of colors and paint schemes. Climate controlled conditions assure proper curing and drying time. A new solvent recovery system keeps the Super Booth environmentally friendly. Today Schwing America has over 326,000 square feet of manufacturing space and employs over 400 people.

E N

S W

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Hydraulic Training General Principles 1. Hydraulic pressure always takes path of least resistance.

2. Hydraulic pressure is created equal in all directions (Pascal's Law). Pascal's Law 2 A 10 pound force applied to a stopper with a surface area of one square inch......

1 The bottle is filled with a liquid, which is not compressible

3 Results in 10 pounds of force on every square inch (pressure) of the container wall

4 If the bottom has an area of 20 square inches and each square inch is pushed on by 10 pounds of force, the entire bottom recieves a 200 pound push.

3. Liquids (oil) are relatively incompressible.

OIL

AIR

1000 lbs of Force

1000 lbs of Force

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OIL

AIR

3

SERVICE TRAINING

4. When hydraulic pressure and flow is not converted into work it is converted into heat.

Open relief (Heat)

5. When oil is heated it will expand (5% or more). Atmospheric pressure forces water past seals

Vacuum formed as hydraulic oil cools Seals

Hydraulic Cylinder

Water Box

6. When oil is heated the viscosity of it changes.

6 bar 4

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SERVICE TRAINING

7. GPM (Gallons Per Minute) only determine the speed at which the actuator (motor or cylinder) operates.

0 GPM

10 GPM

8. P.S.I. (Pounds Per Square Inch) determine only the amount of force exerted upon the load by the actuator. 10,000 LBS LOAD

10 gallon maximum capacity cylinder

10 inch of area on cylinder piston

1000 PSI

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SERVICE TRAINING

9. The resistance created in a hydraulic circuit, whether by the amount of the load on the actuator and/or the pressure drop in a circuit, is what determines how much work is required.

U.S. F = FORCE (in pounds) (lb)

F=PxA

F P

A

P = F/A A = F/P

P = PRESSURE (in pounds per square inch) (P.S.I.) A = AREA (in square inches) (in2)

METRIC F = FORCE (in kilograms) (Kg) P = PRESSURE (in kilograms per square centimeter) (Kg/cm2) A = AREA (in square centimeters) (cm2)

GENERAL POWER =

QxP CONSTANT

Q = FLOW RATE (unit of volume per time period) P = PRESSURE (unit of force per unit of area)

U.S. HP = HORSEPOWER HP =

GPM x PSI 1714

GPM = GALLONS PER MINUTE PSI = POUNDS PER SQUARE INCH 1714 = KNOWN CONSTANT

METRIC KW = KILOWATTS KW =

LPM x BAR 600

LPM = LITERS PER MINUTE BAR = METRIC UNIT OF PRESSURE 600 = KNOWN CONSTANT

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Mechanical Versus Hydraulic

1. An input force of 10 lb.(44.48 N) on a one square inch 2 (6.45 cm ) piston...

COMPARISON OF MECHANICAL FORCES VERSUS HYDRAULIC FORCES 2. will balance 100 lb (444.82 N) here...

1. Ten pounds (44.48 N) here...

3. This pressure will support a 100 lb. (444.82 N) weight if this is a 10 sq. in. (64.52 cm2 ) piston.

100 lb. (444.82 N)

10 lb. (44.48 N) 1 sq. in. (6.45 cm2 )

10 sq. in. (64.51 cm2 )

2. develops a pressure of 10 pounds per square inch(psi) (.69 bar) (68.94 kilopascals) throughout the container. 100 lb. (444.82 N) 10 lb. (44.48 N)

INPUT 4. this arm.

3. if this arm is 10 times as long as...

4. The forces are proportional to the piston areas.

OUTPUT

100 lb. (444.82 N) 10 lb. (44.48 N) = 10 sq. in (64.52 cm2) 1 sq. in (6.45 cm2)

A. SIMPLE MECHANICAL LEVER

B. SIMPLE HYDRAULIC PRESS

Transfer of Energy ENERGY CAN NEITHER BE CREATED NOR DESTROYED 1. Moving the small piston 10 in. 0.25 m) displaces 10 cu. in. (163.87 cm3) of liquid. (1 sq. in. x 10 in. =10 cu. in.) (6.45 cm2 x 25.40 cm = 163.87 cm3)

2. 10 cu. in. (163.8 cm3) of liquid will move the larger piston only 1 in. (2.54 cm) (10 sq. in. x 1 in. = 10 cu. in.) (64.52 cm x 2.54 cm = 163.87 cm )

100 lb. (444.82 N)

10 lb. (44.48 N) 1 sq. in. (6.45 cm2)

10 sq. in. (64.51 cm2) 1 in (0.02 m) 10 in (0.25 m)

4. The energy transfer here also is 100 in. lb. (11.30 Nm) (1 in. x 100 lb. = 100 in. lb.) (.02 m x 444.82 N = 11.30 Nm)

3. The energy transfer here equals 10 lb. x 10 in. (44.48 N x 0.25 m) or 100 in. lb. (11.30 Nm)

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SERVICE TRAINING

Hydraulic Jack

HYDRAULIC ROD

8"

PISTON

Linear & Rotary Actuators LINEAR ACTUATOR

1.The pump pushes the hydraulic liquid into lines.

ROTARY ACTUATOR

2. Lines carry the liquid to actuators which are pushed to cause a mechanical output to move a load.

4. Rotary actuators or motors give the system rotating output. They can be connected to pulleys, gears,rack-and-pinions, conveyors, etc.

MOTOR

PUMP LOAD

PUMP

PISTON & ROD TO RESERVOIR

3. Some actuators operate in a straight line (linear actuators). They are called cylinders or rams. They are used to lift weight, exert force, clamp, etc.

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Training Manual

ROTARY DRIVE SHAFT

SERVICE TRAINING

Basic Hydraulic Components

Check Valve

Throttle Valve

Throttle Check Valve

Switching Valve

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SERVICE TRAINING

Check Valve Comparison

In-Line Check Valve

Cartridge Check Valve

Right Angle Check Valves

10

CHECK VALVE COMPLETE P/N 30333030

CHECK VALVE COMPLETE P/N 30333031

CARTRIDGE W/SEALS P/N 30333032

CARTRIDGE W/SEALS P/N 30333033

SEAL KIT ONLY P/N 30333034

SEAL KIT ONLY P/N 30333035

TORQUE SPECIFICATION 55 ft/lbs.

TORQUE SPECIFICATION 200 ft/lbs.

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SERVICE TRAINING

Shuttle Valve

B

A shuttle valve is used where the higher of the two pressures must be selected, while blocking the lower pressure input.

A

C B

A

C

The valve has two inlet, ports “A” and “C”, and one output port “B”. When either port A or C is pressurized, a ball automatically seals the other inlet and allows the higher pressure fluid to flow to port “B”.

B

B

A

C

Greater pressure from "A" port

A

C Greater pressure from "C" port 39000145.ai

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SERVICE TRAINING

Throttle Check Valve Flow control valve Model MK is pressure, temperature and viscosity dependent throttle/check valves, used to restrict flow. It consists of adjustment sleeve (1) and inner housing (2).

5

4

3

1

6

2

Model MK (Throttle/Check Valve) This valve is capable of flow control in one direction while allowing reverse free flow in the opposite. Fluid passes spring (6), through radial drilling and throttling area (4). Throttling is achieved similarly to the MG valve. In the reverse direction, pressure acts on the area of check valve (5). When pressure exceeds spring force (6), the poppet opens, allowing reverse free flow through the valve. Fluid also passes through the throttle area (4), thereby flushing contamination from the valve.

Throttle Check Valve Model MK

Caution! Do not adjust the valve while under pressure

5

12

4

6

5

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4

6

SERVICE TRAINING

Switching Valves

POPPET END PORT

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 when the pressure from the poppet end port exceeds the pressure at the spring end port by more than 2:1 in most situations

BODY SEAT

O-RING AND BACK-UP RINGS

POPPET HOUSING

SIDE POR (PLUGGED

SIDE PORT POPPET

BODY

O-RING AND BACK-UP RING

SPRING

SIDE PORT

SPRING GUIDE

SPRING END POR T SPRING END PORT

SPRING GUIDE SPRING POPPET POPPET END PORT

Pressure equal on both sid es

POPPET HOUSING

High Pressure pushes poppet backallowing oil to flow through th e side port, sending a signalto S3

Training Manual

Pressure greater onthe Spring End Port forcingthe poppet to close

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SERVICE TRAINING

Hydraulic Pumps

Concrete pump hydraulic pumps

Placing boom hydraulic pumps Load sensing proportional The hydraulic pump for the placing boom is a variable displacement, bent axis, axial piston pump, with load sensing control. It can feed all of the following components: • the hydraulic cylinders on the boom sections • the hydraulic cylinders on the outriggers • the hydraulic motor for the boom slewing gear • the hydraulic motor for the water pump • the hydraulic motor of the compressor (optional equipment)

The hydraulic pumps for the concrete pump circuit are bent axis, 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 truck 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 and the dampener (with single circuit), or the accumulator (with twin circuit). The net effect of these devices is to tell the pump to put out less oil per revolution, as required by the pump operator.

The directional control valves for all of the above circuits are incorporated into control blocks and equipped with hand levers. In addition, the control block for the boom functions have electric over oil piloting for operation via remote control. PumpKit Pumps PumpKit Pumps

Proportional Boom Pump

Boom Pump Accumulator Pump

Oil Cooler Pump

Agitator Pump

Stiebel 4194


Stiebel 4400 PumpKit Pumps

PumpKit Pumps


Accumulator Pump

Oil Cooler Pump

Accumulator Pump Agitator Pump Oil Cooler Pump

Agitator Pump

Stiebel 4194

InLine Drive (other options are available)

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SERVICE TRAINING

Fixed Displacement Pump

Variable Displacement Pump

Rexroth A2F20

Rexroth A7VO

Fixed displacement pumps discharge a set volume of fluid regardless of the system requirements. This volume can be changed only by changing the drive speed of the pump. If the system requires less fluid than the pump is discharging, the balance of the flow must find an alternate pah which is usually over a relief valve and back to the reservoir.

Variable pump with axial tapered piston rotary group of bent axis design, for open circuit hydraulic drives. This pump is suitable for mobile applications. Comprehensive programming of control devices is available. The robust taper roller drive shaft bearings are designed to give long service life. Output flow is proportional to drive speed and pump displacement is steplessly variable between maximum and zero. Horse Power Control (other locations possible) Q min

Q max

Q max

25ß -

0ß

Q min

Horsepower Adjustment Screw (other locations possible)

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SERVICE TRAINING

Variable Displacement Axial Piston Pump RexrothA10VO Variable displacement axial piston A10VO of swash plate design is designed for hydrostatic transmissions in open loop circuits. Flow is proportional to the drive speed and the displacement. By adjusting the position of the swash plate it is possible to smoothly vary the flow.

RexrothA11VO The A11VO is a variable displacement pump of axial piston swash plate design for use in open circuit hydrostatic drives. Designed principally for use in mobile applications. A wide variety of controls are available. Setting of the constant power control is possible via external adjustments, even when the unit is operating. The pump is available with a through drive to accept a gear pump or a second axial piston pump up to the same size (100% through drive). Output flow is proportional to drive speed and pump displacement and is steplessly variable between maximum and zero.

Q min

Pressure Cut-off Screw Q max

16

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SERVICE TRAINING

Rexroth A11VO Adjustments Pressure Cut-Off

Pressure Cut-Off

Delta P

Q min

Q min

Load Sense Port

Q max Q max

A11VO Boom Pump

A11VO Accumulator Pump

Horsepower Control *Stroke Regulation

*Stroke Regulation **Pressure Cut-Off

Pressure Cut-Off

Horsepower Control

Style #1 ***Pressure Cut-Off Q min Horsepower Control

Q min *Stroke Regulation

Style #2 * The beginning of stroke regulation has been increased from 5-7 bar to 8-10 bar on pumps with the following serial numbers:

**

Pressure Cut-Off / Style #1 Turn Clock-wise to increase the pressure Turn Counter-Clock-wise to decrease the pressure

***

Pressure Cut-Off / Style #2 Turn Counter-Clock-wise to increase the pressure Turn Clock-wise to decrease the pressure

A11VO 130 - 21034174, dated 08/22/05 A11VO 190 - 21006318, dated 08/01/05 Pumps with serial numbers below these should also have beginning of stroke regulation pressure set to 8-10 bar.

A11VO 190/130 Main Pumps

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SERVICE TRAINING

Transfer Cases Hydraulic pumps for the concrete pump, placing boom, agitator, etc., are usually mounted on a distribution gearcase. When you are driving the truck, the power of the truck engine is transmitted through the truck transmission, through a propeller shaft, through the bottom of the distribution gearcase, through another propeller shaft, and into the rear end(s) of the truck.

When you are operating the unit, the distribution gearcase interrupts the power to the rear ends, and transmits it to internal gears that turn the hydraulic pumps. Changing between travel and pumping modes is accomplished by means of an air switch in the truck cab.

4194

4195

4400

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SERVICE TRAINING

Relief Valves This is a direct acting non adjustable relief valve. When the oil has enough pressure to over take the spring the relief poppet will start to move out of the way and allow the excess pressure to be relieved to tank. This style pressure relief is not adjustable except by changing the internal spring.The maximum system pressure that this style can be used for is limited because the spring must directly act upon system pressure and thus higher pressures would require a larger spring. When this direct acting design relieves it causes pulsations in the system.

Pressure

This is a pilot operated adjustable relief valve. The relief poppet has a small orifice in it that allows the hydraulic pressure to also be applied on the back side of the poppet. This internal chamber is hydraulically locked and it will hold the main poppet closed as long as it has equal pressure on the front side and the back side. There is also a much smaller pilot poppet, that is operator adjustable. This smaller poppet, with a smaller area, can have a smaller spring controlling it. Once this pilot poppet opens we lose our hydraulic lock, the pressure is reduced on the back side and thus the main poppet can relieve the excess pressure to tank. With this design we are able to control large volumes of oil at high pressures with minimal sized springs.

Pressure

Tank

Tank

This is a direct acting adjustable relief valve. When the oil has enough pressure to over take the spring the relief poppet will start to move out of the way and allow the excess pressure to be relieved to tank. This style is adjustable though a external control which varies the spring tension on the relief poppet.The maximum system pressure that this style can be used for is limited because the spring must directly act upon system pressure and thus higher pressures would require a larger spring.

Pressure

Tank

Pressure Pressure

Tank

Tank

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SERVICE TRAINING

Safety Relief Valves

Pressure Relief Valves Type DBW

Pressure control valve type DB/DBW are pilot operated pressure relief valves. They are used to limit (DB) or unload by means of solenoids (DBW) pressure in a system. Pressure relief valves (DB) consist mainly of a pilot valve with pressure setting element and main valve with main spool insert.

In principle, the function of this valve is the same as that of valve type DB. Unloading at the main spool is achieved by means of actuating the built-on directional control valve.

Pressure Relief Valve Type DB Pressure in line A affects the main spool (1). At the same time there is pressure via control passage (4) and (5) through orifice (2), (3) and (15) to the spring loaded side of the main spool (1) and pilot poppet (6). If system pressure exceeds the value set at the spring (8), pilot poppet (6) opens. The oil on the spring loaded side of the main spool (1) now flows through orifice (3), control passage (5) and poppet (6), and into spring chamber (9). From here it flows internally - type DB.-30/.through passage (10), or externally-type DB.-20/.Y.by means of control port (11) to tank. Orifices (2), (3) and (15) cause a pressure drop at the main spool (1), and the connection from line A to line B opens. The oil now flows from line A to line B, while the set operating pressure in maintained. The valve can be unloaded or switched to a different pressure (second pressure rating) by means of port “X” (13).

VENT LINE

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SERVICE TRAINING

Hydraulic Symbols SHOWING DIN (DEUTSCHE INDUSTRIAL NORM) SYMBOLS USED ON SCHWING SCHEMATICS NO ATTEMPT HAS BEEN MADE TO SHOW EVERY POSSIBLE COMBINATION.

LINE, WORKING P = R 1/2" T = R 1/2" SP = R 3/4" G = R 3/8" AC = R 11/2" Y = R 3/8"

Nitrogen pressure set at 55 bar (800 PSI) G

1.9 mm

LINE, JOINING ("T" FITTING)

S3 0.8 mm hole drilled through spool

190 bar

SP

LINE, PASSING 138 bar Y

This line MUST return to tank by itself. P

NG 10

10

T

Filter

Agitator

LINE TO RESERVOIR (TANK)

2.0 mm

A

LINE, PILOT or SIGNAL

B

300 bar

BP 750 & 1000 TC

S1

(with twin cylinder switching and Hartman control valves)

X

P 0-25 bar

2.0 mm

599010 1-95 RE Y(T) A

125 b bar

LINE, PLUGGED P

RESTRICTION, FIXED (orifice, nozzle) 0.7 mm

100 bar

LINE, WORKING

LINE, PILOT or SIGNAL

Y

G

12

Filter

R

A11VO

LINE, PASSING

LINE TO RESERVOIR (TANK) (ABOVE FLUID LEVEL) (BELOW FLUID LEVEL)

CONNECTOR LINE, PLUGGED LINE, JOINING ("T" FITTING)

RESTRICTION, FIXED (orifice, nozzle)

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1.3

1.3 OR

21

SERVICE TRAINING

Hydraulic Symbols (Cont.)

RESTRICTION, VARIABLE (throttle valve or adjustable orifice)

PUMP, SINGLE FIXED DISPLACEMENT

MANUAL SHUT-OFF VALVE

PUMP, SINGLE VARIABLE DISPLACEMENT

(MANITROL VALVE)

X1 X2

M

A A1

PRIME MOVER, ELECTRIC MOTOR PUMP, SINGLE VARIABLE DISPLACEMENT, SHOWING HORSEPOWER CONTROL CIRCUITS.

D PRIME MOVER, INTERNAL COMBUSTION ENGINE (Diesel shown..."G" if gas.)

MOTOR, ROTARY, FIXED DISPLACEMENT

MOTOR, ROTARY, FIXED DISPLACEMENT BI - DIRECTIONAL

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SERVICE TRAINING


CYLINDER, SINGLE ACTING

PRESSURE GAUGE

CYLINDER, DIFFERENTIAL ROD

TEMPERATURE GAUGE

ACCUMULATOR, GAS CHARGED

CYLINDER, DOUBLE END ROD

ACCUMULATOR, SPRING LOADED

FILTER OR STRAINER

CYLINDER, DOUBLE END ROD WITH GROOVES IN PISTON ROD FOR SWITCHING FUNCTION (ROCK VALVE SHIFTING CYLINDER)

FILTER WITH INTEGRAL BYPASS CHECKVALVE

Training Manual

6 bar

23

SERVICE TRAINING

Hydraulic Symbols (Cont.) OIL COOLER WITH ELECTRIC FAN MOTOR

M

HYDRAULICALLY UNLOCKABLE CHECK VALVE. (CLOSED)

OIL COOLER WITH HYDRAULIC FAN MOTOR

HYDRAULICALLY UNLOCKABLE CHECK VALVE WITH INTEGRAL RELIEF VALVE.

(OPEN)

320 BAR

(H.E.R. BOOM HOLDING VALVE)

BASIC VALVE ENVELOPE PRESSURE SWITCH NORMALLY CLOSED NORMALLY OPEN

PRESSURE RELIEF VALVE (SAFETY VALVE OR SAFETY CARTRIDGE)

CHECK VALVE (BASIC)

CHECK VALVE, FIXED FORCE

280 bar

A 2.0

(SPRING FORCE INDICATED)

PRESSURE RELIEF VALVE WITH EXTERNAL DRAIN

300 bar

(SHOWN WITH A NORMALLY OPEN SOLENOID VALVE... MANY OTHER POSSIBILITIES ARE AVAILABLE).

ADJUSTABLE CHECK VALVE (PRETENSION OR PRELOAD VALVE) (Desired spring force indicated)

6 BAR

300 bar

PRESSURE RELIEF VALVE WITH EXTERNAL DRAIN

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Training Manual

F NR

SERVICE TRAINING

Hydraulic Symbols (Cont.) A

P 0-55 bar

Y(T) A

PRESSURE REDUCING VALVE

ACCUMULATOR UNLOADING VALVE

MANUAL (STROKE LIMITER) OR DAMPNER

P

Y

T

P T

70 bar

B

300 bar

0-50 bar

A

PRESSURE REDUCING VALVE (ELECTRIC STROKE LIMITER)

P

P

T

T

ACCUMULATOR DUMP VALVE (ELECTRIC)

A 55 bar T P T P MY

Pressure reducing valve

MG G Y

A Electric stroke limiter

1.5

THROTTLE CHECK VALVE

FIXED (size shown)

ADJUSTABLE

SLEW BRAKE VALVE

P

P A

CARTRIDGE VALVE (SWITCHING VALVE)

OLD WAY

NEW WAY

SHUTTLE VALVE

SHOWN 2 DIFFERENT WAYS

P

P

Training Manual

A

25

SERVICE TRAINING


X1 X2

A A1

S

B

COMPONENT ENCLOSURE BRAKE VALVE (BERINGER) (USED ON #1 SECTION DOWN FUNCTION)

X

A

BALL COCK (SHUT OFF VALVE, QUARTER TURN VALVE) B

BRAKE VALVE (COUNTERBALANCE VALVE) (USED ON ALL SECTIONS KVM 52 & 55) B R

X

Z

A

Y

BRAKE VALVE (SAUER) (USED ON #1 SECTION DOWN FUNCTION)

Z

VENTED RESERVOIR (TANK)

R

26

Training Manual

X

A

SERVICE TRAINING

Hydraulic Symbols (Cont.) DIRECTIONAL CONTROL VALVES

DIRECTIONAL VALVE: METHODS OF OPERATION

BASIC VALVE SYMBOL MULTIPLE FLOW PATHS PILOT PRESSURE

DIRECTIONAL VALVE

OR

2 POSITION, 3 WAY

SOLENOID

DIRECTIONAL VALVE 2 POSITION, 4 WAY

SPRING

DIRECTIONAL VALVE 3 POSITION, 4 WAY, CLOSED CENTER

MANUAL (HANDLE OR PUSHBUTTON)

DIRECTIONAL VALVE 3 POSITION, 4 WAY, OPEN CENTER

DETENT

DIRECTIONAL VALVE 3 POSITION, 4 WAY CLOSED PRESSURE CENTER

HAND LEVER

DIRECTIONAL VALVE 3 POSITION, 4 WAY, TANDEM CENTER (REQUIRES A HOLLOW SPOOL)

EXAMPLES OF COMBINATIONS OF METHODS

3 POSITION, 6 WAY, CLOSED CENTER (10631)

SOLENOID OPERATED, SPRING RETURN

DIRECTIONAL VALVE, 3 POSITION, 6 WAY, CLOSED PRESSURE CENTER, ORIFICED A & B PORTS IN CENTER (10632F)

HAND LEVER OPERATED WITH DETENT

DIRECTIONAL VALVE, 3 POSITION, 5 WAY, LOAD SENSING, CLOSED PRESSURE CENTER, INFINITE POSITIONING

HAND LEVER OR SOLENOID OPERATED, SPRING CENTERED

DIRECTIONAL VALVE

(PROPORTIONAL)

SOLENOID CONTROLLED, PILOT PRESSURE OPERATED, SPRING CENTERED, WITH HAND LEVER

DIRECTIONAL VALVE, 3 POSITION, 5 WAY, LOAD SENSING, CLOSED CENTER, INFINITE POSITIONING (PROPORTIONAL)

X

P

PRESSURE REGULATOR (REGULATES DELTA P) USED ON LOAD SENSING SYSTEMS

OR

A

T

Training Manual

27

SERVICE TRAINING

Formulas Piston Side

Rod Side

R2

R2

= 3.14 R = 1/2 of Diameter 5

= 3.14 R = 1/2 of Diameter 2.5

10,000 Pounds

3.14(2.5 x 2.5) = 19.625 3.14 x 6.25 = 19.625

3.14(1.25 x 1.25) = 4.90625 3.14 x 1.5625 = 4.90625

Piston - Rod = Rod Side Area

Area of piston = 19.625

19.625 - 4.90625 = 14.719

19.625 10,000 Pounds

10,000 = 509.55 19.625

10,000 = 679.39 14.719

To move this load it will take about 510 psi

To move this load it will take about 680 psi

POWER =

5100 1714

28

14.719 10,000 Pounds

10 GPM x 510 1714 (A Constant)

POWER =

6800 1714

= 2.975 HP

Training Manual

10 GPM x 680 1714 (A Constant) = 3.967 HP

SERVICE TRAINING

Pumpkits Single Circuit Pumpkits

Twin Circuit Pumpkits

800

1200 w/Switching Valves

801

1200 w/MPS

900/1200

2023 Hi-Flow

Hi-Flow

2525 Hi-Flow PumpkitCompare.eps

Training Manual

29

SERVICE TRAINING

800 Gate Valve

30

Training Manual

SERVICE TRAINING

801 Gate Valve

Training Manual

31

SERVICE TRAINING

801 Pumpkit Schematic 5

Pipe Gate

Hopper Gate

9B 9A

6

4

3

7 300 bar

8

10A

10B D

12A

12B

11A

11C 11B

2 6 bar

2 1

39000156.eps

1. Hydraulic oil reservoir

7. Directional control valve S-2

2. Main hydraulic pumps

8. Locking Valve

3. Main pressure relief valve

9A–9B. Needle valves

4. Directional control valve S-1 (forward/reverse)

10A–10B. Hydraulically Unlockable Check valves

5. Gate Valve

11A–11C. Check valves


12A–12B. Differential Cylinders

32

Training Manual

SERVICE TRAINING

Concrete Pump Control Block

T P1

9B 9A

T

9B

6

S3

S1

4

1.5 mm hole drilled through spool

S2

300 bar

B

7

A

3 8

9A

3

8

S-1

S-2 7

S-3 6 39000155.eps

Training Manual

33

SERVICE TRAINING

Stroke Limiter

1

P 2

A 4

T

P

3

0-50 BAR

4 1

3 2

T

A 39000158.eps

494 Block A 5

B

3

agitator motor

6

P 1 2

Agitator pressure*

H2O pump motor

6

3

A B

2

H2O pressure*

5 1

4

2

1

4

39000157.eps

CA B

34

Training Manual

SERVICE TRAINING

Hydraulically Unlockable CheckValve

C B

B

A C

B

2 1

A 1

C

0.7 mm

2

39000160.eps

Gate Valve B

A

B

1

D 1

A

C 2

D 2

C Training Manual

39000163.eps

35

SERVICE TRAINING

36

Training Manual

SERVICE TRAINING

900-1200 Single Circuit

Single Circuit

Training Manual

37

SERVICE TRAINING

900-1200 Single Circuit Schematic

900 Pumpkit - eps

5

1

10A

11

10B

6

7

3

4 10D

10C

D

10E

9A 8A

2

8B

2

12

9B

10F 1


8A–8B. Differential hydraulic cylinders


9A–9B. Switching valves


10A–10F. Check valves


11. Ball cock (Shutoff valve)

5. Rock valve slewing cylinder

12. Hydraulic oil filter with bypass valve (return filter

6. Directional control valve S-3 7. Directional control valve S-2

38

Training Manual

SERVICE TRAINING


P1 X


6

S1

P

10B

P2

T

4

300 bar

S2

B

3

R

X

7

A 10A

Port size limits flow

3

4

S-1

7

S-2

S-3 6

39000147.eps

Training Manual

39

SERVICE TRAINING

Stroke Limiter

1

P 2

A 4

T

P

3

0-50 BAR

4 1

3 2

T

A 39000158.eps

494 Block A 5

B

3

agitator motor

6

P 1 2

Agitator pressure*

H2O pump motor

6

3

A B

2

H2O pressure*

5 1

4

2

1

4

39000157.eps

CA B

40

Training Manual

SERVICE TRAINING

Switching Valve C C B

B 2

1

A

2 1

39000161.eps

A

A7VO

1

A

2

Q min

1 2 B

Q max

A

X1

B

X1 X2

X2

1

A

A A1

1

A1

D 2

2 To Boom Circuit

S

S

Training Manual

39000162.eps

41

SERVICE TRAINING

Rock Valve 1

A 2

B

C

D

A 1

C D

2

E

F GH

B F H

G E 39000164.eps

42

Training Manual

SERVICE TRAINING

Training Manual

43

SERVICE TRAINING

Phase A

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.

First working stroke

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

KEY

4

High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest)

12

18

13

3 S3


S1 300 bar

1 10

2 S2 14

15

20 D

5 6

44

16

8

7

M

17

Training Manual

6 bar

SERVICE TRAINING

Phase B

(1), filter (7) and back to the hydraulic tank.

End of first working stroke

* 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.

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

KEY

4


12

18

13

3 S3


S1 300 bar

1 10

2 S2 14

15

20 D

5 6

16

8

7

M

17

Training Manual

6 bar

45

SERVICE TRAINING

Phase C

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).

Rock valve cylinder getting oil to extend

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

KEY

4


12

18

13

3 S3


S1 300 bar

1 10

2 S2 14

15

20 D

5 6

46

16

8

7

M

17

Training Manual

6 bar

SERVICE TRAINING

Phase D

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).

S2 valve getting signal to shift

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

KEY

4


12

18

13

3 S3


S1 300 bar

1 10

2 S2 14

15

20 D

5 6

16

8

7

M

17

Training Manual

6 bar

47

SERVICE TRAINING

Phase E Left hand differential getting oil to move

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.

KEY

4


12

18

13

3 S3


S1 300 bar

1 10

2 S2 14

15

20 D

5 6

16

8 M

17 Note: Check Valve Must Close

48

7

Training Manual

6 bar

SERVICE TRAINING

Phase F

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.

Middle of the second working stroke (diagram 6)

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

KEY

4


12

18

13

3 S3


S1 300 bar

1 10

2 S2 14

15

20 D

5 6

16

8

7

M

17

Training Manual

6 bar

49

SERVICE TRAINING

Phase G

(3) is relieved via check valve (14), the S2 valve (2), S1 valve (1), filter (7) and back to the hydraulic tank.

End of second working stroke (diagram 7)

* NOTE: If the left hand differential cylinder has not fully retracted at this point because of to much loop oil, high pressure oil will continue to flow through check valve (16) and back to the hydraulic tank until the left hand differential cylinder is fully retracted.

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

KEY

4


12

18

13

3 S3


S1 300 bar

1 10

2 S2 14

15

20 D

5 6

50

16

8

7

M

17

Training Manual

6 bar

SERVICE TRAINING

Phase H Rock valve cylinder getting oil to retract

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).

KEY

4


12

18

13

3 S3


S1 300 bar

1 10

2 S2 14

15

20 D

5 6

16

8

7

M

17

Training Manual

6 bar

51

SERVICE TRAINING

Phase I

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).

S2 valve getting signal to shift

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

KEY

4


12

18

13

3 S3


S1 300 bar

1 10

2 S2 14

15

20 D

5 6

52

16

8

7

M

17

Training Manual

6 bar

SERVICE TRAINING

Phase J

differential cylinder. Please note that check valve (16) must close otherwise the right hand differential cylinder will not retract.

Right hand differential getting oil to move

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

KEY

4


12

18

13

3 S3


S1 300 bar

1 10

2 S2 14

15

20 D

5 6

16

8

7

M

17

Training Manual

6 bar

53

SERVICE TRAINING

Phase K First working stroke

Refer to diagram 1 for explanation of first working stroke.

KEY

4


12

18

13

3 S3


S1 300 bar

1 10

2 S2 14

15

20 D

5 6

54

16

8

7

M

17

Training Manual

6 bar

SERVICE TRAINING

Troubleshooting Differentials start to move before the rock valve has completely shifted. If check valve (A) is stuck open, the left hand differential would start to retract and the right hand differential would start to extend before the rock valve

was completely shifted to the left. This would cause some of the concrete from the right hand material cylinder to be pumped back into the hopper. If the problem occurred while the right cylinder was extended and the left cylinder was retracted, check valve (B) has failed.

KEY High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest)

A OPEN

B


S1 300 bar

S2

D

M 6 bar

Training Manual

55

SERVICE TRAINING

Before rock valve shifts to the right the unit builds high pressure, left differential continues to move, right differential has stopped. The unit has too much rocking oil and the right hand differential has reached it’s stop. The left hand

differential continues to get pressure oil to the rod side so that the excess rocking oil can be exhausted through check valve (A). As soon as the left hand differential has fully retracted a signal will be sent out of the switching valve to S3 valve.



S1 300 bar

S2

D

A

M 6 bar

56

Training Manual

SERVICE TRAINING

Rock valve shifts and as soon as the differential cylinder shifts the rock valve shifts again (machine gunning). The rock valve has shifted to the right and a signal from the rock valve has shifted the S valve to the left. The pressure oil is supposed to go to the rod side of the

right hand differential for the start of the next stroke. However since check valve (A) is stuck open and the pressure oil shifts the S3 valve to the right causing the rock valve to shift to the left. (See diagram 3B).



S1 300 bar

S2 A

B

Note: Stuck Open D

M 6 bar

Training Manual

57

SERVICE TRAINING

Check valve (A) is stuck open and the pressure oil shifts the S3 valve to the right causing the rock valve to shift to the left. After the rock valve shifts to the left a signal is sent to the S2 valve to shift the direction of the differentials.



S1 300 bar

S2 A

B

Note: Stuck Open D

M 6 bar

58

Training Manual

SERVICE TRAINING

The differentials are already in the end position for this mode so a signal is sent to the S3 valve and the rock valve will shift again to the right. Thus we get the machine gun sound and no concrete output.



S1 300 bar

S2 A

B

Note: Stuck Open D

M 6 bar

Training Manual

59

SERVICE TRAINING

Rock valve shifts to the right and then the machine builds high pressure. After the rock valve is done shifting to the right a signal is supposed to be sent to the right hand end cap of the S2 to shift it to the left, however the signal will not reach the S2 end cap because the ball cock is closed.

NOTE: If the ball cock was partially closed the machine would continue to stroke, however there would be a pressure spike between the time the rock valve is done shifting and the differential cylinders start moving.


Ball Cock


S1 300 bar

S2

Note: Stuck Open D

M 6 bar

60

Training Manual

SERVICE TRAINING

High-Flow Single Circuit 2020/2023

Single Circuit S3 shifting by signal from Switching valve

Training Manual

61

SERVICE TRAINING

High-Flow Single Circuit Schematic

1

5

T

ZK2

1.3

ZS2

1.3

SP

ZK1

9A

ZS1

9B XA

XB

A

3.5

3.5

TO STROKE LIMITER PORT "PBP"

B X3

TO STROKE LIMITER PORT "PZ"

A2

B2 B3

A3

S3

10C

6 XB3

XA1

10D

1.5 A

B B1

A1

S2 XA

11

7

XB

PR PP

4

S1 XR

XP

P2

P1

MP

10E 1.8

T2

1.2

3

12

T1

1.4

300 bar

X1

8A

8B

10F

T 1.8

2

2

1






9A–9B. Switching Valves


10A–10F. Check valves


11. Ball cock (Shutoff valve)


12. Main flow poppet relief valve

62

Training Manual

SERVICE TRAINING

Concrete Pump Control Block A2

B2 B3

A3

6

S3

XA1

X1 MP

XB3

R

T

B B1 XB

P1

A

X 1

T1

PR

A

X

7

S2

XA

P2

P

XR

4

P

PP

S1

R

A1

X

A

P2 P

1.5

T2

XP

1 B

X

XP

P1

MP T2

XB

T1

12

300 bar

4

1.2

5

1.4

3

3 XB

B3

B2

A2

A3

X1

T

3

2 1

4

7

5

Training Manual

6

63

SERVICE TRAINING

Switching Manifold

10A

3.5MM Orifice

10B

T

ZK2

SP

ZK1

1.3

9A 3.5MM Orifice

1.3MM Orifice

ZS2

ZS1

1.3

9B 9C

9C

XB

XA A

9A

9B

3.5

3.5

10A

B

10B

X3

MPS_SC.eps

Stroke Limiter with Fast Switch/Dampner MG2

Reversing Valve (for Fast Switch)

6

G2

4

11

Dampner

6

3

7

0.7

20 bar

0-30 bar

1

9

8

X1 MX1

8

3.5-40 bar

12

10

2

4 2

3.5-40 bar

MP

MG1

5

0.7

7 9

12

PBP

10

1

PZ

T

5 11

3 SC_FastSwitchDampner.eps

64

Training Manual

SERVICE TRAINING

Training Manual

65

SERVICE TRAINING

The following diagrams A through D show the switching functions of the concrete pumpkit plumbed on the ROD SIDE with simplified schematics. The agitator, boom, and S-1 control circuits are not shown.

Phase A •

Pressure oil (red) flows through the S3 valve (6) (cross-over position) into the retract side oil port of the rock slewing cylinder (5).

•

The rod of the rock slewing cylinder (5) retracts (shown in the new position).

•

When the slewing cylinder has completely retracted, the switching groove lines up with the switching port and routes pressure oil to the right side end cap of the S2 valve (7).

•

The S2 valve (7) moves into the parallel position (shown in the new position).

•

The oil in the left side end cap of the S2 escapes to tank through thecheck valve (10C.)

•

Pressure oil (red) flows through the cross-over position of the S2 spool (7) into the rod side of the right side differential cylinder (8B). The cylinder retracts, which creates a vacuum in the material cylinder. The right side material cylinder fills with concrete. (This is called the suction stroke).

•

The oil that is forced out of the piston side of the right differential cylinder flows through a hose into the piston side of the left differential cylinder (8A). This oil is called rocking oil (orange).

•

The rocking oil forces the left side differential cylinder (8A) to extend. The concrete in that material cylinder is pumped out of the machine. (This is called the pressure stroke).

•

The oil from the rod side of the left cylinder is routed back to the tank. (Green).

•

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

66

Training Manual

SERVICE TRAINING

Phase

A Hi-Flow Single Circuit

KEY

High Pressure

1

5

Rocking Oil Pressure Low Pressure Zero Pressure (Tank, or oil at rest)

T

ZK2

SP

1.3

ZK1

9A ZS2

1.3

ZS1

9B XA A

XB 3.5

3.5

10A


B

10B

X3


10C

A2

B2 B3

A3

S3

10D

6 XB3

XA1

1.5 A

B

A1

B1

S2

11

7

XA

XB

PR PP

4

S1 XR

XP

P2

P1

MP

10E 1.8

T2

1.2

8A

3 300 bar

T1

12

8B 1.4 X1

T 1.8

2

2

1 10F

Training Manual

67

SERVICE TRAINING

Phase B •

The right side differential cylinder (8B) reaches bottom dead center. If there is not enough rocking oil in the loop to bring the left side cylinder to the top dead center position, oil will be added now through check valve 10F.

•

The left side differential cylinder (8A) reaches top dead center. As the piston reaches the guide bushing, it exposes a port to the end cap of the reversing valve (9B), which becomes connected to high pressure oil (red). The left end cap of the reversing valve (9B) is connected to low pressure oil (green), so the reversing 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 (6) end cap, pushing the valve to the right, which places it into the cross-over position (shown in the new position).

•

The oil on the right end cap of the S3 valve flows through the switching valve and back to tank.

•

In the parallel position, the S3 valve routes oil to the extend port of the rock valve slewing cylinder. The cylinder begins to extend.

•

The oil from the left side of the rock slewing cylinder is routed back to tank.

68

Training Manual

SERVICE TRAINING

Phase

B Hi-Flow Single Circuit

KEY

High Pressure

1

5


T

ZK2

SP

1.3

ZK1

9A ZS2

1.3

ZS1

9B XA A

XB 3.5

3.5

10A


B

10B

X3


10C

A2

B2 B3

A3

S3

10D

6 XB3

XA1

1.5 A

B

A1

B1

S2

11

7

XA

XB

PR PP

4

S1 XR

XP

P2

P1

MP

10E 1.8

T2

1.2

8A

3 300 bar

T1

12

8B 1.4 X1

T 1.8

2

2

1 10F

Training Manual

69

SERVICE TRAINING

Phase C •

The rock valve slewing cylinder (5) reaches the top dead center position.

•

When the slewing cylinder (5) has completely extended, the switching groove lines up with the switching port and routes pressure oil to the left side end cap of the S2 valve (7).

•

The pressure pushes the S2 spool (7) to the right, placing it into the parallel position (shown in the new position).

•

The oil in the right end cap of the S2 escapes to tank through the check valve(10D).

•

Oil from the pump is routed through the S2 valve to the rod side of the left hand differential cylinder 8A.

•

The left side differential cylinder (8A) begins to retract. In the material cylinder, concrete begins to flow in to fill the void left by the retracting rubber ram. (Suction stroke).

•

The oil escaping from the left side differential cylinder travels through the hose to the piston side of the right hand differential cylinder (8B), forcing it to extend. In the material cylinder, the concrete from stage A is forced out into the delivery pipeline. (Pressure stroke).

•

The oil from the rod side of the right hand material cylinder is routed through the S2 valve (7), through the return filter, and back to tank.

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Training Manual

SERVICE TRAINING

Phase

C Hi-Flow Single Circuit

KEY

High Pressure

1

5


T

ZK2

SP

1.3

ZK1

9A ZS2

1.3

ZS1

9B XA A

XB 3.5

3.5

10A


B

10B

X3


10C

A2

B2 B3

A3

S3

10D

6 XB3

XA1

1.5 A

B

A1

B1

S2

11

7

XA

XB

PR PP

4

S1 XR

XP

P2

P1

MP

10E 1.8

T2

1.2

8A

3 300 bar

T1

12

8B 1.4 X1

T 1.8

2

2

1 10F

Training Manual

71

SERVICE TRAINING

Phase D •

The left side differential cylinder retracts (8A) to bottom dead center. The right side differential cylinder extends to top dead center (shown in their new positions).

•

Any excess rocking oil is routed to the tank across check valve 10E.

•

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

•

The S3 valve moves to the left in response to the pilot signal, putting it into the cross-over position (shown in the new position). The oil in the left side end cap of the S2 escapes to tank across check valve (10D).

•

Pressure oil is routed through the S3 valve to the retract port of the rock slewing cylinder.

•

The rock cylinder retracts (5), sending the extend side oil back to tank through the S3 spool.

•

When the rock cylinder reaches bottom dead center, the switching groove lines up with the switching port and oil is routed to the right end cap of the S2 valve.

This brings us back to phase A. The machine has made one complete cycle, which consists of 2 suction strokes and 2 pressure stroke.

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Training Manual

SERVICE TRAINING

Phase

D Hi-Flow Single Circuit

KEY

High Pressure

1

5


T

ZK2

SP

1.3

ZK1

9A ZS2

1.3

ZS1

9B XA A

XB 3.5

3.5


B

X3


10C

A2

B2 B3

A3

S3

10D

6 XB3

XA1

1.5 A

B B1

A1

S2

11

7 XB

XA

PR PP

4

S1 XR

XP

P2

P1

MP

10E 1.8

T2

1.2

8A

3 300 bar

T1

12

8B 1.4 X1

T 1.8

2

2

1 10F

Training Manual

73

SERVICE TRAINING

Twin Circuits Beginning in 1995, most units became available with optional twin circuit switching. “Twin Circuit” refers to the fact that there is one hydraulic circuit to move the differential cylinders, and another separate circuit to switch the rock valve. On single circuit units, the main hydraulic pumps move the main differential cylinders AND the rock valve. There are certain advantages to having a separate hydraulic circuit to switch the rock valve. For example, under the single circuit system, if you were pumping a stiff, lean mix and pressure was running high, it would also take quite a bit of pressure to switch the rock valve. There were even a few isolated cases where the rock valve wouldn’t switch because there wasn’t enough pressure available, usually when pumping straight up. The reason that it was hard to switch the rock valve was because the valve had to try to dislocate a column of concrete that still had pressure on it from the stroke. The next stroke could not begin until the rock valve had completed it’s travel. When using twin circuit, the differential cylinders do not have to wait for the rock valve before they change directions and begin the next stroke. As soon as the S-3 spool changes directions, which gives the rock valve

Single Circuit

the oil to change directions, oil is also routed to the valve that changes the direction of the differential cylinders. If the rock valve cylinder has enough pressure available to switch, it will do so. If not, it will wait. As soon as the differential cylinders have changed directions, one of the following things will happen: If the rock valve has already switched, concrete will immediately be drawn from the hopper, and pushed into the pipeline, which is just a normal stroke. If the rock valve has NOT already switched, concrete will begin to be drawn from the pipeline and pushed into the hopper. This reduces the pressure in the pipeline to zero. As soon as pressure in the pipeline is relieved, the rock valve switches across. It doesn’t slam and it doesn’t pound, it just moves. As soon as the rock valve has moved, concrete is accelerating out of the unit like normal. The concrete is not actually pumped in reverse, because as soon as the pressure in the pipeline drops to zero, the rock valve switches. A complete description of the twin circuit switching sequence is found in this chapter starting on page 56. This system has the added benefit of reducing wear on the cutting ring, the spectacle plate, the kidney seal and kidney plate, as well as the rock valve slewing cylinder.

S1 S2

Twin Circuit

S1 S2

S3 S3

74

Training Manual

SERVICE TRAINING

1200 Twin Circuit with Switching Valves

Twin Circuit with Switching Valves S3 switching by signal from switching valves

Soft switch pressure is used to switch S3

Accumulator oil switches the rock

Rock may or may not shift at the same time as the differential cylinders

Training Manual

75

SERVICE TRAINING

Twin Circuit Schematic w/Soft Switch

14 5

1 11 S3

8A

19

6

15

16

8B

17

9A

18 10C 1 10D

1

9B

10B

10A

22

NG 10

13

23 7

1 4

S2 S1

3

0.7 mm

21 12

24

2

20

1


13. Accumulator unloading valve

2. Main hydraulic pump

14. Accumulator


15. Electric accumulator dump valve


16. Manual accumulator dump valve


17. Accumulator shutoff valve


18. Accumulator safety relief valve


19. Accumulator pressure gauge


20. Accumulator hydraulic pump

9A–9B. Switching valves

21. Accumulator circuit filter

10A–10D. Check valves

22. NG 10 valve for forward/reverse

11. Ball cock

23. Shuttle Valve

12. Hydraulic oil filter with bypass valve (return filter)

24. Soft Switch Valve

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Training Manual

SERVICE TRAINING


P1

7

P

X

S1

4

3

B

T

R

X

300 bar

S2

P2

A


3

1

S-1

2 S-2

39000148.eps

S3 Control Block

6 6

S3

1 39000149.eps

Training Manual

77

SERVICE TRAINING

Soft Switch

2 4 1

3

1

0.7 mm

2

3

4 80 bar Soft switch

39000151.eps

Accumulator Unloader Valve

A

2

1

1

2

P

Y

39000153.eps

78

Training Manual

T

SERVICE TRAINING

Accumulator Control Block/Dump Valve 1 2 Nitrogen pressure set at 100 bar (1450 PSI)

7

3

Accumulator control device

4

3

2

300 bar

1

5 6 6

T

Y

P

5

7 4

39000152.eps

Accumulator Pump

1

A11

A10

200 bar

39000154.eps

1

Training Manual

79

SERVICE TRAINING

The following diagrams A through D show the switching functions of the concrete pumpkit plumbed on the ROD SIDE with simplified schematics. The agitator, boom, and S-1 control circuits are not shown.

•

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

•

The rocking oil forces the left side differential cylinder (8A) to extend. The cylinder rod extends, pushing concrete out of the material cylinder, through the rock valve, and into the pipeline. (This is called the pressure stroke.)

•

The oil from the rod side of the left differential cylinder (8A) is routed back to the tank through the return filter (12). The low pressure oil is shown in green.

•

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

Phase A •

As soon as you switch the unit distribution gearcase to the pumping position, the accumulator hydraulic pump (20) begins pumping high pressure oil (red) to charge the accumulator circuit (14).

•

The high pressure oil (red) from the accumulator circuit charges the accumulator (14). When the accumulator pressure reaches the setting of the accumulator dump valve (13), the accumulator dump valve opens and routes the oil from the accumulator charge pump (20) back to the reservoir (1).

•

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 retract side oil port of the rock slewing cylinder (5).

•

The rod of the rock slewing cylinder (5) retracts, if it is not already retracted.

•

The S1 directional control valve (4), which controls whether the unit pumps in forward, neutral, or reverse, is put into the forward position.

•

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

•

High pressure oil (red) flows from the main hydraulic pump (2) through the parallel position of the S2 valve (7) into the rod side of the rightside differential cylinder (8B). The cylinder retracts, which creates a vacuum in the material cylinder. The right-side material cylinder fills with concrete. (This is called the suction stroke.)

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Training Manual

SERVICE TRAINING

Phase

6.3 mm

A Twin Circuit

14 5 6.3 mm

Nitrogen pressure set at 100 bar (1450 PSI)

1

19

11

15

S3

8A

16

8B

17

6

9A

300 bar

18 10C 1

10D

1

9B

P

22 10B

10A

NG 10

13 T

2.5 mm

7

0.7 mm 2.5 mm

200 bar Y

0.7 mm

P

1 4

S2 S1

320 bar

0.7 mm

3

21 KEY

High Pressure

12


Training Manual

2

20

1

81

SERVICE TRAINING

Phase B •

The right-side differential cylinder (8B) reaches bottom dead center. If there is not enough rocking oil in the loop to bring the left-side differential cylinder (8A) to the top dead center position, oil is added now through check valve 10D.

•

The left-side differential cylinder (8A) reaches top dead center. As the piston reaches the guide bushing, it exposes a port to the poppet end port of the switching valve (9A), which becomes connected to high pressure oil (red). The spring end port of the switching valve (9A) is connected to low pressure oil (green), so the switching valve opens, sending high pressure oil (red) toward the left-side end cap of the S3 valve (6).

•

The pressure signal reaches the S3 valve end cap (6), pushing the valve to the right, which places it into the crossover position.

•

The oil on the right end cap of the S3 valve (6) flows through the check valve (Item 10B) back to tank (1).

•

In the crossover position, the S3 valve (6) routes oil from the accumulators to the extend port of the rock valve slewing cylinder (5). The cylinder begins to extend.

•

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

•

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 to the right, into the crossover position.

•

As the rock valve slewing cylinder (5) extends, pressure in the accumulator circuit falls. When it drops below the set point of the accumulator dump valve (13), the dump valve closes, and the accumulator hydraulic pump (20) begins to recharge the accumulator circuit.

82

Training Manual

SERVICE TRAINING

Phase

6.3 mm

B Twin Circuit

14 5


1

6.3 mm

11

19 15

S3

8A

16

8B

17

6

9A

300 bar

18 10C 1

10D

1

9B P

10B

10A

NG 10

22

13 T

2.5 mm

7

0.7 mm 2.5 mm

200 bar Y

0.7 mm

P

1 4

S2 S1

320 bar

0.7 mm

3

21 KEY

High Pressure

12


2

20

1

28X 1200 TCphaseAoriginal

Training Manual

83

SERVICE TRAINING

Phase C •


•

High pressure oil (red) continues to flow into the accumulator circuit until the accumulators (14) are fully charged to the pressure preset at the accumulator dump valve (13). The accumulator dump valve opens, sending oil from the accumulator hydraulic pump (20) back to the tank (1) without pressure.

•

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

•

As the left-hand differential cylinder (8A) moves, high pressure oil (red) reaches the spring end port of the switching valve (9A). The valve closes by the pressure applied to the spring end port. This removes the pilot signal to the left side of the S3 directional control valve (6).

•

As the left-side differential cylinder (8A) retracts, 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-side differential cylinder (8A) travels through the hoses to the piston side of the right-hand differential cylinder (8B), forcing it to extend. In the material cylinder, the concrete from stage A is forced out into the delivery pipeline (pressure stroke).

•

The oil from the rod side of the right-hand differential cylinder (8B) is routed through the S2 valve (7), through the return filter (12), and back to tank (1).

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Training Manual

SERVICE TRAINING

Phase

6.3 mm

C Twin Circuit

14 5


1

6.3 mm

11

19 15

S3

8A

16

8B

17

6

9A

300 bar

18 10C 1 10D

1

9B

P

10A

10B

NG 10

22

13 T

2.5 mm

7

0.7 mm 2.5 mm

200 bar Y

0.7 mm

P

1 4

S2 S1

320 bar

0.7 mm

3

21 KEY

High Pressure

12


2

20

1

28X 1200 TCphaseAoriginal

Training Manual

85

SERVICE TRAINING

Phase D •

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

•

Any excess rocking oil (orange) is routed to the tank (1) across check valve 10C.

•

When the left-side differential cylinder is in the bottom dead center position, pressure is applied to the poppet end port of the switching valve 9B. The switching valve opens and sends a pilot signal to the right-side end cap of the S3 valve (6).

•

The S3 valve (6) moves to the left in response to the pilot signal, putting it into the parallel position. The oil in the left-side end cap of the S3 valve (6) escapes to tank (1) across check valve 10A.

•

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

•

The rock valve slewing cylinder (5) retracts, sending the extend side oil back to tank (1) through the S3 valve (6) and the return filter (12).

•

When the rock valve slewing cylinder (5) reaches bottom dead center, the switching groove lines up with the switching port and oil is routed to the right end cap of the S2 valve (7).

•

As the rock slewing cylinder (5) extends, pressure in the accumulator circuit falls. When it drops below the set point of the accumulator dump valve (13), the dump valve closes and the accumulator hydraulic pump (20) begins pumping pressure oil (red) to charge the accumulator circuit (14).

•

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

86

Training Manual

SERVICE TRAINING

Phase

6.3 mm

D Twin Circuit

14 5


1

6.3 mm

11

19 15

S3

8A

16

8B

17

6

9A

300 bar

18 10C 1 10D

1

9B

P

10A

10B

22

NG 10

13 T 200 bar

2.5 mm

7

0.7 mm 2.5 mm

Y

0.7 mm

P

1 4

S2 S1

320 bar

0.7 mm

3 21

KEY

High Pressure

12


Training Manual

2

20

1

87

SERVICE TRAINING

88

Training Manual

SERVICE TRAINING

1200 Twin Circuit with MPS

Twin Circuit with MPS Soft Switch

Training Manual

89

SERVICE TRAINING

Twin Circuit with MPS/Soft Switch

14

5

1 19

11 S3

8A

8B

17

6

9A

15

16

18 10C 1

10D

1

9B 22 23 10B

10A

NG 10

13

25

7

1

4

S2 S1

3

0.7 mm

21

12 24

2

20

1

1. Hydraulic oil reservoir 2. Main hydraulic pump 3. Main pressure relief valve 4. Directional control valve S1 5. Rock Valve slewing cylinder 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

90

13. Accumulator unloading valve 14. Accumulator 15. Electric accumulator dump valve 16. Manual accumulator dump valve 17. Accumulator shutoff valve 18. Accumulator safety relief valve 19. Accumulator pressure gauge 20. Accumulator hydraulic pump 21. Accumulator circuit filter 22. Accumulator redundant relief valve 23. NG 10 valve for forward/reverse 24. Soft Switch valve 25. Shuttle valve

Training Manual

SERVICE TRAINING


P1

7

P

X

S1

4

3

B

T

R

X

300 bar

S2

P2

A


3

1

S-1

2 S-2

39000148.eps

S3 Control Block

6 6

S3

1 39000149.eps

Training Manual

91

SERVICE TRAINING

MPS

3

1 2

5

3

4 5

S3

1 3

3

2

92

NG 10

4

Training Manual

5

5

SERVICE TRAINING

Accumulator Control Block/Dump Valve 1 2 Nitrogen pressure set at 100 bar (1450 PSI)

7

3


4

3

2

300 bar

1

5 6 6

T

Y

P

5

7 4

39000152.eps

Accumulator Pump

1

A11

A10

200 bar

39000154.eps

1

Training Manual

93

SERVICE TRAINING

Soft Switch

2 4 1

3

1

0.7 mm

2

3

4 80 bar Soft switch

39000151.eps

94

Training Manual

SERVICE TRAINING

Training Manual

95

SERVICE TRAINING

The following diagrams A through D show the switching functions of the concrete pump kit plumbed on ROD SIDE with simplified schematics. The agitator, boom, and S-1 control circuits are not shown.

•

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

•

The rocking oil forces the left side differential cylinder (8A) to extend. The cylinder rod extends, pushing concrete out of the material cylinder, through the rock valve, and into the pipeline. (This is called the pressure stroke.)

•

The oil from the rod side of the left differential cylinder (8A) is routed back to the tank through the return filter (12). The low pressure oil is shown in green.

•

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

Phase A •

As soon as you switch the unit distribution gearcase to the pumping position, the accumulator hydraulic pump (20) begins pumping high pressure oil (red) to charge the accumulator circuit (14).

•

The high pressure oil (red) from the accumulator circuit charges the accumulator (14). When the accumulator pressure reaches the setting of the accumulator dump valve (13), the accumulator dump valve opens and routes the oil from the accumulator charge pump (20) back to the reservoir (1).

•

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 retract side oil port of the rock slewing cylinder (5).

•

The rod of the rock slewing cylinder (5) retracts, if not already retracted.

•

The S-1 directional control valve (4), which controls whether the unit pumps in forward, neutral, or reverse, is put into the forward position.

•

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

•

High pressure oil (red) flows from the main hydraulic pump (2) through the parallel position of the S2 valve (7) into the rod side of the right side differential cylinder (8B). The cylinder retracts, which creates a vacuum in the material cylinder. The right side material cylinder fills with concrete. (This is called the suction stroke.)

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Training Manual

SERVICE TRAINING

Phase

A MPS Twin Circuit 6.3 mm

14 Nitrogen pressure set at 100 bar (1450 PSI)

5

1

6.3 mm

19

11

15

S3

8A

16

8B 6

9A T

P

B

A

1.0 mm

10C

T

P

1.0 mm

10D

B

A

17

300 bar

18 1

1

9B To e-stop manifold

23 10B

10A

NG 10

22

P

250 bar

13 T

2.5 mm

7

0.7 mm 2.5 mm

200 bar Y

0.7 mm

P

1 4

S2

S1

320 bar

3

0.7 mm

21 KEY

High Pressure

12


Training Manual

2

20

1

97

SERVICE TRAINING

Phase B •

The right side differential cylinder (8B) reaches bottom dead center. If there is not enough rocking oil in the loop to bring the left side differential cylinder (8A) to the top dead center position, oil is added now through check valve 10D.

•

The left side differential cylinder (8A) reaches top dead center. As the piston reaches the guide bushing, it exposes a port to the poppet end port of the switching valve (9A), which becomes connected to high pressure oil (red). The spring end port of the switching valve (9A) is connected to low pressure oil (green), so the switching valve opens, sending high pressure oil (red) toward the left side end cap of the S3 valve (6).

•

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

•

The oil on the right end cap of the S3 valve (6) flows through the check-valve (item 10B) back to tank (1).

•

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

•

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

•

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 to the right, into the cross-over position.

•

As the rock valve slewing cylinder (5) extends, pressure in the accumulator circuit falls. When it drops below the set point of the accumulator dump valve (13), the dump valve closes, and the accumulator hydraulic pump (20) begins to recharge the accumulator circuit.

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Training Manual

SERVICE TRAINING

Phase

B MPS Twin Circuit 6.3 mm


5 6.3 mm

1 19

11

15

S3

8A

16

8B 6

9A T

17

300 bar

P

18

B

A

1.0 mm

T

P

1.0 mm

B

A

10C 1

10D

1


23 10B

10A

NG 10

22

P

250 bar

13 T

2.5 mm

7

0.7 mm 2.5 mm

200 bar Y

0.7 mm

P

1 4

S2

S1

320 bar

3

0.7 mm

To e-stop manifold

21

KEY

High Pressure

12


Training Manual

2

20

1

99

SERVICE TRAINING

Phase C •


•

High pressure oil (red) continues to flow into the accumulator circuit until the accumulators (14) are fully charged to the pressure preset at the accumulator dump valve (13). The accumulator dump valve opens, sending oil from the accumulator hydraulic pump (20) back to the tank (1) without pressure.

•

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

•

As the left hand differential cylinder (8A) moves, high pressure oil (red) reaches the spring end port of the switching valve (9A). The valve closes by the pressure applied to the spring end port. This removes the pilot signal to the left side of the S3 directional control valve (6).

•

As the left side differential cylinder (8A) retracts, 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 side differential cylinder (8A) travels through the hoses to the piston side of the right hand differential cylinder (8B), forcing it to extend. In the material cylinder, the concrete from stage A is forced out into the delivery pipeline. (Pressure stroke.)

•

The oil from the rod side of the right hand differential cylinder (8B) is routed through the S2 valve (7), through the return filter (12), and back to tank (1).

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Training Manual

SERVICE TRAINING

Phase

C MPS Twin Circuit 6.3 mm


5 6.3 mm

1 19

11

15

S3

8A

16

8B 6

9A T

P

B

A

1.0 mm

T

P

1.0 mm

B

A

17

300 bar

18 10C 1

10D

1


23 10B

10A

NG 10

22

P

250 bar

13 T

2.5 mm

0.7 mm

7

200 bar Y

0.7 mm

P

1

2.5 mm

4 S2

S1

320 bar

3

0.7 mm

21 KEY

High Pressure

12


Training Manual

2

20

1

101

SERVICE TRAINING

Phase D •

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

•

Any excess rocking oil (orange) is routed to the tank (1) across check valve 10C.

•

When the left side differential cylinder is in the bottom dead center position, pressure is applied to the poppet end port of the switching valve 9B. The switching valve opens and sends a pilot signal to the right side end cap of the S3 valve (6).

•

The S3 valve (6) moves to the left in response to the pilot signal, putting it into the parallel position. The oil in the left side end cap of the S3 valve (6) escapes to tank (1) across check valve 10A.

•

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

•

The rock valve slewing cylinder (5) retracts, sending the extend side oil back to tank (1) through the S3 valve (6) and the return filter (12).

•

When the rock valve slewing cylinder (5) reaches bottom dead center, the switching groove lines up with the switching port and oil is routed to the right end cap of the S2 valve (7).

•

As the rock slewing cylinder (5) extends, pressure in the accumulator circuit falls. When it drops below the set point of the accumulator dump valve (13), the dump valve closes and the accumulator hydraulic pump (20) begins pumping pressure oil (red) to charge the accumulator circuit (14).

•

This brings us back to phase A. The machine has made one complete cycle, which consists of two suction strokes and two 0pressure strokes.

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Training Manual

SERVICE TRAINING

Phase

D MPS Twin Circuit 6.3 mm


5 6.3 mm

1 19

11

15

S3

8A

16

8B 6

9A T

P

B

A

1.0 mm

T

P

1.0 mm

B

A

17

300 bar

18 10C 1

10D

1


23 10B

10A

NG 10

22

P

250 bar

13 T

200 bar Y

2.5 mm

7

2.5 mm

0.7 mm

0.7 mm

P

1 4

S2

S1

320 bar

3

0.7 mm

21 KEY

High Pressure

12


Training Manual

2

20

1

103

SERVICE TRAINING

Twin Circuit with Variable displacement accumulator pump Schematic

6.3 mm


5 6.3 mm

1 19

11

15

S3

8A

16

8B

17

6

9A T

P

B

A

1.0 mm

T

P

1.0 mm

B

A

300 bar

18 10C 1

10D

1


23 10B

2.5 mm

7

10A

2.5 mm

0.7 mm

22

250 bar

NG 10

0.7 mm

1 4

S2 S1

320 bar

3 To e-stop manifold

21

12 2

20

1 TCVariable.ai

104

Training Manual

SERVICE TRAINING

Model Number Nomenclature The complete model number of Schwing America’s concrete pumps is designated by codes like the following: S 58 SX -125 BPL 2525H-5 120/85MPS The code is broken down as follows:

S 58 SX - 125 BPL 2525H-5 120/85MPS The break down is as follows: S 58 SX- 125 Boom pipe diameter in millimeters Outrigger design Super X Vertical Boom reach in meters Manufacture Schwing BPL 2525H-5 120/85MPS Truck mounted concrete pump (Beton Pumpe Lastkraftwagen) Pump stroke length in meters 2.5 m Material cylinder diameter millimeters 250 mm Factory set up to run on the piston side Liters of hydraulic oil per minute 500 + Hydraulic piston diameter 120 mm Diameter of the piston rod 85 mm Twin circuit pumpkit

Training Manual

105

SERVICE TRAINING

Hi-Flow Pumpkits (2023-2525)

106

Training Manual

SERVICE TRAINING

Hi-Flow Pumpkits (2525H)

Piston Side Operation Optional Waterbox Switching

Training Manual

107

SERVICE TRAINING

Hi-Flow Pumpkits Schematic 5

6

S3

13 16

14

17 18

15 P

9A 9B 20 10A

10B

11 7

S2 S1 4

P

24 3

10C 22

12

21 1.1

8A

23

8B

10D

2

T

19 1

1. Hydraulic oil reservoir 2. Main hydraulic pumps 3. Main pressure relief valve 4. Directional control valve S1 5. Rock valve slewing cylinder 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

108

13. Accumulator 14. Pilot to close accumulator dump valve 15. Manual accumulator dump valve 16. Accumulator pressure maintenance check valve 17. Accumulator relief valve 18. Accumulator pressure gauge 19. Accumulator hydraulic pump 20. NG 10 valve for forward/reverse 21. Soft switch relief valve 22. Soft switch shutoff valve 23. Soft switch reversing valve 24. Main flow poppet valve

Training Manual

SERVICE TRAINING

Concrete Pump Control Block A

B B1

A1 3.0 mm

XA

S2

XB

3.0 mm

PP

0.7 mm

PR

7

4

0.7 mm

S1

T2

XP

P2

P1

T X1 P1

MP T1

T2

24

1.2

A

P P

350 bar

MX

1.4

P2 R R P X

XR

X3

XA

X1

3

22

80 bar

X2

21 X3

XB

1.1 T

23

B

A

7 4

24

A

3 23

The standard Schwing control block has used up to 560 LPM of oil. We have developed a new control block designed for 800 LPM of oil. Called G-3 for 3rd Generation Control Block and is also known as the HiFlow Brain.

21

for compact simpler design The twin circuit machines with G-3 control block will also use the condensed version accumulator (only one larger one).

This block incorporates the soft switch into the relief valve and the accumulator manifold valve into the S-3,

Training Manual

109

SERVICE TRAINING

Main Relief/Soft Switch Block

1

MX

1.4

350 bar X1 2 6

80 bar

X2

3

X3 4

1.1

5

T

6

4

2

3

5 1 39000213.eps

110

Training Manual

SERVICE TRAINING

MPS

10A

3.5MM Orifice

10B

3.5MM Orifice

1.3MM Orifice

9A

9C 9B 9C

9B

10A

9A

The MPS system is an important part of the twin circuit system incorporated in the Hi-flo pump kit. The MPS system consists of three small directional control valves mounted in a manifold. This replaced the two switching valves that were located on the passenger side differential cylinder. The main pressure that is supplied to these directional control valves is supplied by the accumulator. This means we are using accumulator pressure to switch the S3 valve. The end result is a faster, more consistent switch.

10B

cylinders to switch with a minimum delay. The S3 block and the system accumulator are separated from the main control block and located above the hopper end of the material cylinders. Access to these components is facilitated by removing the decking between the water box and the rear boom rest.

The faster switch of the S3 valve allows the differential

Training Manual

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SERVICE TRAINING

S3 Control Block - Machined B

B

A A1

B

1

X

B1

1

S3

XA

XB

A

B

A

1

T

2.0 mm

6 4

300 bar

Mp

5

T

M P

Mp1

3

2

A

M S P 1

8.0 mm

X

7 Psp

T P

P

PS

P

T

7

1 3 6 5 2

4

S0153.eps

112

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B

3

X

B

1

S3 Control Block - Cast

A3

B2

A2

B3

A

1

S3

XB1

2 bar

2.0 mm 3

M P

MSP2

SP P P1 T MS

5

7

MSP1

TUV 330 bar

2 4

P

T

A

MSP3

6.5 mm

X

6

M S P 3

1 A

T3

SP

M S P 2

3

XA1

B

T

MP

3

4 6

1 7 2 5 S0154.eps

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SERVICE TRAINING

2023 Circuit diagram

•

High pressure oil (red) flows from the main hydraulic pump (2) through the parallel position of the S2 valve (7) into the rod side of the right side differential cylinder (8A). The cylinder retracts, which creates a vacuum in the material cylinder. The right side material cylinder fills with concrete. (This is called the suction stroke.)

•

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

•

The rocking oil forces the left side differential cylinder (8B) to extend. The cylinder rod extends, pushing concrete out of the material cylinder, through the rock valve, and into the pipeline. (This is called the pressure stroke.)

•

The oil from the rod side of the left differential cylinder (8B) is routed back to the tank through the return filter (12). The low pressure oil is shown in green.

•

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 ROD SIDE with simplified schematics. The agitator, boom, and S-1 control circuits are not shown.

Phase A Please note that right and left refer to the orientation you would have if you stood on the unit by the rock valve, looking towards the cab of the truck. •

•

As soon as you switch the unit distribution gear case to the pumping position, the accumulator hydraulic pump (20) begins pumping high pressure oil (red) to charge the accumulators.(14). Shown in the beginning position in phase A schematic. High pressure oil (red) continues to flow into the accumulator circuit until the accumulators (14) are charged to the pressure cutoff point of the accumulator hydraulic pump (20). 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 extend side oil port of the rock slewing cylinder (5).

•

The rod of the rock slewing cylinder (5) extends, 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.

•

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.

114

Training Manual

SERVICE TRAINING

Phase

A Hi-Flo

KEY

High Pressure

5

Rocking Oil Pressure Low Pressure Soft Switch Pressure

6

Zero Pressure (Tank, or oil at rest)

S3

14 17

15

18 16

P

9A

9B 23 10A

10B

11 7

S2 S1 4

P

26 3

10C 25

12

24 1.1

8A

27

8B

2

10D

T

20 1 hiflo A.eps

Training Manual

115

SERVICE TRAINING

Phase B Please note that right and left refer to the orientation you would have if you stood on the unit by the rock valve, looking towards the cab of the truck. •

The left side differential cylinder (8B) reaches top dead center. If there is so much rocking oil in the loop that the right side differential cylinder (8A) cannot retract to the bottom dead center position, then oil is removed now through check valve 10C.

•

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 reversing valve (9A), which becomes connected to high pressure oil (red). The left end cap of the reversing valve (9A) is connected to low pressure oil (green), so the reversing 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 accumulators to the retract port of the rock valve slewing cylinder (5). The cylinder begins to retract.

•

The oil from the extend 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.

•

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 (20) increases the flow of hydraulic oil to charge the accumulator circuit (14).

116

Training Manual

SERVICE TRAINING

Phase

B Hi-Flo

KEY

High Pressure

5


6


S3

14 17

15

18 16

P

9A

9B 23 10A

10B

11 7

S2 S1 4

P

26 3

10C 25

12

24 1.1

8A

27

8B

2

10D

T

20 1 hiflo A.eps

Training Manual

117

SERVICE TRAINING

Phase C Please note that right and left refer to the orientation you would have if you stood on the unit by the rock valve, looking towards the cab of the truck. •

The rock valve slewing cylinder (5) reaches the bottom dead center position.

•

High pressure oil (red) continues to flow into the accumulator circuit until the accumulators (14) are charged to the pressure cut-off point of the accumulator hydraulic pump (20). When the cutoff 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 rod side of the left hand differential cylinder (8B).

•

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

•

As the left side differential cylinder (8B) retracts, 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 side differential cylinder (8B) travels through the hoses to the piston side of the right hand differential cylinder (8A), forcing it to extend. In the material cylinder, the concrete from stage A is forced out into the delivery pipeline. (Pressure stroke.)

•

The oil from the rod side of the right hand differential cylinder (8A) is routed through the S2 valve (7), through the return filter (12), and back to tank (1).

118

Training Manual

SERVICE TRAINING

Phase

C Hi-Flo

KEY

High Pressure

5


6


S3

14 17

15

18 16

P

9A 9B 23 10A

10B

11 7

S2 S1 4

P

26 3

10C 25

12

24 1.1

8A

27

8B

2

10D

T

20 1 hiflo A.eps

Training Manual

119

SERVICE TRAINING

Phase D Please note that right and left refer to the orientation you would have if you stood on the unit by the rock valve, looking towards the cab of the truck. •

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

•

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

•

When the left side differential cylinder is in the top dead center position, pressure is applied to the right end cap of the reversing valve 9B. The left end cap of the reversing valve is connected to low pressure, so the valve slides into the parallel position. The reversing 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 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, 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 (20) increases the flow of hydraulic oil to charge the accumulator circuit (14).

•

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).

120

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

Training Manual

SERVICE TRAINING

Phase

D Hi-Flo

KEY

High Pressure

5


6


S3

14 17

15

18 16

P

9A 9B 23 10A

10B

11 7

S2 S1 4

P

26 3

10C 25

12

24 1.1

8A

27

8B

2

10D

T

20 1 hiflo D.eps

Training Manual

121

SERVICE TRAINING

Booms Black & White

Proportional

Electric/Air/Oil - Non Load Sensing

Electric/Oil/Oil - Varable Displacement Pump

Electric/Oil/Oil - Non Load Sensing

Electric/Oil/Oil - Fixed Displacement Pump

Electric/Oil/Oil - Load Sensing BoomCompare.eps

122

Training Manual

SERVICE TRAINING

Black & White Electric/Air/Oil

39000168.eps

Electric/Oil/Oil

39000167.eps

Training Manual

123

SERVICE TRAINING

Electric/Oil/Oil - Load Sensing

39000169.eps

124

Training Manual

SERVICE TRAINING

Proportional Electric/Oil/Oil - Variable

To:Outrigger Function

1PM

P1

P4

T

T

M

P3 P2

39000165.eps

Electric/Oil/Oil - Fixed Displacement

To:Outrigger Function

1PM

P1

P4

T

T

M

P3 P2

39000166.eps

Training Manual

125

SERVICE TRAINING

Boom Holding Valves Schwing uses a specially-designed hydraulically unlockable check valve on all hydraulic cylinders which operate placing boom sections. These valves seal the hydraulic cylinder to prevent it from creeping or moving until pressure is applied to it. A holding valve is installed at both ends of the hydraulic cylinder to prevent movement and limit pressure in either direction.

TRUCK-MOUNTED AND SEPARATE PLACING BOOM HYDRAULIC CYLINDER HOLDING VALVES

HER - SV2 - R 1/2" SCHEMATIC DRAWING

CYLINDER CONNECTION

UNLOCKABLE CHECK

RETURN OIL CONNECTION (LEAKAGE OIL)

RELIEF (NON-ADJUSTABLE) SAFETY VALVE CONTROL LINE CONNECTION (CONNECTED WITH WORKING LINE OF THE OPPPOSITE SIDE)

If oil flowing out uniformly from the leakage oil connection, this indicates that the auxiliary safety valve is not properly sealing. If this holding valve is on boom section 1 cylinder, holding valve replacement is necessary. This auxiliary safety valve protects the cylinder from excess pressure; therefore, this valve must not be set at random. Precision setting for a specific placing boom model is necessary and can only be done with the correct equipment and certified personnel.

BLEED OFF SCREW

PRESSURE CONNECTION (WORKING LINE)

If you should have a problem with a boom section creeping, position the boom in an area which still produces pressure in the corresponding cylinder but leaves the holding valve in an accessible area. Loosen the fitting of the pressure connection of the working line and the leakage oil connection. With the hydraulic pump not turning, you will be able to see which portion of the valve is leaking.

If hydraulic oil is flowing out uniformly from the working line, this indicates that the check valve is not sealing properly, or debris in the oil has caused the unlocking system to hang up and not allow the check valve ball to seat. If there are any questions concerning holding valves or other areas of your Schwing equipment that you need answered, contact your local Schwing dealer or Schwing America, Inc. for more information.

HER VALVE INSTALLATION DRIP-TANK

PORT X

BLOCK A

BLOCK B

LINE B

CYLINDER LINE A

126

PORT Y

Training Manual

CYLINDER ROD

SERVICE TRAINING

28X B&W Boom

300 bar T

Outrigger Jacking Cylinders

B A P1

P

KVM 28

BOOM #2

BOOM #1 (MAIN)

B3

1.3

270 BAR

A3

1.7

270 BAR

B4

1.0

A2

1.7

B2

A1

1.3

B1

1.3

T

SLEWING CYLINDERS

2.0

5 - 7 bar


AIR TANK

140 bar

A4

Low Pressure

1.3

Neutral

Control Pressure

270 BAR

BOOM #3 (Tip)

270 BAR

P

280 bar

T

Reduced Pressure

196101 10/91 RE

W/ MONSUN - TISON HANDVALVES

High Pressure

T

127

Training Manual

SERVICE TRAINING

300 bar T


B A P1

P

KVM 28 196101 10/91 RE

BOOM #2

BOOM #1 (MAIN)

B3

1.3

270 BAR

A3

1.7

270 BAR

B4

1.0

A2

1.7

B2

A1

1.3

B1

1.3

T

SLEWING CYLINDERS

2.0

5 - 7 bar


AIR TANK

140 bar

A4

1.3

Low Pressure

#3 Extend Only

Control Pressure

270 BAR

BOOM #3 (Tip)

270 BAR

P

280 bar

T

Reduced Pressure


High Pressure

T

Training Manual

128

SERVICE TRAINING

300 bar T


B A P1

P

KVM 28 196101 10/91 RE

BOOM #2

BOOM #1 (MAIN)

B3

1.3

270 BAR

A3

1.7

270 BAR

B4

1.0

A2

1.7

B2

A1

1.3

B1

1.3

T

SLEWING CYLINDERS

2.0

5 - 7 bar


AIR TANK

140 bar

A4

Low Pressure

1.3

#1 Retract #3 Extend

Control Pressure

270 BAR

BOOM #3 (Tip)

270 BAR

P

280 bar

T

Reduced Pressure


High Pressure

T

129

Training Manual

SERVICE TRAINING

P

B A P1


PRINT # 329324

300 bar T

T

A P

P

35 bar

270 BAR

BOOM #3 (Tip)

270 BAR

280 bar

T

270 BAR

BOOM #2

1.0 B4

270 BAR

1.3 A4

1.3 B3

140 bar

BOOM #1 (MAIN)

1.7 A3

KVM 28 190321


1.7

A2

B2

1.3 B1

T

T

SLEWING CYLINDERS

2.0

1.3 A1

5-7 bar

Training Manual

130

SERVICE TRAINING

Load Sense Hydraulic Circuits Overview Load sense hydraulic circuits offer advantages over conventional fixed flow circuits. One advantage is improved efficiency. With the conventional system, a fixed displacement hydraulic pump is used to run the boom. This hydraulic pump must have the capability of displacing enough oil volume to run the largest cylinder on the boom. However, because the smaller cylinders on the boom require less oil volume, an inline orifice is used to divert the excess oil to tank via the relief valve. When no boom function is activated, this fixed volume of oil is routed through the handvalve and back to the tank. All of the excess oil is converted to wasted horsepower and heat.

When activating a function by remote on a “black & white” system, the handvalve spool is fully activated and a signal is sent to the hydraulic pump to send the required amount of oil to run that function.

1.0

1.3 A4

P

280 bar

T

39000180.eps

When activating a function on a proportional system, electronics are used to vary the position of the handvalve spool, which in turn varies the speed of the function. The proportional system allows the operator to move the boom as slow and as fast as desired; thus increasing controllability for smoother boom movement, and reducing operator effort. C2

C1 G1/2

39000178.eps

With the original load sense hydraulic circuit, a variable displacement hydraulic pump was used. This hydraulic pump puts out only the required volume of oil needed to run any particular function or combination of functions. This pump also de-strokes to a minimum output when no functions are activated; thus conserving energy and fuel.

A7 VO Pump

A

39000181.eps

NOTE! The complete hydraulic system on a load sense hydraulic circuit must be kept as clean as possible due to many of the components used in these circuits contain precision machined metering passages and spools that could malfunction from contamination.

A1

T

X3

39000177.eps

Training Manual

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SERVICE TRAINING

Components Constant:A theoretical factor that is regarded as invariant in specified circumstances. The constant for calculating hydraulic HP is: 1714 (when psi and gpm are used). The constant for calculating kW is: 600 (when bar and lpm are used). Horsepower (HP):A unit of power in the United States Customary System, equal to 0.7457 kilowatts (kW). To calculate hydraulic horsepower consumption, use the following formula; HP= Pressure multiplied by the Volume, divided by a Constant.

HP =

GPM x PSI 1714

KW =

LPM x BAR 600

Orifice: A restriction installed in either a hydraulic or pneumatic passageway to create a pressure drop. This does not always reduce flow directly, but it may cause enough pressure upstream so that some of the flow would be diverted or reduced elsewhere.

Pressure Drop

Orifice created between the spool and valves walls

39000182

Delta Pressure (Delta-P):The pressure differential between two given points in a hydraulic circuit.

Q-Maximum(Q-max): The highest volumetric flow rate possible from the hydraulic pump. Adjusted with a mechanical stop screw. Turn screw inward to decrease and outward to increase. Q-Minimum(Q-min): The lowest volumetric flow rate possible from the hydraulic pump. Adjusted with a mechanical stop screw. Turn screw inward to increase and outward to decrease. Q-Min Screw

Delta P = 13.8 bar

(200 psi)

1000 PSI 68.95 bar

Q-Max Screw Q-Max

1200 PSI 82.75 bar

Q-Min

Section Compensator: A component in the directional control valves that self-adjusts for supply pressure changes. Also described as a pilot operated pressure compensating valve.

X C1 G1/2

C1

Section Compensator

X3

T

P

39000183.eps

C2

Section Compensator 39000186.eps

132

Training Manual

SERVICE TRAINING

Basic Principles - Simple Circuit In this diagram, the cylinder will take exactly 1 minute to extend with a pressure of 1000 psi. When the cylinder reaches the end of the stroke, something will have to break because there is no relief valve and the hydraulic pump is fixed displacement, meaning the pump will continue to put out oil until it is shut off.

.

10,000 lbs

10”

1000 psi

10 GPM

39000187.eps

Training Manual

133

SERVICE TRAINING

Basic Principles - Orifice In this diagram, we have a 10 gpm fixed displacement pump, an orifice creating a pressure drop of 200 psi, and free-flowing back to tank.

0 psi

200 psi

10 GPM

39000188.eps

134

Training Manual

SERVICE TRAINING

Basic Principles - Without Relief Valve In this diagram, the cylinder will take exactly 1 minute to extend with a pressure of 1000 psi at the cylinder and a pressure of 1200 psi at the pump due to the orifice that caused a pressure drop. The orifice did NOT change the flow rate nor the cylinder speed. When the cylinder reaches the end of the stroke, something will have to break because there is no relief valve. 10,000 lbs

10”

1000 psi

1200 psi

10 GPM

39000189.eps

Training Manual

135

SERVICE TRAINING

Basic Principles - With Relief Valve In this diagram, A relief valve has been added. When the cylinder has bottomed out, the relief valve vents the excess pressure to tank. The pressure vented to tank becomes wasted horsepower and generates heat.

10,000 lbs 10,000 lbs

10” 10”

1000 psi

2000 psi

1200 psi

2000 psi

2000 psi 10 GPM

10 GPM

39000190.eps

136

Training Manual

SERVICE TRAINING

Basic Principles - Delta-P In this diagram, the handvalve is in the neutral position. The pump is only putting out enough oil to maintain Delta -P.

10”

0 psi

Delta P The pressure differential between two given points in a hydraulic circuit

200 psi 2000 psi X

X3

A

T

P

39000191a.eps

Training Manual

137

SERVICE TRAINING

Basic Principles - Delta-P In this diagram, the cylinder will take exactly 2 minutes to extend. There will be a pressure of 1000 psi at the cylinder and a pressure of 1200 psi at the pump. The orifice caused a drop in pressure (Delta-P). The regulator has been adjusted to maintain 200 psi (Delta-

P). The pump is only supplying the amount of oil required to maintain the (Delta-P). In this case, 5 gpm. If the size of the orifice increases, the flow rate will be increased by the Delta-P regulator. That will increase the speed of the cylinder.

10”

1000 psi

Delta P The pressure differential between two given points in a hydraulic circuit

1200 psi

X

X3

A

T

P

39000191.eps

138

Training Manual

SERVICE TRAINING

Basic Principles - Pressure Cut-Off In this diagram, the cylinder is at the end of it’s stroke. There will be a pressure of 3000 psi at the cylinder and a pressure of 3000 psi at the pump. The orifice does NOT cause a drop in pressure because there is no flow.

The regulator has been adjusted to a pressure limit of 3000 psi. The pump is only supplying the amount of oil required to maintain 3000 psi.

10,000 lbs

10”

4350 psi

4350 psi

X

X3

A

T

P

39000192.eps

Training Manual

139

SERVICE TRAINING

Basic Principles - Shuttle Valves

have been replaced by the proportional handvalves. The regulator has been adjusted to a pressure limit of 3000 psi. If any one cylinder reaches the end of it’s stroke, the main pressure will be 3000 psi.

In this diagram, the cylinder with the highest load (2500 psi) will be monitored at the regulator. The regulator will maintain the 200 psi delta-P above that load. The orifices, needed to cause a drop in pressure,

25,000 lbs

20,000 lbs

10”

10,000 lbs

10”

2500 psi

10”

2000 psi

1000 psi

X

X3

A

T

P

39000193.eps

140

Training Manual

SERVICE TRAINING

Basic Principles - Pressure Regulator

Δ P regulator

Δ P regulator

X 20 bar Δ P 300 bar

Pressure Regulator 300 bar

ΔP Regulator 20 bar

A

X

T

0 bar

ORIFICE 0.8 mm KVM 36X . . . . 1.6 mm 0-15 Bar KVM 36 LW . . 1.6 mm KVM 42 . . . . . .1.6 mm KVM 52 . . . . . .not used

P

A

T

P

Pressure Regulator (300 bar) ΔP Regulator (20 bar)

A

P T

39000219.eps

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SERVICE TRAINING

A7 Variable Displacement Hydraulic Pump Training All Functions in Neutral The directional valve is in the neutral position. Hydraulic oil is blocked at the handvalve.

Pressure below 20 bar Pressure below 20 bar

X 20 bar Δ P

X

C2

300 bar

C1 39000197.eps A

T

C1

C2

20 bar spring

A

P 20 bar spring T

Moving the spool to the left will create a passage way from the Control Piston Chamber of the hydraulic pump to tank. Oil blocked by spool

Passageway opened to tank

39000195.eps

The pumps rotary group is at reduced displacement, and is only putting out enough oil to maintain 20 bar (Delta-P)

Passageway opened to tank

X 20 bar Δ P

X

+20 bar pressure pushing on spool Compressed Spring

39000199.eps A

300 bar T

P

A X 20 bar Δ P

This will create a pressure drop on the piston side of the Control Piston Chamber, allowing the spring on rod side of the chamber to decompress. As the spring decompresses the angle of the rotary group will increase. The pump will displace more oil, until 20 bar (Delta-P) reached.

A1

T

300 bar X3

A

T

P

39000194.eps

Not enough pressure to hold back the spring A

+20 bar pressure pushing on spool

X 20 bar Δ P

Compressed Spring

A1

T

300 bar X3

A

A

T P

T

P

39000200.eps

X3

Pressure on the “A” port drops below 20 bar, the force of the spring is greater than the pressure exerted on the spool. The spring will decompress, moving the spool to the left.

X

A

T

P X3

Not enough pressure to hold back the spring

The rotary group angle will increase/decrease as necessary to maintain 20 bar (Delta-P).

142

Training Manual

SERVICE TRAINING

KEY High Pressure

330 bar 320 bar

Low Pressure

310 bar

Control Pressure

320 bar

1.0 mm

Reduced Pressure


1.0 mm

NOTE: On the schematic, the 20 bar Delta P spool and spring is shown above the 300 bar spool and spring. On the Pressure Regulator cut-out, you can see that in reality the 300 bar spool and spring is located above the 20 bar Delta P spool and spring.

Δ P regulator

3

A7 VO Pump X 20 bar Δ P

A

A1

T

300 bar X3

A

T

P

A7 VO Pump

Δ P regulator

A1 Q-MIN Pressure Regulator 300 bar


A

A

T

X

0 bar


P

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Training Manual

143

SERVICE TRAINING

Cylinder Extend Function Initiated The directional valve has been moved to the "cylinder extend" position. Oil travels through the handvalve and to the boom holding valve. A signal is also sent from the handvalve to the Delta P regulator, via the “X” port.

This will create a pressure drop allowing the spring on rod side to decompress, thus changing the angle of the rotary group to displace enough oil to extend the hydraulic cylinder. Decompressed Spring

The pressure from the “X” port plus the 20 bar spring is greater than the pressure on the “A” port side of the spool. This will move the spool to the left, creating a passage way for the oil in the Control Piston Chamber of the hydraulic pump to tank.

A X

A1

20 + Load bar Δ P T 300 bar X3

1 A

Pressure + 20 bar spring signal from handvalve pushing on spool

T

P

39000202.eps

Rotary Group

X

A X

A1

A

X3

20 + Load bar Δ P T

Not enough pressure to hold back the spring

300 bar

Oil enters the holding valve. The hydraulically unlockable check valve “opens” allowing oil to enter the piston side chamber of the hydraulic cylinder. A signal is also sent to the rod side hydraulically unlockable checkvalve. This will open the relief valve and create a passageway for the oil on the rod side chamber to escape to tank.

X3 A

T

T

P

P

Control Piston Chamber

Pressure + 20 bar spring signal from handvalve pushing on spool C1

C2

Open Relief

320 bar X A

T

310 bar

330 bar

320 bar

1.0 mm

P

Control Piston Chamber

1.0 mm

X3

39000201.eps

Open Checkvalve 39000203.eps

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Training Manual

SERVICE TRAINING

KEY High Pressure

330 bar 320 bar

Low Pressure

310 bar

Control Pressure

320 bar

1.0 mm

Reduced Pressure


1.0 mm


Δ P regulator

A7 VO Pump X

A

A1

20 + Load bar Δ P T 300 bar X3

A

T

P

A7 VO Pump

Δ P regulator



A

A

T

X

0 bar


P

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Training Manual

145

SERVICE TRAINING

Hydraulic Cylinder Extending The hydraulic pump is only putting out enough oil to extend the hydraulic cylinder. Depending upon the load requirements, the signal line pressure will increase or decrease accordingly. If the signal line pressure increases, the 20 bar Delta P spool will open, allowing allowing a larger passageway for the Control Piston Chamber oil to escape to tank. This will decrease the pressure on the piston side of the Control Piston Chamber, allowing the spring on the rod side to decompress and the angle of the rotary group to increase, creating more flow to meet the load requirements. Example: Load requirements for a particular function increse. Increased Load

‘X” port pressure on the spring side of the 20 bar spool is greater than the “A” port pressure. The spool will move to the left, creating a larger passageway for the Control Piston Chamber oil to escape to tank. The farther left the spool moves, the larger the opening back to tank X A A

20 + Load bar Δ P

T

39000206.eps

With a larger passageway to tank, pressure decreases in the Control Piston Chamber.

Increased Load X

1.0 mm

320 bar

A1 310 bar

330 bar

T

320 bar

A

T 1.0 mm

39000204.eps

As the load requirements increase, the signal line pressure from the handvalve to the “X” port increases. Increased Load

X3

39000207.eps

With a larger opening created to tank, the pressure on the piston side of the chamber will decrease.

Increased Load C2

C1

Spring decompresses, rotary group angle increases, more flow created.

C1

C2

More oil displaced A1

T

Load increases, signal line pressure increases

X A

X

A

T

20 bar Δ P

39000205.eps

146

Training Manual

X3

39000208.eps

SERVICE TRAINING

KEY High Pressure

330 bar 320 bar

Low Pressure

310 bar

Control Pressure

320 bar

1.0 mm

Reduced Pressure


1.0 mm


Δ P regulator


A

A1

T

300 bar X3

A

T

P

System when equipped with Rexroth hydraulic pump

A7 VO Pump

Δ P regulator



A

A

T

X

0 bar


P

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Training Manual

147

SERVICE TRAINING

Hydraulic Cylinder Fully Extended Pump The cylinder has fully extended.

If pressure reaches over 300 bar. The spring on the 300 bar spool will compress. Creating a passageway for oil from the “A” port to pass through the spool and flow to the piston side of the Piston Control Chamber. 300+ pressure X

T 300 bar

310 bar

320 bar

320 bar

1.0 mm

330 bar

A A1

X3 1.0 mm

P

39000211.eps 39000209.eps

Pressure has been equalized on both ends of the 20 bar (Delta P) spool.

X

A

T

P X3 C2

C1

C1

C2

Pressure on the piston side of the chamber is greater than the rod side pressure, plus spring. The spring will compress, decreasing the angle of the rotary group, resulting in less flow. The pump will only put out enough flow to maintain 300 bar.

Equal pressure

A X

A X

20 bar Δ P

A1

300 bar

X3 X3

T

T

300 bar

T

A

A1

P

39000212.eps

P

X

A

T

P X3

X

A

T

P X3 39000210.eps

148

The rotary group angle will increase/decrease putting out more/less oil to maintain 300 bar.

Training Manual

SERVICE TRAINING

KEY High Pressure

330 bar 320 bar

Low Pressure

310 bar

Control Pressure

320 bar

1.0 mm

Reduced Pressure


1.0 mm


Δ P regulator


A

A1

T

300 bar X3

A

T

P


A7 VO Pump

Δ P regulator



A

A

T

X

0 bar


P

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Training Manual

149

SERVICE TRAINING

Fixed Displacement Pump Training All Function in Neutral

EB ∅1.0

B1

290 bar

320 bar

B2

330 bar T

300 bar

A2

A1 ∅1.0 EA

C1

C2 G1/2

C1

C2

PP

G1/2

15 bar

0.2 mm

300 bar P

.061 mm

LS

T

KEY High Pressure Reduced Pressure Pretension Pressure High pressure filter

Low Pressure Zero Pressure (Tank, or oil at rest)

2.0 atmospheres

150

Training Manual

SERVICE TRAINING

Boom Function Activated

EB ∅1.0

B1

290 bar

320 bar

B2

330 bar T

300 bar

A2

A1 ∅1.0 EA

C1

C2 G1/2

C1

C2

PP

G1/2

15 bar

0.2 mm

300 bar P

.061 mm

LS

T



2.0 atmospheres

Training Manual

151

SERVICE TRAINING

Cylinder Pressurized at the End of Stroke

EB ∅1.0

B1

290 bar

320 bar

B2

330 bar T

300 bar

A2

A1 ∅1.0 EA

C1

C2 G1/2

C1

C2

PP

G1/2

15 bar

0.2 mm

300 bar P

.061 mm

LS

T



2.0 atmospheres

152

Training Manual

SERVICE TRAINING

Output Charts

•

maximum strokes per minute of your pumpkit model.

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 change their displacement per revolution, resulting in less flow and fewer 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 pumpkit model. • maximum output (in cubic yards per hour) of the pumpkit model.

•

maximum output (in liters per minute, L/min) of your hydraulic pumps.

•

expected output at various pumping pressures.

•

condition of your hydraulic pumps when used in conjunction with a flowmeter.

•

breakpoint of your hydraulic system.

BPL 1200 HDR-23

Pumpkit model

PERFORMANCE CHARACTERISTICS OF THE AXIAL PISTON HYDRAULIC PUMP

ROD SIDE (bar)

PISTON SIDE (bar)

An explanation of an output chart is shown on the following pages, followed by some examples of chart usage. The output chart of the pumpkit shipped with this manual is shown later.

PUMP SPEED 2100 RPM HYDRAULIC RELIEF VALVE IS SET AT 300 BAR MAX. PRESSURE (4350 PSI).

350 PISTON SIDE

Piston side breakpoint

200

ROD SIDE

131

1800

124

1700

117

1600

110

1500

103

83

1100

76

1000

70

900

62

800

The breakpoint specification is listed here.

52

48 41

200

500

34

150

400

28

300

21

200

14

100

7

100 50 breakpoint 0 178 bar

13

26

39

52

65

78

92

105 118 131 144 103 CONCRETE OUTPUT (cu yd / h)

157 170 183 196 170.5

26 5 50 PISTON SIDE

10 100

150

5 100

15 200

10 200

300

20 250

300

15.5 15

20

400

500

25 350

400 25

OIL VOLUME (liter / min.) 30 NUMBER OF STROKES (stroke / min.) OIL VOLUME (liter / min.)

Material Cylinders Bore dia. x Stroke length

Hydraulic Pumps Type / KW

125 mm / 80 mm x 2000 mm

230mm x 2000 mm

2 x A7VO-107 2 x 66KW

Slewing cylinder 80 / 45 x 185

Training Manual

Concrete output is shown here, with max shown for both piston and rod side configurations.

30 NUMBER OF STROKES (stroke / min.)

Differential Hydraulic Cylinder Bore dia. / Rod dia. x Stroke length

output chart explain.eps

Concrete pressure is shown here. Max. pressure is shown for both piston and rod side configurations

55

600

250

ROD SIDE

Hydraulic liters per minute and the corresponding strokes per minute for both piston and rod side.

758

700

100

50

97 88.6 90

1200

Rod side breakpoint

300 150

1900

1300 1285

250

350

CONCRETE PRESSURE (BAR) 138

1400

300

OIL PRESSURE (BAR)

Hydraulic oil pressure shown here, ranging from zero to the relief valve setting.

CONCRETE PRESSURE (PSI) 2000

Information about the pumpkit and hydraulic pumps is shown here.

153

SERVICE TRAINING

Using the Chart

the 220 bar oil pressure marking on the rod side scale (item A in the example below). Then draw a line straight across the page until you intersect with the horsepower curve (Item B). Next, 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.

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. To determine whether your unit is acting normally, locate


ROD SIDE (bar)

PISTON SIDE (bar)

output chart use.eps


350 PISTON SIDE

B. Draw a line STRAIGHT across the page until you contact the horsepower curve of the rodside. Then draw a line straight down from the intersection point.

OIL PRESSURE (BAR)

300

A. Find 220 bar on the rod side oil pressure scale.

250

200

ROD SIDE

350

250 200

EXAMPLE 1

100 150 50

50

131

1800

124

1700

117

1600

110

1500

103

1400

97

1300 1285

88.6 90

1200

83

1100

76

1000

70

900

62 758

52

55

700

48

600

41

500

34

400

28

13

graph tells you how 14 many 200 yards/hour you can expect (in this100case, about 7138). Where the line crosses the number 26 39 52 65 78 92 105 118 131 144 157 170 183 196 of strokes scale tells 103 170.5 you how many strokes per minute you can expect (in CONCRETE OUTPUT (cu yd / h) this case, a little over 21). 26

ROD SIDE

5 50

PISTON SIDE

10 100

150

5 100

15 200

10 200

300

20 250

300

15.5 15

20

400

500

Example 2—Checking your hydraulic pumps To determine whether your pumps are still in good working condition, use the output chart and a flow meter. Test one pump at a time, multiply the readings

154

1900

21 the 300 the line leaves C. Where

100

breakpoint 0 178 bar


800

300 150


25 350

400 25

30 NUMBER OF STROKES (stroke / min.) OIL VOLUME (liter / min.) 30 NUMBER OF STROKES (stroke / min.) OIL VOLUME (liter / min.)

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.

Training Manual

SERVICE TRAINING

To test your pumps: • Use use the chart that applies to your unit (see Output Chart in the Appendix of your Operation Manual). • Select the proper truck transmission gear for pumping (found on the information plate mounted in the truck cab). • Set the pump speed (input drive shaft) RPM. Pump speed information is found on line 16 of the Delivery Inspection Report which arrived with your unit when it was new. A difference of even a few RPM will give you a bad reading. Check the RPM with a digital tachometer if one is available. • Know how to use your flowmeter. Read the instructions that came with it. A flowmeter must be calibrated periodically.

Make two copies (one for each pump tested) of the Output Chart located in the Appendix of the Operation Manual. Don’t use the original copy, you will need additional copies of the original for future tests.

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

1st Pump

breakpoint specification

150 or

•

liters/min (read on meter)

2nd Pump Total (for plotting)

liters/min (read on meter)

Total (for plotting)

0 bar

x2

x2

100 bar

x2

x2

breakpoint

x2

200 bar

x2

x2

250 bar

x2

x2

300 bar

x2

x2

breakpoint

x2

checking output form

As an example, we’ll assume that we have just taken the following readings.

Training Manual

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SERVICE TRAINING

Plot the readings on the output chart. Take a clean output chart and proceed as follows: • Lay a straight edge horizontally across the page at the pressure point you are plotting. Draw a light line across the chart. In the example below, we use the rod side scales and curve (you could use the piston side scale and curve instead). The ruler is shown ready to draw a line at 250 bar hydraulic pressure.

•

Turn the ruler sideways and draw a light line up the page from the liters/minute reading you took at that pressure. (Remember to multiply the reading by 2.) In our example, we measured 276 liters at 250 bar.

•

Put a dot at the point where the two lines intersect.

•

Do the same thing with each pressure reading. You should end up with six dots.


ROD SIDE (bar)

PISTON SIDE (bar)

1checking output.eps


350 PISTON SIDE

OIL PRESSURE (BAR)


1900

131

1800

124

1700

117

1600

110

1500

103

1400

97

1300 1285

300

250

200


1200

83

1100

76

1000

70

900

62

ROD SIDE

350

800

300 150

250

1 200

2

3

4

5

6

7

8

9

10

100 150 50

50 13

26

39

52

65

78

92


5 50

PISTON SIDE

100

150

5 100

156

10

15 200

10 200

300

20 250

300

15.5 15

20

400

500

Training Manual

52

55 48

600

41

11 500

34

400

28

300

21

200

14

100

7

157 170 183 196 170.5

26 ROD SIDE

758

700

100


88.6 90

25 350

400 25

30 NUMBER OF STROKES (stroke / min.) OIL VOLUME (liter / min.) 30 NUMBER OF STROKES (stroke / min.) OIL VOLUME (liter / min.)

SERVICE TRAINING

•

the upper right of the spec, you have done the test incorrectly, or you are using the wrong chart. In our example, the pump is okay. (See the plot which follows.)

Connect the dots. If your plotted line reasonably matches the specification plot on the chart, the pump is fine. If your line is to the lower left of the spec, the pump is getting weak. If your line is to

ROD SIDE (bar)

CONCRETE PRESSURE (PSI) 2checking output.eps

300 bar

350

83

1100

76

1000

70

900

62

Breakpoint 800

300 OIL PRESSURE (BAR)

1200

250 bar

ROD SIDE

250 200

200 bar

150 100 50


100 bar

OK 13

26

0 bar 39

52

65

78

92

105 118 131 144

CONCRETE PRESSURE (BAR)

758

52

55

700

48

600

41

500

34

400

28

300

21

200

14

100

7

157 170 183 196 170.5

CONCRETE OUTPUT (cu yd / h) 26 ROD SIDE

5 50

10 100

150

15 200

20 250

(234)

300 (276)

25 350 (338)

400

30 NUMBER OF STROKES (stroke / min.) OIL VOLUME (liter / min.)

(388) (398) (392)

Check the second pump. We hook up the flowmeter just as when we checked the first pump. Again, be sure that you have the correct speed, gear, chart, and so on. This time our example will have worse results.

Training Manual

157

SERVICE TRAINING

Plot the results again 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 next chart.)

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.

handy when you call to get a replacement. Also, please advise us if you have changed differential cylinders, material cylinders, or hydraulic pumps, because you may need a different output chart than the one that was originally shipped with the unit.

NOTE! Never try to make up for this weak pump by increasing the speed of the engine. As the pump turns faster than specifications, 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 results. 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 America Service Department for the procedure. There are many different possible pumpkits and power settings for this unit. If you accidentally destroy your original output chart, please have your serial number

158

Training Manual

SERVICE TRAINING

Using a Nomograph General information NOTE! If you have read the original Schwing America publication, Nomographs—A Guide to Usage, you will notice several changes in this document. Because not all of the power from the truck engine is used for the concrete pump, the TK number of the engine has no meaning. Therefore, this section about using nomographs has been adapted especially for boom pumps. You can still figure out the TK of the job to do, but the suitability of the pump has to be determined in a different manner. To make the pump numbers and job numbers match, we will use a “Power Factor number,” which takes into account the power of the hydraulic pumps instead of the engine and is easy to use with cubic yards per hour and PSI instead of cubic meters per hour and bar. Concrete pumps are limited in what jobs they can do by three factors: 1. The amount of power available. 2. The maximum concrete output available. 3. The maximum concrete pressure available. To estimate the power a pump requires to complete a particular job and to determine which pump is appropriate, a nomograph is used.

With a concrete pump that is driven by its own prime mover, such as a trailer-mounted concrete pump or a truck-mounted pump with a separate drive engine, the power rating (in Kw) is shown for the engine or electric motor. With 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.) If you know the required output for the job, the nomograph will help you calculate the required pressure. If you know the output and pressure, you can calculate the power requirement. The nomograph was developed by extensive trial-anderror testing and has proven to be accurate to ±10% in nearly all pumping applications. The original nomographs used “spread measure” of fresh concrete instead of slump, and the two are not directly interchangeable. Some approximations are used in translating the charts from spread measure to slump, but the ±10% accuracy still applies. In all cases, it is assumed that you will receive fresh, high-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 fill the cylinders only 80%, you should multiply the required output by 1.25 (1÷80%). The nomograph is divided into four quadrants .

Upper left quadrant

Upper right quadrant

Figure 1 Quadrants Lower left quadrant

Training Manual

Lower right quadrant

159

SERVICE TRAINING

To use the nomograph, you begin at output required and move clockwise 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 2).

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 concrete output and pipeline diameters. The lower right quadrant accounts for the resistance to flow of the entire pipeline system. The lower left quadrant accounts for the pumpability of the concrete.

Pipeline diameter in inches

(72600) 200

For vertical placing, add 1.105 PSI per foot of level difference.

180 160

Q in yd3/hr.

boom-small-no blocks-eps

TK number does not apply to truck mounted units. Curve shown is the Power Factor number (PF).

6"

5"

4.5"

140

4"

120 116

Rod side

100 80 Piston side

60

67

40 132 KW

20 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 1566 870 P in PSI

600

400

200

100 200 2" 300 400

2.5"

500 600 3" 4"

5"

6"

Slump of fresh concrete in inches

Pumpkit Model: 120/80 x 1600:200 Power: 132 KW

3000 2500 2000 1800 1500

1200

1000

800

Proportional value of pipeline in feet

Figure 2 Moving around a nomograph To illustrate the use of a nomograph, we will use a hypothetical job situation with the following specifications. 1. We will need an average output of 75 cubic yards per hour, 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, and taking care of miscellaneous jobs. This means that when we are actually pumping, we will need an output rate of 75 ÷.75 = 100 yd3/hr. 2. We will use 5-in.-diameter pipeline. 3. We will need the following pipeline lengths: Separately laid pipeline. • 40 ft of 5-in. rubber hose • 150 ft of 5-in. horizontal steel pipe

160

Boom pipe, elbows, and deck system. • 13 ft of 5-in. rubber hose • 144 ft of 5-in. steel pipe (on the boom and pump deck) • 5.25 ft of 6–to–5-in. reducer (on the pump) • 4 5-in. 45° elbows, radius 250 mm • 11 5-in. 90° elbows, radius 250 mm • 2 6-in. 90° elbows, radius 250 mm 4. We will specify a slump of 5-6 in. and use the 5-in. line on the chart. 5. In addition, when we add the pressure for the vertical run, we will have to add 1.1 times 70 ft = 77 PSI. All of these criteria will be explained in detail as we go through the individual quadrants.

Training Manual

SERVICE TRAINING

The quadrants


Kw rating

180 160

Example Job

Working power (in kW)

Power curve

200

Power factor number (replaces TK) Q in. yd3/hr.

upper left quad-eps

Power factor number (PF) English to Metric Conversion Factor is PF Ö 18.966

56,650

1. The upper left quadrant describes the power curve of a given hydraulic pump Kw rating and the maximum output and maximum pressure of a particular model of concrete pump (Figure 3).

140 120 100 Maximum output and 80maximum pressure of a specific unit 60 40 20

103 KW 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 P in PSI

Figure 3 Upper left quadrant Any concrete pump selected for a job must meet three technical parameters: • The power factor number of the pump must be equal to or greater than the power factor number of the job. • The maximum output required by the job must be available from the pump. • The maximum pressure required by the job must be available from the pump. It is important to notice the pump maximum pressure and maximum output, even if the power factor number of the pump is larger than the job requires. These parameters are decided during the design stage of the unit and cannot be adjusted on the job. If the unit is able 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 the same amount. The power factor number (PF) replaces the TK number on a truck-mounted unit. It is the Kw multiplied by a constant (550) that has several

efficiency factors figured in. When using an Americanized nomograph (pressure in PSI and flow in cubic yards per hour), the pressure multiplied by the output must always be less than or equal to the PF of the pump. For example, if you needed 50 cubic yards per hour and determined that this will require 750 PSI, you can multiply 50 by 750, which equals 37,500. Any pump you select must have a PF of 37,500 or greater. If you are using a nomograph that has been converted to metric units of measure (pressure in bar and output in cubic meters per hour), you can still multiply the pressure by the output, but you must multiply the answer by the conversion factor between metric and English units of measure to get the PF. The conversion factor for cubic yards to cubic meters and bar to PSI is 18.966. For all practical purposes, you can use 19. For example, if you need 50 cubic meters per hour and determine that your job setup will require 65 bar, you can multiply 50 by 65, which equals 3250. Multiply this by 19, and you find that your PF requirement is 61,750. Again, any pump you select for the job in this example should have a PF of 61,750 or greater.

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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 material cylinders. The unit is usually designed so maximum output can be achieved only at less than maximum pressure. 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 contract to pump a job that requires only 20 yards per hour, but you calculate that you will need 2100 PSI pressure. The PF of this job is 42,000 (20 x 2100). The pump shown in Figure 3 has a TK of 72,600, so there is enough power available. However, the maximum pressure available from the pump is only 1570 PSI. This pump would not do the job. 6. 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-inch pipeline than, for example, a 4-inch pipeline. When pressure is exerted on concrete in a pipeline, a paste of water and cement fines coats the inside of the pipe-

line and forms a slippery layer on which the bulk of the concrete slides. While it is true that a 6-inch pipeline has 49 percent more surface area to coat than a 4-inch pipeline, the volume of concrete that can move on the layer is increased by 12 percent, 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-inch pipe may be able to do it easily through 6-inch pipe. Note! Experience has taught us that 5-inch is the optimum pipeline size for lengthy vertical runs such as those found on high-rise buildings. It is large enough for most aggregate, but small enough that you minimize the amount of concrete that slides back into the hopper when the concrete valve cycles, which we call backwash. You must also consider the people at the point of placement. Very few hose handlers, if any, can move 6-inch 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-inch to 4-inch, pipe, you should calculate the chart as if you were using 4-inch pipe for the entire distance. This will not be completely accurate, but you will be safe in your pressure calculation. In our example (Figure 4) we use 5-inch pipeline.

Q in yd3/hr.

Pipeline diameter in inches 6"

5"

4.5" 4"

Make a 90° turn when you intersect with the pipeline diameter that applies to your job. uppr rght quad-eps

Figure 4 Upper right quadrant—Pipeline diameter

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When the output line intersects the pipeline diameter that corresponds to your job, draw a line straight down into the lower right quadrant, as shown in Figure 4. 7. 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 number of bends, the increased resistance of flow in rubber hose, and other factors. It is more a measure of the resistance to flow than a measure of length. In calculating the proportional value of your pipeline, always apply the following criteria: Each 90° bend with a radius of 250 mm (boom elbow) = 3.5 feet. boom 4 nomo.eps

•

• • •

•

•

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 three 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). Figure all horizontal and vertical distances equally. The increased pressure required to push concrete vertically is accounted for by adding pressure, not distance. An example pipeline is shown below (Figure 5).

150 ft. pipe

40 ft. hose

70 ft. level difference

elbow - 90°, r = 250 mm...3.5 feet elbow - 90°, r = 1 meter...10 feet elbow - 30° or 45°, r = 250mm or 1 meter...3 feet Note! Proportional value of the 39X boom and deck pipe system is 261 feet. This value includes elbows, reducer, and tip hose. Example: You must go 150 feet out through the deck and boom pipe, including the tip hose, then through 40 feet of rubber hose. Calculate the proportional value as follows: all boom system = 261. feet (includes a 12-ft long, 5-in. tip hose) 15 10-foot pipe sections = 150. feet 40 x 3 = 120. feet (for the rubber hose) Total = 531. feet. Round the total to 500 feet to make it easy to use the following chart (Figure 6).

Figure 5 Calculating proportional values

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intersection, make a 90° turn clockwise, into the lower left quadrant. As noted above, we are using 500 feet as our proportional value (Figure 6).

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

Make a 90° turn when you intersect with the proportional value that applies to your job.

Figure 6 Lower right quadrant - proportional value of pipeline right quadrant until it intersects with the 5-inch slump line, then make a 90° turn clockwise. This will lead you back into the upper left quadrant through the pressure scale (Figure 7).

8. The lower left quadrant refers to the pumpability of the concrete. If the concrete specifications allow a range in slump (for example 5–6 in.), always use the lower end to be safe. In our example, we use 5inch slump. You extend the line from the lower

Figure 7 Lower left quadrant— pumpability of the concrete

Make a 90° turn when you intersect with the slump that applies to your job.

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

upper left quad-eps

We need a unit that is capable of 627 PSI, and 100 yd3/ hr. The PF of this job is: PF = (627 x 100) PF = 62,700 The unit must have a PF over 62,700 and it must be able to pump 100 yd3/hr and 627 PSI simultaneously. Look at the pump shown in our sample nomograph (Figure 8). • Can the unit pump at 627 PSI? Yes • Can the unit pump 100 yd3/hr? Yes • Can the unit pump both simultaneously? No! This unit will not do the job.

Power factor number (PF) English to Metric Conversion Factor is PF Ö 18.966


180 160

Example Job


200

Q in. yd3/hr.

550 PSI + 77 PSI = 627 PSI

The nomograph is now complete. The PF of our job can be calculated like this: PF = PSI x yd3/hr

56,650

As you can see by the chart in Figure 7, we are reentering the upper left quadrant through the pressure scale at about 550 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 70-foot vertical run, we must now add 1.1 x 70 = 77 PSI to the 550 PSI from the chart.

140 120 100 80 60 40 20

103 KW 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 P in PSI

Figure 8 Is this unit sufficient for the job? The engine is a little too small. The intersection of 100 yards3/hr and 627 PSI has been plotted for visual representation, but you will see immediately that the PF of the job (62,700) is bigger than the PF of the unit (56,650). The curved black line represents the PF of the unit. If the unit is going to be able to handle the job, the intersection of pressure and yd3/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 hydraulic pumps. What if we could order this same unit with the

pumps set to a higher Kw? The PF of the higher Kw unit is 72,600. This should work. Plotting the intersection of our hypothetical job again, you will see that it falls within the power zone of the hydraulic pumps (Figure 9)

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•

•

Pump the top of the building at 85 yd3/hr instead of 100 yd3/hr. Pump the top of the building at a 6-inch slump instead of 5-inch. (This would still be within specifications.) Remove some of the rubber hose at the end of the horizontal run. Normally, with job circumstances that did not require a substantial vertical run, you could also use 6-inch instead of 5-inch-diameter pipeline, but in our example, the entire vertical run was made with the boom. The boom can never support 6-inch pipeline.

Power Factor number (PF) English to Metric Conversion factor is PF

18.966


200


180 160 140 120 100

Example Job

80 60 40 20

132 kW

3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 P (in PSI)

600

400

Figure 9 Same model pump with larger Kw hydraulic pumps

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up1ft 132Kw Quad 2000R.eps

Q (in yd3/hr)

•

72,600

The nomograph should only be considered accurate to within ±10 percent. You should always calculate conservatively, and allow for the graph tolerance. In the case of the pump in Figure 9, we should still be safe even if the pressure required were 10 percent greater (690 PSI).What if you already own the pump shown in Figure 8? Is there anything that can be done to the job specifications to make the unit with the less powerful pumps work? You could use the smaller PF unit shown in Figure 8 if you can get permission to do any of the following things:

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Minimum Pipe Wall Thickness

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Preventative Maintenance The table below lists the normal recommended maintenance schedules (after the break-in period). A description of each maintenance task is on the pages of this manual listed in the page number column.

This is only a generic sample of a maintenance chart. Please refer to your O/M manual for your specific unit’s break-in period.

As Indicated

Annually

Semi-annually

Quarterly

Change main hydraulic oil filter

√

Change high pressure oil filter

√

Change water system inline filter

√

Check truck fluid levels

√

Bleed moisture from air tank

√

Check tires

√

Check hydraulic oil

√

Bleed moisture from hydraulic tank

√

Check differential cylinder rod packings

√

Inspect bolts on Rock Valve and rams

√

Grease Rock Valve and agitator bearings

√

Grease Rollix bearing and hollow pin

√

Check optional auto greaser reservoir

√ √

Fill optional auto greaser reservoir

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Monthly

Task

Weekly

Daily

Scheduled Maintenance

Inspect for damage and leaks

√

Check if maintenance is due

√

Grease boom zerks

√

Check pipe wall thickness

√

Check oil in optional air compressor

√

Check Rock Valve tension nut

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Inspect cutting ring/rotate if needed

√

Lubricate mechanical moving parts

√

Check tapered bend wedge bolt

√

Check boom slewing gearcase oil level

√

Clean slewing gearcase breather cap

√

Check function of mech. boom brake

√

Clean and repack the Rollix gear

√

Inspect the turret bolts for tightness

√

Check fluid in distribution gearcase

√

Check unit mounting hardware

√

Check hydraulic pressures

√

Clean hydraulic oil cooler fins

√

Check drive pinion mounting screw

√

Change oil in optional compressor

√

Δ

√

Δ

√

Change oil in distribution gearcase Change oil in boom slewing gearcase

√

Test dirty filter lamp circuit

√

Change hydraulic oil for age reasons

√

Clean optional compressor

√

Change corrosion inhibitors

√

Periodic - structural inspection

As Indicated

Annually

√

Change hydraulic oil for temp. reasons Check the accumulator pre-charge

Semi-annually

Quarterly

Monthly

Task

Weekly

Daily

Scheduled Maintenance (Continued)

√

Δ = Breakin period

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Filtration General information relates to all concrete pumps. Specific information contains information the relates to your Schwing concrete pump.

General information Filtration is the single most important method of keeping the concrete pump 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 filtered. In fact, new hydraulic oil is only filtered at the refinery to 40m (40 microns). The oil in a Schwing concrete pumps must be filtered to a minimum of 25m, and preferably finer than that. Filters are rated by: • the size of particles they trap and whether that size is nominal, or absolute, • the dirt holding capacity in grams, and • the clean element pressure drop for a given flow rate as well as the ratio of particles of a given size encountered versus particles passed through the filter (referred to as the beta ratio). (The flow rate can be in PSI and gallons per minute or bar and liters per minute.) 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 example would be β12 = 200. A courser filter example would be β25 = 75. Concrete pumps require medium to fine 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 400 liters per minute (element only) + 2 PSI for the housing, for a total of 8 PSI ΔP when the element is clean. The pressure drop varies with the viscosity of the oil, that is why you can ignore the dirty filter light until the oil is heated to normal operating temperatures. The filter holds between 65 and 80 grams of dirt when operating at a flow rate of 400 L/m. The flow rate is important because the filter would hold more if you 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 rises. This pressure difference (commonly referred to as a pressure differential) is called delta P and is shown as ΔP. When the ΔP 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, and the element itself would become a contaminant.

Specific information

Changing hydraulic oil filters

Here are some facts regarding filtration as they relate to your pump. • As delivered from the factory, each Schwing concrete pump is equipped with a return filter that is rated at 12 micron (shown as 12μ) absolute. • The beta ratio is β12 = 200. This means that for every 200 particles of 12 microns or larger that hit the filter media, one makes it through. Although we are not happy about the one particle that is allowed through, we do not use finer filtration

Your concrete pump is equipped with a ΔP sensing switch in the filter housing that turns on a light on the operator’s panel when the filter is in bypass. While the light is on, the oil is not being filtered. When the oil is cold, the filter may go into bypass simply because the oil is stiff enough to create 50 PSI ΔP. When the oil reaches operating temperature, the light should go off. If it doesn’t, the filter is plugged with dirt. If you have a filter with you, install it at the first opportunity. If you do not have a spare filter, change it as soon as you get

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back to the shop, or order the filter so it can be replaced soon. Remember, unfiltered oil wears out every hydraulic component on the concrete pump. Your concrete pump may be equipped with a main return oil filter mounted on top of the hydraulic oil reservoir or an inline filter located on the passenger side just above the hydraulic oil cooler. (Both types of filter are shown in. t

The boom/outrigger circuit is equipped with an in-line high-pressure filter. This filter is in a canisters rated to handle the pressure that is felt by this circuit. There is no integral bypass in this filter. The filter is not fitted with a ΔP switch, so you should change it whenever the return filter light comes on. The rating on the filter is β25 = 200. We install this filter to catch large particles that may cause a boom valve or holding valve to stick in an open position. Because the boom circuit gets its oil from the same tank as the return filter, the oil should be clean anyway. The oil tank breather filter is mounted on top of the hydraulic oil tank. This filter should be changed when the main return oil filter is changed. The high pressure oil filter is located on the passenger side of the unit. The type of filters installed on your unit are the result of years of experience and testing. We recommend that you do not change the housing or element to some other type. You may learn that in the long run, cheaper is more expensive.

Changing high pressure water filter The optional high pressure water pump has an inline filter between the water tank and the optional high pressure water pump. This filter needs to be inspected, cleaned, or replaced at the same time hydraulic oil filters are changed. This filter will also need inspection and cleaning if water is not flowing through the high pressure water system. The part number for the filter element is in the Parts List manual supplied with your concrete pump.

Hydraulic Oils General information relates to all hydraulic oils. Specific information contains hydraulic oil recommendations for Schwing concrete pumps.

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. One brand, Mobil EAL 224-H, has been accepted for use in Schwing pumps, and other brands 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 change from mineral oil. 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, 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 America, we recommend ISO VG 46 for the winter and ISO VG 68 or VG 100 for the summer, depending on how hot it gets. The lower the ISO VG number the thinner the oil and the lower the pour point of the oil. On the other hand, the thinner the oil, the lower the temperature will have to be before it breaks down the lubricating film that protects your components.

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The quality of the oil needed for use in a Schwing concrete pump 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 concrete pumps.

Specific information Most concrete pumps leave the Schwing factory filled with Texaco Rando HD 46 hydraulic oil, which has an ISO viscosity rating of VG 46. Rando HDZ 46, an extended-viscosity oil designed for use under severe conditions, is available on request. If you want your new concrete pump filled with a different brand or different viscosity oil, you should specify it when ordering. Many other brands of oil have been approved for use in Schwing concrete pumps, including: •

Mobil DTE

•

Shell Tellus oil

•

BP Energol

•

Aral Vitam

•

Esso Nuto

•

Esso Univis

•

Total Azolla

•

Wintershall Wiolan

The order of the brands listed is not significant. Any oil that meets the quality and viscosity standards described above can be used.

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

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Electrical

Introduction This guide will help you learn how to service current and future Schwing electrical systems. Even if you have little or no experience with electrical repairs, this guide will help. It begins with the basic definition of electricity and continues all the way through the troubleshooting process. It will show you how to use Ohm’s law, identify series, parallel and series-parallel circuits, and troubleshoot circuits using various testers. It’s a fairly complete journey from concepts to applications.

Electrons (13) -

-

-

-

-

-

-

-

-

-

-

-

What is Electricity?

Nucleus (w/13 Protons)

Figure 1. Aluminum atom (Neutral state)

-

-

-

-

-

-

-

-

-

One Electron Is Forced From The Atom Leaving Only 12 -

-

-

Electricity is the flow or displacement of electrons. Normally, the atoms in a substance are balanced in an electrically neutral state. They’re made up of equal numbers of positively-charged protons and negativelycharged electrons. However, it is possible to strip electrons from atoms. This creates areas of positive and negative charge in a substance: positive charge where there are atoms without the normal number of electrons, and negative charge where there are excess electrons. As you might have guessed, these two oppositely charged areas attract each other. Why? Because the unbalanced atoms and stray electrons always want to return to the balanced, or electrically neutral, state. On the other hand, areas with the same charge repel.

The Atom is Unbalanced With 13 Protons Resulting In A Positively Charged Atom

Figure 2. How a positively charged aluminum atom is created

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Static electricity is electricity that does not move. It’s created when electrons are rubbed off one material by friction and deposited on another. A common example of this is when a balloon is rubbed against some fabric. The fabric gives up some electrons to the balloon. This makes the balloon negatively charged and the fabric positively charged. Since opposite charges attract each other, this causes the balloon and fabric to stick together. And since like charges repel, two of these negatively-charged balloons will push each other apart.

Figure 3. Opposite charges attract

The attractive and repulsive forces created by static electricity work like magnets. This principle is used in copy machines, CRT’s and electrostatic painting processes. Unfortunately, static electricity has its bad side too. Unwanted discharges, like the zap you get when you touch a metal doorknob, can be dangerous. For example, truck drivers who transport flammable materials such as gasoline have to make sure that no sparks caused by ESD are created when gasoline is being loaded or unloaded. In addition, even a small discharge packs a high-voltage punch that may damage sensitive electronic parts and modules. Be careful not to touch the terminals of an electronic module. A static discharge through the component’s circuitry can destroy it.

Figure 4. Like charges repel

Figure 5. Typical static discharge

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Dynamic electricity is moving electricity that’s created when electrons flow from atom to atom through a substance. It’s the type that flows through power lines to homes or that lights the headlights on a truck.

Electrons (13)

-

-

-

The flow of electrons is called an electric current. To understand how it works, picture a row of atoms: An electric current starts when an electron is stripped from an atom at the end of the row. This now positively charged atom then attracts a negatively charged electron from its neighbor, leaving its neighbor positively charged. The neighboring atom then attracts an electron from its neighbor and so on down the line.

-

Figure 6. Electron Flow=Current Flow

For current to flow then, there must be a complete path of atoms (called a closed circuit) and an electron “pump”, that can trip electrons from atoms on one side using a strong positive charge and push them through the circuit on the other side using a strong negative charge. In a typical Schwing concrete pump circuit, wires provide the path of atoms, and the battery is the pump that forces the electrons to flow from atom to atom. Figure 7. AC current flow periodically reverses direction

AC and DC. Two types of electric currents exist; AC, for Alternating Current, and DC, for Direct Current. In DC currents, the electrons flow in one direction only. So, in all the diagrams you’ll be looking at, DC current flows from the positive battery terminal to the negative.

+

DC current is used to power the electrical systems of all Schwing concrete pump. It has important properties you must understand to properly repair electrical circuits. Those properties are amperage, voltage, and resistance.

-

Figure 8. DC current flow constantly in one direction only

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Amperage Seconds 0 3

Amperage describes the rate of current flow. It is measured in amps, using an ammeter. The higher the amperage, the greater the number of electrons flowing past a single point in one second.

1 2

6.28 Billion Billion Electrons Per Second 1 Amp

Figure 9. Amperage is the rate of current flow Low Current Flow Low Heat

High Current Flow High Heat

Figure 10. Relationship of current flow and heat CURRENT CAPACITY INCREASES

WIRE RESISTENCE DECREASES

Figure 11. Relationship of current capacity and resistance to wire thickness

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It helps to think to current as water, and amperage as the rate of water flow through a pipe. You can measure the rate of water flowing in a pipe in gallons per second. Similarly, one amp is equal to 6.28 billion electrons passing a single point in one second.

Current flow and heat are related. As amperage increases, more electrons flow and more heat is generated. Any electrical component that carries current, generates heat. For this reason, the wires in a Schwing concrete pump are sized according to the amount of current they must carry. Thick wires carry large currents, while thin wires are used for small currents. Thick wires can handle a large current without burning up because they are made up of more atoms with more available electrons. They therefore resist the flow of current less than thin wires.

Wire gauge sizes describe the thickness or thinness of a wire. Gauge size refers to the wire core, not the insulation covering it. Two numbering systems are used to designate wire sizes: American Wire Gauge (AWG) and metric. In the AWG system, as the wires get thicker, the number designation decreases. For example, a 20 AWG wire is very thin, while a 4 AWG wire is much thicker. The metric system works in the opposite way. As the wires get thicker, the number designation increases. So, a.5 metric gauge wire is very thin, and a 19 metric gauge wire is much thicker.

Because insulation sizes vary, never try to judge the thickness of a wire core by looking at the size of the insulation. Always refer to the code or measure the thickness with an appropriate tool. And always replace a wire with new one of the same gauge or thicker. A wire that is too thin poses a fire hazard because it may overheat and burn.

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Electron Flow

Wire Conductor

Figure 12. Voltage is the push, or pressure, on electrons

Voltage Allows Less Flow (Amps)

Voltage is the force that moves electrons through a circuit. It’s also known as “electromotive force,” or “EMF”. Technically, it is the potential difference in electron pressure between any two points. Voltage is measured in volts, using a voltmeter.

Allows More Flow (Amps)

The higher the voltage, the more force is available to cause electrons to flow. The lower the voltage, the less available force.

1000

10 Figure 13. A resistence is a restriction

Allows Less Flow (Amps)

Voltage is like the water pressure in a pipe. At 10 psi of pressure, water flows through a pipe at a certain rate. At 20 psi, the water will flow almost twice as fast. The relationship is similar in an electrical circuit. For example, at 12 volts, current flows through a particular circuit at a rate of 12 amps. At 24 volts, however, current flow through that same circuit at a rate of 24 amps.

Infinite

Resistance Allows More Flow (Amps) 0 Figure 14. The two extremes of resistence

Resistance descries how much a component or circuit resists, or restricts, current flow. Think of it as a kind of electrical friction. The greater the resistance, the less current flows. The less the resistance, the greater the current flow. Resistance is measured in ohms, using an ohmmeter.

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Copper Wire

POWER 1000

500

200

200

BATT 9V

20

200u

2000 m

Conductors. Some materials have very low resistance to current flow because they have many electrons, called “free” electrons, that can be made to move easily. These are called “conductors.” Most metals are good conductors. Copper and aluminum wires, switches, and connector terminals and the iron and steel of the truck’s engine and chassis are typical conductors in a Schwing electrical circuit.

20m 200m

200m

200

2000k 200k

20k

2000

Besides the thickness of a wire, several other factors affect the resistance of a conductor. They include condition, length and temperature. For instance, a wire in poor condition with a partially cut core, has increased resistance because the narrower width at the cut restricts the movement of electrons. In fact, the partially cut wire operates in a circuit as if its entire length were of the reduced diameter at the point of the cut.

200 mA FUSED

500V max 500V

COM

V mA

Figure 15. Copper conductor

Short Wire Offers Less Resistence

The length of the conductor also affects its resistance. A longer wire offers more resistance than a shorter wire (of the same diameter) because the voltage has to move the electrons through it farther.

Long Wire Offers More Resistence Figure 16. Resistence of short vs. long wires

RESISTANCE

Why does temperature affect a conductor? At lower temperatures, the atoms in a conductor remain rigidly aligned and don’t move around much. Resistance and heat are low because electrons flow relatively smoothly from atom to atom.

.05Ω

.04Ω 70˚F

170˚F

TEMPERATURE Figure 17. Resistence to temperature relationship in 10ft. long wire

178

Heating a conductor increases its resistance: The higher the temperature, the greater the resistance. In addition, conductors themselves generate heat as current flows through them. This heat also causes the resistance of a conductor to increase as it is warms up and decrease as it cools down. As long as a conductor is properly sized, the amount of resistance it offers in a circuit is so low that it can usually be disregarded, and the amount of heat it generates won’t damage the circuit.

At higher temperatures, however, the atoms in a conductor are less well aligned and move around a lot more. Many electrons collide with electrically balanced atoms before reaching positively charged atoms. The increased frequency of these collisions increase resistance and generates excess heat.

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Insulation

POWER 1000

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Insulators. Materials with a very high resistance to current flow are called “insulators.” Insulators have no free electrons that can conduct a current. They’re used to keep current flowing in a particular circuit and covers a wire to keep current flowing through its copper conductor and prevent any unwanted contact with another conductor. Glass, rubber, and ceramic are other examples of typical insulators.

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Figure 18. Wire insulation

Circuit Breaker

V mA

Basic Circuits A typical Schwing concrete pump circuit is made of a voltage source, a circuit protection device, a load, a control and a ground.

The voltage source is the pressure source or electron pump that creates the force necessary to make current flow. The battery is ultimately the voltage source for all circuits in a truck. However, the alternator is the voltage source for most circuits when the engine is running.

Batteries convert chemical energy to electrical energy using the reaction of two different conductive metals in an acid solution. Alternators convert the mechanical energy of the rotating crankshaft into electrical energy.

Figure 19. Circuit breakers

Circuit protection devices such as fuses and circuit breakers are designed to protect a circuit’s wiring and components by cutting off current flow when it becomes too high. They do this by switching off or melting. This opens, or breaks, the circuit.

Loads are electrical devices designed to perform various useful functions. They convert electrical energy into other forms of energy. For instance, a light bulb converts electrical energy into light energy, a starter motor converts it into mechanical energy, and a resistor converts it into heat energy. AC compressor clutches, relay coils, horns, and gauges are other examples of loads.

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+

A load has resistance and draws a certain amount of current in a circuit. It also uses up voltage as current passes through it. This is called “voltage drop”; it is measured by connecting a voltmeter across a load. A circuit will operate properly as long as the resistance and voltage drop of its load remain normal.

-

A good conductor, however, has a small resistance and causes very little or no (measurable) voltage drop. A conductor with high resistance and high voltage drop is faulty in some way. Typical faults include cut wires and loose or corroded connections. If the voltage drop across a wire or connection is sever enough, the circuit will not operate, or will operate improperly – the light dim, cranking slows, or the battery discharges frequently.

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Figure 20. Measuring voltage drop

Potentiometer

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Figure 21. Rheostat

Controls are used to turn circuits on and off. The simplest type of control is the on-off switch. Opening a switch turns off the circuit by breaking the path of current flow and creating an open circuit. Closing a switch turns on a circuit by completing the path of current flow and creating a closed circuit.

V mA

Other types of controls vary the function of a load by increasing or decreasing current flow. Variable resistors, do this by allowing you to vary the amount of resistance in the circuit. So, in a light dimming circuit, for example, the higher the resistance, the dimmer the lights, and the less resistance, the brighter the lights. A ground is a return for current flow to the voltage source. Ultimately, the negative battery terminal serves as the ground for all the circuits in Schwing concrete pumps. However, since the frame and engine are also connected to this terminal and are conductors, most ground connections are made to them, not the battery terminal. When working on a Schwing concrete pump, always be sure to note the proper ground polarity. Reversing battery or jumper cable connections can instantly destroy solid-state parts and modules.

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Schematics

Circuit Types

Electrical diagrams, also called “schematics” represent the different components of a circuit using various symbols. Most of the symbols shown on page 138-140 are standard; be sure to familiarize yourself with them. However, be aware that some components may be represented differently on other schematics. If a symbol is unfamiliar, refer to the legend for the schematic.

When two or more loads are use in a circuit, they can be connected to form any one of three different types of circuits: series, parallel, and series-parallel.

Schwing America produces a variety of Electrical System Manuals for different electrical control systems. The schematics they contain are great troubleshooting aids that allow you to examine a circuit on paper and figure how it should work. You can locate the likely causes of a problem on the schematic and go directly to those places on the truck. This can save you a great deal of time by reducing the number of components you have to remove and the number of wires you have to trace.

Series. A series circuit exists when the loads are connected end-to-end in one continuous path. In this type of circuit, one of the loads is disconnected or develops an open, all of them stop functioning.

Parallel. A parallel circuit exists when the loads are connected side-by-side so that there are a number of paths for current flow. In this arrangement, if one load is disconnected or open, the others continue to function.

+

To read a schematic, follow the current flow from the positive battery terminal to the negative. Since switches and relay contacts are usually shown in the off or deenergized position, you’ll have to determine how a circuit operates by following current flow as if these components were on or energized.

-

Figure 23. Typical series circuit SWITCHE RELAYS S: Methods of operation SHOWING DIN (DEUTSCHE INDUSTRIAL NORM) SYMBOLS, PLUS COMMONLY Normally closed N.C. =ON Normally open USED A.N.S.I. SYMBOLS AS SHOWN SCHWING SCHEMATICS : N.O. = KEY PUSHBUTTO N (EMERGENCY STOP) Relays

SWITCHES KEY: N.O. = Normally open Solid line = position of

LINE

operational Position ofCONNECTOR functions (detented "ON", shown) spring returned "OFF" Method of operation: (double throw switch shown)

Control s) MAGNET COIL (DIN drawing DIN ANSI shown) FOR HYDRAULIC VALVE

Contacts (Bosch brand (higher current rating) 1 N.O. and 1N.C. contact PUSHBUTTON shown

as

ON O OFF

In this example, contact is made between terminals 1 and 2 in the "ON" position

OFF

3

2

BATTERY shown Pivot point of the switch line indicates below the activation would be that the contact lever #2 in the drawn towards contact

FUNCTION WHEN ACTIVATED "ON"

"ON" position

CHASSIS GROUND "OFF" position activated, indicated by solid line

d during Spring is compresse that it will activation, indicating return to "O" when released

as

ON O OFF

1

In this example, contact is made

STARTER between terminals

OR

B+ 86

DIN

2

DIN

TACHOMETER SENDING UNIT (PROXIMITY SWITCH, DIN - ANALOG CONVERTER) ANSI DIGITAL 87a 87

(L.E.D.) N.C. contacts 50a N.O. contact wire N.C. contact are underlined OVER-CURR ENT SWITCH 30 numbers SHIELDED CABLE (Always normally closed) N.C. CR 3 14 (Show all conductors 1 9 5 inside shield) 8 STARTER DIN

OL

CR 3 FLOAT SWITCH 1 1 9 Level)

common hot

M

15

CR 2 2

+

8

16

ANSI

MISC. DEVICES

ANSI

RESISTOR (VALUE INDICATED IN OHMS) (K = 1000)

POTENTIOMETER (Value indicated) OR T

2.5 K

POT

1K 1K DIN

CURRENT FLOWS IN THIS DIRECTION

Primary

120V 60 HZ

ANSI

-

120V 60 HZ

TRANSFORMER Secondary

12V

12V

DIN

ANSI

BRIDGE RECTIFIER (A.C. to D.C. converter)

ANSI

FS

TERMINAL CONNECTORS

31 9 (Oil

shown ELECTRIC MOTOR Pivot point of the switch line indicates below the activation would be FUNCTION WHEN that the contact lever #3 in the ACTIVATED "OFF" pushed towards contact "OFF" position

plug TGS.

which relay these numbers denote coil will operate the contact

DIN

receptacle

D.P.D.T.

ALTERNATOR

OL

ANSI

TGS.

on one part If the relay coil is drawn contacts K3 MECHANICA andLthe SWITCH schematic, of the31 D30 part, the relay (V-BELT on another SWITCH) are drawn NONE K3) will be listed number (in this example, as shown here. OIL TEMPERATURE AVAILABLE in both places + TRANSMITTER DIN ANSI (both DIN) these numbers Control Relays ) show the location TAS (ANSI "ladder" drawing (line number) contacts of the N.O. Relay coil Relay terminal °C that the relay coil DIODE numbers TEMPERATU will operateBLOCKED RE SWITCH CURRENT TAS IN THIS DIRECTION line numbers N.C. OR CR 2 °C 2 CR 1 3 8, 9 13 9LIGHT EMITTING DIODE 1 5 1 DIN 9 CR 7 ANSI

OFF

3

20A 20A MOTOR OVERLOAD RELAY

S.P.S.T.

0 1 2

D+

lens color)

ANSI

0,1,2

1 and 3 in the "OFF" position

ON

DIN

ANSI

PLUG AND RECEPTACLE

OR

85

1

PS.

PS.

FUSE 87 RATING INDICATED) 87a(AMP

K3

ON

ANSI

K3 TOGGLE SWITCH G 30 85 ALTERNATOR

switch In the "ON" position, detent is held in place by the line) (indicated by the vertical

ANSI

CB / DISC

CIRCUIT BREAKER / DISCONNECT SWITCH (Letter R indicates

N.O.

Component N.C. enclosure DIN

86

AS DRAWN ("O" POSITION)

"ON" position activated, indicated by solid line

DIN

OR

Contacts (2 N.O. contacts shown).

Dashed lines = available positions of switch

DIN

Q

PRESSURE SWITCH

LINES,3 PASSING

2

DIN

DISC.

Q

If the contact operator is shown extending beyond the last contact, it indicates that this operator will also work a contact shown elsewhere on the schematic. ANSI

N.C.

LAMP 85WITH BULB

30

ON OFF

86

87

87a

Terminals (Numbers shown if they are presesnt on the switch)

1

Relay coil (very small current N.O. draw)

MOMENTARY CONTACT HORN

LINES, JOINING

ON O OFF

Component enclosure

DISCONNECT SWITCH

N.C. = Normally closed

switch as drawn

21

21

22

DIN

22

ANSI

N.O.

Q

G

2

CAPACITOR FS

Q DIN

common N.C. neutral

(VALUE INDICATED POSITIVE NEGATIVE TERMINALS TERMINALS FARADS)

IN

(μ = micro or 1 millionth)

ANSI

Figure 22. Typical electrical symbols

2 μF DIN

2 μF ANSI

Figure 24. Typical parallel circuit

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Series-Parallel. Any circuit that combines series and parallel connections is called a series-parallel circuit. On Schwing concrete pumps, batteries may be connected in parallel or series. When batteries are connected in parallel, the available current of each battery adds to the first, but the voltage output remains the same. So, if you connect two 12 volt/85 amp batteries in parallel, the output from both will be 12 volts/170 amps.

+

-

Figure 25. Typical series - Parallel circuit 12V

-

The opposite effect occurs when you connect batteries in series. The voltage output of each battery adds to the first, but the available current remains the same. Thus, two 12 volt/85 amp batteries in series yield 24 volts/85 amps of output.

+ POWER

12V

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Figure 26. Batteries in parallel

12V

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Figure 27. Batteries in series

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I=

Ohm’s Law

E R

Amperage, voltage, and resistance are related in a circuit. Ohm’s law describes this relationship and can be used to find a missing value when the other two are known.

E=IxR

The basic equation of the law is I equals E divided by R. I is the current in amps, E is the voltage, and R is the resistance in ohms.

R= E I Figure 28. The different forms of Ohm’s Law

E I R

You should memorize the different forms of Ohm’s law because you’ll need them when troubleshooting circuits.

Figure 29. Memory aid for Ohm’s Law

+

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Here’s a quick way to remember Ohm’s law: Arrange the letters of the law as shown in Figure 29. Then cover the letter of the value you want to solve. The positions of the other two letters will show you how to solve for the one you covered.

1Amp= 12V 12

Examples of how to use Ohm’s law to solve for amperage, voltage, resistance and voltage drop follow:

12 ohm load

Figure 30. Typical amperage calculation

12V = 4A x 3

To solve for voltage, the equation can be rearranged like this: E=I x R. And to solve for resistance, the equation is R equals E/I.

Amperage. What’s the current flow in a closed circuit having a 12 ohm load connected to a 12 volt battery? The answer is 1 amp. (12volts/12ohms=1 amp)

Voltage. Now, what’s the voltage in a circuit with 4 amps of current flowing through a 3 ohm load? It’s 12 volts. (4 amps x 3 ohms = 12 volts.)

Figure 31. Typical voltage calculation

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Resistance. What’s the resistance in a circuit with a 12 volt battery and 12 amps of current flow? It’s 1 ohm. (12 volts/12amps = 1 ohm.)

1

= 12V 12A

Figure 32. Typical resistance calculation

+

Voltage Drop. Now, what should be the voltage drop across the 12 ohm load in that first circuit? (Figure 32) It’s 12 volts. (1 amp x 12 ohms =12 volts.) The load uses up all the voltage in order to operate. If you get a significantly lower reading, you’d know the circuit had a poor connection or damaged conductor that was adding unwanted resistance to (and stealing voltage from) the circuit. What should be the voltage drop across the 12 ohm load if the circuit is opened? Zero volts. (0 amps x 12 ohms = 0 volts.) With no current flowing, the load doesn’t operate and can’t use up any voltage.

-

12V=1 Amp x 12

12 ohm load POWER 500

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Figure 33. Typical voltage drop calculation

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0V=0 Amp x 12

12 ohm load POWER 1000

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Figure 34. Voltage drop in open circuit

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Series Circuit Laws

+

When there is more than one load in a circuit, determining the values to plug into Ohm’s law requires a little more effort. That’s because series and parallel circuits obey different rules. For series circuits, those rules are:

-

4

4

4

Figure 35. Series circuit

+

-

4 +4 4 12

•

First, the sum of the individual resistances in a series circuit equals the total circuit resistance.

•

Second, current has the same value at any point in the circuit.

•

Third, the sum of the individual voltage drops across the loads equals the source voltage.

Total Resistance. For example, what’s the total resistance in a circuit with a 12 volt battery connected to three 4 ohm loads wire in series? It’s 12 ohms; you just add up the resistance. (4 ohms + 4 ohms + 4 ohms = 12 ohms.)

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Amperage. What’s the amperage in this circuit. Since it’s the same throughout the circuit, you can use Ohm’s law:

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Figure 36. Total resistence in series circuit

+

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12 volts/12 ohms = 1 amp.

1Amp= 12V 12

Figure 37. Amperage in series circuit

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Voltage Drop. Now, what’s the voltage drop across one of the loads. To figure that, you use Ohm’s law and plug in the total circuit current and the resistance of one load. 1 amp x 4 ohms = 4 volts.

+

-

This result also agrees with the rule that current is the same throughout the circuit. If you plug the voltage drop and resistance of one load into Ohm’s law, you get the same current value: 4 volts/4 ohms = 1 amp of current flow.

4V=1 Amp x 4

POWER 500

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The third rule also proves out. Each 4 ohm load causes a 4 volt drop, and 4 volts + 4 volts + 4 volts = 12 volts – the source voltage.

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Figure 38. Voltage drop of one load in series circuit

Parallel Circuit Laws The rules that parallel circuits follow are:

+

-

12 Volts

POWER 1000

500

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200

BATT

•

First, the voltage drop across each branch of the circuit is the same as the source voltage.

•

Second, the total amperage in a parallel circuit is equal to the total of the individual branch amperages. This means you can treat each individual branch of the circuit as a series circuit, and add up their individual amperages to find the total flowing through the parallel circuit.

•

Third, the total resistance in a parallel circuit is less than the value of the smallest branch resistance. Another formula must be used to calculate this total resistance value.

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Figure 39. Sum of voltage drops equals source voltage

+

-

RT =

1 1 + 1 + 1 R1 R2 R3 etc.

Now, let’s apply these rules:

Figure 40. Parallel circuit

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+

Total Amperage. What is the total amperage in a circuit with a 12 volt battery connected to three 12 ohms loads wired in parallel? You know from the first rule that the voltage drop across each of the loads is 12 volts, since that’s what the source voltage is. If each load is 12 ohms, the amperage through each branch is 1 amp. (12 volts/12ohms = 1 amp.) The total current then is 3 amps.

-

(1 amp + 1 amp + 1 amp = 3 amps.) POWER 1000

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Figure 41. Measuring total amperage in a parallel circuit Total Resistance

1 = 1 1 + 1 + 1 3 12 12 12 12 Add Fractions Find a Common Denominator, If Necessary

1 = 1x 4 = 4 1 1 4

Simplify Fraction

Invert Fraction and Multiply

Figure 42. Calculating total resistance in a parallel circuit

+

Total Resistance. To find the total resistance of this circuit, you plug numbers into the total resistance equation. See Figure 42 for an illustration of how to solve the equation for this example. The total resistance in this circuit is 4 ohms. This number also agrees with the 3 amps of total current: Using Ohm’s law, 12 volts/ 4 ohms = 3 amps.

An important difference between parallel and series circuits is that as you add more branches to a parallel circuit, its total resistance decreases instead of increases. And this, of course, increases the current in the circuit. For instance, add another 12 ohm load in parallel with the previous circuit, and the total resistance goes down to 3 ohms, while the amperage increases to 4 amps.

+ -

-

POWER 1000

500

200

200

BATT 9V

20

POWER 1000

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BATT

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Figure 43. Measuring total resistance in a parallel circuit

Figure 44. Total total resistance in a parallel circuit

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Series – Parallel Circuits 12 V -

That brings us to series-parallel circuits. When you’re trying to calculate values in these circuits, you have to simplify parts of the circuit. That usually means substituting an equivalent resistance for the parallel part of the circuit, and then applying the series laws to determine values for the overall circuit.

+

For instance, suppose you had a circuit like the one shown in Figure 45. What is the total resistance of this circuit? To figure that out, first find an equivalent resistance for the two 12 ohm loads in parallel. Using the parallel resistance equation, you’ll find the equivalent resistance is 6 ohms. Now, to find the total resistance, treat the circuit as if it were a simple series circuit: 6 ohms + 6 ohms = 12 ohms. You can find the amperage and voltage drops easily now: The amperage is 1 amp, and 6 volts are dropped across each load.

Figure 45. Series - Parallel circuit

1 = 1 1 + 1 2 12 12 12

1 = 1x 6 = 1 1 6

Figure 46. Equivalent resistance for parallel part of previous series - parallel circuit

12 V -

+

Figure 47. Previous series - parallel circuit simplified

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Circuit Faults

+

-

Opens. An open puts unwanted infinite resistance into the circuit. Because there’s a break, however, no current flows, the components in the circuit do not operate and no heat is generated. As a result, an ammeter will not give a reading, but a voltmeter, depending on where it is placed, may or may not show a voltage reading.

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Electrical circuits fail when they are open or shorted. An open circuit occurs when there’s an unwanted break in the circuit resulting in no current flow. The break may be in the wiring or a component.

200 mA FUSED

500V max 500V

Figure 48. Voltage reading before opne

+

-

These unwanted resistances allow current to flow, but at a reduced amount. This causes components either to stop operating or to operate at a reduced level. The starter motor turns too slowly or the lights dim, for instance.

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Unwanted Resistances. Opens are one extreme of unwanted added resistance. But problems also occur when any unwanted, but less then infinite, resistance is added in series to a circuit. This may be caused by a wire of incorrect size or material, a damaged wire, loose or dirty connectors, or corroded connections or terminals.

2000

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Figure 49. Voltage reading after open

+

Shorts. A short circuit occurs when previously unconnected conductors touch one another allowing current to bypass a part of a circuit. Shorts may occur within a component, such as a starter motor or relay coil, or across conductors in one or more circuits.

-

Figure 50. Short across conductors in separate circuits

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Shorts often provide current with an alternate path of lower resistance. A common example of this is a short to ground. This makes bypassed components inoperative and increases current flow. The increased flow creates heat which usually causes a fuse or circuit breaker to blow, adding an open to the short condition.

-

However, if the short bypasses the circuit protection, components and wiring may burn up from the increased heat. A short may also bypass current so that the controls of one circuit operate the components in another. For example, lights that were previously controlled by one switch may now go on whenever another set of lights is switched on. Or a short may bypass the controls of a circuit so that it operates continuously and can’t be controlled by it’s switch. These are called “shorts to voltage.”

Figure 51. Short to ground

+

Using Test Equipment

-

To diagnose circuit faults, you’ll have to use test equipment. One very useful test instrument is the digital multimeter. This device combines the functions of an ammeter, voltmeter, and ohmmeter, so you don’t separate pieces of equipment to measure these values.

Figure 52. Short voltage across switch

However, jumper wires and self-powered and unpowered test lights are also useful troubleshooting tools, but can cause other problems if not used correctly.

Jumper Wire

CAUTION: Never begin to test a circuit without knowing whether it contains any solid-state components. Jumper wires and self-powered test lights can damage circuits containing solid-state components, and low-impedance analog (needle reading type) meters can give misleading readings. Use only a high impedance (10 mega-ohms or more) digital mulitmeter for testing circuits containing solid-state components.

Unpowered Test Light

Self - Powered Test Light Figure 53. Other useful troubleshooting tools

190

Jumper Wire. A jumper wire is simply a length of insulated wire with clips or probes on each end. You use a jumper wire to bypass a suspected fault and see whether the circuit operates correctly. If it does, a fault exists in the part of the circuit you’ve bypassed.

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+

Fused jumper wires are recommended to protect the circuit you’re testing. A 5 amp fuse in the wire will adequately protect most circuits. Of course, you can use a larger fuse if the circuit you’re testing normally draws more than 5 amps of current.

-

Be cautious when using a jumper wire: Never bypass a load of any kind. The lower resistance of the wire will increase current flow and may cause the wiring or components to overheat or burn.

Figure 54. Jumper wire bypassing an opening

Test Light "On"

+

-

CAUTION Unpowered Test Light. An unpowered testlight is simply a bulb with leads attached to the bulb’s terminals. A 12 volt light is used on 12 volt systems, a 6 volt light on 6 volt systems. This type of test light must be used in a powered, or active, circuit, since the only way the bulb will light is when current flows from the circuit and through the light to ground. You can check for voltage in a circuit by touching one lead to ground and probing the circuit with the other lead. This type of testing, however, only tells you where voltage is present. To find out how much, you must use a voltmeter.

Figure 55. Voltage check with a unpowered test light

+

-

Test Light "Off"

You can test continuity of parts of a circuit by connecting the light into the circuit. Continuity, or a complete current path, exists when the bulb lights fully. A dim light means there is an additional resistance in the circuit before or after the points where the light was connected. No light means there is an open.

Figure 56. Continuity check with an unpowered test light

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Test Light "On"

+

-

Self-Powered Test Light. A self-powered test light has its own battery, so it must be used in an unpowered circuit. You use it to check for continuity.

Short to Ground Figure 57. Checking for a short to ground with an unpowered test light

Test Light "On"

+

Connecting the light in series allows you to check for a short to ground. Just disconnect the loads in the circuit, and put the light in series where the fuse should be. If the bulb lights with the circuit on, you know there’s a short to ground in the circuit.

If touch the probes to different ends of a conductor (wire, switch, connector, etc.) and the bulb lights, you know there’s continuity through the conductor. If the bulb is dim or does not light, there is an added resistance or an open exists in the conductor. To find out just how much resistance there is, you must use a ohmmeter.

Check for a short to ground by disconnecting the normal ground connection of the circuit (including any redundant grounds) and connecting the light between a part of the circuit and ground. If the bulb lights, a short to ground exits.

-

Test Light "On"

Figure 58. Test light indicating continuity

Test Light "Off"

+ +

-

Figure 59. Test light indicating an opening

192

-

Figure 60. Checking for a short to ground with a self-powered test light

Training Manual

SERVICE TRAINING

POWER 1000

500

BATT

200

200

9V

20

200u

2000 m

20m 200m

200m

200

2000k

Red Lead

200k

20k

2000

200 mA FUSED

500V max 500V

Black Lead

COM

V mA

Figure 61. Proper Fluke multimeter lead connections for measuring amperage

+

-

POWER 1000

500

200

200

BATT 9V

20

200u

2000 m

20m 200m

200m

the meter on its proper care and use. In particular, note how the test leads should be connected to the instrument for different tests. And make sure the meter will not be damaged when used to measure amperage in the ranges you expect.

Always observe the proper polarity when connecting the meter leads. Properly connect the leads to the meter. Then, always connect the negative battery terminal and the positive, or red, lead to the conductor connected to the positive battery terminal. With a digital meter, but it will indicate a negative reading on the display when it should be positive.

Units of Measurement. One of the things you’ll have to get used to when using a multimeter is understanding the different units of measure. The symbols for these units mean the following: Capital K, for kilo, is 1,000. Capital M, for mega, is 1,000,000. Small m, for milli, is one-thousandth and small u, for micro, means one-millionth. A number without one of these symbols behind it stands for a basic amps, volts or ohms measurement. A number with one of these symbols behind it means the basic value is multiplied of dividend by 1,000 or 1,000,000. For instance, 20K stand for 20,000 and 200, stands for.200 (200 thousandths).

200

2000k 200k

20k

2000

200 mA FUSED

500V max 500V

COM

V mA

Figure 62. Observing proper polarity when making a connections

To change a given measurement from one unit to another, find both units on this chart. Then move the decimal point the (total) number of places indicated, in the direction that matches the direction of your desired change.

Digital Multimeters are preferred over other types of meters because they are more accurate and will not damage most electronic circuits.

3

MEGA (M)

3

It is important to remember how to connect a mulitmeter to obtain the proper reading and prevent damage to the meter or sensitive electronic circuit. First, read and follow the instructions that come with

KILO (K)

3

BASE UNITS VOLTS OHMS AMPS 3

MILLI (m)

MICRO (u)

3

Figure 63. Converting units of measure

Training Manual

193

SERVICE TRAINING

connected on the instrument.

+

When measuring the amperage, always connect the meter in series with the circuit so that current flows through it. Initially, make your connections with the circuit unpowered. Then turn the meter to the correct range and turn on the circuit.

-

Current clamps are also available for use with a digital multimeter. These allow you to measure amperage without wiring the meter into the circuit. You just close the clamp around the conductor and the meter reads the current flow in amps. Usually, the mulitmeter must be set to a mV (millivolts) scale for use with current clamp. However, the reading on the meter still indicated amperage.

Figure 64. Measuring amperage

+

Voltage. When measuring voltage or voltage drop, always connect the meter in parallel so that it’s across a device or a part of the circuit. This is an advantage over amperage and resistance measurements, because you can often leave the device or circuit connected. Take your measurements with the circuit device powered.

-

Conductors should have almost no voltage drop. A drop greater than 0.1 volt in a low-current conductor, or 0.3 volts in a high-current conductor (such as a battery cable) indicates a damaged conductor or a poor connection.

POWER 1000

500

200

200

BATT 9V

20

200u

2000 m

20m 200m

200m

200

2000k 200k

20k

2000

200 mA FUSED

500V max 500V

COM

V mA

Figure 65. Measuring resisitance of a load You’ll sometimes find it necessary to convert between the different units of measure. This is simply a matter of moving decimal point and adding or subtracting zeros. (Actually, you’re multiplying or dividing by the number of thousands between units.) For instance, 1M ohm equals, 1,000K ohms, and 2.2m amps equals.0022 amps. See Figure 65 for how to make conversions. Amperage. Before measuring amperage, make sure the meter is capable of handling the amount of current flow you want to measure. Many digital meters will only handle 2 amps of current, some even less. Others with different connections, can handle up to 10 or 20 amps. Also make sure you have the leads properly

194

Resistance measurements must be made with the circuit unpowered and the components under test isolated. This always means turning off the power and sometimes means disconnecting the components or wiring you want to test from the rest of the circuit.

Remember, zero ohms of resistance indicates a complete circuit with no resistance. Conductors should have zero or very close to zero ohms of resistance. A resistance greater than 0.1 ohm indicates a damaged conductor or a poor connection. On the other hand, an infinite resistance reading, usually a “1-” or “OL” reading on the meter, indicates an open.

Training Manual

SERVICE TRAINING

The Troubleshooting Process A logical, step-by-step approach to troubleshooting is absolutely necessary. A good general approach is to observe all symptoms. Perform a visual inspection, test the circuit, make repairs, then test the repair. Observe and Verify. When observing symptoms, first make sure that there really is a problem, and the operator is not merely mistaking the normal operation of a system for a malfunction. If you don’t notice a problem, it may be intermittent. In this case, you need to recreate the conditions that caused the malfunction in order to find it. This means operating the unit under the same conditions it failed under. If you still can’t find it, don’t give up yet. There are still some things you can do during testing that may reveal it. Next, perform a visual check of the problem circuit. Look for broken, loose, or corroded connections or wires, burned –out bulbs, blown fuses, misadjusted switches, etc. The problem may be nothing more then a disconnected connector. Looking for the simple things now can help you solve the problem quickly. Test. If the cause of the malfunction is still a mystery, it’s time to test the circuit. To do this properly, refer to the wiring diagram for the unit. Note the path that current must take in order for the circuit to operate correctly. Check the operation of those components which share sources of power or ground with problem circuit. If such components operate correctly, you can eliminate part of the circuit, up to the point where it connects with a working component, as a source of the problem. On the other hand, if you find that a couple of circuits are operating incorrectly, you can begin testing at the points these circuits have in common, if any. Refer to the proper Service Manuals or Service Bulletins for recommended tests. If non, apply, start testing near the middle of the circuit where the wires or components can be easily reached, unless your initial observations lead you to a specific part of circuit. What tests you choose are up to you. As long as you progress in an orderly manner and understand the readings you get, you’ll solve the problem. If necessary, record your test results so you can analyze them more carefully.

Training Manual

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SERVICE TRAINING

Electrical Symbols SHOWING DIN (DEUTSCHE INDUSTRIAL NORM) SYMBOLS, PLUS COMMONLY USED A.N.S.I. SYMBOLS AS SHOWN ON SCHWING SCHEMATICS LINE MAGNET COIL FOR HYDRAULIC VALVE CONNECTOR

DIN

ANSI

HORN

LINES, JOINING

LAMP WITH BULB

(Letter indicates lens color)

R DIN

ANSI

LINES, PASSING 20A

20A

FUSE (AMP RATING INDICATED) DIN

ANSI

G receptacle ALTERNATOR

PLUG AND RECEPTACLE

OR

plug

B+

DIN

ANSI

D+

ALTERNATOR

31

TACHOMETER SENDING UNIT (PROXIMITY SWITCH, DIGITAL - ANALOG CONVERTER)

DOIL TEMPERATURE TRANSMITTER (both DIN)

+ BATTERY

OR

T

CURRENT FLOWS IN THIS DIRECTION

DIODE CURRENT BLOCKED IN THIS DIRECTION

OR

CHASSIS GROUND

LIGHT EMITTING DIODE (L.E.D.) 50a 30 STARTER

STARTER

31

ELECTRIC MOTOR

196

SHIELDED CABLE (Show all conductors inside shield)

TERMINAL CONNECTORS

21

21

POSITIVE TERMINALS

M

Training Manual

22

22

NEGATIVE TERMINALS

SERVICE TRAINING

Electrical Symbols SWITCHES

RELAYS

KEY: N.O. = Normally open N.C. = Normally closed

KEY: N.O. = Normally open N.C. = Normally closed Control Relays (DIN drawings) (Bosch brand shown)

Solid line = position of switch as drawn Position of operational functions (detented "ON", spring returned "OFF" shown) Method of operation: (double throw switch shown)

ON O OFF

1

Contacts (higher current rating) 1 N.O. and 1N.C. contact shown

Terminals (Numbers shown if they are presesnt on the switch)

Relay coil (very small current draw)

87a

86

87

85

30

ON OFF

2

3

OR Component enclosure

Component enclosure

Contacts (2 N.O. contacts shown).

Dashed lines = available positions of switch

86

AS DRAWN ("O" POSITION)

87a 87

K3 85 In the "ON" position, switch is held in place by the detent (indicated by the vertical line)

"ON" position activated, as indicated by solid line

OR 86

K3

ON O OFF

ON

30

1

85

In this example, contact is made between terminals 1 and 2 in the "ON" position

OFF

2

3

Pivot point of the switch shown below the activation line indicates that the contact lever would be drawn towards contact #2 in the "ON" position

87a 87

If the relay coil is drawn on one part of the schematic, and the contacts are drawn on another part, the relay number (in this example, K3) will be listed in both places as shown here.

K3

Control Relays (ANSI "ladder" drawing) FUNCTION WHEN ACTIVATED "ON"

Relay terminal numbers

Relay coil

line numbers Spring is compressed during activation, indicating that it will return to "O" when released

"OFF" position activated, as indicated by solid line

ON O OFF

ON

1

Pivot point of the switch shown below the activation line indicates that the contact lever would be pushed towards contact #3 in the "OFF" position

13

1

9

N.C. contact 1

In this example, contact is made between terminals 1 and 3 in the "OFF" position

8

3 CR

9

5

N.O. contact

CR 3

1

9

5

these numbers show the location (line number) of the contacts that the relay coil will operate

2

8, 9

N.C. contacts are underlined

wire numbers

14

these numbers denote which relay coil will operate the contact

OFF

2

CR 2

CR 1 7

30

3 9

FUNCTION WHEN ACTIVATED "OFF"

1

common hot

Training Manual

CR 3 9

1

15

CR 2 2

8

16

G

2

common neutral

197

SERVICE TRAINING

Electrical Symbols SWITCHES: Methods of operation PUSHBUTTON (EMERGENCY STOP) DIN

If the contact operator is shown extending beyond the last contact, it indicates that this operator will also work a contact shown elsewhere on the schematic.

ANSI

DISC.

Q

DISCONNECT SWITCH

DIN

ANSI

N.O.

PUSHBUTTON MOMENTARY CONTACT

CB / DISC

Q N.C. DIN

CIRCUIT BREAKER / DISCONNECT SWITCH

ANSI PS.

N.O.

PRESSURE SWITCH

PS.

N.C. DIN

MOTOR OVERLOAD RELAY

ANSI

TOGGLE SWITCH

TGS.

OL

DIN

S.P.S.T.

ANSI

MISC. DEVICES TGS.

0 1 2

RESISTOR (VALUE INDICATED IN OHMS) (K = 1000)

D.P.D.T. 0,1,2

DIN

2.5 K

ANSI POT

MECHANICAL SWITCH (Hopper Grate Switch)

NONE AVAILABLE DIN

1K

POTENTIOMETER (Value indicated)

1K

ANSI

DIN

ANSI

Primary

120V 60 HZ

120V 60 HZ

Secondary

12V

12V

DIN

ANSI

DIN

ANSI

TAS

N.O.

¡C TEMPERATURE SWITCH

TRANSFORMER

TAS

¡C

N.C.

DIN

OVER-CURRENT SWITCH (Always normally closed)

ANSI

OL

N.C. DIN

BRIDGE RECTIFIER (A.C. to D.C. converter)

ANSI FS

N.O.

Q FLOAT SWITCH (Oil Level)

FS

Q DIN

198

N.C.

CAPACITOR (VALUE INDICATED IN FARADS) ( = micro or 1 millionth)

ANSI

Training Manual

2 F DIN

2 F ANSI

SERVICE TRAINING

Controller Systems Analog

39000170.eps

Digi-Prop (Microwave)

40

60

20

0 0 0 0 0

80

1 10

100

C HOURS

P

VDO

C

Filter in Bypass

15 10

MAT

20

U/minx100

5

25 30

0

35 OIL COOLER ON

OFF

3034

1803

30339533 4

5

6

3

7

2

8

1

9 10

0

39000171.eps

Comfort Control

0

0

0

0

0

0

0

!

3034

1221

30339533 4

5

6

3

7

2

8

1

9 10

0

39000172.eps

Training Manual

199

SERVICE TRAINING

C32 OUTPUT

PARAM VALUE THRESHOLD

20

D

2_

25 O

T O P E R AT E D Z O N E!

RE

NO

N

U/minx100 I

5

POWER

START PWM

3_

30

0

REAR CTR

KEY

MAX

1_

15 10

4_ MAX PWM

35

5_

UMB CTR RAMP UP

6_ RADIO CTR ID

+

RAMP DOWN

-

MIN

LINK 40

ALARM

60

20

80

100

C

E-STOP

STORE VDO


3034 4

5

1803

6

3

7

30339533

2

8

1

9 4

5

6

10 7

3

L1357-01

0

2

8

1

9 10

0

39000173.eps

30339530

CPC OUTPUT

PARAM VALUE

KEY

MAX

1_ THRESHOLD

2_ START PWM

3_

RPM

POWER

4_ MAX PWM

REAR CTR

5_

UMB CTR RAMP UP

6_ RADIO CTR ID LINK

+

C NORMAL

RAMP DOWN

-

MIN

BYPASS

ALARM E-STOP

STORE


3034

Reset

30345602

L1357-01

5

4

6

3

7

2

8

1

9 10

0

39000174.eps

30351405A

CPC II OUTPUT

PARAM VALUE MAX

1_

KEY

THRESHOLD

2_ START PWM

3_

RPM

POWER

4_ MAX PWM

REAR CTR

5_

UMB CTR RAMP UP

6_ RADIO CTR ID LINK

C NORMAL

+

-

RAMP DOWN

MIN

BYPASS

ALARM E-STOP

STORE

∅


∅

Reset

4

5

6

3

7

L1357-01

2

8

1

9

0

200

Training Manual

30357944

39000175.eps

10

CPC 2

8540

SERVICE TRAINING

Vector - Current Production

1

OK

2

OFF

x1000 3 0 PTO 1500 rpm 62˚C

Menu: [ENTER]=ON

1

HOME

+

HELP

START

2

30356534 C

3 HP

R

4

5

6

3

7

8

2

QUIT

9

1

ENTER

0

-

P

10

CLEAR

30362348

39000176.eps

Training Manual

201

202

X2 Terminal Block 3 - TB #3 1 - TB #1

2

Training Manual Non-joining lines 2

1.5 - 1.5 SQ. MILS all 3 wires

Relay coil location 11 - page 11 2 - reference 2

Joining lines

K12 Relay contact ".1" - reference 1 same page

K12 relay location same page .2 - reference 2

6 - 6 SQ. MILS (wire size)

(Reference #’s)

X11 - Plug connector X11 B2 - pin on X11

SERVICE TRAINING

SERVICE TRAINING

28X Truck and Pumpkit Circuit

2

JunctionBox (see boom schematic)

1

orange

Trouble Light Receptacle at Operator’s Panel

Panel Light

+

to Pin 2/5

brown

G G

brown brown

brown from Pin 1/11

Emergency stop button

10 gauge 12 gauge

red

orange

red

brown

= = =

Remote thermometer for Pass. Side oil tank

grey

brown

brown

G Small On-Off switch

All fuses 20 amp (AGC size)

Remote thermometer for Driver’s side oil tank orange

red

16 gauge

brown

Tachometer

Panel Light

G

brown

brown

orange red black

purple

purple

white

white

USA 28M 1/94 GRP

white with black stripe

electric oil cooler only green

yellow

Continuous duty solenoid

Switch on pump air shift lever

blue

brown

yellow

purple

Oil cooler light (red)

cooler M Oil motor 12V

purple

red

purple

red

white & black stripe

H Hour meter

Oil cooler On/Off switch

white

Warning lamp

white

black

In line fuse

25 A

25 A

red

purple Dirty oil filter light (red) brown

Key switch terminal - Hot when in "On" brown position blue black

12 volt +

Tachometer sending unit (proximity switch)

+

Trouble Light Receptacle at Center of Unit

Dirty hyd. oil filter pressure switch 35 PSID (2.4 bar)

Training Manual

Passenger side hyd. oil temperature sending unit

Driver’s side hyd. oil temperature sending unit

203

SERVICE TRAINING

28X Boom Circuit

U.S.A. 28 METER AS WIRED...1989 and LATER yellow

1. OPERATOR’S PANEL 2. REMOTE CONTROL BOX-992.900.100.900 3. REMOTE CORD (red) 992.900.801.900 4. CABLE DRUM/90 FEET-992.903.000.100 5. JUNCTION BOX (12 volt) 992.900.104.800 6. DISCONNECT BOX (assembly consisting of 303394,303393, 303395, 992.900.700.700) 7. CABLE TREE 305609

red

R= Remote Control L= Local Control brown

white

R Off L

brown

86

3

1

SEE TRUCK/PUMP SCHEMATIC

3

1

87 Off

30

85 blue

2

4

2

4

NOT-AUS (Emergency Stop) red

brown red

NORMALLY OPEN BYPASS VALVE (boom and outrigggers)

20 Amp x 5

white

1

B

C

D

E

F

G

G+

H

25 A

S O P

G-

2

Continuous Duty Solenoid (See truck/pump schematic)

A

STOP

white

P

A2 A2

A3 A3

A4 A4

A5 A5

B1 B1

B2 B2

B3 B3

C5 C5

B4 B4

B5 B5

1

2

3

4

5

6

7

8

15

9

10

1

2

3

4

5

6

7

8

15

9

1

2

3

4

5

6

7

8

15

9

1

2

3

4

5

6

7

8

15

9

1/1

1/2

1/3

1/4

1/5

1/6

1/7

1/8

1/12

C2 C2

C4 C4

C3 C3

C1 C1

16

14

12

13

11

10

16

14

12

13

11

10

16

14

12

13

11

10

16

14

12

13

11

2/4

2/11

2/5

2/2

2/1

10 d1 11

1/9 1/10

10 d2 11

4 5

8

6 2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

8

d1

d2

5

5

2/7

1

3

2/3 2/12

A1 A1

1/9 1/10 1/11 2/6 2/7 2/8 2/9

10 12 9 11 9 10 11 12

+

204

-

1

2

3

4

5

6

7

8

9

10

11

Training Manual

12

13

2

P2

14

15

16

17 CONCRETE PUMP REVERSE

+ 2

CONCRETE PUMP FORWARD

2

1

CONCRETE PUMP REVERSE RELAY

H

1

CONCRETE PUMP FORWARD RELAY

G2

THROTTLE DOWN

F2

THROTTLE UP

E2

1

Components 2 thru 5 BYPASS VALVE

C2 D 2

1

#2 BOOM RETRACT

1

#2 BOOM EXTEND

B2

1

#3 BOOM RETRACT

A2

1

#3 BOOM EXTEND

2

1

SLEWING CW

1

SLEWING CCW

1

#1 BOOM DOWN

1

#1 BOOM UP

1

12 Volt

7

S

18

19

2/90 RE

SERVICE TRAINING

Misc Procedures Material Cylinder Alignment 1. To visually inspect the alignment, put a trouble light in the waterbox, at the opening to the cylinder being aligned (See Figure 66). Be careful with fingers and hands in the waterbox. Put the trouble light in the waterbox, then remove your hand BEFORE proceeding to the next step.

Figure 67 Material Cylinder Alignment Tool LIGHT RAYS

CYLINDER WALL

ALIGNMENT TOOL

Figure 66 Placing a spot light in the waterbox 2. Select the “forward” mode of the S1 valve, AT THE SLOWEST POSSIBLE SPEED! Look into the material cylinder from the valve end. The gap between the alignment tool (See Figure 67) and the cylinder wall should be seen as even rays of light (See Figure 68). When the cylinder gets fully extended, the alignment tool may drop a small amount or even barely touch the material cylinder wall.

Figure 68 Light rays in material cylinder If the alignment tool should contact the cylinder wall at any time, return the pump to neutral immediately! Damage may occur to cylinder wall.

Training Manual

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SERVICE TRAINING

3. If, for example, the alignment tool contacts the cylinder on the lower side, loosen the mounting bolts at the waterbox a little bit, then tighten the LOWER bolts first (See Figure 69). This will lower the bottom of the material cylinder. When the alignment is close, tighten the top bolts and recheck the alignment. When the alignment is within specification, the alignment tool will travel the entire length of the cylinder without touching the cylinder wall. If the alignment tool is not always located exactly in the middle of the cylinder during the travel, but DOES NOT TOUCH, then realignment is not necessary. Minor misalignments are compensated for with the rubber ram. Repeat procedure for the other cylinder.

9. 10.

11. 12. 13.

NOTE! If a squeaking sound indicates the alignment tool is dragging on the material cylinder, turn off the pump IMMEDIATELY! If there is no dragging, you may proceed to step 11. If dragging does happen, repeat the visual checks. Loosen the bolts on the material cylinders and valve housing, and at the machine frame, and repeat the alignment procedure. Check the mounting of the pump kit and its mounting to the pump kit frame. Tighten all bolts. Complete the reassembly of valves, and install the rubber rams.

NOTE! If proper alignment cannot be achieved otherwise, tightening torques may be exceeded by 10% over the charts specs. If further alignment problems persist, please contact the Schwing Service Department.

MOUNTING BOLTS

Figure 69 Mounting bolts 4. Grease new o-rings and insert in the valve housing. 5. Carefully slide the valve housing onto the material cylinders, and rest the valve housing on the machine frame. 6. Bolt the valve housing and material cylinder flanges together making sure that the alignment is being maintained. 7. Bolt the valve housing to the machine frame. 8. Check alignment with the tool once more, at slowest possible speed.

206

Training Manual

SERVICE TRAINING

Pumping on piston side

tools to install them.

(Available on some units only) Piston side pumping changes your concrete pump from a low-pressure, high-volume machine into a high pressure, low-volume machine. This would be handy, for example, to pump long distances horizontally or vertically. 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 be maintained in likenew condition. Remember that pipe wall thickness wears with each yard of concrete pumped. Inspect the wall thickness regularly. The maximum material pressure available on the piston side depends on which differential and material cylinders you purchased with your unit. The maximum material pressure is recorded on the main ID tag. To convert your machine to piston side operation, you must have some additional hoses and fittings, plus the

When changing the hoses from the rod side port to the piston side port, you must cross them. This keeps the machine in the same sequence of events as when it is hooked up for rod side pumping. Failure to cross the hoses will result in pumping in reverse whenever you select forward. When you have finished with the need for piston side operation, change it back to rod side immediately. When you are configured on the piston side, the safety rules for the following topics become even more important: • Opening lines under pressure • Sucking back plugged lines before opening • Pressure-handling capacity of pipes, hoses, and clamps in your delivery system • The dangers of blockages All of these items are covered in the Safety Manual. Understand the rules and live by them .

Loosen for rotation

Add dead plugs (1200’s only)

This hose 1200’s only Add hose and fittings to each side

Loosen for rotation

rod/piston change.eps

Loosen for rotation

Loosen for rotation

Rod Side Configuration

Changes

Training Manual

Piston Side Configuration

207

SERVICE TRAINING

Shimming the Differential Cylinders

Tension Ring

Determining the proper shimm size When ever you rebuild differential cylinders, it may be necessary to add shimms to the tension ring. Adding shimms protects the cylinder rod from the cheveron seals in the event the cheveron seals expand. Use the following procedure to determine the proper amount of shimming necessary.

Cheveron Seal Set

Dimension A

Tape

Using a caliper measure the distance from the top of the bushing down to the bushing seal recess. See Figure 70.

Figure 71 Compacting the Cherevon seals Use the caliper to measure the distance between the top and the bottom of the compacted cheveron seals. See Figure 72.

Dimension A = 57.12 mm 57.12 mm is the depth of the guide bushing seal recess.

Dimension B = 57.4 mm

Tension Ring Bushing Seal Recess

Bushing

Dimension B Cheveron Seal Set

Dimension B

Figure 70 Measuring for dimension A

Figure 72 Measuring for dimension B

Dimension B Leave the tape around the cheveron seals to hold them into place. On a solid flat surface place the Tension ring on top of the cheveron seals. This will compact the cheveron seals to the proper size. See Figure 71.

208

Training Manual

SERVICE TRAINING

Formula

A should equal B B - A = shims required In this example:

57.40 - 57.12 .28 mm (.011") Refer to SAIE 5221 Figure 73 Formula for determining shimm size In this example, we would need to add 1 - 0.5mm shimm to the Tension ring. This will ensure that the cheveron seals will not expand, thus preventing wear on the cylinder rod.

NOTE! A maximum of 5 shimms can be used.

NOTE! Dimension B can never be greater than dimension A or cylinder rod damage can occur.

Training Manual

209

SERVICE TRAINING

Apitech Control Chamber Air Bleed Procedure The mounting orientation of the Apitech boom control handvalve makes a difference in the way the air is bled out of the control chambers. Normally, if the valve was installed at the factory then there is no reason to bleed the air from the control chambers. But if a spool or solenoid is replaced, then air can enter the control chambers and may need to be bled. The following is a list of the potential mounting orientations of the valve and the procedure to remove the air from the control chambers, if ever required.

If the valve is mounted in it’s normal horizontal position with solenoids above the main spool (Figure 75), then the valve will automatically purge the air from the control chambers, as the valve is actuated.

Spool

Spool

Solenoid

Figure 76 Horizontal mounted - Solenoids below the main spool • The PC2 control chamber (spring side) is bled by loosening the spool plug with flow limiter several turns in order for the O-ring to disengage with the lead-in surface of the SAE port (Figure 77). Then supply a pilot signal to the end chamber by energizing the solenoid closest to the plug with 100% input signal. Once there is no more air exiting from the threads of the plug, turn the plug into the valve housing until the O-ring contacts the lead-in surface. Then remove the pilot signal and any other positive pressure from the valve. Tighten the plug into the valve housing to 10 - 30 ft. lbs. of torque.

Figure 74 Typical Apitech Handvalve

Solenoid

Solenoid

O-ring

Spool Plug with Flow Limiter

PC2 Control Chamber

Solenoid

Figure 77 Bleeding the PC2 control chamber Figure 75 Normal Horizontal Position If the valve is mounted with the main spool horizontal and the solenoids (Figure 76) are below the main spool, then the following must be done:

210

• The PC1 control chamber (handle side) is bled by loosening the port plug several turns (Figure 78). Then supply a pilot signal to the end chamber by energizing the solenoid closest to the port plug with a 100% input signal. Once there is no more air

Training Manual

SERVICE TRAINING

exiting from around the threads of the port plug, turn in the port plug into the valve housing until the seal contacts the valve housing surface. Then remove the pilot signal and any other positive pressure from the valve. Tighten the port plug into the valve housing to 25 – 35 in. lbs. of torque.


O-ring PC2 Control Chamber

Port Plug

PC2 Control Chamber

Figure 78 Bleeding the PC1 control chamber If the valve is mounted with the main spool horizontal and the solenoids are to the left or the right of the main spool in the same horizontal plane (Figure 79), then the following must be done:

Figure 80 Bleeding the PC2 control chamber • The PC1 control chamber (handle side) is bled by loosening the spool plug with flow limiter several turns in order for the O-ring to disengage with the lead-in surface of the SAE port (Figure 81). Then supply a pilot signal to the end chamber by energizing the solenoid closest to the plug with 100% input signal. Once there is no more air exiting from the threads of the plug, turn the plug into the valve housing until the O-ring contacts the lead-in surface. Then remove the pilot signal and any other positive pressure from the valve. Tighten the plug into the valve housing to 10 - 30 ft. lbs. of torque.

NOTE! Solenoid

Solenoid Spool

Figure 79 Spool Horizontal - Solenoids to the left and right of main spool

Due to the internal core of the casting, it may be necessary to slightly tilt either the valve or the equipment in which the valve is mounted on, so that the end plug is the highest point of the valve section, in order to remove all the air from the control chamber.

• The PC2 control chamber (spring side) is bled by loosening the spool plug with flow limiter several turns in order for the O-ring to disengage with the lead-in surface of the SAE port (Figure 80). Then supply a pilot signal to the end chamber by energizing the solenoid closest to the plug with 100% input signal. Once there is no more air exiting from the threads of the plug, turn the plug into the valve housing until the O-ring contacts the lead-in surface. Then remove the pilot signal and any other positive pressure from the valve. Tighten the plug into the valve housing to 10 - 30 ft. lbs. of torque.

Training Manual

211

SERVICE TRAINING


O-ring PC2 Control Chamber

signal. Once there is no more air exiting from the threads of the plug, turn the plug into the valve housing until the O-ring contacts the lead-in surface. Then remove the pilot signal and any other positive pressure from the valve. Tighten the plug into the valve housing to 10 - 30 ft. lbs. of torque.


Figure 81 Bleeding the PC1 control chamber

O-ring

If the valve is mounted with the main spool vertical (Figure 82), then the following must be done: Upper Control Chamber

Upper Chamber

Figure 83 Bleeding the upper control chamber using spool plug with flow limiter


O-ring

Upper Control Chamber

Figure 82 Vertically mounted handvalve • Only the upper control chamber needs to be bled since the air in the lower control chamber will rise and the air will purge out of the control chamber through the clearance around the main spool (Figure 83 or Figure 84 depending upon the orientation of the valve).The upper control chamber is bled by loosening the spool plug with flow limiter several turns in order for the O-ring to disengage with the lead-in surface of the SAE port. Then supply a pilot signal to the end chamber by energizing the solenoid closest to the plug with 100% input

212

Figure 84 Air bleeding the upper control chamber using the port plug

Training Manual

SERVICE TRAINING

Hydraulic Pump Adjustments Adjustment Knob

Main System Pumps A11VO To perform the proper adjustments of flow, horsepower, beginning of stroke limitation and the pressure cut-off to the tandem A11VO main system hydraulic pumps, the following steps must be done in order that they are listed;

T P T

MG

P MY

G Y

Setting the Flow Rate Before flow metering the pumps, ensure that the maximum engine Rpm’s are set to the proper specifications. All Schwing units have a metal ID tag located inside the cab displaying the specific RPM settings for that particular unit. Set the supplement system pressure to 0 bar by turning the adjustment knob all the way out on the electric stroke limiter. This will avoid false readings of the flow rate until the maximum flow rate and horsepower break points are set.

Adjustment Knob

Adjustment Knob

Figure 85 Electric Stroke Limiters Install the flow meter. (Consult the operation manual for proper installation and use of the flow meter). Set the engine Rpm’s at maximum and set the maximum flow at the Q max screw to the proper specifications per the output chart. (Check your operators manual for the proper output chart for your specific unit).

A11VO130 / A11VO130

Q-max Screws

A11VO130 / A11VO190

Q-max Screws

Training Manual

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SERVICE TRAINING

Horsepower Setting Adjustment Knob

After the flow rate is set, the horsepower setting then must be done. The horsepower break point must be set to the proper specifications per the output chart. CONCRETE PRESSURE


ROD SIDE

4500

350 300

4000 3500 3000 2500 2000 1500 1000

250 200

131

117

HYDRAULIC RELIEF VALVE IS SET AT 350 BAR MAX. PRESSURE (5075 PSI).

1600

110

1500

103

P

1400

97

MY

1300

90

1200

83

1100

76

200 Kw

150 100

Break Point 180 Kw = 182 bar 200 KW = 202 bar At 350 bar 180 Kw = 278 l/m 200 Kw = 309 l/m

0

10

20

7.5 15

30 40

50 60

70 80

900

62

800

55

700

48

600

41

500

34

400

27

300

21

200

14

100

7

208 90 100 110 120 130 140 150 160 170 180 190 200 210 220

23 30.5 38 46 53.5 61 69 76.5 84 92 99 107 114 122 130 137 145 153 160 168

cu yd / h cu meters/ h

CONCRETE OUTPUT 5

10 100

15 200

20 300

25 400

30 500

32

535

P T

MG G Y

1000 1007 69

50 500

T

124

1700

SA

OIL PRESSURE

5000

Bar 138

1900 1800

180 Kw

5500

PSI 2000

PUMP SPEED 2100 RPM

M PL E

Piston Side Bar

Piston Side PSI

BPL 2023-5 350 or 400 HP truck

Number of strokes (stroke / min.) Oil volume (liter / min.)

Break Points

Figure 86 Sample output chart

Setting Stroke Limitation Now that the maximum flow rate and horsepower settings have been made, the beginning of stroke limitation can be set. Adjust the supplement system pressure to the maximum pressure of 50 bar. 1. Make sure the stroke limit potentiometer at the rear operation panel or remote box is at the maximum material output setting.

Adjustment Knob

Adjustment Knob

Figure 88 Stroke Limiters (two generations) 3. Increase the engine Rpm's to the maximum setting and while watching the flow meter scale, slowly turn the stroke limit potentiometer to the minimum material output until the maximum flow rate begins to drop. 4. When the flow rate begins to drop, stop turning the potentiometer and read the pressure on the 0 to 40 bar gauge. The reading that is seen is the beginning of stroke limitation. The reading should be between 5 to 7 bar. If it is not, then adjust the beginning of stroke limitation screw accordingly to achieve the proper pressure reading. a. If the pressure is too high, then turn the screw counter-clockwise (out) to reduce the pressure. b. If the pressure is too low, then turn the screw clockwise (in) to increase the pressure.

Q-min Output Flow

Figure 87 Stroke Limiter Potentiometer 2. Install a 0 to 40 bar gauge in the electric stroke limit line going to the Y port of the hydraulic pumps, at this time the reading on the gauge should be 0.

214

Once the beginning of stroke limitation is set, the next step is to check the Q min output flow. 1. With the 0 to 40 bar gauge still in the electric stroke limit line going to the Y port of the hydraulic pumps. Increase the engine Rpm's to the maximum setting and while watching the flow meter scale, turn the stroke limit potentiometer to the minimum material output. The 0 to 40 bar gauge should be reading approximately 25 bar more than the beginning of stroke limitation setting to ensure the hydraulic pumps are all the way to the minimum against the Q min stop. The Q min reading should be between 15 to 25 liters per minute. If it is too high, turn the Q min screw out

Training Manual

SERVICE TRAINING

until the reading is correct or if it is to low, turn the Q min screw in until the reading is correct. When the Q min has been set, the flow meter can now be removed. A11VO190

A11VO130

1. Locate the agitator shutoff valve and close it. NOTE! If your unit does not have a shutoff valve, order one from the Schwing Spare Parts Department using part number 10004680 (valve), and number 30303432 (tube). Contact the Service Department for installation instructions. 14. Activate the agitator. With the valve closed the agitator will not be able to turn and the oil will be forced over the relief valve. At an idle (about 600 RPM), 4.5 horsepower is being converted to heat.

0

Q min Screw Q min Screw

Figure 89 Q-min screw locations agitoff.eps

2. Repeat steps 2 through 6 on the second main system pump before attempting to set the pressure cut-off on both pumps.

NOTE! All screw adjustments with the system relief’s and pressure cut-off must be done while the unit (pumpkit) is in the neutral position.

Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components. The specifications for each circuit are shown on the hydraulic schematics found in the Appendix of this manual. The hydraulic schematics are the only documents in this manual that have been updated specifically for your unit, by the serial number, so in each of the following procedures you will be told to refer to the schematic for the pressure required. •

Figure 90 Agitator shutoff valve 15. When the oil temperature gauge shows 50˚C, open the shutoff valve.

Setting pressures on Hi-flo -6 pumpkits a. To set the pressure of the main relief valve on Hiflo pumpkits, you must first disable the soft switch circuit. Simply locate the ball cock for the soft switch circuit (Figure 91) and close it by rotating the handle 90 degrees. b. The quarter turn shutoff valve for the concrete pump (Figure 91) will also need to be closed during this procedure.

NOTE!

Preheat the hydraulic oil

Pressure settings must be made with the oil at normal operating temperatures (40°− 60° C). In the past we could pressure out a function in the boom or outrigger system to create heat, but load sensing systems no longer allow maximum oil flow to be forced over relief. Because of this the agitator circuit must be used to heat the hydraulic oil. To preheat the hydraulic oil:

Main system adjustments are preset at the factory. The following procedure begins with adjustment of the main relief cartridge and pressure cutoff. If proper pressures can not be obtained through these steps, refer to the beginning of this procedure for specific instructions on the adjustment of flow, horsepower, beginning of stroke regulation and Q-min.

Training Manual

215

SERVICE TRAINING

Pressure setting procedure: Soft switch shutoff valve Main Pressure Gauge port

Concrete pump shutoff valve

hif

lob

rn

.e

ps

Figure 91 Concrete pump and Soft switch shutoff valves

23. Stop the truck engine and put the key in your pocket. Adjust the pressure cutoff screw (Figure 92) on each pump, by backing off the jam nut with a 13mm wrench. Using a 4mm allen wrench, turn the adjustment screw in (clockwise) one full turn and tighten the jam nut. Restart the truck engine. 24. Adjust the engine RPM to maximum specification. (See decal in truck cab) 25. Pressure out the system by activating the concrete pump forward switch on the rear panel. Using the rear panel controls will allow you to read the concrete pump main system pressure gauge, near the estop manifold, from a safe distance.

NOTE!

1. Be sure that the waterbox covers and guards are in place any time you will be working in the area around the main control block. 16. Wear safety glasses when working around a concrete pump.

NOTE! It is vital that each adjustment screw be properly identified prior to making any adjustment. All screw adjustments for the system relief must be made with the pumpkit in the neutral position and adjustments for pressure cutoff must be made with the engine shut off. 17. Start the truck engine, and put the PTO in gear just as you would to pump a job.

26.

18. If you have not already closed the soft switch shutoff valve and the concrete pump shutoff valve (Figure 91) do so at this time. 19. At the rear panel, select “local” control with the “local/remote” switch and turn the electric stroke limiter knob clockwise to maximum strokes per minute. 20. The main system control block pressure must be set first to properly set the pressure cutoff on both pumps. Begin by backing off the jam nut of the main relief cartridge (Figure 93) with a 9/16 inch wrench. 21. Using a 5/32 inch allen wrench, turn the adjustment screw out (counterclockwise) until you can feel no spring tension on the adjustment screw. 22. Now, turn the screw back in (clockwise) two or three full turns to give you a proper starting point and tighten the jam nut.

216

27. 28.

29.

Because you turned out the pressure relief cartridge in step 21., the system pressure should read low at this time. If it does not and the gauge spikes to 320 bar or more, disengage the pump immediately. Turn the relief cartridge out (counterclockwise) more. For safety, it is important to adjust the pressure up from below the specified target pressure rather than down from a pressure which exceeds the target. Continue this procedure until the main system pressure gauge reads lower than the specified target. To increase the pressure put the pump in the neutral position and adjust the relief cartridge by turning it in (clockwise). When increasing the pressure, the adjustments should be made in quarter turn increments. If you make adjustments to increase the pressure but the pressure does not come up, you are probably reading the pressure cutoff of the pumps, if so proceed to the next step otherwise skip to step 29.Turn the relief cartridge adjustment screw back out (counterclockwise) until you can no longer see a pressure drop and tighten the jam nut. Stop the truck engine, put the key in your pocket. Go to the pressure cutoff screw on both hydraulic pumps (Figure 92) and back off the jam nut with a 13mm wrench. Turn the adjustment screws in with a 4mm allen wrench one or two more turns, restart the engine and check the pressure again. Repeat this procedure until the main system relief can be set to the target pressure. When the proper main relief pressure is achieved, pressure cutoff can be set. Shut off the engine, put the key in your pocket and install 0-600 bar gauges with whip hoses to the “M1” gauge ports on the

Training Manual

SERVICE TRAINING

bottom of the two hydraulic pumps (Figure 92). You must be able to read both gauges simultaneously to ensure that one pump is not more dominant than the other.

NOTE! The gauges in the M1 ports will read considerably less than the cutoff pressure of the pump. On a -6 (190/130 pump combination) the 190 will usually read 85 to 90 bar while the 130 reads about 110 bar. They could read the same however, at approximately 110 bar, but the 190 must never read higher than the 130. The actual cutoff pressure will be read on the concrete pump main system pressure gauge near the e-stop manifold.

130ajst.eps

Figure 92 Adjustment screw locations Soft switch shutoff valve

30. Activate concrete pump forward to pressure out the pump and read the pressure on the two gauges in the “M1” ports.

32. When you have achieved the same pressure on the M1 port gauges, you can begin to adjust the pressure cutoff screws in or out simultaneously until you achieve the desired pressure setting of 350 bar (again, confirm the pressure specification with the hydraulic schematic). After pressure cutoff is set, return the pump to neutral, bring engine RPM to idle, open the soft switch quarter turn valve, and either proceed to other pressure settings or take the transmission and PTO out of gear and shut off the truck.

Concrete pump shutoff valve

Closed

hif

lob

rn

.e

ps

Open

31. Always stop the truck engine and put the key in your pocket before making any adjustment on the hydraulic pump. If the cutoff on one pump is set higher than the other, that pump will be more dominant. The pressure gauge in the M1 port of the dominant pump will however, read lower than the other. To equalize the two pumps you must either adjust the cutoff screw in (clockwise) to increase the pressure of the pump showing the higher reading or adjust the cutoff screw of the dominant pump showing the lower reading out (counterclockwise) to reduce the pressure. These adjustments must be made until the two gauges in the M1 ports are reading approximately the same.

Main Pressure Gauge port

Figure 93 Soft switch circuit/Main relief valve

Setting the soft switch relief pressure First, open the soft switch quarter turn valve (Figure 93) that you closed in the previous procedure. The rest of the unit should still be set up as if you were going to check the main relief valve pressure (concrete pump shutoff valve still closed).

Training Manual

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SERVICE TRAINING

When you put the pump in forward now, the main concrete pump pressure gauge should read the pressure shown on the schematic for soft switch. If adjustment is needed, loosen soft switch relief valve jam nut (Figure 93) with a 9/16 open end wrench, and use a 5/32 allen wrench to adjust the pressure. Turn the adjustment screw in (clockwise) to raise the pressure or out (counter clockwise), to lower the pressure. When you attain the required pressure, tighten the jam nut while holding the allen wrench to keep the pressure from rising. Be sure to open the concrete pump shutoff valve on the side of the brain (Figure 93) when you are finished. The unit will not stroke with this valve closed

218

Training Manual

SERVICE TRAINING

Accumulator Bypass Retrofit

mechanical dump valve on the accumulator manifold, start the machine and engage the PTO, bring the oil up to operating temperature (60c – 80 c), and check all work for leaks.

Service Bulletin 1001-03 Reference page 4 for schematic. Before installing this kit make sure that the engine is off, the key is removed, and the accumulator system is de-energized by confirming that the accumulator pressure gauge is at zero and the manual dump valve on the accumulator manifold is opened. Install check valve and fittings, items 8, 9, and 10 in the pressure line from the outlet of the hydraulic pump. Make sure that the check valve is installed in the correct orientation (free flow from the pump) as shown in Figure 1. These items must be installed between the outlet of the pump and where the line is “Teed” for the e-stop manifold so that the accumulator system will be de-energized when an e-stop button is depressed or the machine is taken out of PTO mode. Reconnect all lines. ACCUMULATOR SYSTEM

11

2

1

3

To test the bypass operation you need to disconnect the pressure line from the accumulator hydraulic pump. Plug the hose and pump using items #12, 13, and 14 as in Figure 2. ACCUMULATOR SYSTEM

AGITATOR VALVE 9

10

E-STOP

AGITATOR VALVE 9

10 14 13

3

4

5

B CLOSED FOR BYPASS

A

A 2.0 bar 39000215.eps

12 13

ACCUMULATOR PUMP

4

Figure 2 Plugging the hose and pump

5

B CLOSED FOR BYPASS

A

A 2.0 bar

8

1

B

6

E-STOP

2

6

7

B

11

7

39000214.eps

ACCUMULATOR PUMP

Figure 1 Installing Checkvalves and Fittings Confirm the 1/4 turn valve shutoff on the agitator system is installed in the B line of the agitator system as shown in Figure 1. If your machine is not equipped with a 1/4 turn shutoff, p/n 10004680, one must be installed. Disconnect the 1/4 turn valve from the tube or hose going to the agitator hydraulic motor. Install items 5, 4, 3, 1, 2, and hose 11. Make sure that the check valve is installed in the correct orientation (free flow from agitator to accumulator system). Reconnect the tube or hose going to the agitator motor. Route hose 11 under the deck and “T” it into the P port of the accumulator manifold using items 6 and 7.

Close the 1/4 turn valve on the accumulator system and stroke the machine with water in the hopper. The accumulator gauge should respond very similar as it does with the accumulator pump. Also, you must confirm that the e-stop manifold does de-energize the accumulator system. Retrofit Assembly Kit# 30364723 SEQ QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 14

1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 2.00 2.00 1.00

PART# 10102204 10008108 10020109 10019122 10018848 10018849 10008033 10019728 10008110 10003861 10049909 10016789 10001741 10008093

DESCRIPTION VALVE CHECK S10A 0.0 FITTING STR GES-16-SR 1/2î FITTING STR EGESD-16-SR 1/2” – WD FITTING EL EWSD-16-S FITTING TEE ELSD-16-S FITTING STR REDSD 20/16S FITTING TEE ELSD-20-S FITTING STR EGESD 20 SR 3/4” –WD FITTING STR GES 20-SR 3/4” VALVE CHECK S 15 A 2/0 HOSE H.P. DN 13/4 X 1700 DKO-S FITTING PLUG VS 20 S CAP NUT M 20 S FITTING STR GS-20-S

After the installation is complete, you need to close the

Training Manual

219

SERVICE TRAINING

Trouble Shooting Kit

These kits contain a 0-600 Bar pressure gauge, a 0-40 Bar pressure gauge, plus all the necessary fittings, locking plugs, manitrol valves, and hoses to plumb the gauges into any hydraulic circuit on the unit. These kits include the heavy duty foam lied carrying case. Schwing Part Number: Trouble Shooting Kit for BPA’s • Part # 30308552 Trouble Shooting Kit BPA’s and BPL’s • Part # 30308553 (shown)

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Visual Inspection General Instructions ....................... 3 Periodic Maintenance ....................................................3 Safety Decals ................................................................4 General Items ................................................................5 Clearance at Front Boom Rest ......................................6 Outriggers .....................................................................7 Do not partially extend outriggers ................................8 Tower ............................................................................9 Turret ...........................................................................11 Slewing Gear ...............................................................12 Boom Sections ............................................................13 Concrete Delivery Pipeline .........................................15 SAIE 5158 ...................................................................17

Training Manual

Table of Contents

Table of Contents

SERVICE TRAINING

Service Manual

Visual Inspection General Instructions NOTE! The following pages contain suggestions about what to look for during routine visual inspections. A complete structural inspection must still be done according to the manufacturers recommended schedule.

Periodic Maintenance A complete structural inspection of the concrete pump, boom, and outrigger assembly should be performed by a qualified boom inspector, at the following intervals: • The first five years - at least once per year. • Five to ten years - every 6 months • Ten years and older - every 500 working hours, or at least once per year, whichever occurs first.

Figure 2 Visible rust, indicating a possible crack. If paint is found to have split and rust is coming through, remove the paint and do a close visual inspection. If a crack is found a Schwing approved boom inspector must be called in for analysis. Please contact SAI Engineering if you have any questions.

At least once per week the unit should have a complete visual inspection. The unit should be clean and dry prior to inspection including inside the tower. Freshly painted units aren’t likely to show cracks (paint covers them up). Cracks typically won’t show up until at least 150 pumping hours after painting. Visual inspection of all components, however, must still be done each week. Check safety decals for proper positioning. Remember that safety decals and labels are available, free of charge, from the SAI Spare Parts Department. Order replacements whenever these labels are damaged or missing. Please have the serial number of the unit available when you call Spare Parts.

Figure 3 Crack on a welded joint.

All areas of discontinuity in a weldment and the weld seams are considered critical areas to inspect. Pipeline holders and/or supports must also be inspected.

Figure 1 Paint crack - may indicate a crack in the metal.

Figure 4 Dented corners, indicating damage.

Training Manual

3

Safety Decals Each machine is equipped with a set of warning labels specific to the model, boom style and installed options. Safety decals MUST be replaced if they are damaged, faded, missing, or unreadable for any reason. Ultraviolet radiation, rain, steam cleaning, and other factors cause these labels to fade in time. Sets include outrigger load labels, but they do not include metal plates, which can be ordered separately. For installation locations, see the decal location guide insert found in the Appendix section of the Operation manual. To get replacement labels, identify which label(s) you need

from the diagrams and lists, get the serial number of the unit from the serial number plate, and call Schwing America at (800) 328-9635. The person taking the order will make a note of the serial number of the unit for our files and send you the labels you need. You may order complete sets or single labels. 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.

SERVICE TRAINING

SERVICE TRAINING

58p6.eps

WARNING

CAUTION

3

4

TION SO C IA

E CONCRET

BOOM UP

Operation of this machine requires training. You must read all warning labels on the unit items covered on specific warning labels are not covered here. There are other hazards and safety rules that are ONLY covered in the safety manual or operation manual.

2.

Only the operator may authorize access to the unit or surrounding area.

3.

Safety devices and guards must NOT be altered or removed.

4.

Stop the operation if any malfunctions, failures or structural faults occur. DO NOT restart until repaired.

5.

NEVER try to finish the operation with the emergency stop dump valves bypassed.

6.

You must always be able to see the point of discharge. If this is impossible, an assistant (spotter) MUST be used. The spotter must be positioned to see both the operator and point of discharge for the purpose of giving instructions to the operator.

7.

Ensure the stability of the unit. Use adequate outrigger cribbing for soil conditions. Level the unit to within 3.

8.

Check for obstructions before unfolding or slewing the boom or outriggers.

9.

DO NOT unfold the boom unless the outriggers are fully extended and properly jacked. Shortrigging is NEVER allowed on the side of the pour.

P/N 30345427

10.

Maintain a safe distance from excavations or cliffs. Stay as far back from the edge as the depth of the excavation or cliff. (This is the one to one rule).

11.

Never retract the outriggers until the boom is folded into the transport position.

Factory-filled with

Rando HD P/N 30345426

TEXACO

1. TO RELEASE, PULL SLIDE-PLATE DOWN AND PIVOT HANDLE OUT AND UP COMPLETELY.

TIE-DOWN STRAP AND RATCHET

4. 5. 6. BOOM RIGHT OPEN OR CLOSE OR EXTEND BOOM RETRACT BOOM

1.

Rando HDZ TEXACO

S MP ING A

2. 3. BOOM DOWN BOOM LEFT

Stand clear of outriggers when activating.

5 Factory-filled with

SAFETY INSTRUCTIONS 1. Release tie-down strap before lifting boom. 2. Lower boom into cradle and reattach tie down strap before transport. SLIDE-PLATE

1.

SAFETY INSTRUCTIONS

WARNING

Do not use the boom as a crane or hoist.

2

ERICAN AM

PU

WARNING

The hydraulic oil filters on this unit are disposable. Cleaning and re-use is not possible. It is time to replace the filter if the oil is at normal operating temperature and the "dirty filter" indicator light is illuminated. Normal operating temperature is needed because, on some machines, when the oil is cold the "dirty filter" lamp may illuminate even if the filter is clean.

Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).

When light is on, hydraulic pumps are engaged. Do not put transmission in reverse. Do not drive unit.

8

IMPORTANT

DANGER

Falling hazard. Not a work platform.

1

IMPORTANT

30355887

Use A MOBIL PRODUCT

HANDLE

Change all filter elements if the dirty filter lamp illuminates when oil is above 20 C. If unit does not have electrical filter lamp, change the filter elements every 13,000 yds or every 6 months, whichever occurs first.

11

Mobil DTE® 25

10

DATE OF LAST CHANGE

DATE OF LAST CHANGE

DATE OF LAST CHANGE

12.

Be sure outriggers are retracted and pinned before driving the unit.

13.

NEVER drive the unit with extended outriggers or an unfolded placing boom! Not even a few feet.

14.

The supplied safety cable MUST be used to secure the discharge hose or reducer to the tip section.

15.

DO NOT overload the boom. The maximum allowable weight from hose or reducer/hose combination is 376 pounds, which is equivalent to one 12 foot long 5 inch hose, OR a 5 inch to 4 inch reducer and one 12 foot long 4 inch hose. NEVER use the boom as a hoist or crane. NEVER attach a structural extension to the boom.

16.

In the event of a thunderstorm or high winds (over 48 MPH), the boom must be folded into the transport position.

WARNING 7. 8. 9. 10. 11. STOP BOOM START PUMP SLOW PUMP STOP PUMP LITTLE BIT SPEED UP DOWN

12. ADD WATER 4-GALLONS

13. ALL DONE CLEAN UP

2. TO REATTACH, PULL 2" OF STRAP THRU RATCHET

7

PUMP THE HANDLE TO TIGHTEN.

PUSH HANDLE DOWN TO LOCK.

Do not operate at pressures exceeding the rating of the entire material delivery system.

12

9

DANGER

ROCK VALVE

TM

16

3,409,334 3,580,696 3,640,303 3,685,543 3,741,691 3,829,251 4,019,839

4,057,373 4,178,142 4,191,513 4,260,338 4,343,598 4,373,225 4,373,875

4,392,510 4,437,817 4,465,441 4,472,118 4,556,370 4,621,375 4,681,022

4,708,288 4,852,467 4,978,073 5,066,203 5,106,225 5,106,272 5,224,654

5,257,912 5,263,828 5,281,113 5,332,366 5,346,368 5,401,140

Re. 32,041 Re. 32,657 Re. 32,719

30308020 C

WARNING

WARNING

22

CAUTION

You can order additional operation manuals, spare parts books, safety manuals and decal sets by contacting us at: Schwing America, Inc. 1-(800)-328-9635 6:00 AM to 9:00 PM Central Time Monday through Friday

27

26

Keep hands out of waterbox. Stop engine/motor if access is required. Keep covers closed.

WARNING Keep hands out of hopper and valve assembly. See operation manual if access is required.

Keep hands out of waterbox. if Stop engine/motor access is required. Keep covers closed.

Do not operate this machine without training. Understand the warnings in safety manuals and on decals.

SAFETY

23

MANUAL

29

Electric Motors 1. Stop the electric motor.

2. Remove the key, place it in your pocket, and put a "DO NOT OPERATE" tag on the switch.

2. Lock out the power source according to an approved lockout-tagout program.

3. Check accumulator circuit pressure gauge (if so equipped) to verify zero system pressure.

3. Check accumulator circuit pressure gauge (if so equipped) to verify zero system pressure.

32

2.

25

35

34 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS

This unit will NOT operate unless one of these plugs is connected to the control receptacle.

USE OF THE TOWING EYES You MUST pull within 15 of straight when attached to these towing eyes, or unit damage may result.

1. The radio remote control receiver (if so equipped). 2. The cable remote. 3. The shorting plug (supplied).

WARNING

40

Put all remote control functions in OFF position BEFORE connecting cable.

36

37

WARNING

EXTEND OUTRIGGER TO HERE BEFORE UNFOLDING BOOM

44

WARNING

(shown on dummy receptacle)

24 Volts Here

Do not touch hydraulic oil leaks. Get immediate medical attention if oil penetrates skin.

radio or cable remote plug (shown on control receptacle)

=

47

2. For a hydraulic problem, the inlet plumbing to the nonworking system must be plumbed out of the manifold. With the engine stopped, disconnect the plumbing for the nonworking system at the fitting pointed out BY-PASS Boom/outrigger below. Plug both NORM. BY-PASS circuit dump open fittings that valve result, using hydraulic blocking plugs. Be Accumulator sure to tighten the circuit dump plug/fitting connecvalve tion before restarting Concrete pump the engine. dump valve Boom/outrigger 3. The emergency stop system plumbing manifold is now plumAccumulator bed out of the system. Concrete pump system plumbing Make repairs before system plumbing reusing the machine.

=

40A

-

+

-

+

-

+

-

49 WARNING

30353078

-

+

-

+

-

+

-

EMERGENCY POWER SOURCE

30350982 A

46

45

Total weight of all hanging hoses, reducers and clamps must NOT exceed 215 pounds including concrete. Do NOT hang 5 inch (125mm) system from this boom.

Emergency stop switches do NOT function when manual bypass is depressed.

+

24 Volts Here

1. Remove nuts from battery connections on outside left battery. 2. Bend cables out of the way as shown 3. Install jumper cable as shown 4. 24 volts now available as shown

NORMAL POWER SOURCE

WARNING

WARNING

48

30A

+

30343571

SAFETY INSTRUCTIONS

1. Turn the bypass key switch to "BY-PASS" position. If control is restored, there is an electrical problem in the control circuits. You can clean out and fold up with the key switch override. If control is not restored, there is a hydraulic problem; proceed to step 2.

IGN 12V GND

24V

SAFETY INSTRUCTIONS Extend outriggers until striped decals are visible, as shown in illustrations.

43

42 OVERRIDE OF EMERGENCY STOP MANIFOLD • Use ONLY for emergency foldup and cleaning. • Emergency stop buttons DO NOT WORK when procedure is used.

SAFETY INSTRUCTIONS

Unit will tip if outriggers are not fully extended.

shorting plug

30343260 A

41 Stand clear of outriggers when activating.

Use retaining pins in all delivery system clamps.

WARNING Clear area before activating outriggers

15 15

EMERGENCY STOP PARO DE EMERGENCIA ARRÉT D'URGENCE

39

38

MANUAL

1.

30

Total weight of all hanging hoses, reducers and clamps must NOT exceed 376 pounds including concrete.

Do not operate this machine without training. Understand the warnings in safety manuals and on decals.

SAFETY

33 WARNING

31 WARNING

WARNING

WARNING Boom strap MUST be used during travel.

1. Raise #2 boom.

CUIDADO WARNING

WARNING WARNING Safety guard is missing.

BEFORE REMOVING HOPPER GRATE OR PERFORMING ANY SERVICE:

PROCEDURE FOR RAISING THE BOOM Unfold the boom in this order to avoid damage to the truck cab.

24


28

SAFETY INSTRUCTIONS Gasoline or Diesel Engines 1. Stop the engine.

SAFETY INSTRUCTIONS

WARNING

2. Raise #1 boom.

Keep hands out of hopper and valve assembly. See operation manual if access is required.

IMPORTANT

Do not stand on hopper grates.

20 Boom may float down without warning if tip is brought into hazard zone.

Before opening a blocked pipeline, relieve pressure by making 2 reverse strokes.

21

WHEN PERFORMING ANY WELDING ON THIS UNIT IT IS NECESSARY TO DISCONNECT ALL THE WIRING FROM THE DUVAC II SYSTEM. FAILURE TO DO THIS MAY DAMAGE THE COMPONENT.

HAZARD ZONE (During operation, tip hose must never enter this zone)

19

WARNING

WARNING

HAZARD ZONE

SAFE ZONE (During operation, tip hose must always be in this zone)

18

This machine is remote controlled and may start at any time. Stop engine before servicing unit. WARNING

SAFE ZONE

Stay clear. Contact will result in death or serious injury if the unit becomes electrically charged.

This product is covered by one or more of the following U.S. patents:

15

WARNING

DANGER


14

6

13

ADVENTENCIA

WARNING

WARNING

NO!

IMPORTANT!

Los interruptores de emergencia de paro no funcionan cuando se activa el sobre paso manual

=

WARNING Emergency stop switches do NOT function when manual override is activated.

=

WATER ONLY 58

DIESEL ONLY 59

57

WARNING SAFETY INSTRUCTIONS

Clear discharge area when first starting the pump, restarting after moving, or whenever air is present in the delivery system. See Safety Manual.

OVERRIDE OF EMERGENCY STOP MANIFOLD • Use ONLY for emergency foldup and cleaning. • Emergency stop buttons DO NOT WORK when procedure is used. 1.

2.

Pull override handle and hold. If control is restored, there is a control system electrical problem. You can fold up and clean out by holding the override handles. Be careful where you position yourself when lowering the boom and closing the outriggers. If control is not restored, there is a hydraulic problem; Accumulator proceed to step 2. system plumbing Boom/outrigger F o r a system plumbing hydraulic problem, the inlet plumbing to the nonworking system must be plumbed out of the manifold. With the engine stopped, disconnect the plumbing for the nonworking system at the fitting pointed out at right. Plug both open fittings that result, using

51

SAFETY INSTRUCTIONS

Explosion / fire hazard. Stop engine before refueling.

Boom/outrigger circuit override handle

• Shutoff valve - closed to preheat hydraulic oil by creating high pressure.

NEVER PARTIALLY EXTEND OUTRIGGERS

2. 3.

Outriggers must NEVER be partially extended when the boom will be used, or when the truck will be raised. The forces transmitted to the outriggers must be absorbed by the outrigger reinforcements. Partial extension defeats the reinforcements. Outriggers must be fully extended or fully retracted. If the outrigger is fully retracted (shortrigged), different hazards are present. See the Safety Manual, or your Operation Manual for information regarding

NO!

Serial #: Was built according to these drawings.

Agitator shutoff valve

52

SAFETY INSTRUCTIONS

WARNING

ATTENTION!

hydraulic: hyd. boom:

60

output chart: 30357363

61

Do not partially extend outriggers. See Safety Instructions. 30358147

Outrigger Outer Box Reinforcements

62

Figure 5 Sample decal location guide. See your Operation Manual for your specific unit.

4

Training Manual

WARNING

OK Outrigger Inner Box Reinforcements

electric:

• Shutoff valve - open for normal operation.

30354564

55

54

Open

Concrete pump, accumulator override handle

56

Do not insert solid objects into waterbox cleanout holes. 1.

Fire extinguisher inside. 30354741

53

Closed

Concrete pump system plumbing

50

Stop agitator before putting any solid object in hopper.

Tipping hazard. Additional cribbing needed for many soil types, including asphalt. See manual.

Outrigger Reinforcements Aligned

30358148

30359230

63

General Items Items to check:

• • • • • • • •

Boom Tie Down Straps Rear Steps Bearings and Pins Greased Tie Down Plates/Channels to Chassis Tower Tie-Down Bolts and Detach Tower Pins Hopper Grate Water Box Covers Clearance at Front Boom Rest (See SAIE 5158) Figure 8 Make sure all bearings and pins are greased.

Figure 6 Check for frayed edges and a working locking mechanism on the boom tie-down strap.

Figure 9 Check for cracks on the Tie Down Plates/ Channels

Figure 7 Check for damaged or missing steps. Figure 10 On SPB booms, make sure the detach tower pins are in place and not damaged.

Training Manual

5

Figure 11 Check the hopper grate for damage. Make sure the hopper grate switch works properly.

Correct

Figure 12 Make sure the water box covers and safety grates are in place.

Incorrect

In the transport position, each boom rest should be in contact with the boom and slightly compressed, (approximately 1/16 to 3/32 of an inch compression of the rubber rest). The load of the boom should not be on the boom hook. Maintain some clearance between the boom hook and the boom hook pin.

Clearance at Front Boom Rest SAIE 5158 covers the proper procedure for setting the clearance of the boom rests. Improper clearance may result in damage to the placing boom during travel.

6

Training Manual

Outriggers Items to check:

• • • • •

Structural members and welded seams for cracks, deformation and wear Operation/Functions Outrigger Tubes Outrigger Pads Pins, Pin Bores and Safety Devices

Figure 15 Check for cracks on the outrigger pin, also make sure the pin is in place and functioning properly.

Figure 13 Check for cracks on the outrigger structure.

Figure 16 Check for damage on all 4 outrigger pads.

Figure 14 Make sure the outriggers are functioning properly. Check for proper vertical alignment. Outrigger tubes must be replaced if wear is greater than 10 percent of original wall thickness.

Figure 17 Check for cracks on outrigger tube, pay special attention to all welded seams

Training Manual

7

Do not partially extend outriggers Structural damage could result.

NO! .ep

s

58

04

00

Force Fulcrum

Outrigger Inner Box Reinforcements

1. Outrigger fully retracted.

Outrigger Outer Box Reinforcements

No lever action. Force absorbed by reinforcements. Force must be low, or unit will tip.

Figure 18 Transparent outrigger shows reinforcement areas (curved outriggers have the same limitations)

Fulcrum

Force

CAUTION Force

Fulcrum

000467.eps

Structural damage to outriggers is possible. Do not jack outriggers unless they are either fully extended or fully retracted.

2. Outrigger fully extended.

Partial extension of telescoping outriggers is not acceptable at any time. Jacking the outriggers while they are in any position other than fully extended or fully retracted could cause structural damage to the outrigger outer box and/or the inner box (Figure 18). The three illustrations shown on the right explain the configurations of the outrigger in all positions. Remember that in configuration number 1, the boom must never be extended over a retracted outrigger.

Lever action present, but force absorbed by reinforcements.

Fulcrum

Force Force

NO!

Fulcrum

3. Outrigger partially extended. Lever action present, but force transmitted to areas with no reinforcements. Outrigger bends, bottom plate dents, or both. 000459.eps

8

Training Manual

Tower Items to check:

• • • • • •

Structural members and welded seams for cracks, deformation and wear Tie-Down Bolts Rubber Dust Cover Hydraulic Hoses Slewing Cylinders Tower Bolts, Bushing and Main Column

Figure 21 Crack on subframe inside bottom corner. (view from under tower.)

Figure 19 Cracks on tower gussets

Figure 22 Check tie-down bolts and plates for damage.

Figure 20 Crack on upper tower plate Figure 23 Check for missing or worn rubber dust cover.

Training Manual

9

Figure 24 Check for damaged or worn hydraulic lines.

Figure 26 Check for missing or damaged tower bolts. It is recommended that the anchor bolts for the tower be replaced every three years.

Figure 25 Make sure the cover for the slewing cylinders is in place and not damaged.

10

Training Manual

Turret Items to check:

• • •

Structural members and welded seams for cracks, deformation and wear Hollow Pin Mounting Bolts and Snap Ring Internal Structure

Figure 29 Pipeline clamp rubbing on hollow pin.

Figure 27 Damage on tower.

Figure 30 Dislodged hollow pin bushing. Damaged retaining ring.

Figure 28 Improper hollow pin mounting bolt.

Figure 31 Cracks inside the turret

Training Manual

11

Slewing Gear Items to check:

• • • •

Structural members and welded seams for cracks, deformation and wear Bolts Tight Drive Gear Wear or Deterioration Slewing Bearing Gear Wear or Deterioration

Figure 34 Excessive Wear on slew drive

Figure 32 Check for wear or deterioration on slew drive

Figure 33 Check tightness of bolts

12

Training Manual

Boom Sections Items to check:

• • • • • • •

Structural members and welded seams for cracks, deformation and wear Articulated Joints and Guide Levers Bearing Pins and Safety Devices Latch Hook and Assembly, Hook Support Hydraulic Lines Hydraulic Cylinder Threaded Pins

Figure 37 Crack on side plate

Figure 35 Damaged head section Figure 38 Crack on the end plate

Figure 36 Crack on bottom plate

Figure 39 Check for cracks and damage on the guide levers.

Training Manual

13

Figure 40 Bent keeper bolt

Figure 43 Check for leaks and damage on boom cylinder. Make sure the boom cylinder is operating properly.

Figure 41 Make sure the boom hook is working properly.

Figure 44 Damage on threaded pin

Figure 42 Check for damaged hydraulic lines on boom section

14

Training Manual

Concrete Delivery Pipeline Items to check:

• • • •

Mounting Hardware - U-Bolts/Nuts/Saddles Clamps with Safety Devices Reducer safety cable/nylon choker End Hose Safety Cable

Figure 47 Check pipeline clamps for damage.

Figure 45 Make sure all U-bolts and related hardware are in place and are not damaged.

Figure 48 Make sure nylon choker and safety cable are in place and are not damaged.

Figure 46 Damaged U-Bolts

Figure 49 Check for broken or damaged pipe arm clamps.

Training Manual

15

16

Training Manual

SAIE 5158 Standard: 5158 Page: 1 of 5

SAIE STANDARD Subject: Procedures for Setting Boom Rests

The following procedures are for Schwing America personal to follow and adhere to in regards to the setting of the boom rests for the following units: KVM 17, KVM 23, KVM 26, KVM 28X, 31 EZ, KVM 32 XL, KVM 34X, KVM 36 X, KVM 39 X AND THE KVM 42, S 45/47 SX, KVM 52/55, S 58/61 SX and an others. 3 Section Booms 1. The boom must be folded up unto the main rest and all four outriggers must be raised off the ground so there is no outrigger contact with the ground 2. Raise the #1 boom section enough that the #2 boom section is off the A-Frame boom rest :A:. Then make sure that all boom sections are folded together. Each boom rest section should be folded into the mating boom section rest without causing the boom section to bow. 3. Then lower the #1 boom section until the #2 boom section comes in contact with the A-frame boom rest rubber “A”. The #2 boom section should come in contact with the rubber rest enough to be slightly compressed, approximately 1/16 to 3/32 of an inch compression of the rubber rest. 4. Position the #2 front boom rest “B” to have a 1/8 of an inch clearence with the #2 boom section. The key to this setting must be when the #2 boom section is in the rear A-frame rest and the #2 boom is extended (lowered) to touch the front boom rest, there is still clearence between the boom hook and the boom hook pin. The load of the boom should never be on the boom hook while in the traveling position.

Prepared by: Jim Issue: 11/11/99

Mielke/Mark Berggren

Approved by: Jason

Mehl

05/29/06

Training Manual

17

Standard: 5158 Page: 2 of 5


4 Section Booms - Except 34X, 39X, 45 SX, 47SX and 52M 1. The boom must be folded up into the main rest and all four outriggers must be raised off the ground so there in no outrigger contact with the ground 2. Raise the #1 boom section enough that the #2 boom section is off the A-frame boom rest “A”. Then make sure that all boom sections are folded together. Each boom rest section should be folded into the mating boom section rest without causing the boom to bow. 3. Then lower the #1 boom section until the #2 boom section comes in contact with the A-frame boom rest rubber “A’. The #2 boom section should come in contact with the rubber rest enough to be slghtly compressed, approximately 1/16 to 3/32 of an inch compression of the rubber rest. 4. Install the #4 boom rest “D” for a 1/4 to 3/8 of an inch gap between the rubber rest and the #4 boom section. 5. After the #4 boom rest “D” is installed, lower the #4 boom section to just come in contact with the 34 boom rest “D’. 6. Then position the rear #4 boom rest “B” to touch the #4 boom section. At this time, both #4 boom rests should be in contact with the #4 boom section. 7. Position the #2 boom rest “C” to have a 1/8 of an inch clearance with the #2 boom section. The key to this setting must be when the #2 boom section is in the rear A-frame rest and the #2 boom is extended (lowered) to touch “A” the front boom rest, there is still clearance between the boom hook and the boom hook pin. The load of the boom should never be on the hook while in the traveling position.


18


Approved by: Jason

05/29/06

Training Manual

Mehl


SAIE STANDARD Subject: Procedures for Setting Boom Rests with preload

The boom should be completely folded so that all hydraulic cylinders are retracted to their furthermost position. The #2 boom should be in the main rear rest. All four outriggers must be raised off the ground so there is no outrigger contact with the ground. The front #4 boom rest dimension should be taken from the bottom of the folded #4 boom., to the top of the tower plate on the pedestal weldment. The dimesion should be noted and 1-1/2” added to that dimension this will be the overall length for the front boom rest with the rubber pad bolted on. Then the #4 rear boom rest should be measured from the bottom of the folded #4 boom, to the top of the rear pedestal boom rest. Again this dimension should be noted this time 1” should be added. This will be the overall length for the rear boom rest with the rubber pad bolted on.



Approved by: Jason

Mehl

05/29/06

Training Manual

19




20


Approved by: Jason

05/29/06

Training Manual

Mehl





Approved by: Jason

Mehl

05/29/06

Training Manual

21

22

Training Manual

SERVICE TRAINING

Schematics Output Chart - Sample .........................................................2 Nomograph - Sample ...........................................................3 Accumulator Bypass Retrofit - Reference ...........................4 800 ........................................................................................5 801 ........................................................................................6 900 ........................................................................................7 900 w/o FAST SWITCH ......................................................8 900 WITH FAST SWITCH .................................................9 900 WITH FAST SWITCH and DAMPNER ....................10 1200 TC WITH SWITCHING VALVES ..........................11 1200 TC WITH MPS .........................................................12 HI-FLOW - SINGLE CIRCUIT ........................................13 2023-4 ................................................................................14 2023-5 ................................................................................15 2525H .................................................................................16 KVM 31 EZ Boom .............................................................17 KVM 32XL ........................................................................18 32XLG ...............................................................................19 34 XG .................................................................................20 KVM 39X ..........................................................................21 S 39/41 SX .........................................................................22 S 42 SX ..............................................................................23 S 42 SX ..............................................................................24 S 45 SX ..............................................................................25 S 45 SX ..............................................................................26 52 M ...................................................................................27 52 M ...................................................................................28 S 58 SX ..............................................................................29 S 58 SX ..............................................................................30

Training Manual

Table of Contents

Table of Contents

Training Manual

Output Chart - Sample



1900

131

1800

124

1700

117

1600

110

1500

103

1400

97


ROD SIDE (bar)

PISTON SIDE (bar)

BPL 1200 HDR-23


350 PISTON SIDE

1300 1285

OIL PRESSURE (BAR)

300

250

200

1200

83

1100

76

1000

70

900

62

ROD SIDE

350

800

300 150

758

52

55

700

48

600

41

200

500

34

150

400

28

300

21

200

14

100

7

250

100

50

88.6 90

100 50 Breakpoint =178 bar @ 300 bar =238 l/m

0

13

26

39

52

65

78

92


157 170 183 196 170.5

26 5

ROD SIDE 50 PISTON SIDE

10 100

150

5 100

15 200

10 200

300

20 250

300

15.5 15

20

400

500

25 350


400 25


Differential Hydraulic Cylinder Bore dia. / Rod dia. x Stroke length

Material Cylinders Bore dia. x Stroke length

Hydraulic Pumps Type / KW

125 mm / 80 mm x 2000 mm

230mm x 2000 mm

2 x A7VO-107 2 x 66KW

Slewing cylinder 80 / 45 x 185 SAIE 5240-029 Rev. 100296

THE PERFORMANCE CURVE INDICATES THAT THERE IS NO ALLOWANCE FOR FILLING EFFICIENCY OF THE CONCRETE CYLINDER.

Training Manual

2

Nomograph - Sample

Model: BPL 900 320 l/m Revision date: 042298 Power: 132 Kw

By: Number:

Pumpkit Model:

TK number does not apply to truck mounted units. Curve shown is the Power Factor number (PF).

(72600)

Pipeline diameter in inches 180 160

Q in yd3/hr.


Max Q

120/80 x 1600:200

200

012

Number:

Max Q

Model: BPL 900 320 l/m Revision date: 042298 Power: 132 Kw

012

6"

5"

4.5"

140

4"

120 116

Rodside

100 80 67

Pistonside 60 40

132 KW

20 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 1566 870 P in PSI

600

400

200

100 200 2" 300 400

2.5"

500 600 3" 4"

5"

6"

3000 2500 2000 1800 1500

1200

1000

800

Proportional value of pipeline in feet

Slump of fresh concrete in inches

Training Manual

3

Accumulator Bypass Retrofit - Reference Service Bulletin Number:

* Normal Mode Bypass Mode

-

Valve Open Valve Closed

1001-03

WHITE BEAR, MINN. 55127 Name: Accumulator Bypass Retrofit

Assembly: N/A

Product: Twin Circuit Models Drawn By: MB P A1

A

B

7

1.5 mm

S3 11

6.0 mm

Psp

6

B

9 T

Agitator

This line must return to tank by itself

3

4

Mp

Truck air supply

A 5-7 bar

B

B

10 bar

T(A)

P(B)

CLOSED FOR BYPASS

Emergency stop manifold

A

SP

T

2.0 bar

MP2

MP3 P2

0.9

ZK1

P3

ACCUMULATOR PUMP

1.3 mm

Shut-Off* Valve

2nd agitator with long rock and sloped side units

5

A

8

ZK2

2

1

T

AGITATOR VALVE

P

10

T

2.0 mm


1.3 mm

XB

Mp1

300 bar

E-STOP

Approved

200 bar

ACCUMULATOR XA SYSTEM Nitrogen pressure set at 100 bar (1450 PSI)

Checked

FOR REFERENCE ONLY SERVICE BULLETIN 1001-03

T

B1

Date 08/14/03

1

2 1.6

Note: Pressures are set to the accuracy of the gauge as received from the manufacturer.

A

FOR REFERENCE ONLY SERVICE BULLETIN 1001-03 ZS1

B

Figure 1

XB

0.9

XA

1

B

3.5 mm

3.5 mm

A

Concrete Pump Forward/Off/Reverse

MP1

P1

2 1.6

3

X3

See boom schematic

ZS2

3

T

T

T

T

P

P

MG 7-105 bar

ACCUMULATOR SYSTEMA

G

B

A1 3.0 mm

B1

7 S2 XA

11 3.0 mm

XB

XP

B

AGITATOR VALVE

MP

9 T2

T1 1.2

2.0 bar

350 bar

12 13 80

13

bar

1.3 X3

1.8 mm

4 X1

A1

5

B 2.0 bar

P1

10

1.1 T

Y

A

S1

E-STOP P2

1.8 mm

3

MY

Y3

PP

14

1

6

PR

XR

2

0-35 bar

1.4

A

See boom schematic

CLOSED FOR BYPASS

A

S

MX X1

X1 Y3

X2

A

10 bar

ACCUMULATOR PUMP

A1

Rexroth A7VO-LRDH Hydraulic pumps

50 psi ΔP

Figure 2

200 bar

M Hyd. oil cooler w/elec fan

Training Manual

S

4

800

Training Manual

5

801

A agitator motor

B

Pipe Gate

BPL 601, 801, 1001, 1201 HDD KVM 28, 31, 36

P Agitator pressure*

Hopper Gate

H2O pump motor

A B M Hydraulic stroke limiter added 1982 and later

P H2O pressure*

P 0-50 BAR

Position 1 = Spring Return

T

2

1

S3 S1

Position 2 = Detent

A CA B


5.5 bar

300 bar

*Agitator pressure = with gearcase 70 bar with direct drive 200 bar

S2

*Waterpump pressure = with agitator gearcase 200 bar with direct drive agitator 210 bar

A3V hydraulic pumps used prior to 1982. A7VO shown. X1

X1 X2

X2 A

M

A A1

A1

D 0.7 mm

To Boom Circuit

6 bar

1.0 mm orifice on 1001 and 1201 S

Training Manual

S

6

900

PRINT # 329325

A

BPL 900 HDR KVM 23, 28, 32

B

Equipped with OF - 494 control block

P 200 bar A B M

P

P

0-50 BAR

210 bar

T

Position 1 = Spring Return

A

2

1

S3

Position 2 = Detent

S1 T1 1.5 mm hole drilled through spool

CA B

T 5.5 bar

300 bar

S2

X1

X1 X2

X2 A

A A1

A1

D M To Boom Circuit

6 bar S

Training Manual

S

7

900 w/o FAST SWITCH

BPL 900 HDR KVM 32XL, 24-4, 26-4

P

with Single circuit switching, 7 place boom manifold, & 10167892 (12v) or 10167893 (24v) emergency stop manifold

0-55 bar Y(T) STROKE LIMITER

A

T A B

Agitator


200 bar Hydraulic style remote throttle actuation

P

AIR TANK

only needed with

5 - 7 bar

P

hydraulic style

C

remote throttle

P

actuation

S3 S1

See boom schematic

P4 MP4

To boom circuit

T

300 bar

Concrete Pump For. / Neut. / Rev.

X1

MP1

P1

260 bar

350 bar

T

MP2-4

1.5

1.5 1.6


1.6 2

1

2

3

1

3

A

A A1

Change

X1 Y3

Y3

A1

D To Boom Circuit

35 PSI P

S

Training Manual

S

SAIE 10057

M

initials

B


P2

Swap P3 and P4 on e-stop manifold.

A

P3

Rev.061198


S2

T

6 bar

8

900 WITH FAST SWITCH

Remote controlled stroke limiter

T A

Remote Throttle Actuation (hyd. version)

Agitator

T

B

70 bar

B

P

Change

P

P

A

A NG 6

T

B

AIR TANK

200 bar P Gauge Port 0-400 bar

Water pump

5 - 7 bar

0.7 mm

A

T B



S1

C

initials

FAST SWITCH P X

with Single Circuit Switching, fast switch, and 344780 (12v) or 344781 (24v) E-stop manifold

Release

A

6 bar

Rev.032697

STROKE LIMITER

T

SAIE 10038

BPL 900 HDR KVM 28X KVM 26-4

Compressor (Optional)

0-55 bar Y(T)

P

T 210 bar P

A

300 bar

S2

B T


See boom schematic D

X1


C

B

A

X1

Y3

Y3

A

A

A1

250 bar

A1 Emergency stop manifold

D

E

F

M To Boom Circuit

3.5 bar

A7VO-80 LR

S

Training Manual

S

A7VO-80 LR

9

900 WITH FAST SWITCH and DAMPNER

Remote controlled stroke limiter (Hartman style)

Remote controlled stroke limiter (Rexroth style)

Agitator

T A

P B

T 0-55 bar Y(T)

B

A

70 bar

A P

DAMPENER

FAST SWITCH P X

T

A

B

with Single Circuit Switching, 4 or 5 place b & w boom manifold, 30344780 (12v) or 30344781 (24v) E-stop manifold

NG 6

P

Compressor (Optional) Water pump

A

initials

BPL 1200 HDR KVM 28X / 26-4 / 32 XL

Release

200 bar

Gauge Port 0-400 bar

Rev.082797

A

SAIE 10055

STROKE LIMITER

Change

T P

T B

0.7 mm 0-55 bar Y(T)

A 0.7 mm AIR TANK

S3 C


210 bar

6 bar

P

S1 See boom schematic

A

D

C

B

A

B 300 bar

S2

T

250 bar

F


E Emergency stop manifold

X1


X1

Y3

Y3

A

A

A1

M 3.5 bar


A1

D To Boom Circuit

5.5 bar

A7VO-107 LR

Training Manual

S

S

A7VO-107 LR

10

1200 TC WITH SWITCHING VALVES



Rev.112596

0-55 bar

B

Release

initials

P P

Change

SAIE 10026

T

70 bar

BPL 900-1200 KVM 36X

TWIN CIRCUIT

A

with electric over air pilot

Y(T) A

300 bar

S3


Manual stroke limiter


P This line must return to tank by itself.

C

P

Accumulator pump unloading valve

Concrete Pump Forward/Neutral/Reverse

T 200 bar

AIR TANK

Y

P

B

NG 10

A

6 bar

250 bar 0.7 mm

0.7 mm 2.5 mm

T

Agitator

2.5 mm

S2 B

A

200 bar

S1 320 bar

P

T


0.7 mm

X1

X1

A2F-23

A2F-10

Y3

120 bar

Hyd. oil cooler w/elec fan

Soft switch

M


Y3 A

A A1

A1

P T

35 psi ΔP

6 bar

1200 = A7VO-107 LR 900 = A7VO-80 LR

S

See boom schematic

S

1200 = A7VO-107 LR 900 = A7VO-80 LR

Training Manual

11

1200 TC WITH MPS

Change

SAIE 10025 Rev.071797

6.3 mm


,, ,, ,, ,,


initials

BPL 900-1200 KVM 36X

T

MPS - TWIN CIRCUIT

P P

6.3 mm

0-55 bar

add c.p. checkvalve to e-stop circuit

with electric over air pilot, emergency stop manifold

70 bar

B


A Y(T) A

300 bar

S3

Manual stroke limiter

Accumulator control device T

P

B

A

1.0 mm

T

P

1.0 mm

B

P This line must return to tank by itself.

A A

P

C

Accumulator pump unloading valve

Concrete Pump Forward/Neutral/Reverse

T

A

200 bar

AIR TANK

Y

P

B

NG 10

A

6 bar

T 0.7 mm 2.5 mm

0.7 mm Agitator

2.5 mm

S2 B

A

200 bar

S1 320 bar

P

T


0.7 mm

X1

A2F-10

Y3

80 bar


Soft switch

M


X1

A2F-23

Y3 A

See boom schematic

A A1

A1

D

C 250 bar

B

A

P T

35 psi ΔP

E

1200 = A7VO-107 LR 900 = A7VO-80 LR

S

See boom schematic

S

1200 = A7VO-107 LR 900 = A7VO-80 LR

Training Manual


F

6 bar

12

HI-FLOW - SINGLE CIRCUIT Change

SAIE 10207 Rev. 102901

P

T Truck air supply

initials

200 bar

330 bar 3

1.6 2

5-7 bar

P1

2020-4, 2023-4 KVM 32 XG HI-FLOW - SINGLE CIRCUIT

1

0.9

See boom schematic

A

MP1

with Rexroth A7VO hydraulic pumps and cartridge type MPS manifold

B Agitator

P(B)

T(A)

Release.

3

1.6

P3

2

P2

1

0.9

Emergency stop manifold T MP3

MP2

A T

SP

B ZK2

1.3

ZK1

ZS2

1.3

ZS1


T

MP MG2 20 bar

XA A

XB 3.5

3.5

G2

PBP

B

3.5-40 bar

X3

PZ 0.7

3.5-40 bar 0.7

T

A2

B2

0-30 bar

B3

A3

S3

XA1

MG1

XB3

MX1

X1

1.5 A

X1

B

A1

B1 Y3

S2

XA

A

XB A1

PR PP

S1

XR

XP

P2

P1 S

MP T2

1200 or 2020/2023 = A7VO-107 LR 900 = A7VO-80 LR

T1 1.2

See boom schematic

X1 300 bar

1.4 Y3

X1 1.8

A A1

T

M

10 bar

S

1.8

Training Manual

1200 or 2020/2023 = A7VO-107 LR 900 = A7VO-80 LR

13

P Truck air supply

5-7 bar

T

A1

A

B

A

Agitator

B1

B

S3

1.5 mm

XA

XB


B


A

2020-4, 2023-4 KVM 34 X MPS - TWIN CIRCUIT

T


6.0 mm

Psp

Mp1

2.0 mm

300 bar


Mp


200 bar P

T

with Rexroth A7VO hydraulic pumps and cartridge type MPS manifold


initials

Change

Correct max. pressure for 2020 versions.

SAIE 10115

C

Rev. 120798

2023-4

P

G2 MG2 T

SP MP5

ZK2

Remote Throttle Actuation (hyd. version used when engine not electronically controlled)

ZK1

T

P4


0-30 bar

P3

0.9 1

X1 P2

2 1.6

MX1

3

ZS2

MP2

3.5-55 bar

260 bar

ZS1

MG1

MP1

P 0.9

XB

B

T 1

A

5.5 bar

X3

A

XA

3

P1

MP

PBP

PZ

T

B

A1 3.0 mm

2 1.6

See boom schematic

XA

B1

S2

XB

3.0 mm

X1 Y3

PR 0.7 mm

PP XR

S1

0.7 mm

A A1

XP

P2

See boom schematic

P1

MP T2

T1

S

1.2 2023 = 350 bar 2020 = 328 bar

1.4

1200 = A7VO-107 LR 900 = A7VO-80 LR

MX X1

X1 1.8

80 bar

Y3 A

X2


A1

A7VO-LRDH Hydraulic pumps are used only on -4 machines

M

X3 1.1

1.8

T

35 psi ΔP

200 bar

S

Training Manual

1200 = A7VO-107 LR 900 = A7VO-80 LR

14

B1

T

S3

XA

XB T


6.0 mm

Psp

200 bar This line must return to tank by itself

Agitator

Mp1

2.0 mm

300 bar

Acumulator control device

Truck air supply

A


Mp T

B

5-7 bar

initials

B

Change

A

3.5 mm and 1.3 mm nozzles adde to A, B, ZS2, and ZK2 ports on MPS manifold.

P A1

SAIE 10139

10 bar

Rev. 110499


2023-5

P

T(A)

P(B) Emergency stop manifold T

SP

MP5

T

2023-5 KVM 39X, 34X MPS - TWIN CIRCUIT

MP2 P4

ZK2

P3

0.9

ZK1

1.3 mm

1 3

ZS2

260 bar

ZS1

1.3 mm

e-stop manifold 10167892 (12v) or 10167893 (24v)

P2

2 1.6

A B

MP1


XA 1

B

A

3.5 mm

3.5 mm

P1

2 1.6

3

X3

See boom schematic

0.9

XB

T

P1

P A

B

A1 3.0 mm

XA

S2

XB

PR 0.7 mm

PP XR

T

B1 3.0 mm

Pressure reducing valve 55 bar

0.7 mm

P T A

S1

XP

P2

P1

Y

T2

R

T1

G

Z

A

M

Y T2

R

T1

G

Z

A

M

A Electric stroke limiter

MP T2

see note

T1

see note

1.2

360 bar

1.4

MX See boom schematic

X1

1.8 mm

80 bar

X2


X3 M1

1.1

1.8 mm

T

35 psi P

Training Manual

S

M1

S

M Note: A11VO-LRDH Hydraulic pumps are limited to 350 bar by pressure cutoff.

200 bar

15

T

2525H KVM 52 MPS - TWIN CIRCUIT

A

Agitator B

2nd agitator with long rock and sloped side units A1

B

A

B1

S3

XA

XB T


6.0 mm

Psp

With switching signal from waterbox end



200 bar P

Mp1

2.0 mm Acumulator control device

300 bar

Mp T

initials

Change

3.5 mm and 1.3 mm nozzle added to A, B, ZS2, and ZK2 ports on MPS manifold.

SAIE 10143

Rev. 110399

2525H

P MP5

T

MP2 P4

1

Remote Throttle Actuation (hyd. version used when engine not electronically controlled)

T 1.1

C

P3

0.9

P

P2

2 1.6

3

260 bar MP1

Truck air supply

X3 1

80 bar

X2

P1

2 1.6

350 bar

3

P

X1

See boom schematic

0.9

B Concrete Pump Forward/Off/Reverse

A

5-7 bar

T

T 360 bar

1.4

MX

Emergency stop manifold 1.2

T1

T2

P

MP P1

P2

0.7 mm XP

XR

T A

S1

55 bar

PP PR 0.7 mm

3.0 mm XB

Pressure reducing valve

XA 3.0 mm

S2

A1

B1 B

A

P T M

X3

Z

G

T1

R

T2

Y M

A

Z

G

T1

R

T2

Y

2.0 mm 3.5 mm

3.5 mm

see note

B

XA

XB

ZS1

ZS2

see note

A

5.5 bar

A

A

Electric stroke limiter

See boom schematic


1.3 mm ZK1

M ZK2

1.3 mm SP

35 psi ΔP

S

M1

S

M1 A11VO-LRDH Hydraulic pumps are limited to noted pressure by pressure cutoff.

T

Training Manual

200 bar

16

KVM 31 EZ Boom

BOOM #2 150/90 x 1195

BOOM #1 (MAIN) 260/160 x 11 80

BOOM #4 (TIP) 120/70 x 805

BOOM #3 170/90 x 1200

BOOM #1 (Extend) 130/80 x 4645

SLEWING (LEFT - RIGHT)

Outrigger Jacking Cylinders 125/100 x 550 Rear Front

Outrigger Extension Cylinder Rear 60/40 x 1520

A1

A2

A1

10

14

160 bar

150 bar

T

250 bar

240 bar

T

A1

1.0 mm

EA

A2

310 bar

B1 300 bar

330 bar

A1

1.0 mm

EA

10

10188569

EA

1.0 mm

B2

T

A2

1.0 mm

EB

B1 320 bar

290 bar

A2

B1

1.0 mm

B2

T

8

10189483

EB

220 bar

190 bar

270 bar

320 bar 180 bar

B2

B1 280 bar

B2

T

7

10189484

1.0 mm

230 bar

A1 300 bar

A2

EB

1.0 mm

210 bar

6

10189485

EB

1.0 mm

240 bar

5

10160891

EA

1.0 mm

300 bar

4

HOME

Outrigger Extension Cylinder Front 70/50 x 2300

9

B2

T A1

P

B

B1

0 - 16 bar

1.0 mm

A

125 bar

B1

X

B

A

B

A

125 bar

B

A

125 bar

C 125 bar

3

EB

EA

150 bar

150 bar

13 150 bar

T1

14 bar

21 T A

B

Front of Unit Water pump

Optional HP water pump

Optional air compressor

2

or

280 bar

T1

35 l/m

180 bar

C2

C1

C2

G1/2

1

C1

C2

C1

G1/2

G1/2

C2

C1 G1/2

C2

C1 G1/2

C2

C2

C1

C2

C1

G1/2

G1/2

C1

22

14

C1

125 bar

MPS

125 bar

125 bar

125 bar

G1/2

T

B

P

A

B

A

10

B

A

B

A

C

10

140 bar 30 bar 1

1

1

1

1

1

1

1

0

0

0

0

0

0

0

0

2

2

2

2

2

2

2

2

15 bar

MP


18

P2

350 bar

Outrigger Jacking Cylinders 125/100 x 550 Rear Front


∅ 0.55

P T

LS

T

14

HYDRAULIC SCHEMATIC KVM 31 EZ boom from GmbH 10200675

P

11 X

T2

T1

G

A

M

See concrete pump schematic

MP3

P2


GD# 10200675 Rev. 112904

initials

A

G

X

T1

R T2

17 MP1

MP2 2.0 bar

Z To concrete pump circuit

0.3 bar

hydraulic pump, port Z.

310 bar

T

Change

SAIE 10235

High pressure filter P1 330 bar

P3

20 bar Δ P

1.5 bar

20 M

M

Not used without 3-circuit control.

Emergency stop manifold 0.9

1.6

0.9

12

1.6

g maxV

g minV

Release. M1

2.5 bar

S

A11 VO DRS

Training Manual

S

M1

A11 VO DRSP

17

KVM 32XL

Driver Side BOOM #1 (MAIN) 200/125 x 1030

10151785 320 bar

BOOM #2 180/110 x 1300

10151785

T

320 bar

310 bar

P1 E

X

E

320 bar

P2 X

E

X

E

P1

P2

10151785

T

310 bar

P1

P2 X

BOOM #3 150/90 x 800

P2

BOOM #4 (TIP) 110/70 x 670

10151785

T

310 bar

320 bar

P1 E

X

E

P1

HOME

T

Outrigger Jacking Cylinders 90/60 x 650

Outrigger Extension Cylinders Rear Front 60/40 x 1520 70/50 x 2300

P2 X

E

X

E

P1

P2

Water pump

310 bar

P1

P2 X



P2

P1 320 bar

320 bar

310 bar

10151785

T

310 bar

10151785

320 bar T

310 bar

10151785

320 bar T

310 bar A1

T

10151785

B1

X

0 - 16 bar

200 bar

200 bar

P 14 bar

140 bar

T A

80 bar

140 bar

T

80 bar

B

80 bar

140 bar

80 bar

140 bar P

280 bar

P1

T 140 bar

C2

C1

C2

G1/2

C1

C2

G1/2

C1

C2

C1

G1/2

C2

G1/2

C1

C2

G1/2

C1

C2

G1/2

C1

MPS

G1/2

30 bar

15 bar

Outrigger Extension Cylinders Rear 60/40 x 1520

Front 70/50 x 2300 Outrigger Jacking Cylinders 90/60 x 650

MP

350 bar

P2 P T

LS

HYDRAULIC SCHEMATIC KVM 32XL

St

w/meter out spools applies to proportional units only and E-stop manifold number 10181606 (12v) or 10181607 (24v)

0 See concrete pump schematic

P3 MP2

initials

P1

P regulator

330 bar

A A1

X

MP5

20 bar

T

0.9

2

A 3

To LS port of Apitech

X3

1.6 2

1

T

300 bar

0.9 1.6


X P

T

Rev. 061900 Release

Change

MP1

P

SAIE 10188

P2

I

A


2.0 atmospheres

High pressure filter

1

T

P

3


Training Manual

System when equipped with Voac hydraulic pump

18

32XLG

BOOM #2 180/110 x 1300

BOOM #1 (MAIN) 200/125 x 1030

BOOM #4 (TIP) 110/70 x 670

BOOM #3 150/90 x 800


HOME

10151785 10151785 1.0 mm

10151785

1.0 mm

310 bar

10151785

1.0 mm

310 bar

1.0 mm

310 bar

Water Tank

310 bar

320 bar

320 bar

320 bar

320 bar

320 bar

320 bar

320 bar

320 bar

SR SR1

310 bar

310 bar

1.0 mm

1.0 mm

A1

1.0 mm

1.0 mm

10151785

10151785

Water pressure

310 bar

310 bar

B1

X

0 - 16 bar

10151785

10151785

High pressure water (optional)

200 bar

200 bar

Driver Side 14 bar


T A



B

P

140 bar

140 bar

C2

C1 G1/2

C2

C1

C2

G1/2

C1 G1/2

C2

C1

C2

G1/2

C1

C2

G1/2

C1 G1/2

C2

C1

140 bar

80 bar

T

80 bar

MPS

G1/2

15 bar

80 bar

0.76 mm

140 bar

80 bar

140 bar P

280 bar

0.61 mm

0.2 mm

P1

300 bar

T P LS

T

See pump schematic

HYDRAULIC SCHEMATIC 32XLG

MP2

w/fixed displacement boom pump and proportional Inlet control valve XLG units SN170522735 and higher

MP3

P3

P2

Change

P1







Passenger Side

T 0.9

SAIE 10229

MP1

0.9 1.6 2 1

1.6 2 3

1

3

Rev. 120403 Release

2.0 atmospheres

initials

Training Manual

19

34 XG

BOOM #2 180/125 x 151 0 EB ∅1.0

B1

∅1.0

B2

A2

EB

B2

∅1.0

320 bar

B1

A2

EA

290 bar A1

∅1.0

M

∅1.0

T

A1

∅1.0

B2

330 bar

T

330 bar


EB

320 bar

310 bar

B1

320 bar

190 bar

B2

180 bar

T

A2

320 bar

330 bar

EB

280 bar

∅1.0

A1

HOME

BOOM #4 (TIP) 110/60 x 805

A2

EA

Grayed components represent optional equipment

140 bar

B1 320 bar

EA

BOOM #3 150/100 x 1173

290 bar

BOOM #1 (MAIN) 225/125 x 880

B

Water Tank

330 bar A

T

300 bar

T

Water pump

A1

∅1.0

HP water pump

Water pressure

EA A1

B1

X

High pressure water

0 - 16 bar

150 bar

150 bar

Driver Side Outrigger Extension Cylinder 14 bar


Outrigger Extension Cylinder

T A

Front 60/40 x 1520

Rear 70/50 x 2300

B

Compressor

P 140 bar

140 bar C1

C2 G1/2

C1

C2

C1

G1/2

C2 G1/2

C1

C2 G1/2

C1

C2 G1/2

C1

C2 G1/2

C1

C2

140 bar

80 bar

T

80 bar

PP

G1/2

15 bar

80 bar

140 bar

80 bar

140 bar P

280 bar 0.2 mm

300 bar P

.061 mm

LS

T

T

HYDRAULIC SCHEMATIC 34 XG w/fixed displacement boom pump and proportional control valve 330 bar


SAIE 10187 GD# Rev. 070803





Passenger Side

Change Compressor circuit, outrigger cyl. sizes, brake valve pressures corrected.

2.0 atmospheres

initials

Training Manual

20

KVM 39X Driver Side BOOM #2 200/140 x 1620

BOOM #1 (MAIN) 240/180 x 1080

BOOM #4 (TIP) 120/70 x 805

BOOM #3 150/80 x 1173



Water pump

HOM

10151786


1.0 mm 1.0 mm

330 bar 320 bar

1.0 mm 1.0 mm

1.0 mm

1.0 mm

10180550

320 bar

320 bar 330 bar 310 bar

310 bar

310 bar

330 bar 320bar

300 bar

320 bar

310bar

330 bar

Outrigger Extension Cylinder Front 95/82 + 58/44 X 3561

1.0 mm

1.0 mm

320 bar

320 bar


10180549

10180551 A1

B1

X

10151785

0 - 16 bar

200 bar

200 bar

P 14 bar

140 bar

T A

140 bar

80 bar

T

80 bar

B

80 bar

140 bar

80 bar

140 bar P

280 bar

P1

200 bar

C2

C1 G1/2

C2

C1 G1/2

C2

C1

C2

G1/2

C1

C2

G1/2

C1 G1/2

C2

C1

T

C2

G1/2

C1

MPS

G1/2

30 bar

15 bar

Outrigger Extension Cylinder Rear 70/50 x 2075 MP

350 bar


Outrigger Extension Cylinder Front 95/82 + 58/44 X 3561

P2 P T

LS

HYDRAULIC SCHEMATIC KVM 39X See concrete pump schematic

MP3

P3

P2

P1

2.0 atmospheres



w/slewing motor manifold, Apitech control block, and emergency stop manifold 10181606 (12 volt) or 10181607 (24 volt)


MP1 330 bar

Δ P regulator

A X

MP2 T

20 bar Δ P

A1

T

300 bar

SAIE 10162 X3

A

T

P

Rev. 120299

Change E-stop manifold symbol corrected.

initials


Training Manual

21

S 39/41 SX 14.03.2006

HOME

Training Manual

22

S 42 SX

HOME

Driver Side Outrigger Extension Cable


Outrigger Slewing Cylinder 100/40 x 327

Front

Front

Rear Rear

A1

B1

A2

B2

B3

A3

B4

A4

T

P 200 bar

T2

350 bar

300 bar

200 bar

To/From Boom System (10233-2)

T1

350 bar

P1

C

T

A4

B4

A3

B3

A2

B2

A1

B1

HYDRAULIC SCHEMATIC KVM 42 SX applies to units w/ symetrical outrigger valves, and Apitech boom control valves.


Rear Outrigger Slewing Cylinder 100/40 x 327

Front Rear Outrigger Jacking Cylinders 110/80 x 750

Front Outrigger Extension Cable

Passenger Side Change

SAIE 10233-1/2 Rev. 090904

Release

initials

Training Manual

23

S 42 SX

BOOM #4 (TIP) 110/70 x 1000


HOME

10151788 320 bar

Grayed components represent optional equipment

A1

Water Tank

B1

X

200 bar

320 bar

E

X

E

320 bar

X

E

X

E

320 bar

10039659

400 bar

400 bar

P2 X

E

X

E P2

320 bar

300 bar

10151788

10039659

T

P2

T

BOOM #1 (MAIN) 180/110 x 1300

300 bar

P2

300 bar

10151788

10151788

T

P2

320 bar

BOOM #2 225/140 x 1600

300 bar

P2 X

P1

200 bar

10151788

T

300 bar

P1

0 - 16 bar

BOOM #3 160/110 x 1200

T

300 bar

10151788

T

320 bar

320 bar

10049891

10049891

14 bar

T

Water pump

#1 Down - brake valve

HP water pump

To/From Outrigger System (10233-1)

A

Water pressure

B

B

High pressure water

0.35

T1 0.35

T2

X

Y

A

P1

PP

C2

MP

C1

C2

C1

C2

C1

C2

C1

C2

C1

C2

C1

C2

C1

90 bar

190 bar 15 bar 30bar

P2 350 bar

P T

see concrete pump schematic P3 P2 MP3

LS

MP1

HYDRAULIC SCHEMATIC KVM 42 SX

P1


W/ Apitech boom control valves, and e-stop manifold 10181607

320 bar MP2

Δ P regulator

T

X 0.9

20 bar Δ P

0.9 1.6

1.6 2

A

A1

T

300 bar

2

3

1


A

T

Change

SAIE 10233-2/2

3

Rev. 090904

P Boom hydraulic pump

Training Manual

initials

Release

2.0 atmospheres

X3 1


24

S 45 SX

HOME

Driver Side Outrigger Jacking Cylinders 110/80 x 750 Rear


Outrigger Extension Cable

Rear

Front

Front

A1

B1

A2

B2

A3

B3

A4

B4

T

P T1

350 bar

200 bar

T2

200 bar

300 bar

350 bar

P1

C

T

A4

B4

A3

B3

A2

B2

A1

B1

HYDRAULIC SCHEMATIC KVM 45 SX applies to unit SN 70526011, 170526002 and later


Front

Rear



Rear

Front Outrigger Jacking Cylinders 110/80 x 750

Passenger Side SAIE 10047-1/2 Rev. 040898

initials

Change Correct p.s. outrigger slewing/350 bar secondary relief connection

Training Manual

25

S 45 SX

HOME

Water pump



BOOM #4 (TIP) 115/70 x 995

HYDRAULIC SCHEMATIC KVM 45 SX

10151788 320 bar

applies to unit SN 70526011, 170526002 and later

BOOM #3 200/110 x 1200

10151786

T

300 bar

330 bar

A1


B1

X

200 bar

P1

X

E

P1

X

E

200 bar

320 bar

X

E

P1

X

E

Change

Rev. 040898

Change adjustable checkvalve to fixed spring checkvalve, change pilot valve to 35 bar, assign flow to outrigger supply valve.

initials

14 bar

280 bar

330 bar T

350 bar

T

330 bar

P2 P1

X

E

P1

X

E

P2 P1

X

E

P1

X

E

P2

320 bar

320 bar T

10151786

10151784

T

P2

260 bar

10151787

BOOM #1 (MAIN) 340/115 x 2290

310 bar

P2 P1

P2

SAIE 10047-2/2

10151785

T

320 bar

P2 0 - 16 bar

BOOM #2 260/160 x 1990

P2

310 bar

10151785

350 bar T

330 bar

10151784

T

T A

B

A4

A3

B3

A2

B2

A1

B1

P

Pv

Ls

160 - 200 μ

L

B4

P X Y Ls

T1

Dr2-a'

b

P1

35 bar

b'

230 bar

a

a'

Dr1-b'

T2

350 bar 40 bar

A

B

b

a

A

B

A

B

T

30 l max.

a2

b1

a1 A-G 4-a1

b2

A-G 2-b1

a3

B-G 1-a2

b3

B-G 3-b2

a4

C-G 4-a3

b4

C-G 2-b3

Y D-G 1-b4

X

D-G 3-a4

200 bar

LS see concrete pump schematic MP2

T

PST

P P2

1

2

1

3

2

4

1

3

C-G 4-a3

C-G 2-b3

D-G 3-a4

D-G 1-b4

A-G 4-a1

A-G 2-b1

B-G 3-b2

B-G 1-a2

Dr 1-a'

Dr 1-b'


2

P regulator

20 bar

A

A1

X

4

P3

P

MP1

T

310 bar P

T

P

T

P

P1

X3

T A

T

330 bar

P Boom hydraulic pump

Training Manual

MP3


T

2.0 atmospheres

26

52 M

HOME

Driver Side Outrigger Jacking Cylinders Rear 180/150 x 900

Outrigger Slewing Cylinder

Front 180/150 x 900

Rear 140/90 x 300

A1

B1

A2

Extension Cylinder

Front 140/90 x 1145

B2

Front 90/70 x 1870

A3

B3

A4

B4

T

P

350 bar

350 bar

50 bar

T1

T2

See SAIE 10079 page 2 of 2

P1

150 bar

350 bar

350 bar

50 bar

P

C

A1

B1

A2

B2

A3

B3

A4

B4

T

HYDRAULIC SCHEMATIC KVM 52 1 of 2 (outrigger circuit) Note: Pressures are set to the accuracy of the gauge as received from the manufacturer.


SAIE 10079-1/2 Rev. 102298

Change

Rear 180/150 x 900

Front 180/150 x 900

Outrigger Slewing Cylinder Rear 140/90 x 300

Front 140/90 x 1145

Extension Cylinder Front 90/70 x 1870

change main outrigger relief to 150 bar

Passenger Side

initials

Training Manual

27

52 M

HYDRAULIC SCHEMATIC KVM 52

BOOM #2 280/160 x 2100

BOOM #3 210/110 x 1173


BOOM #4 (TIP) 130/80 x 1069

2 of 2 (boom circuit) w/10167892 (12v) or 10167893 (24v) Estop manifold

all changes on page 1 of 2

0 - 16 bar


10065681 320 bar

10065681 320 bar

10065680 350 bar

10065681 320 bar

A1

B1

X

10065680 350 bar

10047783 350 bar

10065681 320 bar

10047784 260 bar

280 bar 200 bar

200 bar

initials

14 bar

M

B

B

M

M

B

B

T

M

A

A

See SAIE 10079 page 1 of 2

A

A

A

M

B

B

B

X

A

A

M

B

B

M

A A

X

M

X

X

A

A

A

A A

X

X

A

A

X

X

A

1.5

P1

adjusted to 20 bar dynamic pressure

T1


T2


Pst

Pst L 50 bar


30 bar a4 b1

b1 a1

a1 b2

b2 a2

a2 b3

b3 a3

b4

a3

b4 a4

a4 b5

b5 a5

a5

b6

b6

a6

A4

B4

a5

A5

B5

a6

a6

A6

B6

a1

A1

B1

a2

A2

B2

a3

A3

B3

T

T

190 bar

350 bar

L(T)

10146289

190 bar

10146290

X (LS)

P

X (LS)

P b4

b5

b6

b1

b2

T

b3


P3

P4

P2

MP1

P1

3

2

a6

4

b6

1

a5

2

b5

3

a4

4

b4

1

a3

2

b3

3

a2

4

b2

MP2

a1

P

b1

Rev. 102298

SAIE 10079-2/2

Change

HOME

BOOM #1 (MAIN) 350/160 x 2730

Water pump

330 bar

1

P regulator High pressure filter


X

20 bar P

T

A1

A MP5

P

T

P

T

P

0.9 1.6

T Emergency stop manifold

310 bar

0.9 1.6 2 1

T

3

2 1

X3

3

P

T

A

5.5 bar

Boom hydraulic pump

Training Manual

28

S 58 SX

BOOM #4 (TIP) 160/80 x 1110


BOOM #3 240/120 x 1500

BOOM #2 320/200 x 2200

BOOM #1 (MAIN) 400/180 x 3450

Water pump

HP water pump

HOME EB

260 bar

A1 250 bar

330 bar

T

A2

A1

T

320 bar

310 bar

320 bar

A1

1.0 mm

EA 250 bar

330 bar

A2

A2

B1

330 bar

260 bar

A1

1.0 mm

B2

T

270 bar

320 bar

A2

0 - 16 bar

B1

T

250 bar

240 bar

A1

X

EA 1.0 mm

1.0 mm

B2

330 bar

B1 320 bar

B2

B1

EB

1.0 mm

340 bar

EB 1.0 mm

B2

B1

1.0 mm

1.0 mm

EA

water tank

EB

EA

250 bar

water output

HP water output

M

14 bar

T B

240 bar

A

P1

T1 0.55 mm

A

B

A

B

A

B

A

B

A

B

B

A

B

A

B

Z

R

M

LS T

P

T2

300 bar

300 bar R1

a

a

a

a

a

a

a

o

o

o

o

o

o

o

b

b

b

b

b

b

360 bar

A A 280 bar

b

20 bar

B 180 bar

230 bar

HYDRAULIC SCHEMATIC S 58, 61 SX boom page 1 0f 2

T2

20 bar

initials

Change Update to match GmbH rev. Add "61."

G

A

M

P

MP3 P2

P

P3

Emergency stop manifold MP1

P1

T

350 bar

1.5 bar


Rev. 102502

X


w/estop manifold 10181606 (12V) or 10181607 (24V) from Gmbh print #10185941

SAIE 10197-1/2

T1

B


MP2 T

310 bar

M A11VO 170 l/m

5 bar M1

S

Training Manual

29

S 58 SX Driver Side HOME



Rear

Rear

A1

B1

Front

A

A

B

B

A2

B2

Outrigger Roller 22 x 33


Front

A3

B3

A4

B4

T

P P1

350 bar

210 bar

210 bar 200 bar

T1

200 bar

T2

200 bar

350 bar 210 bar

200 bar

310 bar

210 bar

C T

T

A4

B4

A3

B3

A2

A

Rear

B1

HYDRAULIC SCHEMATIC S 58, 61 SX page 2 of 2

A

B


A1

B2

B

Rear

Front



Front


Outrigger Roller 22 x 33

SAIE 10197-2/2 Rev. 102502

Change Update to match GmbH rev. Add "61."

initials

Passenger Side

Training Manual

30

SCHWING TrainingManual

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