Professional Documents
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SERVICE TRAINING
TRAINING MANUAL
5900 Centerville Road White Bear, MN 55127 TEL 651-429-0999 FAX 651-429-2112 www.schwing.com
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OR
Branches
Florida............................................................. 1-813-985-8311
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Texas .............................................................. 1-972-245-5166
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Table of Contents
The Schwing Group ............................................................ 1 Phase I ........................................................................52
Schwing America, Inc. ................................................. 1 Phase J ........................................................................54
Phase K .......................................................................56
Hydraulic Training Troubleshooting .................................................................58
Differentials start to move before the rock valve
General Principles ............................................................... 3 has completely shifted. ...............................................58
Mechanical Versus Hydraulic ............................................. 7 Before rock valve shifts to the right the unit
Transfer of Energy .............................................................. 7 builds high pressure, left differential continues
to move, right differential has stopped. ......................60
Hydraulic Jack ..................................................................... 8
Rock valve shifts and as soon as the differential
Linear & Rotary Actuators .................................................. 8 cylinder shifts the rock valve shifts again
Basic Hydraulic Components .............................................. 9 (machine gunning). .....................................................62
Check Valve Comparison ................................................. 10 Check valve (A) is stuck open and the pressure
oil shifts the S3 valve to the right causing the
Shuttle Valve ..................................................................... 11
rock valve to shift to the left. ......................................64
Throttle Check Valve ........................................................ 12 The differentials are already in the end position
Switching Valves .............................................................. 13 for this mode so a signal is sent to the S3 valve
Hydraulic Symbols (Cont.) ............................................... 14 and the rock valve will shift again to the right. ..........66
Rock valve shifts to the right and then the
Hydraulic Symbols (Cont.) ............................................... 15
machine builds high pressure. ....................................68
Hydraulic Symbols (Cont.) ............................................... 16
High-Flow Single Circuit ..................................................70
Hydraulic Symbols (Cont.) ............................................... 17 High-Flow Single Circuit Schematic ..........................71
Hydraulic Symbols (Cont.) ............................................... 18 Concrete Pump Control Block ....................................72
Hydraulic Symbols (Cont.) ............................................... 19 Switching Manifold ....................................................73
Stroke Limiter with Fast Switch/Dampner .................73
Hydraulic Symbols (Cont.) ............................................... 20
Phase A .......................................................................74
Hydraulic Pumps ............................................................... 21 Phase B .......................................................................76
Placing boom hydraulic pumps .................................. 21 Phase C .......................................................................78
Concrete pump hydraulic pumps ............................... 21 Phase D .......................................................................80
Fixed Displacement Pump ................................................ 22 Twin Circuits .....................................................................82
Rexroth A2F20 ........................................................... 22
Twin Circuit .......................................................................83
Variable Displacement Pump ............................................ 22 Twin Circuit Schematic w/Soft Switch ......................84
Rexroth A7VO ........................................................... 22 Concrete Pump Control Block ....................................85
Variable Displacement Axial Piston Pump ....................... 23 S3 Control Block ........................................................85
RexrothA10VO .......................................................... 23 Soft Switch .................................................................86
RexrothA11VO .......................................................... 23 Accumulator Unloader Valve .....................................86
Rexroth A11VO Adjustments .................................... 24 Phase A .......................................................................88
Voac V30D Pumps .................................................... 25 Phase B .......................................................................90
Formulas ............................................................................ 26 Phase C .......................................................................92
Phase D .......................................................................94
800 Gate Valve .................................................................. 27
Twin Circuit with MPS/Soft Switch ..................................97
801 Gate Valve .................................................................. 28
Twin Circuit with MPS/Soft Switch ...........................98
Single Circuit .................................................................... 29 MPS ............................................................................99
Single Circuit Pumpkit ............................................... 30 Accumulator Control Block/Dump Valve ................100
Concrete Pump Control Block ................................... 31 Soft Switch ...............................................................101
Phase A ...................................................................... 36 Phase A .....................................................................102
Phase B ....................................................................... 38 Phase B .....................................................................104
Phase C ....................................................................... 40 Phase C .....................................................................106
Phase D ...................................................................... 42 Phase D .....................................................................108
Phase E ....................................................................... 44 Twin Circuit with Variable displacement
Phase F ....................................................................... 46 accumulator pump Schematic 110
Phase G ...................................................................... 48
Model Number Nomenclature .........................................111
Phase H ...................................................................... 50
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Table of Contents
Hi-Flow Pumpkits (2023-2525) ......................................112 Electrical Symbols .......................................................... 174
Hi-Flow Pumpkits Schematic ...................................113 28X Truck and Pumpkit Circuit ...................................... 175
Concrete Pump Control Block .................................114
28X Boom Circuit ........................................................... 176
MPS ..........................................................................115
S3 Control Block - Machined ...................................116
S3 Control Block - Cast ...........................................117 Basic Electrical
2023 Circuit diagram ................................................118
Introduction ..................................................................... 177
Phase A .....................................................................118
Phase B .....................................................................120 What is Electricity? ......................................................... 177
Phase C .....................................................................122 Amperage ........................................................................ 180
Phase D .....................................................................124 Voltage ............................................................................ 181
Boom Holding Valves .....................................................126 Resistance ........................................................................ 181
28X B&W Boom .............................................................127 Basic Circuits .................................................................. 183
Load Sense Hydraulic Circuits ........................................131 Schematics ...................................................................... 185
Load Sense Series #1 ................................................132
Load Sense Series #2 ................................................133 Circuit Types ................................................................... 185
Load Sense Series #3 ................................................134 Ohm’s Law ...................................................................... 187
Load Sense Series #4 ................................................135 Series Circuit Laws ......................................................... 189
Load Sense Series #5a ..............................................136 Parallel Circuit Laws ....................................................... 190
Load Sense Series #5 ................................................137
Load Sense Series #6 ................................................138 Series – Parallel Circuits ................................................. 192
Load Sense Series #7 ................................................139 Circuit Faults ................................................................... 193
Load Sense Series #7 (Cont.) ...................................140 Using Test Equipment ..................................................... 194
Load Sense Series #8 ................................................141 The Troubleshooting Process .......................................... 199
Load Sense Series #8 (Cont.) ...................................142
A7 Variable Displacement Hydraulic Pump Training ....143
Fixed Displacement Pump Training ................................146
Misc Procedures
Transfer Cases .................................................................149 Material Cylinder Alignment .......................................... 201
Relief Valves ...................................................................150 Pumping on piston side ................................................... 203
(Available on some units only) ................................ 203
Safety Relief Valves ........................................................151
Shimming the Differential Cylinders .............................. 204
Output Charts ...................................................................152
Determining the proper shimm size ......................... 204
Using the Chart ................................................................153 Dimension A ............................................................ 204
Using a Nomograph .........................................................158 Dimension B ............................................................ 204
General information .................................................158 Formula .................................................................... 205
The quadrants ...........................................................160 Apitech Control Chamber Air Bleed Procedure ............. 206
Minimum Pipe Wall Thickness .......................................166 Hydraulic Pump Adjustments ......................................... 209
Preventative Maintenance ...............................................167 Main System Pumps A11VO ................................... 209
Scheduled Maintenance ............................................167 Setting the Flow Rate ............................................... 209
Filtration ..........................................................................169 Horsepower Setting .................................................. 210
General information .................................................169 Q-min Output Flow .................................................. 210
Specific information .................................................169 Check all hydraulic pressures. ................................. 211
Changing hydraulic oil filters ...................................169 Setting pressures on Hi-flo -6 pumpkits .................. 211
Changing high pressure water filter .........................170 Pressure setting procedure: ...................................... 212
Setting the soft switch relief pressure ...................... 213
Hydraulic Oils .................................................................170
General information .................................................170 Trouble Shooting Kit ...................................................... 215
Specific information .................................................171
When to change your hydraulic oil ..........................171
Electrical Symbols ...........................................................172
Electrical Symbols ...........................................................173
Training Manual
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SERVICE TRAINING
Training Manual 1
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SERVICE TRAINING
In 1995 we completed construction of a 62,000 sq. ft. concrete pumps in the world. The six-story structure
state of the art Weld Shop. combines with retractable roof panels to accommodate
In addition, in 1996 we added the 15,000 sq. ft. unfolded booms. Painters will use catwalks to cover
machining center, which is home of the new Forrest every surface with high quality acrylic urethane in an
Line machining Center. endless array of colors and paint schemes. Climate
controlled conditions assure proper curing and drying
time. A new solvent recovery system keeps the Super
For the year 2000, Schwing America, Inc. has added a Booth environmentally friendly.
75,000 sq. ft paint booth. This state-of-the-art
Today Schwing America has over 326,000 square feet
behemoth is the largest building in the surrounding
of manufacturing space and employs over 400 people.
communities. Dubbed the “Super Booth” by industry
insiders. This is the largest facility for painting
N S
2 Training Manual
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Hydraulic Training
General Principles
1. Hydraulic pressure always takes path of least
resistance.
Pascal's Law
Training Manual 3
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SERVICE TRAINING
Seals
Hydraulic Cylinder
Water Box
6 bar
4 Training Manual
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SERVICE TRAINING
0 GPM 10 GPM
10 gallon maximum
capacity cylinder
10 inch of area on
cylinder piston
1000 PSI
Training Manual 5
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SERVICE TRAINING
U.S.
F = FORCE (in pounds) (lb)
P = PRESSURE
(in pounds per square inch) (P.S.I.)
F F=PxA
A = AREA (in square inches) (in2)
P = F/A
P A METRIC
A = F/P
F = FORCE (in kilograms) (Kg)
P = PRESSURE
(in kilograms per square centimeter) (Kg/cm2)
A = AREA (in square centimeters) (cm2)
GENERAL
Q = FLOW RATE
QxP (unit of volume per time period)
POWER = P = PRESSURE
CONSTANT
(unit of force per unit of area)
U.S.
HP = HORSEPOWER
GPM x PSI GPM = GALLONS PER MINUTE
HP =
1714
PSI = POUNDS PER SQUARE INCH
1714 = KNOWN CONSTANT
METRIC
KW = KILOWATTS
LPM x BAR
KW = LPM = LITERS PER MINUTE
600
BAR = METRIC UNIT OF PRESSURE
600 = KNOWN CONSTANT
6 Training Manual
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SERVICE TRAINING
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)
Transfer of Energy
ENERGY CAN NEITHER BE CREATED NOR DESTROYED
1. Moving the small piston 10 in. 2. 10 cu. in. (163.8 cm3) of liquid
0.25 m) displaces 10 cu. in. will move the larger piston only
(163.87 cm3) of liquid. 1 in. (2.54 cm)
(1 sq. in. x 10 in. =10 cu. in.) (10 sq. in. x 1 in. = 10 cu. in.)
(6.45 cm2 x 25.40 cm = 163.87 cm3) (64.52 cm x 2.54 cm = 163.87 cm )
100 lb.
10 lb. (444.82 N)
(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)
Training Manual 7
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SERVICE TRAINING
Hydraulic Jack
HYDRAULIC
8"
ROD
PISTON
MOTOR
PUMP
LOAD
PUMP
TO RESERVOIR ROTARY
DRIVE SHAFT
8 Training Manual
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SERVICE TRAINING
Check Valve
Throttle Valve
Switching Valve
Training Manual 9
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SERVICE TRAINING
CARTRIDGE CARTRIDGE
W/SEALS W/SEALS
P/N 30333032 P/N 30333033
TORQUE TORQUE
SPECIFICATION SPECIFICATION
55 ft/lbs. 200 ft/lbs.
10 Training Manual
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SERVICE TRAINING
Shuttle Valve
A shuttle valve is used where the higher of the two B
pressures must be selected, while blocking the lower
pressure input.
A C
The valve has two inlet, ports “A” and “C”, and one A C
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 A C
Greater pressure from "A" port Greater pressure from "C" port
39000145.ai
Training Manual 11
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SERVICE TRAINING
5 4 3 1 6 2
5 4 6 5 4 6
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SERVICE TRAINING
Switching Valves
SWITCHING VALVE
The switching valves have a logic function in that they AS MANUFACTURED
POPPET END PORT
sense multiple pressures simultaneously and will route
oil from the poppet end port to the output port only BODY
when the pressure from the poppet end port exceeds the SEAT
O-RING POPPET
pressure at the spring end port by more than 2:1 in most AND HOUSING
situations BACK-UP
RINGS
SPRING
GUIDE
SIDE PORT
POPPET
Training Manual 13
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SERVICE TRAINING
LINE, WORKING
P = R 1/2"
T = R 1/2"
SP = R 3/4"
Nitrogen pressure set at 55 bar G = R 3/8"
(800 PSI) AC = R 11/2"
Y = R 3/8"
G
1.9 mm
LINE, JOINING
S3 ("T" FITTING)
P T
NG
10 10 Filter
Agitator
A LINE, PLUGGED
P R
RESTRICTION, FIXED
(orifice, nozzle)
100 G Y
bar
0.7 mm
12 Filter
A11VO
LINE, WORKING
LINE, PASSING
LINE, PLUGGED
LINE, JOINING
("T" FITTING)
1.3 1.3
RESTRICTION, FIXED
(orifice, nozzle) OR
14 Training Manual
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SERVICE TRAINING
X1
M X2
A
A1
PRIME MOVER,
ELECTRIC MOTOR
PUMP, SINGLE
VARIABLE DISPLACEMENT,
SHOWING HORSEPOWER S
CONTROL CIRCUITS.
PRIME MOVER,
INTERNAL COMBUSTION ENGINE
(Diesel shown..."G" if gas.) MOTOR, ROTARY,
FIXED DISPLACEMENT
MOTOR, ROTARY,
FIXED DISPLACEMENT
BI - DIRECTIONAL
Training Manual 15
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SERVICE TRAINING
ACCUMULATOR,
GAS CHARGED
FILTER OR STRAINER
16 Training Manual
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320 BAR
HYDRAULICALLY UNLOCKABLE
CHECK VALVE WITH INTEGRAL
RELIEF VALVE.
(H.E.R. BOOM HOLDING VALVE)
NORMALLY OPEN
A 2.0
CHECK VALVE, FIXED FORCE
(SPRING FORCE INDICATED) 300 bar
PRESSURE RELIEF VALVE
WITH EXTERNAL DRAIN
(SHOWN WITH A NORMALLY
OPEN SOLENOID VALVE...
MANY OTHER POSSIBILITIES
ARE AVAILABLE).
Training Manual 17
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SERVICE TRAINING
P 0-55 bar A
Y(T)
A
PRESSURE REDUCING VALVE ACCUMULATOR P Y T
MANUAL (STROKE LIMITER) OR UNLOADING VALVE
DAMPNER
B 70 bar 300
0-50 bar
bar
A
PRESSURE REDUCING VALVE
(ELECTRIC STROKE LIMITER) P
ACCUMULATOR DUMP VALVE
P
(ELECTRIC)
T T
A 55 bar
T
P
T
MG Pressure
P
G
reducing valve A
MY Y
Electric
stroke limiter
1.5
P P
A
A
P
18 Training Manual
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SERVICE TRAINING
X1
X2
A
A1
COMPONENT ENCLOSURE
BRAKE VALVE
(BERINGER) X A
(USED ON #1 SECTION
DOWN FUNCTION)
BALL COCK
(SHUT OFF VALVE,
QUARTER TURN VALVE)
B
BRAKE VALVE
(COUNTERBALANCE VALVE)
(USED ON ALL SECTIONS KVM 52 & 55)
X A
B
R Z
X A Y
BRAKE VALVE (SAUER)
(USED ON #1 SECTION
DOWN FUNCTION)
Z VENTED RESERVOIR
(TANK)
Training Manual 19
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SERVICE TRAINING
SPRING
DIRECTIONAL VALVE
3 POSITION, 4 WAY, CLOSED CENTER
MANUAL
DIRECTIONAL VALVE (HANDLE OR PUSHBUTTON)
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
X OR
PRESSURE REGULATOR P
(REGULATES DELTA P) A T
USED ON LOAD SENSING SYSTEMS
20 Training Manual
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SERVICE TRAINING
PumpKit Pumps
Boom Pump
Accumulator Pump
Agitator Pump
Stiebel 4194 Stiebel 4400
PumpKit Pumps
Proportional Boom Pump PumpKit Pumps
Accumulator Pump
Training Manual 21
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SERVICE TRAINING
Q min
Q max
Q min
0ß
25ß -
Q max
22 Training Manual
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SERVICE TRAINING
Variable displacement axial piston A10VO of swash Designed principally for use in mobile applications. A
plate design is designed for hydrostatic transmissions wide variety of controls are available. Setting of the
in open loop circuits. Flow is proportional to the drive constant power control is possible via external
speed and the displacement. By adjusting the position adjustments, even when the unit is operating. The
of the swash plate it is possible to smoothly vary the pump is available with a through drive to accept a gear
flow. pump or a second axial piston pump up to the same size
(100% through drive).
Q min
Q max
Training Manual 23
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SERVICE TRAINING
Pressure Cut-Off
Pressure Cut-Off
Delta P
Q min Q min
Load Sense Port
Q max
Q max
Horsepower Control
Stroke Stroke Regulation
Regulation Pressure Cut-Off
Pressure Cut-Off
Horsepower
Control
Style #1
Pressure Cut-Off
Q min
Horsepower
Q min Control
Stroke Regulation
Style #2
24 Training Manual
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SERVICE TRAINING
Horsepower Control
Q min
Q max
Q min Q max
Pressure Cut-off
Q min Q max
Pressure Cut-off
Training Manual 25
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SERVICE TRAINING
Formulas
5 2.5
10,000
Pounds
To move this load it will take To move this load it will take
about 510 psi about 680 psi
5100 6800
= 2.975 HP = 3.967 HP
1714 1714
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Training Manual 27
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28 Training Manual
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Single Circuit
Single Circuit
Training Manual 29
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10A 10B 11
7 3
4
10D
10C
10E D
9A
2 2
8A 8B
9B 12
10F
30 Training Manual
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SERVICE TRAINING
P1
S3 P2
X
P
1.5 mm
T
hole drilled
through spool
2
S1 1
X
R
B
3
300 bar
4 A
S2
Port size
limits flow
S-1
S-2
S-3
39000147.eps
Training Manual 31
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32
A
with
Fast Switching P
200 bar
P B
0-50 M
BAR
P
T
210 bar
A
Position 1 =
NG 6 P T Spring Return
X
2 1 Position 2 =
Detent
S3 A B
S1
0.7mm
T1 T CA B
1.5 mm
hole drilled
through spool 5.5 bar
300
bar
Training Manual
S2
X1 X1
SERVICE TRAINING
X2 X2
A A
A1 A1
D
M
To
Boom
6 bar Circuit
S S
HOME
PRINT
Equipped with
OF - 494 control block P
200 bar
B
M
P
P
0-50
BAR 210 bar
T
Position 1 =
Spring Return
A 2 1 Position 2 =
Detent
S3
S1
T1 T CA B
1.5 mm
hole drilled
through spool 5.5 bar
300
bar
Training Manual
S2
SERVICE TRAINING
X1 X1
X2 X2
A A
A1 A1
D
M
To
Boom
6 bar Circuit
S S
33
HOME
34
A
agitator
motor
BPL 900 HDR B
PRINT
#2
Middle of the P
first stroke H2O pump
200 bar
motor
B
M
P
210 bar
P
0-50
BAR Position 1 =
Spring Return
T 2 1 Position 2 =
Detent
S3
S1 A
CA B
1.5 mm
hole drilled
through spool 5.5 bar
300
bar
Training Manual
S2
X1 X1
SERVICE TRAINING
X2 X2
A A
A1 A1
D
M
To
Boom
6 bar Circuit
S S
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Training Manual 35
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SERVICE TRAINING
Phase A
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
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.
36 Training Manual
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SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
12 13 18
Zero Pressure
(Tank, or oil at rest)
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 37
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SERVICE TRAINING
Phase B
End of first working stroke
The differential cylinders have reached the end of their
stroke position*. Switching valve (5) is sending a high
pressure signal to the left hand end cap of S3 valve (3).
Oil from the right hand end cap of the S3 valve (3) is
relieved via check valve (15), the S2 valve (2), S1 valve
(1), filter (7) and back to the hydraulic tank.
38 Training Manual
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SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
12 13 18
Zero Pressure
(Tank, or oil at rest)
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 39
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SERVICE TRAINING
Phase C
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
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).
40 Training Manual
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KEY
High Pressure
Rocking Oil
Low Pressure
12 13 18
Zero Pressure
(Tank, or oil at rest)
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 41
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SERVICE TRAINING
Phase D
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
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).
42 Training Manual
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SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
12 13 18
Zero Pressure
(Tank, or oil at rest)
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 43
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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.
44 Training Manual
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KEY
High Pressure
Rocking Oil
Low Pressure
12 13 18
Zero Pressure
(Tank, or oil at rest)
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 45
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SERVICE TRAINING
Phase F
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
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.
46 Training Manual
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SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
12 13 18
Zero Pressure
(Tank, or oil at rest)
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 47
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SERVICE TRAINING
Phase G
End of second working stroke (diagram 7)
The left hand differential cylinder has now fully
retracted*. Switching valve (6) is sending a high
pressure signal to the right hand end cap of the S3
valve (3). Oil from the left hand end cap of the S3 valve
(3) is relieved via check valve (14), the S2 valve (2), S1
valve (1), filter (7) and back to the hydraulic tank.
48 Training Manual
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SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
12 13 18
Zero Pressure
(Tank, or oil at rest)
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 49
HOME PRINT
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).
50 Training Manual
HOME PRINT
SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
12 13 18
Zero Pressure
(Tank, or oil at rest)
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 51
HOME PRINT
SERVICE TRAINING
Phase I
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
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).
52 Training Manual
HOME PRINT
SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
12 13 18
Zero Pressure
(Tank, or oil at rest)
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 53
HOME PRINT
SERVICE TRAINING
Phase J
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
differential cylinder. Please note that check valve (16)
must close otherwise the right hand differential
cylinder will not retract.
54 Training Manual
HOME PRINT
SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
12 13 18
Zero Pressure
(Tank, or oil at rest)
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 55
HOME PRINT
SERVICE TRAINING
Phase K
First working stroke
Refer to diagram 1 for explanation of first working
stroke.
56 Training Manual
HOME PRINT
SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
12 13 18
Zero Pressure
(Tank, or oil at rest)
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 57
HOME PRINT
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.
58 Training Manual
HOME PRINT
SERVICE TRAINING
KEY
High Pressure
Rocking Oil
A Low Pressure
OPEN B
Zero Pressure
(Tank, or oil at rest)
S3
1.5 mm
hole drilled
through spool S1
300
bar
S2
6 bar
Training Manual 59
HOME PRINT
SERVICE TRAINING
60 Training Manual
HOME PRINT
SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
S3
1.5 mm
hole drilled
through spool S1
300
bar
S2
6 bar
Training Manual 61
HOME PRINT
SERVICE TRAINING
62 Training Manual
HOME PRINT
SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
S3
1.5 mm
hole drilled
through spool S1
300
bar
S2
B
A
Note:
Stuck Open
6 bar
Training Manual 63
HOME PRINT
SERVICE TRAINING
64 Training Manual
HOME PRINT
SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
S3
1.5 mm
hole drilled
through spool S1
300
bar
S2
B
A
Note:
Stuck Open
6 bar
Training Manual 65
HOME PRINT
SERVICE TRAINING
66 Training Manual
HOME PRINT
SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
S3
1.5 mm
hole drilled
through spool S1
300
bar
S2
B
A
Note:
Stuck Open
6 bar
Training Manual 67
HOME PRINT
SERVICE TRAINING
68 Training Manual
HOME PRINT
SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
Ball Cock
Zero Pressure
(Tank, or oil at rest)
S3
1.5 mm
hole drilled
through spool S1
300
bar
S2
Note:
Stuck Open
6 bar
Training Manual 69
HOME PRINT
SERVICE TRAINING
Single Circuit
S3 shifting by signal from Switching valve
70 Training Manual
HOME PRINT
SERVICE TRAINING
5 1
T SP
9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B
X3
A2 B2
A3 B3
10C S3 6 10D
XA1 XB3
1.5
A B
A1 B1
S2 7
XA XB
11 PR
PP
S1 4
XR XP
P2 P1
MP
10E
1.8 T2 T1
1.2
12
3 1.4
300 bar
8A X1
8B 10F
T
1.8
2 2
1
Training Manual 71
HOME PRINT
SERVICE TRAINING
A2 B2
A3 B3
3
XA1 S3 XB3 X1 MP P2
T2
P
1.5
R
A B
T
X
R
A1 B1
X
2
A
S2
XA XB
P1
T1
X
A
PR
1
PP
P
P
S1 1
XR XP
P2 P1
XP
X
B
A3
1
MP
T2 T1
XB A2
7 1.2 4
3 B2
5
XB B3
1.4
300 bar
X1
6
T
5 6
72 Training Manual
HOME PRINT
SERVICE TRAINING
Switching Manifold
10B T SP
9A
3.5MM Orifice 1.3MM Orifice
ZS2 1.3 ZS1
9C 9B
9C
XA XB
A 3.5 3.5 B
10A 10B
9A
9B X3
MG2 G2 6
Reversing Valve 4
(for Fast Switch) 11
Dampner 3
6 7 20 0.7
bar
0-30
bar
1 9 X1
8 MX1
3.5-40 8
12 bar
2 10 MG1 5
4
2 0.7
MP 3.5-40
bar
9
12
PBP PZ T
10
5
11
1
3
SC_FastSwitchDampner.eps
Training Manual 73
HOME PRINT
SERVICE TRAINING
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).
74 Training Manual
HOME PRINT
SERVICE TRAINING
T SP
9A
ZS2 1.3 ZS1
9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B
10A 10B
X3
10C A2 B2 10D
A3 B3
S3 6
XA1 XB3
1.5
A B
A1 B1
S2 7
11 XA XB
PR
PP
S1 4
XR XP
P2 P1
MP
10E
1.8 T2 T1
1.2 12
8A 8B
3 1.4
300 bar
X1
2 2
1.8
T 1
10F
Training Manual 75
HOME PRINT
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.
76 Training Manual
HOME PRINT
SERVICE TRAINING
T SP
9A
ZS2 1.3 ZS1
9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B
10A 10B
X3
10C A2 B2 10D
A3 B3
S3 6
XA1 XB3
1.5
A B
A1 B1
S2 7
11 XA XB
PR
PP
S1 4
XR XP
P2 P1
MP
10E
1.8 T2 T1
1.2 12
8A 8B
3 1.4
300 bar
X1
2 2
1.8
T 1
10F
Training Manual 77
HOME PRINT
SERVICE TRAINING
Phase C
• The rock valve slewing cylinder (5) reaches the
top dead center position.
78 Training Manual
HOME PRINT
SERVICE TRAINING
T SP
9A
ZS2 1.3 ZS1
9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B
10A 10B
X3
10C A2 B2 10D
A3 B3
S3 6
XA1 XB3
1.5
A B
A1 B1
S2 7
11 XA XB
PR
PP
S1 4
XR XP
P2 P1
MP
10E
1.8 T2 T1
1.2 12
8A 8B
3 1.4
300 bar
X1
2 2
1.8
T 1
10F
Training Manual 79
HOME PRINT
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).
80 Training Manual
HOME PRINT
SERVICE TRAINING
T SP
9A
ZS2 1.3 ZS1
9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B
X3
10C A2 B2 10D
A3 B3
S3 6
XA1 XB3
1.5
A B
A1 B1
S2 7
11 XA XB
PR
PP
S1 4
XR XP
P2 P1
MP
10E
1.8 T2 T1
1.2 12
8A 8B
3 1.4
300 bar
X1
2 2
1.8
T 1
10F
Training Manual 81
HOME PRINT
SERVICE TRAINING
Twin Circuits the oil to change directions, oil is also routed to the
valve that changes the direction of the differential
Beginning in 1995, most units became available with cylinders. If the rock valve cylinder has enough
optional twin circuit switching. “Twin Circuit” refers to pressure available to switch, it will do so. If not, it will
the fact that there is one hydraulic circuit to move the wait. As soon as the differential cylinders have changed
differential cylinders, and another separate circuit to directions, one of the following things will happen:
switch the rock valve. On single circuit units, the main
If the rock valve has already switched, concrete will
hydraulic pumps move the main differential cylinders
immediately be drawn from the hopper, and pushed
AND the rock valve.
into the pipeline, which is just a normal stroke.
There are certain advantages to having a separate
hydraulic circuit to switch the rock valve. For example, If the rock valve has NOT already switched, concrete
under the single circuit system, if you were pumping a will begin to be drawn from the pipeline and pushed
stiff, lean mix and pressure was running high, it would into the hopper. This reduces the pressure in the
also take quite a bit of pressure to switch the rock pipeline to zero. As soon as pressure in the pipeline is
valve. There were even a few isolated cases where the relieved, the rock valve switches across. It doesn’t slam
rock valve wouldn’t switch because there wasn’t and it doesn’t pound, it just moves. As soon as the rock
enough pressure available, usually when pumping valve has moved, concrete is accelerating out of the
straight up. The reason that it was hard to switch the unit like normal.
rock valve was because the valve had to try to dislocate The concrete is not actually pumped in reverse,
a column of concrete that still had pressure on it from because as soon as the pressure in the pipeline drops to
the stroke. The next stroke could not begin until the zero, the rock valve switches. A complete description
rock valve had completed it’s travel. of the twin circuit switching sequence is found in this
When using twin circuit, the differential cylinders do chapter starting on page 56. This system has the added
not have to wait for the rock valve before they change benefit of reducing wear on the cutting ring, the
directions and begin the next stroke. As soon as the S-3 spectacle plate, the kidney seal and kidney plate, as
spool changes directions, which gives the rock valve well as the rock valve slewing cylinder.
S1
Single Circuit
S2 Twin Circuit
S1
S2
S3
S3
82 Training Manual
HOME PRINT
SERVICE TRAINING
Twin Circuit
Accumulator oil switches the rock Rock may or may not shift at the
same time as the differential cylinders
Training Manual 83
HOME PRINT
SERVICE TRAINING
14
5 1
11 19
S3 6 15
16
8A 8B 17
9A
18
10C
1
10D 1
9B
22 NG
10B 10A 10 13
23
7 1
4
S2
S1 3
0.7 mm
21
24 12
2 20
1
84 Training Manual
HOME PRINT
SERVICE TRAINING
P1
P2
X
P
S1 1
T
2 3
300 bar
B
X
S2
R
Port size
A
limits flow
S-1
2
S-2
39000148.eps
S3 Control Block
1
S3
39000149.eps
Training Manual 85
HOME PRINT
SERVICE TRAINING
Soft Switch
2
4
3
1
0.7 mm
3 2
80
bar
Soft switch
39000151.eps
A
2
1
1
2
P Y T
39000153.eps
86 Training Manual
HOME PRINT
SERVICE TRAINING
Training Manual 87
HOME PRINT
SERVICE TRAINING
The following diagrams A through D show the • The oil that is forced out of the piston side of the
switching functions of the concrete pumpkit plumbed right differential cylinder (8B) flows through
on the ROD SIDE with simplified schematics. The hoses into the piston side of the left differential
agitator, boom, and S-1 control circuits are not shown. cylinder (Item 8A). This oil is called rocking oil
(orange).
Phase A
• The rocking oil forces the left side differential
• As soon as you switch the unit distribution cylinder (8A) to extend. The cylinder rod extends,
gearcase to the pumping position, the accumulator pushing concrete out of the material cylinder,
hydraulic pump (20) begins pumping high through the rock valve, and into the pipeline. (This
pressure oil (red) to charge the accumulator circuit is called the pressure stroke.)
(14).
• The oil from the rod side of the left differential
• The high pressure oil (red) from the accumulator cylinder (8A) is routed back to the tank through
circuit charges the accumulator (14). When the the return filter (12). The low pressure oil is shown
accumulator pressure reaches the setting of the in green.
accumulator dump valve (13), the accumulator
dump valve opens and routes the oil from the • The oil shown in blue, such as the oil in the
accumulator charge pump (20) back to the reservoir, is at rest, or pressureless.
reservoir (1).
88 Training Manual
HOME PRINT
SERVICE TRAINING
6.3
Phase A Twin Circuit
mm
14
Nitrogen pressure
5 1 set at 100 bar
6.3 (1450 PSI)
mm
19
11
S3 15
16
8A 8B 17
9A 6 300
bar
18
10C
1
10D 1
9B
22 NG
10 13
10B 10A
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
S1 320 3
0.7 mm bar
21
KEY
High Pressure
12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
Training Manual 89
HOME PRINT
SERVICE TRAINING
Phase B
• The oil from the left side of the rock valve slewing
cylinder (5) is routed back to tank (1).
90 Training Manual
HOME PRINT
SERVICE TRAINING
6.3
Phase B Twin Circuit
mm
14
Nitrogen pressure
5 1 set at 100 bar
6.3 (1450 PSI)
mm
11 19
S3 15
16
8A 8B 17
9A 6 300
bar
18
10C
1
10D 1
9B
P
22 NG
10B 10A 10 13
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
S1 320 3
0.7 mm bar
21
KEY
High Pressure
12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
28X 1200 TCphaseAoriginal
Training Manual 91
HOME PRINT
SERVICE TRAINING
Phase C
• The rock valve slewing cylinder (5) reaches the
top dead center position.
92 Training Manual
HOME PRINT
SERVICE TRAINING
6.3
Phase C Twin Circuit
mm
14
Nitrogen pressure
5 1 set at 100 bar
6.3 (1450 PSI)
mm
11 19
S3 15
16
8A 8B 17
9A 6 300
bar
18
10C
1
10D 1
9B
22 NG
10B 10A 10 13
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
S1 320 3
0.7 mm bar
21
KEY
High Pressure
12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
28X 1200 TCphaseAoriginal
Training Manual 93
HOME PRINT
SERVICE TRAINING
Phase D
94 Training Manual
HOME PRINT
SERVICE TRAINING
6.3
Phase D Twin Circuit
mm
14
Nitrogen pressure
5 1 set at 100 bar
6.3 (1450 PSI)
mm
11 19
S3 15
16
8A 8B 17
9A 6 300
bar
18
10C
1
10D 1
9B
22 NG
10B 10A 10 13
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
S1 320 3
0.7 mm bar
21
KEY
High Pressure
12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
Training Manual 95
HOME PRINT
SERVICE TRAINING
96 Training Manual
HOME PRINT
SERVICE TRAINING
Training Manual 97
HOME PRINT
SERVICE TRAINING
14
5 1
19
11
S3 15
16
8A 8B 17
6
9A
18
10C
1
10D 1
9B
22
23 NG
10 13
10B 10A
25
7 4 1
S2
S1
0.7 mm 3
21
12
24
2 20
1
98 Training Manual
HOME PRINT
SERVICE TRAINING
MPS
1 5
3
2 4
S3
1
3
3
2 4 NG
10
5 5
Training Manual 99
HOME PRINT
SERVICE TRAINING
1
2
Nitrogen pressure set
7 at 100 bar (1450 PSI)
4 2 300 1
3 bar
5
6
6
T Y P
5
7
39000152.eps
Accumulator Pump
200 bar
A11 A10
39000154.eps
1
SERVICE TRAINING
Soft Switch
2
4
3
1
0.7 mm
3 2
80
bar
Soft switch
39000151.eps
SERVICE TRAINING
The following diagrams A through D show the • The oil that is forced out of the piston side of the
switching functions of the concrete pump kit plumbed right differential cylinder (8B) flows through
on ROD SIDE with simplified schematics. The agitator, hoses into the piston side of the left differential
boom, and S-1 control circuits are not shown. cylinder (item 8A). This oil is called rocking oil
(orange).
Phase A
• The rocking oil forces the left side differential
• As soon as you switch the unit distribution cylinder (8A) to extend. The cylinder rod extends,
gearcase to the pumping position, the accumulator pushing concrete out of the material cylinder,
hydraulic pump (20) begins pumping high through the rock valve, and into the pipeline. (This
pressure oil (red) to charge the accumulator circuit is called the pressure stroke.)
(14).
• The oil from the rod side of the left differential
• The high pressure oil (red) from the accumulator cylinder (8A) is routed back to the tank through
circuit charges the accumulator (14). When the the return filter (12). The low pressure oil is shown
accumulator pressure reaches the setting of the in green.
accumulator dump valve (13), the accumulator
dump valve opens and routes the oil from the • The oil shown as blue is at rest, or pressureless,
accumulator charge pump (20) back to the such as the oil in the reservoir.
reservoir (1).
SERVICE TRAINING
9B
To e-stop
manifold
22 P
NG 250 bar
23
10 13
10B 10A
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
320
bar
3
S1
0.7 mm
21
KEY
High Pressure 12
Rocking Oil Pressure
Low Pressure 20
2
Zero Pressure
(Tank, or oil at rest) 1
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 oil from the left side of the rock valve slewing
cylinder (5) is routed back to tank (1).
SERVICE TRAINING
9B
To e-stop
manifold
22 P
NG 250 bar
23
10 13
10B 10A
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
320
bar
3
S1
0.7 mm
To e-stop
manifold
21
KEY
High Pressure 12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
SERVICE TRAINING
Phase C
• The rock valve slewing cylinder (5) reaches the
top dead center position.
SERVICE TRAINING
9B
To e-stop
manifold
22 P
NG 250 bar
23
10 13
10B 10A
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
320
bar
3
S1
0.7 mm
21
KEY
High Pressure 12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
SERVICE TRAINING
Phase D
SERVICE TRAINING
9B
To e-stop
manifold
22 P
NG 250 bar
23
10 13
10B 10A
T
200
bar
Y P
0.7 0.7
2.5 mm
7 2.5 mm
mm mm
1
4
S2
320
bar
3
S1
0.7 mm
21
KEY
High Pressure 12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
SERVICE TRAINING
6.3
mm 14
Nitrogen pressure
set at 100 bar
(1450 PSI)
5 1
6.3
mm
19
11
S3 15
16
8A 8B 17
6 300
9A bar
T P
18
B A 1.0
mm
10C
1.0 1
T P mm 10D 1
B A
9B
To e-stop
manifold
22
NG 250 bar
23
10
10B 10A
0.7 0.7
2.5 mm
7 2.5 mm
mm mm
1
4
S2
S1 320 3
bar
To e-stop
manifold
21
12
2 20
1
TCVariable.ai
SERVICE TRAINING
BP L 20 23 HDR -5
2023exp.eps
In practical usage, this unit is referred to as the “2023/ unit with a 1200 pumpkit, the model number of the
39” or simply the “39”. same unit would become BPL 1200 HDR-23, KVM
The boom size generally determines the style of the 39/35 - 125.
entire unit because the outrigger and tower structural The pumpkit has its own complete model number. You
requirements dictate the design criteria to the will find this used on the output charts and nomographs
engineers. Other pumpkits are available for this boom for specific machines. For example:
style, and using any of them would change the model
number of the unit. For example, if you ordered this
39PmpKit.eps
125/80 x 2000:230
SERVICE TRAINING
Pumpkit Comparison
SERVICE TRAINING
6 S3
14
17 15 18
16
P
9A
9B
23
10A 10B
11
S2 7
S1 4
26
3
10C
25 12
24
1.1 27 10D 2
8A 8B
T
20
1
SERVICE TRAINING
A B
A1 B1
3.0 3.0
mm
XA S2 XB mm
PR
6 PP
0.7
mm
X3 P2
T2
0.7 5
mm
XR
S1 XP
P X
R R
P2 P1
MP T
X1
T2
4
1.2
T1
P1
P
7 1.4 MX
P
350 bar
3
X1
X2
XA
80 bar
A
X3
2 B
1.1
1
XB
T
7 3
The standard Schwing control block has used up to 560 for compact simpler design
LPM of oil. We have developed a new control block The twin circuit machines with G-3 control block will
designed for 800 LPM of oil. Called G-3 for 3rd also use the condensed version accumulator (only one
Generation Control Block and is also known as the Hi- larger one).
Flow Brain.
This block incorporates the soft switch into the relief
valve and the accumulator manifold valve into the S-3,
SERVICE TRAINING
MPS
10B
9C
9B
9C
9A 10A 10B
9B
The MPS system is an important part of the twin circuit cylinders to switch with a minimum delay. The S3
system incorporated in the Hi-flo pump kit. The MPS block and the system accumulator are separated from
system consists of three small directional control the main control block and located above the hopper
valves mounted in a manifold. This replaced the two end of the material cylinders. Access to these
switching valves that were located on the passenger components is facilitated by removing the decking
side differential cylinder. The main pressure that is between the water box and the rear boom rest.
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.
The faster switch of the S3 valve allows the differential
SERVICE TRAINING
A B
B
A1 B1
X
1
B
1
XA S3 XB B
A
T
1
A
7 8.0
1
P
S
M
mm
P
Psp
M
Mp1
X
2.0 T
mm 6 300 Mp
bar
T
P
3 4 5
P
PS
2
3
6
2 4
S0153.eps
SERVICE TRAINING
1
B
X
3
B
A3 A2 B2 B3
B
XA1
1
S3 A
XB1
2
P
1 A
S
T3
3
P
S
M
P
M
MSP3
T
A
6 6.5
X
SP mm MSP2
SP
2 2.0 5
bar mm 7 MSP1
TUV
3 2 330
P 4 bar
P P1
MP
T T MS
1
7
5
S0154.eps
SERVICE TRAINING
SERVICE TRAINING
Phase A Hi-Flo
KEY
5 High Pressure
Rocking Oil Pressure
Low Pressure
Soft Switch Pressure
Zero Pressure
6 S3
(Tank, or oil at rest)
14
17 15 18
16
P
9A
9B
23
10A 10B
11
S2 7
S1 4
26
3
10C
25 12
24
1.1 27 10D 2
8A 8B
T
20
1
hiflo A.eps
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.
SERVICE TRAINING
Phase B Hi-Flo
KEY
5 High Pressure
Rocking Oil Pressure
Low Pressure
Soft Switch Pressure
Zero Pressure
6 S3
(Tank, or oil at rest)
14
17 15 18
16
P
9A
9B
23
10A 10B
11
S2 7
S1 4
26
3
10C
25 12
24
10D 2
1.1
27
8A 8B
T
20
1
hiflo A.eps
SERVICE TRAINING
Phase C
SERVICE TRAINING
Phase C Hi-Flo
KEY
5 High Pressure
Rocking Oil Pressure
Low Pressure
Soft Switch Pressure
Zero Pressure
6 S3
(Tank, or oil at rest)
14
17 15 18
16
P
9A
9B
23
10A 10B
11
S2 7
S1 4
26
3
10C
25 12
24
10D 2
1.1
27
8A 8B
T
20
1
hiflo A.eps
SERVICE TRAINING
SERVICE TRAINING
Phase D Hi-Flo
KEY
5 High Pressure
Rocking Oil Pressure
Low Pressure
Soft Switch Pressure
Zero Pressure
6 S3
(Tank, or oil at rest)
14
17 15 18
16
P
9A
9B
23
10A 10B
11
S2 7
S1 4
26
3
10C
25 12
24
10D 2
1.1
27
8A 8B
T
20
1
hiflo D.eps
SERVICE TRAINING
Boom Holding Valves If you should have a problem with a boom section
creeping, position the boom in an area which still
Schwing uses a specially-designed hydraulically produces pressure in the corresponding cylinder but
unlockable check valve on all hydraulic cylinders leaves the holding valve in an accessible area. Loosen
which operate placing boom sections. These valves the fitting of the pressure connection of the working
seal the hydraulic cylinder to prevent it from creeping line and the leakage oil connection. With the hydraulic
or moving until pressure is applied to it. A holding pump not turning, you will be able to see which portion
valve is installed at both ends of the hydraulic cylinder of the valve is leaking.
to prevent movement and limit pressure in either
direction. If oil flowing out uniformly from the leakage oil
connection, this indicates that the auxiliary safety valve
TRUCK-MOUNTED AND SEPARATE is not properly sealing. If this holding valve is on boom
PLACING BOOM HYDRAULIC CYLINDER HOLDING VALVES section 1 cylinder, holding valve replacement is
necessary.
HER - SV2 - R 1/2" CYLINDER CONNECTION
SCHEMATIC DRAWING
This auxiliary safety valve protects the cylinder from
PRESSURE
BLEED OFF
SCREW
excess pressure; therefore, this valve must not be set at
CONNECTION
(WORKING LINE)
random. Precision setting for a specific placing boom
model is necessary and can only be done with the
correct equipment and certified personnel.
UNLOCKABLE
CHECK RETURN OIL
CONNECTION
If hydraulic oil is flowing out uniformly from the
(LEAKAGE OIL) working line, this indicates that the check valve is not
sealing properly, or debris in the oil has caused the
RELIEF (NON-ADJUSTABLE)
SAFETY VALVE unlocking system to hang up and not allow the check
CONTROL LINE CONNECTION
valve ball to seat. If there are any questions concerning
(CONNECTED WITH WORKING LINE holding valves or other areas of your Schwing
OF THE OPPPOSITE SIDE)
equipment that you need answered, contact your local
Schwing dealer or Schwing America, Inc. for more
information.
PORT X
BLOCK A BLOCK B
LINE B
CYLINDER
LINE A PORT Y
CYLINDER ROD
140 bar
1.7 2.0
Training Manual
1.3 1.0 1.7 1.3 1.3 1.3
A4 B4 A3 B3 A2 B2 A1 B1
P T
B A P1
280 bar
T T
300 bar
AIR TANK
28X B&W Boom
T P
KVM 28 Neutral
W/ MONSUN - TISON HANDVALVES 5 - 7 bar
196101
10/91
RE
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure (Tank, or oil at rest)
PRINT
HOME
BOOM #3 (Tip) BOOM #2 BOOM #1 (MAIN) SLEWING CYLINDERS
Outrigger Jacking Cylinders 270 BAR 270 BAR
SERVICE TRAINING
Training Manual
1.3 1.0 1.7 1.3 1.3 1.3
A4 B4 A3 B3 A2 B2 A1 B1
B A P1 T
P
280 bar
300 bar T T
T P
KVM 28 AIR TANK
W/ MONSUN - TISON HANDVALVES
196101 #3 Extend Only
10/91
RE 5 - 7 bar
PRINT
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure (Tank, or oil at rest)
128
HOME
129
BOOM #3 (Tip) BOOM #2 BOOM #1 (MAIN) SLEWING CYLINDERS
Outrigger Jacking Cylinders 270 BAR 270 BAR
270 BAR 270 BAR
SERVICE TRAINING
140 bar
1.7 2.0
Training Manual
1.3 1.0 1.7 1.3 1.3 1.3
A4 B4 A3 B3 A2 B2 A1 B1
B A P1 T
P
280 bar
300 bar T T
T P
KVM 28 AIR TANK
W/ MONSUN - TISON HANDVALVES
196101 #1 Retract
10/91
RE #3 Extend 5 - 7 bar
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure (Tank, or oil at rest)
PRINT
HOME
PRINT # 329324
BOOM #3 (Tip) BOOM #2 BOOM #1 (MAIN) SLEWING CYLINDERS
Outrigger Jacking Cylinders
270 BAR 270 BAR
SERVICE TRAINING
Training Manual
35 bar
1.3 1.0 1.7 1.3 1.3 1.3
B A P1
A4 B4 A3 B3 A2 B2 A1 B1
T
P
300 bar
T P 280
bar
T T
A 5-7
bar
T P
KVM 28
W/ MONSUN - TISON HANDVALVES
190321
PRINT
130
HOME
HOME PRINT
SERVICE TRAINING
SERVICE TRAINING
10,000 LBS
LOAD
10 GALLON MAXIMUM
CAPACITY CYLINDER
(PISTON SIDE)
10 INCH OF AREA ON
CYLINDER PISTON
1000 PSI
10 GPM FIXED
DISPLACEMENT PUMP
COLOR KEY
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure
(Tank, or oil at rest)
SERVICE TRAINING
10 GPM FLOW
OUTPUT
0 PSI
200 PSI
10 GPM FIXED
DISPLACEMENT PUMP
COLOR KEY
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure
(Tank, or oil at rest)
SERVICE TRAINING
10000 LBS
LOAD
10 GALLON MAXIMUM
CAPACITY CYLINDER
10 INCH OF AREA ON
CYLINDER PISTON
1000 PSI
ORIFICE
1200 PSI
10 GPM FIXED
DISPLACEMENT PUMP
LOAD SENSE (series #3)
COLOR KEY
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure
(Tank, or oil at rest)
SERVICE TRAINING
10,000 LBS
LOAD
10 GALLON MAXIMUM
CAPACITY CYLINDER
10 INCH OF AREA ON
CYLINDER PISTON
3000 PSI
ORIFICE
3000 PSI
RELIEF ADJUSTED
TO 3000 PSI
(Bulids Heat)
10 GPM FIXED
DISPLACEMENT PUMP
LOAD SENSE (series #4)
COLOR KEY
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure
(Tank, or oil at rest)
SERVICE TRAINING
10,000 LBS
load
10 GALLON MAXIMUM
CAPACITY CYLINDER
10 INCH OF AREA ON
CYLINDER PISTON
0 PSI
P2
ORIFICE
200 PSI
P
Regulator P
P1 200 PSI
Q 10 GPM Q-MAXIMUM
Variable Displacement
Pump
COLOR KEY
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure
(Tank, or oil at rest)
SERVICE TRAINING
Load Sense Series #5 P). The pump is only supplying the amount of oil
required to maintain the (Delta-P). In this case, 5 gpm.
In this diagram, the cylinder will take exactly 2 minutes
If the size of the orifice increases, the flow rate will be
to extend. There will be a pressure of 1000 psi at the
increased by the Delta-P regulator. That will increase
cylinder and a pressure of 1200 psi at the pump. The
the speed of the cylinder.
orifice caused a drop in pressure (Delta-P). The
regulator has been adjusted to maintain 200 psi (Delta-
10,000 LBS
load
10 GALLON MAXIMUM
CAPACITY CYLINDER
10 INCH OF AREA ON
CYLINDER PISTON
1000 PSI
P2
ORIFICE
1200 PSI
P
Regulator P
P1 200 PSI
Q 10 GPM Q-MAXIMUM
Variable Displacement
Pump
COLOR KEY
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure
(Tank, or oil at rest)
SERVICE TRAINING
Load Sense Series #6 The regulator has been adjusted to a pressure limit of
3000 psi. The pump is only supplying the amount of oil
In this diagram, the cylinder is at the end of it’s stroke.
required to maintain 3000 psi.
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.
10,000 LBS
load
10 GALLON MAXIMUM
CAPACITY CYLINDER
10 INCH OF AREA ON
CYLINDER PISTON
3000 PSI
P2
ORIFICE
3000 PSI
P
P1
3000
PSI
Q P
Regulator
200 PSI
10 GPM Q-MAXIMUM
VARIABLE DISPLACEMENT
PUMP LOAD SENSE (series #6)
COLOR KEY
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure
(Tank, or oil at rest)
SERVICE TRAINING
10 GALLON MAXIMUM
CAPACITY CYLINDERS
10 INCH OF AREA ON
CYLINDER PISTONS
200 PSI
3000
P1 PSI
P
Regulator
200 PSI
Q 10 GPM Q-MAXIMUM
VARIABLE DISPLACEMENT
PUMP
LOAD SENSE (series #6)
COLOR KEY
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure
(Tank, or oil at rest)
SERVICE TRAINING
COLOR KEY
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure
(Tank, or oil at rest)
SERVICE TRAINING
10 GALLON MAXIMUM
CAPACITY CYLINDERS
10 INCH OF AREA ON
CYLINDER PISTONS
2700 PSI
3000
P1 PSI
P
Regulator
200 PSI
Q 10 GPM Q-MAXIMUM
VARIABLE DISPLACEMENT
PUMP
LOAD SENSE (series #8)
COLOR KEY
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure
(Tank, or oil at rest)
SERVICE TRAINING
COLOR KEY
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure
(Tank, or oil at rest)
SERVICE TRAINING
X E
2. The directional valve is in the neutral position.
X E
G1/2
C1
C2
KEY
High Pressure
1
Reduced Pressure
Δ P regulator A7 VO Pump A
Control Pressure A1
3 X
Low Pressure 20
bar Δ P T
Zero Pressure
(Tank, or oil at rest)
300
NOTE: On the schematic, the 20 bar
bar Delta P spool and spring is X3
shown above the 300 bar spool
and spring. On the Pressure P
Regulator cut-out, you can see A T
that in reality the 300 bar spool
and spring is located above the System when equipped with Rexroth hydraulic pump
20 bar Delta P spool and spring.
Δ P regulator A7 VO Pump
1 A1
Q-MIN
Pressure
Regulator
300 bar
ΔP
Regulator A
20 bar
X 0 bar
A T
ORIFICE
KVM 36X . . . . 1.6 mm
P 0.8 mm
KVM 36 LW . . 1.6 mm
0-15 Bar Q-MAX
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
X3
HT001.ai
SERVICE TRAINING
X E
2. The hydraulic pump is putting out only
enough oil to extend the hydraulic cylinder. X E
P1 P2
3. Oil is routed through the holding valve and
pushing on the piston side of the hydraulic
cylinder, causing it to extend. 3
T
KEY
High Pressure 2
Reduced Pressure
Δ P regulator A7 VO Pump A
Control Pressure 4 A1
X
Low Pressure 20
bar Δ P T
Zero Pressure
(Tank, or oil at rest)
300
NOTE: On the schematic, the 20 bar 5
bar Delta P spool and spring is X3
shown above the 300 bar spool
and spring. On the Pressure P
Regulator cut-out, you can see A T
that in reality the 300 bar spool
and spring is located above the System when equipped with Rexroth hydraulic pump
20 bar Delta P spool and spring.
Δ P regulator A7 VO Pump
A1
2 Q-MIN
Pressure
Regulator
300 bar
ΔP
4
Regulator A
20 bar
X 0 bar
A T
ORIFICE
KVM 36X . . . . 1.6 mm
P 0.8 mm
KVM 36 LW . . 1.6 mm
0-15 Bar Q-MAX
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
X3
HT002.ai
SERVICE TRAINING
X E
2. Pressure has been equalized on both ends of
the Delta P spool. X E
P1 P2
3. Pressure has now built to over 300 bar,
allowing the 300 bar pressure regulator spring 1
to compress. Which allows some oil to move
T
through the spool.
G1/2
C1
towards minimum allowing only enough oil to
maintain 300 bar.
C2
KEY
High Pressure
Reduced Pressure
Δ P regulator A7 VO Pump A
Control Pressure 2 X
A1
Low Pressure 20
bar Δ P T
Zero Pressure
(Tank, or oil at rest)
3 300
bar
NOTE: On the schematic, the 20
bar Delta P spool and spring is X3
4
shown above the 300 bar spool
and spring. On the Pressure P
Regulator cut-out, you can see A T
that in reality the 300 bar spool
and spring is located above the System when equipped with Rexroth hydraulic pump
20 bar Delta P spool and spring.
Δ P regulator A7 VO Pump
A1
Q-MIN
Pressure
Regulator
300 bar
ΔP
Regulator A
20 bar
X 0 bar
A T
ORIFICE
KVM 36X . . . . 1.6 mm
P 0.8 mm
KVM 36 LW . . 1.6 mm
0-15 Bar Q-MAX
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
X3
HT003.ai
SERVICE TRAINING
∅1.0
B2 B1
320 bar
330 bar
290 bar
300 bar
A2 A1
∅1.0
EA
C1 C2 C1 C2 PP
G1/2 G1/2
15
bar
0.2
mm
300
bar
.061 mm P
T
LS
KEY
High Pressure
Reduced Pressure
Pretension Pressure
High pressure filter
Low Pressure
Zero Pressure
(Tank, or oil at rest)
2.0
atmospheres
SERVICE TRAINING
∅1.0
B2 B1
320 bar
330 bar
290 bar
300 bar
A2 A1
∅1.0
EA
C1 C2 C1 C2 PP
G1/2 G1/2
15
bar
0.2
mm 300
bar
.061 mm
P
T
LS
KEY
High Pressure
Reduced Pressure
Pretension Pressure
Low Pressure High pressure filter
Zero Pressure
(Tank, or oil at rest)
2.0
atmospheres
SERVICE TRAINING
Cylinder Pressurized at EB
End of Stroke B2
∅1.0
B1
320 bar
330 bar
290 bar
300 bar
A2 A1
∅1.0
EA
C1 C2 C1 C2 PP
G1/2 G1/2
15
bar
0.2
mm 300
bar
.061 mm
P
T
LS
KEY
High Pressure
Reduced Pressure
Pretension Pressure
Low Pressure High pressure filter
Zero Pressure
(Tank, or oil at rest)
2.0
atmospheres
SERVICE TRAINING
Transfer Cases When you are operating the unit, the distribution
gearcase interrupts the power to the rear ends, and
Hydraulic pumps for the concrete pump, placing boom, transmits it to internal gears that turn the hydraulic
agitator, etc., are usually mounted on a distribution pumps. Changing between travel and pumping modes
gearcase. When you are driving the truck, the power of is accomplished by means of an air switch in the truck
the truck engine is transmitted through the truck cab.
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.
4194 4195
4400
SERVICE TRAINING
Pressure Pressure
Tank Tank
Pressure
Pressure
Tank
Tank
SERVICE TRAINING
VENT
LINE
SERVICE TRAINING
(bar)
2100 RPM
1700 117 pressure is
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110 shown for
350
PISTON SIDE
1500 103 both piston
1400 97
Hydraulic oil pres- and rod side
300 Piston side 1300 1285 88.6 90
sure shown here, configurations
breakpoint 1200 83
150 250
700 48
Concrete out-
600 41
200 500 34
put is shown
100
150 400 28 here, with max
100
300 21 shown for both
50 200 14
piston and rod
50 7
100
The breakpoint side configura-
breakpoint 0
specification is 178 bar
13 26 39 52 65 78
103
92
105 118 131 144 157 170 183 196
170.5
tions.
listed here. CONCRETE OUTPUT (cu yd / h)
26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
Hydraulic liters per 15.5
PISTON 5 10 15 20 25 30 NUMBER OF STROKES
minute and the cor- SIDE (stroke / min.) Information
OIL VOLUME
responding strokes 100 200 300 400 500 (liter / min.) about the
per minute for both Differential Hydraulic Cylinder Material Cylinders Hydraulic Pumps
pumpkit and
piston and rod side. Bore dia. / Rod dia. x Stroke length Bore dia. x Stroke length Type / KW
hydraulic
125 mm / 80 mm x 2000 mm 230mm x 2000 mm 2 x A7VO-107
output chart explain.eps
2 x 66KW pumps is
Slewing cylinder 80 / 45 x 185 shown here.
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
Example 1—Checking flow at a given pressure straight across the page until you intersect with the
Your unit is configured on the rod side (standard from horsepower curve (Item B). Next, draw a straight line
the factory). You notice that your machine is not getting down from the intersection point until you pass through
as many strokes per minute as you are used to seeing. the rod side number of strokes scale, and read the
You count the strokes and see that you are getting about strokes per minute. At 220 bar you should be getting a
21 1/2 per minute. You check your pressure gauge and little more than 21 strokes per minute. Your unit is fine.
see that the hydraulic oil pressure is at 220 bar. To
determine whether your unit is acting normally, locate
CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
output chart use.eps
2000 138
PERFORMANCE CHARACTERISTICS OF
1900 131
PISTON SIDE
(bar)
2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110
Example 2—Checking your hydraulic pumps by 2, and chart the result. You multiply the readings
To determine whether your pumps are still in good because the chart is based on the output of two pumps,
working condition, use the output chart and a flow but we are only testing one at a time.
meter. Test one pump at a time, multiply the readings
SERVICE TRAINING
To test your pumps: • Make two copies (one for each pump tested) of
• Use use the chart that applies to your unit (see the Output Chart located in the Appendix of the
Output Chart in the Appendix of your Operation Operation Manual. Don’t use the original copy,
Manual). you will need additional copies of the original for
• Select the proper truck transmission gear for future tests.
pumping (found on the information plate mounted
in the truck cab). Read the flow at 0 bar, 100 bar, 150 or 200 bar, 250 bar,
• Set the pump speed (input drive shaft) RPM. and 300 bar. Also document the breakpoint. The
Pump speed information is found on line 16 of the breakpoint is where the flow drops off rapidly. You will
Delivery Inspection Report which arrived with be able to notice it on the flowmeter. If you think it
your unit when it was new. A difference of even a
would be helpful, copy the chart below. Check which
few RPM will give you a bad reading. Check the
RPM with a digital tachometer if one is available. reading you used (150 or 200 bar). The breakpoint will
• Know how to use your flowmeter. Read the be very close to either 150 or 200 bar, so it is not
instructions that came with it. A flowmeter must necessary to take both readings. The breakpoint
be calibrated periodically. specification is shown on each output chart.
100 bar x2 x2
breakpoint x2 x2
breakpoint
150 or 200 bar x2 x2
250 bar x2 x2
300 bar x2 x2
checking output form
SERVICE TRAINING
Plot the readings on the output chart. Take a clean • Turn the ruler sideways and draw a light line up
output chart and proceed as follows: the page from the liters/minute reading you took
• Lay a straight edge horizontally across the page at at that pressure. (Remember to multiply the
the pressure point you are plotting. Draw a light reading by 2.) In our example, we measured 276
line across the chart. In the example below, we use liters at 250 bar.
the rod side scales and curve (you could use the • Put a dot at the point where the two lines intersect.
piston side scale and curve instead). The ruler is
shown ready to draw a line at 250 bar hydraulic • Do the same thing with each pressure reading. You
pressure. should end up with six dots.
CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
1checking output.eps
2000 138
PERFORMANCE CHARACTERISTICS OF
1900 131
PISTON SIDE
(bar)
2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110
1000 70
300 21
100
50 200 14
50 7
100
breakpoint 0 13 26 39 52 65 78 92
105 118 131 144 157 170 183 196
178 bar 103 170.5
CONCRETE OUTPUT (cu yd / h)
26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
15.5
PISTON 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
100 200 300 400 500 (liter / min.)
SERVICE TRAINING
• Connect the dots. If your plotted line reasonably the upper right of the spec, you have done the test
matches the specification plot on the chart, the incorrectly, or you are using the wrong chart. In
pump is fine. If your line is to the lower left of the our example, the pump is okay. (See the plot
spec, the pump is getting weak. If your line is to which follows.)
CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
2checking output.eps
1200 83
ROD SIDE
300 bar
(bar)
1100 76
1000 70
250
600 41
200 500 34
7
100
26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
(234) (276) (338) (388) (398)
(392)
SERVICE TRAINING
CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
3checking output.eps
1200 83
ROD SIDE
300 bar
(bar)
1100 76
1000 70
250
600 41
200 500 34
400 28
150 200 bar
300 21
100 100 bar
50
WEAK 0 bar
200
100
14
7
26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
(138) (204) (274) (332) (366)(390)
When you connect the dots, the line is completely handy when you call to get a replacement. Also, please
below the specifications. This pump is very weak and advise us if you have changed differential cylinders,
will completely stop pumping oil soon. You may notice material cylinders, or hydraulic pumps, because you
high heat with this unit, if you are pumping at high oil may need a different output chart than the one that was
pressures. 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
SERVICE TRAINING
Using a Nomograph power rating (in Kw) is shown for the engine or electric
motor. With a truck-mounted pump that uses a PTO
General information from the truck engine, the power rating reflects the
power output of the hydraulic pumps only. (All the
NOTE! power from the truck engine is normally not available
If you have read the original Schwing Amer- to the concrete pump and should not be used for power
ica publication, Nomographs—A Guide to
Usage, you will notice several changes in this calculations.) If you know the required output for the
document. Because not all of the power job, the nomograph will help you calculate the required
from the truck engine is used for the con- pressure. If you know the output and pressure, you can
crete pump, the TK number of the engine calculate the power requirement.
has no meaning. Therefore, this section
about using nomographs has been adapted The nomograph was developed by extensive trial-and-
especially for boom pumps. You can still fig- error testing and has proven to be accurate to ±10% in
ure out the TK of the job to do, but the suit- nearly all pumping applications. The original
ability of the pump has to be determined in nomographs used “spread measure” of fresh concrete
a different manner. To make the pump num- instead of slump, and the two are not directly
bers and job numbers match, we will use a
“Power Factor number,” which takes into interchangeable. Some approximations are used in
account the power of the hydraulic pumps translating the charts from spread measure to slump,
instead of the engine and is easy to use with but the ±10% accuracy still applies. In all cases, it is
cubic yards per hour and PSI instead of assumed that you will receive fresh, high-quality
cubic meters per hour and bar.
concrete on your job and that the concrete will be
Concrete pumps are limited in what jobs they can do by plastic enough to flow into the material cylinders. If
three factors:
you know that the concrete will be hard to feed into the
1. The amount of power available. cylinders, you should adjust the output requirement to
2. The maximum concrete output available. compensate for incomplete filling. For example, if you
3. The maximum concrete pressure available. will need 50 cubic yards per hour into the form but the
To estimate the power a pump requires to complete a concrete is so stiff that it will fill the cylinders only
particular job and to determine which pump is 80%, you should multiply the required output by 1.25
appropriate, a nomograph is used. (1÷80%).
With a concrete pump that is driven by its own prime The nomograph is divided into four quadrants (Figure
mover, such as a trailer-mounted concrete pump or a 1).
truck-mounted pump with a separate drive engine, the .
'
&
*+
&
Figure 1
Quadrants
Lower left quadrant Lower right quadrant
!,
-) ( )
! " "
.) *+
! "
"
SERVICE TRAINING
The upper left quadrant is the beginning and end point To use the nomograph, you begin at output required
of the graph and shows maximum output, pressure, and and move clockwise until you encounter the lines that
power for a specific machine. The upper right quadrant represent your job situation. Each time you meet the
accounts for the relationship between concrete output line that applies, you make a 90° turn until you come to
and pipeline diameters. The lower right quadrant
a point on the bottom of the upper left quadrant that
accounts for the resistance to flow of the entire pipeline
system. The lower left quadrant accounts for the shows pressure required (Figure 2).
pumpability of the concrete.
Q in yd3/hr.
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
6" 5" 4.5"
140
4"
120 116
Rod side
100
80
Piston side 67
60
40
132 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI 1566 870
100
200
2"
300
400
2.5"
500
600
3"
4" 5" 6" Pumpkit Model: 120/80 x 1600:200 3000 2500 2000 1800 1500 1200 1000 800
Slump of fresh concrete in inches Power: 132 KW Proportional value of pipeline in feet
Figure 2
Moving around a nomograph
To illustrate the use of a nomograph, we will use a Boom pipe, elbows, and deck system.
hypothetical job situation with the following • 13 ft of 5-in. rubber hose
specifications. • 144 ft of 5-in. steel pipe (on the boom and pump
1. We will need an average output of 75 cubic yards deck)
per hour, but we will be pumping only 75% of the • 5.25 ft of 6–to–5-in. reducer (on the pump)
time. The rest of the time will be spent moving • 4 5-in. 45° elbows, radius 250 mm
hose, removing pipe lengths, waiting for concrete
• 11 5-in. 90° elbows, radius 250 mm
trucks, and taking care of miscellaneous jobs. This
means that when we are actually pumping, we will • 2 6-in. 90° elbows, radius 250 mm
need an output rate of 75 ÷.75 = 100 yd3/hr. 4. We will specify a slump of 5-6 in. and use the 5-in.
line on the chart.
2. We will use 5-in.-diameter pipeline.
5. In addition, when we add the pressure for the verti-
3. We will need the following pipeline lengths: cal run, we will have to add 1.1 times 70 ft = 77
Separately laid pipeline. PSI.
• 40 ft of 5-in. rubber hose All of these criteria will be explained in detail as we go
• 150 ft of 5-in. horizontal steel pipe through the individual quadrants.
SERVICE TRAINING
The quadrants
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 par-
ticular model of concrete pump (Figure 3).
Power factor
56,650
Power factor number (PF) number
upper left quad-eps
English to Metric Conversion Factor is PF Ö 18.966 (replaces TK)
200
Q in. yd3/hr.
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
140
Example Job
Working power (in kW)
120
Power curve 100
Maximum output and
80maximum pressure
of a specific unit
60
Kw rating
40
103 KW 20
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 efficiency factors figured in. When using an
technical parameters: Americanized nomograph (pressure in PSI and flow in
• The power factor number of the pump must be cubic yards per hour), the pressure multiplied by the
equal to or greater than the power factor number output must always be less than or equal to the PF of
of the job. the pump. For example, if you needed 50 cubic yards
• The maximum output required by the job must be per hour and determined that this will require 750 PSI,
available from the pump. you can multiply 50 by 750, which equals 37,500. Any
pump you select must have a PF of 37,500 or greater. If
• The maximum pressure required by the job must
you are using a nomograph that has been converted to
be available from the pump.
metric units of measure (pressure in bar and output in
It is important to notice the pump maximum pressure cubic meters per hour), you can still multiply the
and maximum output, even if the power factor number pressure by the output, but you must multiply the
of the pump is larger than the job requires. These answer by the conversion factor between metric and
parameters are decided during the design stage of the English units of measure to get the PF. The conversion
unit and cannot be adjusted on the job. If the unit is factor for cubic yards to cubic meters and bar to PSI is
able to go from rod side to piston side, maximum 18.966. For all practical purposes, you can use 19. For
pressure and output can be exchanged—that is, you can example, if you need 50 cubic meters per hour and
decrease one while increasing the other the same determine that your job setup will require 65 bar, you
amount. can multiply 50 by 65, which equals 3250. Multiply
The power factor number (PF) replaces the TK this by 19, and you find that your PF requirement is
number on a truck-mounted unit. It is the Kw 61,750. Again, any pump you select for the job in this
multiplied by a constant (550) that has several example should have a PF of 61,750 or greater.
SERVICE TRAINING
The maximum output (abbreviated as max Q) is and forms a slippery layer on which the bulk of the
determined by the size of the hydraulic pumps, the concrete slides. While it is true that a 6-inch pipe-
number of strokes per minute, and the size of the line has 49 percent more surface area to coat than a
differential and material cylinders. The unit is usually 4-inch pipeline, the volume of concrete that can
designed so maximum output can be achieved only at move on the layer is increased by 12 percent,
less than maximum pressure. which results in lower velocity of the concrete (in
Maximum pressure (abbreviated as max P) is feet per second), lower friction, and therefore lower
determined by the size of the differential and material pressure. A pump that may not be capable of com-
cylinders and the setting of the main relief valve. To be pleting a difficult job through 4- or 5-inch pipe may
sure that the unit will handle the job, be careful to be able to do it easily through 6-inch pipe. Note!
notice max P and max Q. Here is an example of why Experience has taught us that 5-inch is the opti-
that is important: You contract to pump a job that mum pipeline size for lengthy vertical runs such
requires only 20 yards per hour, but you calculate that as those found on high-rise buildings. It is large
you will need 2100 PSI pressure. The PF of this job is
enough for most aggregate, but small enough
42,000 (20 x 2100). The pump shown in Figure 3 has a
that you minimize the amount of concrete that
TK of 72,600, so there is enough power available.
However, the maximum pressure available from the slides back into the hopper when the concrete
pump is only 1570 PSI. This pump would not do the valve cycles, which we call backwash. You must
job. also consider the people at the point of place-
ment. Very few hose handlers, if any, can move
6. Follow the chart in a straight line from required
output into the upper right quadrant until you 6-inch hose on a slab all day. There is no provi-
come to the size of the pipeline that you will use. A sion in the nomograph for mixing pipeline sizes.
good rule of thumb for sizing pipeline is to use the For example, if you will be reducing from 5-inch to
largest-diameter pipeline that you can. It takes less 4-inch, pipe, you should calculate the chart as if
force to move concrete through a 6-inch pipeline you were using 4-inch pipe for the entire distance.
than, for example, a 4-inch pipeline. When pressure This will not be completely accurate, but you will
is exerted on concrete in a pipeline, a paste of water be safe in your pressure calculation. In our example
and cement fines coats the inside of the pipeline (Figure 4) we use 5-inch pipeline.
Figure 4
Upper right quadrant—Pipeline diameter
SERVICE TRAINING
When the output line intersects the pipeline diameter • Each 90° bend with a radius of 1 meter (long
that corresponds to your job, draw a line straight down sweep) = 10. feet.
into the lower right quadrant, as shown in Figure 4. • Each 30° or 45° bend with a radius of 1 meter or
7. The lower right quadrant refers to the propor- 250 mm = 3 feet.
tional value of your pipeline. It is a way of taking • Each section of rubber hose causes three times as
into account not only the length of the pipeline, but much resistance as the same length of steel pipe
also the number of bends, the increased resistance (e.g., 12 feet of rubber hose has the same
of flow in rubber hose, and other factors. It is more resistance as 36 feet of pipeline).
a measure of the resistance to flow than a measure • Figure all horizontal and vertical distances
of length. In calculating the proportional value of equally. The increased pressure required to push
your pipeline, always apply the following criteria: concrete vertically is accounted for by adding
• Each 90° bend with a radius of 250 mm (boom pressure, not distance.
elbow) = 3.5 feet. • An example pipeline is shown below (Figure 5).
boom 4 nomo.eps
40 ft.
hose
150 ft. pipe
70 ft.
level
difference
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
SERVICE TRAINING
Once you have calculated the proportional value of intersection, make a 90° turn clockwise, into the lower
your pipeline, extend your line down from the upper left quadrant. As noted above, we are using 500 feet as
right quadrant until it intersects with the line that our proportional value (Figure 6).
represents your pipeline. When you reach the
8. The lower left quadrant refers to the pumpability right quadrant until it intersects with the 5-inch
of the concrete. If the concrete specifications allow slump line, then make a 90° turn clockwise. This
a range in slump (for example 5–6 in.), always use will lead you back into the upper left quadrant
the lower end to be safe. In our example, we use 5- through the pressure scale (Figure 7).
inch slump. You extend the line from the lower
Figure 7
Lower left quadrant—
pumpability of the
concrete
SERVICE TRAINING
As you can see by the chart in Figure 7, we are The nomograph is now complete. The PF of our job
reentering the upper left quadrant through the pressure can be calculated like this:
scale at about 550 PSI. Remember, we now have to add PF = PSI x yd3/hr
the head pressure for our vertical rise. At 1.1 PSI per
We need a unit that is capable of 627 PSI, and 100 yd3/
foot of level difference, and our 70-foot vertical run,
hr. The PF of this job is:
we must now add 1.1 x 70 = 77 PSI to the 550 PSI
from the chart. PF = (627 x 100)
PF = 62,700
550 PSI + 77 PSI = 627 PSI
The unit must have a PF over 62,700 and it must be
NOTE! able to pump 100 yd3/hr and 627 PSI simultaneously.
When calculating the head pressure from Look at the pump shown in our sample nomograph
vertical runs, it doesn’t matter if the pipe- (Figure 8).
line runs straight up and down, or if it runs
uphill at an angle. Only the level difference • Can the unit pump at 627 PSI? Yes
in feet is needed for the pressure calculation. • Can the unit pump 100 yd3/hr? Yes
If the pipeline is running downhill, the oper- • Can the unit pump both simultaneously? No! This
ator will need special knowledge, but you unit will not do the job.
don’t need to add any head pressure to the
nomograph.
56,650
Power factor number (PF)
upper left quad-eps
English to Metric Conversion Factor is PF Ö 18.966
200
Q in. yd3/hr.
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
140
Example Job
Working power (in kW)
120
100
80
60
40
103 KW 20
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 pumps set to a higher Kw? The PF of the higher Kw
yards3/hr and 627 PSI has been plotted for visual unit is 72,600. This should work. Plotting the
representation, but you will see immediately that the intersection of our hypothetical job again, you will see
PF of the job (62,700) is bigger than the PF of the unit that it falls within the power zone of the hydraulic
(56,650). The curved black line represents the PF of the pumps (Figure 9)
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
SERVICE TRAINING
The nomograph should only be considered accurate to • Pump the top of the building at 85 yd3/hr instead
within ±10 percent. You should always calculate of 100 yd3/hr.
conservatively, and allow for the graph tolerance. In the • Pump the top of the building at a 6-inch slump
case of the pump in Figure 9, we should still be safe instead of 5-inch. (This would still be within
even if the pressure required were 10 percent greater specifications.)
(690 PSI).What if you already own the pump shown in • Remove some of the rubber hose at the end of the
horizontal run. Normally, with job circumstances
Figure 8? Is there anything that can be done to the job
that did not require a substantial vertical run, you
specifications to make the unit with the less powerful could also use 6-inch instead of 5-inch-diameter
pumps work? You could use the smaller PF unit shown pipeline, but in our example, the entire vertical run
in Figure 8 if you can get permission to do any of the was made with the boom. The boom can never
following things: support 6-inch pipeline.
72,600
Power Factor number (PF)
English to Metric Conversion factor is PF 18.966
200
Q (in yd3/hr)
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
Working power (in kW)
140
120
100
Example Job 80
60
40
132 kW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
up1ft 132Kw Quad 2000R.eps
P (in PSI)
Figure 9
Same model pump with larger Kw hydraulic pumps
SERVICE TRAINING
3000 210
L
200
AL
2800 EM
EM
190 T
ST
YS
DB
180 EM
SY
2600 S
T
&
ID
YS
D
5"
D
170
I
S
TE
4"
2400 ID
EA
160 6"
TR
2200 150 AT
CONCRETE PRESSURE
140
HE
2000
ID
130
5"
1800
120
1600 110
100
1400
90
1200 80
1000 70
400 30
20
200
10
0 0
PSI BAR
0 .050" .100" .150" .200" .250" .300" .350" .400" .450" .500"
.025" .075" .125" .175" .225" .275" .325" .375" .425" .475"
PIPE WALL THICKNESS
Notes:
1. This chart assumes a safety factor of 3:1. Higher safety factors may be required in some circumstances.
2. Wear reduces wall thickness. Thickness must be checked on a regular basis.
3. Pressures may be limited even more by clamp style or pipe end used.
4. The chart is based on 52,000 PSI tensile strength. Heat-treated calculations are based on a 50 percent
increase in tensile strength.
5. The chart is for pressure calculations only. There is no allowance made for mechanical forces due to
improper support or restraint.
6. The chart does not take into account metal fatigue caused by pressure cycles.
This chart is intended for concrete pumping applications and is subject to the notes,
assumptions, and conditions noted above. Any other use of this chart is not recommended.
SERVICE TRAINING
Scheduled Maintenance
Semi-annually
As Indicated
Quarterly
Annually
Monthly
Weekly
Daily
Task
SERVICE TRAINING
Semi-annually
As Indicated
Quarterly
Annually
Monthly
Weekly
Daily
Task
Δ = Breakin period
SERVICE TRAINING
SERVICE TRAINING
back to the shop, or order the filter so it can be replaced General information
soon. Remember, unfiltered oil wears out every
hydraulic component on the concrete pump. Hydraulic oils are rated for viscosity, heat dissipation,
foaming characteristics, pour point, antiwear additives,
Your concrete pump may be equipped with a main anticorrosive additives, lubricating qualities,
return oil filter mounted on top of the hydraulic oil compressibility, temperature range, temperature
reservoir or an inline filter located on the passenger stability, and other functions. Although many different
side just above the hydraulic oil cooler. (Both types of brands of oil meet these specifications, they may use
filter are shown in. different chemical additive packages to achieve the end
t
result. For this reason, you should not mix two different
The boom/outrigger circuit is equipped with an in-line
brands of oil. The additive package from one brand
high-pressure filter. This filter is in a canisters rated to
may be incompatible with the additive package from
handle the pressure that is felt by this circuit. There is
the other, rendering both packages useless.
no integral bypass in this filter. The filter is not fitted
with a ΔP switch, so you should change it whenever Recently a few manufacturers have introduced
the return filter light comes on. The rating on the biodegradable hydraulic oils onto the market. These
filter is β25 = 200. We install this filter to catch large oils are based on vegetable extracts instead of mineral
particles that may cause a boom valve or holding valve extracts. They are considered safer for the environment
to stick in an open position. Because the boom circuit in the event of a spill, although the additive packages
gets its oil from the same tank as the return filter, the oil are not inert. One brand, Mobil EAL 224-H, has been
should be clean anyway. accepted for use in Schwing pumps, and other brands
The oil tank breather filter is mounted on top of the are under consideration and testing. These oils must not
hydraulic oil tank. This filter should be changed when be mixed with mineral-based hydraulic oils, even in
the main return oil filter is changed. very small amounts. If you will be pumping a job in an
environmentally sensitive location and want to use this
The high pressure oil filter is located on the passenger type of hydraulic oil, please contact the Schwing
side of the unit. Service Department at (651) 429-0999 for instructions
The type of filters installed on your unit are the result on making the change from mineral oil.
of years of experience and testing. We recommend that Viscosity of hydraulic oil is similar in concept to the
you do not change the housing or element to some different weights of motor oil. For example, in the
other type. You may learn that in the long run, cheaper winter you may run 5W-30 in your car, while in the
is more expensive. summer you run 10W-40. The same is true for
hydraulic systems. If you live in a climate where the
Changing high pressure water filter weather is changing from extremely hot conditions to
extremely cold conditions, you should consider
The optional high pressure water pump has an inline
changing the weight of the hydraulic oil that you use by
filter between the water tank and the optional high
the season. The International Standards Organization
pressure water pump. This filter needs to be inspected,
(ISO) has developed a method of grading hydraulic oils
cleaned, or replaced at the same time hydraulic oil
for viscosity. For summer in northern North America,
filters are changed. This filter will also need inspection
we recommend ISO VG 46 weight oil, while in the
and cleaning if water is not flowing through the high
winter we recommend ISO VG 32 or even VG 22,
pressure water system. The part number for the filter
depending on how cold it gets in your area. For
element is in the Parts List manual supplied with your
southern North America and Central America, we
concrete pump.
recommend ISO VG 46 for the winter and ISO VG 68
or VG 100 for the summer, depending on how hot it
Hydraulic Oils gets. The lower the ISO VG number the thinner the oil
and the lower the pour point of the oil. On the other
General information relates to all hydraulic oils. hand, the thinner the oil, the lower the temperature will
Specific information contains hydraulic oil have to be before it breaks down the lubricating film
recommendations for Schwing concrete pumps. that protects your components.
SERVICE TRAINING
Specific information
• Mobil DTE
• BP Energol
• Aral Vitam
• Esso Nuto
• Esso Univis
• Total Azolla
• Wintershall Wiolan
SERVICE TRAINING
Electrical Symbols
LINE
MAGNET COIL
FOR HYDRAULIC VALVE
CONNECTOR DIN ANSI
HORN
LINES, JOINING
(Letter
LAMP WITH BULB R indicates
lens color)
DIN ANSI
LINES, PASSING
31 D-
+ OIL TEMPERATURE
TRANSMITTER OR T
(both DIN)
BATTERY
- CURRENT FLOWS
IN THIS DIRECTION
DIODE
CURRENT BLOCKED
IN THIS DIRECTION
CHASSIS GROUND OR
LIGHT EMITTING DIODE
(L.E.D.)
50a
30
SHIELDED CABLE
(Show all conductors
STARTER STARTER inside shield)
21 21 22 22
31 TERMINAL CONNECTORS
POSITIVE NEGATIVE
TERMINALS TERMINALS
ELECTRIC MOTOR M
SERVICE TRAINING
Electrical Symbols
SWITCHES RELAYS
KEY: N.O. = Normally open N.C. = Normally closed KEY: N.O. = Normally open N.C. = Normally closed
ON OFF
30 85
2 3
OR
Component
Component Contacts (2 N.O.
Dashed lines = enclosure
enclosure contacts shown).
available positions
of switch
86 87a 87
AS DRAWN
("O" POSITION) K3
85 30
contact is made CR 3
1 14
between terminals 8 5 9
1 and 3 in the
"OFF" position these numbers denote which relay
ON OFF
coil will operate the contact
2 3
CR 3 CR 2
1 15 16 2
Pivot point of the switch shown
9 9 1 2 8 G
below the activation line indicates
common common
that the contact lever would be hot neutral
pushed towards contact #3 in the
FUNCTION WHEN
"OFF" position ACTIVATED "OFF"
SERVICE TRAINING
Electrical Symbols
MOMENTARY CONTACT
N.C.
CIRCUIT BREAKER /
DIN ANSI DISCONNECT
SWITCH
PS.
N.O.
N.C.
MISC. DEVICES
TGS.
0 1 2
D.P.D.T. RESISTOR
2.5 K
0,1,2 (VALUE INDICATED IN OHMS)
(K = 1000)
DIN ANSI
POT
MECHANICAL SWITCH 1K
(Hopper Grate Switch) NONE POTENTIOMETER
AVAILABLE (Value indicated)
1K
DIN ANSI DIN ANSI
TAS
120V 120V
N.O. Primary 60 HZ 60 HZ
¡C
TEMPERATURE SWITCH TRANSFORMER
TAS
N.C. Secondary
¡C 12V 12V
OVER-CURRENT SWITCH OL
(Always normally closed) N.C. BRIDGE RECTIFIER
(A.C. to D.C. converter)
DIN ANSI
DIN ANSI
FS
N.O.
Q CAPACITOR
FLOAT SWITCH FS
(VALUE INDICATED IN
(Oil Level) N.C.
FARADS) 2 F 2 F
Q ( = micro or 1 millionth) DIN ANSI
DIN ANSI
SERVICE TRAINING
JunctionBox
(see boom orange
Trouble Light brown
2 1 schematic)
Receptacle at Tachometer
Operator’s Panel Panel
Panel Light Light
G
to Pin 2/5 + brown brown G
brown brown
from Pin 1/11 red red
orange
brown Remote
thermometer for Remote thermometer
Emergency
stop button
Pass. Side oil tank for Driver’s side oil tank
orange
= 10 gauge
= 12 gauge grey brown brown
= 16 gauge red G G
Small
All fuses On-Off
20 amp switch brown brown
(AGC size) orange
red
black purple
white purple
USA 28M
black stripe
white with
1/94 GRP
electric oil
white cooler only
green yellow
red white
25 A
In line
fuse
25 A
H
purple
purple
purple
yellow
white & black stripe
black
white
Tachometer Trouble Light Dirty hyd. oil Passenger side Driver’s side
12 volt sending unit Receptacle filter pressure hyd. oil hyd. oil
+ (proximity switch) at Center of switch 35 PSID temperature temperature
Unit (2.4 bar) sending unit sending unit
SERVICE TRAINING
STOP
25 A
A B C D E F G H G+ G- S O P
2
2/7 2/9
6 10 12
1 2 3 4 5 6 7 8 9 11
1 2 3 4 5 6 7 8 9
10
11
12
7 +
12 Volt
1 1 1 1 1 1 1 1 1 1 1 1
2 A2 B2 C2 D 2 E2 F2 G2 H 2 + 2 - 2 P2 S
-
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
#1 BOOM UP
#1 BOOM DOWN
SLEWING CCW
SLEWING CW
#3 BOOM EXTEND
#3 BOOM RETRACT
#2 BOOM EXTEND
#2 BOOM RETRACT
THROTTLE UP
THROTTLE DOWN
CONCRETE PUMP
FORWARD RELAY
CONCRETE PUMP
REVERSE RELAY
CONCRETE PUMP
FORWARD
CONCRETE PUMP
REVERSE
Components 2 thru 5
BYPASS VALVE
2/90 RE
SERVICE TRAINING
- - - - What is Electricity?
-
Electricity is the flow or displacement of electrons.
Nucleus Normally, the atoms in a substance are balanced in an
(w/13 Protons) electrically neutral state. They’re made up of equal
numbers of positively-charged protons and negatively-
Figure 1. Aluminum atom (Neutral state) charged electrons.
SERVICE TRAINING
SERVICE TRAINING
Figure 7. AC current flow periodically AC and DC. Two types of electric currents exist; AC,
reverses direction for Alternating Current, and DC, for Direct Current.
+ resistance.
SERVICE TRAINING
Amperage
Seconds
0 Amperage describes the rate of current flow. It is
measured in amps, using an ammeter. The higher the
3 1 amperage, the greater the number of electrons flowing
past a single point in one second.
2
1 Amp
Current flow and heat are related. As amperage
Figure 9. Amperage is the rate of current flow increases, more electrons flow and more heat is
generated. Any electrical component that carries
Low Current Flow
current, generates heat. For this reason, the wires in a
Low Heat 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.
SERVICE TRAINING
Voltage
Voltage is the force that moves electrons through a
Allows Less
Flow (Amps) 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
1000
measured in volts, using a voltmeter.
Figure 13. A resistence is a restriction 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
Allows Less circuit at a rate of 12 amps. At 24 volts, however,
Flow (Amps) current flow through that same circuit at a rate of 24
amps.
Infinite
Resistance
Allows More Resistance descries how much a component or circuit
Flow (Amps) resists, or restricts, current flow. Think of it as a kind of
electrical friction. The greater the resistance, the less
0 current flows. The less the resistance, the greater the
current flow. Resistance is measured in ohms, using an
Figure 14. The two extremes of resistence ohmmeter.
SERVICE TRAINING
200
1000
500 200 BATT
9V
steel of the truck’s engine and chassis are typical
20
2000
m
200u
20m
conductors in a Schwing electrical circuit.
200m
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V
Besides the thickness of a wire, several other factors
COM V mA
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
Figure 15. Copper conductor partially cut wire operates in a circuit as if its entire
length were of the reduced diameter at the point of the
cut.
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.
SERVICE TRAINING
200
1000
500 200 BATT
9V
with another conductor. Glass, rubber, and ceramic are
20
2000
m
200u
20m
other examples of typical insulators.
200m
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V
Basic Circuits
COM V mA
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.
SERVICE TRAINING
9V
200u
loose or corroded connections. If the voltage drop
2000
m
200m
200m
20m
across a wire or connection is sever enough, the circuit
2000k
200k
20k
2000
200 mA FUSED
200
COM V mA
frequently.
Figure 20. Measuring voltage drop
+12V -0V 20
200 9V
200u
2000
m 20m
200m
200m Other types of controls vary the function of a load by
increasing or decreasing current flow. Variable
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V
resistors, do this by allowing you to vary the amount of
COM V mA
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.
Figure 21. Rheostat 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.
SERVICE TRAINING
+
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 de- -
energized position, you’ll have to determine how a
circuit operates by following current flow as if these
components were on or energized.
+
as 0 1 2
"ON" position activated, is held in place by the
detent TGS. DIN ANSI
indicated by solid line (indicated by the vertical
line) 86 D+
D.P.D.T. RESISTOR
K3 TACHOMETER
0,1,2 SENDING UNIT (VALUE INDICATED IN OHMS) 2.5 K
85 (PROXIMITY SWITCH, (K = 1000)
ON O OFF 1 ALTERNATOR
In this example, DIN
DIGITAL 87a 87
- ANALOG CONVERTER)
ANSI
contact is made
on one part
between terminals If the relay coil is drawn
MECHANICA contacts K3
D- andLpart,
1 and 2 in the schematic, the
SWITCH
of the31 30
"ON" position (V-BELT
are drawn SWITCH)the relay
on another POT
K3) will be listed NONE POTENTIOMETER 1K
ON OFF number (in this example,
here. OIL TEMPERATURE AVAILABLE (Value indicated)
2 3 + as shown
in both places
TRANSMITTER
DIN ANSI
OR T 1K
(both DIN)
BATTERY Control Relays these numbers DIN ANSI
) show the location
(ANSI "ladder" drawing TAS
-
Pivot point of the switch
shown (line number) CURRENT FLOWS
line indicates - of the contacts
N.O. IN THIS DIRECTION
below the activation Relay terminal Relay coil
¡C that the relay coil
120V 120V
would be DIODE Primary
that the contact lever FUNCTION WHEN TEMPERATnumbers URE SWITCH
60 HZ 60 HZ
#2 in the will operateBLOCKED
drawn towards contact ACTIVATED "ON"
CURRENT TRANSFORMER
"ON" position line numbers IN THIS DIRECTION
TAS
Figure 22. Typical electrical symbols Figure 24. Typical parallel circuit
SERVICE TRAINING
- +
POWER
500 200 BATT
12V
1000
200 9V
20 200u
2000
m 20m
200m
- +
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V
COM V mA
12V
- + POWER
1000
500 200 BATT
200 9V
20 200u
12V 2000
m
200m
200m
20m
2000k 200
200k 2000
-
20k
+ 200 mA FUSED
500V max
500V
COM V mA
SERVICE TRAINING
Ohm’s Law
I= E Amperage, voltage, and resistance are related in a
R 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= E R. I is the current in amps, E is the voltage, and R is the
I resistance in ohms.
SERVICE TRAINING
12 ohm load
POWER
500 200 BATT
1000
200 9V
20 200u
2000
m 20m
200m
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V
COM V mA
+
- 0V=0 Amp x 12
12 ohm load
POWER
500 200 BATT
1000
200 9V
20 200u
2000
m 20m
200m
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V
COM V mA
SERVICE TRAINING
20 200u
2000
200m
200m
2000k 200
200k
20k
2000
200 mA FUSED
500V max
500V
it’s the same throughout the circuit, you can use Ohm’s
COM V mA law:
12 volts/12 ohms = 1 amp.
Figure 36. Total resistence in series circuit
+
- 1Amp= 12V
12
SERVICE TRAINING
+
- 4V=1 Amp x 4 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.
POWER
500 200 BATT
1000
200 9V
20 200u
2000
m 20m
200m
2000k
200k 2000
200m
200 The third rule also proves out. Each 4 ohm load causes
20k
200 mA FUSED
500V max
500V a 4 volt drop, and 4 volts + 4 volts + 4 volts = 12 volts –
COM V mA
the source voltage.
Figure 38. Voltage drop of one load in series
circuit
POWER
1000
500 200 BATT
• Second, the total amperage in a parallel circuit is
equal to the total of the individual branch
200 9V
20 200u
2000
m 20m
200m
2000k
200m
200
amperages. This means you can treat each
individual branch of the circuit as a series circuit,
200k 2000
20k
200 mA FUSED
500V max
500V
SERVICE TRAINING
20 200u
2000
m 20m
200m
2000k
2000
200
200m
200 mA FUSED
500V max
circuit, you plug numbers into the total resistance
Figure 41. Measuring total amperage in a equation. See Figure 42 for an illustration of how to
parallel circuit solve the equation for this example. The total resistance
in this circuit is 4 ohms. This number also agrees with
Total the 3 amps of total current: Using Ohm’s law, 12 volts/
Resistance 4 ohms = 3 amps.
1 = 1 1 = 1x 4 = 4
1 + 1 + 1 3 1 1 An important difference between parallel and series
12 12 12 12 4 circuits is that as you add more branches to a parallel
circuit, its total resistance decreases instead of
Add Fractions increases. And this, of course, increases the current in
Find a Common Invert
Denominator, If Simplify Fraction and the circuit. For instance, add another 12 ohm load in
Necessary Fraction Multiply parallel with the previous circuit, and the total
resistance goes down to 3 ohms, while the amperage
Figure 42. Calculating total resistance in a increases to 4 amps.
parallel circuit
+
+ -
-
POWER
500 200 BATT
1000
200 9V
20 200u
POWER
2000
500 200 BATT m 20m
1000
200 9V
200m
200m
20 200u
2000k 200
2000
m 20m 200k 2000
20k
200k 2000
20k
COM V mA
200 mA FUSED
500V max
500V
Figure 43. Measuring total resistance in a Figure 44. Total total resistance in a parallel
parallel circuit circuit
SERVICE TRAINING
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.
1 = 1 1 = 1x 6 =
1 + 1 2 1 1
12 12 12 6
12 V
- +
SERVICE TRAINING
Circuit Faults
200
1000
500 200 BATT
9V
operate and no heat is generated. As a result, an
20
2000
m
200u
20m
ammeter will not give a reading, but a voltmeter,
depending on where it is placed, may or may not show
200m
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V a voltage reading.
Figure 48. Voltage reading before opne
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.
20
2000
m
200u
20m
starter motor turns too slowly or the lights dim, for
200m
2000k
200m
200
instance.
200k 2000
20k
200 mA FUSED
500V max
500V
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.
+
-
SERVICE TRAINING
Figure 52. Short voltage across switch However, jumper wires and self-powered and
unpowered test lights are also useful troubleshooting
Jumper Wire tools, but can cause other problems if not used
correctly.
SERVICE TRAINING
CAUTION
Unpowered Test Light. An unpowered
Figure 54. Jumper wire bypassing an opening 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
Test Light "On" 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 cur-
rent 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 volt-
age is present. To find out how much, you
must use a voltmeter.
SERVICE TRAINING
+
- 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.
+
+ -
-
SERVICE TRAINING
200m
200m
20
200
1000
500 200 BATT
9V
200u
stand for 20,000 and 200, stands for.200 (200
thousandths).
2000
m 20m
200m
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V
COM V mA
3 3 3 3
First, read and follow the instructions that come with Figure 63. Converting units of measure
SERVICE TRAINING
POWER
20
200
1000
500 200 BATT
9V
200u
Conductors should have almost no voltage drop. A
2000
m
200m
200m
20m
drop greater than 0.1 volt in a low-current conductor, or
2000k
200k
20k
2000
200 mA FUSED
200
COM V mA
connection.
SERVICE TRAINING
(Reference #’s)
200
PRINT
2
6 - 6 SQ. MILS
(wire size)
Non-joining lines
Training Manual
2
1.5 - 1.5 SQ. MILS
all 3 wires
SERVICE TRAINING
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 Figure 68
Placing a spot light in the waterbox Light rays in material cylinder
2. Select the “forward” mode of the S1 valve, AT If the alignment tool should contact the cyl-
THE SLOWEST POSSIBLE SPEED! Look into inder wall at any time, return the pump to
the material cylinder from the valve end. The gap neutral immediately! Damage may occur to
between the alignment tool (See Figure 67) and the cylinder wall.
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.
SERVICE TRAINING
3. If, for example, the alignment tool contacts the cyl- NOTE!
inder on the lower side, loosen the mounting bolts If a squeaking sound indicates the align-
at the waterbox a little bit, then tighten the ment tool is dragging on the material cylin-
LOWER bolts first (See Figure 69). This will lower der, turn off the pump IMMEDIATELY!
the bottom of the material cylinder. When the 9. If there is no dragging, you may proceed to step 11.
alignment is close, tighten the top bolts and If dragging does happen, repeat the visual checks.
recheck the alignment. When the alignment is 10. Loosen the bolts on the material cylinders and
within specification, the alignment tool will travel valve housing, and at the machine frame, and
the entire length of the cylinder without touching repeat the alignment procedure.
the cylinder wall. If the alignment tool is not 11. Check the mounting of the pump kit and its mount-
always located exactly in the middle of the cylinder ing to the pump kit frame.
during the travel, but DOES NOT TOUCH, then
12. Tighten all bolts.
realignment is not necessary. Minor misalignments
are compensated for with the rubber ram. Repeat 13. Complete the reassembly of valves, and install the
procedure for the other cylinder. rubber rams.
NOTE!
If proper alignment cannot be achieved oth-
erwise, 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 slow-
est possible speed.
SERVICE TRAINING
Add hose
and fittings
to each side
Loosen for
rotation
SERVICE TRAINING
Dimension A
Tape
Using a caliper measure the distance from the top of
the bushing down to the bushing seal recess. See Figure Figure 71
70. 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
Tension Ring
Bushing Dimension B
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.
SERVICE TRAINING
Formula
A should equal B
B - A = shims required
In this example:
57.40
- 57.12
.28 mm (.011")
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.
SERVICE TRAINING
Figure 77
Bleeding the PC2 control chamber
Figure 75 • The PC1 control chamber (handle side) is bled
Normal Horizontal Position by loosening the port plug several turns (Figure
If the valve is mounted with the main spool horizontal 78). Then supply a pilot signal to the end chamber
and the solenoids (Figure 76) are below the main spool, by energizing the solenoid closest to the port plug
then the following must be done: with a 100% input signal. Once there is no more air
SERVICE TRAINING
Port Plug
PC2 Control
Chamber
Figure 80
Bleeding the PC2 control chamber
• The PC1 control chamber (handle side) is bled
by loosening the spool plug with flow limiter sev-
Figure 78 eral turns in order for the O-ring to disengage with
Bleeding the PC1 control chamber the lead-in surface of the SAE port (Figure 81).
Then supply a pilot signal to the end chamber by
If the valve is mounted with the main spool horizontal energizing the solenoid closest to the plug with
and the solenoids are to the left or the right of the main 100% input signal. Once there is no more air exit-
spool in the same horizontal plane (Figure 79), then the ing from the threads of the plug, turn the plug into
following must be done: 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 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
Spool mounted on, so that the end plug is the high-
est point of the valve section, in order to
Figure 79 remove all the air from the control chamber.
Spool Horizontal - Solenoids to the left and
right of main spool
• The PC2 control chamber (spring side) is bled
by loosening the spool plug with flow limiter sev-
eral 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 exit-
ing 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
SERVICE TRAINING
Figure 81
O-ring
Bleeding the PC1 control chamber
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
Figure 82 Chamber
Vertically mounted handvalve
• Only the upper control chamber needs to be Figure 84
bled since the air in the lower control chamber will Air bleeding the upper control chamber using
rise and the air will purge out of the control cham- the port plug
ber through the clearance around the main spool
(Figure 83 or Figure 84 depending upon the orien-
tation 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 sup-
ply a pilot signal to the end chamber by energizing
the solenoid closest to the plug with 100% input
SERVICE TRAINING
listed; T
P
MG
G
MY Y
A11VO130 / A11VO130
Q-max Screws
A11VO130 / A11VO190
Q-max Screws
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
BPL 2023-5 PRESSURE
350 or 400 HP truck PSI Bar
2000 138
Piston Side
Bar
PUMP SPEED
E
2100 RPM 1700 117 P
T
HYDRAULIC RELIEF VALVE IS SET AT 1600 110
350 BAR MAX. PRESSURE (5075 PSI). MG
1500 103 P
G
PL
1400 97
MY Y
1300 90
4500
300
OIL PRESSURE
4000 800 55
250 700 48
3500
3000 600 41
200
SA
2500
2000
150
500
400
34
27
Figure 88
1500
1000
100 300
200
21
14
Stroke Limiters (two generations)
50
500
0
100 7
3. Increase the engine Rpm's to the maximum setting
Break Point 208
180 Kw = 182 bar
200 KW = 202 bar
At 350 bar
180 Kw = 278 l/m
10 20
7.5 15
30 40 50 60 70 80 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
and while watching the flow meter scale, slowly
200 Kw = 309 l/m
CONCRETE OUTPUT
32
turn the stroke limit potentiometer to the minimum
material output until the maximum flow rate begins
5 10 15 20 25 30 Number of strokes
(stroke / min.)
Oil volume
100 200 300 400 500 535 (liter / min.)
SERVICE TRAINING
until the reading is correct or if it is to low, turn the 1. Locate the agitator shutoff valve and close it.
Q min screw in until the reading is correct. When NOTE! If your unit does not have a shutoff valve,
the Q min has been set, the flow meter can now be order one from the Schwing Spare Parts Depart-
removed. ment using part number 10004680 (valve), and
number 30303432 (tube). Contact the Service
A11VO190 Department for installation instructions.
14. Activate the agitator. With the valve closed the agi-
tator will not be able to turn and the oil will be
A11VO130 forced over the relief valve. At an idle (about 600
RPM), 4.5 horsepower is being converted to heat.
Q min Screw 0
Q min Screw
Figure 89
Q-min screw locations
2. Repeat steps 2 through 6 on the second main agitoff.eps
SERVICE TRAINING
Pressure setting procedure: 23. Stop the truck engine and put the key in your
pocket. Adjust the pressure cutoff screw (Figure
Soft switch 92) on each pump, by backing off the jam nut with
shutoff valve a 13mm wrench. Using a 4mm allen wrench, turn
the adjustment screw in (clockwise) one full turn
Main Pressure
Gauge port 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
Concrete pump pump forward switch on the rear panel. Using the
hif
shutoff valve lob
rn
.e
ps
rear panel controls will allow you to read the con-
crete pump main system pressure gauge, near the e-
stop manifold, from a safe distance.
Figure 91
Concrete pump and Soft switch shutoff valves NOTE!
1. Be sure that the waterbox covers and guards are in Because you turned out the pressure relief
place any time you will be working in the area cartridge in step 21., the system pressure
around the main control block. should read low at this time. If it does not
and the gauge spikes to 320 bar or more,
16. Wear safety glasses when working around a con- disengage the pump immediately. Turn the
crete pump. relief cartridge out (counterclockwise) more.
For safety, it is important to adjust the pres-
NOTE! sure up from below the specified target pres-
It is vital that each adjustment screw be sure rather than down from a pressure
properly identified prior to making any which exceeds the target. Continue this pro-
adjustment. All screw adjustments for the cedure until the main system pressure gauge
system relief must be made with the pump- reads lower than the specified target.
kit in the neutral position and adjustments 26. To increase the pressure put the pump in the neutral
for pressure cutoff must be made with the position and adjust the relief cartridge by turning it
engine shut off.
in (clockwise). When increasing the pressure, the
17. Start the truck engine, and put the PTO in gear just adjustments should be made in quarter turn incre-
as you would to pump a job. ments. If you make adjustments to increase the
18. If you have not already closed the soft switch shut- pressure but the pressure does not come up, you are
off valve and the concrete pump shutoff valve (Fig- probably reading the pressure cutoff of the pumps,
ure 91) do so at this time. if so proceed to the next step otherwise skip to step
19. At the rear panel, select “local” control with the 29.Turn the relief cartridge adjustment screw back
“local/remote” switch and turn the electric stroke out (counterclockwise) until you can no longer see
limiter knob clockwise to maximum strokes per a pressure drop and tighten the jam nut.
minute. 27. Stop the truck engine, put the key in your pocket.
20. The main system control block pressure must be set 28. Go to the pressure cutoff screw on both hydraulic
first to properly set the pressure cutoff on both pumps (Figure 92) and back off the jam nut with a
pumps. Begin by backing off the jam nut of the 13mm wrench. Turn the adjustment screws in with
main relief cartridge (Figure 93) with a 9/16 inch a 4mm allen wrench one or two more turns, restart
wrench. the engine and check the pressure again. Repeat
21. Using a 5/32 inch allen wrench, turn the adjustment this procedure until the main system relief can be
screw out (counterclockwise) until you can feel no set to the target pressure.
spring tension on the adjustment screw. 29. When the proper main relief pressure is achieved,
22. Now, turn the screw back in (clockwise) two or pressure cutoff can be set. Shut off the engine, put
three full turns to give you a proper starting point the key in your pocket and install 0-600 bar gauges
and tighten the jam nut. with whip hoses to the “M1” gauge ports on the
SERVICE TRAINING
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 Concrete pump
higher than the other, that pump will be more dom- shutoff valve hif
lob
rn
.e
ps
SERVICE TRAINING
When you put the pump in forward now, the main con-
crete 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 ris-
ing. Be sure to open the concrete pump shutoff valve
on the side of the brain (Figure 93) when you are fin-
ished. The unit will not stroke with this valve closed
SERVICE TRAINING
SERVICE TRAINING
CONCRETE CONCRETE
BPL 1200 HDR-23 PRESSURE PRESSURE
(PSI) (BAR)
2000 138
PERFORMANCE CHARACTERISTICS OF
1900 131
PISTON SIDE
THE AXIAL PISTON HYDRAULIC PUMP
ROD SIDE
PUMP SPEED 1800 124
(bar)
(bar)
2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110
Breakpoint 0 13 26 39 52 65 78 92
105 118 131 144 157 170 183 196
=178 bar
@ 300 bar 103 170.5
=238 l/m
CONCRETE OUTPUT (cu yd / h)
26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
15.5
PISTON 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
100 200 300 400 500 (liter / min.)
Nomograph - Sample
Q in yd3/hr.
320 l/m
For vertical placing, 180
Max Q
add 1.105 PSI per foot
of level difference. 160
6" 5" 4.5"
Number:
012
140
4"
120 116
Rodside
100
80
Pistonside 67
60
40
132 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI 1566 870
100
200
2"
300
400
2.5"
500
600
3"
4" 5" 6" 3000 2500 2000 1800 1500 1200 1000 800
Slump of fresh concrete in inches Proportional value of pipeline in feet
800
PRINT
HOME
PRINT
HOME
801
A
agitator
motor
B
Pipe Gate
B
M
0-50
BAR Position 1 =
Spring Return
T 2 1 Position 2 =
Detent
S3
S1 A
CA B
1.5 mm
hole drilled
through spool 5.5 bar
300 *Agitator pressure =
bar with gearcase 70 bar
with direct drive 200 bar
S2 *Waterpump pressure =
with agitator gearcase 200 bar
with direct drive agitator 210 bar
X2 X2
M A A
A1 A1
0.7 To
mm Boom
6 bar Circuit
900
PRINT # 329325 A
B
M
P
P
0-50
BAR 210 bar
T
Position 1 =
Spring Return
A 2 1 Position 2 =
Detent
S3
S1
T1 T CA B
1.5 mm
hole drilled
through spool 5.5 bar
300
bar
S2
X1 X1
X2 X2
A A
A1 A1
D
M
To
Boom
6 bar Circuit
S S
PRINT
HOME
Note:
Pressures are set to the 200 bar
accuracy of the gauge as
received from the P Hydraulic style
manufacturer. remote throttle
actuation
AIR TANK
Change
Y3
A A
A1 A1
D
M
To
Boom
35 PSI P
Rev.061198
Circuit
SAIE 10057
initials
S S
PRINT
HOME
Remote controlled
stroke limiter T
A
Remote Throttle
T Agitator Actuation (hyd. version)
B
P
Change
70
B bar
P
P
A
0-55 bar T
Y(T) BPL 900 HDR 6
bar
Release
STROKE A KVM 28X 200 bar
LIMITER P
KVM 26-4
with Single Gauge Port
Rev.032697
SAIE 10038
0-400 bar
initials
Circuit Switching,
fast switch,
FAST
SWITCH P and 344780 (12v) or
T
Compressor
344781 (24v) E-stop manifold
(Optional)
X
A B AIR TANK
Water
NG 6 pump
5 - 7 bar A T B
0.7 mm
Note:
Pressures are set to the
S3 accuracy of the gauge as
received from the
manufacturer.
1.5 mm
hole drilled
through spool S1 C P
T
210 bar
P
A
300 bar B
S2
T Concrete Pump
For. / Neut. / Rev.
See boom
schematic
D C B A
X1 X1
Port size
250
limits flow Y3 Y3 bar
A A
A1 A1
A7VO-80 LR S S A7VO-80 LR
PRINT
HOME
Change
P
T
0-55 bar 70
Y(T)
B bar
STROKE A A
LIMITER
A 200 bar
Release
P
Gauge Port
0-400 bar
Rev.082797
SAIE 10055
BPL 1200 HDR
initials
KVM 28X / 26-4 / 32 XL Compressor
(Optional)
FAST
with Single Circuit Switching, Water
pump
SWITCH P T 4 or 5 place b & w boom manifold,
DAMPENER X
NG 6
30344780 (12v) or
A B 30344781 (24v) E-stop manifold A T B
P
0.7 mm
0-55
bar
Y(T)
A
0.7 mm
AIR TANK
C P
1.5 mm
hole drilled
through spool S1
See boom
schematic
A D C B A
B
300 bar
S2 250
bar F
T
Concrete Pump
For. / Neut. / Rev. E
X1 X1
Port size
limits flow Y3 Y3
A A
A1 A1
Note: D
Pressures are set to the
M accuracy of the gauge as
received from the
To
manufacturer. Boom
3.5 bar Circuit
5.5 bar
A7VO-107 LR S S A7VO-107 LR
PRINT
HOME
Remote controlled
Nitrogen pressure set at 100 bar stroke limiter
(650 PSI) SAIE 10026 Change
T Rev.112596 Release
initials
P
P 70
0-55 B bar BPL 900-1200 KVM 36X
bar
TWIN CIRCUIT
A with electric over air pilot
Y(T) Note:
Pressures are set to the
300 A accuracy of the gauge as
S3 bar Manual stroke received from the
limiter manufacturer.
Accumulator control device
P
C P
This line must
return to tank Accumulator pump
by itself. unloading valve Concrete Pump
Forward/Neutral/Reverse
T
200
bar AIR TANK
Y P B
NG
10 A 6 bar
250 bar T
0.7 0.7
mm mm
S2
B A
200
bar
S1
320
bar
P T
Port size
0.7 mm limits flow
X1 X1 Remote Throttle
A2F-23 A2F-10 Actuation (hyd. version)
Y3 Y3
A A
120 Hyd. oil cooler
A1 A1
bar w/elec fan
Soft switch M P
35 psi T
ΔP
6
bar
1200 = A7VO-107 LR S See boom schematic S 1200 = A7VO-107 LR
900 = A7VO-80 LR 900 = A7VO-80 LR
PRINT
HOME
,,
Nitrogen pressure set
A Note:
Pressures are set to the
Y(T) accuracy of the gauge as
received from the
300 A manufacturer.
S3 bar Manual stroke
limiter
Accumulator control device
T P
B A 1.0 mm
P
C P
T P This line must
1.0 mm
return to tank Accumulator pump
by itself. unloading valve Concrete Pump
B A
Forward/Neutral/Reverse
A A T
200
bar AIR TANK
Y P B
NG
10 A 6 bar
0.7 0.7
mm mm
S2
B A
200
bar
S1
320
bar
P T
Port size
0.7 mm limits flow
X1 X1 Remote Throttle
A2F-23 A2F-10 See boom
Actuation (hyd. version)
schematic
Y3 Y3
A A
80 Hyd. oil cooler
A1 A1 D C B A
bar w/elec fan
250 bar
Soft switch M P
35 psi T
E
ΔP
6
Emergency stop F bar
1200 = A7VO-107 LR S See boom schematic S 1200 = A7VO-107 LR manifold
900 = A7VO-80 LR 900 = A7VO-80 LR
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HOME
Emergency stop
manifold
T
MP3 MP2
A
T SP Concrete Pump
Forward/Off/Reverse
B
MG2
20
bar
XA XB G2
PBP
A 3.5 3.5 B 3.5-40
bar
X3
PZ
3.5-40 0.7
bar
0.7
T
A2 B2
0-30
A3 B3 bar
1.5
A B X1
A1 B1
Y3
A
XA S2 XB
A1
PR
PP
S1
XR XP
P2 P1
M
10 bar
S
1200 or 2020/2023 = A7VO-107 LR
1.8 900 = A7VO-80 LR
PRINT
HOME
2023-4
Change
T 5-7 bar
A
A1 A B B1 Agitator
B
2nd agitator with B Concrete Pump
XA
1.5
mm
S3
XB
long rock and
sloped side units A
Forward/Off/Reverse 2020-4, 2023-4
T
KVM 34 X
Rev. 120798
Nitrogen pressure set at
SAIE 10115
100 bar (1450 PSI)
6.0 mm
MPS - TWIN CIRCUIT
Psp Mp1
with Rexroth A7VO hydraulic pumps
Note:
initials
2.0 This line must return
mm 300 Mp to tank by itself Pressures are set to the and cartridge type MPS manifold
Accumulator control device bar 200 bar accuracy of the gauge as
T P received from the
manufacturer.
P
G2
MG2
T SP
MP5 T MP2
Remote Throttle Emergency stop P4
0-30
Actuation (hyd. version manifold bar
ZK2 ZK1 0.9 P3
used when engine not X1
electronically controlled) P2
1 2 1.6 MX1
3 3.5-55
ZS2 ZS1 260 bar
bar
MG1
MP1
P
0.9
XA XB
A B
A1 B1
3.0 3.0 X1
mm S2 mm
XA XB
Y3
PR 0.7 A
mm
PP A1
0.7
mm S1
XR XP
P2 P1 See boom
schematic
MP
T2 T1 S 1200 = A7VO-107 LR
1.2 900 = A7VO-80 LR
X1
X1
Y3
1.8 80 X2 A
bar Hyd. oil cooler A1
w/elec fan
A7VO-LRDH
X3 M
Hydraulic pumps are
1.1 used only on -4 machines
35 psi 200 bar
T ΔP
1.8
S 1200 = A7VO-107 LR
900 = A7VO-80 LR
PRINT
HOME
2023-5
Change
Note:
P
A1 A B B1
T
XA S3 XB 200 bar
This line must return
to tank by itself
T
Nitrogen pressure set at
100 bar (1450 PSI) 6.0
Rev. 110499
SAIE 10139
mm Agitator
Psp Mp1 Truck air supply
2.0
mm 300 Mp 2nd agitator with A
initials
Acumulator control device bar long rock and
T sloped side units B 5-7 bar
P
T(A)
P(B)
Emergency stop
manifold 2023-5
T SP
MP5 T MP2 KVM 39X, 34X
P4
0.9
X3
P
A B
A1 B1 T
3.0 3.0
mm S2 mm
XA XB Pressure P
reducing
PR 0.7 valve 55 bar
PP
mm T
0.7
mm S1 A
XR XP
P2 P1 Y T2 R T1 G Z A M Y T2 R T1 G Z A M
A
MP Electric
stroke limiter
see see
T2 T1 note note
1.2
See boom
X1 schematic
1.8
mm
80 X2
bar
35 psi
M
T P Note: A11VO-LRDH
1.8 Hydraulic pumps are 200 bar
mm limited to 350 bar
by pressure cutoff.
PRINT
HOME
2525H
Change
2nd agitator with
long rock and With switching signal
sloped side units
from waterbox end
A1 A B B1
Note:
Pressures are set to the
accuracy of the gauge as
XA S3 XB received from the
This line must return
to tank by itself 200 bar manufacturer.
T
P
Nitrogen pressure set at
100 bar (1450 PSI) 6.0
Rev. 110399
SAIE 10143
Psp mm Mp1
2.0
mm 300 Mp
initials
Acumulator control device bar
T
P
MP5 T MP2
P4
0.9 P3 C P
P2
1 2 1.6
3
Remote Throttle 260
bar
T Actuation (hyd. version
used when engine not MP1
1.1
electronically controlled) Truck air supply
0.9
1.2
T1 T2
MP P
P1 P2 T
0.7 mm XP XR
S1 A 55 bar
PP
PR 0.7 mm Pressure
3.0 mm
reducing valve
XB XA 3.0 mm
S2
B1 A1
B A
T
M A Z G T1 R T2 Y M A Z G T1 R T2 Y
X3 2.0 mm
See boom
schematic
ZS1 ZS2 Hyd. oil cooler
w/elec fan
1.3
mm
M
ZK1 ZK2
1.3 35 psi S M1 S M1
mm ΔP
SP T A11VO-LRDH
Hydraulic pumps are
limited to noted pressure 200 bar
by pressure cutoff.