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SERVICE MANUAL CONCRETE PUMPS
Sections Safety Manual Maintenance, Lubrication & Schedules Rock Valve & Gate Valve Pumpkits Hydraulic Pumps Hydraulic Parts Pressure Settings Hydraulic Pump Adjustments Electrical Radio Remotes Formulas, Conversions & Specifications Special Tools
Fittings Book Copyright All rights reserved. The information and drawings contained herein must not be duplicated, used improperly, or communicated to third parties without the consent of Schwing America Inc. All Information is subject to revision
5900 Centerville Road White Bear, MN 55127 TEL 651-429-0999 FAX 651-429-2112 www.schwing.com
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SCHWING SERVICE DEPARTMENT (651) 429-0999 OR
1-888-292-0262 OR
FAX (651) 429-2112 8:00 A.M. TO 5:00 P.M. (Central Time) (MONDAY THROUGH FRIDAY)
SCHWING PARTS DEPARTMENT 1-800-328-9635 OR
FAX (651) 429-2112 6:00 A.M. - 9:00 P.M. (Central Time) (MONDAY THROUGH FRIDAY)
24 Hour Service Hotline 1-888-292-0262 (MONDAY THROUGH SATURDAY)
Branches Florida............................................................. 1-813-985-8311 Northern California........................................ 1-925-371-8595 Southern California ....................................... 1-562-493-1012 Georgia ........................................................... 1-678-560-9801 Texas .............................................................. 1-972-245-5166
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Table of Contents
Table of Contents
Product Data .........................................................................23 Features .................................................................................23 Uses ......................................................................................23 Maintenance of Hydraulic Cylinders ........................................24 Lubrication Specs for Schwing Placing Booms .......................26 Boom Inspections ........................................................................27
Table of Contents Maintenance Maintenance Chart ...................................................................... 1 Operators Check list for Weekly Maintenance (Ex.) ............... 3 Size Comparison of Particles ...................................................... 4 Filtration Ratings ......................................................................... 5 Nominal Rating ...................................................................... 5 Absolute Rating ..................................................................... 5 Filtration Ratio(bn) ................................................................ 5 Filter Facts ............................................................................. 5 Fluid Contamination and Control .............................................. 6 Primary sources of contamination ......................................... 6 Control Methods .................................................................... 6 Handling, Storing & Dispensing Lubricating fluids ................. 7 Hydraulic Oils .............................................................................. 8 General information ............................................................... 8 Specific information .............................................................. 8 Hydraulic Oils ........................................................................ 9 When to change your hydraulic oil ........................................ 9 Hydraulic Oil Viscosity Chart .................................................. 10 Lubrication Prefix Codes .......................................................... 11 Standard codes used ............................................................. 11 Hydraulic oil codes .............................................................. 11 “Industrial” gear lubricant codes ......................................... 11 Lubrication Recomendations .................................................... 12 Motor Vehicle Gearbox Oil ................................................. 12 Compressor Oil .................................................................... 13 Filling Capacities ........................................................................ 14 Hydraulic Reservoirs ........................................................... 14 Transmissions ...................................................................... 15 Gear Boxes ........................................................................... 16 Spicer Transmisions .................................................................. 17 Lubrication Specs ................................................................ 17 Recommended Lubricants ................................................... 17 Oil Changes .......................................................................... 17 Over-Filling ......................................................................... 17 ZF Transmissions ....................................................................... 18 Lubrication Specs ................................................................ 18 Steyr Gear Boxes ........................................................................ 19 Lubrication Specs ................................................................ 19 Transfer Case Gear Oil Capacities are as Follows: ............. 19 Stiebel Gear Boxes ..................................................................... 20 Lubrication Specs ................................................................ 20 FABCO Gear Boxes ................................................................... 21 Lubrication Specs ................................................................ 21 ZF Torque Converters ............................................................... 22 Lubrication Specs ................................................................ 22 WSK Torque Converters ..................................................... 22 Hydraulic Pump Spline Lubrication ........................................ 23
Rock Valve Safety Instruction .......................................................................29 Rock Valve Parts Identification - “M” Rock ...........................30 Rock Valve Parts Identification - “E” Rock ............................31 Rock Valve Parts Identification - “B” Rock ............................32 Rock Valve Lubrication Points .................................................33 Rotating The Cutting Ring ........................................................34 Replacing the Cutting Ring .......................................................35 Tension Nut/Pressure Spring .....................................................37 Pressure Spring ...........................................................................37 Determining Wear on Kidney Seal and Kidney Plate .............38 Replacing the Kidney Seal .........................................................39 Kidney Seal ...........................................................................39 Spectacle Plate .............................................................................43 Lengthening the Service Life of the Housing Lining-Inlet Side ...................................................................43 Replacement of Spectacle Plate .................................................45 Replacement of Outlet Housing Lining (Kidney Plate) Plate .46 Replacement of Outlet Insert (Cover Lining) ..........................47 Rock Valve Body .........................................................................48 Pivot Shaft ...................................................................................49 Pivot Shaft Bushing ....................................................................51 Setting Pivot Angles ....................................................................54 Replacement of Pivot Shaft Bushings .......................................55
E-Rock Additional Mounting Instructions for E-Rock Assembly .......57 Rock-Extension pre assembly: .....................................57 Mounting of E-Rock-Valve and Cover ........................58 Placing the Counter-Nut at the lever side: ....................59 Rock Slewing Cylinder ...............................................................60 Welding Procedures-SAIE 5312 ................................................61 Rock Valve with Insert - Conversion ........................................62
Small Rock Valve - Repair Safety ............................................................................................63 Parts Identification .....................................................................64 Lubrication Points ......................................................................65 Lengthening the Service Life of the Spectacle Plate and Cutting Ring ................................................................................66 Rebuilding of Rock Valve ..........................................................68
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Table of Contents Determining Wear on the Kidney Seal Housing Lining - Outside ......................................................................... 78 Replacement of Cutting Ring and Kidney Seal ....................... 79 Adjustment of the Slewing Cylinder and Installation of the Slewing Yoke .................................................................... 83 Slewing Yoke Timing .......................................................... 83 Rock Slewing Cylinder .............................................................. 84
Pumpkits Specifications .............................................................................. 85 2023-4 .................................................................................. 85 2023-5 .................................................................................. 85 2023H-6 ............................................................................... 85 2525H-5 ............................................................................... 85 2525H-6 ............................................................................... 85 Change rams ............................................................................... 86 Changing the material cylinders .............................................. 90 Material Cylinder Alignment ................................................... 90 Pumping on piston side .............................................................. 92 Sealing Gland Replacement ...................................................... 93 Shimming the Differential Cylinders ....................................... 94 Determining the proper shimm size ..................................... 94 Dimension A ........................................................................ 94 Dimension B ........................................................................ 94 Formula ................................................................................ 95
Hydraulic Parts Boom Handvalves .....................................................................116 “SP” Series directional valves ............................................124 Adjustable Ofifice ...............................................................125 Flow Limiter .......................................................................125 42 - Rexroth - Hand valve Shuttles ....................................128 Preload block for Rexroth Hand valve ...............................129 Apitech Cut-Away ..............................................................144 Boom Holding Valves ...............................................................145 Load Holding Valve/Brake Valve ......................................149 BRAKE VALVES ..............................................................150 Sauer Brake Valve ......................................................150 Beringer Brake Valve .................................................151 Slewing Brake Valves ...............................................................152 Boom Slewing Brake Valve - Rexroth Spec Sheet ....152 Boom Regulator ........................................................................158 Counter Balance Valve .............................................................159 Control Blocks ...........................................................................160 S3/Accumulator Valve ..............................................................164 Machined Block ..........................................................164 Stroke Limiters .........................................................................168 Outrigger Handvalves ..............................................................180 E-Stop Manifolds ......................................................................192
Pressure Settings General ......................................................................................209 Stroke Limiter Adjustment .................................................209 Check the accumulator Pre-Charge ....................................210
Hydraulic Pumps Hydraulic Pump Drive .............................................................. 97 Placing boom hydraulic pumps ................................................ 97 Concrete pump hydraulic pumps ............................................. 97 Hydraulic Pump Locations ....................................................... 98 Fixed Displacement Pump A2FO ............................................. 99 Rexroth/Hydromatik Model A7V Series 2 ............................ 100 Constant Pressure Control DR ........................................... 101 Constant Horsepower Control LV ..................................... 101 Commencement of control: 50 bar min. ............................ 101 Auxiliary Equipment: Stroke Limiter ................................ 102 Rexroth/Hydromatik Model A7V Series 6 ............................ 103 LR Constant Power Control ............................................... 104 LRH Constant Power Control With Hydraulic Stroke Limiter .................................................................... 104 Variation: Hydraulic Stroke Limiter (H...) ........................ 105 H1/H5 (Negative Control Function): Vg max to Vg min .. 105 DR Constant Pressure Control ........................................... 105 Rexroth/Hydromatik Model A10VO ..................................... 107 Rexroth/Hydromatik Model A11VO ..................................... 109 Linde Hydraulik BPR 105 ....................................................... 112 Constant Power Regulator (LR) ........................................ 113 Power Regulator With Hydraulic Stroke Limiter (LRH) .. 113 Voac Variable Displacement Axial Piston Pump .................. 114
Hydraulic Pump Adjustments Main System Pumps A11VO ...................................................215 Setting the Flow Rate .........................................................215 Horsepower Setting ............................................................216 Setting Stroke Limitation ....................................................216 Q-min Output Flow ............................................................216 Check all hydraulic pressures. ............................................217 Setting pressures on Hi-flo -6 pumpkits .............................217 Pressure setting procedure: .................................................218 Setting the soft switch relief pressure .................................219 BPL 500 .....................................................................................221 BPL 2000 ...................................................................................227 BPL 4000 ...................................................................................231 KVM 17M ..................................................................................243 Setting concrete pump pressure ..........................................244 Setting the soft switch circuit relief pressure ......................246 Setting accumulator E-Stop manifold pressure (original production) ...........................................................246 Setting the accumulator unloading valve (original production) ...........................................................247 Setting accumulator E-Stop manifold pressure (current production) ............................................................247 Setting the accumulator unloading valve (current production) ............................................................248
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Table of Contents Setting the boom E-Stop manifold pressure ...................... 248 Setting the boom/outrigger pressure .................................. 249 Setting the outrigger pressure ............................................ 249 Setting the boom pressures ................................................ 250 Set boom section #1 down pressure ................................... 251 Setting water pump pressure .............................................. 252 Setting the agitator pressure ............................................... 253 KVM 28X .................................................................................. 255 Check hydraulic pressure ................................................... 255 Set the concrete pump main relief valve (single- circuit). . 257 Setting the soft switch circuit relief pressure ..................... 259 Set accumulator circuit hydraulic oil pressure (units with a pressure- compensated pump) 260 Setting the outrigger pressure ............................................ 262 Check or set ∆P .................................................................. 264 Check or set Q-min ............................................................ 265 Set boom pressures (load sensing proportional booms) .... 265 Set the down side relief valve pressure .............................. 267 Set 15 bar pretension .......................................................... 268 Set water pump pressure .................................................... 269 Set the agitator pressure ..................................................... 269 31 EZ ......................................................................................... 271 Check all hydraulic pressures ............................................ 271 Preheat the hydraulic oil .................................................... 271 Check the concrete pump pressure -4 pumpkits ................ 272 To check or set the concrete pump pressure adjustments, follow these steps: ................................. 272 Setting the main relief valve .............................................. 272 Setting the soft switch circuit relief pressure ..................... 274 To check or adjust the soft switch pressure setting, proceed as follows: .................................................... 274 Setting pressures on load-sensing booms .......................... 274 Preheat the oil .................................................................... 274 About proportional boom systems ..................................... 274 Setting DP .......................................................................... 275 Setting Q-min ..................................................................... 277 Setting boom pressures ...................................................... 277 There are several devices on the boom circuit which control boom pressure (Figure 226): ............... 277 Raise the pressure of the lowest circuit ............................. 278 Setting the outrigger pressures ........................................... 278 To set the 280 bar relief valve for the outrigger circuit: ........................................................ 278 Setting 15 bar pretension ................................................... 280 To check or set pretension, follow these steps: ................. 280 Setting the agitator circuit pressure ................................... 281 Setting accumulator circuit pressure .................................. 282 32XL Single Circuit ................................................................. 285 Check hydraulic pressures ................................................. 285 Preheat the hydraulic oil .................................................... 285 Check the concrete pump pressure (900 or 1200) ............. 285 Setting boom pressures ...................................................... 286 Preheat the oil ............................................................ 286 About proportional boom systems ............................. 287 Setting DP .......................................................................... 287 Setting Q-min ..................................................................... 288 Setting boom pressures ...................................................... 289 Setting the 140 bar down side relief valve pressure .......... 290
Setting the outrigger pressures (7 place boom valve systems) .............................292 Setting 15 bar pretension ....................................................294 To set the agitator circuit pressure: .....................................294 32 XL Twin Circuit ...................................................................297 Units up to 450 l/m .....................................................297 Check hydraulic pressures ..................................................297 Preheat the hydraulic oil .............................................297 Check the concrete pump pressure (900-1200 - MPS pumpkits) ...............................................297 Setting the soft switch circuit relief pressure ......................299 Setting the boom pressures .................................................299 Load-sensing boom pressures .............................................301 Preheat the oil .............................................................301 About proportional boom systems ..............................301 Setting DP ...........................................................................302 Setting Q-min .....................................................................304 Setting boom pressures ...............................................304 Setting the 140 bar down side relief valve pressure ...........306 Setting the outrigger pressures (7 place boom valve system) ..............................306 Setting the water pump hyd. pressure .................................308 To set the agitator circuit pressure: .....................................308 32 XL Hi-Flow B&W ................................................................311 Units up to 450 l/m .............................................................311 Check hydraulic pressures ..................................................311 Preheat the hydraulic oil .............................................311 Location of pressure setting/checking devices ...........312 Check the concrete pump pressure (2020, 2023, 2525 pumpkits) ..............................................313 Setting the main relief valve ...............................................314 Setting the soft switch circuit relief pressure ......................315 Setting the boom pressures .................................................315 Setting the 140 bar down side relief valve pressure ...........318 Setting the outrigger pressures (7 place boom valve systems) .............................................319 To set the agitator circuit pressure: .....................................321 32 XL High Flow Proportional ................................................323 Units up to 450 l/m .............................................................323 Check hydraulic pressures ..................................................323 Check the concrete pump pressure (2020, 2023, 2525 pumpkits) ..............................................323 Setting the main relief valve ...............................................324 Setting the soft switch circuit relief pressure ......................326 Load-sensing boom pressures .............................................326 Preheat the oil .............................................................327 About proportional boom systems ..............................327 Setting DP ...........................................................................327 Setting Q-min .....................................................................329 Setting boom pressures .......................................................329 Setting the 140 bar down side relief valve pressure ...........331 Setting the outrigger pressures ...........................................331 Setting the water pump hyd. pressure .................................333 Setting 15 bar pretension ....................................................333 To set the agitator circuit pressure: .....................................334 32 XL Hi-Flow Prop, A11VO ..................................................337 Units above 450 l/m (-5 and -6 units) .................................337 Check hydraulic pressures ..................................................337
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Table of Contents Preheat the hydraulic oil .................................................... 337 Check the concrete pump pressure (2020, 2023, 2525 pumpkits) ............................................. 337 Setting the main relief valve .............................................. 339 Setting the soft switch circuit relief pressure ..................... 340 Setting boom pressures ...................................................... 340 Preheat the oil ............................................................ 341 About proportional boom systems ............................. 341 Setting DP .......................................................................... 341 Setting Q-min ..................................................................... 343 Setting boom pressures ...................................................... 343 Setting the 140 bar down side relief valve pressure .......... 345 Setting the outrigger pressures (7 place boom valve systems) ............................................ 346 Setting 15 bar pretension ........................................... 348 To set the agitator circuit pressure: .................................... 348 KVM 34X .................................................................................. 351 Check hydraulic pressures ................................................. 351 Preheat the hydraulic oil .................................................... 351 Check the concrete pump pressure (2020, 2023, 2525 pumpkits) ............................................. 351 Setting the main relief valve .............................................. 352 Setting the soft switch circuit relief pressure ..................... 354 Load-sensing boom pressures ............................................ 355 Preheat the oil .................................................................... 355 About proportional boom systems ............................. 355 Setting DP .......................................................................... 355 Setting Q-min ..................................................................... 357 Setting boom pressures ...................................................... 357 Setting the 140 bar down side relief valve pressure .......... 358 Setting the outrigger pressures ........................................... 358 Setting the water pump hydraulic pressure ........................ 360 Setting 15 bar pretension ................................................... 361 Setting the agitator circuit pressure ................................... 361 Setting accumulator circuit pressure .................................. 363 KVM 36X-42M (pre-1998) ...................................................... 365 Pressure Settings for KVM 36X Proportional Load Sensing ...................................................................... 365 Component Location Guide KVM 36 X W/Rexroth Handvalves ...................................................... 366 Pressure Settings for KVM 36X Proportional Load Sensing ...................................................................... 367 Pressure Regulator Cutaway .............................................. 368 Pressure Settings for Regulator and Releif Valves ............ 369 KVM 36 LW & 36 X W/Rexroth Boom Handvalve ......... 370 Pressure Settings for KVM 42 (B&W Load sensing and Proportional Load Sensing ........ 371 Component Location Guide KVM 42 W/Rexroth Handvalves ...................................................... 372 Pressure Settings for KVM 42LW Proportional Load Sensing ................................................. 373 Pressure Regulator Cutaway .............................................. 374 Pressure Settings for Regulator and Relief Valves KVM 42 ............................................................................. 375 KVM 42 LW, W/Rexroth BoomHandvalve ...................... 376 KKVM 36X ............................................................................... 377 Check hydraulic pressure ................................................... 377 Set the soft switch circuit relief pressure ........................... 381
Set accumulator circuit hydraulic oil pressure (units with a pressure- compensated pump) .......................382 Setting the outrigger pressure .............................................383 Check or set ∆P ...................................................................386 Set boom pressures (load sensing proportional booms) .....387 Set water pump pressure .....................................................389 Set the agitator pressure ......................................................389 KVM 39X ...................................................................................391 Check hydraulic pressures ..................................................391 Set the soft switch circuit relief pressure ............................394 Set accumulator circuit hydraulic oil pressure (units with a pressure- compensated pump) .......................395 Set the outrigger pressure ...................................................396 Check or set ∆P ...................................................................399 Check or set Q-min .............................................................399 Set boom pressures (load sensing proportional booms) .....400 Set 15 bar pretension ..........................................................402 Set water pump pressure .....................................................402 Set the agitator pressure ......................................................402 KVM 42SX ................................................................................405 Setting Pressures .......................................................................405 Check all hydraulic pressures .............................................405 Preheat the hydraulic oil .............................................405 Setting pressures on Hi-flo -6 pumpkits .............................406 Setting the soft switch relief pressure .................................408 Setting boom circuit pressures ............................................408 Load-sensing boom hydraulic controls ...............................408 Setting delta P pressure .......................................................409 Setting Q-min .....................................................................411 Setting boom pressures .......................................................411 Setting outrigger pressure ...................................................412 Setting the agitator pressure ...............................................413 Setting accumulator circuit pressure ...................................414 KVM 42M - Proportional (Apitech) Single Circuit ...............417 Check hydraulic pressures ..................................................417 Preheat the hydraulic oil .....................................................417 Setting concrete pump pressure (single-circuit units) ........417 Setting boom circuit pressures ............................................420 Load-sensing boom hydraulic controls ...............................420 Setting DP ...........................................................................420 Setting Q-min .....................................................................422 Setting boom pressure ........................................................422 Setting pretension ...............................................................425 KVM 42M - Proportional (Apitech) Twin Circuit ................427 Check hydraulic pressures ..................................................427 Preheat the hydraulic oil .....................................................427 Setting concrete pump pressure (High-flow pumpkits) ......427 Setting the soft switch circuit relief pressure ......................429 reheat the oil to check pressures .........................................430 Load-sensing boom hydraulic controls ...............................430 Setting DP ...........................................................................431 Setting Q-min .....................................................................433 Setting boom pressure ........................................................433 Setting 15 bar pretension ....................................................435 KVM 42M - Proportional (Rexroth) .......................................437 Check hydraulic pressures ..................................................437 Preheat the hydraulic oil .....................................................437 Setting concrete pump pressure (single-circuit units) ........437
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Table of Contents Setting boom circuit pressures ........................................... 440 Load-sensing boom hydraulic controls .............................. 440 Setting DP .......................................................................... 441 Setting Q-min ..................................................................... 443 Setting boom pressure ........................................................ 444 Set the #1 down side pressure ............................................ 445 Setting outrigger pressure .................................................. 446 Set accumulator circuit hydraulic oil pressure (units with accumulator unloading valves) ........................ 449 KVM 45/47SX .......................................................................... 453 Setting Pressures ...................................................................... 453 Check all hydraulic pressures. ........................................... 453 Setting pressures on Hi-flo -6 pumpkits ............................ 453 Setting the soft switch relief pressure ................................ 456 Setting boom circuit pressures ........................................... 456 Load-sensing boom hydraulic controls .............................. 456 Setting delta P pressure ...................................................... 457 Setting Q-min ..................................................................... 459 Setting boom pressures ...................................................... 459 Setting outrigger pressure .................................................. 460 Set the agitator pressure ..................................................... 461 Set accumulator circuit pressure ........................................ 462 KVM 45SX Hi-Flow - 6 ........................................................... 465 Setting Pressures ...................................................................... 465 Check all hydraulic pressures. ........................................... 465 Setting the main relief pressure and pressure cutoff on Hi-flo -6 pumpkits .............................................. 466 Setting the soft switch relief pressure ................................ 468 Setting boom circuit pressures ........................................... 468 Load-sensing boom hydraulic controls .............................. 468 KVM 52M (pre-1998) .............................................................. 469 Pressure Settings for KVM 52 Proportional Load Sensing ............................................................................... 469 Component Location Guide- KVM 52 .............................. 470 Pressure Settings for KVM 52 Proportional Load Sensing ............................................................................... 470 Pressure Regulator Cutaway KVM 52 ............................... 472 Pressure Settings for Regulator and Releif Valves KVM 52 ............................................................................. 473 Setting Pretension Pressure(Refer to Figure 5) .................. 473 Control Block 1 for KVM 52 Boom 3, Boom 4, & Slewing .............................................................................. 474 Control Block 2 for KVM 52 Boom 1, Boom 2, & Outriggers .......................................................................... 474 Pre-Control Block 1-A for KVM 52 ................................. 476 Pre-Control block 1-B for KVM 52 .................................. 477 Pre-Control Block 1-C for KVM 52 ................................. 478 Pre-Control Block 2-A for KVM 52 ................................. 479 Pre-Control Block 2-B for KVM 52 ................................. 480 Electric Bypass Valve for KVM 52 ................................... 481 KVM 52M ................................................................................. 483 Setting relief pressure and pressure cutoff on Hi-flo -6 pumpkits ............................................................. 483 Setting the soft switch circuit relief pressure ..................... 486 Set boom circuit pressures ................................................. 486 Checking and Setting DP pressure ..................................... 487 Set Q-min ........................................................................... 488 Checking boom pressures .................................................. 489
Setting main boom circuit pressures ...................................490 Checking pretension pressure .............................................491 Set the outrigger pressure ...................................................492 Set the agitator pressure ......................................................493 KVM 55M ..................................................................................495 Check all hydraulic pressures .............................................495 Preheat the hydraulic oil .....................................................495 Setting relief pressure and pressure cutoff on Hi-flo -6 pumpkits ..............................................................496 Setting the soft switch circuit relief pressure ......................498 Setting boom circuit pressures ............................................499 Checking and setting DP pressure ......................................499 Setting Q-min .....................................................................501 Checking boom pressures ...................................................501 Setting main boom circuit pressures ...................................502 Checking pretension pressure .............................................503 Setting the outrigger pressure .............................................504 Set the agitator pressure ......................................................505 Set accumulator circuit pressure .........................................506 S 58/61SX ...................................................................................509 Check all hydraulic pressures .............................................509 Preheat the hydraulic oil .............................................509 Setting pressures on Hi-flo -6 pumpkits .............................509 Pressure setting procedure: .........................................509 Setting the soft switch relief pressure .................................512 Setting boom circuit pressures ............................................512 Load-sensing boom hydraulic controls ...............................512 Setting Delta P pressure ......................................................513 Setting Q-min .....................................................................514 Setting boom pressures .......................................................515 Setting main pressure ..................................................515 Setting boom pressure (redundant) relief ...................515 Setting pressure cut-off ...............................................516 Setting slewing pressure .............................................516 Setting outrigger pressure ..................................................517 Setting the agitator pressure ...............................................517 Setting accumulator circuit pressure ...................................518
Electrical Information Boom Control Systems and the Advantages of Each ............521 Boom Control Systems .............................................................523 Introduction to Proportional Controls ...................................524 The Joystick with Potentiometer ........................................524 The Proportional Amplifier ................................................525 The Solenoid Valves ...........................................................525 The Proportional Amplifier in Use with the Radio ...............526 Motherboard for Proportional Units ......................................527 Power Supply - Slot 9 ...............................................................528 Proportional Amplifier - Slot 1,2,3 ..........................................529 Calibration of Proportional Amplifier Cards ........................530 Linear Signal Diagram .............................................................531 Decal of Proportional Motherboard .......................................532 Wiring Diagram - DUVAC II 12V / 24V Transformer .........533 Wiring Diagram - DUVAC II 12V / 24V Transformer .........534 Digital Proportional - Overview (1 of 5) .................................535
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Table of Contents Overview ............................................................................ 535 M.A.T. ................................................................................ 536 Processor Unit .................................................................... 537 Card Functions ................................................................... 538 Control System Arrangement ............................................ 539 Digital Proportional - Programming ...................................... 540 Programming ..................................................................... 540 MAT Operation .................................................................. 540 Menu Structure .................................................................. 541 Moving Through The Menu Survey .................................. 542 Access The Service Menu .................................................. 543 Identifying the Entries and Parameters .............................. 544 “SCV” Card Main Menus .................................................. 544 “?PAR” Main Menu ........................................................... 544 Submenus Functions and Parameters ................................ 545 “?SELECT ” Submenu Functions and Parameters (In Service Menu Only!) .................................................... 546 “?V24” Submenu Functions and Parameters ..................... 547 “?DIN” Main Menu ........................................................... 547 “?RACK” Submenu Functions and Parameters ................ 548 “?BDI A” Submenu Functions and Parameters ................ 549 “?BDI F” Submenu Functions and Parameters ................. 550 “?SOUT" Main Menu ........................................................ 551 “?POUT” Main Menu ........................................................ 552 “?DIAG” Main Menu ........................................................ 553 “?SYSTEM” Main Menu .................................................. 553 “?GERAET” Main Menu (In Service Menu Only!) .......... 554 V2.4 Menus ........................................................................ 554 Software Versions .............................................................. 555 Digital Proportional - Balancing Valve Currents ................. 577 Hysteresis ........................................................................... 579 Diagnostic Signal ............................................................... 579 Setting Valve Currents ....................................................... 579 Digital Proportional - Troubleshooting ................................. 581 Troubleshooting procedure 1 ............................................. 583 Troubleshooting procedure 2 ............................................. 583 Troubleshooting procedure 3 ............................................. 583 Troubleshooting procedure 4 ............................................. 583 Troubleshooting The Radio ............................................... 584 Operation ........................................................................... 585 Emergency Stop ................................................................. 586 Automatic Shut down ........................................................ 586 Trouble-shooting ................................................................ 587 Troubleshooting tables ....................................................... 588
Comfort Control Manual 1.0 Working with the info & diagnosis system ................. 592 1.1 Introduction into the info & diagnosis system ..... 592 1.2 Menu structure info & diagnosis system / Operation data display ..................................................... 594 1.2.1 Standard display & malfunction messages ....... 594 1.2.2 Main menu ........................................................ 595 1.2.3 "PUMP VPUME" sub-menu ............................. 596 1.2.4 "OPERATION DATA" sub-menu .................... 596 1.2.5 "MALFUNCTION LIST" sub-menu ................ 597 1.2.6 "LUBRICATION-UNIT" sub-menu ................ 597 1.2.7 "I/O DISPLAY" sub-menu ............................... 597
1.2.8 SCROLLING" sub-menu ..................................598 2.0 Concrete pump efficiency parameter setting / Central lubrication / Prop characteristics ..........................599 2.1 Password entry and parameter selection menu .....599 2.2 Setting the concrete pump efficiency for pumped volume determination ...................................600 2.3 Adjusting the central lubrication ..................................601 2.4 Adjusting the proportional parameters for boom functions .............................................................................602 Proportional characteristics adjustment for the BOOM SLEW function with PROP valve types : ..............603 Proportional characteristics adjustment for the BOOM 1 function with PULSAR valve types : .................604 3.0 I/O status display - signals & references ......................605 3.1 Machine control ....................................................605 3.2 Concrete pump control .........................................607 3.3 Boom control ........................................................608 3.4 Rear panel .............................................................610 3.5 Extension module .................................................611 4.0 Fault messages and fault causes ...................................612 4.1Introduction ...........................................................612 4.2 Control diagnosis electronic modules.......................... (fault code S !) ............................................................613 4.3 Remote-control system diagnosis (fault code F!) .614 4.5 Engine/PTO Diagnosis (fault code D!) ................617 4.6 Concrete pump diagnosis (fault code B!) .............618 4.7 Boom control diagnosis (fault code M!) ...............619 4.8 Central lubrication/extension diagnosis (fault code Z/E!) .........................................................621 5.0 Output signal interdependence list ...............................622 Part 1 Operation .......................................................................638 Commissioning ...................................................................638 Selecting local control ........................................................639 Selecting remote control .....................................................640 Ram change mode: .............................................................641 Emergency stop buttons ......................................................642 Override of the E-stop manifold .........................................642 Bypass mode ...............................................................642 Options box .........................................................................643 Night light switch .......................................................643 Concrete shut-off valve switch ...................................643 Control and monitoring components ..................................644 Controller cabinet (Figure 13) ....................................644 Display window (Figure 14) .......................................644 Control status indications ...........................................644 Operating mode display ..............................................644 Menu control .......................................................................645 Basic functions of the keys (Figure 15) ......................645 Fast selection/abbreviated function keys (shortcuts): .645 Local control .......................................................................646 Remote control ...................................................................647 Menu overview - Main menu .............................................648 Menu overview - Main menu (continued) ..........................649 Menu overview - submenus ................................................652 Menu operation - Example: ................................................653 Diagnostic system/”Fault handling” ...................................654 Display language ........................................................655 Acknowledging messages ...........................................656
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Table of Contents Acknowledging faults ........................................................ 656 Fault definition ................................................................... 656 Low level fault ........................................................... 656 High level faults ......................................................... 656 Silent diagnostic ......................................................... 657 Reporting and acknowledging of faults ..................... 658 Acknowledging of several faults ............................... 663 Switching off the control system ............................... 663 Summary of messages ....................................................... 664 Heat the oil first ................................................................. 676 Restore original factory settings ................................ 676 Setting parameters ...................................................... 677
Radio Remotes Cross Reference Wiring Chart ............................................... 683
Radio Control FW 18 Table of Contents ..................................................................... 685 1. Safety and Accident Prevention Regulations .................... 685 Safety Regulations - Concrete Pumps with placing booms .................................................................... 686 Traveling ............................................................................ 686 Jacking ............................................................................... 686 Concrete Pump ................................................................... 686 Placing Boom ..................................................................... 686 Pipelines ............................................................................. 687 Remote Controls ................................................................ 687 Electrical Connections on the site-Hydraulic Power Packs, etc. ............................................................... 687 2. Short Instructions ................................................................ 688 Preparing the Commissioning ............................................ 688 Making Ready for Operation ............................................. 688 Operating Mode ................................................................. 688 Reasons for Automatic Switch-off .................................... 688 3. Preface ................................................................................... 688 4. Extract from the Terms of Warranty ................................ 689 5. Model Plates ......................................................................... 690 6. Technical Data ...................................................................... 690 7. Brief Description .................................................................. 690 Transmitter ......................................................................... 690 Receiver ............................................................................. 691 8. Control and Monitoring Equipment .................................. 692 Radio Remote .................................................................... 692 Receiver ............................................................................. 693 9. Commissioning ..................................................................... 694 Preparations ....................................................................... 694 Ready for operation ........................................................... 694 10. Operating the Radio Remote Control .............................. 695 Transmitter mode ............................................................... 695 Transmitter range ............................................................... 696 Putting out of Operation .................................................... 697 Changeover to Cable Remote Control ............................... 697 12. Safety Facilities .................................................................. 698 Fuses .................................................................................. 698
13. Maintenance Works and Checks .......................................699 Changing the transmitter battery ........................................699 Charging the transmitter battery .........................................699
Radio Control FW 20 Table of Contents ......................................................................701 2. Short Operating Instructions ..............................................702 Preparations ........................................................................702 Ready-for-Operation State ..................................................702 Emergency Shut-Off ...........................................................702 Automatic Shut-Off ............................................................702 Interruptions of Work .........................................................702 3. Foreward ...............................................................................703 4. Designated Use ......................................................................703 Non Designated Use ..................................................................703 Extract from Terms of Warranty ...........................................704 5. Safety Rules and Accident Prevention Regulations ...........705 7. Short Description ..................................................................706 8. Technical Data: .....................................................................707 Transmitter ..........................................................................707 Receiver ..............................................................................708 9. Monitoring-, Warning-, and Control Elements .................709 10. Pre-Operational Instructions .............................................712 11. Operation .............................................................................716 Battery Capacity .................................................................716 Disturbances .......................................................................717 Frequency Change ..............................................................717 12. Emergency Shut-Off ...........................................................717 13. Interruptions of Work/End of Operation .........................718 14. Replacing the Battery .........................................................719 Recharging of Battery .........................................................719 15. Malfunctions ........................................................................720 Message Interference ..........................................................721 Trouble Shooting ......................................................................722 Troubleshooting: Receiver LEDs .......................................722 Troubleshooting Controller (MC1) ....................................724 Troubleshooting Table: Transmitter LED’s ......................724 16. Maintenance ........................................................................726 Replacing of Fuses ..............................................................726 17. Repair ..................................................................................727
Radio Control FW 24 Safety Instructions ....................................................................730 Scope of Application .................................................................731 Start-Up .....................................................................................732 Operation ...................................................................................735 Charging the Battery ................................................................736 Maintenance ..............................................................................737 Operation Fault Indicators ......................................................738
C32/CPC Radio Remote
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Table of Contents Spread Spectrum Technology ................................................. 741 Mounting the Receiver Antenna: ........................................... 742 Transmitter Operation ............................................................ 743 Remote Radio Controller ........................................................ 746
Omnex Radio Control System 1. Introduction .......................................................................... 751 2. Physical Mounting ............................................................... 752 3. Considerations for Electrowelding ..................................... 752 4. Receiver Connector Assignments ....................................... 753 5. Cable Unit Connector Assignments ................................... 754 6. Fuses ...................................................................................... 754 7. Operations ............................................................................ 755 7.1 Receiver ....................................................................... 755 7.1.1 Receiver Lights - General Function .................. 755 7.1.2 Receiver Lights - Error Conditions ................... 755 7.1.3 Operator Adjustments: ...................................... 756 7.2 Transmitter ................................................................... 757 7.2.1 Transmitter Lights ............................................. 757 7.2.2 Operator Controls: ............................................ 758 7.3 Cable Unit .................................................................... 758 7.3.1 Cable Unit Lights .............................................. 758 7.3.2 Operator Controls: ............................................ 759 8. Troubleshooting Information ............................................. 759 8.1 I24-MC Board .............................................................. 759 8.2 Receiver TPCB-1527-01 Board ................................... 759
Piston Installation Tools for Differential Cylinders ..............804 Gland Packing Installation Tools for Differential Cylinders 805 Seal Replacement Tools ............................................................806 Piston Seal Guide Tool .......................................................806 Piston Seal Form Tool ........................................................806 Bushing Installation Tool .........................................................806 Rock Shaft Bushing Installation Tool ................................806 Accumulator Charging Kit ......................................................807 Adjustment Meters for Analog Proportional Cards .............807 Analog Adjustment Meter ..................................................807 Technition Support Kit ............................................................807 Electrical Tools and Accessories ..............................................808 Spanner Socket Tools for Boom Pins ......................................809 Truck Engine Tools ..................................................................810 Pro-Link 9000 .....................................................................810 Micellaneous Tools ...................................................................810 Whip Hose and Fittings ......................................................810 Rock Valve Cover Alignment ............................................810
Conversion Charts Fluid Power Formulas ............................................................. 766 Torque Specifications .............................................................. 768 Torque Specification: Slewing Roller Bearing Bolts ............ 772 WP Number Codes .................................................................. 776 BP Model Number Codes ........................................................ 777 Outrigger Spreads and Loads ................................................. 778 Boom Pin Clearances ............................................................... 779 Nozzle Chart ............................................................................. 788 Boom Times/Without Weights ................................................ 789 Boom Pressures & Nozzle Chart Size .................................... 791 Boom Pressures & Nozzle Chart Size .................................... 792 Rotek Bearing Clearance Instructions - SAIE - 5114 ........... 793
Special Tools Hydraulic Trouble Shooting Kits ........................................... 801 Schroeder Filter Cart .............................................................. 801 Features: ..................................................................... 801 Flow Meters and Accesories .................................................... 802 Flow Meter Y223 Model HT200 ............................... 802 Specifications: ............................................................ 802 Accessories: ............................................................... 802 Material Cylinder Alignment Tool ......................................... 803
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Maintenance Maintenance Chart
As Indicated
Annually
Semi-annually
Quarterly
Monthly
Task
Weekly
Daily
Table 1. Scheduled Maintenance
Change main hydraulic oil filter
√
Change high pressure oil filter
√
Change water system inline filter
√
Check truck fluid levels
√
Bleed moisture from air tank
√
Check tires
√
Check hydraulic oil
√
Bleed moisture from hydraulic tank
√
Check differential cylinder rod packings
√
Inspect bolts on Rock Valve and rams
√
Grease Rock Valve and agitator bearings
√
Grease Rollix bearing and hollow pin
√
Check optional auto greaser reservoir
√ √
Fill optional auto greaser reservoir Inspect for damage and leaks
√
Check if maintenance is due
√
Grease boom zerks
√
Check pipe wall thickness
√
Check oil in optional air compressor
√
Check Rock Valve tension nut
√
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Inspect cutting ring/rotate if needed
√
Lubricate mechanical moving parts
√
Check tapered bend wedge bolt
√
Check boom slewing gearcase oil level
√
Clean slewing gearcase breather cap
√
Check function of mech. boom brake
√
Clean and repack the Rollix gear
√
Inspect the turret bolts for tightness
√
Check fluid in distribution gearcase
√
Check unit mounting hardware
√
Check hydraulic pressures
√
Clean hydraulic oil cooler fins
√
Check drive pinion mounting screw
√
Change oil in optional compressor
√
a
√
Change oil in boom slewing gearcase
√
Test dirty filter lamp circuit
√
Change hydraulic oil for age reasons
√
Clean optional compressor
√
Change corrosion inhibitors
√ √
Periodic - structural inspection a. break-in
As Indicated
√
a
Change oil in distribution gearcase
2
Annually
√
Change hydraulic oil for temp. reasons Check the accumulator pre-charge
Semi-annually
Quarterly
Monthly
Task
Weekly
Daily
Table 1. Scheduled Maintenance (Continued)
period
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Operators Check list for Weekly Maintenance (Ex.) Operator’s Check List for Unit # 1 = Once per Week 2 = Twice per Week E = Everyday
MON
Week Ending
TUE
WED
THU
FRI
SAT
SUN
( E ) Truck Engine Oil ( E ) Hydraulic Oil Level - TANKS ( E ) Water Box Level & TANKS ( E ) Flush Grease Lines ( E ) Hoses & Pipes ( E ) Clamps & Rubbers ( E ) All Tools & SAFETY Gear ( E ) Grease Agitator Bearings ( 2 ) Agitator Gearbox Oil Level-90W ( 2 ) Transfer Case Oil Level ( 2 ) Transmission Oil Level ( 2 ) Hyd. Pump Gear Oil Level ( 1 ) Bleed Air from A3V Hyd. Pump ( 1 ) Bleed Water from Air/Oil Tanks ( 1 ) Check Pipeline Structural Pts. ( 1 ) Check Oil Filter Light
Daily Yards Pumped (1 st Job) Daily Yards Pumped (2 nd Job)
S0021.eps
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Size Comparison of Particles SCREEN SIZES U.S. SIEVE NUMBER
OPENING (micro-meters)
OPENING (inches)
50
297
0.0117
60
238
0.009
70
210
0.0083
100
149
0.0059
140
105
0.0041
200
74
0.0029
270
53
0.0021
325
44
0.0017
PAPER
10
0.00039
PAPER
5
0.00019
SIZES OF FAMILIAR OBJECTS SUBSTANCE
MICRO-METERS
INCHES
Grain of Table Salt
100
0.004
Human Hair
70
0.0027
Lower Limit of Visibility
40
0.00158
White Blood Cell
25
0.001
Talcum Powder
10
0.0004
Red Blood Cell
8
0.0003
Bacteria (average)
2
0.00008 149 mm (100 Mesh)
SIZES IN MICRO-METERS (Magnification 500x)
74 mm (200 Mesh)
44 mm (325 Mesh)
25 mm
2 mm
5 mm
10 mm S0022.eps
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Filtration Ratings
Filter Facts
Nominal Rating An arbitrary micrometer value indicated by the filter manufacturer. Due to lack of reproducibility, this rating is deprecated.
Absolute Rating The diameter of the largest hard spherical particle that will pass through a filter under specified test conditions. This is an indication of the largest opening in the filter element.
• • • • • • •
Fine Filters have ∆P Fine filters have long life Harmful particles cannot be seen 1 micron nominal filters pass 10 micron particles Fine filters remove silt, not additives Metal mesh breathers allow airborne ingression New oil can be very dirty
BETA RATINGS Particles in this range (and smaller) should pass through the filter.
Filtration Ratio(βn) The ratio of the number of particles greater than a given size (n) in the influent fluid to the number of particles greater than the same size (n) in the effluent fluid.
Particles in this range (and larger) should be removed by the filter.
HOW BETA WORKS IN
β=
OUT
β X = 200
{
{
example: β12 = 200. This means that for every 200 particles of 12 microns or larger that hit the media, 1 will make it through.
IN OUT
PARTICLES > 5 m
UPSTREAM
FILTER
IN
OUT
β5
FILTER A
10,000
5000
2
FILTER B
10,000
100
100
FILTER C
10,000
1
10,000 S0023.eps
DOWNSTREAM FLOW
β X = 75
example: β12 = 75. This means that for every 75 particles of 12 microns or larger that hit the media, 1 will make it through. (225 particles shown entering, 3 coming out)
Figure 2 Figure 2: The filtration ratio or Beta is calculated by dividing the number of particles entering the filter by the number of particles exiting the filter. β5 represents the filtration ratio at 5 micrometers or the ratio of upstream to the downstream particles larger than 5 micrometers.
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DOWNSTREAM
FLOW
S0024.eps
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Fluid Contamination and Control
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Control Methods •
The sources of contamination in hydraulic and lubricating systems are divided into three general categories. The degree of importance of each source depends on: system design, operating environment, and maintenance practices
•
Primary sources of contamination •
Bulit-In Contamination (dirt, shavings, slag, and etc. that may be present during assembly).
•
Ingressed Contamination (is an environmental type which happens during routine servicing or from lack of maintenance).
•
Internally Generated Contamination (occurs from the rubbing and grinding of all moving parts inside each and every component of the system).
•
Built in a. Clean all components before installation b. Use only straight thread fittings or flange fittings c. Flush new systems with high efficiency filters Ingressed a. Use reservoir breather filters that are as fine as the system filters b. Use high quality seals in all system components c. Always keep maintenance environment clean d. Pre-filter the new oil prior to dispensing to tank Internally Generated a. Always use fine "silt control" filters b. Use specified lubricants for components c. Eliminate water from the system to reduce rust d.
S0025.eps
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Handling, Storing & Dispensing Lubricating fluids To obtain optimum performance from oil, proper handling, storing and dispensing is required. These steps are necessary to preserve the integrity of the product. It is uneconomic to buy a high quality lubricant and then permit degradation through contamination. Unless simple precautions are observed, contamination of lubricants can occur during storage; or during transfer of oil from the original container to the dispensing equipment; or during dispensing of oils to the equipment to be lubricated. Pumps, oil cans, measures, funnels and other dispensing equipment must be kept clean at all times and covered when not in use. Storing oil drums, fill carts, or other containers outside of climate controlled areas is a poor practice. Water and moisture may get into the drum around the bungs and contaminate or destroy the drum’s contents. A drum standing on end with the bungs facing up can collect rain water or condensation inside the chime. This water can gradually be drawn in around the bungs by the breathing of the drum as the ambient temperature rises and falls. This can occur even with bungs drawn tight and the tamper-proof seals in place. In addition, the dirt and rust that can accumulate inside the chime and around the bungs may contaminate the drum’s contents when the drum is opened for use. As a general rule, lubricants in drums smaller than 16 gallon capacity should never be stored outside. However if drums must be stored outside, a temporary shelter or lean-to, and/or a waterproof tarpaulin is highly recommended for protecting the drum from rain
chime
air space
standing water
RAIN
and snow. The proper storing position of an oil drum is: drum should be laid on it’s side with the bungs approximately horizontal and at the lowest point. In this position, water and moisture cannot collect in the chime and because the bungs are below the level of the drum’s contents, the incidence of water being drawn into the drum from normal breathing is greatly reduced. For maximum protection, drums should be stood on end with bungs down on a well-drained surface. In circumstances when all the aforementioned storing methods are impractical, drum covers should be used. Covers are available in both metal and plastic. Drums with a bung on the side should be stored either on their end, or on their side with the bung facing down. Regardless of the position, drums should always be placed on blocks or racks several inches from the ground to avoid contact with moisture or standing water. When drums must be stored outside with the bung end upward, they should be blocked up in a manner that will keep the drum teetered to provide sufficient draining of water. The drum should be rotated on the blocks so that any water collecting on the top of the drum surface does not come in contact with or submerge the bung openings. Before opening a drum that has been stored outside, the bung and chime areas should be cleaned thoroughly to eliminate the hazard of collected rust, scale and dirt from falling into the drum. Always use the oldest oil first. The probability of oxidation, contamination and attack by heat and cold, increase with age. If the oil quality is suspect due to long periods of storage, have the oil analyzed before using it.
SUN
bungs
air space reduced
COOL
Clean oil in sealed drum as delivered and then stored outside standing on end
WARM
Oil and air in drum expand from heat exposure forcing air out through top
powerful suction created
water
COOLING
Contaminating water is drawn into drum through the bungs when oil and air cools and contracts
S0026.eps
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Hydraulic Oils General information relates to all hydraulic oils. Specific information contains hydraulic oil recommendations for Schwing concrete pumps.
General information Hydraulic oils are rated for viscosity, heat dissipation, foaming characteristics, pour point, antiwear additives, anticorrosive additives, lubricating qualities, compressibility, temperature range, temperature stability, and other functions. Although many different brands of oil meet these specifications, they may use different chemical additive packages to achieve the end result. For this reason, you should not mix two different brands of oil. The additive package from one brand may be incompatible with the additive package from the other, rendering both packages useless. Recently a few manufacturers have introduced biodegradable hydraulic oils onto the market. These oils are based on vegetable extracts instead of mineral extracts. They are considered safer for the environment in the event of a spill, although the additive packages are not inert. One brand, Mobil EAL 224-H, has been accepted for use in Schwing pumps, and other brands are under consideration and testing. These oils must not be mixed with mineral-based hydraulic oils, even in very small amounts. If you will be pumping a job in an environmentally sensitive location and want to use this type of hydraulic oil, please contact the Schwing Service Department at (651) 429-0999 for instructions on making the change from mineral oil. Viscosity of hydraulic oil is similar in concept to the different weights of motor oil. For example, in the winter you may run 5W-30 in your car, while in the summer you run 10W-40. The same is true for hydraulic systems. If you live in a climate where the weather is changing from extremely hot conditions to extremely cold conditions, you should consider changing the weight of the hydraulic oil that you use by the season. The International Standards Organization (ISO) has developed a method of grading hydraulic oils for viscosity. For summer in northern North America, we recommend ISO VG 46 weight oil, while in the winter we recommend ISO VG 32 or even VG 22, depending on how cold it gets in your area. For southern North America and Central America, we recommend ISO VG 46 for the winter and ISO VG 68 or VG 100 for the summer, depending on how hot it
8
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gets. The lower the ISO VG number the thinner the oil and the lower the pour point of the oil. On the other hand, the thinner the oil, the lower the temperature will have to be before it breaks down the lubricating film that protects your components. See the hydraulic oil chart on page 9 of this manual for help in selecting the proper oil for your requirements. The quality of the oil needed for use in a Schwing concrete pump is rated in the DIN system. The ratings have to do with the chemical additive package that is introduced into the oil. Both the DIN rating HLP and HV qualities are approved for use in our concrete pumps.
Specific information All concrete pumps leave the Schwing factory filled with Texaco Rando HD 46 hydraulic oil, which has an ISO viscosity rating of VG 46. Rando HDZ 46, an extended-viscosity oil designed for use under severe conditions, is available on request. If you want your new concrete pump filled with a different brand or different viscosity oil, you should specify it when ordering. Many other brands of oil have been approved for use in Schwing concrete pumps, including: •
Mobil DTE
•
Shell Tellus oil
•
BP Energol
•
Aral Vitam
•
Esso Nuto
•
Esso Univis
•
Total Azolla
•
Wintershall Wiolan
The order of the brands listed is not significant. Any oil that meets the quality and viscosity standards described above can be used.
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When to change your hydraulic oil
VG 32 = Winter application conditions in Central Europe.
Change your hydraulic oil at least once a year. If you use good filters, and change them when they are dirty, the oil will be clean even after a year. The chemical additive packages that give the oil its properties will break down with time, however and no amount of filtration will bring them back.
VG 46 = Summer application conditions in Central Europe. VG 68 = Excessive heat indoors application or in the Tropics.
ISO viscosity / DIN quality ARAL - VITAM BP - ENERGOL ESSO - NUTO MOBIL - DTE SHELL - TELLUS OIL TOTAL - AZOLLA TEXACO - RANDO OIL HD* WINTERSHALL - WIOLAN
VG 32 / HLP GF 32 HLP 32 H 32 24 32 ZS 32 A-32 HS 32
VG 46 / HLP GF 46 HLP 46 H 46 25 46 ZS 46 B-46 HS 46
VG 68 / HLP GF 68 HLP 68 H 68 26 68 ZS 68 C-68 HS 68
* Factory Fill oil at Schwing America Inc.
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Hydraulic Oil Viscosity Chart The illustration below shows the relationship between the oil temperature and its viscosity. As you can see, the oil gets thicker when the temperature is low and thinner as the temperature rises. • The cold start limit represents the coldest temperature at which the oil is thin enough to flow into the hydraulic pumps. Anything colder, and the pumps would not be able to suck in the oil (cavitation).
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•
•
The minimum permissible viscosity represents the warmest temperature at which the oil will still be thick enough to provide lubrication and sealing. Anything warmer, and the components will have metal-to-metal contact (thermal breakdown). The optimum operating viscosity is the range of oil thickness at which the oil works best (thin enough to flow easily yet thick enough to protect the system components).
An example of how to read a chart for VG-46 oil is given in the chart below. The chart shows the cold start limit as –8°C (18°F) and the minimum permissible viscosity as 90°C (194°F). The optimum range is 50°– 76°C.
Temperature of Hydraulic Oil (°C)
Water boils
0 10 VG 8 6 VG 6 4 VG 2 3 VG 2 2
VG
Water freezes
Cold Start Limit (very thick oil)
temp chart.eps
Optimum Operating Viscosity
Minimum permissible viscosity
(°C) (°F) °C = degrees Celsius °F = degrees Fahrenheit
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Lubrication Prefix Codes
“Industrial” gear lubricant codes CLP
Standard codes used API
American Petroleum Institute
BI
Main Association of the German Construction Industry. As an alternative to the recommended lubricants and operating agents, the standard lubricants with this prefix may be substituted.
DIN
Deutche Industrie Norm (German Industry Norm)
An "industrial" gear lubricant oil with additives to improve corrosion protection, aging stability, and protection against wear in areas with many types of friction, and to increase gear stability under load. Meets DIN 51517.
Vehicle gear box oil codes GO 90
BI standard lubricant, a gear box oil that meets API-GL 5.
ISO
International Standardization Organization
MIL-L
American Military Standard for Lubricants
MIL-L-2105B Motor vehicle gear lubricant oil for hypoid bevel gear lubrication under highest demands in gears and axles. Roughly corresponds to API-GL 5.
SAE
Society of Automotive Engineers
Compressor oil codes
VG
Viscosity in millimeters 3/s @ 10° F (40° C)
VDL
Hydraulic oil codes API-CD Engine oil for heavily loaded diesel engines with or without superchargers. EO
BI standard lubricant, a quality engine oil.
HLP
Hydraulic oils with additives to improve corrosion protection, aging stability, and protection against wear in areas with many types of friction. Meets DIN 51524. Temperature Range: 0° F up to 180° F.
HV
Hydraulic oils with low viscositytemperature dependance, otherwise like HLP. Meets DIN 51524. Temperature Range: -30° F (-34° C) up to 180° F (82° C).
VG 32
Oil viscosity for winter application conditions in Northern USA or Central Europe.
VG 46
Oil viscosity for summer application conditions in Northern USA or Central Europe.
VG 68
Oil viscosity for extremely high temperatures such as in the tropics, or within very hot enclosed rooms.
VG 220 Corresponds approximately to SAE 90 for Industrial Gear Lubrication.
Mineral oil for air compressors with additives to improve corrosion protection and aging stability. Coke residue after aging is no more than 3%. Meets DIN 51532.
Grease codes KP 2 K Grease for high pressure load; in working temperature range from -20° C to 140° C; worked penetration from 265 to 295; and minor or no changes due to presence of water. MPG-A BI standard lubricant, a grease in accordance to KP 2 N. Meeting more requirements than KP 2 K and K 2 K. If hydraulic oil of another manufacturer is to be used, or oil of a different type; e.g. HP instead of HLP, a complete oil change is necessary. Mixing different viscosities of oil of the same manufacturer is permissible in some cases. Consult the oil manufacturer to be sure, and take into account that the new viscosity is dependent on the ratio of the mixture. All hydraulic oil should be filtered from the storage container to the concrete pump hydraulic system. This filtering must be performed with a filter rated at 10 micron. For additional information on oil and specific viscosities, refer to Service Bulletin G112/84 and 103/ 97.
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Lubrication Recomendations Industrial Gear Lubricant Oil ISO viscosity / DIN quality
VG 220 / CLP
ARAL
DEGOL BG 220, DEGOL BMB 220
BP
ENERGOL GR-XP 220
ESSO
SPARTAN - EP 220
MOBIL
MOBILGEAR 630
SHELL
OMALA OIL 220
TEXACO
MEROPA 220
WINTERSHALL
WIOLAN - IT 220
BI
-
Motor Vehicle Gearbox Oil ISO viscosity / MIL-L quality
90 (85w-90) / 2105 B
ARAL
GEARBOX OIL HYP
BP
ENERGEAR HYPO 90, HYPOGEAR 90
ESSO
GEAR OIL GX-D, GEAR OIL GX
MOBIL
MOBILUBE HD
SHELL
SPIRAX HD, SPIRAX MB
TEXACO
GEARTEX EP-C
WINTERSHALL
WIOLAN HYPOID GEARBOX OIL 90
BI
GO 90
The gear lubricant oils Industrial and Motor Vehicle are suitable for continuous ambient temperatures of approximately -10° C to approximately +40° C.
12
Under extreme conditions, please inquire as to suitability. The viscosity class ISO-VG 220 roughly corresponds to SAE 90.
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Maintenance, Lubrication Schedules, etc. Compressor Oil VG 100 = AMBIENT TEMPERATURE 0° C to +10° C VG 150 = AMBIENT TEMPERATURE ABOVE +10° C
ISO viscosity / DIN quality
VG 100 / VDL
VG 150 / VDL
ARAL
MOTANOL - HE 100
MOTANOL - HE 150
BP
ENERGOL - RC 100
ENERGOL - RC 150
MOBIL
RARUS 427
RARUS 429
SHELL
CORENA - H 100
CORENA - H 150
TEXACO
COMP. OIL - EP 100
COMP. OIL - EP 150
WINTERSHALL
WIOLAN - CD 100
WIOLAN - CD 150
Operating the compressor below 0° C may only be done according to manufacturer’s specifications.
For an explanation of the various lubricant prefix codes for determining suitable lubricant substitutes, refer to page 11 of this section in this Service Manual.
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Filling Capacities Hydraulic Reservoirs Model
System 1 & 2
BPL 500
66 gallons
BPA 750
37 gallons
BPA 750-18/1000
75 gallons
BPL 750/1000
66 gallons
BPA 2000
100 gallons
BPL 2000
120 gallons
BP 3000/3001
126 gallons
BP 4000
126 gallons
System 3
BPL 4000 BP 5000
126 gallons
BP 8000
126 gallons
KVM 17M
102 gallons
KVM 23M KVM 23-4H
102 gallons
26.5 gallons
KVM 24-4
102 gallons
26.5 gallons
102 gallons
26.5 gallons
KVM 25 KVM 26M KVM 26-4 KVM 28M
14
KVM 28 XL
125 gallons
KVM 31 EZ
127 gallons
KVM 32M
132 gallons
KVM 32 XL
127 gallons
KVM 34 X
127 gallons
KVM 36M
147 gallons
KVM 36XL
127 gallons
KVM 39XL
127 gallons
KVM S 39/41 SX
110 gallons
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System 1 & 2
System 3
KVM 42M
147 gallons
KVM S 42 SX
169 gallons
KVM 45/47 SX
169 gallons
KVM 52/55 M
206 gallons
KVM 58/61 SX
153 gallons
SPB Power Pack
30 gallons
Slew Drives Schwing Model
Model
Part Number
Liters
KVM 32 XL
ZHP
10072000
2.25 liters
KVM 36M
ZHP 3.19
10150116
3.0 liters
KVM 34X/36X
ZHP 3.19
10117070
3.0 liters
KVM 39X
ZHP 3.20
10174652
5.0 liters
KVM 42M
ZHP 3.20
10150115
4.5 liters
DVM 42M
ZHP 3.21L
10013890
5.0 liters
KVM 45/47 SX
ZHP 3.20
10174104
4.0 liters
KVM 52 M
ZHP 3.25
10154423
3.7 liters
KVM 58/61 SX
ZHP 3.25
10188099
9 liters
Transmissions Model Number
Quarts/Liters
‘ZF Model WSK 400
21.5 quarts
ZF Model 4-S-150 GPA
20 quarts
ZF Model 16-S-190 A
20 quarts
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Gear Boxes
16
Model Number
Quarts/Liters
STEYR Model VG2000
9 quarts
STEYR VG2000 w/cooler
10 quarts
STIEBEL Model 4190
NA
STIEBEL Model 4193
4.5 Liters
STIEBEL Model 4194
5.5 Liters
STIEBEL Model 4195
3.0 Liters
STIEBEL Model 4196
3.8 Liters
STIEBEL Model 4252
NA
STIEBEL Model 4400
NA
FABCO Transfer Case
NA
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Spicer Transmisions Lubrication Specs To ensure proper lubrication and operating temperatures in these units, it is important that the proper lubricants be used and that correct oil levels be maintained.
Recommended Lubricants The following lubricants are recommended for use in all SPICER Unit Power Transmissions, Auxiliary Transmissions, and Transfer Cases. 1. Above 0° F, use SAE 50, 40, or 30 heavy duty engine oil, API service classification MS, DG, DM, or DS. 2. Below 0° F, use SAE 30 heavy duty engine oil, API service classification MS, DG, DM, or DS. DO NOT USE EXTREME PRESSURE ADDITIVES - such as found in multi-purpose or rear axle type lubricants. These additives are not required in SPICER transmissions, and may in some cases create transmission problems. Multi-purpose oils as a group have; relatively poor oxidation stability, a high rate of sludge formation, and a greater tendency to react on or corrode the steel or bronze parts within the unit.
Oil Changes SPICER recommends an initial oil change and flush after the transmission is placed in actual service. This oil change can be made any time following 1000 miles
of over-the-road service, but not exceeding 4000 miles. In off-highway use, the oil change should be made after 24 elapsed hours, but not exceeding 100 elapsed hours of service. There are many factors that influence the following oil change periods and we have not specified a definite mileage interval. In general, it is suggested that a drain and flush period be scheduled every 20,000 miles for normal over-theroad service. Off-highway service usually requires an oil change every 30 days. The oil level in the transmission should be checked every 2000 miles (onhighway), or every 24 hours (off-highway). The correct oil level in all SPICER transmissions is established by the filler plug opening. TO REFILL: Remove all dirt around the filler plug before unscrewing plug; then refill with new oil of a grade recommended for the present season and prevailing service. Fill to the bottom of the leveltesting plug positioned on the side of the transmission.
Over-Filling Do not over-fill the transmission. Over-filling usually results in oil breakdown due to excessive heat and aeration from the churning action of the gears. Breakdown of the oil will result in heavy varnish and sludge deposits that plug up oil ports and build up on splines and bearings. Also, overflow from overfilling of oil usually escapes onto clutch or parking brake area, causing additional trouble.
TRANSMISSION CAPACITY MODEL (PINTS)
TRANSMISSION CAPACITY MODEL (PINTS)
UNIT POWER TRANSMISSIONS
UNIT POWER TRANSMISSIONS (cont)
3152, 3153 5652 5662 5752, 5753 5852, 5853 6352, 6354 6452, 6453, 6454, 6455, 6456 6852, 6853, 6854, 6855 7016, 7216 (4x4) 7352 7452, 7453 8012, 8212, 8512 (4x3) 8016, 8216, 8516, 8716 (4x4), P8516, P8716 8041, 8045, 8542, 8544 8051, 8055, 8553, 8555 8052, 8054, 8552, 8554 8241, 8245, 8742, 8744
10 13 17 15 15 17 17 17 28 18 18 36 36 16 24 24 16
8251, 8255, 8753, 8755 1062, 1262, 1263, 1010 *1211 Auxiliary Unit *1020 Auxiliary Unit 8440, 8445, 8842, 8844
24 28 10 10 28 10 16
* These transmissions have separate oil suppliers. Each pod must be selected and filled separately.
AUXILIARY TRANSMISSIONS 5831 6041 7041 7231 8031, 8035 8431, 8345, P8341, P8345 9341 9441
4 8 11 8 12 12 18 12 S0028.eps
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ZF Transmissions
oil. (Please ask the oil supplier to certify fulfillment of these conditions).
Lubrication Specs
In torrid zones, oil grades SAE 85 W/90 or SAE 90 can be used if the grades 80 W, 80 W/85 W or 80 W/90 are not available.
• •
ZF-Synchromesh gearboxes ZF-Constant mesh gearboxes W/splitter group & range change gearboxes ZF-Gearboxes with disc-clutch operated NMV ZF-Transfer gearboxes
• •
The oil grades listed on the following page are in accordance with specification MIL-L-2105 and API classification GL-4. Gear oils of viscosity group SAE 80 W, must be used. These oils are partly available in viscosity grades SAE 80 W/85 and SAE 80 W/90. These multi-grade gear oils can be used instead of SAE 80 W, under the condition that in addition to the EP additives, (the type and concentration of which are specified by ZF), any other dissolved components (VI-Improver, Pour point depressant) DO NOT exceed 2% (weight) of the basic
If these gear oils cannot be obtained, engine oils SAE30 or SAE-40 in accordance with specification APICC, CD, SE, SF, or MIL-L-2104 C, MIL-L-2104 D, MIL-L-46152 A & B should be used as a substitute. In this case, intervals between oil changes are to be reduced by half. NOTE! Multi-grade engine oils ARE NOT approved. THE SELECTOR TRANSMISSION MUST BE FILLED WITH OIL WHICH CONFORMS TO THE FOLLOWING LUBRICANT LIST: TE-ML 02 (API GL-4, SAE 80W) UNIT CAPACITY = APPROXIMATELY 20 QUARTS
TE-ML 10 APPROVED LUBRICANTS FOR SERVICE FILL
TRANSMISSION 16 S 151 16 S 160 (A) 16 S 190 (A) 16 S 220 (A) 16 S 221 16 S 251
+WSK +WSK +WSK +WSK +WSK +WSK
3 DS 18
4 S 120 GP 4 S 150 GP (A) S 6-65 S 6-90 9 S 75 9 S 109 16 S 150
+WSK +WSK +WSK +WSK +WSK +WSK +WSK
Engine oils - API CD / CE / CF / SF / SG - MIL-L-2104C / -D / -E - MIL-L-46152C / -D / -E -SAE 20W-20
Engine oils - API CD / CE / CF / SF / SG - MIL-L-2104C / -D / -E - MIL-L-46152C / -D / -E - SAE 10W for ambient temperatures above-10ßC, (14ßF) - SAE 30 for ambient temperatures above-10ßC, (14ßF)
+WSK 244
Add
Add
Dip Stick Oil Level Indicator Plug Drain
Drain
Drain
Drain
16 S 190 A
18
4 S-150 GPA
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Steyr Gear Boxes Lubrication Specs 1. Steyr specifies 85-140 weight gear oil and strongly advises a change of gear oil on all their transfer cases every 3300 hours or once per year. 2. Whenever leakage of gear oil is discovered, preventative measures must be taken. 3. Operating the transfer case with too low an oil level WILL result in severe damage to the unit. 4. IMPORTANT! A proper oil level check can only be done by dispensing new oil into the filling port at position #1 of figure 5; be sure that vehicle is on level surface before removing any port plugs.
Remove the proper level checking plug (either #3 or #5), if no oil comes from the port, start to dispense new oil into the filling port until oil starts to over-flow out the checking port, then replace all plugs and tighten. 5. With this method, proper oil filling is achieved without over-filling.
Transfer Case Gear Oil Capacities are as Follows: • •
Model VG2000 w/o cooler ...........2.25gal/8.5 liters Model VG2000 w/cooler ..............2.50gal/9.5 liters
Breather
Oil Filler Plug
Oil Drain Plugs
Oil Level Plug (only for models with oil cooler)
Oil Drain Plugs S0031.eps
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Stiebel Gear Boxes Lubrication Specs 1. Reducers are supplied without oil. For filling capacity, please see data on the gear plate. 2. Refilling is only necessary in case of oil leakage due to defective seals or defective gear case gaskets. Such defects should be repaired immediately. 3. First change of oil should be after 200 operating hours. 4. Drain the old oil immediately after the stopping of reducer operation, while oil is still warm. Prior to refilling the gear case, dispense some new oil into the top of case to flush remaining old oil out.
SERVICE TRAINING
5. Subsequent oil changes should occur every 2000 operating hours or at least, every 12 months. 6. The oil type and quality approved by Stiebel is determined by the following index. In situations when an oil from this index cannot be acquired, use EP SAE 90 with viscosity 220 cST at 40° C. 7. Special conditions and applications will require special lubricants. Consult the gear manufacturer for special recommendations. • GEAR OIL SAE 90 (or as we call it: 90W) IS A SINGLE RANGE OIL. • GEAR OIL SAE 85-90 IS A MULTIGRADE OIL. • EITHER OF THESE OILS MAY BE USED
ARAL
Aral Degol BG 220, or Aral Degol BMB 220, or Aral Getriebeol EP 90
BP
BP Energol GR-XP 220, or BP Getriebeoel EP SAE 90, or BP Gear Oil 90 EP
COLYPSOL
UK-ECUBSOL OL 8050, or UK-ECUBSOL OL DB 90
CHEVRON
Universal Gear Lubricant E SAE 85W-90, or Non-Leaded Gear Compound 220
ESSO
SPARTAN EP 220, or ESSO GETRIEBEOEL GP-D 90, or ESSO GEAR OIL GP 90
MOBIL
Mobilgear 630, or Mobil SHC 630, or Mobilube GX 85W-90-A
SHELL
Shell Spirax EP 90, or Shell Omala Ol 220
TEXACO
Meropa 220, or Geartex EP-D SAE 85W/90, or Geartex EP-A SAE 85W/90
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FABCO Gear Boxes Lubrication Specs
Lubricating Oil for Fabco TC-143 Transfer Case OIL CHANGE
LUBRICATION
The transfer case lubricant should be changed on all new transfer cases after the first 3,000 to 5,000 miles (on-highway), or the first 40 hours (off-highway): thereafter, oil changes should be done at the following intervals:
RECOMMENDED LUBRICANTS On Highway Vehicles 1. Heavy-Duty Engine Oil: Temperature
Grade
Above + 10 F Below + 10 F
SAE 50 SAE 30
On Highway Service...........10,000-15,000 miles Off-Highway Service (Logging, dirt moving, mining, and associated operations)..500-750 hr.
Be sure to specify heavy-duty type MIL-L-2104B specifications. 2. Mineral Gear Oil: Temperature
Grade
Above + 10 F Below + 10 F
SAE 90 SAE 80
Must be inhibited against corrosion, oxidation, and foam. 3. MIL-L-2105B E.P. Oil, except sulfer-chlorine-lead type: Temperature
Grade
Above + 10 F Below + 10 F
SAE 90 SAE 80
Extreme pressure oils under some conditions might form carbon deposits on gears, shafts, and bearings, which will result in transfer case malfunctions and premature failure. It is suggested that if these conditions exsist, and E.P. oil is being used, a change should be made to mineral gear oil or heavy-duty engine oil as recommended. Off Highway & Mining Equipment
The recommended oil change and inspection periods are based on the average use and operating conditions that the unit may encounter. It is suggested that the individual owner make a periodic lab analysis of the lubricant to determine contamination based on the unit’s specific operating conditions. With this data, the oil change and inspection periods can be better determined.
DRAINING THE OIL Draining is best accomplished after the vehicle has been operated briefly, allowing the oil to become warm and flow more freely. Remove both drain and fill plugs. Allow the housing to empty completely. Before the unit is refilled, it should be thoroughly flushed with clean flushing oil or kerosene. If the unit is equipped with an oil pump, the lube oil filter should be replaced whenever the oil is changed. The element is of the spin-on type. A film of clean oil should be applied to the rubber gasket of the new element before installing. Do not overtighten.
REFILLING THE OIL
1. Heavy-Duty Engine Oil: Temperature
Grade
Above + 10 F SAE 50 Below + 10 F SAE 30 Be sure to specify heavy-duty type MIL-L-2104B specifications. 2. Special Recommendation: For extreme cold weather where temperature is consistently below 0ßF, use SAE 20W heavy-duty engine oil meeting MIL-L2104B specifications
If the transfer case has been removed from the vehicle for service, it is best to refill the oil after the unit has been reinstalled into the vehicle. Clean and replace the drain plug and fill the transfer case with the appropriate oil with the vehicle on level ground. Fill the transfer case to the level of the fill plug. On transfer cases equipped with a proprtional differential, it may take some time for the oil to flow into the main housing; therefore, it is necessary to fill the unit to the level of the fill plug, wait a few minutes, and top off the oil level. It may be necessary to do this several times. The plug should be installed only after the oil level has stabilized.
S0035.ai
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ZF Torque Converters
WSK Torque Converters
Lubrication Specs
Independent oil circuit in convertor and clutch unit and selector transmission systems.
HE TORQUE CONVERTOR and CLUTCH SYSTEM MUST BE filled with the SPECIFIED ENGINE OILS or with AUTOMATIC TRANSMISSION FLUIDS which conform to the following lubricant list; TE-ML 14. UNIT CAPACITY= APPROXIMATELY 21.5 QUARTS.
NOTE! When using Dexron II products, particular care must be taken to ensure that the trade name and the "D" number on the oil barrel correspond. If ATF is not available, SAE 10W mono-grade engine oils conforming to the following specifications may also be used: MIL-L-2104 C, or MIL-L-2104 D, or MIL-L-46152 A, or MIL-L-46152 B, or API-CC, CD, SC, SD, SE, or SF.
ADD
OIL LEVEL INDICATOR PLUG DRAIN
The ATF (Automatic Transmission Fluid) oil grades on the following list may be used with all the WSK Transmissions.
NOTE! When engine oils are used in place of ATF, there may be a loss in shifting comfort because the shifting elements and friction are adapted to ATF.
DRAIN S0032.eps
A range of suitable engine oils are also included in the following list.
TE-ML 09 APPROVED LUBRICANTS FOR SERVICE FILL
VERSION
Automatic Transmission Fluid (ATF) - Dexron¤ - IID / -IIE / -III - Mercon¤ -M
Hydraulic power-assisted steering systems Hydrostatic steering systems In-line boosters Oil pumps Intermediate drives
TE-ML 14 APPROVED LUBRICANTS FOR SERVICE FILL
VERSION
Ecomat
1. 1.1
Automatic Transmission Fluid (ATF) Base oil: mineral - Dexron - IID - Mercon - M
1.2
- Dexron - III - Mercon - M
2.
Base oil semi-synthetic/hydrocracked - Dexron - IID - Mercon - M
3. 3.1
Base oil synthetic - Dexron - IID / -IIE - Mercon - M (Not approved for transmissions with ratio 5.6-0.83/ 1.0)
3.2
22
- Dexron -III - Mercon -M
Service Manual
RECOMMENDED ALTERNATIVES
Engine oils - API CD / CE / CF / SF / SG - MIL-L-2104C / -D / -E - MIL-L46152C / -D / -E -SAE 10W The shift elements and friction linings are designed for use with ATFs. Using engine oils may result in reduced shift comfort.
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Hydraulic Pump Spline Lubrication
Product Data
It is highley recommended prior to the installation of any model/manufaturer of hydraulic pump(s) that the drive spline be lubricated with a special pre-assembly grease--Optimoly Paste White T. Following this procedure will add extended life to the spline and related parts. Optimoly Paste White T is available in cartridge (p/n 30346107) or aerosol (p/n 30346108) from, and can also be used in other pre-assembly work.
Optimoly Paste White T - white paste for clean assembly work, prevents fretting corrosion (false brinelling). Tight fitting components may be disassembled without any difficulties even after many years of operation. Optimoly Paste White T - is excellently suited for all assembly work and for base thin-film lubrication in all engineering areas. Optimoly Paste White T - is also available as a spray.
Typical Hydraulic Pump Spline S0036.eps
Features
Uses
• • • • • • • • •
•
•
inhibits fretting corrosion and false brinelling clean handling facilitates assembly and disassembly good separating effect for all types of contact resistant to cold and hot water excellent rust protection even in salt water white, almost colorless in thin layer easy application (spray-without CFC) temperature application range: -30˚C/-22˚F to +250˚C/+482F USDA-H2 approval
•
Assembly paste with universal application range due to its clean handling and long-term separating and lubrication effect. Superior to lack assembly lubricants in performance test for a variety of applications. Prevents fretting corrosion on bearing seals, spline shafts, torque loaded connections.
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Maintenance of Hydraulic Cylinders
then piston sealing and/or holding valve on the piston side have internal leakage. 1. Remove the hose connections at the holding valve on the piston side. 2. If no oil runs out of the hose connections at the holding valve, then that means the piston seal is leaking, allowing oil to by-pass from the piston side of the cylinder to the rod side of the cylinder. 3. If oil runs out of the hose connected to the holding valve, then the holding valve on the piston side is defective.
WARNING
READ FIRST!
S0101.ai
Warning! Danger of crushing! Before removing any holding valve, the boom MUST be completely supported so that removal of the valve will not cause the boom to fall. If an extended boom is unsupported when a holding valve is removed, oil will escape under high pressure, and can cause serious injury. Warning! Before removing any holding valve, hoses, tubes or fittings, the engine or motor MUST be shut off; the key removed; and a "DO NOT OPERATE" tag attached to the door of the truck or in case of an electric motor as the unit’s prime mover, the electrical panel MUST be "locked out" and "tagged out", preventing any accidental power up. 1. To check the piston side holding valves: Set the boom into a horizontal position, but do not completely extend the boom cylinder. Make a mark on the piston rod (with a felt pen) and observe if there is any movement indicating leakage. a. If there is no movement of the cylinder rod, then piston sealing and holding valve are free from internal leakage. b. If there is movement of the cylinder rod,
2. To check the rod side holding valve: Set the boom section to be checked in the retracted position, but do not completely retract. Make a mark on the piston side rod (with a felt tip pen) and observe if there is any movement indicating leakage. a. If there is no movement of the cylinder rod, then piston sealing and holding valve are free from internal leakage. b. If there is movement of the cylinder rod, then piston sealing and/or holding valve on the rod side have internal leakage. 1. Remove the hose connecting at the holding valve on the piston side. 2. If no oil runs out of the hose connections at the holding valve, then that means the piston seal is leaking, allowing oil to by-pass from the rod side of the cylinder to the piston side of the cylinder. 3. If oil runs out of the hose connections at the holding valve, then the holding valve on the rod side is defective.
Holding valves mounted on a hydraulic cylinder (H.E.R. Valves)
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Maintenance, Lubrication Schedules, etc. 3. Check Outrigger Cylinder for: a. Any missing or damaged parts, then check for leakage of shut-off valves or cylinder seals. b. With no load applied to the outrigger cylinder, close the shut-off valve and remove the hydraulic line between this valve, and the outrigger cylinder. Engage control valve for the outrigger cylinder to level position, “front” to extend the outrigger cylinder. If the valve is leaking, oil will run out of the shut-off valve. c. Slew the extended boom over the outrigger cylinder which is to be checked. Close the shut-off valve and remove the hydraulic line between this valve and the boom control block. Mark the cylinder rod (with a felt tip pen) and observe. If the cylinder retracts and no oil runs out of the shut-off valve, then the piston sealing is leaking. 4. Check the control block for: a. Any missing parts (knobs, symbol of switching levers, etc.), damaged or leaking parts, and cleanliness.
5. 6.
7.
8. 9. 10.
b. Check the lever position with the respective cylinder movements. Test is to be carried out while you have an operating oil temperature of approximately 30˚ to 50˚ (86˚ to 122˚ F.) Check the #1 boom down relief - Refer to Service Bulletin G-103-89 for checking this function. Check boom slewing cylinders for: a. Exterior damage of cylinders tubes and mounting flanges. b. Leakage and correct movement. Check the hydraulic tank for: a. Proper oil level and leakage b. Contamination and oil purity. (if necessary, take an oil sample for evaluation). Check boom operation speed (too fast / too slow), with unstressed boom as per Boom Time Chart. Check remote control motions with all switch functions and operation symbols. Check remote control safety switch (emergency stop button) for proper operation.
S0099.eps
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Lubrication Specs for Schwing Placing Booms •
Maintenance of the collar bearing, step bearing on the shorter booms and rollix bearing for the slewing gear of longer booms should be lubricated daily. The boom should be rotated while grease is applied to achieve adequate lubrication. The outriggers and boom should be greased monthly.
• •
The grease recommendations are as follows: 1. The bronze tower or column bushings must be greased with a moly additive which has a minimum of 3% molybdenum disulfide.
equivalent with the below listed minimum characteristics: • Base Type....................................................Lithium • NLG1 No. ..............................................................2 • cSt @ 40˚ C (104˚ F) ........320 summer, 150 winter • Molybdenum disulfide.......................3% minimum • ASTM dropping point (degrees F..... 350 degrees F minimum 2. All other bearings must be greased with a lithium grease such as Mobil Grease HP, CM-S, or an equivalent. In order to ensure that the grease is uniformly distributed on the bearing surface, you must lubricate while slowly rotating the boom.
32XLZerks above stack.eps L
Greasing zerks.eps L
Greases such as Lubriplate Mo-Lith No. 2, Texaco Molytex EP2, Mobil Grease CM-P may be used or an
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Boom Inspections Inspections of the boom, outriggers, subframe, tower, and guide levers are recommended by Schwing America Inc. according to the following schedule: Years of Service First 4 years 4 to 8 years 8 years or more
Inspection Interval every 12 months every 6 months 12 months or 500 working hours
This schedule must be a planned schedule based on the age of the unit. It is the concrete pump owner who is responsible for completing scheduled inspections, either by himself or whomever he authorizes to do so. Upon request however, Schwing America will provide a qualified service person to aid pump owners in doing boom inspections. To request a service person to do your inspections, or to request guidebooks and inspection forms for doing your own inspections, make a copy of the “Inspection Request Form” printed on the reverse side of this page, complete the form and mail to Schwing America Inc. Attn.: Service Dept. Manager.
S0162.eps
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BOOM INSPECTION REQUEST FORM TODAY S DATE:
/
/
COMPANY: STREET ADDRESS: CITY:
STATE: PHONE: (
CONTACT:
ZIP: )
LIST ALL MACHINES REQUIRING INSPECTION(S)/REPAIR(S) BELOW: MODEL
SERIAL NO.
LOCATION
PLEASE FILL OUT AND FAX OR MAIL THIS FORM TO: SERVICE DEPARTMENT SCHWING AMERICA INC. 5900 CENTERVILLE ROAD WHITE BEAR, MN 55127 FAX: 651/429-2112 SAISVC 018REV05/03/00
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Rock Valve
Rock Valve Safety Instruction When performing maintenance on Schwing Equipment, the safety regulations must be followed. The observation of these regulations is the responsibility of the maintenance personnel. The following are some supplementary recommendations.
WARNING
READ FIRST! 1. WARNING! Read and understand the operation manual of the machine before attempting any repairs. If in doubt, call the manufacturer. Incorrectly done repairs endanger operational safety of the machine. 2. WARNING! Burning hazard! Never work on a hydraulic system with hot oil. 3. WARNING! Falling hazard! If you cannot work at ground level, you must use a suitable work platform. 4. WARNING! If maintenance work requires that you use a crane, hoist, fork truck, etc., you must read and understand the safety regulations for that equipment. 5. WARNING! If working the machine requires that it be operated, and you are not qualified as an operator, you must get someone who is qualified to assist you. 6. WARNING! If you will be working in a hidden area inside the machine, protect yourself by taking the key from the ignition and putting a “DO NOT OPERATE” sign on the controls. In the case of electrically driven units, disconnect the main circuit breaker and lock it in the disconnected position. 7. WARNING! Never activate the system hydraulics without checking if another workman is in a hidden position. Always yell “CLEAR”, and allow time for response, before starting the prime mover. 8. WARNING! Never use gasoline or diesel fuel as a cleaning solvent. This is critical to remember when cleaning hydraulic oil reservoirs, because gas and diesel fuels are highly explosive, and gasoline or diesel fuel traces left in the oil may ignite when compressed. 9. WARNING! Always use the correct tools for the job. Tools should be kept clean, and in good condition. 10. If you see a co-worker engaging in an unsafe practice, explain the dangers. Safety is always in the hands of those on the job. 11. WARNING! Never work on a pressurized hydraulic system. Stop the prime mover and relieve the accumulator circuit (if so equipped) before you open the hydraulic system.
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Rock Valve
Rock Valve Parts Identification - “M” Rock !
# !
$ % & " '
" $ % &! " '
$
( " ! & '
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Rock Valve
Rock Valve Parts Identification - “E” Rock Pivot Lever Cover Bolt
Cover Bearing Bushing
Cover
Bearing Bushing Sealing Cover
Slewing Lever Pivot Bushing Wearing Insert (Right Hand)
Pivot Bushing
"E" Rock Valve Housing Wearing Insert (Left Hand) Plate Spectacle Plate
Wearing Plate
Cutting Ring Outlet Side Housing Lining (Kidney Plate) End Cover
Pivot Shaft
End Cover Bolt
"E" Rock Extension Pressure Spring
Bearing Bushing
Support Ring
Setting Disc "E" Rock Valve
Tension Nut
Keeper Bolt
Kidney Seal
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Rock Valve
Rock Valve Parts Identification - “B” Rock Cover Pivot Lever Cover Bolt
Bearing Bushing
Bearing Bushing Cover
Sealing Cover
Slewing Lever Pivot Bushing Wearing Insert (Right Hand)
Pivot Bushing
"B" Rock Valve Housing Wearing Insert (Left Hand) Spectacle Plate
Plate Wearing Plate
Outlet Side Housing Lining (Kidney Plate)
Pivot Shaft
End Cover End Cover Bolt
Bearing Bushing
Cutting Ring Pressure Spring "B" Rock Valve
Setting Disc Tension Nut
Kidney Seal
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Keeper Bolt
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Rock Valve
Rock Valve Lubrication Points If your unit is not equipped with an auto-lube, grease your agitator bearings. There is one zerk on each side of the hopper. Grease every 200 or 300 yards, as the pour allows. Grease your agitator bearings. There is one zerk on each side of the hopper. Re-grease every two or three hundred yards, as the pour allows. NOTE! You don’t grease agitator bearings like you grease most other bearings. That is, if you normally pump in grease until you see it squirting out somewhere, you will ruin your agitator seals. When you grease the agitator bearings, watch the rubber grease cones that are located inside the hopper. You want the cones to bulge out slightly because they are full of grease, but you don’t want to have the grease come out around the shaft, because where the grease comes out concrete will be able to go in. Once concrete makes it inside of the grease cone, you will quickly wear out the bearings. When re-greasing after the hopper is full of concrete and you can no longer see the cones, just give the zerks a couple of squirts. This is one of the few times when it is better to under grease than to over grease. Grease the rock valve lubrication points before the pour begins. Once you start pumping, grease them every couple of hours. There are six zerks to grease for the rock valve, plus the two for the agitator. If your unit is equipped with an auto-lube, greasing is accomplished automatically. The grease timers in the cab must be adjusted to assure proper grease flow from each feeder. Check with SAI’s Service Department for timer adjustment instructions. The timers are usually mounted on the top of the doghouse between the seats.
Grease Zerk #7
Grease Zerk #6
zerks.eps L
Grease Zerk #8
Grease Zerk #5
Grease Zerk #1,2,3,4
Locations of the six Rock Valve greasing points (1-5,7) and the two agitator grease points (6,8)
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Rotating The Cutting Ring 45 rock valve assembly.eps L
Setting Disc Keeper bolt Tension nut Wrench flats Wedge Tapered bend
6-inch clamp Cover bolts
WARNING Never rotate the cutting ring without disabling the unit’s hydraulic system. Amputation hazard! 1. 2. 3. 4. 5. 6.
7. 8.
9. 10.
11. 12. 13. 14.
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First, shut off the truck engine and put the key in your pocket. Remove the 6-inch clamp between the tapered bend and the 6-inch elbow. Remove the wedge from the tapered bend, and pull the tapered bend away from the 6-inch clamp. Loosen the tension nut as explained previously. Loosen the seven cover bolts two or three full turns, but do not remove the bolts. Push forward on the end of the rock valve slewing cylinder. Because it has a single pivot point, it will push the rock valve backwards toward the loosened cover. If you meet resistance, do not force it. After you have removed the hopper grate, you can gently pry the rock valve backward from inside the hopper. Remove the hopper grate. From inside the hopper, tap the cutting ring forward, toward the spectacle plate. The ring should pop loose. If it doesn’t, loosen the cover bolts a little more, then gently pry the rock valve rearward a little more until it does. Rotate the ring 90° clockwise. (It doesn’t really matter which way you rotate, but to keep from forgetting which way you went last time, Schwing recommends going clockwise each time.) Be sure that the ring is centered in the rock valve. Tighten the cover bolts slightly, if needed, to be sure that the ring isn’t cocked one way or the other. Be sure there is no debris between the back cover and the rock valve housing. If there is, clean it out. Tighten the cover bolts just enough to bring the back plate up against the rock housing. Then tighten each bolt equally, using a torque wrench. Alternate which bolts you tighten, as you would when tightening a wheel on a car. The torque specification for these bolts (M24 x 60, 8.8 hardness) is 485 ft./lb. Replace the bolts once per year. Position the hopper grate over the hopper. Bolt it into place. Tighten the tension nut. Tighten the keeper bolt. Push the tapered bend closed and install the wedge. Remember to install the hairpin. Install the 6-inch clamps and the hairpin.
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Replacing the Cutting Ring 1. Loosen the bolt on the Pivot Lever a few turns with a 30 mm. wrench.
2. Remove the Housing End Cover Bolts with a 36 mm. wrench.
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3. Pry the End Cover away from the housing as far as the Pivot Lever will allow.
NOTE! Remove the Cutting Ring, and replace it with the new part.
NOTE! When reassembling, make sure that the Cutting Ring fits correctly and that the Pressure Spring is in full contact with the face of the Cutting Ring. Reassembly is opposite to the procedure above.
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Tension Nut/Pressure Spring Do not use the Tension Nut to adjust the position of the Cutting Ring. Excessive wear of the Inlet Housing Lining, Cutting Ring, Pressure Spring, and Kidney Seal would result. The Tension Nut adjusts the Kidney Seal area of the Rock Valve ONLY. To check or adjust, remove the Keeper Bolt will line up with a threaded hole in the Setting Disc. If you are between two holes, loosen the Tension Nut so it lines up with the previous hole. Do not use a wrench to tighten. The flat sides of the Tension Nut are to loosen the nut only. Please call the Schwing Service Department if you have any questions.
Adjustment Screw
Pressure Spring If the Pressure Spring has to be replaced, dismantle the old spring and clean the vacant area thoroughly to clear it of cement dust, etc. If dust and residue are ignored, the new spring cannot be installed correctly, and the flow of concrete can pull it out of the groove. Furthermore, the high pretension leads to premature wear of the Cutting Ring and Housing Lining. Inlet Housing Lining
Cutting Ring Rock Valve Pressure Spring
A
NOTE! Slightly grease the new Pressure Spring when installing it. The same applies to the Kidney Seal. Do not use too much grease, because grease accumulating in the spring chamber operates as a spacer, and the consequently increased spring pretension can lead to the same damages as described above.
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Determining Wear on Kidney Seal and Kidney Plate Replace the kidney seal if any of the following conditions exist: 2
2
Spring installed
M d
1
mm
Figure 1
•
The seal is swollen due to use of aggressive or harsh cleaning agents. (See Service bulletin G-113-84, dated July 18, 1984) A considerable formation of cracks are found in the areas marked by arrows. (fig. 1) This problem is very rare. Lip (Item 1, fig. 1) is completely worn to the point that the pressure relief grooves (Items 2, fig. 1) are no longer recognizable. The distance indicated by “M” of the Kidney Seal (when force is relieved) does not exceed 30mm (1 3/16”).
• • •
Replace the Housing Lining-Oulet Side (Kidney Plate) only if scores deeper than 2.5mm are found, in the area that contacts the Kidney Seal, that are deeper than 2.5mm. You can measure this by placing a steel ruler across the kidney Plate in several places, and using a depth gauge to determine the gap.
NOTE! Outside of the area that contacts the Kidney Seal, you may detect scores that are due to aggregate particles stuck between the Rock Valve and the Kidney Plate. (See fig. 2 and fig. 3) THESE SCORES DO NOT MATTER IN THE LEAST!
We would like to draw your attention to the fact that under no circumstances should you allow the Kidney Seal to be run with a dry hopper. This will destroy the Kidney Seal, and is the primary cause of premature wear encountered at the outlet side of the Rock Valve. If you will be repairing the Rock, or troubleshooting a problem, always fill the hopper with water to the top of the Rock Valve before switching.
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Replacing the Kidney Seal Kidney Seal 1. Remove the Keeper Bolt from the Tension Nut using a 24 mm. wrench.
Keeper Bolt
2. Remove the Tension Nut using a 60 mm. wrench.
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Rock Valve 3. Remove the Setting Disc from the Rock pivot shaft.
4. Remove the bolts from the End Cover and insert the two Guide/Support Rods into the upper holes using a 36 mm. wrench.
5. Slide the End Cover along the inserted Guide/Support Rods.
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6. Remove the Kidney Seal with a screw driver or similar tool.
7. Clean the Kidney Seal groove of the Rock Valve thoroughly. 8. Replace the Kidney Seal while making sure that the flat surface is toward the End Cover. 9. Push the End Cover back into place and replace the bolts. Clean away any debris that would prevent the cover from sitting flat. 10. Replace the Setting Disc onto the square portion of the Rock Pivot Shaft.
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11. Replace the Tension Nut onto the Rock Pivot Shaft, and tighten it by hand. In this position, the clearance between the Rock Valve and the housing should be 1.5 to 2.0 mm.
Rock
1.5 to 2.0mm
Kidney Plate
NOTE! If either the Spectacle Plate or the Cutting Ring are not replaced at the same time as the Kidney Seal, the clearance will be greater and can be adjusted by further tightening of the Tension Nut to the next Setting Disc hole only. 12. Replace the Keeper Bolt.
Keeper Bolt
13. IMPORTANT! At no time should the Rock Valve be operated without first lubricating the outlet wear plate. Usually, spraying the plate with water or oil prior to start-up will be adequate. Moving the kidney seal against a dry plate will cause excessive wear to the seal and will lead to premature failure. If switching the Rock Valve is necessary for shop work (adjusting, inspecting, etc.), you must take the necessary precautions and ensure that the plate and seal are properly lubricated.
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Spectacle Plate Lengthening the Service Life of the Housing Lining-Inlet Side The amount of wear on the Housing Lining and the Cutting Ring will vary, and it will affect the length of time they can safely be used. The condition of each part depends on outside influences that affect them daily, including varying concrete mixes and changing weather conditions. The Cutting Ring and Housing Lining cannot be expected to wear equally and will need to be replaced accordingly.
NOTE! The grooves in the Base Plate (Spectacle Plate) resulting from basic operation are irrelevant as long as the hard facing is in good working condition. To assist in achieving uniform wear and, thus, considerably longer service lives, we recommend: 1. moving the Rock Valve to the left and right end positions once a week--after thorough cleaning--and checking the condition of the cutting ring & housing lining. Friction and stone crushing
Friction
Friction and stone crushing Friction Figure 1
2. turning the Cutting Ring 90 degrees if there is a visible space between the Cutting Ring and the Housing Lining that is greater than 1.0-1.5 mm. (.0393”-.0590”). Check for this gap at several points along the circumference. Instructions for cutting ring can be found on page 4 of this document.
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3. checking the distance between the Cutting Ring and the Rock Valve after each turn of the Cutting Ring. If it exceeds 8 mm. (.31”), the pretension of the Pressure Spring is not enough to correctly press the Cutting Ring to the inlet side of the Housing Lining, and the Cutting Ring should be changed.
Inlet Housing Lining
Cutting Ring Rock Valve Pressure Spring
A
Figure 1
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Replacement of Spectacle Plate Check the plate for wear, and if replacement is necessary, follow these steps: 1. Loosen the bolt on the Pivot Lever a few turns with a 30 mm. wrench.
2. Remove the Housing End Cover Bolts with a 36 mm. wrench. 3. Pry the End Cover away from the Housing Cover as far as the Pivot Lever will allow. 4. Using a 14 mm. allen wrench, remove the socket head bolts that secure the plate.
5. Pry the Spectacle Plate (Base Plate) away from the pumping cylinders.
Remove spectacle plate
NOTE! In some old models, the transition pieces may come out with the Spectacle Plate. If this becomes a problem, see Service Bulletin G-104/89 for assistance. 6. Thoroughly clean the area where the plate is to be mounted, install the new Spectacle Plate, and secure it. Reassembly requires following the above steps in reverse order.
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Rock Valve
Replacement of Outlet Housing Lining (Kidney Plate) Plate Check the plate for wear, and if replacement is necessary, follow these steps: 1. Remove the Keeper Bolt from the tension nut using a 24 mm. wrench. 2. Remove the Tension Nut using a 60 mm. wrench. 3. Remove the Setting Disc from the Rock Pivot Shaft. 4. Remove the bolts from the End Cover and insert the two Guide/Support rods into the upper holes using a 36 mm wrench. 5. Slide the end cover along the inserted Guide Rods. 6. To replace the lining, remove both Securing Bolts in the End Cover using a 24 mm wrench.
1. Free the lining from the End Cover, and remove it. It is heavy...get help if needed
Lining
2. Thoroughly clean the entire area that the Outlet Housing Lining touches. 3. Fit a new O-ring into the replacement lining, and reassemble by following steps 1-7 in reverse order.
O-Ring
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Replacement of Outlet Insert (Cover Lining) (TO BE REPLACED AT THE SAME TIME AS THE KIDNEY SEAL AND/OR OUTLET HOUSING LINING) 1. Remove the Tapered-Bend (Reducing Elbow) from the Pipe Bend (Connection Piece).
2. Remove the Outlet Housing Lining (End Cover Lining) as described in the Outlet Housing Lining Replacement section. 3. Remove the Pipe Bend from the End Cover. 4. Press out the Cover Lining.
5. Grease the outer surface of the Cover Lining before reinstalling it into the End Cover. 6. Clean all of the contacted areas, replace the O-ring, replace the Pipe Bend, and reassemble by following the above directions in reverse order.
O-Ring
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Rock Valve Body NOTE!
1. 2. 3. 4. 5.
Because this is a major procedure, we recommend close inspection of the Spectacle Plate (Base Plate), Outlet Housing Lining (End Cover Lining), and all other parts that require periodic replacement, so you can replace all necessary parts at the same time. Remove the agitator motor along with the hydraulic lines that are connected to it. Remove any and all electric wires from the hopper. Mark the wires to aid in reassembly. Completely remove the hopper. Remove the End Cover as explained in the Kidney Seal or Outlet Housing Lining replacement section. Remove the bolts from the Rock Valve while making sure to support it from underneath.
Bolts
6. Remove the Rock Valve body. 7. Install new rubber seals. IMPORTANT: Be sure that the Pressure Spring is properly inserted into the housing (most easily done by hand). The thick rubber goes on the inside towards the concrete. 8. Check the condition of the Rock Pivot Shaft Bushings, as well as the condition of the parts mentioned in the note above, to see if anything else needs to be replaced while you’ve got the unit disassembled. 9. Reassemble the Rock Valve in reverse order.
Thin rubber layer Reinforced layer Thick rubber layer
Pressure Spring
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Pivot Shaft 1. Remove the Rock Valve as described in the previous section. 2. Remove the Pivot Level Bolt and Cover Plate.
3. Remove the Pivot Cylinder Pin Retainer Bolt and Keeper Bar.
4. Remove the Pivot Cylinder Pin from the slewing lever.
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5. Move the Pivot Lever away from the Cylinder Rod, and remove it from the shaft. 6. Remove the Pivot Shaft from the Bearing Housings. 7. Examine and, if necessary, replace the bearing bushings as described later.
NOTE! The pivot shaft seals should always be replaced when replacing the Pivot Shaft. 8. Install the Pivot Shaft with the alignment marking on the top.
9. Assemble the Pivot Lever onto the Pivot Shaft, making sure the markings are in alignment.
Alignment Markings
IMPORTANT: If the markings are not correctly aligned, the Cutting Ring will not cover the ports in the Spectacle Plate.
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Pivot Shaft Bushing 1. Remove the Pivot Shaft as described in the Pivot Shaft replacement section of this manual. 2. To replace the bushings, remove the Seal Cover and Bolts.
Bushing Seal Cover
Bushing
Seal Cover 3. Remove the bushings from the housing. 4. Clean the housing bores.
NOTE! To replace the bushings, use the installation tool.
5. Fit the rear bushing (pivot lever side) first with a 46 mm wrench.
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6. Insert the bushing so that it is flush with the end of the bushing housing.
7. Now replace the front bushing (Spectacle Plate Side) with the installation tool, tightening the nut from the opposite end.
NOTE! When the bushing is correctly installed, it will protrude 5 mm from the housing on the Spectacle Plate side.
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8. Install a new O-ring into the Seal Cover, and secure the Seal Cover onto the 5 mm of protruding bushing.
O-Ring
9. 10. 11. 12.
Remove the Bushing from the End Cover using a hydraulic press or similar tool. Thoroughly clean the Bushing housing bore. Install the new Bushing using the installation tool, and ensure that it is fully in place. Install a new O-ring into the seat.
13. Install the Pivot Shaft as described in the Pivot Shaft replacement section of this manual. 14. Finally, inject grease through the grease zerks provided.
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Setting Pivot Angles After any repairs or dismantling, the pivot angles must be checked and reset, if necessary. 1. The distance between the Pivot Pin and the Cylinder Body must be approximately 185 mm(7 9/32”) with the cylinder fully retracted.
185 mm
2. To adjust the correct setting, loosen the Piston Rod Locknut and adjust as required.
NOTE! After approximately setting the Piston Rod, check that the Rock Valve travels across the Spectacle Plate, and ensure that the Cutting Ring is centered over each port. When stopped in the end position equally on both sides. 3. To check the setting, fully unscrew the pressure reducing valve and close the ball cock.Then, move the pivot cylinder to the end of its stroke. 4. In this position, check that the ports are completely covered by the cutting ring by looking through the pipe bend (connection piece). If they are not, make adjustments using the Piston Rod. 5. After the setting is checked, tighten the locknut onto the Piston Rod.
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Replacement of Pivot Shaft Bushings When changing the pivot on a Rock Valve Slewing Cylinder, please be sure that you install new bushings in the pivot eyelets. These bushings are not automatically shipped with a pivot, so please order them with the pivot if you don’t have them in stock. The part number for this bushing is: 10006726. Bushings
Pivot
Also, when you change the pivot, we recommend that you change the Pivot Bushings, if your unit has the thin, teflon coated bushings. The part number on these thin bushings is: 10016324. If your unit has the thick, steel bushing, you need not change it out. To tell if your unit has a thin or thick bushing, you must remove the rock cylinder from the rock housing. The thick bushing is one piece, about 1/4” thick. The thin bushings are in two pieces. If you don’t want to pull your slewing cylinder just to find out, we would recommend ordering the thin bushings. If you don’t need them, return them to us for credit. Pivot Bushings
Pivot Bushing
If any “clearance” is detected in the bushing of the Rock Slewing Pivot, the bushing should be checked immediately in order to prevent further damage. Bushings
Pivot
To check the bushing bore, drive out the thin, Teflon Coated Bushings or the Single Style Bushing.
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Pivot Bushings
Pivot Bushing
If the thin, teflon coated bushings are used, they can be replaced with new ones providing that the bore diameter is 80mm to a maximum of 80.20mm. A diameter over 80.20mm must be re-worked on a boring machine and bored to 90mm and the new style solid steel bushing* pressed in.
If the single slotted bushing* is used, the bore diameter is 90mm to a maximum of 90.20mm. A diameter of over 90.20mm can be repaired by the use of a repair kit (Part no. 10063611).
NOTE! The single slotted bushing is no longer available, but it has been replaced with a solid steel bushing with the same part number.
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E-Rock Additional Mounting Instructions for E-Rock Assembly The E-rock is generally assembled by the same procedure as any other standard M-Rock. Only the Rock-Extension and a Counter Nut have been added. The Back-up ring will act as an axial bearing if the Counter-NUt is in place and has been directly adjusted. Rock-Extension pre assembly:
1. 2. 3. 4.
Place the pivot shaft onto the rock and push it against the “stop” before tightening the screws. Push the Rock-Extension supplied with O-rings over the pivot shaft and into the Rock. Extension and Rock are held together by two screws. Protection-Ring is placed inside the Extension and spot welded at four places around the circumference.
Pivot Shaft Screw
Rock Extension Pivot Shaft
O-Rings
Rock Extension Screw
Rock
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Rock Valve Mounting of E-Rock-Valve and Cover
The pre assembled E-Rock-Valve (supplied with kidney seal and cutting ring assembly) is pushed into the Housing till the cutting rings hit the wear insert (spectacle plate). The end-cover will then compress the E-Rock-Valve assembly and the swivel shaft will be ready to be fixed by the Adjusting nut and Locking-Ring by the following procedure: 1. Place the Locking-Ring onto the square section at the shaft end. 2. Screw on the Adjusting-Nut till it hits the Locking-Ring and make up HAND TIGHT. 3. Turn the Adjusting-Nut clockwise only till the next possible hole of the Locking-Ring is reached to place the Locking Screw for securing the Adjustment-Nut.
Locking Ring
Swivel Shaft Adjusting Nut
Locking Screw
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Placing the Counter-Nut at the lever side:
Only the E-Rock Valve requires an additional Counter-Nut to compensate for internal thrust forces when the system is in operation. The Counter-Nut can only be adjusted after the swivel drive is completely assembled. The Counter-Nut has a pitch of 2 mm. 1. Place the Ring and Lever supplied with the O-rings onto the Swivel Shaft. The parts are in the right position if the marked points (at the face) are matching. 2. Insert Ring into the Lever and watch out for the O-ring. 3. Screw on the Counter-Nut till it hits the Ring and make it hand tight. 4. Screw back the Counter-Nut by 1/4 turn and measure the gap. (approx. 0.5mm). 5. Secure the Counter-Nut by it’s 3 worm screws. 6. Place the Cover over the Counter-Nut and secure with Bolt. Don’t forget the O-Ring.
Bolt Cover Worm Screws
Swivel Shaft
O-Ring
Insert Ring
Counter Nut
Lever
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Rock Valve
Rock Slewing Cylinder
21 1 17
2
18 19
15
20
14 13
16
34 8
7
22 23 24
9 10
6 5
34
11
3
12 11
12
4
4 10
9
3
8 26 28
31
29
13 14
34
30 32 33 32
Pos Qty. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
60
1 1 8 8 1 1 1 2 2 2 2 2 2 2 1 1 2 2 2 2 1 2 1 1 1 1 1 1 1 1 4 2 1 1
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Description SCREW DIN 908 R 3/8", 5.8.................................................................................................. SEALING RING DIN 7603 A 17 X 21 CU............................................................................... NUT DIN 6915 M 20, 10......................................................................................................... DISC DIN 6916 M 21 C.45 ..................................................................................................... PIPE PROTECTION............................................................................................................... O-RING 56 X 4 ....................................................................................................................... CYLINDER HEAD .................................................................................................................. BALL STEEL .......................................................................................................................... SPRING BOLT EV 105-0199 ................................................................................................. SPRING PRESSURE............................................................................................................. SEALING RING DIN 7603 A 21 X 26 CU............................................................................... VALVE PLUG EV 105-006C .................................................................................................. O-RING 72 X 4 ....................................................................................................................... BACK-RING PTFE 80/73.6 X 1.5........................................................................................... CYLINDER PIPE .................................................................................................................... SLEWING PIVOT ................................................................................................................... BUSHING MB 3530................................................................................................................ BOLT ...................................................................................................................................... GREASE NIPPLE DIN 71412 CM 10 X 1, 5.8 ....................................................................... SCREW DIN 933 M 10 X 20, 8.8 ........................................................................................... CYLINDER BEARING ............................................................................................................ RING SAFETY 68 X 2.5 DIN 472........................................................................................... ROD EYE ............................................................................................................................... BEARING ARTUCULATED GE 45 DO-2 RS......................................................................... NUT HEX DIN 934 M 42 X 3 8 ............................................................................................... SCRAPER 45 X 44 X 7 P 6-45............................................................................................... RING TENSION ..................................................................................................................... ROD SEALING R 32510055 45 X 60 X 11 ............................................................................ CYLINDER HEAD .................................................................................................................. PISTON ROD ......................................................................................................................... ANCHOR SCREW 20 X 570 M20 X 40 10.9.......................................................................... GUIDE BAND 9287 - 076.519................................................................................................ PISTON SEALING OMK - 5 - 80............................................................................................ SEAL KIT FOR SLEWING CYLINDER ..................................................................................
Service Manual
Part No. 10001767 10003956 10001232 10001509 10017554 10000749 10017555 10006002 10017561 10013054 10004056 10017562 10000933 10016238 10017557 10118218 10006726 10058467 10007884 10001855 10058466 10016233 10017560 10019455 10017021 10006804 10017559 10016236 10094649 10017556 10016797 10016234 10016235 10064756
27 34
25 34
22
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Welding Procedures-SAIE 5312 SAIE STANDARD Subject:
WELDING PROCEDURES - ROCK VALVE HOUSING
SAIE - 5312
No. : Date :
12-10-92
By : Sheet :
Rev :
TA 1 of 1
For general welding on the rock valve housing, Schwing Germany recommends a UTPO68HH DIN 1736, S-NiCr 19 Nb, material number 2.4648. An equivalent American electrode must have the following physical and chemical properties:
Alloy by % Weight
Permissible Additives
Ni - at least 67 Cr - 18.0 to 22.0 Mn - 2.0 to 6.0 Nb - 1.5 to 3.0
C - 0.1% S - 0.015% Co - 0.1% Si - 1.0% Cu - 0.5% Ti - 0.5% Fe - 4.0% Mo - 2.0% other elements total - 0.5%
Melting range - approx. 1400 C (2550 F). Nb is Niobium and it can be replaced by Ta (Tantalum) Preheat the electrodes for 2 to 3 hours at 250 to 300 C (480 to 570 F) The electrode must be high Ni and Cr content and high elongation. For example, Huntington INCONEL #82 wire, (AWS-ERNICRS) and Huntington INCO weld A, for 1/8" (Schwing Part#30352281) or 3/32"(Schwing Part#30352282) electrode AWS-ENICRFE2 or equivalent.
The parts to be welded must be very clean. Preheat the area to be welded to 250 to 300 C (480 to 570 F). Incline the electrode slightly and weld with short arcing. To prevent final crater cracks, fill up the crater as well as possible and lift-off the arcing at the side. To prevent cracking, we recommend placement of the casting into a preheated oven and letting it cool from 600 F to room temperature over 12 hours. If an oven is not available in your city, you can try to let the weld cool slowly under an asbestos blanket, an aluminum cover, or sand.
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Rock Valve with Insert - Conversion Procedure for converting older Rock Valves to accept removable pressure spring insert.
2
1
1. Weld per SAIE 5125 using E7108 and preheat to 200˚F complete 360˚ of weld circle. 2. Addition of the insert requires a depth of 2.047. So if the Rock Valve has the standard depth 1.732 then it must be machined to 2.047 at the same 9.843 Dia.
3. To machine Rock Valve for insert use P/N 30348121 (Machine 0.315 deeper as shown in detail A).
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Small Rock Valve - Repair Safety When performing maintenance on Schwing Equipment, the safety regulations must be followed. The observation of these regulations is the responsibility of the maintenance personnel. The following are some supplementary recommendations.
WARNING
READ FIRST! 1. WARNING! Read and understand the operation manual of the machine before attempting any repairs. If in doubt, call the manufacturer. Incorrectly done repairs endanger operational safety of the machine. 2. WARNING! Burning hazard! Never work on a hydraulic system with hot oil. 3. WARNING! Falling hazard! If you cannot work at ground level, you must use a suitable work platform. 4. WARNING! If maintenance work requires that you use a crane, hoist, fork truck, etc., you must read and understand the safety regulations for that equipment. 5. WARNING! If working the machine requires that it be operated, and you are not qualified as an operator, you must get someone who is qualified to assist you. 6. WARNING! If you will be working in a hidden area inside the machine, protect yourself by taking the key from the ignition and putting a “DO NOT OPERATE” sign on the controls. In the case of electrically driven units, disconnect the main circuit breaker and lock it in the disconnected position. 7. WARNING! Never activate the system hydraulics without checking if another workman is in a hidden position. Always yell “CLEAR”, and allow time for response, before starting the prime mover. 8. WARNING! Never use gasoline or diesel fuel as a cleaning solvent. This is critical to remember when cleaning hydraulic oil reservoirs, because gas and diesel fuels are highly explosive, and gasoline or diesel fuel traces left in the oil may ignite when compressed. 9. WARNING! Always use the correct tools for the job. Tools should be kept clean, and in good condition. 10. If you see a co-worker engaging in an unsafe practice, explain the dangers. Safety is always in the hands of those on the job. WARNING! Never work on a pressurized hydraulic system. Stop the prime mover and relieve the accumulator circuit (if so equipped) before you open the hydraulic system.
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Rock Valve
Parts Identification Spectacle or Inlet Plate Spectacle or Inlet Plate Cutting Ring Bushing Seal Cover
Rock Valve Kidney or Outlet Plate Locking Bolt
Pressure Spring
Kidney Seal
Centering Screw Setting Disc Tension Nut Locking Washer
B
2.5mm (.098") 1.5 - .2.0mm (.060 - .080")
Dimensions shown are with all new wear parts. When Dimension B exceeds 8mm (.315") the cutting ring is worn out
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Lubrication Points Use a grease gun with the recommended grease listed in the chart below. Locate the grease points, clean the grease fitting before filling it, and inject grease until you see old grease displaced by the new grease. Lubricate the grease points at 8 hour intervals and whenever the machine work is completed for the day.
Grease Points
Minimum Specifications for grease. Lithium base high-pressure grease KP 2 K per DIN 51502. BP
Energrease LS2
MOBIL
Mobilith AW 2
SHELL
Alvania grease R2
TEXACO
Multifak 20
ARAL
HLP 2
ESSO
Beacon 2
OPTIMAL
Olitsa longtme 2EP
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Rock Valve
Lengthening the Service Life of the Spectacle Plate and Cutting Ring Conditioned by outside influences (material variations), as well as by differing work strains on partial sections, the cutting ring and the housing lining wear out unequally. The grooves resulting from operation are irrelevant as long as the armouring is not worn out completely. Friction and stone crushing
Friction
Friction and stone crushing Friction Figure 1
To ensure uniform wear and, thus, CONSIDERABLY LONGER SERVICE LIVES, we recommend the following: 1. Move the Rock Valve to the left and right end position once a week after thorough cleaning, and check the condition of both the Cutting Ring and the Housing Lining. 2. Turn the Cutting Ring 90 degrees when there is a clearance greater than 1.0mm-1.5mm (.0393”-.0590”) between the Cutting Ring and the Housing Lining. Housing Lining
Housing Lining
max 1.5mm 0.590"
Cutting Ring
Cutting Ring max 1.5mm 0.590"
Check for the gap at several points along the Cutting Ring circumference, and always turn the Cutting Ring in the same direction.
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It is only necessary to loosen the Securing Bolts of the Housing Cover approximately 10mm (.3937”) in order to release the Pressure Spring and turn the Cutting Ring. 3. Check the distance between the Cutting Ring and the Rock after each turn of the Cutting Ring. If it exceeds 8mm (.315”), the pretension of the Pressure Spring is not enough to correctly press the worn cutting ring up against the Spectacle Plate. In this case, the Cutting Ring has to be replaced. Inlet Housing Lining Cutting Ring Rock Valve Pressure Spring
B
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Rock Valve
Rebuilding of Rock Valve 1.
Remove the Locking Bolt from the Tension Nut.
2. Loosen the Tension Nut.
NOTE! It’s ok to remove the Tension Nut with a wrench, but it must never be tightened move than hand tight.
3. Remove the Tension Nut.
Tension Nut
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4. Remove the Setting Disc.
Setting Disc
5. Remove the special Centering Screws (SAI Part #10069857).
NOTE! It is important that these Centering Screws get installed in the same holes upon reassembly.
Centering Screw
6. Install the alignment rods (SAI Part #30309007).
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7. Slide the rear housing cover back slightly.
NOTE! Some versions of the Rock Valve have a sealing cord under the cover.
8. Remove the Locking Bolt for the Cylinder Pin on the Slewing Yoke.
Locking Bolt
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9. Remove the Locking Bolt for the Cylinder Pin on the barrel end of the cylinder.
Locking Bolt
10. Using a drift pinch and a hammer, drive the Cylinder Pins out and remove the hydraulic cylinder.
Drift Punch Hammer
11. With the Rear Cover Housing moved back, remove the Kidney Seal for inspection or replacement.
Kidney Seal
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Rock Valve 12. Slide the Rock back about 1.5 inches.
13. Remove the Cutting Ring. Cutting ring being removed
14. Remove the Pressure Spring.
Pressure spring being removed
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15. Loosen the bolts and slide the Sealing Cover back on the Rock Shaft. Sealing Cover
16. Carefully remove the Rock Valve from the housing.
NOTE! The Slewing Yoke will be removed from the shaft at this time. It may bind up, so you will have to pry or tap the yoke with a hammer to remove it. Upon reassembly, refer to the previous section in this manual regarding installation of the Slewing Yoke for the proper yoke alignment procedure.
NOTE! In the event that the Rock Shaft Bushings require replacement, proceed to steps 19 &20.
17. Remove the Seal Cover from the Rock Slewing Shaft and remove the O-ring.
Seal Cover
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Rock Valve
18. Remove the O-ring from the groove of the Rock shaft bushing on the Rear Cover Housing. O-ring
19. Using the correct size bushing driver, drive the old Rock shaft bushing out of the front cover of the Rock housing. Bushing Driver
Hammer
20. Using the correct size bushing driver, drive the old Rock Shaft Bushing out of the Rear Cover Housing.
Bushing Driver
Hammer
Rear Cover Housing
21. Remove the two bolts attaching the Spectacle Plate to the Front Cover.
Counter Sunk Bolts
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22. Carefully remove the Spectacle Plate from the Rock Housing. Spectacle Plate
23. Remove the four bolts from the rear cover that attach the Kidney Plate to the rear cover.
NOTE! On some versions of the Rock Valve, these four bolts are under the delivery pipe. The delivery pipe will have to be unbolted to gain access.
24. Remove the Kidney Plate.
NOTE! The Kidney Plate should have a smooth, mirror-like finish, free of any scratches, gouges, or wear grooves. Before reassembly, make sure that all components are thoroughly cleaned.
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25. Reassemble the Rock Valve assembly in the reverse order that it was disassembled. Slide the cover back in place.
NOTE! Upon reassembly, generously grease the Kidney Seal and the Kidney Plate. Also, generously grease the Cutting Ring and the Spectacle Plate. This is important, because after you have assembled the Rock and done some necessary adjustment, you are going to have to shift the Rock several times before making the final adjustments.
26. Adjust the Tension Nut, which is tightened only hand tight. If the Locking Bolt shown can be installed in the Setting Disc freely, then do so. If the hole in the Tension Nut does not align with the thread hole in the Setting Disc, loosen the Tension Nut to the previous hole, and install the Locking Bolt.
NOTE! Check to make sure that the proper clearance is obtained between the Rock Valve and the Cutting Ring and between the Rock Valve and the Kidney Plate. If the Rock components are worn, the dimensions may be larger that specified. If the dimensions are too small, loosen the Adjusting Nut and pry the Rock Valve in the direction needed. Stroke the unit several times, and recheck the dimensions. If the dimensions are correct, reinstall the Tension Nut and readjust.
Locking Bolt
IMPORTANT! At no time should you operate the Rock Valve without first lubricating the outlet wear plate. Spraying the plate with water or oil will usually be adequate prior to start-up for pumping. Moving the kidney seal against a dry plate will cause excessive wear and premature failure.
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If the Pressure Spring has to be replaced, remove the old spring and clean the vacant area thoroughly to clear it of concrete residue. If dust and residue is ignored, the new spring cannot be installed correctly, and the flow of concrete could pull it out of the groove. Furthermore, the high pretension resulting from reassembling with concrete residue in the area of the spring leads to premature wear of the Cutting Ring and Housing Lining.
B Rock Valve
Inlet Housing Lining
Pressure Spring
Cutting Ring
Figure 1
NOTE! Slightly grease the new Pressure Spring when installing it. The same applies to the Kidney Seal. Do not use too much grease, because grease accumulating in the spring chamber operates as a spacer, increasing the spring pretension. Although these components will withstand a great deal of hard usage, the Pressure Spring and Kidney Seal should be inspected whenever the Cutting Ring is replaced.
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Rock Valve
Determining Wear on the Kidney Seal Housing Lining - Outside Replace the kidney seal if any of the following conditions exist: • • •
A considerable formation of cracks are found in the areas marked by arrows. This problem is very rare. The lip is completely worn to the point that the pressure relief grooves are no longer recognizable. The distance indicated by “M” of the released kidney seal does not exceed 30mm (1.1875"). 2
2
Spring installed
M d
1
mm
Figure 1
Replace the outlet housing lining (kidney plate) only if scores deeper than 1.5mm are found in the area that contacts the kidney seal. You can measure this by placing a steel ruler across the kidney plate in several places and using a depth gauge to determine the gap.
NOTE! Outside of the area that contacts the Kidney Seal, you may detect scores that are due to aggregate particles stuck between the Rock Valve and the Kidney Plate. (See fig. 2 and fig. 3) THESE SCORES DO NOT MATTER IN THE LEAST!
Figure 2
Figure 3
CAUTION! Under no circumstances should you allow the kidney seal to be run with a dry hopper. This will destroy the kidney seal and is the primary cause of premature wear encountered at the outlet side of the Rock Valve. If you will be repairing the Rock or troubleshooting a problem, always fill the hopper with water to the top of the Rock Valve before switching.
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Replacement of Cutting Ring and Kidney Seal 1. Remove the Locking Bolt from the Tension Nut.
2. Loosen the Tension Nut
NOTE! It’s ok to remove the Tension Nut with a wrench, but it must never be tightened move than hand tight.
3. Remove the Tension Nut.
Tension Nut
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Rock Valve 4. Remove the Setting Disc.
Setting Disc
5. Remove the special Centering Screws (SAI Part #10069857).
NOTE! It is important that these centering screws get installed in the same holes upon reassembly.
Centering Screw
6. Install the Alignment Rods (SAI Part #30309007).
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7. Slide the rear housing cover back slightly.
NOTE! Some versions of the Rock Valve have a sealing cord under the cover.
8. Remove the Kidney Seal for inspection, and replace it if necessary. See the previous section of this manual entitled Determining Wear on the Kidney Seal and Housing Lining--Outlet Side for reference.
Kidney Seal
9. Slide the Rock Valve back about 1.5 inches, and carefully remove the cutting ring.
NOTE! If you are going to turn the Cutting Ring, you only have to move the Rock back far enough to allow you to loosen the ring and turn it 90 degrees. To determine if your Cutting Ring needs to be turned, refer to the previous section of this manual entitled Lengthening the Service Life of the Spectacle Plate & Cutting Ring.
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10. Make sure that all parts are thoroughly cleaned, and reassemble in reverse order. Slide the Rock cover back into place, and secure it with bolts.
11. Adjust the Tension Nut, which is tightened only hand tight. If the Locking Bolt shown can be installed in the Setting Disc freely, then do so. If the hole in the Tension Nut does not align with the thread hole in the Setting Disc, loosen the Tension Nut to the previous hole, and install the Locking Bolt.
NOTE! Check to make sure that the proper clearance is obtained between the Rock Valve and the Cutting Ring and between the Rock Valve and the Kidney Plate. If the Rock components are worn, the dimensions may be larger that specified. If the dimensions are too small, loosen the Adjusting Nut and pry the Rock Valve in the direction needed. Stroke the unit several times, and recheck the dimensions. If the dimensions are correct, reinstall the Tension Nut and readjust.
Locking Bolt
IMPORTANT! At no time should you operate the Rock Valve without first lubricating the outlet wear plate. Spraying the plate with water or oil will usually be adequate prior to start-up for pumping. Moving the kidney seal against a dry plate will cause excessive wear and premature failure.
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Adjustment of the Slewing Cylinder and Installation of the Slewing Yoke Please be advised that there is no possible adjustment to align the Rock Valve with the material cylinder openings. Our service personnel have been made aware that some maintenance personnel have been unscrewing the slewing yoke to compensate for the Rock missing the holes while shifting. This is absolutely NOT to be done! By unscrewing the slewing yoke, you risk tearing off the threads on the end of the cylinder rod, which would cause immediate breakdown of the unit. 2 1
Figure 1
These units were designed to have no adjustment. If you replace a shifting cylinder or a slewing yoke, you must make sure it is screwed the full distance on the threads and then locked down. If you do notice that the Rock is missing the material cylinder openings, you must check to see where the problem may be (i.e., articulated bearings, shifting cylinder (internal), or Rock slewing lever may need adjustment). Please call the Schwing Service Department at (651) 429-0999 with any questions regarding this matter.
Slewing Yoke Timing (Viewed From Cylinder End)
CL
CL
The slewing yoke is installed properly when the center line of the hydraulic cylinder rod is in line with the center line of both the slewing shaft and the inlet or cutting ring.
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Rock Valve
Rock Slewing Cylinder
2 13
6
10 11
3
9
8
4
5 1
7
12
1. Cylinder Pipe
8. O-Ring
2. Rod Eye
9. Snap Ring
3. Tension Ring
10. Rod Scraper Seal
4. Guide Bushing
11. Rod Seal
5. Piston and Rod Assembly
12. Tension Ring Bolt
6. Articulated Bearing
13. Clamping Bolt
7. Piston Rings
IMPORTANT! Due to the various applications of the small style Rock Valve, a variety of seals and sealing materials are used. Please consult the parts manual for the specific machine you are working on for the correct parts, which may differ from what has been illustrated here.
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Pumpkits
•
Specifications
• •
2023-4
•
• • • • •
130/80 x 2000 Pump Kit A7VO 107 Hydraulic Pumps A10VO 28 Accumulator Pump with Through Drive Standard 4194 Stiebel Gearbox Separate Cooling System High Flow DN 30 S1-S2 Control Block.
• • • •
• • • • • •
130/80 x 2000 Pump Kit Two tandem mounted A11VO 130 Hydraulic Pumps A11VO 60 Boom Pump with A10VO 28 Accumulator Pump with Through Drive tandem mounted 4400 Stiebel Gearbox Separate Cooling System (Standard on S 45 SX) High Flow DN 30 S1-S2 Control Block
A11VO 60 Boom Pump with A10VO 28 Accumulator Pump with Through Drive Tandem Mounted 4400 Stiebel Gearbox Separate Cooling System(Standard on the S 45 SX) High Flow DN 30 S1-S2 Control Block
120/85 x 2500 Pump Kit Two Tandem Mounted A11VO 130 Hydraulic Pumps A11VO 60 Boom Pump with A10VO 28 Accumulator Pump with Through Drive Tandem Mounted 4400 Stiebel Gearbox Separate Cooling System(Standard on S 45 SX) High Flow DN 30 S1-S2 Control Block
2525H-6 • • • • •
2023H-6 • •
Pumpkits
2525H-5
2023-5 • •
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120/80 x 2000 Pump Kit A11VO 190 with A11VO 130 Hydraulic Pumps Tandem Mounted PUMPK I T
PUMP CYL. (Dia)
DIFFERENTAL CYLINDER (Diameter)
500-18x 900 HDR 1250 1200 HDR-20 1200 HDR-23 2023-4 2023-5 2023H-6 2525H-5 2525H-6 750-18R
7 8 7 8 9 9 9 9 10 10 7
3.1 4.7 (120mm) 3.14
117 -
75 67 95
870 -
870 1565 942
30 -
27 17 34
55 63 55
5.1 5.1 4.7 4.7 4.7
170 209 182 181 213 -
69
1007 1007 1233 1169 1169 -
870
26 32 28 18 22 -
34
79 79 79 98 98 39
(130mm) (130mm) (120mm) (120mm) (120mm) 3.1
MAX. CONCRETE OUTPUT ROD PISTON (cu. Yd/hr) (cu. Yd/hr)
120/85 x 2500 Pump Kit, A11VO 190 with A11VO 130 Hydraulic Pumps Tandem Mounted A11VO 60 Boom Pump with A10VO 28 Accumulator Pump with Through Drive Tandem Mounted 4400 Stiebel Gearbox Separate Cooling System(Standard on S 45 SX) High Flow DN 30 S1-S2 Control Block
MAX. PRESS. ON CONCRETE ROD PISTON (psi) (psi)
Service Manual
MAX. THEORY STROKES/MIN ROD PISTON
STROKE LENGTH (IN.)
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Change rams
• •
When you begin to see not just cement dust in your waterbox at the end of the day, but also small bits of sand or even pebbles, it is time to change the rams. When changing rams, you will have to put your hands in the waterbox on several occasions. In the past, we instructed you to stop the engine each and every time before putting your hands into the waterbox, and we still highly recommend this practice. The local control on-off switch for the concrete pump and the manual handle for activating the concrete pump are located in positions that make them impossible for you to activate while your hands are in the waterbox. If however, another person has access to these devices, or the “ram change” operation panel, the danger of accidental activation increases.
•
•
The stroke limiter is set to minimum output. The operation stations (the rear control panel, the cable remote box, the radio remote box) are disabled. Three LEDs (oil cooler status, oil filter status, and E-Stop status) on the rear control panel will be flashing. These LEDs will continue to flash as long as the O I switch is in the I position. Three LEDs (rear control, cable control, radio control) on the CPC will be OFF.
The concrete pump can only be actuated with the Forward/Reverse switch to the right of the O I selector switch. This momentary switch is spring loaded to the center position and activates only while it is being held in a forward or reverse position. While operating in ram change mode the pistons will move at the slowest possible speed. ramctrl.eps
Crushing/amputation hazard. Disable the hydraulic system before removing waterbox guards.
• •
W007.eps
WARNING
If you insist on changing rams with the motor running, you must take the following precautions to avoid amputation of hands, arms, and fingers: Do not use the remote controller for this procedure! Unplug it, and store it. Do not allow anyone else at the rear control panel or the forward/reverse hand valve when you are changing rams. The chances of accidental amputation are greatly increased if more than one person is around. You will have fewer distractions when you are alone. If someone approaches you when you are changing rams, stop working until the person leaves.
rd
orwa F e s r Reve
Select the ram change mode
OIsw
Select local control on the rear control panel and then select I (ON = ram change mode) with the O I selector switch located on the ram change station (Figure 1). When I (ram change mode) is selected the following things happen automatically: • The diesel engine R.P.M. will return to idle
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O = Off
tch.e
ps
I = On
Figure 1 Ram change station on rear boom cradle “A” frame (current production)
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Remove the old rams.
Use the following procedure to remove the old rams. 1. Close the shutoff valve (also known as the ball cock and quarter turn valve). The shut-off valve is located on the concrete pump control block (Figure 2). This gives you control over the direction of travel of the differential cylinders.
dogbone1.eps
Soft switch shutoff valve
Figure 3 Retract the driver’s side rod into the waterbox all but about an inch and a half
Concrete pump shutoff valve
39
5. A 55mm open end wrench and a 24 - 30 mm box end wrench were supplied with the unit; you will need them for this step. Locate the 55mm wrench on the dog bone to hold the assembly from turning. You can rest the handle against the side of the waterbox (Figure 4). Unscrew the 4 M20 bolts that hold the assembly together.
hif
low
.ep
s
Figure 2 Concrete pump shutoff valve
dogbone2.eps
2. Drain the waterbox. Remove the waterbox cover and the bolt down grate. 3. Retract the driver side differential rod almost all the way into the waterbox (Figure 3). Leave about 1.5 inches of travel, which will allow you to remove the spacer coupling (dogbone). 4. Push the emergency stop button on the operator’s panel. Stop the engine, and put the key in your pocket. (Stopping the engine before putting your hands in the waterbox is mentioned at every appropriate spot.) Figure 4 Remove the bolts from the dogbone 6. Be sure all personnel and tools are out of the waterbox, then start the engine. Release the emergency stop button. Finish retracting the driver side rod into the waterbox. The dogbone will fall out. 7. Push the emergency stop button on the operator’s
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Pumpkits panel. Stop the engine, and put the key in your pocket. 8. Remove the dogbone from the waterbox (Figure 5).
ramflang.eps
.
dogbone3.eps
Figure 6 Removal bolt grooves on flanges 11. Start the engine. Release the emergency stop button, and slowly retract the cylinder rod until the ram is clear of the material cylinder (Figure 7). Figure 5 Remove the dogbone
ram install fig 3
9. Start the engine. Release the emergency stop button. Slowly extend the cylinder rod until it just contacts the rubber ram flange. NOTE! Be careful not to drive the rubber ram into the material cylinder. If it happens that you accidentally knock the ram into the material cylinder so far that you can’t reach it, you will have to remove it by knocking it out from the Rock Valve end of the unit. Call the Schwing America Service Department at (651) 429-0999 for instructions on this procedure. 10. Push the emergency stop button on the operator’s panel. Stop the engine, and put the key in your pocket. There is a groove in the ram flange that will line up with a groove in the cylinder flange. An M12 x 45 bolt with nut will drop into this groove and allow you to pull the ram out. The fit should be snug, but there is no need to tighten the nut with tools (Figure 6). (Note that the ram flange and cylinder flange are shown outside of the waterbox for clarity of the illustration.)
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Figure 7 Slowly bring the ram into the waterbox 12. Push the emergency stop button on the operator’s panel. Stop the engine, and put the key in your pocket. Remove the nut and bolt, and the ram will be free to come out of the waterbox. 13. Clean and inspect the bolts and cone washers, the dogbone, and the cylinder flange. Replace any damaged or worn parts with new ones. Install the new rams.
Use the following procedure to install the new rams. 1. Apply Loc-tite primer (or equivalent) to the M20 bolts. Allow the primer to dry. 2. While the primer is drying, apply a liberal coat of clean grease to the new rams. There is no such thing as too much grease here, because the excess
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will be wiped off by the material cylinders during installation. 3. With the engine still stopped, hold the new ram up to the cylinder flange. Line up the grooves, and drop your nut and bolt into place to hold the assembly together. Again, you should only tighten the nut finger tight. 4. Start the engine. Release the emergency stop button. Slowly extend the cylinder until the ram is installed in the material cylinder but the mounting flange is still exposed enough to remove the nut and bolt (Figure 8).
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8. Start the engine. Release the emergency stop button. Slowly move the cylinder down to where the flange butts up to the dogbone. Be careful not to go too far! (Figure 9).
ram install fig 3
ram install fig 2
Figure 9 Slowly move the cylinder to meet the dogbone
Figure 8 Slowly push the new ram into the material cylinder 5. Push the emergency stop button on the operator’s panel. Stop the engine, and put the key in your pocket. Remove the nut and bolt. 6. Start the engine. Release the emergency stop button. Slowly retract the rod again until there is room to install the dogbone. 7. Push the emergency stop button on the operator’s panel. Stop the engine, and put the key in your pocket. Apply Loc-tite 242 or equivalent to two of the M20 bolts. Place the dogbone up against the flange of the new ram. Install two of the M20 bolts (with Loc-tite) and the cone washer sets. At this time finger tighten only.
9. Push the emergency stop button on the operator’s panel. Stop the engine, and put the key in your pocket. You may have to slightly rotate the dogbone to align the bolt holes with the cylinder flange. When aligned, coat the two remaining M20 bolts with Loc-tite and install, including the cone washer sets. Once all four bolts are started, you may tighten the bolts to the torque specification for M20 10.9 bolts (420 ft/lbs). 10. Repeat all steps in the Remove the old rams procedure and Install the new rams procedure for the passenger side ram. 11. Open the shutoff valve. Note that the unit will not cycle with this valve closed.
NOTE! It is important to install the dogbone against the new ram first, not the cylinder flange. This gives you an extra 6 to 8 inches of safety margin when you extend the cylinder to meet the dogbone. If you attach to the cylinder flange first, chances are good that you will accidentally knock the new ram into the material cylinder so far that you won’t be able to reach it.
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Changing the material cylinders The material cylinders also eventually wear out. They are considered worn out when the inside diameter has grown 3 millimeters beyond the specification for new. For example, a 750-18 has 180mm material cylinders. When the inside diameter reaches 183 mm, they are worn out. With 150’s they are worn out at 153, etc. Normally, it is the end attached to the rock valve that wears out first, because it sees the most concrete. The waterbox end may be in brand new condition, because that end never experiences concrete. For this reason, the material cylinders were designed to be able to flip end for end. That way you can move the worn out part to the waterbox and the like-new part to the concrete valve for double the life. If you are going to do this, you have to catch the wear on the material cylinders before they get too thin or break through in one or more spots. Once that happens you can’t flip them, because they would be structurally too weak to hold the pressure forces at the waterbox end.
2. Select the “forward” mode of the S1 valve, AT THE SLOWEST POSSIBLE SPEED! Look into the material cylinder from the valve end. The gap between the alignment tool and the cylinder wall should be seen as even rays of light. When the cylinder gets fully extended, the alignment tool may drop a small amount or even barely touch the material cylinder wall LIGHT RAYS
CYLINDER WALL
The procedure for changing and aligning the material cylinders is the subject of Service Bulletin G-102/88. Contact the Schwing America Service Department at (651) 429-0999 if you need a copy of the bulletin
Material Cylinder Alignment 1. To visually inspect the alignment, put a trouble light in the waterbox, at the opening to the cylinder being aligned. 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.
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ALIGNMENT TOOL
NOTE! If the alignment tool should contact the cylinder wall at any time, return the pump to neutral immediately! Damage may occur to cylinder wall. 3. If, for example, the alignment tool contacts the cylinder on the lower side, loosen the mounting bolts at the waterbox a little bit, then tighten the LOWER bolts first. This will lower the bottom of the material cylinder. When the alignment is close, tighten the top bolts and recheck the alignment. When the alignment is within specification, the alignment tool will travel the entire length of the cylinder without touching the cylinder wall. If the alignment tool is not always located exactly in the middle of the cylinder during the travel, but DOES NOT TOUCH, then realignment is not necessary. Minor misalignments are compensated for with the rubber ram. Repeat procedure for the other cylinder.
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NOTE! If proper alignment cannot be achieved otherwise, tightening torques may be exceeded by 10% over the charts specs. If further alignment problems persist, please contact the Schwing Service Department.
MOUNTING BOLTS
Figure 3.1 - Mounting Bolts 4. Grease new o-rings and insert in the valve housing. 5. Carefully slide the valve housing onto the material cylinders, and rest the valve housing on the machine frame. 6. Bolt the valve housing and material cylinder flanges together making sure that the alignment is being maintained. 7. Bolt the valve housing to the machine frame. 8. Check alignment with the tool once more, at slowest possible speed.
9. 10.
11. 12. 13. 14.
NOTE! If a squeaking sound indicates the alignment tool is dragging on the material cylinder, turn off the pump IMMEDIATELY! If there is no dragging, you may proceed to step 11. If dragging does happen, repeat the visual checks. Loosen the bolts on the material cylinders and valve housing, and at the machine frame, and repeat the alignment procedure. Check the mounting and shimming of the pump kit and its mounting to the pump kit frame. Tighten all bolts. Complete the reassembly of valves, and install the rubber rams. Reopen the ballcock or throttle valves NOTE! The poppet valve housing must be off to do this alignment procedure. Also when the rod gets fully extended, it may touch the cylinder walls.
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Pumping on piston side Piston side pumping changes your concrete pump from a low-pressure, high-volume machine into a high pressure, low-volume machine. This would be handy, for example, to pump long distances horizontally or vertically. Piston side operation dramatically raises the maximum pressure on the concrete. For this reason, it is crucial that your entire material delivery system be rated to handle the available pressure and be maintained in likenew condition. Remember that pipe wall thickness wears with each yard of concrete pumped. Inspect the wall thickness regularly. The maximum material pressure available on the piston side depends on which differential and material cylinders you purchased with your unit. The maximum material pressure is recorded on the main ID tag. To convert your machine to piston side operation, you must have some additional hoses and fittings, plus the tools to install them. Loosen for rotation
When changing the hoses from the rod side port to the piston side port, you must cross them. This keeps the machine in the same sequence of events as when it is hooked up for rod side pumping. Failure to cross the hoses will result in pumping in reverse whenever you select forward. When you have finished with the need for piston side operation, change it back to rod side immediately. When you are configured on the piston side, the safety rules for the following topics become even more important: • Opening lines under pressure • Sucking back plugged lines before opening • Pressure-handling capacity of pipes, hoses, and clamps in your delivery system • The dangers of blockages All of these items are covered in the Safety Manual. Understand the rules and live by them.
Add dead plugs (1200’s only)
This hose 1200’s only Add hose and fittings to each side
Loosen for rotation
rod/piston change.eps
Loosen for rotation
Loosen for rotation
Rod Side Configuration
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Changes
Service Manual
Piston Side Configuration
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Subtract Dimension A from Dimension B. The difference is the amount of thickness in spacing disks required between the cylinder housing and tension ring for assembly.
3.
SPACING DISKS AS REQUIRED
PISTON ROD
GUIDE BUSHING
SPACING DISK
FIGURE 1
Service Manual
SEALING GLAND SET
TENSION RING
SCRAPER
Subject: ASSEMBLY INSTRUCTIONS FOR SEALING GLAND IN Product: THE DIFFERENTIAL CYLINDERS
FIGURE 2
B
SCRAPER
TENSION RING
SEALING GLAND SET
A
CYLINDER BARREL
SAIE STANDARD
Sheet
The packings must never be under compression from the tension ring. If the packings are under compression from the tension ring, it is possible that the cylinder rod may become scored after a short period of time during operation. Therefore when Dimension A is subtracted from Dimension B, the dimension of the spacing disks must equal the difference with a tolerance of minus nothing, plus 1 mm or .039 inch.
Set the packing set (unwrapped) on a at surface and set the tension ring on top of the packing set. Measure the distance from the at surf ace to the bottom side of the tension ring that mates to the cylinder housing when assembled (Figure 2, Dimension B).
Measure the distance from the bottom of the bore on the guide bushing to the outside machine surface of the cylinder housing where the tension ring bolts to it (Figure 1, Dimension A).
2.
1.
The following steps must be followed to ensure proper installation of the sealing glands (rod packings) on differential cylinders:
ASSEMBLY INSTRUCTIONS FOR SEALING GLAND IN THE DIFFERENTIAL CYLINDERS
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By: T.A. 1
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Pumpkits
Sealing Gland Replacement No.: SAIE - 5221
Date: 12-19-95 Rev.: D of 1
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Shimming the Differential Cylinders
Tension Ring
Determining the proper shimm size When ever you rebuild differential cylinders, it may be necessary to add shimms to the tension ring. Adding shimms protects the cylinder rod from the cheveron seals in the event the cheveron seals expand. Use the following procedure to determine the proper amount of shimming necessary.
Cheveron Seal Set
Dimension A Tape
Using a caliper measure the distance from the top of the bushing down to the bushing seal recess. See Figure 1.
Figure 16 Compacting the Cherevon seals Use the caliper to measure the distance between the top and the bottom of the compacted cheveron seals. See Figure 3.
Dimension A = 57.12 mm 57.12 mm is the depth of the guide bushing seal recess.
Dimension B = 57.4 mm
Tension Ring Bushing Seal Recess
Bushing
Dimension B Cheveron Seal Set
Dimension B
Figure 15 Measuring for dimension A
Figure 17 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 2.
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Formula A should equal B B - A = shims required In this example:
57.40 - 57.12 .28 mm (.011") Refer to SAIE 5221 Figure 18 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. See Figure 4
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.
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Hydraulic Pumps Hydraulic Pump Drive All hydraulic pumps, such as the one for the concrete pump, placing boom, and agitator, are mounted on the distribution gearcase. When you are driving the truck, the power of the truck engine is transmitted through the truck transmission, through a propeller shaft, through the bottom of the distribution gearcase, through another propeller shaft, and into the rear end of the truck. When you are operating the unit, the distribution gearcase interrupts the power to the rear end of the truck and transmits it to internal gears that turn the hydraulic pumps. Changing between travel and pumping modes is accomplished by means of a power takeoff (PTO) switch in the truck cab
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Hydraulic Pumps
Schwing, we route signals to the pump from the hydraulic stroke limiter and on single circuit units with the dampener. The effect of these devices is to tell the pump to put out a different amount of hydraulic oil per revolution, to accommodate the pump operator. Your unit may be equipped with an A7VO pump or an A11VO pump.
Placing boom hydraulic pumps
A7VO
The hydraulic pumps for the placing boom is a variable displacement pump, either a swash plate (A11VO), or an axial piston (A7VO). Both have load sensing control and feed all of the following components: • the hydraulic cylinders on the boom sections • the hydraulic cylinders on the outriggers • the hydraulic motor for the boom slewing gear • the hydraulic motor for the water pump • the hydraulic motor of the compressor (optional equipment) The directional control valves for each of the afore mentioned circuits are incorporated into control blocks and equipped with hand levers. In addition, the control block for the boom functions have electric over oil piloting for operation via remote control. A11VO S103.eps
Concrete pump hydraulic pumps The hydraulic pumps for the concrete pump circuit are bent axis, variable displacement piston pumps (A7VO) or a swash plate pumps (A11VO). They are horsepower controlled, which means that as pressure rises, the flow decreases, so the power consumption remains constant. We use this type of pump so the truck engine will not bog down under hard pumping conditions. The pumps also accept external signals for control of the output. At
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Hydraulic Pumps
Hydraulic Pump Locations
PumpKit Pumps
Proportional Boom Pump
Accumulator Pump Agitator Pump
Stiebel 4194
Oil Cooler Pump
PumpKit Pumps
Proportional Boom Pump
Accumulator Pump
Oil Cooler Pump
Agitator Pump
Stiebel 4400 S0064.eps
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Fixed Displacement Pump A2FO
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Hydraulic Pumps
the fixed displacement of the pump. The pump is suitable for use in mobile and industrial applications.
Fixed displacement axial piston pumps of bent axis design for use in hydrostatic drives in open circuits. The output flow is proportional to the input speed and
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Hydraulic Pumps
Rexroth/Hydromatik Model A7V Series 2 Note: After replacing any A7VO hydraulic pump, the unit must be bled before start-up. • If there is a U-Port on the pump, this is the bearing flush and that is where the pump should be bled from. • If there is not a U-Port, the pump should be bled from the highest case drain. Variable displacement pump, axial piston, bent axis design, fir hydraulic transmissions in open circuits.
100
The flow is proportional to the drive speed and the displacement and is steplessly variable at constant drive speed. Comprehensive program of control devices for every control and regulating function. High performance rotary group with well-proven spherical control area offering the following advantages: self-centering, low peripheral speed, high efficiency.
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Constant Pressure Control DR
Constant Horsepower Control LV
The constant pressure control maintains the pressure in a hydraulic system constant within its control range in spite of changing pump flow requirements. The variable pump supplies only the volume of fluid required by the services. Should operating pressure exceed the set pressure, the pump is automatically swivelled back to a smaller angle and the deviation in control corrected.
The constant HP control flow in relation to pressure, thereby maintaining hydraulic power constant.
The required pressure is set either direct at the pump (valve built-in, standard model) or at the separate sequence valve for the model with remote control.
P = Power [kW] p•Q P= = constant 600
p = Pressure [bar] Q = Flow [l/min]
(Provided that the drive speed is constant)
Setting range from 50 to 350 bar. Setting range for remote control 50 to 315 bar.
max. 10 bar
Setting range from 50 to 350 bar. Setting range for remote control 50 to 315 bar P max
350
315
Operating pressure acts on a pilot piston, causing it to press on a set of springs. If the hydraulic force exceeds the spring force, pilot oil is fed to the adjusting piston, which swivels the pump back to a smaller angle and therefore a smaller flow.
Commencement of control: 50 bar min.
300 150
setting range
Operating pressure PB (bar)
A (B)
R
200
G
100
50 0 Flow Q (L/min.)
S
Figure 19 - Pressure Setting Ranges
Figure 21 - Schematic of a A7V Variable Displacement Pump
Summation HP control is made possible by means of throttles via port G. A (B)
R T
P
X3
S
A
T
Figure 20 - Schematic of a A7V Variable Displacement Pump With Remote Control
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Hydraulic Pumps Auxiliary Equipment: Stroke Limiter A (B)
R X2 G
X1 S
Figure 22 - Schematic of a A7V Variable Displacement Pump With Hydraulic Stroke Limiter
By Means of a mechanical or hydraulic stroke limiter, the maximum displacement can be infinitely varied or limited. Adjusting range from Vg max to Vg min. A pilot pressure (port X1) of at least 10% of the operating pressure is required for the hydraulic stroke limiter. Maximum permissible pressure at port X1 = 200 bar (for all sizes). If it is required to limit the flow at an operating pressure < 50 bar, then a boost pressure of minimum 50 bar must be applied at port X2 (at port X1 then, minimum 10% = 5 bar)
Q min
Q max S0098.eps
Figure 23 - Q Min and Q Max Locations on a A7V Variable Displacement Pump
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Rexroth/Hydromatik Model A7V Series 6
Hydraulic Pumps
Comprehensive programming of control devices is available. The robust taper roller drive shaft bearings are designed to give long service life. Output flow is proportional to drive speed and pump displacement is steplessly variable between maximum and zero.
25ß -
0ß
Variable pump with axial tapered piston rotary group of bent axis design, for open circuit hydraulic drives. This pump is suitable for mobile applications.
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Hydraulic Pumps LR Constant Power Control The constant power control controls the output volume of the pump in relation to the operating pressure so that, at a constant drive speed, the preset drive power is not exceeded.
pB
p B = operating pressure
V = constant g
V = pump displacement g
Optimum power usage is obtained by accurately following the power hyberbola
Operating pressure p B (bar)
350 300
A (B)
R
250 220 bar
200
100
50 bar
50 0
G
Adjust. range Start of control
150
0
V
g
0.2 min
0.4
0.6
Displacement
0.8 V
1.0 g
max
Figure 24 - A7VO Variable Displacement Output Chart
Operating pressure applies a force on a piston within the control piston on to a rocker arm. An externally adjustable spring force is applied to the other side of the rocker arm to determine the power setting. Should the operating pressure exceed the set spring force, the pilot control valve is operated via the rocker arm, allowing the pump to swivel towards zero output. This in turn reduces the effective moment on the arm of the rocker, thus allowing the operating pressure to rise in the same ratio by which the output flow is reduced (Vg = constant). When the pump is bypassing at zero pressure, a spring ensures that the pump is swivelled to max. displacement (Vg max).l
S
Figure 25 - Schematic of a A7VO Variable Displacement Pump
LRH Constant Power Control With Hydraulic Stroke Limiter
X1 Y3 A A1
S
A7VO-107 LR
Figure 26 - Schematic of a A7VO Variable Displacement Pump With Hydraulic Stroke Limiter
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Variation: Hydraulic Stroke Limiter (H...) The hydraulic stroke limiter allows the maximum displacement to be infinitely varied or limited as required. Control range Vg max to Vg min. The displacement is set by means of the pilot pressure applied at port X1. The hydraulic stroke limiter is overridden by the constant power control, i.e. below the power curve (power hyperbola), displacement is adjusted in relation to pilot pressure. If the set flow or the operating pressure is such that the power curve is exceeded, the constant power control overrides the stroke limiter and reduces displacement until the power hyperbola is restored.
H1/H5 (Negative Control Function): Vg max to Vg min As pilot pressure increases the pump swivels towards lower displacement. (Starting position at zero pressure: Vg max). Start of control: adjustable between 4 and 15 bar.
Horsepower Adjustment Screw
Figure 28 - Horsepower Adjusting Screw on a A7VO Variable Displacement Pump
H1 pilot pressure increase (Vg max - Vg min) _____ p = 25 bar.
Q min
40
0ß
35
25ß -
30
pilot press. PSt in bar setting range
25 20 15
Q max
10
Figure 29 - Q Min and Q Max on a A7VO Variable Displacement Pump
4 0
0,2
Vg min Displacement
0,4
0,6
0,8
1,0
Vg Vg max
Vg max
Figure 27 - Displacement Output Chart
DR Constant Pressure Control The constant pressure control maintains the pressure in a hydraulic system constant within it’s control range in spite of changing pump flow requirements. The variable pump supplies only the volume of fluid required by the consumer. Should operating pressure exceed the set pressure, the pump is automatically swivelled back to a smaller angle and the deviation in control corrected. In un-operated (zero pressure) condition, the pump is swivelled to it’s starting position (Vg max) by means of a control spring. Setting range from 50 to 350 bar.
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max. 10 bar
Setting range from 50 to 350 bar. Setting range for remote control 50 to 315 bar P max
350
315 300
setting range
Operating pressure PB (bar)
150
200
100
50
0 Flow Q (L/min.)
Figure 30 - Pressure Setting Ranges
Variation: Remote constant pressure control (G) A sequence valve with subplate takes over the pressure control function. The valve is mounted separate from the pump, and the piping length should not exceed 5 m. High pressure is supplied from the pump to the valve via part A1, and the valve control oil is fed back to the pump via Port X, causing the pump to swivel back towards Vg min. Port T of the sequence valve and T1, the pilot drain from the pump must be connected back to tank (cooler). Pressure may be set between 50 and 315 bar. Sequence valve: DZ5DP2-1X/315 Y SO21 (Id.-Nr. 154 869) Subplate: G 115/1 (Id.-Nr. 153 138)
∆ P regulator High pressure filters
X 20 bar ∆ P
A A1
290 bar
T A
T
P
X3
Boom hydraulic pump
Figure 31 - Schematic of a A7VO Variable Displacement Pump
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Rexroth/Hydromatik Model A10VO Variable displacement axial piston A10VO of swashplate design is designed for hydrostatic
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Hydraulic Pumps
transmissions in open loop circuits. Flow is proportional to the drive speed and the displacement. By adjusting th position of the swashplate it is possible to smoothly vary the flow.
Pressure Cut-off Screw
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S0081.eps
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Hydraulic Pumps DR Pressure Control The pressure control serves to maintain a constant pressure in the hydraulic system, within the control range of the oump. The pump therefore supplies only the amount of hydraulic fluid required by the actuators. Pressure may be smoothly set at the pilot valve.
Figure 32 - Static Operating Curve
Figure 33 - Schematic of A10V0 Variable Displacement Pump
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Rexroth/Hydromatik Model A11VO
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pump is available with a through drive to accept a gear pump or a second axial piston pump up to the same size (100% through drive).
The A11VO is a variable displacement pump of axial piston swashplate design for use in open circuit hydrostatic drives. Designed principally for use in mobile applications. A wide variety of controls are available. Setting of the constant power control is possible via external adjustments, even when the unit is operating. The
Output flow is proportional to drive speed and pump displacement and is steplessly variable between maximum and zero.
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pB
p B = operating pressure
V = constant g
M A G
V = pump displacement g
T1 R T2
Optimum power usage is obtained by accurately following the power hyberbola
Operating pressure p B (bar)
350 320 bar
300 250
220 bar Setting range Start of control
200 150
Vg max
100 0
Vg min
50 bar
50 0
V
g
0.2 min
0.4
0.6
Displacement
0.8 V
1.0 g
max
Figure 34 - A11VO Variable Displacement Output Chart
s
The constant power control controls the output volume of the pump in relation to the operating pressure so that, at a constant drive speed, the preset drive power is not exceeded.
M1
Figure 35 - Schematic of a A11VO Variable Displacement Pump
35
Should the operating pressure exceed the set spring force, the pilot control valve is operated via the rocker arm, allowing the pump to swivel towards zero output. This in turn reduces the effective moment on the arm of the rocker, thus allowing the operating pressure to rise in the same ratio by which the output flow is reduced (pB • Vg = constant).
30 25
pilot press. PSt in bar setting range
Operating pressure applies a force on a piston within the control piston on to a rocker arm. An externally adjustable spring force is applied to the other side of the rocker arm to determine the power setting.
20 15 10 4 0
0,5
1,0
Vg min
Vg Vg max
Vg max
Displacement
Figure 36 - A11VO Variable Displacement Output Chart
Variation: Hydraulic Stroke Limiter (LRH...) The hydraulic stroke limiter allows the maximum displacement to be infinitely varied or limited as required. Control range Vg max to Vg min. The displacement is set by means of the pilot pressure applied at port Y (max. 40 bar). The hydraulic stroke limiter is overridden by the constant power control, i.e. below the power curve (power hyperbola), displacement is adjusted in relation
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to pilot pressure. If the set flow or the operating pressure is such that the power curve is exceeded, the constant power control overrides the stroke limiter and reduces displacement until the power hyperbola is restored.
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Hydraulic Pumps
Pressure Cut-Off Delta P Q min Load Sense Port
H1 bzw. H5 > function: Vg max to Vg min (negative control) As pilot pressure increases the pump swivels towards lower displacement. (starting position at zero pressure: vg max). Start of control, (at Vg max), settable _______ 4 - 10 bar.
Q max
H1 > pilot pressure increase (Vg max - Vg min), ________ ∆p = 25 bar. M A G
T1 R T2
A11VO Boom Pump
Y Stroke Regulation Horsepower Control Pressure Cut-Off Stroke Regulation Pressure Cut-Off Horsepower Control Q min
Vg max
Vg min Q min
A11VO 130/190 Main Pumps
s
M1
Schematic of a A11VO Variable Displacement Pump With Stroke Limiter
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Hydraulic Pumps
Linde Hydraulik BPR 105 Our BPR, bent-axis, variable displacement pumps are self-priming units primarily for use in open circuit applications. Six sizes are available with displacement
112
from 3.06 to 15.86 cid. Pressure ratings are 5000 psi intermittent and 3000 psi continuous duty.
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Power Regulator With Hydraulic Stroke Limiter (LRH) The LRH is similar to the constant power regulator but has a second sensor which responds to a low-pressure pilot signal allowing the pump to be de-stroked on demand. The pump's reduced displacement is proportional to the signal and gives overriding control within the set power band. This control is useful where it is necessary to alter maximum flow to accommodate certain conditions.
P RE
PC RB Q
L
P
U
T
P
Y
X
Figure 37 - BPR 105 Variable Displacement Output Chart
Constant Power Regulator (LR) This regulator is designed so that an exact hyperbola curve of pressure/flow is realized. Therefore, the pump makes maximum use of available power. Setting the required power output simply involves setting the pressure at which the regulator begins to destroke the pump. The pump then follows a constant power curve throughout the regulated range. It is also possible to adjust the regulator to compensate for altitude changes, prime engine options or usage changes.
L
P
U
T
P
Figure 39 - Schematic of a BPR 105 Variable Displacement Pump With Stroke Limiter
Y
Figure 38 - Schematic of a BPR 105 Variable Displacement Pump With Stroke Limiter
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Hydraulic Pumps
Voac Variable Displacement Axial Piston Pump Variable displacement pumps work according to the swash plate pricipal: 9 pistons operate in a rotating cylinder barrel where they fulfill one suction and one presssure stroke per rotaiton. The axial movement of the pistons is provided by an adjustable swash plate. he setting angle (0-17˚) is varied in proportion to the
desired displacement flow. The setting range can be mechanically limited by setting screws. The position of the swash plate can be controlled via a visual mechanical indicator. The latest knowledge and experience with regard to noise reduction has been used in the development of V30D. All components used in the V30D are manufactured from high grade materials and machined with close tolerances.
Horsepower Control
Q min
Q max
Q min
Q max
Pressure Cut-off (200bar)
Pressure Cut-off
VOAC Accumulator Pump
VOAC Main Pump
Delta P Adjustment Screw
Q min
Q max
Pressure Cut-off
VOAC Boom Pump
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Hydraulic Parts
Hydraulic Parts 2
1 4 6
3 7
5
* Locations dependent of model
1 Boom Handvalves
5 Control Blocks
2 Boom Holding Valves
6 Stroke Limiters T P T
MG
P MY
3 Brake Valves
G Y
7 Outrigger Handvalves
(Boom Brake Valve) (Brake Valve Slewing)
4 Boom Regulator
8 E-Stops
S0141.eps
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Hydraulic Parts
Boom Handvalves Table 1: 36 Hydrel Item#
Part
How it Functions
1
Directional Spool
Directs hydraulic oil from the hydraulic pump to extend or retract the boom cylinder
2
Electric/Oil Directional Control Solenoid
Electric solenoid controls the direction of the pilot oil, which controls the direction of the main spool (Item#1)
3
Handle
Manual override which provides a direct link to the main spool (Item#1)
4
Throttle Check Valve
Limits the flow of oil returning from the piston side of boom cylinder #3 when the boom cylinder is retracting. Allows free flow of oil when extending boom#3 cylinder
5
Orifice
Restricted flow in both directions to the boom cylinder
6
Main Relief - Right Hand Bank
Limits maximum pressure in right hand bank - As pressure reaches 280 bar, the relief valve will open and allow oil to be directed to tank until the proper pressure is maintained.
7
Main Relief - Left Hand Bank
Limits maximum pressure in left hand bank - As pressure reaches 280 bar, the relief valve will open and allow oil to be directed to tank until the proper pressure is maintained.
8
Throttle Check Valve
Limits the flow of oil returning from the piston side of boom cylinder #1 when the boom cylinder is retracting. Allows free flow of oil when extending the rod side of boom#1
9
#1 Down Side Relief Valve
Limits pressure on the rod side of boom cylinder #1, the purpose of which is to protect the boom cradle from excessive pressure.
10
Throttle Check Valve
Limits the flow of oil returning from the piston side of boom cylinder #2 when the boom cylinder is retracting. Allows free flow of oil when extending the rod side of boom#2
11
Orifice
Restricts the flow of oil when the hydraulic cylinder is either extending or retracting
12
Orifice
Restricts the flow of oil when the hydraulic cylinder is either extending or retracting
13
Adjustable Check Valve (Right)
Pretension check valve that generates back pressure which is used for pilot oil.
14
Adjustable Check Valve (Left)
Pretension check valve that generates back pressure which is used for pilot oil.
15
Throttle Check Valve
Limits the flow of oil returning from the piston side of boom #4 when the boom cylinder is retracting. Allows free flow of oil when extending the rod side of boom#4
16
Orifice
Restricts the flow of oil when the hydraulic cylinder is either extending or retracting
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Hydraulic Parts
15 80 bar
9
13
10 1.8
1.3
4
14
12
11
5
1.3
0.9
16
3
1.7
8 2
1 280 bar
280 bar
6
7
2 14
13
3 7
6 15
8
11
10
16
1
4
12
5 9
HV03.eps
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Hydraulic Parts
Table 2: Monson Tison Electric/Air/Oil - Black and White Item#
Part
How it Functions
A
Open Center Passage
Allows oil to flow to tank unrestricted when no functions are being used
B
Pressure Passage
Supplies pressure oil to each working segment
1
Handle
Manual override which controls the position of the directional spool. The spool is spring centered, so if force is not applied to the handle, the spool along with the handle will return to the neutral position.
2
Main Relief Valve
Limits maximum pressure in the hand valve - As pressure reaches 280 bar, the relief valve will open and allow oil to be directed to tank until the proper pressure is maintained.
3
Check Valve in pressure passage
Restricts any back flow in the pressure passage.
4
Electric/Air/Oil Solenoid
Electric solenoid controls the direction of the pilot air, which in turn controls the direction of the main spool.
5
Orifice
Restricts the speed of the boom cylinder by restricting the flow of hydraulic oil. This allows the boom to move at specified speeds, set by the factory.
6
Orifice
Restricts the speed of the boom cylinder by restricting the flow of hydraulic oil. This allows the boom to move at specified speeds, set by the factory.
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5
6 0.8
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1.1
A4
B4
1.1
1.2
1.5
A3
B3
A2
B2
A1
1.2 B1
4 B 3 T
P
290 bar
A
2
1
T
T
2
5 6
4
1
3
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Hydraulic Parts
Table 3: Monson Tison Electric/Oil/Oil - Black and White Item#
Part
How it Functions
A
Open Center Passage
Allows oil to flow to tank unrestricted when no functions are being used
B
Pressure Passage
Supplies pressure oil to each working segment
1
Handle
Manual override which controls the position of the directional spool. The spool is spring centered, so if force is not applied to the handle, the spool along with the handle will return to the neutral position.
2
Main Relief Valve
Limits maximum pressure in the hand valve - As pressure reaches 280 bar, the relief valve will open and allow oil to be directed to tank until the proper pressure is maintained.
3
Check Valve in pressure passage
Restricts any back flow in the pressure passage.
4
Electric/Oil/Oil Solenoid
Electric solenoid controls the direction of the pilot oil, which in turn controls the direction of the main spool.
5
Orifice
Restricts the speed of the boom cylinder by restricting the flow of hydraulic oil. This allows the boom to move at specified speeds, set by the factory.
6
Orifice
Restricts the speed of the boom cylinder by restricting the flow of hydraulic oil. This allows the boom to move at specified speeds, set by the factory.
120
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35 bar
6
1.3 A4
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Hydraulic Parts
5
1.0 B4
1.7 A3
1.3 B3
A2
1.3 A1
B2
1.3 B1
4 B 3
A
T
P 280 bar
2
1
T
5-7 bar
T
2
5 6
4
1
3 HV08.eps
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Hydraulic Parts
Table 4: 36 Rexroth - Proportional Item#
Part
How it Functions
1
Shuttle Valve
The shuttle valve system uses passage ways to deliver the highest working pressure signal to the load sensing port of the boom regulator.
2
Handle
Manual override which controls the position of the directional spool. The spool is spring centered, so if force is not applied to the handle, the spool along with the handle will return to the neutral position.
3
Pressure Compensator
Maintains constant flow for an individual function. Even when the pressure changes from a variation in load of the activated function or from multiple functions being activated.
4
Proportional Solenoid
Proportionally directs pilot oil to move the main spool.
5
Proportional Solenoid
Proportionally directs pilot oil to move the main spool.
6
Pressure Reducing Valve
Reduces pilot pressure to a maximum of 25 bar.
7
Main Relief Valve
Limits maximum pressure in the hand valve - As pressure reaches 350 bar, the relief valve will open and allow oil to be directed to tank until the proper pressure is maintained.
8
Pretension Secondary Relief Valve
Limits the maximum pressure in pretension circuit to 40 bar.
9
Control Block Housing Valve Section
Enclosure that houses the hand valve spools and cartridges
10
Inlet Block Section
Enclosure that houses the cartridges and filter for the pilot oil system (pretension oil), load sense output, main relief and gauge ports.
11
Control Block Housing Valve Section
Enclosure that houses the hand valve spools and cartridges
12
Flow Limiter
Adjustable orifice that limits the amount of oil flow to a particular function
13
Filter (Pretension)
Filters the pretension oil passing through the hand valve. Used to protect the pilot oil system from debris in the system.
14
Orifice
Reduces the flow of oil going into the pretension filter. Protects the pretension filter from pressure spikes.
15
Mechanical Stop
Limits maximum spool movement, limiting the amount of flow
122
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B4
P
M
P1
PRINT
Hydraulic Parts
A7
A5
B7
3
15
12
160-200
1
13
2
2 14
25 bar
6 340 bar 15
8 7
4
5
4
40 bar
9
10
Y
PV
T
5
11
12
7 6
13 14
4 11
3 15
1 2
8
5 10
4 9
2 15
5 HV04.eps
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Hydraulic Parts “SP” Series directional valves SP” Series directional valves are 4-way valves. As opposed to the normal 4-way valves, these valves have drillings for load pressure sensing, which are connected to each other via shuttle valves. This means that the highest load pressure is passed through the chain of shuttle valves to the sensing system of the pump. B
A
A throttle installed in the place of the load-holding valve allows the maximum flow across the spool to be matched to particular requirements. If a cylinder requires varying flows, a mechanical stroke limiter is fitted, In the same way as for “SM” Series valves, the spool is matched to the spool boring in the valve body.
As opposed to the previous solution (with pilot oil carrying plate), the new series has an internal pilot oil supply by means of drillings in the valve body.
Load Sensing Port
Pilot Oil
Xe
Leak Oil
Xa Xe
The leak oil of the pilot system is drained internally passing directly via the return line.
B A
P
Xa
T
S0110.eps
S0112.eps
As opposed to the previous solution (with pilot oil carrying plate), the new series has an internal pilot oil supply by means of drillings in the valve body.
The leak oil of the pilot system is drained internally passing directly via the return line.
Pilot Oil Leak Oil S0112.eps
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Hydraulic Parts
Adjustable Ofifice Mounted between the A& B port on the backside of the handvalve. Used on all four boom sections, throttle and outrigger functions.
Maximum Flow 70 Liters
S01
Flow Limiter 5 liter used on slewing function P/N 10062506 20 liter used on water pump function P/N 10058993 mounted between the A & B port on the back side of the handvalve. If both of your flow limiters are the tall version you can tell them apart by looking at the orifice drilled in the poppet end of the cartridge. Orifice in
5 liter = 1.4mm (0.055 inch)
Orifice in 20 liter = 3.3mm (0.130 inch)
Orifice in 5 liter = 1.4mm (0.055 inch) Orifice in 20 liter = 3.3mm (0.130 inch)
Orifice
5 Liter
S0113b.eps
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5 Liter or 20 Liter
125
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Hydraulic Parts
Table 5: 42 - Rexroth - Proportional Item#
Part
How it Functions
1
Main Relief Valve
Limits maximum pressure in the hand valve - As pressure reaches over 330 bar, the relief valve will open and allow oil to be directed to tank until the proper pressure is maintained.
2
Pretension Filter
Filters the pretension oil passing through the hand valve. Used to protect the pilot oil system from debris in the system.
3
Orifice
Reduces the flow of oil going into the pretension filter. Protects the pretension filter from pressure spikes.
4
#1 Down Side Relief Valve
Limits the amount of pressure allowed when boom # 1 is retracted to 80 bar. Limiting the amount of pressure prevents the boom cradle from being damaged, while the boom is in the stowed position
5
Pretension Relief
Limits the maximum pressure in pretension circuit to 34 bar.
6
Pressure Compensator
Maintains constant flow for an individual function. Even when the pressure changes from a variation in load of the activated function or from multiple functions being activated.
7
Handle
Manual override which controls the position of the directional spool. The spool is spring centered, so if force is not applied to the handle, the spool along with the handle will return to the neutral position.
8
Mechanical Stop
Limits maximum spool movement, limiting the amount of flow
9
Proportional - Electric/Oil/Oil Solenoid
Proportionally directs pilot oil to move the main spool.
10
Control Block Housing
Enclosure that houses the cartridges and filter for the pilot oil system (pretension oil)
11
Control Block Housing Valve Section
Enclosure that houses the hand valve spools and cartridges
12
Shuttle Valve
The shuttle valve system uses passage ways to deliver the highest working pressure signal to the load sensing port of the boom regulator.
13
Flow Limiter
Adjustable orifice that limits the amount of oil flow to a particular function
14
Pretension Pressure Reducing Valve
Reduces pilot pressure to a maximum of 25 bar.
126
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Hydraulic Parts
4
#1 dn relief 80 bar Control block relief
A
P X
1
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
12 13 330 bar
7
6
2
PV
25 bar
3 14
8
34 bar
9
5
9 T
10
11
13
6
8 12
4 9
11
2
1
3 5 10
7
14
8 9
HV05.eps
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127
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Hydraulic Parts 42 - Rexroth - Hand valve Shuttles
Old Style Pin Type Shuttle
A
B
T
P
Hand valve with shuttle and section compensator. Used on 42m proportional units.
128
New Style Ball & Seat Shuttle
A
B
T
P
Hand valve with shuttle and flow limiter: (5 or 20 liter). Used on the water pump and slewing functions for the 42m B & W unit.
Service Manual
A
B
T
P
Hand valve with shuttle and adjustable orifice. Used on the boom functions of the 42m B & W
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Hydraulic Parts
Preload block for Rexroth Hand valve Pv
P
T
Pv (X)
P
Orifice
Filter
O-ring
O-ring
Pv (X) Pv 34 bar
T 25 bar
160 m
P
S0115.eps
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Hydraulic Parts
Table 6: 45/47 Proportional Item#
Part
How it Functions
1
Main Relief Valve
Limits maximum pressure in the hand valve - As pressure reaches 350 bar, the relief valve will open and allow oil to be directed to tank until the proper pressure is maintained.
2
Piston Downside Relief Valve
Limits the amount of pressure allowed when boom # 1 is retracted to 80 bar. Limiting the amount of pressure prevents the boom cradle from being damaged, while the boom is in the stowed position
3
Pretension Relief
Limits the maximum pressure in pretension circuit to 40 bar.
4
Electric/Oil Proportional Solenoid
Proportionally directs pilot oil to move the main spool.
5
Mechanical Stop
Limits the amount of travel on the main spool, which in turn reduces the amount of flow.
6
Mechanical Stop
Limits maximum spool movement, limiting the amount of flow
7
Pressure Compensator
Maintains constant flow for an individual function. Even when the pressure changes from a variation in load of the activated function or from multiple functions being activated.
8
Pretension Pressure Reducing Valve
Reduces pilot pressure to a maximum of 35 bar.
9
Pretension Filter
Filters the pretension oil passing through the hand valve. Used to protect the pilot oil system from debris in the system.
130
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A4
B4
A3
B3
A2
B2
PRINT
Hydraulic Parts
A1
B1
P
160 - 200
P X Y Ls
9
Ls
5
8
7 2
1
230 bar
35 bar
350 bar 40 bar
6
3
4 b1
a1 A-G 4-a1
a2 A-G 2-b1
b2 B-G 1-a2
a3 B-G 3-b2
b3 C-G 4-a3
a4 C-G 2-b3
b4 D-G 3-a4
Y D-G 1-b4
X
T
8
pretension only 33-35 bar
3 9 4
7 4 Up 3 Up 2 Up 1Down 6 4 Down 3 Down 2 Down
1
HV06.eps
2 5
1Up
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Hydraulic Parts
Table 7: 45/47 Proportional Item#
Part
How it Functions
1
Inlet Segment
Enclosure that houses the load sennse check valve
2
Load Sense Check Valve
3
Pretension Filter
Filters the pretension oil passing through the hand valve. Used to protect the pilot oil system from debris in the system.
4
Work Segment
Enclosure that houses the Pretension Filter
6
Mechanical Stop
Limits maximum spool movement, limiting the amount of flow
7
Electric/Oil/Oil Solenoid
Electric solenoid controls the direction of the pilot oil, which in turn controls the direction of the main spool.
8
Handle
Manual override which controls the position of the directional spool. The spool is spring centered, so if force is not applied to the handle, the spool along with the handle will return to the neutral position.
9
Relief Valve
Limits the maximum amount of pressure in the water pump to 190 bar. As the pressure increases to190 bar, the relief opens and allows oil to return to tank until the proper pressure is maintained.
10
Pressure Compensator
Maintains constant flow for an individual function. Even when the pressure changes from a variation in load of the activated function or from multiple functions being activated.
11
Shuttle Valve
The shuttle valve system uses passage ways to deliver the highest pressure signal to the load sensing port.
End Plate
Caps off the valves body sections
5
12 13
132
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A
B
b
a
A
B
A
PRINT
Hydraulic Parts
B
6 7
9
3
200 bar
11
11
10
2
11
10
30 l max.
8
LS
5
T
PST 12
13
P
4
8
1
1 5
4 2
12
3
10
9 11 10
11
7
11 13
6
7 S0161.eps
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Hydraulic Parts
Table 8: 52/55 Proportional - Main Valve Item#
Part
How it Functions
1
Main Relief Valve
Limits maximum pressure in the hand valve - As the pressure increases to 350 bar, the relief valve will open and allow oil to escape to tank until the proper pressure is maintained.
2
Shuttle Valve
The shuttle valve system uses passage ways to deliver the highest pressure signal to the load sensing port.
3
Flow Limiter
Adjustable orifice that limits the amount of oil flow to a particular function
4
Pressure Compensator
Maintains constant flow for an individual function. Even when the pressure changes from a variation in load of the activated function or from multiple functions being activated.
5
Slewing Relief Valve
Limits the maximum amount of pressure in the slew function to 190 bar. As the pressure increases to190 bar, the relief opens and allows oil to return to tank until the proper pressure is maintained.
6
Mechanical Stop
Limits the amount of travel on the main spool, which in turn reduces the amount of flow.
7
Spool
Directs hydraulic oil from the hydraulic pump to extend or retract the boom cylinder
8
Throttle Check Valve
Limits the flow of oil returning from the rod side of boom cylinder #1 when the boom cylinder is retracting. Allows free flow of oil when extending the rod side of boom#1
Table 9: 52/55 Proportional - Pilot Valve Item#
Part
How it Functions
1
Pretension Filter
Filters the pretension oil passing through the hand valve. Used to protect the pilot oil system from debris in the system.
2
Pretension Pressure Reducing Valve
Reduces pilot pressure to a maximum of 30 bar.
3
Pretension Relief
Limits the maximum pressure in pretension oil to 40 bar.
4
Electrical/Oil/Oil - Proportional Solenoid
Proportionally directs pilot oil to move the main spool.
5
Shuttle Valve
The shuttle valve system uses passage ways to deliver the highest pressure signal to the load sensing port of the boom regulator.
134
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Hydraulic Parts adjusted to 20 bar dynamic pressure
a1
A1
B1
a2
A2
B2
a3
A3
B3
a4
A4
PRINT
B4
a5
8
A5
B5
a6
A6
B6
T
T
5
6 5 190 bar
7
350 bar
190 bar
3 4
10146289
X (LS)
P
2
4
1
10146290
7
3
X (LS)
P b1
b2
b3
b4
b5
b6
3 3
8
6
5 7 7 2
5
Shuttle valves access thru hole in the bottom under the mounting plate
1
4
4
Pst
Pst
3
4
4
L
2 50 bar
5
30 bar
5
1 P
L(T)
b1
b1 a1
a1 b2
b2 a2
a2 b3
b3 a3
a3
b4
b4 a4
a4 b5
b5 a5
a5
b6
b6
a6
a6
2 1
5
5
4
4
HV07.eps
3
Service Manual
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Hydraulic Parts
Table 10: Hawe Handvlave Item#
136
Part
How it Functions
1
Handle
Manual override which controls the position of the directional spool. The spool is spring centered, so if force is not applied to the handle, the spool along with the handle will return to the neutral position.
2
Directional Spool
Directs hydraulic oil from the hydraulic pump to either the water pump or high pressure water pump.
3
High Pressure Water Pump Relief Valve
Limits the amount of pressure allowed when the high pressure water pump is activated to 280 bar.
4
Water Pump Relief Valve
Limits the amount of pressure allowed when the water pump is activated to 180 bar
5
Pressure Compensator
Maintains constant flow for an individual function. Even when the pressure changes from a variation in load of the activated function or from multiple functions being activated.
6
Shuttle Valve
The shuttle valve system uses passage ways to deliver the highest pressure signal to the load sensing port.
7
Electrical/Oil/Oil - Proportional Solenoid w/quarter turn type plug
Proportionally directs pilot oil to move the directional spool.
8
Main Relief Valve
Limits maximum pressure in the hand valve - As the pressure increases to 360 bar, the relief valve will open, dropping pressure on the spring side of the inlet compensator. The inlet compensator will open allowing a larger volume oil to escape to tank.
9
Pretension Pressure Reducing Valve
Reduces pilot pressure to a maximum of 20 bar.
10
Inlet Compensator
Used in conjugations with the main relief cartridge. When pressure reaches 360 bar the main relief valve will open. This will lower the pressure on the spring side of the inlet compensator. Higher pressure oil will push the inlet compensator open allowing oil to escape to tank.
11
Pretension Filter
Filters the pretension oil passing through the hand valve. Used to protect the pilot oil system from debris in the system.
12
Directional Spool
Directs hydraulic oil from the hydraulic pump to either enable the boom or outrigger functions.
13
Boom Slewing Relief Valves
Reduces boom slewing pressure to a maximum of 300 bar.
14
Sub-Plate
Block containing a “P” (Inflow) and “R” (Return) port as well as an additional control and measurement ports LS, Z and M.
15
Control Block Housing Valve Section
Enclosure that houses the hand valve spools and cartridges
16
Check Valve
Pretension check valve that generates back pressure which is used for pilot oil.
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Hydraulic Parts
14 13 A
B
A
B
A
B
A
A
B
B
B
A
B
A
B
Z
R
M
LS T
P
300 bar
16
13
300 bar
R1
6
6 7
5
7
a
a
a
a
a
a
a
o
o
o
o
o
o
o
10 360 bar
A b
b
b
b
12
b
20 bar
B
180 bar
18
b
8
15
B 230 bar
17
280 bar
b
11
2
A
4
1
9
3
8 7 9
"Z" "T"
(Pretension)
10
(Tank)
11
2
"P" (Pressure)
7 6 5
12
3 15
6
4
1
18
14
17
13
16 13
Service Manual
S0151.eps
137
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Hydraulic Parts
Table 11: Hawe Handvlave Item#
Part
17
Blank Cartridge
18
Boom #1 Relief Valve
138
How it Functions
Limits the amount of pressure allowed when boom #1 is activated to 230 bar.
Service Manual
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Hydraulic Parts
14 13 A
B
A
B
A
B
A
A
B
B
B
A
B
A
B
Z
R
M
LS T
P
300 bar
16
13
300 bar
R1
6
6 7
5
7
a
a
a
a
a
a
a
o
o
o
o
o
o
o
10 360 bar
A b
b
b
b
12
b
20 bar
B
180 bar
18
b
8
15
B 230 bar
17
280 bar
b
11
2
A
4
1
9
3
8 7 9
"Z" "T"
(Pretension)
10
(Tank)
11
2
"P" (Pressure)
7 6 5
12
3 15
6
4
1
18
14
17
13
16 13
Service Manual
S0151.eps
139
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Hydraulic Parts
Table 12: Apitech Hand valve Item#
Part
How it Functions
1
Handle
Manual override which provides a direct link to the main spool (Item#2)
2
Main Spool
Directs hydraulic oil from the hydraulic pump to extend or retract the boom cylinder
3
Load Sense Shuttle Valve
The shuttle valve system uses passage ways to deliver the highest pressure signal to the load sensing port of the boom regulator.
4
Pulsar Valve
Uses pulse width modulated signal to pulse valve open and close.
5
Compensator
Maintains constant flow for an individual function. Even when the pressure changes from a variation in load of the activated function or from multiple functions being activated.
6
Pretension Relief
Limits the maximum pressure in pretension oil to 30 bar.
7
Main Relief Valve
Limits maximum pressure in the hand valve - As pressure reaches 350 bar, the relief valve will open and allow oil to be directed to tank until the proper pressure is maintained
8
Pretension (Pressure Reducing Valve)
Reduces pilot pressure to a maximum of 15 bar.
9
End Plate
Caps off the valves body sections
10
Work Segment
Enclosure that houses the spool and compensator.
11
Inlet Segment
Enclosure which houses the main relief valve along with the pretension relief valves and filter.
140
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C1
C2
C1
G1/2
PRINT
Hydraulic Parts
C2
PP
G1/2
1 30 bar
2
8 15 bar
6 7 4
5
12
P2
350 bar
3
P T
9
LS
10
11
4
Torque to: 10-30 ft. lbs. Mechanical Stop
2
5
9
6
3
1
Non-Adjustable
4 10 Not Used for Adjustment
AP
12
Torque to: 10-30 ft. lbs. Mechanical Stop
ITE
CH
11
7 8
Torque to: 15-20 ft. lbs.
Service Manual
Non-Adjustable
HV02.eps
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Hydraulic Parts
Table 13: Apitech Hand valve - Fixed Displacement Item#
Part
How it Functions
1
Handle
Manual override which provides a direct link to the main spool (Item#2)
2
Main Spool
Directs hydraulic oil from the hydraulic pump to extend or retract the boom cylinder
3
Load Sense Shuttle Valve
The shuttle valve system uses passage ways to deliver the highest pressure signal to the load sensing port of the boom regulator.
4
Pulsar Valve
Uses pulse width modulated signal to pulse valve open and close.
5
Compensator
Maintains constant flow for an individual function. Even when the pressure changes from a variation in load of the activated function or from multiple functions being activated.
7
Main Relief Valve
Limits maximum pressure in the hand valve - As pressure reaches 300 bar, the relief valve will open and allow oil to be directed to tank until the proper pressure is maintained
8
Pretension (Pressure Reducing Valve)
Reduces pilot pressure to a maximum of 15 bar.
9
End Plate
Caps off the valves body sections
10
Work Segment
Enclosure that houses the spool and compensator.
11
Work Segment
Enclosure that houses the spool and compensator.
12
Inlet Segment
Enclosure which houses the main relief valve along with the pretension relief valves and filter.
13
Filter
6
14
142
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C2
C1
C2
G1/2
1
Hydraulic Parts
C1
MPS
G1/2
4
8
15 bar
1 2
2
6
5 0.61 mm
3
7 0.2 mm
4
13
0.76 mm
14
4
PRINT
300 bar
P T
LS
9
10
11
12
4 4 9 Torque to: 10-30 ft. lbs. Mechanical Stop
2 2 1
5 10
3 4
1
6 CH
ITE
AP
11 Not Used for Adjustment
13
Torque to: 10-30 ft. lbs. Mechanical Stop
12
14
8
7
Service Manual
Torque to: 15-20 ft. lbs.
HV09.eps
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Hydraulic Parts Apitech Cut-Away
LOAD B LOAD A TANK
TANK PULSARS
PULSARS
MAXIMUM SET SCREW
MAXIMUM SET SCREW PRETENSION
COMPENSATOR SYSTEM PRESSURE
S0121.eps
144
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Boom Holding Valves Schwing uses a specially-designed hydraulically unlockable check valve on all hydraulic cylinders which operate placing boom sections. These valves seal the hydraulic cylinder to prevent it from creeping or moving until pressure is applied to it. If too much weight is applied to a boom section, it also acts as a structural safety valve and relieves that excess pressure at a controlled rate. A holding valve is installed at both ends of the hydraulic cylinder to prevent movement and limit pressure in either direction. If you should have a problem with a boom section creeping, position the boom in an area which still produces pressure in the corresponding cylinder but leaves the holding valve in an accessible area. Loosen the fitting of the pressure connection of the working line and the leakage oil connection. With the hydraulic pump not turning, you will be able to see which portion of the valve is leaking.
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Hydraulic Parts
If oil flowing out uniformly from the leakage oil connection, this indicates that the auxiliary safety valve is not properly sealing. If this holding valve is on boom section 1 cylinder, holding valve replacement is necessary. This auxiliary safety valve protects the cylinder and the boom from excess pressure; therefore, this valve must not be set at random. Precision setting for a specific placing boom model is necessary. If hydraulic oil is flowing out uniformly from the working line, this indicates that the check valve is not sealing properly, or debris in the oil has caused the unlocking system to hang up and not allow the check valve ball to seat. If there are any questions concerning holding valves or other areas of your Schwing equipment that you need answered, contact your local Schwing dealer or Schwing America, Inc. for more information.
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Hydraulic Parts
This style valve is used on 32 meter and 42 meter black and white untis on each boom cylinder. It is also used on 42 meter proportional units for the first boom section only. it is either fully open or fully closed.
B
Y X
A
Y
X
A
PROPORTIONAL HOLDING VALVE
P2
X
P2
X
P1
P1 X
X
P1
P2
P2
(SERIES 1) Valve at normal position, and/or holding a load.
P1
(SERIES 2) Valve in freeflow position, (P1 to P2).
P2
X P1 X
P2
P1
(SERIES 3) Valve in unlocking position, and metering a load.
146
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S0118.eps
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Hydraulic Parts
KVM 52 HOLDING VALVE UNLOCKABLE CHECK CARTRIDGE (RATIO = 8.8 to 1) Part #995 050 004 282
Y(T) A1 M
A
A1
A Y(T)
X
X
KVM 52 HOLDING VALVE RELIEF CARTRIDGE
Y(T) X
M Y(T)
A1
A
A M
X S0119.eps
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A1
A
A1
X
A
Y
Y
X
KVM 52 HOLDING VALVE CARTRIDGE (SERIES #1)
A1
A
A1
X
Y
A
Y
X
KVM 52 HOLDING VALVE CARTRIDGE (SERIES #2)
A1
A
A X
A1 Y
Y
X
KVM 52 HOLDING VALVE CARTRIDGE (SERIES #3) S0120.eps
148
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Hydraulic Parts
Load Holding Valve/Brake Valve A2
1
B2
3
5 A2 B2
EA
8
EB
6
7 2
A1
9
4
T
B1
2 1
3
4 6 7
5
8 9
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Hydraulic Parts BRAKE VALVES Sauer Brake Valve
Jam Nut The "Z" screw adjusts how quickly the boom STARTS moving when the handvalve is activated.
B R
Z Z
X
A
The large screw adjustment found under this cap controls how smoothly the boom comes down. Adjust clockwise if the boom comes down in jerks, and counter-clockwise if the boom is smooth but very slow.
R
Y
The "R" screw adjusts how quickly the boom STOPS moving once the hand valve is released.
#1 Boom Raising B Z
R
Z R X
A
T
X
A
B
T
X
A
B
T
X
A
B
T
#2 Boom Lowering B Z
R
Z R X
A
#3 Return to Neutral
T
B
Z
R
Z R X
150
A
T
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Hydraulic Parts
Beringer Brake Valve
B 1 2
3
3
F /D F
1
2
X
A
Service Manual
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Slewing Brake Valves
Flow When Lowering:
Boom Slewing Brake Valve - Rexroth Spec Sheet
Model MHB 10 is a load lowering valve which prevents a negative load from causing hydraulic motor or cylinder “run away”, and allows hydraulically controlled, cavitation-free lowering operation.
When the driven unit is supplied with fluid, the pilot pressure acts on the spool area (6) through port A. When the pressure exceeds the opening force required by the spring, the load lowering spool (2) opens and connects ports B2 to B1.
Basically they consist of a housing (1), load lowering spool (2), check valve (3), secondary relief valve (4) and spring (5).
The valve opening is proportional to the opening pressure. When the pressure in the pilot line drops, the load lowering spool (2) is moved into a new position by the spring. Thus, due to the force balance, an automatic load lowering operation is achieved.
Free Reverse Flow:
Any pressure spikes caused when the load is stopped are captured by the pressure relief valve (4).
Fluid may flow port B1 via the check valve (3) to port B2 or to the driven unit.
Leak free closure: When the pilot signal is removed and the check valve closes: port B2 is sealed off from port B1
4 1
M
3
B2
2 6
A
5
152
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Hydraulic Parts
KVM 42 Slewing Brake Valve - Model 1E80
1.5 (38) HEX.
3 PILOT PORT
2 VALVE PORT
1 CYLINDER PORT
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Table 14: Slew Brake Valve (Proportional Units) Item#
Part
How it Functions
1
Valve Body
Enclosure for the slewing brake cartridges and shuttle valve.
2
Throttle Check Valve
Allows free flow of hydraulic oil into the slewing brake when a slewing function is activated. Restricts the amount of flow returning from the slewing brake.
3
Slewing Brake Valve
Controls the slewing movement and prevents the slewing hydraulic motor from running faster than the pump. This cartridge also has over pressure protection and helps hold the boom in position along with the clutch disc brake
4
Blank Cartridge
Used to seal off unused ports and passages in the valve body
5
Shuttle Valve
The shuttle valve allows the highest pressure signal from either the “A” or “B” port to pass through the valve
6
Reversing Valve
When a slewing function is activated, pilot oil is sent to the right side of the reversing valve causing it to move over and suppling pressure to release the slew brake.
154
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A1
PRINT
Hydraulic Parts
B1
X
!
!
200 bar
0 - 16 bar
200 bar
$
14 bar
T
#
A
B
$
" !
#
" !
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Hydraulic Parts
Table 15: Slew Brake Valve (Black & White Units) Item#
Part
How it Functions
1
Valve Body
Enclosure for the slewing brake cartridges and shuttle valve.
2
Throttle Check Valve
Allows free flow of hydraulic oil into the slewing brake when a slewing function is activated. Restricts the amount of flow returning from the slewing brake.
3
Slewing Brake Valve
Controls the slewing movement and prevents the slewing hydraulic motor from running faster than the pump. This cartridge also has over pressure protection and helps hold the boom in position along with the clutch disc brake
4
Throttle Check Valves
Used to control boom slewing times
5
Shuttle Valve
The shuttle valve allows the highest pressure signal from either the “A” or “B” port to pass through the valve
6
Reversing Valve
When a slewing function is activated, pilot oil is sent to the right side of the reversing valve causing it to move over and suppling pressure to release the slew brake.
156
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A1
PRINT
Hydraulic Parts
B1
X
!
0 - 16 bar
!
200 bar
200 bar
$
14 bar
T
"
A
"
#
B
"
$ !
#
" !
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Hydraulic Parts
Boom Regulator ∆ P regulator X 20 bar ∆ P 290 bar
A
P
P
T
(Series A) - NEUTRAL, Machine shut off, or E-stop button pushed down
(Series B) - All functions in NEUTRAL, but E-stop button is in the "UP" position.
Pressure Regulator
Pressure Regulator
P Regulator
P Regulator
A
0 Bar
T
ORIFICE KVM 36X . . . . 1.6 mm KVM 36 LW . . 1.6 mm KVM 42 . . . . . .1.6 mm KVM 52 . . . . . .not used
P
X
0 Bar
20 Bar
A
(Series D) - Boom stopped because cylinder is fully extended.
Pressure Regulator
P Regulator
P Regulator
T P
ORIFICE 0.8 mm KVM 36X . . . . 1.6 mm 0-15 Bar KVM 36 LW . . 1.6 mm KVM 42 . . . . . .1.6 mm KVM 52 . . . . . .not used
0 bar
P
Pressure Regulator
A
X
ORIFICE 0.8 mm KVM 36X . . . . 1.6 mm 0-15 Bar KVM 36 LW . . 1.6 mm KVM 42 . . . . . .1.6 mm KVM 52 . . . . . .not used
0.8 mm
0 Bar
(Series C) - Boom Moving
250 Bar
T
X 230 bar
290 Bar
A ORIFICE KVM 36X . . . . 1.6 mm KVM 36 LW . . 1.6 mm KVM 42 . . . . . .1.6 mm KVM 52 . . . . . .not used
T
X 290 bar
P
0.8 mm 0-15 Bar
S01028
158
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Hydraulic Parts
Counter Balance Valve COUNTERBALANCE VALVE (SERIES 1) A
M B M
X
X A B
COUNTERBALANCE VALVE (SERIES 2) A
M B M
X
X A B
COUNTERBALANCE VALVE (SERIES 3) A
M B M
X
X A B
COUNTERBALANCE VALVE (SERIES 4) A
M B M
X
X A B
COUNTERBALANCE VALVE (SERIES 5) A
M B M
X
X A B
COUNTERBALANCE VALVE (SERIES 6) A
M B
X
M
X A B
Service Manual
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Control Blocks Table 16: Hi-Flow S1/S2 Control Valve Item#
160
Part
How it Functions
1
Soft Switch Cartridge
Transfers oil from the 350 bar main relief valve to the 80 bar relief valve. This allows the brain to only build 80 bar of pressure before the relief valve will open up, providing a smoother rock valve switch.
2
Soft Switch Relief Cartridge
A relief valve that opens up when pressure build higher than 80 bar and allows oil to escape to tank until 80 bar of pressure is maintained.
3
Main Relief Cartridge
A relief valve that opens up when pressure build higher than 350 bar and allows oil to escape to tank until 350 bar of pressure is maintained.
4
Poppet Valve
Used in conjugations with the main relief cartridge and the soft switch cartridge. When the soft switch circuit is not engaged, it will take 350 bar of pressure to open the poppet valve and allow oil to drain to tank. When the soft switch circuit is engaged, the poppet will open when pressure climbs above 80 bar.
5
S1 Spool
Controls the Forward/Neutral/Reverse direction of the concrete pump, by redirecting the flow of hydraulic oil in the system.
6
S2 Spool
Directs the hydraulic oil to either the left or right differential cylinders. The spool is moved by pilot oil coming from the MPS control block.
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T
1 1.1
X3
X3
2 3 1.4
MX
T X1 P1
350 bar
7
4
1.2 T1
T2
PP
MP
XP
XR
0.7 mm
PP
3.0 mm
XB
S1
0.7 mm
5
6
XA
P
P2
X
P1
T2
PR
S2
B1 B
R XR
X1
P2 P
X2
80 bar
XA 3.0 mm A1
XB
B
A
A
1
2 3
7
4
5 6
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Table 17: Single Circuit Item#
Part
How it Functions
1
S1 Spool
Controls the Forward/Neutral/Reverse direction of the concrete pump, by redirecting the flow of hydraulic oil in the system.
2
S3 Spool
Directs the hydraulic oil to either extend or retract the “Rock Valve” or to shift the gate valves, depending on which valve is used. This spool is activated by pilot oil coming from the differential cylinders.
3
S2 Spool
Directs the oil to cycle the differentail cylinders, this spool is activated by pilot oil coming from the rock valve or gate valve.
4
Main Relief Valve
Limits maximum pressure in the control block- When pressure reaches over 300 bar, the relief valve will open and allow oil to escape to tank until the proper pressure is maintained.
162
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P1 P
X
S3 1.5 mm hole drilled through spool
PRINT
P2
T
2 S1
1
300 bar
S2
B
4
R
X
3
A
Port size limits flow
4
1
S-1
3
S-2
S-3 2
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S3/Accumulator Valve Machined Block
Table 18: Accumulator Valve - Machined block Item#
Part
How it Functions
1
S3 Spool
Directs the hydraulic oil to either extend or retract the “Rock Valve”. This spool is activated by pilot oil coming from the MPS valve.
2
Check Valve
Allows free flow of oil into S3 valve, while preventing oil from escaping, during Accumulator discharge
3
Hydraulically Lockable Check Valve
When pressure enters through the “P” port, a signal line is sent to the Hydraulically Lockable Check Valve. Pressure from the signal line holds the checkvalve shut, preventing oil from escaping to tank. If no pressure is applied the checkvalve is free to be opened, allowing oil to escape to tank.
4
Manual Bleed Valve
When the unit is shut-off, pressurized oil can remain trapped in the accumulator valve. When opened the Manual Bleed valve allows oil to escape to tank.
5
Relief Valve
Limits maximum pressure in the control block- When pressure reaches over 300 bar, the relief valve will open and allow oil to escape to tank until the proper pressure is maintained.
6
2.0 mm Orifice
Drops the pressure of the hydraulic oil before it passes through the Hydraulically Lockable Check Valve
8.0 mm Orifice
Controls the oil flowing through the S3 control block, determining the speed of the Rock Valve shift. With a larger orifice, the Rock Valve will shift faster, a smaller orifice, the Rock Valve will switch slower.
7
164
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B
A1
B
A
PRINT
B
1
X
B1
1
S3
XA
XB
B
A A
1
T
2.0 mm
6 4
300 bar
Mp
5
T
P M
Mp1
3
2
A
M
S
P
1
8.0 mm
X
7 Psp
T P
P
PS
P
T
7
1 3 6 5 2
4
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Table 19: Accumulator Valve - Cast block Item#
Part
How it Functions
1
S3 Spool
Directs the hydraulic oil to either extend or retract the “Rock Valve”. This spool is activated by pilot oil coming from the MPS valve.
2
Hydraulically Unlockable Check Valve
When pressure enters through the “P” port, a signal line is sent to the Hydraulically Lockable Check Valve. Pressure from the signal line holds the checkvalve shut, preventing oil from escaping to tank. If no pressure is applied the checkvalve is free to be opened, allowing oil to escape to tank.
3
Check Valve
Allows free flow of oil into S3 valve, while preventing oil from escaping, during Accumulator discharge
4
Manual Bleed Valve
When the unit is shut-off, pressurized oil can remain trapped in the accumulator valve. When opened the Manual Bleed valve allows oil to escape to tank.
5
Relief Valve
Limits maximum pressure in the control block- When pressure reaches over 330 bar, the relief valve will open and allow oil to escape to tank until the proper pressure is maintained.
6
6.5 mm Orifice
Controls the oil flowing through the S3 control block, determining the speed of the Rock Valve shift. With a larger orifice, the Rock Valve will shift faster, a smaller orifice, the Rock Valve will switch slower.
7
2.0 mm Orifice
Drops the pressure of the hydraulic oil before it passes through the Hydraulically Lockable Check Valve
166
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B
3
X
B
1
Hydraulic Parts
A3
B2
A2
B3
A
1
S3
XB1
2 bar
2.0 mm 3
P
M
S
P
3
M P M
MSP2
SP P P1 T MS
5
7
MSP1
TUV 330 bar
2 4
P
T
A
MSP3
6.5 mm
X
6
S
1 A
T3
SP
2
3
XA1
B
T MP
3
4 6
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Stroke Limiters Table 20: Stroke Limiter Item#
Part
How it Functions
1
Pressure Reducing Valve
Reduces the pressure coming from the “P” port to 70 bar.
2
Adjustable Spring
The spring is set to collapse at 70 bar, but can be adjusted to collapse either at a higher or lower setting
3
Proportional Solenoid
A solenoid that allows for variable current levels to move the pressure reducing valve to the desired pressure.
4
Pressure Reducing Valve
Reduces the pressure of the hydraulic oil, in accordance to how much current is being sent to the solenoid valve
168
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Remote controlled stroke limiter T
1 3
P 2
70 bar
B
4
A
3 4
2
1
B
P
A
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Table 21: Stroke Limiter Item#
Part
How it Functions
1
Valve Body
Encloser for the electric pressure reducing cartridge
2
Pressure reducing valve (Electric)
Reduces the pressure of the hydraulic oil, in accordance to how much current is being sent to the solenoid valve. (Used as a stroke limiter to destroke the hydraulic pumps to control concrete volume)
3
Valve Body
Encloser for the stroke limiter cartridge
Pressure reducing valve (Manual)
Allows system pressure to be reduced from 0 to 55 bar, in accordance to the tension setting of the spring. (Used to supply supplemental pressure to the hydraulic pumps so the stroke limiter can be used at lower operating pressures)
4
170
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3 4
T
Pressure reducing valve 55 bar
P
2
T
A
1 A Electric stroke limiter
2
1
14
3*
4 S0134.eps
* Twin Circuit units only
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Table 22: Stroke Limiter (German) Item#
Part
How it Functions
1
Manual Directional Valve
Switches the stroke limiter from electronic control to manual control for emegency operation.
Pressure Reducing Valve(Manual)
Allows system pressure to be reduced from 0 to 55 bar, in accordance to the tension setting of the spring. (Used to supply supplemental pressure to the hydraulic pumps so the stroke limiter can be used at lower operating pressures)
3
Pressure Reducing Valve (Electric)
Reduces the pressure of the hydraulic oil, in accordance to how much current is being sent to the solenoid valve. (Used as a stroke limiter to destroke the hydraulic pumps to control concrete volume)
4
Gauge Port (MG2)
Used to check the pressure
5
Gauge Port (MG1)
Used to check the pressure
6
Orifice
When the Manual Directional Valve is switched to the manual control position, signal pressure is bleeded back to tank through the orifice. If signal pressure were to remain, the shuttle valve may not seat properly when the Manual Directional Valve is switched back to the electronic control postion.
7
Check Valve
Supplies a passage way for oil to escape in the event of a system shutdown (E-stop button pressed)
2
172
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4
PRINT
Hydraulic Parts
G2
MG2
3
0-30 bar
X1
1
MX1 3.5-55 bar
7
5
2
MG1
6 MP
PBP
PZ
T
4
3
2
1
5
7
6
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Table 23: Stroke Limiter with Dampner(German) Item#
Part
How it Functions
1
Manual Directional Valve
Switches the stroke limiter from electronic control to manual control for emegency operation.
Pressure Reducing Valve (Manual)
Allows system pressure to be reduced from 3.5 to 40 bar, in accordance to the tension setting of the spring. (Used to supply supplemental pressure to the hydraulic pumps so the stroke limiter can be used at lower operating pressures)
3
Pressure Reducing Valve (Electric)
Reduces the pressure of the hydraulic oil, in accordance to how much current is being sent to the solenoid valve. (Used as a stroke limiter to destroke the hydraulic pumps to control concrete volume)
4
Gauge Port (MG2)
Used to check the pressure
5
Gauge Port (MG1)
Used to check the pressure
6
Fast Switch Valve
Blocks the output of the stroke limiter valve (manual or electric) to the X1 port of the hydraulic pump. Allowing the hydraulic pumps to put out maximum flow during Rock valve shifting.
7
Pressure Reducing Valve (Dampener)
Allows pressure to be reduced from 3.5 to 40 bar, in accordance to the tension setting of the spring. Prevents damage caused by excessive speed and acceleration during Rock valve shifting.
8
Shuttle Valve
The shuttle valve allows the highest pressure signal from either the Dampener or Stroke limiter to pass through the valve
9
Shuttle Valve
The shuttle valve allows the highest pressure signal from either the Dampener or Stroke to pass through the valve
Orifice (0.7)
When the Manual Directional Valve is switched to the manual control position, signal pressure is bleeded back to tank through the orifice. If signal pressure were to remain, the shuttle valve may not seat properly when the Manual Directional Valve is switched back to the electronic control postion.
11
Orifice (0.7)
When signal pressure opens the reversing valve (item 6), the orifice is small enough, that it doesn’t effect the signal. When the signal is lost, oil bleeds back to tank through the orifice. This assists in returning the reversing valve to the at rest position.P
12
Check Valve
Supplies a passage way for oil to escape in the event of a system shutdown (E-stop button pressed)
2
10
174
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4 MG2
6
G2
11
3 0.7
20 bar
0-30 bar
1
9
X1 MX1
8
3.5-40 bar
12
10
2 3.5-40 bar
MP
MG1
5
0.7
7
7
6
PBP
T
PZ
8 4
3
2
9
12
1 10
5 11
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Table 24: Stroke Limiter Item#
Part
How it Functions
Pressure Reducing Valve (Electric)
Reduces the pressure of the hydraulic oil, in accordance to how much current is being sent to the solenoid valve. (Used as a stroke limiter to destroke the hydraulic pumps to control concrete volume)
2
Pressure Reducing Valve (Manual)
Allows system pressure to be reduced from 0 to 55 bar, in accordance to the tension setting of the spring. (Used to supply supplemental pressure to the hydraulic pumps so the stroke limiter can be used at lower operating pressures)
3
Gauge Port “MG”
Used to check the pressure after it has passed through the manual pressure reducing valve
4
Gauge Port “MY”
Used to check the pressure after it has passed through the electric stroke limiter valve
5
Gauge Port “P”
Used to check the system pressure going into the stroke limiter
6
Valve Block
Enclosure that houses the pressure reducing valves
1
176
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P
PRINT
Hydraulic Parts
5
P
T
T
2
6
Pressure reducing valve 55 bar
1
G
Electric stroke limiter
Y MG
MY
3
4
1
2
11 T P T
5
P MY
3
MG G Y
6 S0136.eps
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Table 25: E-Stroke Limiter Item#
Part
How it Functions
Pressure Reducing Valve (Electric)
Reduces the pressure of the hydraulic oil, in accordance to how much current is being sent to the solenoid valve. (Used as a stroke limiter to destroke the hydraulic pumps to control concrete volume)
2
Pressure Reducing Valve (Manual)
Allows system pressure to be reduced from 7 to 105 bar, in accordance to the tension setting of the spring. (Used to supply supplemental pressure to the hydraulic pumps so the stroke limiter can be used at lower operating pressures)
3
Gauge Port “MG”
Used to check the pressure after it has passed through the manual pressure reducing valve
4
Gauge Port “MY”
Used to check the pressure after it has passed through the electric stroke limiter valve
5
Gauge Port “P”
Used to check the system pressure going into the stroke limiter
6
Valve Block
Enclosure that houses the pressure reducing valves
1
178
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6
T
T 5
P
2
1
MG 7-105 bar
0-35 bar
G
3
P
Y
MY 4
3
2
6
4 1
5
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Outrigger Handvalves Table 26: Outrigger Valve 45/47 Item#
Part
How it Functions
A
Open Center Passage
Allows oil to flow to tank unrestricted when no functions are being used.
B
Pressure Passage
Supplies pressure oil to each working segment
1
Main Relief Valve
Limits maximum pressure in the hand valve- As pressure reaches over 300 bar, the relief valve will open and allow oil to be redirected to tank until the proper pressure is maintained.
2
Hose Reel Motor Relief Valves
Limits the amount of pressure going to the hose reel motor to 200 bar. As pressure rises to 200 bar, the relief valve opens and allows pressure to be re-directed to tank, until the pressure drops below 200 bar. The relief valves protects the hose reel motor.
3
Outrigger Slewing/350 bar Secondary Relief Valve
Protects hydraulic cylinders and structure from damage
4
Spool
Directs hydraulic oil from the hydraulic pump to activate an outrigger function
5
Fitting - Power Beyond
A special fitting that blocks the system pressure flowing through the hand valve from returning to tank and instead allow the oil to flow through the hand valve and unto the next one.
180
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200 bar
#
!
350 bar
PRINT
"
300 bar P1
C
) * T
A4
B4
A3
B3
A2
B2
A1
B1
!
"
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Table 27: Outrigger Handvalve 52/55 Item#
Part
How it Functions
A
Open Center Passage
Allows oil to flow to tank unrestricted when no functions are being used.
B
Pressure Passage
Supplies pressure oil to each working segment
1
Main Relief valve
Limits maximum pressure in the hand valve - As pressure reaches over 150 bar, the relief valve will open and allow oil to be redirected to tank until the proper pressure is maintained
2
Spool
Directs hydraulic oil from the hydraulic pump to activate an outrigger function
3
Spring
The spring returns the spool to the neutral position when a function in no longer being activated
4
Outrigger Slewing/350 bar Secondary Relief Valve
Protects hydraulic cylinders and structure from damage
5
Extension Cylinder Relief Valve Piston Side
Limits the amount of pressure used to extend the Outrigger Extension Cylinder to 50 bar, As the pressure rises to 50 bar, the relief valve will open - allowing oil to be re-directed to tank, until the 50 bar pressure is maintained. This relief valve protects the extension cylinder from being damaged
6
Spool
Directs hydraulic oil from the hydraulic pump to activate an outrigger function
7
Handle
Manual override which provides a direct link to the main spool
8
Fitting - Power Beyond
A special fitting that blocks the system pressure flowing through the hand valve from returning to tank and instead allow the oil to flow through the hand valve and unto the next one.
182
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150 bar
4
1
350 bar
2
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Hydraulic Parts
5
4
350 bar
50 bar C
P
A
8
6 3
7
B A1
B1
A2
B2
A3
B3
A4
B4
A5
B5
T
8
7
5
1
4
6
3 2
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Table 28: Outrigger Handvalve 58/61 Passenger Side Item#
Part
How it Functions
A
Open Center Passage
Allows oil to flow to tank unrestricted when no functions are being used.
B
Pressure Passage
Supplies pressure oil to each working segment
1
Throttle Check Valves
Used to control the speed of the front outrigger extension and retraction.
2
Hose Reel Motor
Extends and retracts the hose reel, when activated.
3
Spool
Directs hydraulic oil from the hydraulic pump to activate an outrigger function
4
Handle
Manual override which provides a direct link to the main spool
5
Spring/Mechanical Stop
The spring returns the spool to the neutral position when a function in no longer being activated. The mechanical stop limits the maximum travel of the spool.
6
Outrigger Slewing/350 bar Secondary Relief Valve
Protects hydraulic cylinders and structure from damage
7
Hose Reel Motor Relief Valves
Limits the amount of pressure going to the hose reel motor to 200 bar. As pressure rises to 200 bar, the relief valve opens and allows pressure to be re-directed to tank, until the pressure drops below 200 bar. The relief valves protects the hose reel motor.
8
Outrigger Jacking/210 bar Secondary Relief Valve
Protects hydraulic cylinders and structure from damage
9
Throttle Check Valves
Used to control the speed of the rear outrigger slewing
Hydraulically Unlockable Check valves
When pressure flows through the “A1” port, the checkvalve is opened allowing oil into the rod side of the piston. A signal line is also sent to the piston side Hydraulically Lockable Check Valve. Pressure from the signal line holds the piston side checkvalve open, allowing oil from the piston side of the cylinder to escape to tank. If no pressure is applied the checkvalve is free to be opened, allowing oil to escape to tank.
10
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Hydraulic Parts
Front
Rear A
A
B
B
PRINT
Front
Rear
10
10
2
1
1 9
9
A1
B1
A2
4
B2
4 3
B
A3
B3
A4
4 3
B4
T
4 3
3
P 350 bar
A 5
210 bar
5
6
8
7
210 bar
5
8
200 bar
5
7
7 200 bar
8 6
7 10 10
9
5
9
3 1 4
1
2
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Table 29: Outrigger Handvalve 58/61 Driver Side Item#
Part
How it Functions
A
Open Center Passag
Allows oil to flow to tank unrestricted when no functions are being used.
B
Pressure Passage
Supplies pressure oil to each working segment
1
Throttle Check Valves
Used to control the speed of the front outrigger extension and retraction.
2
Hose Reel Motor
Extends and retracts the hose reel, when activated.
3
Spool
Directs hydraulic oil from the hydraulic pump to activate an outrigger function
4
Handle
Manual override which provides a direct link to the main spool
5
Spring/Mechanical Stop
The spring returns the spool to the neutral position when a function in no longer being activated. The mechanical stop limits the maximum travel of the spool.
6
Outrigger Slewing/350 bar Secondary Relief Valve
Protects hydraulic cylinders and structure from damage
7
Hose Reel Motor Relief Valves
Limits the amount of pressure going to the hose reel motor to 200 bar. As pressure rises to 200 bar, the relief valve opens and allows pressure to be re-directed to tank, until the pressure drops below 200 bar. The relief valves protects the hose reel motor.
8
Outrigger Jacking/210 bar Secondary Relief Valve
Protects hydraulic cylinders and structure from damage
9
Throttle Check Valves
Used to control the speed of the rear outrigger slewing
10
Hydraulically Unlockable Check valves
When pressure flows through the “A1” port, the checkvalve is opened allowing oil into the rod side of the piston. A signal line is also sent to the piston side Hydraulically Lockable Check Valve. Pressure from the signal line holds the piston side checkvalve open, allowing oil from the piston side of the cylinder to escape to tank. If no pressure is applied the checkvalve is free to be opened, allowing oil to escape to tank.
11
Main Relief Valve
Limits maximum pressure in the hand valve- As pressure reaches over 300 bar, the relief valve will open and allow oil to be redirected to tank until the proper pressure is maintained.
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5
350 bar
8
5
8
210 bar
210 bar
6 C
3
200 bar
5
3
200 bar
PRINT
Hydraulic Parts
7
5
310 bar
7
11
3
3
T
4 T
A4
9
B4
4 A3
B3
4 A2
4 B1
A1
B2
9
1
1 A
10
A
B
10
B
2 Front
Front
Rear Rear
7
8 6
7 10 10
5 9
9
3 11
4
1 1
2
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Hydraulic Parts
Table 30: Outrigger Handvalve Item#
Part
How it Functions
A
Open Center Passage
Allows oil to flow to tank unrestricted when no functions are being used.
B
Pressure Passage
Supplies pressure oil to each working segment
1
Main Relief Valve
Limits maximum pressure in the hand valve - As pressure reaches over 280 bar, the relief valve will open and allow oil to be redirected to tank until the proper pressure is maintained
2
Check Valve in Pressure Passage
Restricts any back flow in the pressure passage
3
Port Relief Valve
Limits the maximum amount of spressure in a specified port to 190 bar
4
Handle
Manual override which provides a direct link to the main spool
5
Fitting - Power Beyond
A special fitting that blocks the system pressure flowing through the hand valve from returning to tank and instead allow the oil to flow through the hand valve and unto the next one.
6
Spring
The spring returns the spool to the neutral position when a function in no longer being activated
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280 bar
PRINT
Hydraulic Parts
1
3 4
A
5
P
T 190 bar
B
190 bar
190 bar
190 bar
2
6
6
1
3
5
2
4
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Hydraulic Parts
Table 31: Outrigger Handvalve Item#
Part
How it Functions
A
Open Center Passage
Allows oil to flow to tank unrestricted when no functions are being used.
B
Pressure Passage
Supplies pressure oil to each working segment
1
Main Relief Valve
Limits maximum pressure in the hand valve - As pressure reaches over 280 bar, the relief valve will open and allow oil to be directede to tank until the proper pressure is maintained
2
Port Relief Valve
Limits the maximum amount of spressure in a specified port to 140 bar
3
Port Relief Valve
Limits the maximum amount of spressure in a specified port to 80 bar
4
Check Valve in Pressure Passage
Restricts any back flow in the pressure passage
5
Spring
The spring returns the spool to the neutral position when a function in no longer being activated
6
Fitting - Power Beyond
A special fitting that allows the oil from the open center passage to be directed to another handvalve rather than back to tank. The oil in the handvalve is re-directed to an auxiliary tank port
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# $
80 bar
140 bar
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Hydraulic Parts *
"
80 bar
140 bar
)
280 bar
P1 !
P
!
T
#
!
!
!
!
"
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Hydraulic Parts
E-Stop Manifolds Table 32: E-Stop Manifold Item#
Part
How it Functions
1
Pressure Relief Valve with external drain and solenoid
Limits maximum pressure in the E-stop block - When pressure reaches over 330 bar, the relief valve will open and allow oil to escape to tank until the proper pressure is maintained
2
Dump Valve - Solenoid Operated/ Spring Return
When a signal is sent to the solenoid valve, the dump valve will move into the closed position and block the hydraulic oil from escaping to tank. When no signal is sent to the solenoid, the spring on the valve will return it to the open position, allowing the hydraulic oil to escape to tank. This will disengage the concrete pump
3
Secondary Pressure Relief Valve
When the dump valve is closed, the relief valve will limit the amount of pressure in the E-stop manifold, to the set amount of the relief spring. (Example 260 bar)
Dump Valve - Solenoid Operated/ Spring Return
When a signal is sent to the solenoid valve, the dump valve will move into the closed position and block the hydraulic oil from escaping to tank. The oil will then be allowed to flow to the S3 control block. When no signal is sent to the solenoid, the spring on the valve will return it to the open position, allowing the hydraulic oil to escape to tank. This will disengage the rock valve
4
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Hydraulic Parts see concrete pump schematic
Emergency stop manifold P1
MP1
P3 MP3
P2
10047
MP2
T 1
2
330 bar
3
4
4
1
2
3
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Hydraulic Parts
Table 33: E-Stop Manifold Item#
Part
How it Functions
1
Redundant Relief Valve
When the dump valve is closed, the relief valve will limit the amount of pressure in the E-stop manifold, to the set amount of the relief spring. (Example 250 bar)
Dump Valve - Pilot Operated
This valve works in conjuction with the Solenoid/Manual Dump Valve (Item#4). When this valve is open pilot pressure cannot build on the spring side of the dump valve. Pressure from the concrte pump will force the valve open and allow the oil to flow to tank.
3
Dump Valve - Pilot Operated
This valve works in conjuction with the Solenoid/Manual Dump Valve (Item#4). When this valve is open pilot pressure cannot build on the spring side of the dump valve. Pressure from the water pump and agitator will force the valve open and allow the oil to flow to tank.
4
Dump Valve - Solenoid/Manual Operated - Spring Return
Normally closed when in operation. When a signal is no longer being sent to the solenoid, the valve will open allowing pilot pressure within the block to be lost. This will allow the dump valves (Item#2 and #3) to open and dump the system pressure to tank.
2
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C
B
PRINT
Hydraulic Parts
A
10045
250 bar
2
1
4 3
E
F
1 1 4 2
3
OR
C B A
E D
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Table 34: E-Stop Manifold Item#
Part
How it Functions
1
Dump Valve - Solenoid/Manual Operated - Spring Return
Normally closed when in operation. When a signal is no longer being sent to the solenoid, the valve will open allowing pilot pressure within the block to be lost. This will allow the dump valves (Item#4 and #5) to open and dump the system pressure to tank.
2
Dump Valve - Pilot Operated
Not used in this application
3
Redundant Relief Valve for the Boom System
This relief is set higher the than maximum operating pressure which could be set by a relief valve or pressure cutoff on the pump
Dump Valve - Pilot Operated
This valve works in conjuction with the Solenoid/Manual Dump Valves (Items#1 and #6). When this valve is open pilot pressure cannot build on the spring side of the dump valve. Pressure from the water pump and agitator will force the valve open and allow the oil to flow to tank.
5
Dump Valve - Pilot Operated
This valve works in conjuction with the Solenoid/Manual Dump Valves (Items#1 and #6). When this valve is open pilot pressure cannot build on the spring side of the dump valve. Pressure from the concrte pump will force the valve open and allow the oil to flow to tank.
6
Dump Valve - Solenoid/Manual Operated - Spring Return
Normally closed when in operation. When a signal is no longer being sent to the solenoid, the valve will open allowing pilot pressure within the block to be lost. This will allow the dump valves (Item#4 and #5) to open and dump the system pressure to tank.
4
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Hydraulic Parts
See boom schematic D
C
1
B
10037
250 bar
2
A
6
5
4 3
E
F
3 3
OR
4 5
D C B A
E F
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Table 35: E-Stop Manifold Item#
Part
How it Functions
Directional Spool Valve
When energized the Directional Spool Valve will open a passage way for the oil coming from the P1 port to the spring side of the poppet valve. This pressure along with the spring will force the poppet valve shut, allowing oil to flow to the boom system. When de-energized the Directional Spool Valve will block the flow of oil to the spring side of the poppet valve. With no pressure on the spring side of the poppet valve. Oil from the P1 port will open the poppet valve and will be routed to tank. This will disable the boom system.
2
Directional Spool Valve
When energized the Directional Spool Valve will open a passage way for the oil coming from the P2, P3 & P4port to the spring side of the poppet valve. This pressure along with the spring will force the poppet valve shut, allowing oil to flow to the concrete pumping system. When de-energized the Directional Spool Valve will block the flow of oil to the spring side of the poppet valve. With no pressure on the spring side of the poppet valve. Oil from the P2 & P3 ports will open the poppet valve and will be routed to tank. This will disable the concrete pumping system.
3
Orifice
Restricts the flow of oil
4
Poppet Valve
The poppet valve will open, allowing oil from the P1 port to be routed to tank. This will disable the boom system
5
Orifice
Restricts the flow of oil
6
Poppet Valve
When the dump valve is closed, pressure on the spring side of the poppet valve is no longer available. When pressure from the P1 port becomes greater than the spring tension. The poppet valve will open, allowing oil to escape to tank, thus disabling the system.
7
Orifice
Restricts the flow of oil
8
Redundant Relief Valve for the Boom System
This relief is set higher the than maximum operating pressure which could be set by a relief valve or pressure cutoff on the pump
9
Check Valve
Allows free flow of oil into the E-stop manifold
10
Check Valve
Allows free flow of oil into the E-stop manifold
11
Check Valve
Allows free flow of oil into the E-stop manifold
12
Gauge Port (MP5)
Used to check the pressure on the P3 Port
13
Gauge Port (MP2)
Used to check the pressure on the P2 Port
14
Secondary Pressure Relief Valve
When the dump valve is closed, the relief valve will limit the amount of pressure in the E-stop manifold, to the set amount of the relief spring. (Example 260 bar)
1
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Emergency stop manifold
SERVICE TRAINING
MP5
1
3
1
2
5
3
2
1.6
1
3
0.9
7
4
7
6
12
T 10
Hydraulic Parts
2
1.6
0.9
11
PRINT
260 bar
9
8
13
P1
MP1
P2
P3
MP2
P4
14
See boom schematic
2
10
9
6
11
1
5
3
7
14
4 12
13
T
8
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Table 36: E-Stop Manifold Item#
Part
How it Functions
1
Redundant Relief Valve for the Boom System
This relief is set higher the than maximum operating pressure which could be set by a relief valve or pressure cutoff on the pump
2
Poppet Valve
The poppet valve will open, allowing oil from the P2 and P3 port to be routed to tank. This will disable the concrete pumping system
3
Poppet Valve
The poppet valve will open, allowing oil from the P1 port to be routed to tank. This will disable the boom system
Directional Spool Valve
When energized the Directional Spool Valve will open a passage way for the oil coming from the P2 & P3 port to the spring side of the poppet valve. This pressure along with the spring will force the poppet valve shut, allowing oil to flow to the concrete pumping system. When de-energized the Directional Spool Valve will block the flow of oil to the spring side of the poppet valve. With no pressure on the spring side of the poppet valve. Oil from the P2 & P3 ports will open the poppet valve and will be routed to tank. This will disable the concrete pumping system.
5
Directional Spool Valve
When energized the Directional Spool Valve will open a passage way for the oil coming from the P1 port to the spring side of the poppet valve. This pressure along with the spring will force the poppet valve shut, allowing oil to flow to the boom system. When de-energized the Directional Spool Valve will block the flow of oil to the spring side of the poppet valve. With no pressure on the spring side of the poppet valve. Oil from the P1 port will open the poppet valve and will be routed to tank. This will disable the boom system.
6
Gauge Port
Used to check the pressure of the P2 port
7
Gauge Port
Used to check the pressure of the P3 port
8
Orifice
Restricts the flow of oil
9
Check Valve
Allows free flow of oil into the E-stop manifold
10
Check Valve
Allows free flow of oil into the E-stop manifold
11
Orifice
Restricts the flow of oil
12
Orifice
Restricts the flow of oil
4
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1
3
1
2
Hydraulic Parts
3 2
4
1.6
1.6
11
0.9
5 12
0.9
2
3
8
T
PRINT
8 1
MP2
6 7
9
10
MP3
P2
MP1
P3
P1 See boom schematic
4 5
2 T
T
8
11
12
9 8 3
10
T
1
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Hydraulic Parts
Table 37: 2023-4 Hydraulic Pumps Item#
Part
How it Functions
A
A7V0107LRH1 Variable Displacement pump
Variable displacement hydraulic pump that supplies hydraulic oil to the pumpkit
B
A7V0107LRH1 Variable Displacement pump
Variable displacement hydraulic pump that supplies hydraulic oil to the pumpkit
C
A7V055D RG Variable Displacement pump
Proportional boom pump
D
A10VO28DR Variable Displacement pump
Accumulator pump
E
W9A2-31-11-R-3-F-27/24-NN
Agitator Pump
F
W9A2-31-11-R-3-F-27/24-NN
Oil cooler pump
G
Pressure Regulator Valve
A valve containing two spools. the 300 bar pressure regulator spool and the 20 bar Delta P spool.
Delta P (20 bar) Spool
The valve compares pressure before and after the orifice and maintains the pressure drop (differential pressure ∆p) across the orifice – and therefore the pump flow – constant. If differential pressure ∆p increases, the pump is swivelled back towards Vg min, and if ∆p decreases the pump is swivelled out towards Vg max until a balance is restored within the valve.
Pressure Regulator Spool (load sensing valve)
The load sensing valve is a flow control valve which operates as a function of the load pressure to regulate the pump displacement in order to match the requirement of the actuator. The pump flow is influenced by the external orifice (control block, throttle) fitted between pump and actuator, but is not affected by load pressure throughout the range below the set pressure.
Pressure Compensator
The pressure compensator serves to maintain a constant pressure in the hydraulic system, within the control range of the pump. The pump therefore supplies only the amount of hydraulic fluid required by the actuators.
Stroke Regulation/Begining of Regulation Spring
The hydraulic stroke limiter is used to smoothly adjust the flow between Vg max and Vg min. The power control overrides it. Displacement is set by the pilot pressure existing at port X1. The hydraulic stroke limiter takes the required positioning pressure from the high pressure.
Horsepower Spool (Constant Power)
The Horsepower spool controls the output flow of the pump in relation to the pressure so that the power of the drive unit is not exceeded. As the pressure increase, the Horsepower Spool will open, allowing a passage way for oil to move through the Horsepower Spool and push against the swashplate piston, destroking the pump.
1
2
3
4
5
202
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X1
1
X
A
20 bar
2
A1
PRINT
Y3 A
300 bar
T
A1
4
P A X3
G
See Detail 1
C
5 S
A
Detail 1
Rexroth A7VO-LRDH Hydraulic pumps X1 Y3 A
F
A1
3
E
4
200 bar
5
D
S
2
B
4 A
G 5 1
5
4 B
C
D
3
F E
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Hydraulic Parts
Table 38: 2023-5 Hydraulic Pumps Item#
Part
How it Functions
A
A11VO130LRDH1 Variable Displacement pump
Pumpkit
B
A11VO130LRDH1 Variable Displacement pump
Pumpkit
C
A11VO60DRS Variable Displacement pump
Proportional Boom pump
D
A10VO28DR Variable Displacement pump
Accumulator pump
E
W9A2-31-11-R-3-F-27/24-NN
Agitator Pump
F
W9A2-31-11-R-3-F-27/24-NN
Oil Cooler Pump
1
Horsepower Spool (Constant Power)
The Horsepower spool controls the output flow of the pump in relation to the pressure so that the power of the drive unit is not exceeded. As the pressure increase, the Horsepower Spool will open, allowing a passage way for oil to move through the Horsepower Spool and push against the swashplate piston, destroking the pump.
2
Pressure Cut-off (350 bar)
Pressure cut-off corresponds to a pressure control which adjusts the pump displacement back to Vg min when the pressure signal reaches 350 bar.
Stroke Regulation
When the pressure signal from the stroke limiter exceeds the Stroke Regulation pressure spring. The Stroke Regulation spool will open, allowing a passage way for the oil to move through the Stroke Regulation spool
Delta-P Spool
The valve compares pressure before and after the orifice and maintains the pressure drop (differential pressure ∆p) across the orifice – and therefore the pump flow – constant. If differential pressure ∆p increases, the pump is swivelled back towards Vg min, and if ∆p decreases the pump is swivelled out towards Vg max until a balance is restored within the valve.
Pressure Regulator Spool
The load sensing valve is a flow control valve which operates as a function of the load pressure to regulate the pump displacement in order to match the requirement of the actuator. The pump flow is influenced by the external orifice (control block, throttle) fitted between pump and actuator, but is not affected by load pressure throughout the range below the set pressure.
Pressure Compensator
The pressure compensator serves to maintain a constant pressure in the hydraulic system, within the control range of the pump. The pump therefore supplies only the amount of hydraulic fluid required by the actuators.
3
4
5
6
204
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SERVICE TRAINING
M
A
Z
G
T1
RZ
Hydraulic Parts
T2
Y
M
A
G
2
T1
R
T2
see note
3
F
E
D
Y
2 see note
See boom schematic
PRINT
3
1
1
C B
Note Pressure settings: 2023 = 350 bar 2020 = 328 bar
Hydraulic pumps are limited to noted pressures by pressure cutoff.
6
A
200 bar
C
T2
X
T1
G
A
M
20 bar ∆ P
4 5 1
310 bar
2
M
3 1
A11VO 170 l/m
2
M1
S
3
5
A
4 B C 6
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Hydraulic Parts
Table 39: 2525-6 Hydraulic Pumps Item#
Part
How it Functions
A
A11VO190LRDH1 Variable Displacement pump
Pumpkit
B
A11VO190LRDH1/11RNZD12K83
Pumpkit
C
A11VO60DRS/10RNZC12K02
Proportional Boom Pump
D
A10VO28DR/31R-PSC62K01
Accumulator Pump
E
W9A2-31-11-R-3-F-27/24-NN
Agitator Pump
F
W9A2-31-11-R-3-F-27/24-NN
Oil Cooler Pump
G
W9A2-31-11-R-3-F-27/24-NN
Oil Cooler Pump
1
Pressure Cut-off (330 bar)
Pressure cut-off corresponds to a pressure control which adjusts the pump displacement back to Vg min when the pressure signal reaches 350 bar.
Horsepower Control
The Horsepower spool controls the output flow of the pump in relation to the pressure so that the power of the drive unit is not exceeded. As the pressure increase, the Horsepower Spool will open, allowing a passage way for oil to move through the Horsepower Spool and push against the swashplate piston, destroking the pump.
Stroke Regulation
When the pressure signal from the stroke limiter exceeds the Stroke Regulation pressure spring. The Stroke Regulation spool will open, allowing a passage way for the oil to move through the Stroke Regulation spool
Delta-P
The valve compares pressure before and after the orifice and maintains the pressure drop (differential pressure ∆p) across the orifice – and therefore the pump flow – constant. If differential pressure ∆p increases, the pump is swivelled back towards Vg min, and if ∆p decreases the pump is swivelled out towards Vg max until a balance is restored within the valve.
5
Pressure Compensator
The pressure compensator serves to maintain a constant pressure in the hydraulic system, within the control range of the pump. The pump therefore supplies only the amount of hydraulic fluid required by the actuators.
6
Pressure Cut-off
Pressure cut-off corresponds to a pressure control which adjusts the pump displacement back to Vg min when the pressure signal reaches 200 bar.
2
3
4
206
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Y
T2
R
T1
G
Z
A
M
Y T2
R
T1
1
G
Z
A
Hydraulic Parts
M
1
see note
see note
3 2
3 2
E S
M1
B
C
S
200 bar
M1
A
PRINT
F
G
6
Note: Pressure in A11VO-LRDH hydraulic pumps are limited by pressure cutoff. This configuration set at 330 bar. Other configurations have other pressure ratings.
D C
T2
X
T1
G
A
M
20 bar ∆ P
4 5
3
2
310 bar
M A11VO 170 l/m
1
M1
3
2
S
1
4
5
6
A
B
C D
E F G
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SERVICE TRAINING
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Pressure Settings
Pressure Settings General Stroke Limiter Adjustment
Override Button
Pressure Reducing Valve Pressure Adjustment
B
P
A Remote controlled stroke limiter T P
A
Output to hydraulic pumps via dampner shuttle valve
B
70 bar
A
B
C
A
Line from manual stroke limit valve
PRINT
B C
Adjustment Procedure 1.
Disconnect line at A port of shuttle valve and install a 0-200 bar gauge in the end of the hose.
2.
Push override button in all the way.
3.
Pressure out pumpkit.
4.
Set relief valve to 70 bar.
5.
Set max. pressure on computer card for 35-40 bar with override button de-activated and the stroke limit knob on remote box at min. strokes.
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Pressure Settings Check the accumulator Pre-Charge After charging an accumulator that has had no initial gas pre-charge, allow 20 to 30 minutes for the gas temperature and pressure to stabilize. Recheck the gas pre-charge pressure and adjust if necessary. After the accumulator has been put in service it is important that the pre-charge pressure is checked at least once in the first week to verify the initial precharge has not changed due to temperature and pressure stabilization. If the check reveals no loss in pressure, the pre-charge should be checked on the following schedule: • 1st Check - 1 week • 2nd Check - 3 months • 3rd Check - 1 year • 4th Check and continued - yearly
WARNING EXPLOSION CAUSED BY IMPROPER ACCUMULATOR CHARGING CAN RESULT IN DEATH OR SERIOUS INJURY! * Follow the charging instructions exactly! * Use ONLY dry nitrogen to charge the accumulator! * NEVER use oxygen or compressed air to charge the accumulator!
Read all instructions for charging accumulators before beginning the charging procedure. Accumulators must be charged only with dry nitrogen. Compressed air and oxygen must never be used, because oxygen molecules combine with hydraulic oil, lower the flash point of the oil to less than room temperature, and cause an explosion. Workers have died using compressed air or oxygen to charge accumulators (Figure 40). Use only dry nitrogen, never liquid nitrogen. explwarn.eps
Figure 40 Charging accumulators improperly can cause injury or death The procedure for checking the accumulator charge pressure and the procedure for charging the accumulator are described in the following steps: 1. Before you begin, you will need a charging kit (Figure 41). Do not attempt to charge the accumulators without one. Order the charge valve assembly from Schwing America using part number 30355436. 2. You must use a high-pressure regulator with the nitrogen bottle. If it was not supplied with the bottle, order one before proceeding with this job. Before beginning the charging procedure, stop the engine, remove the key, and put a “Do Not Operate” tag over the key switch. Put the key in your pocket, so no one can start the engine
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Tank Regulated Pressure Pressure
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Pressure Settings
High pressure gas regulator is not included with the kit. These are available from the nitrogen supplier.
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Nitrogen Bottle
charge valve assy 100
150
1500 2000 2500 1000
50
500
200
3000
hose
3500
0
250
30355456 accuman1.eps
BPL HYDAC bladder Accumulator
ACCUMULATOR CHARGING KIT (Includes hose and charge valve assy) SCHWING PART NUMBER: 30355436 chargkit.eps
Figure 41 Accumulator charge kit for HYDAC bladder accumulators
.
3. The accumulators should dump pressure when the engine is stopped, but you must still verify zero accumulator pressure. Dump the accumulator pressure using the manual bleed valve on the accumulator unloading valve (Figure 42). Verify zero accumulator pressure on the concrete pump’s accumulator pressure gauge.
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um
ma
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Figure 42 Accumulator manual bleed valves 4. Refer to Figure 13 for component location on the charge valve assembly while performing the following steps.
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Pressure Settings
Tank Regulated Pressure Pressure Nitrogen Supply Valve
Regulator Adjustment Handle
Nitrogen Bottle
Push Button Pressure Gauge 100
1500 2000 2500 1000
50
500
Charge Valve Stem
150
200
3000 3500
0
250
Swivel Nut
Bleed Valve
HYDAC bladder Accumulator chgvalve.eps
Figure 43 Charge valve assembly
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5. Remove the valve protection cap and the valve seal cap from the accumulator (Figure 44). Leave the valve protection cap on the accumulator until you actually begin the procedure.
Valve Protection Cap
Valve Seal Cap
Valve Stem O-ring
HYDAC bladder Accumulator accum closeup
Figure 44 Detail of accumulator gas valve area 6. On the charge valve assembly (Figure 43, close the bleed valve (turn it clockwise all the way in). If a hose is connected to the charge valve stem, disconnect the hose from the charge valve stem. This step closes the charge valve stem to prevent the gas pressure from escaping out of the hose. It ensures that the initial pressure reading is accurate. 7. Find the swivel nut on the charge valve assembly (Figure 43). Screw the swivel nut onto the accumulator gas valve. Tighten to 10–15 in./lb. 8. After the swivel nut is attached, depress the push button on the top of the charge valve assembly (Figure 43). This presses a pin into the accumulator gas valve and opens it. Read the pressure on the charge valve assembly pressure gauge. The pressure should read 100 bar (1450 PSI). • If pressure must be added, proceed to Step 10. • If pressure is too high, skip to Step 14. • If no adjustment is necessary, skip to Step 17.
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Pressure Settings
9. Be sure that the nitrogen bottle supply valve is firmly closed. Attach the high-pressure regulator to the nitrogen bottle, then attach the hose to the highpressure regulator. Finally, attach the other end of the hose to the charge valve stem on the charge valve assembly (Figure 43. 10. Do not open the nitrogen bottle supply valve yet. Turn the regulator adjustment handle on the highpressure regulator (Figure 43) counter clockwise to its minimum setting (closed). 11. Slowly open the nitrogen bottle supply valve (Figure 43). You will get a reading on the tank pressure gauge side of the regulator. If there is enough pressure in the nitrogen bottle to do the job, proceed to Step 13.
NOTE! If there is not at least 1450 PSI in the nitrogen bottle (as shown on the regulator gauge at this time), you will not be able to charge the accumulator nitrogen to the 1450 PSI specification. If that is the case, you will need a new bottle of nitrogen before proceeding. 12. Adjust the regulator adjustment handle clockwise, raising the regulated pressure. The accumulator will begin to fill. Continue filling until the charge valve assembly pressure gauge (Figure 43) reads the desired pressure of 1450 PSI. Close the nitrogen bottle supply valve. 13. If you overcharge the nitrogen pressure, refer to (Figure 43) and proceed as follows: • Close the nitrogen bottle supply valve. • Depress the push button on the top of the charge valve assembly. • Slowly open the bleed valve on the charge kit. Close the bleed valve when the correct pressure is reached on the charge valve pressure gauge.
NOTE! Never let nitrogen out of the accumulator by pressing the gas valve pin with a foreign object. The high pressure may rupture the valve seal! 14. Let the nitrogen sit in the accumulator for 10 to 15 minutes. This allows the gas temperature to stabilize. Depress the push button on top of the charge valve assembly. Recheck the pressure on the charge valve assembly pressure gauge.
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Pressure Settings 15. Add or release nitrogen until the pressure is correct. Be sure that the bleed valve is closed before adding pressure and that the nitrogen bottle supply valve is closed before releasing pressure. 16. When the correct pressure is reached, refer to (Figure 43) and proceed as follows: • Close the nitrogen bottle supply valve. • Open the charge valve assembly bleed valve. This releases the pressure in the hose, charge valve assembly, and regulator. • While holding the charge valve assembly on the accumulator, unscrew the charge valve swivel nut. • Remove the charge valve assembly. • If you are finished with the charge valve assembly, remove the hose and regulator. 45. Make a bubbly mixture from soap and water. Spread the mixture around the accumulator gas valve to check for gas leaks. Gas leaks will push the bubbles away from the area of the leak. If you find a leak, replace the accumulator or have it repaired by qualified personnel. Never repair an accumulator yourself. 46. Replace the gas valve seal cap (tighten to 22 ft/lb), and hand-tighten the valve protection cap. 47. If your concrete pump has two accumulators, repeat this procedure for each accumulator.
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Hydraulic Pump Adjustments
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Pressure Settings
Adjustment Knob
Main System Pumps A11VO To perform the proper adjustments of flow, horsepower, beginning of stroke limitation and the pressure cut-off to the tandem A11VO main system hydraulic pumps, the following steps must be done in order that they are listed;
Setting the Flow Rate Before flow metering the pumps, ensure that the maximum engine Rpm’s are set to the proper specifications. All Schwing units have a metal ID tag located inside the cab displaying the specific RPM settings for that particular unit. Set the supplement system pressure to 0 bar by turning the adjustment knob all the way out on the electric stroke limiter. This will avoid false readings of the flow rate until the maximum flow rate and horsepower break points are set.
A11VO130 / A11VO130
Q-max Screws
A11VO130 / A11VO190
Q-max Screws
T P T
MG
P MY
G Y
Adjustment Knob
Adjustment Knob
Figure 48 Electric Stroke Limiters Install the flow meter. (Consult the operation manual for proper installation and use of the flow meter). Set the engine Rpm’s at maximum and set the maximum flow at the Q max screw to the proper specifications per the output chart. (Check your operators manual for the proper output chart for your specific unit).
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Pressure Settings Horsepower Setting After the flow rate is set, the horsepower setting then must be done. The horsepower break point must be set to the proper specifications per the output chart. CONCRETE PRESSURE
PERFORMANCE CHARACTERISTICS OF THE AXIAL PISTON HYDRAULIC PUMP
4500
350 300
4000 3500 3000 2500 2000 1500 1000
250 200
131
117
HYDRAULIC RELIEF VALVE IS SET AT 350 BAR MAX. PRESSURE (5075 PSI).
1600
110
1500
103
P
1400
97
MY
1300
90
1200
83
1100
76
200 Kw
150 100
Break Point 180 Kw = 182 bar 200 KW = 202 bar At 350 bar 180 Kw = 278 l/m 200 Kw = 309 l/m
0
10
20
7.5 15
30 40
50 60
70 80
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800
55
700
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600
41
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14
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208 90 100 110 120 130 140 150 160 170 180 190 200 210 220
23 30.5 38 46 53.5 61 69 76.5 84 92 99 107 114 122 130 137 145 153 160 168
cu yd / h cu meters/ h
CONCRETE OUTPUT 5
10 100
15 200
20 300
25 400
30 500
32
535
P T
MG G Y
1000 1007 69
50 500
T
124
1700
SA
OIL PRESSURE
5000
Bar 138
1900 1800
180 Kw
5500
PSI 2000
PUMP SPEED 2100 RPM
M PL E
Piston Side Bar
Piston Side PSI
BPL 2023-5 350 or 400 HP truck
ROD SIDE
Adjustment Knob
Number of strokes (stroke / min.) Oil volume (liter / min.)
Break Points
Figure 49 Sample output chart
Setting Stroke Limitation Now that the maximum flow rate and horsepower settings have been made, the beginning of stroke limitation can be set. Adjust the supplement system pressure to the maximum pressure of 50 bar. 1. Make sure the stroke limit potentiometer at the rear operation panel or remote box is at the maximum material output setting.
Figure 50 Stroke Limiter Potentiometer 2. Install a 0 to 40 bar gauge in the electric stroke limit line going to the Y port of the hydraulic pumps, at this time the reading on the gauge should be 0.
Adjustment Knob
Adjustment Knob
Figure 51 Stroke Limiters (two generations) 3. Increase the engine Rpm's to the maximum setting and while watching the flow meter scale, slowly turn the stroke limit potentiometer to the minimum material output until the maximum flow rate begins to drop. 4. When the flow rate begins to drop, stop turning the potentiometer and read the pressure on the 0 to 40 bar gauge. The reading that is seen is the beginning of stroke limitation. The reading should be between 5 to 7 bar. If it is not, then adjust the beginning of stroke limitation screw accordingly to achieve the proper pressure reading. a. If the pressure is too high, then turn the screw counter-clockwise (out) to reduce the pressure. b. If the pressure is too low, then turn the screw clockwise (in) to increase the pressure.
Q-min Output Flow Once the beginning of stroke limitation is set, the next step is to check the Q min output flow. 1. With the 0 to 40 bar gauge still in the electric stroke limit line going to the Y port of the hydraulic pumps. Increase the engine Rpm's to the maximum setting and while watching the flow meter scale, turn the stroke limit potentiometer to the minimum material output. The 0 to 40 bar gauge should be reading approximately 25 bar more than the beginning of stroke limitation setting to ensure the hydraulic pumps are all the way to the minimum against the Q min stop. The Q min reading should be between 15 to 25 liters per minute. If it is too high, turn the Q min screw out until the reading is correct or if it is to low, turn the
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Q min screw in until the reading is correct. When the Q min has been set, the flow meter can now be removed. A11VO190
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Pressure Settings
Parts Department using part number 10004680 (valve), and number 30303432 (tube). Contact the Service Department for installation instructions. 2. Activate the agitator. With the valve closed the agitator will not be able to turn and the oil will be forced over the relief valve. At an idle (about 600 RPM), 4.5 horsepower is being converted to heat.
A11VO130
agitoff2.eps
Q min Screw Q min Screw
Figure 52 Q-min screw locations 2. Repeat steps 2 through 6 on the second main system pump before attempting to set the pressure cut-off on both pumps.
NOTE! All screw adjustments with the system relief’s and pressure cut-off must be done while the unit (pumpkit) is in the neutral position.
Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components. The specifications for each circuit are shown on the hydraulic schematics found in the Appendix of this manual. The hydraulic schematics are the only documents in this manual that have been updated specifically for your unit, by the serial number, so in each of the following procedures you will be told to refer to the schematic for the pressure required. • Preheat the hydraulic oil Pressure settings must be made with the oil at normal operating temperatures (40°− 60° C). In the past we could pressure out a function in the boom or outrigger system to create heat, but load sensing systems no longer allow maximum oil flow to be forced over relief. Because of this the agitator circuit must be used to heat the hydraulic oil. To preheat the hydraulic oil: 1. Locate the agitator shutoff valve (Figure 53) and close it. NOTE! If your unit does not have a shutoff valve, order one from the Schwing Spare
Figure 53 Agitator shutoff valve 3. When the oil temperature gauge shows 50˚C, open the shutoff valve.
Setting pressures on Hi-flo -6 pumpkits a. To set the pressure of the main relief valve on Hi-flo pumpkits, you must first disable the soft switch circuit. Simply locate the ball cock for the soft switch circuit (Figure 54) and close it by rotating the handle 90 degrees. b. The quarter turn shutoff valve for the concrete pump will also need to be closed during this procedure.
NOTE! Main system adjustments are preset at the factory. The following procedure begins with adjustment of the main relief cartridge and pressure cutoff. If proper pressures can not be obtained through these steps, refer to the beginning of this procedure for specific instructions on the adjustment of flow, horsepower, beginning of stroke regulation and Q-min.
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Pressure Settings Pressure setting procedure: Soft switch shutoff valve Main Pressure Gauge port
Concrete pump shutoff valve
hif
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Figure 54 Concrete pump and Soft switch shutoff valves 1. Be sure that the waterbox covers and guards are in place any time you will be working in the area around the main control block. 2. Wear safety glasses when working around a concrete pump.
7. Stop the truck engine and put the key in your pocket. Adjust the pressure cutoff screw (Figure 55) on each pump, by backing off the jam nut with a 13mm wrench. Using a 4mm allen wrench, turn the adjustment screw in (clockwise) one full turn and tighten the jam nut. Restart the truck engine. 8. Adjust the engine RPM to maximum specification. (See decal in truck cab) 9. Pressure out the system by activating the concrete pump forward switch on the rear panel. Using the rear panel controls will allow you to read the concrete pump main system pressure gauge, near the e-stop manifold, from a safe distance.
NOTE!
NOTE!
1. 2.
3.
4.
5.
6.
It is vital that each adjustment screw be properly identified prior to making any adjustment. All screw adjustments for the system relief must be made with the pumpkit in the neutral position and adjustments for pressure cutoff must be made with the engine shut off. Start the truck engine, and put the PTO in gear just as you would to pump a job. If you have not already closed the soft switch shutoff valve and the concrete pump shutoff valve (Figure 54) do so at this time. At the rear panel, select “local” control with the “local/remote” switch and turn the electric stroke limiter knob clockwise to maximum strokes per minute. The main system control block pressure must be set first to properly set the pressure cutoff on both pumps. Begin by backing off the jam nut of the main relief cartridge (Figure 56) with a 9/16 inch wrench. Using a 5/32 inch allen wrench, turn the adjustment screw out (counterclockwise) until you can feel no spring tension on the adjustment screw. Now, turn the screw back in (clockwise) two or three full turns to give you a proper starting point and tighten the jam nut.
1.
2. 3.
4.
Because you turned out the pressure relief cartridge in step 7, the system pressure should read low at this time. If it does not and the gauge spikes to 320 bar or more, disengage the pump immediately. Turn the relief cartridge out (counterclockwise) more. For safety, it is important to adjust the pressure up from below the specified target pressure rather than down from a pressure which exceeds the target. Continue this procedure until the main system pressure gauge reads lower than the specified target. To increase the pressure put the pump in the neutral position and adjust the relief cartridge by turning it in (clockwise). When increasing the pressure, the adjustments should be made in quarter turn increments. If you make adjustments to increase the pressure but the pressure does not come up, you are probably reading the pressure cutoff of the pumps, if so proceed to the next step otherwise skip to step 15.Turn the relief cartridge adjustment screw back out (counterclockwise) until you can no longer see a pressure drop and tighten the jam nut. Stop the truck engine, put the key in your pocket. Go to the pressure cutoff screw on both hydraulic pumps (Figure 55) and back off the jam nut with a 13mm wrench. Turn the adjustment screws in with a 4mm allen wrench one or two more turns, restart the engine and check the pressure again. Repeat this procedure until the main system relief can be set to the target pressure. When the proper main relief pressure is achieved, pressure cutoff can be set. Shut off the engine, put the key in your pocket and install 0-600 bar gauges with whip hoses to the “M1” gauge ports on the bottom of the two hydraulic pumps (Figure 55).
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NOTE! The gauges in the M1 ports will read considerably less than the cutoff pressure of the pump. On a -6 (190/130 pump combination) the 190 will usually read 85 to 90 bar while the 130 reads about 110 bar. They could read the same however, at approximately 110 bar, but the 190 must never read higher than the 130. The actual cutoff pressure will be read on the concrete pump main system pressure gauge near the e-stop manifold. 1. Activate concrete pump forward to pressure out the pump and read the pressure on the two gauges in the “M1” ports. 2. Always stop the truck engine and put the key in your pocket before making any adjustment on the hydraulic pump. If the cutoff on one pump is set higher than the other, that pump will be more dominant. The pressure gauge in the M1 port of the dominant pump will however, read lower than the other. To equalize the two pumps you must either adjust the cutoff screw in (clockwise) to increase the pressure of the pump showing the higher reading or adjust the cutoff screw of the dominant pump showing the lower reading out (counterclockwise) to reduce the pressure. These adjustments must be made until the two gauges in the M1 ports are reading approximately the same. 3. When you have achieved the same pressure on the M1 port gauges, you can begin to adjust the pressure cutoff screws in or out simultaneously until you achieve the desired pressure setting of 350 bar (again, confirm the pressure specification with the hydraulic schematic). After pressure cutoff is set, return the pump to neutral, bring engine RPM to idle, open the soft switch quarter turn valve, and either proceed to other pressure settings or take the transmission and PTO out of gear and shut off the truck.
Pressure Settings
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Figure 55 Adjustment screw locations Soft switch shutoff valve Main Pressure Gauge port
Concrete pump shutoff valve
Closed
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Open soft switch relief valve
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You must be able to read both gauges simultaneously to ensure that one pump is not more dominant than the other.
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Main relief valve 5/32" Allen head 9/16" jam nut Figure 56 Soft switch circuit/Main relief valve
Setting the soft switch relief pressure First, open the soft switch quarter turn valve (Figure 56) that you closed in the previous procedure. The rest of the unit should still be set up as if you were going to check the main relief valve pressure (concrete pump shutoff valve still closed). When you put the pump in forward now, the main concrete pump pressure gauge should read the pressure shown on the schematic for soft switch. If adjustment
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Pressure Settings is needed, loosen soft switch relief valve jam nut (Figure 56) with a 9/16 open end wrench, and use a 5/ 32 allen wrench to adjust the pressure. Turn the adjustment screw in (clockwise) to raise the pressure or out (counter clockwise), to lower the pressure. When you attain the required pressure, tighten the jam nut while holding the allen wrench to keep the pressure from rising. Be sure to open the concrete pump shutoff valve on the side of the brain (Figure 56) when you are finished. The unit will not stroke with this valve closed
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Pressure Settings
BPL 500
E-Stop Manifold Valves and Gauge Ports
Concrete Pump Shutoff Valve
Water Pump Hand Valves and Gauge Port
Concrete Pump Soft Switch Accumulator Unloading Manifold Valve
Concrete Pump
and Gauge Port
Pressure Gauge Main Relief Valve
Manual (forward/reverse) Agitator Hand Valve
Control Lever.
and Gauge Port Main Control Panel Agitator Shutoff Valve
Figure 57 General location of components used to set hydraulic pressures •
Heating hydraulic oil. Pressure settings must be made with the oil at normal operating temperatures (40°– 60°C). The agitator circuit must be used to heat the hydraulic oil. Do not jam the paddles to force the oil over the relief valve by stopping the movement of the agitator. To preheat the hydraulic oil using the agitator circuit, follow these instructions. 1. Locate the agitator shutoff valve and close it (Figure 58). The general location of the agitator shutoff valve is shown in Figure 57. 2. Position the agitator hand valve in the forward or reverse position. The agitator will not be able to turn, and the oil will be forced over the relief valve. At idle speed (about 600 RPM), about 4.5
horsepower is being converted to heat. Shut off the concrete pump when the temperature gauge on the operator’s panel shows 50°C. 3. Open the agitator shutoff valve or remove plug and reconnect hose to agitator motor.
NOTE! If your unit does not have a shutoff valve, order one, using part #10004680 (valve), and #30303432 (tube). Contact the Schwing Service Department for installation instructions. If you can’t wait for a shutoff valve, you will need to remove one of the hoses from the agitator motor and plug the hose and open fitting with approved hydraulic
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Pressure Settings
a
dead plugs. Do not substitute other plugs, such as a steel bearing inside a cap fitting. You will need: - Qty 2 VS-16S locking plugs, part number 10016803 - Qty 1 GS-16S straight fitting, part number 10008088 - Qty 2 16S capnuts, part number 10001743. CLOSED
Valve is shown in the OPEN position
6. Using the concrete pump “forward/neutral/ reverse” control lever, put the concrete pump into the “forward” position. The unit will cycle one stroke, then the rock valve cylinder will retract. Oil will have nowhere to go except over the main relief valve. 7. Read the pressure on the concrete pump gauge, located on the main control block. It should read 300 bar. If no adjustment is needed, skip to Step 12. 8. If adjustment is required, loosen the jam nut on the main relief valve adjusting screw (requires a 13mm spanner wrench). 9. Turn the knob on the relief valve to adjust the pressure. Screw the handle in to raise pressure, out to lower the pressure. 10. Retighten the jam nut. (Tightening the jam nut tends to raise the pressure. If it becomes a problem, hold the knob while tightening the jam nut) . 17mainreliefvalv
Figure 58 Agitator shut off valve
NOTE!
•
Pressure setting shown in these procedures are for the BPL 500 HDR-18. Pressure setting will be different for each type of pump kit. Refer to the hydraulic schematic in the Appendix of your Operation manual for the correct pressure settings. Set the concrete pump pressure. The Schwing concrete pump circuit on the BPL 500 is designed to be operated at a maximum pressure of 300 bar (4350 PSI). It is controlled by the main relief valve, which is located at the rear of the main control block (Figure 59).
To check or set the main relief pressure: 1. Be sure that the waterbox covers are installed on the waterbox. We do not recommend using the remote control box for the following procedure. 2. Wear safety glasses when setting pressures. 3. Close the concrete pump shutoff valve and the soft switch shutoff valve (Figure 6-223). 4. Put the operator’s panel “remote/local” switch into the “local” position. 5. Using the switch on the operator’s panel, rev the engine up to full RPM.
Jam nut Relief Valve
Figure 59 11. Put the concrete pump into the “forward” position again. The machine will not stroke this time, but will again develop maximum pressure. Read the pressure on the gauge. If more adjustment is needed, return the pump to “neutral,” then repeat steps 9. thru 11. until the pressure is at 300 bar. Return the pump to the “neutral” position.
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SERVICE TRAINING
Concrete pump
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shutoff valve
;@;@;@;@;@;@;@;@;@;@ ;@;@ @ ; @ ; @ ; @ ; ;@ ;@ @ ; @ @;@;@;@;@;@ @; ; Q @; ; Q @; ; Q @; ; Q @; ; Q @ ; Q ;@ @ ; Q @ ; @ ; Q @ @ ; Q ; Q @ @ @ ; Q ; Q @ @ @ ; Q ; Q @ @ ; ; Q @ @ ; @ ; Q @ ; @ ; Q @ ; @ ; Q @ ; @ ; Q @ ; @ ; Q @ ; Q @;@;@;@;@ @; ; Q @ ; ; Q @; ; Q @; ; Q @; ; Q ;@;@ @ @ @ @;@;@ Soft switch
shutoff valve
closed
Soft Switch
Relief Valve
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open
170-bar
138-bar
NOTE! If you cannot adjust the pressure up to 300 bar, you have a problem. To ensure that the pressure will not be to high when the problem is found, turn the main relief knob OUT several turns to lower the pressure. Contact Schwing America’s service department for advice on how to continue. 12. If you will not be setting the soft switch pressure, open both shutoff valves. The unit will not stroke with closed shutoff valves. 13. Return the RPM to an idle and go on to the other pressure settings, as required. • Setting the soft switch circuit relief pressure. To check or adjust the soft switch pressure setting, perform the following steps: 1. Close the concrete pump shutoff valve. Open the soft switch shutoff valve.
Pressure Settings
2. High-pressure the concrete pump. The control block pressure gauge should read 100-bar (1450 PSI) instead of 300 bar. If adjustment is needed, loosen the 2.5-mm allen screw on the face of the soft switch relief valve cartridge (Figure 60). Using a screwdriver, adjust the pressure up or down as needed, and lock into place with the 2.5-mm allen screw. Use a screwdriver, if necessary, to prevent the cartridge from turning while tightening the allen screw. Be sure to open the concrete pump shutoff valve when you are finished. The unit will not stroke with this valve close • Setting accumulator E-Stop manifold pressure. The accumulator E-Stop manifold pressure circuit is set to a maximum of 260-bar (3771 PSI) by its relief valve on the emergency stop manifold. To check the setting of the valve with the highest pressure, you must first raise the pressure of the lower three: 1. Locate the accumulator unloading valve and its relief valves (Figure 61).
Blckgrvs.eps
Figure 60 Concrete pump shut off valves
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230-bar
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Figure 61 Accumulator unloading valve
2. Loosen the jam nut of the high pressure valve (230-bar) adjustment screw. With an allen wrench turn the adjustment screw in one-and-a-half turns. This will raise the pressure on the valve above 260bar.
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Pressure Settings 3. Loosen the jam nut of the open valve (170-bar) and the close valve (138-bar) pressure adjustment screws. With an allen wrench turn both adjustment screws in two-and-a-half turns. This will raise the pressure on both valves above 260-bar. 4. Connect the whip hose of a 0–400 or 0–600 bar gauge into the gauge port of the E-Stop manifold (Figure 62). 17e-stopman.epsL
Relief valve Gauge port
Figure 62 E-Stop manifold accumulator relief valve
5. High-pressure the concrete pump. The pressure gauge should read 260-bar (3771 PSI) 6. If adjustment is needed, loosen the jam nut and with a allen wrench turn the adjustment screw on the relief valve (Figure 62). Turn in to raise pressure, turn out to lower pressure. 7. Repeat steps (5) and (6) until the gauge reads 260bar. 8. Tighten the jam nut on the adjustment screw, remove the whip hose and gauge from the gauge port, and replace the cap on the gauge port. • Setting the accumulator unloading valve. Use an allen wrench to make these adjustments 1. High-pressure the concrete pump. 2. Turn the high pressure (230-bar) adjustment screw out one-and-a-half turns or until the gauge on the accumulator unloading valve reads 230-bar (Figure 61).
3. Turn the open valve (170-bar) adjustment screw out two-and-a-half turns or until the gauge on the accumulator unloading valve reads 170-bar (Figure 61). 4. Turn the close valve (138-bar) adjustment screw out two-and-a-half turns or until the gauge on the accumulator unloading valve reads 138-bar (Figure 61 5. Tighten the jam nuts on all three adjustment screws. • Set the water pump/agitator pressures. You will need an assistant to perform this procedure. The location of all the components needed for this procedure are shown in (Figure 57). This hydraulic circuit has a maximum pressure of 200 bar (2900 PSI), limited by the relief valve on the water pump handvalve. To set the water pump/agitator hydraulic circuit pressures perform the following steps. 1. Stop the unit, and put the key in your pocket. 2. Install the whip hose of a 0–400 or 0–600 bar gauge on to the gauge port located on the waterpump handvalve. The location of the water pump hand valve if shown in Figure 57. Make sure the whip hose connection is tight. 3. To check or set the highest pressure of this circuit, you must first raise the pressure of the agitator relief valve. Turn the body of the relief valve in (clockwise) one and one half turns on the agitator hand valve. (The location of the water pump and the agitator hand valve are shown in Figure 57.) This will increase the circuit pressure over the 200 bars needed to set the water pump relief valve. 4. Start the unit engine and set the transmission and PTO as you would to pump concrete. 5. Locate the relief valve on the water pump hand valve. It will be on the bottom, passenger side, of the water pump handvalve. 6. Be sure that all personnel are clear. 7. Bring the engine to full RPM. 8. Locate the agitator shutoff valve and close it (Figure 58) The general location of the agitator shutoff valve is shown in Figure 57. 9. Position the agitator hand valve in the forward or reverse position. The agitator will not be able to turn, and the oil will be forced over the water pump relief valve.
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10. The gauge attached to the water pump hand valve should read 200 bar. 11. To adjust the pressure, turn the outside body of the water pump pressure relief valve (shown in Figure 58) clockwise to increase, or counterclockwise to decrease until 200 bar is showing the pressure gauge.
200 bar Relief Valve
Turn body of valve to adjust. Higher Lower
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Figure 63 Water pump relief valve 12. Return the agitator handvalve to the neutral position. 13. Turn the body of the agitator relief valves out (counter clockwise) one and one half turns. This will return the agitator relief valve to its original settings. 14. Remove the pressure gauge from the water pump hand valve and replace the cap nut on the gauge port. 15. Install the whip hose of a 0–400 or 0–600 bar gauge on to the gauge port located on the passenger side agitator hand valve. Make sure the whip hose connection is tight. 16. Close the agitator shutoff valve (Figure 58) 17. Be sure that all personnel are clear. 18. Bring the engine to full RPM. 19. Hold the agitator lever in the forward or reverse position. This will send the oil against the highpressure plug. The oil will return to the tank over the relief valve in the agitator hand valve. The
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Pressure Settings
pressure at which the valve relieves can be seen on the pressure gauge attached to the agitator hand valve. It should read 150 bar (2175 PSI). 20. To adjust the pressure, turn the outside body of the agitator pressure relief valve, located on the bottom of the agitator hand valve. It is the smaller of the two cartridges extending from the bottom of the valve (Figure 63). Turn the body of the relief valve clockwise to increase or counter clockwise to decrease until 150 bar is showing the pressure gauge.
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BPL 2000 NOTE! Pressure settings must be made with the hydraulic oil at normal operating temperatures (40°–60°C). To heat the oil to operating temperature use one of the following procedures: 1. When the oil is very cold (at or below the pour point of your hydraulic oil), bring engine RPM to an idle. Let the engine idle until the temp. gauge on the operator’s panel reads 40°C. 2. If your concrete pump unit has an agitator shutoff valve, refer to Preheating the hydraulic oil in the Operation section of this manual. • Set the concrete pump pressure. The Schwing concrete pump circuit on the BPL 2000 is designed to be operated at a maximum pressure of 300 bar (4350 PSI). It is controlled by the main relief valve, which is located on the top of the main control block (Figure 64). To check or set the main relief pressure:
Lower pressure
Raise pressure
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Figure 64 Concrete pump circuit main relief valve 3. Be sure that the waterbox covers are installed on the waterbox. We do not recommend using the remote control box for the following procedure.
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Pressure Settings
4. Wear safety glasses when setting pressures. 5. Start the engine. 6. Close the concrete pump shut-off valve (also known as the ballcock or quarter-turn valve). (See Figure 65.) 7. Put the operator’s panel “remote / local” switch into the “local” position. 8. Using the switch on the operator’s panel, rev the engine up to full RPM. 9. Using the concrete pump “forward / neutral / reverse” handle, put the concrete pump into the “forward” position. The unit will stroke no more than once, then the rock cylinder will retract. Oil will have nowhere to go except over the main relief valve. 10. Read the pressure on the concrete pump gauge, located on the main control panel. It should read 300 bar. Return the pump to “neutral” whether in needs adjustment or not. If no adjustment is needed, skip to Step 13. 11. If adjustment is required, loosen the jam nut on the relief valve adjusting screw (requires a 13 mm spanner wrench). 12. 13. Turn the knob on the relief valve to adjust the pressure. Screw the handle in to raise pressure, out to lower the pressure. 14. Retighten the jam nut. (This step is necessary because tightening the nut tends to raise the pressure. If it becomes a problem, hold the knob while tightening the jam nut). 15. Put the concrete pump into the “forward” position again. The machine will not stroke this time, but will again develop maximum pressure. Read the pressure on the gauge. If more adjustment is needed, return the pump to “neutral,” then repeat steps i. thru l. until the pressure is at 300 bar. Return the pump to the “neutral” position. 16. Open the quarter turn valve. 17. Return the RPM to an idle and go on to the other pressure settings, as required.
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Pressure Settings
Closed
Ball cock grooves.eps
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Figure 65 Concrete pump shutoff valve
NOTE!
•
If you cannot adjust the pressure up to 300 bar, you have a problem. In this case, unscrew the adjustment knob by several turns so that your pressure isn’t too high once the problem is found. Contact Schwing America’s service department for advice on how to continue. Set the agitator/water pump/outrigger pressure. The hydraulic circuit has a maximum pressure of 200 bar (2900 PSI), limited by the relief valve located on the outrigger handvalve (Figure 66).
Relief Valve
OU TR IG GE R R ET
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Figure 66 Outrigger handvalve
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To set the agitator/water pump/outrigger hydraulic circuit pressure use the following steps: 1. Stop the unit, and put the key in your pocket. 2. Install the whip hose of a 0–400 or 0–600 bar gauge on to the gauge port located below the outrigger handvalve. Make sure the whip hose connection is tight. 3. Start the unit engine and set the transmission and PTO as you would to pump concrete. 4. Locate the relief valve on the outrigger handvalve. It will be on back left side of the outrigger handvalve. 5. Be sure that all personnel are clear. 6. Restart the engine and bring it to full RPM. 7. Activate the outrigger handvalve in the retract position. Hold the handvalve in retract position to cause the outrigger (left or right) to bottom out in the retract position. This will send the oil against the high-pressure plug. The oil will return to the tank over the relief valve in the handvalve. The pressure at which valve relieves can be seen on the attached pressure gauge. It should read 200 bar. 8. To adjust the pressure, turn the pressure relief valve (location shown in Figure 66) clockwise to increase, or counterclockwise to decrease until 200 bar is showing the pressure gauge. 9. Return the outrigger handvalve to the neutral position. 10. Stop the engine and put the key in your pocket.
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11. Remove the pressure gauge and replace the cap nut on the gauge port. 12. The unit can now be restarted, if necessary. Remember to put the key back in the engine before you go home.
NOTE! If your unit is equipped with an agitator pressure gauge on the panel below the main control panel, you only need to perform Steps 6, 7, and 8 of the previous procedure. The circuit pressure can be set to 200 bar on the agitator pressure gauge.
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Pressure Settings
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Pressure Settings
BPL 4000
E-Stop Manifold Valves and Gauge Ports
Concrete Pump Shutoff Valve
Water Pump Hand Valves and Gauge Port
Concrete Pump Soft Switch and Relief Valve
Main Relief Valve Accumulator Unloading Manifold Valve
Concrete Pump
and Gauge Port
Pressure Gauge
Outrigger Hand Valve
Outrigger Hand Valve
and Gauge Port
and Gauge Port Main Control Panel
Agitator Hand Valve and Gauge Port Agitator Shutoff Valve
Figure 67 General location of components used to set hydraulic pressures (original production)
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Pressure Settings
E-Stop Manifold Valves and Gauge Ports
Concrete Pump Soft Switch
Water Pump Hand Valves and Gauge Port
Concrete Pump Shutoff Valve
Main Relief Valve and Soft Switch Relief Valve
Accumulator Unloading Manifold Valve
Concrete Pump
and Gauge Port
Pressure Gauge
Outrigger Hand Valve
Outrigger Hand Valve
and Gauge Port
and Gauge Port Main Control Panel
Agitator Hand Valve and Gauge Port Agitator Shutoff Valve
Figure 68 General location of components used to set hydraulic pressures (current production) Pressure settings must be made with the oil at normal operating temperatures (40°– 60°C). The agitator circuit is used to heat the hydraulic oil. Do not jam the paddles to force the oil over the relief valve by stopping the movement of the agitator. To preheat the hydraulic oil using the agitator circuit, follow these instructions: 1. Locate the agitator shutoff valve and close it (Figure Figure 68). 2. Position the agitator hand valve in the forward or reverse position. The agitator will not be able to turn, and the oil will be forced over the relief valve. At idle speed (about 600 RPM), about 4.5 horsepower is being converted to heat. Shut off the concrete pump when the temperature gauge on the operator’s panel shows 50°C. 3. Open the agitator shutoff valve or remove plug and reconnect hose to agitator motor.
NOTE! If your unit does not have a shutoff valve, order one, using part #10004680 (valve), and #30303432 (tube). Contact the Schwing Service Department for installation instructions. If you can’t wait for a shutoff valve, you will need to remove one of the hoses from the agitator motor and plug the hose and open fitting with approved hydraulic dead plugs. Do not substitute other plugs, such as a steel bearing inside a cap fitting. You will need: - Qty 2 VS-16S locking plugs, part number 10016803 - Qty 1 GS-16S straight fitting, part number 10008088 - Qty 2 16S capnuts, part number 10001743.
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Pressure Settings
CLOSED
Valve is shown in the OPEN position
Figure 69 Agitator shut off valve •
Set the concrete pump pressure (original production) - The concrete pump circuit on the BPL 4000 is designed to be operated at a maximum pressure of 320 bar (4640 PSI). It is controlled by the main relief valve, which is
located at the front of the main control block (Figure 70). To check or set the main relief pressure perform the following steps.
relieflocMPS.eps
Main relief valve
Concrete pump shutoff valve Lower pressure
Raise pressure
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Figure 70 Concrete pump shutoff valve and main relief valve 1. Be sure that the waterbox covers are installed on the waterbox. We do not recommend using the remote control box for the following procedure.
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2. Wear safety glasses when setting pressures.
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Pressure Settings 3. Close the concrete pump shutoff valve (Figure 6234) and the soft switch shutoff valve (FigureFigure 72).
Closed
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Open
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Figure 71 Concrete pump shutoff valve
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7.
8.
Relief valve
Figure 72 Soft switch shutoff valve and relief valve
9.
10.
11. 4. Position the “remote / local” switch, on the main control panel, to the “local” position. 5. Use the throttle switch, on the main control panel, to rev the engine up to full RPM. 6. Use the concrete pump “forward / neutral / reverse” switch to put the pump into the “forward” position. The unit will stroke only once, then the
rock cylinder will retract. Oil will have nowhere to go except over the concrete pump main relief valve. Read the pressure on the concrete pump pressure gauge, located on the main control block (Figure 70.) It should read 320 bar. Position the throttle switch to the “neutral” position. If no adjustment is needed, skip to Step 12. If adjustment is required, loosen the jam nut on the relief valve adjusting screw with a 13-mm spanner wrench (Figure 70). Turn the adjustment knob on the relief valve to adjust the pressure. Turn the adjustment knob in to raise pressure, out to lower the pressure. Retighten the jam nut. (tightening the jam nut tends to raise the pressure. If this happens, hold the adjustment knob while tightening the jam nut). Put the concrete pump into the “forward” position again. The machine will not stroke this time, but will develop maximum pressure. Read the pressure on the gauge. If more adjustment is needed, return the pump to “neutral,” then repeat Steps 8. through 11. until the pressure is at 320 bar. Position the throttle switch to the “neutral” position.
NOTE! If you cannot adjust the pressure up to 320 bar, you have a problem. In this case, turn
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12.
•
1. 2.
•
1.
2.
the adjustment knob out by several turns so that your pressure isn’t too high once the problem is found. Contact Schwing America’s service department for advice on how to continue. If you are not setting the soft switch pressure, open both shutoff valves. The unit will not stroke with the shutoff valves closed. Setting the soft switch circuit relief pressure (original production) - To check or adjust the soft switch pressure setting, perform the following steps: Open the soft switch shutoff valve. Close the concrete pump shutoff value. Rev the engine to full RPM. The control block pressure gauge should read 80-bar (1160 PSI) instead of 320 bar. If adjustment is needed, loosen the 2.5-mm allen screw on the face of the soft switch relief valve cartridge (Figure 72). Using a screwdriver, adjust the pressure up or down as needed, and lock into place with the 2.5-mm allen screw. Use a screwdriver, if necessary, to prevent the cartridge from turning while tightening the allen screw. Be sure to open the concrete pump shutoff valve when you are finished. The unit will not stroke with the shutoff valve closed. Set the concrete pump pressure (current production) - The concrete pump circuit on the BPL 4000 is designed to be operated at a maximum pressure of 320 bar (4640 PSI). It is controlled by the main relief valve, which is located at the front of the main control block (Figure 70). To check or set the main relief pressure perform the following steps. Be sure that the waterbox covers are installed on the waterbox. We do not recommend using the remote control box for the following procedure. Wear safety glasses when setting pressures.
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Pressure Settings
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Pressure Settings
Soft switch shutoff valve
Gauge or gauge port
Concrete pump shutoff valve
Pressure control position (closed)
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Groove lined up with ports - open grooves.eps
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Operating position (open)
Figure 73 Concrete pump shutoff valve and soft switch shutoff valve 3. Close the concrete pump shutoff valve and the soft switch shutoff valve (Figure 73). 4. Position the “remote / local” switch, on the main control panel, to the “local” position. 5. Use the throttle switch, on the main control panel, to rev the engine up to full RPM. 6. Use the concrete pump “forward / neutral / reverse” switch to put the pump into the “forward” position. The unit will stroke only once, then the rock cylinder will retract. Oil will have nowhere to go except over the concrete pump main relief valve.
7. Read the pressure on the concrete pump pressure gauge, located on the main control block (Figure 73.) It should read 320 bar. Position the throttle switch to the “neutral” position. If no adjustment is needed, skip to Step 12. 8. If adjustment is required, loosen the 9/16 inch jam nut on the main relief valve (Figure 73). 9. Use a 5/32 inch allen wrench to adjust the pressure to 320 bar. Turn the adjustment screw in to raise pressure, out to lower the pressure.
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10. Retighten the jam nut. (tightening the jam nut tends to raise the pressure. If this happens, hold the allen wrench in position while tightening the jan nut). 11. Put the concrete pump into the “forward” position again. The machine will not stroke this time, but will develop maximum pressure. Read the pressure on the gauge. If more adjustment is needed, return the pump to “neutral,” then repeat Steps 8. through 11. until the pressure is at 320 bar. Position the throttle switch to the “neutral” position.
NOTE!
12.
•
1. 2. 3.
4. 5.
6.
7.
If you cannot adjust the pressure up to 320 bar, you have a problem. In this case, turn the adjustment knob out by several turns so that your pressure isn’t too high once the problem is found. Contact Schwing America’s service department for advice on how to continue. If you are not setting the soft switch pressure, open both shutoff valves. The unit will not stroke with the shutoff valves closed. Setting the soft switch circuit relief pressure (current production) - To check or adjust the soft switch pressure setting, perform the following steps: Open the soft switch shutoff valve. Close the concrete pump shutoff value (Figure 73.) Use the throttle switch, on the main control panel, to rev the engine up to full RPM. Use the concrete pump “forward / neutral / reverse” switch to put the pump into the “forward” position. The control block pressure gauge should read 80-bar (1160 PSI) instead of 320 bar. If adjustment is required, loosen the 9/16 inch jam nut on the soft switch relief valve (Figure 73). Use a 5/32 inch allen wrench to adjust the pressure to 80 bar. Turn the adjustment screw in to raise pressure, out to lower the pressure. Retighten the jam nut. (tightening the jam nut tends to raise the pressure. If this happens, hold the allen wrench in position while tightening the jan nut). Put the concrete pump into the “forward” position again. The machine will not stroke this time, but will develop maximum pressure. Read the pressure on the gauge. If more adjustment is needed, return
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Pressure Settings
the pump to “neutral,” then repeat Steps 1. through 6. until the pressure is at 80 bar. Position the throttle switch to the “neutral” position. 8. Be sure to open the concrete pump shutoff valve when you are finished. The unit will not stroke with the shutoff valve closed. • Set accumulator circuit hydraulic oil pressure (units with pressure- compensated pumps) - You will need an assistant for parts of this procedure. To check or adjust the hydraulic pressure in the accumulator circuit, perform the following steps: 1. Stop the truck, put the key in your pocket, and place a “Do Not Operate” sign on the windshield. 2. Loosen the jam nut on the pressure regulator of the accumulator hydraulic pump. Turn the screw in two-and-a-half turns. This will raise the regulator pressure above 300 bar (Figure 74). .
Accumreg.eps
Accumulator pump pressure regulator
Figure 74 Accumulator pump pressure regulator 3. Connect the whip hose of a 0-600 bar gauge into the gauge port of the E-Stop manifold (Figure 75). 4. Loosen the jam nut on the accumulator relief valve, located on the E-Stop manifold. Turn the screw in two turns. This will raise the relief setting above 300 bar (Figure 75).
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Relief Valve and Gauge Port
Relief Valve Figure 75 E-Stop manifold accumulator relief valve
5. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to maximum. 6. Read the pressure on the accumulator circuit gauge located just between the hopper and the A-frame. Pressure should read 300 bar (4350 PSI). If no adjustment is needed, skip to (Step 8). 7. If additional pressure adjustment is needed, locate the accumulator manifold pressure relief valve (Figure 76). Loosen the jam nut, and turn the screw in to increase pressure, or out to decrease pressure. Tighten the jam nut when pressure is at 300 bar.
Figure 76 Accumulator manifold pressure relief valve
8. You will need an assistant for this step. With the engine still running, adjust the relief valve of the EStop manifold. Back out the adjustment screw until pressure reads 260 bar (3770 PSI) on the gauge connected to the E-Stop manifold.
WARNING Stop the truck engine before proceeding to the next Step. Entanglement hazard
9. After the truck engine is stopped, back out the accumulator circuit hydraulic pump pressure regulator two-and-a-half-turns. This restores the pressure regulator to its original setting (Figure 74). 10. Clear all personnel from the drive line area, start the truck, and rev the engine RPM to maximum. 11. Read the pressure on the accumulator gauge. It should read 260 bar (3770 PSI). 12. If additional adjustment is needed, you must stop the truck engine, each time you approach the accumulator circuit hydraulic pump (Figure 74). Adjust the accumulator pump pressure regulator
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screw in to increase pressure, or out to decrease pressure. Lock the jam nut when pressure is correct. • Set accumulator circuit hydraulic oil pressure (units with accumulator unloading valves) - You will need an assistant for parts of this procedure. To check or adjust the hydraulic pressure in the accumulator circuit, follow these steps: 1. Stop the truck, put the key in your pocket, and place a “Do Not Operate” sign on the windshield. 2. Connect the whip hose of a 0-600 bar gauge into the gauge port of the E-Stop manifold (Figure 78). 3. Locate the accumulator unloading valve. The location of this valve on the pump unit may vary. Loosen the jam nut on the accumulator unloading valve. Turn the screw in two-and-a-half turns. This will raise the pressure above 300 bar (Figure 77).
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Relief Valve and Gauge Port
Figure 78 E-Stop manifold accumulator relief valve
Adjustment Screw
un
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Figure 77 Accumulator unloading valve
4. Loosen the jam nut on the accumulator relief valve, located on the E-Stop manifold. Turn the screw in two turns. This will raise the relief setting above 300 bar (Figure 78).
5. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to maximum. 6. Read the pressure on the accumulator circuit gauge located just between the hopper and the A-frame. Pressure should read 300 bar (4350 PSI). If no adjustment is needed, skip to (Step 8). 7. If additional pressure adjustment is needed locate the accumulator manifold pressure relief valve (Figure 79). Loosen the jam nut, and turn the screw in to increase pressure, or out to decrease pressure. Tighten the jam nut when pressure is at 300 bar.
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Pressure Settings . 45s3blck.epsL
Relief Valve
Figure 79 Accumulator manifold pressure relief valve 8. You will need an assistant for this step. With the engine still running, adjust the accumulator relief valve on the E-Stop manifold (Figure 78). Back out the adjustment screw until pressure reads 260 bar (3770 PSI) on the gauge connected to the EStop manifold. 9. Back out the accumulator unloading valve adjustment screw two-and-a-half-turns. This restores it to its original setting. 10. Read the pressure on the accumulator gauge. It should read 260 bar (3770 PSI). 11. If additional adjustment is needed, adjust the screw on the accumulator relief valve (Figure 63) in to increase pressure, out to decrease pressure. Lock the jam nut when pressure is correct. 12. Remove the pressure gauge from the outrigger hand valve and replace the cap nut on the gauge port. • Set the water pump/outrigger/agitator pressures - You will need an assistant to perform this procedure. The location of all the components needed for this procedure are shown in (Figure 57). This hydraulic circuit has a maximum pressure of 210 bar (3045 PSI), limited by the relief valve on the water pump handvalve. To set the water pump/outrigger/agitator hydraulic circuit pressures, perform the following steps: 1. Stop the unit, and put the key in your pocket.
2. Install the whip hose of a 0–400 or 0–600 bar gauge on to the gauge port located on the waterpump handvalve. The location of the water pump hand valve if shown in Figure 57. Make sure the whip hose connection is tight. 3. To check or set the highest pressure of this circuit, you must first raise the pressure of the lower two relief valves. Turn the body of the relief valves in (clockwise) one and one half turns on the agitator hand valve and the passenger side outrigger hand valve. (The location of the water pump and the agitator hand valve are shown in Figure 57.) This will increase the circuit pressure over the 210 bars needed to set the water pump relief valve. 4. Start the unit engine and set the transmission and PTO as you would to pump concrete. 5. Locate the relief valve on the water pump hand valve. It will be on the bottom, passenger side, of the water pump handvalve. 6. Be sure that all personnel are clear. 7. Bring the engine to full RPM. 8. Push the outrigger enable push button, located next to the outrigger control lever. Hold the outrigger control lever in the retract position to cause the outrigger to bottom out in the retract position. This will send the oil against the high-pressure plug. The oil will return to the tank over the relief valve in the water pump hand valve. The pressure at which the valve relieves can be seen on the pressure gauge attached to the water pump hand valve. It should read 210 bar.
NOTE! You cannot use the extend position for this adjustment because extend position has a non-adjustable, secondary relief functions built into the valve. 9. To adjust the pressure, turn the outside body of the water pump pressure relief valve (shown in Figure 80) clockwise to increase, or counterclockwise to decrease until 210 bar is showing the pressure gauge.
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210 bar Relief Valve
Turn body of valve to adjust. Higher Lower
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Pressure Settings
17. To adjust the pressure, turn the outside body of the outrigger pressure relief valve, located on the back of the outrigger hand valve (Figure 81), clockwise to increase or counter clockwise to decrease until 200 bar is showing the pressure gauge.
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WARNING
Clear area before activating outriggers
IN RETRACT OUTRIGGER OUT EXTEND
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Figure 80 Water pump relief valve 10. Return the outrigger handvalve to the neutral position. 11. Turn the body of the relief valves out (counter clockwise) one and one half turns on the agitator hand valve and the passenger side outrigger hand valve. This will return the these relief valves to their original settings. 12. Remove the pressure gauge from the water pump hand valve and replace the cap nut on the gauge port. 13. Install the whip hose of a 0–400 or 0–600 bar gauge on to the gauge port located on the passenger side outrigger hand valve. Make sure the whip hose connection is tight.(Figure 65). 14. Be sure that all personnel are clear. 15. Rev the engine to full RPM. 16. Activate the passenger side outrigger handvalve in the retract position. Hold the handvalve in retract position to cause the outrigger to bottom out in the retract position. This will send the oil against the high-pressure plug. The oil will return to the tank over the relief valve in the outrigger hand valve. The pressure at which the valve relieves can be seen on the pressure gauge attached to the outrigger pump hand valve. It should read 200 bar (2900 PSI).
Outrigger Relief Valve and Gauge Port Figure 81 Outrigger relief valve 18. Return the outrigger handvalve to the neutral position. 19. Remove the pressure gauge from the passenger side outrigger hand valve and replace the cap nut on the gauge port. 20. Close the agitator shutoff valve (Figure 82). 21. Install the whip hose of a 0–400 or 0–600 bar gauge on to the gauge port located on the drivers side agitator hand valve (Figure 83). Make sure the whip hose connection is tight.
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Pressure Settings WARNING
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CLOSED Do not stand on hopper grates. SAFETY INSTRUCTIONS
HOPPER GRATE OR BEFORE REMOVING SERVICE: PERFORMING ANY Electric Motors Engines Gasoline or Diesel motor. 1. Stop the electric 1. Stop the engine. 2. Lock out the power an place it 2. Remove the key, source according to put in your pocket, and approved lockout-tagout a "DO NOT OPERATE" program. tag on the switch. 3. Check accumulator accumulator 3. Check circuit pressure gauge verify circuit pressure gauge (if so equipped) to verify (if so equipped) to zero system pressure. pressure. zero system
Valve shown in the OPEN position
Gauge Port @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; QQQQQQQQQQQQQQQQQQQQ @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; QQQQQQQQQQQQQQQQQQQQ @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; QQQQQQQQQQQQQQQQQQQQ @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; QQQQQQQQQQQQQQQQQQQQ @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; QQQQQQQQQQQQQQQQQQQQ @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; AMERICA INC. WHITE BEAR, MINNESOTA PHONE 612-429-0999 TWX: 910-563-3539
WEIGHT
Clear area before activating outriggers
22. Be sure that all personnel are clear. 23. Rev the engine to full RPM. 24. Hold the agitator lever in the forward or reverse position. This will send the oil against the highpressure plug. The oil will return to the tank over the relief valve in the agitator hand valve. The pressure at which the valve relieves can be seen on the pressure gauge attached to the agitator hand valve. It should read 200 bar (2900 PSI). 25. To adjust the pressure, turn the outside body of the agitator pressure relief valve, located on the bottom of the agitator hand valve. It is the smaller of the two cartridges extending from the bottom of the valve (Figure 83). Turn the body of the relief valve clockwise to increase or counter clockwise to decrease until 200 bar is showing the pressure gauge.
F. W.
GMBH. HERNE 2/ GERMANY 7871
REVERSE - FORWARD
YEAR
LBS.
MATERIAL PRESSURE
MAX.
STROKES PER MINUTE
SYSTEM 1
SYSTEM 1
This product is covered by one or more of the following 3,409,334 3,580,696 3,640,303 3,685,543 3,741,691 3,829,251 4,019,839
4,057,373 4,178,142 4,191,513 4,260,338 4,343,598 4,373,225 4,373,875
AGITATOR
PHONE (02325) TELEX 820 348
4.373.875
SERIAL NO.
MAXIMUM HYDRAULIC PRESSURE
WARNING
Figure 82 Close agitator shutoff valve
SUBSIDIARY OF
U. S. PATENTS: 3.146.721; 3.640.303; 3.409.334;
MODEL
4,392,510 4,437,817 4,465,441 4,472,118 4,556,370 4,621,375 4,681,022
4,708,288 4,852,467 4,978,073 5,066,203 5,106,225 5,106,272 5,224,654
5,257,912 5,263,828 5,281,113 5,332,366 5,346,368 5,401,140
SYSTEM 1
U.S. patents: Re. 32,041 Re. 32,657 Re. 32,719
IN RETRACT OUTRIGGER OUT EXTEND
Agitator Relief Valve Figure 83 Agitator relief valve 26. Return the agitator handvalve to the neutral position. 27. Remove the pressure gauge from the outrigger hand valve and replace the cap nut on the gauge port.
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SERVICE TRAINING
KVM 17M •
Check hydraulic pressures. Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components. The specifications for all circuits are shown on the Hydraulic Schematics in the Appendix of this manual.
Pressure settings must be made with the oil at normal operating temperatures (40°C – 60°C). The agitator circuit must be used to heat the hydraulic oil. Do not jam the paddles to force the oil over relief by stopping the movement of the agitator. To preheat the hydraulic oil using the agitator circuit, follow these instructions. 1. Locate the agitator shutoff valve and close it (Figure 98). The general location of the agitator shutoff valve is shown in Figure 84.
NOTE! If your unit does not have a shutoff valve, order one, using part #10004680 (valve), and #30303432 (tube). Contact the Schwing Service Department for installation instructions. If you can’t wait for a shutoff valve, you will need to remove one of the hoses from the agitator motor and plug the hose and open fitting with approved hydraulic dead plugs. Do not substitute other plugs, such as a steel bearing inside a cap fitting. 2. Position the agitator lever in the forward or reverse position (Figure 98). The agitator will not be able to turn, and the oil will be forced over the relief valve. 3. At idle speed (about 600 RPM), about 4.5 horsepower is being converted to heat. Shut off the concrete pump when the temperature gauge on the operator’s panel shows 50°C. 4. Open the agitator shutoff valve or remove plug and reconnect hose to agitator motor. The general location of the components used to check or set hydraulic pressures in shown in Figure 84.
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Pressure Settings
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Pressure Settings
•
Boom (Section #1) Down Pressure Relief Valve and Gauge Port
•
Boom Hand Valves and Gauge Port
•
Boon/Outrigger Hand Valve and Gauge Port
•
E- Stop Manifold Valves and Gauge Ports
•
Concrete Pump Shutoff Valve •
Water-Pump/Compressor Hand Valve and Gauge Port
•
Soft Switch Shutoff Valve
•
Accumulator Unloading Manifold Valve and Gauge
•
Main Relief Valve
•
Concrete Pump Pressure Gauge
•
Outrigger Hand Valve and Gauge Port
•
Main Control Panel
•
Agitator Hand Valve and Gauge Port •
Outrigger Hand Valve
•
Agitator Shutoff Valve
Figure 84 General location of components used to set hydraulic pressures
Setting concrete pump pressure The MPS pumpkits used on the KVM 17 are designed to be operated at a maximum pressure of 300-bar (4350 PSI). The pressure in the system is limited by the relief valve located on the rear (toward the hopper) of the main control block (Figure 85).
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SERVICE TRAINING
17mainreliefvalve.eps
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Pressure Settings
8. Read the pressure on the control block pressure gauge, shown in Figure 59. It should read 300-bar. Return the pump control to “neutral,” whether it needs adjustment or not. If no adjustment is needed, skip to Step 13. 17valves.epsL
Concrete pump shutoff valve
Jam nut Relief Valve
@ ; ;@;@;@;@;@;@;@;@;@ ;@;@ @ ; @ ; @ ; @ ; @ ; ;@ ;@ @ @ ;@;@;@;@;@ @; ; Q @; ; Q @; ; Q @; ; Q @; ; Q @; ; Q ;@ @ ; Q @ ; @ ; Q @ @ ; Q @ ; Q @ @ ; Q @ ; Q @ @ ; Q @ ; Q @ @ ; Q @ ; @ ; Q @ ; @ ; Q @ ; @ ; Q @ ; @ ; Q @ ; @ ; Q @ ; Q @ ; @ ; Q @ ; Q ;@;@;@;@ @; ; Q @; ; Q @; ; Q ;@;@;@ @ @ @;@;@ Soft switch
Figure 85 Concrete pump main relief valve
shutoff valve
Soft Switch
To check or set concrete pump circuit pressures, perform the following steps. 1. Wear safety glasses when setting pressures. 2. Be sure that the waterbox covers and guards are installed on the waterbox. Schwing does not recommend using the remote control box when setting the main relief pressure. 3. Start the truck engine, and put the PTO and transmission into gear, just as you would to pump a job. 4. Locate and close the concrete pump shutoff valve (quarter-turn valve), and the soft switch shutoff valve (quarter-turn valve) (Figure 86). 5. Put the operator’s panel “remote / local” switch into the “local” position. 6. Using the switch on the operator’s panel, rev the truck engine up to full RPM. 7. Put the operator’s panel “forward / neutral / reverse” switch into the “forward” position. The unit will stroke only once, then the rock cylinder will retract. The oil leaving the hydraulic pumps will be forced over the main relief valve. This procedure is called high-pressuring the concrete pump.
Relief Valve
closed
Blckgrvs.eps
open Figure 86 Concrete pump shut off valves 9. Using a 13-mm spanner wrench, loosen the jam nut on the relief valve adjusting screw (Figure 86). 10. Turn the knob on the relief valve to adjust the pressure. Screw the handle in to raise pressure, out to lower pressure. 11. Retighten the jam nut. Tightening the nut tends to raise the pressure. If the rise in pressure becomes a problem, hold the knob while tightening the jam nut.
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Pressure Settings
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12. High-pressure the concrete pump again. Read the pressure on the control block pressure gauge. If more adjustment is needed, return the concrete pump switch to “neutral,” then repeat Steps (5) through (8) until the pressure is correct.
NOTE! If you cannot adjust the pressure up to specification, you have a problem. In this case, unscrew the adjustment knob several turns so that your pressure is not too high when you find the problem. Contact Schwing America’s Service Department at (651) 4290999 for advice on how to continue. 13. If you will not be setting the soft switch pressure, open the shutoff valves. The unit will not stroke with closed shutoff valves.
Setting the soft switch circuit relief pressure To check or adjust the soft switch pressure setting, perform the following steps. 1. Open the soft switch shutoff valve. The rest of the unit should still be set up as if you were going to check or set concrete pump pressure. 2. High-pressure the concrete pump. The control block pressure gauge should read 100-bar (1450 PSI) instead of 300 bar. If adjustment is needed, loosen the 2.5-mm allen screw on the face of the soft switch relief valve cartridge (Figure 86). Using a screwdriver, adjust the pressure up or down as needed, and lock into place with the 2.5-mm allen screw. Recheck. Use a screwdriver, if necessary, to prevent the cartridge from turning while tightening the allen screw. Be sure to open the concrete pump shutoff valve when you are finished. The unit will not stroke with this valve close
Setting accumulator E-Stop manifold pressure (original production) The accumulator E-Stop manifold pressure circuit is set to a maximum of 260-bar (3771 PSI) by its relief valve on the emergency stop manifold. To check or adjust this setting, you must first raise the pressure of the accumulator unloading valves to 260-barr or higher.
170-bar
138-bar
@@@@ ;;;; QQQQ @@@@ ;;;; QQQQ @@@@ ;;;; QQQQ @@@@ ;;;; QQQQ
230-bar
17accum.epsL
Figure 87 Accumulator unloading valve (original production)
1. Locate the accumulator unloading valve (Figure 87). 2. Loosen the jam nut of the high pressure valve (230-bar) adjustment screw. With an allen wrench turn the adjustment screw in one-and-a-half turns. This will raise the pressure on the valve above 260bar. 3. Loosen the jam nut of the open relief valve (170bar) and on the close valve (138-bar) pressure adjustment screws. With an allen wrench turn both adjustment screws in two-and-a-half turns. This will raise the pressure on the valve above 260-bar. 4. Connect the whip hose of a 0–400 or 0–600 bar gauge into the gauge port of the E-Stop manifold (Figure 88).
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SERVICE TRAINING
17e-stopman.epsL
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Pressure Settings
4. Turn the close valve (138-bar) adjustment screw out two-and-a-half turns or until the gauge on the accumulator unloading valve reads 138-bar (Figure 87). 5. Tighten the jam nuts on all three adjustment screws.
Setting accumulator E-Stop manifold pressure (current production) Relief valve Gauge port
The accumulator E-Stop manifold pressure circuit is set to a maximum of 260-bar (3771 PSI) by its relief valve on the emergency stop manifold. To check or adjust this setting, you must first raise the pressure of the accumulator unloading valves to 260-barr or higher.
17accum2.eps
Figure 88 E-Stop manifold accumulator relief valve 5. High-pressure the concrete pump. The pressure gauge should read 260-bar (3771 PSI). 6. If adjustment is needed, loosen the jam nut and with a allen wrench turn the adjustment screw on the relief valve (Figure 88). Turn in to raise pressure, turn out to lower pressure. 7. Repeat steps (5) and (6) until the gauge reads 260bar. 8. Tighten the jam nut on the adjustment screw, remove the whip hose and gauge from the gauge port, and replace the cap on the gauge port
Setting the accumulator unloading valve (original production) Use an allen wrench to make these adjustments 1. High-pressure the concrete pump. 2. Turn the high pressure (230-bar) adjustment screw out one-and-a-half turns or until the gauge on the accumulator unloading valve reads 230-bar (Figure 87). 3. Turn the open valve (170-bar) adjustment screw out two-and-a-half turns or until the gauge on the accumulator unloading valve reads 170-bar (Figure 87).
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@@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; Gauge @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; 230-bar relief @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; 170-bar relief @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; Figure 89 Accumulator unloading valve (current production
1. Locate the accumulator unloading valve (Figure 89). 2. Loosen the jam nut of the high pressure valve (230-bar) adjustment screw. With an allen wrench turn the adjustment screw in one-and-a-half turns. This will raise the pressure on the valve above 260bar. 3. Loosen the jam nut of the open relief valve (170bar.) With an allen wrench turn the adjustment screw in two-and-a-half turns. This will raise the pressure on the valve above 260-bar. 4. Connect the whip hose of a 0–400 or 0–600 bar gauge into the gauge port of the E-Stop manifold (Figure 90.)
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Pressure Settings 17e-stopman.epsL
Relief valve Gauge port
Figure 90 E-Stop manifold accumulator relief valve
Setting the boom E-Stop manifold pressure The boom E-Stop manifold pressure circuit is set to a maximum of 350-bar (5076 PSI) by its relief valve on the emergency stop manifold. To check the setting of the valve with the highest pressure, you must first raise the pressure of the lower two: 1. Locate the boom/outrigger hand valve (Figure 92). 2. Turn the outside body of the 300-bar relief valve that is located at the bottom of the boom/outrigger hand valve in two-and-one-half turns. This will raise the pressure on the valve above 350-bar. 3. Locate the boom hand valves (Figure 92). 4. Turn the outside body of the (280-bar) relief valve that is located at the back of the boom hand valve in two-and-one-half turns. This will raise the pressure on the valve above 350-bar. 5. Connect the whip hose of a 0–400 or 0–600 bar gauge into the gauge port of the boom E-Stop manifold valve (Figure 91). 17e-stop.epsL GREASE TOWER BEARINGS
Setting the accumulator unloading valve (current production) Use an allen wrench to make these adjustments 1. High-pressure the concrete pump. 2. Turn the high pressure (230-bar) adjustment screw out one-and-a-half turns or until the gauge on the accumulator unloading valve reads 230-bar (Figure 89.) 3. Turn the open valve (170-bar) adjustment screw out two-and-a-half turns or until the gauge on the accumulator unloading valve reads 170-bar (Figure 89.) 4. Tighten the jam nuts on all adjustment screws.
Gauge port and
GREASE TOWER BEARINGS ONLY GREASE WHICH HAS THE FOLLOWING CHARACTERISTICS. USE LUBRIPLATE MO-LITH NO 2, TEXACO MOLYTEX EP 2 OR EQUAL. BASE TYPE LITHIUM NLGI NO 2 WORKING PENETRATION RANGE AT 77°F 265/295 MOLYBDENUM DISULPHIDE 3% MINIMUM ASTM DROPPING POINT °F 350 MINIMUM
relief valve on cab side of
SAFETY INSTRUCTIONS
= =
STOP
WARNING
manifold block.
Emergency stop switches do NOT function when manual bypass is depressed.
ATTT TEEN NTTI IO ONN! !
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5. High-pressure the concrete pump. The pressure gauge should read 260-bar (3771 PSI) 6. If adjustment is needed, loosen the jam nut and with a allen wrench turn the adjustment screw on the relief valve (Figure 90). Turn in to raise pressure, turn out to lower pressure. 7. Repeat steps (5) and (6) until the gauge reads 260bar. 8. Tighten the jam nut on the adjustment screw, remove the whip hose and gauge from the gauge port, and replace the cap on the gauge port.
WARNING Do not operate at pressures exceeding the rating of the entire material delivery system.
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Figure 91 E-Stop manifold boom relief valve
6. Pressure out any boom cylinder except #1 in a retract position. You can pressure out a cylinder by retracting a fully retracted cylinder or extending a fully extended cylinder. The oil will have nowhere to go but over the relief valve. 7. The pressure gauge on the boom E-Stop manifold should read 350-bar.
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8. If adjustment is needed, loosen the jam nut and turn the adjustment screw on the relief valve that is located on the boom E-Stop manifold valve (Figure 91). Turn in to raise pressure, turn out to lower pressure. 9. Repeat steps (4) thorough (6) until the gauge reads 350-bar. 10. Tighten the jam nut on the boom E-Stop manifold adjustment screw, remove the whip hose and gauge from the gauge port, and replace the cap on the gauge port. 11. Turn the outside body of the 300-bar relief valve that is located at the bottom of the boom/outrigger hand valve out two-and-one-half turns. 12. Turn the outside body of the (280-bar) relief valve that is located at the back of the boom hand valve out two-and-one-half turns. 13. Set or reset the boom and the outrigger hydraulic pressures.
NOTE!
6. 7.
8.
9.
300 bar Relief Valve
Turn body of valve to adjust. Higher Lower
Pressure Settings
1. Connect the whip hose of a 0–400 or 0–600 bar to the gauge port of the boom/outrigger hand valve. 2. If this is not already done, start the truck engine and set the transmission and PTO as you would for a pumping job. 3. Locate the 300-bar relief valve on the bottom of the boom/outrigger hand valve. 4. Set the engine RPM to maximum. 5. Push the outrigger enable pushbutton located next to the outrigger hand valves. Hold the outrigger hand valve lever in the retract position. The oil coming from the pump has nowhere to go but over the relief valve on the boom/outrigger hand valve.
Setting the boom/outrigger pressure The outrigger circuit is set to a maximum of 300-bar (4350 PSI) by the relief valve on the boom/outrigger hand valve. This handvalve is located on the drivers side of the turret (Figure 92). Due to the location of the boom/outrigger handvalve and the outrigger control lever used in this procedure, you will need an assistant to make the adjustments and read the gauge.
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10.
You cannot use the outrigger extend position for this adjustment because extend has nonadjustable secondary relief functions built into the valve. The pressure on the pressure gauge should read 300-bar. If adjustment is needed, turn the outside body of the relief valve that is located at the bottom of the boom/outrigger hand valve. Turn in to raise pressure, turn out to lower pressure. Activate the enable pushbutton and the hand valve and read the pressure on the gauge again. Repeat steps (7) and (8) until the gauge reads 300-bar. When the pressure is 300-bar, release the enable pushbutton and the outrigger hand valve. Remove the whip gauge from the boom/outrigger hand valve, and replace the cap on the gauge port.
Setting the outrigger pressure The outrigger circuit is set to a maximum of 280-bar (4060 PSI) by the relief valve located on the drivers side outrigger hand valve assembly (Figure 93). The valve routes the oil to the two outrigger hand valve banks, one on each side of the unit. A relief valve inside the drivers side bank limits the entire outrigger circuit to 280-bar.
tr ou
PS X.E -28 lve va om o ig/b
Figure 92 Boom/outrigger hand valve
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Pressure Settings
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17dshopper.epsL
Do not stand on hopper grates. SAFETY INSTR
UCTIONS
OR HOPPER GRATE BEFORE REMOVING ANY SERVICE: PERFORMING Electric Motors motor. 1. Stop the electric
Engines Gasoline or Diesel 1. Stop the engine.
key, place it 2. Remove the and put in your pocket, a "DO NOT OPERATE" tag on the switch.
3. Check accumulator gauge circuit pressure to verify (if so equipped) zero system pressure.
WARNING Stored hydraulic energy. Release all hydraulic pressure and verify zero pressure on gauge before servicing.
power 2. Lock out the to an source according t approved lockout-tagou program.
3. Check accumulator gauge circuit pressure to verify (if so equipped) zero system pressure.
@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;; WARNING
Stored hydraulic energy. Release all hydraulic pressure and verify zero pressure on gauge before servicing.
This product is covered by one or more of the following U.S. patents: 3,409,334 3,580,696 3,640,303 3,685,543 3,741,691 3,829,251 4,019,839
4,057,373 4,178,142 4,191,513 4,260,338 4,343,598 4,373,225 4,373,875
4,392,510 4,437,817 4,465,441 4,472,118 4,556,370 4,621,375 4,681,022
4,708,288 4,852,467 4,978,073 5,066,203 5,106,225 5,106,272 5,224,654
5,257,912 5,263,828 5,281,113 5,332,366 5,346,368 5,401,140
Re. 32,041 Re. 32,657 Re. 32,719
30308020 C
WARNING Clear area before activating outriggers
FRONT FOOT
8. Activate the enable pushbutton and the hand valve and read the pressure on the gauge again. Repeat steps (7) and (8) until the gauge reads 280-bar. 9. When the pressure is 280-bar, release the enable pushbutton and the outrigger hand valve. 10. Remove the whip hose and gauge from the boom hand valve, and replace the cap on the gauge port.
Setting the boom pressures The boom circuit is set to a maximum of 280-bar (4060 PSI) by the relief valve on the boom hand valve assembly (Figure 94).
REAR FOOT
Relief Valve
Figure 93 Outrigger hand valve 1. Connect the whip hose of a 0–400 or 0–600 bar gauge into the gauge port on the drivers side outrigger hand valve. 2. If this is not already done, start the truck engine and set the transmission and PTO as you would for a pumping job. 3. Locate the 280-bar relief valve on the back of the drivers side boom/outrigger hand valve, as shown in Figure 93. 4. Set the engine RPM to maximum. 5. Push the outrigger enable pushbutton located next to the outrigger hand valves. Hold the outrigger hand valve lever in the retract position. The oil coming from the pump has nowhere to go but over the relief valve.
NOTE! You cannot use the extend position for this adjustment because extend has a nonadjustable secondary relief functions built into the valve. 6. The pressure on the pressure gauge should read 280-bar. 7. If adjustment is needed, turn the outside body of the relief valve that is located at the back of the drivers side outrigger hand valve. Turn in to raise pressure, turn out to lower pressure.
@; @;@;@; ;;;;;;;;;; @@@@@@@@@@ @; @;@;@;@;@;@;@;@;@; ;;;;;;;;;; @@@@@@@@@@ @; @;@; @;@;@;@;@; ;;;;;;;;;; @@@@@@@@@@ @; ;;;;;;;;;; @@@@@@@@@@ @;@;@;@;@;@;@;@; @; Figure 94 Boom hand valves 1. Connect the whip hose of a 0–400 or 0–600 bar gauge to the gauge port on the back of the boom hand valve. 2. If this is not already done, start the truck engine and set the transmission and PTO as you would for a pumping job. 3. Locate the 280-bar relief valve on the back of the boom hand valve, as shown in Figure 95.
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SERVICE TRAINING
Pressure Settings
Turn body of valve to adjust.
Higher
280 bar Relief Valve
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Lower
ps
7.e
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bo
Figure 95 Boom control relief valve 4. Pressure out any boom cylinder except #1 in a retract position. You can pressure out a cylinder by retracting a fully retracted cylinder or extending a fully extended cylinder. The oil will have nowhere to go but over the relief valve. 5. Have your assistant read the pressure on the gauge at the boom hand valve. It should read 280-bar. If no adjustment is needed, skip to Step 8. 6. To adjust the boom pressure, locate the relief valve on the back of the boom control block (Figure 95). 7. If adjustment is needed, turn the outside body of the relief valve that is located at the back of the boom hand valve. Turn in to raise pressure, turn out to lower pressure. 8. When the pressure is 280-bar, release the boom hand valve. 9. Remove the whip hose and gauge from the boom hand valve, and replace the cap on the gauge port.
Set boom section #1 down pressure Because gravity wants to pull your boom down, high pressure is not needed to bring section #1 down. Allowing high pressure to be available leaves open the possibility of an inattentive operator’s causing damage
to the boom or the A frame when folding into the transport position. To prevent this, there is a secondary relief valve that regulates only the pressure on the #1 retract function. The #1 boom down pressure should be 170-bar (2465 PSI). To check or adjust the down side relief valve: You have to raise the boom and rotate it for this procedure, so you must set the outriggers as you would to pump a job. Release the boom strap. To adjust the valve, you will need a 2.5 mm allen wrench and a standard screwdriver. 1. Connect the whip hose of a 0-400 or 0–600-bar gauge into the gauge port shown in Figure 96.
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Pressure Settings
170-bar gauge port 170-bar relief valve
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Figure 96 Section #1 down relief valve
NOTE! For the following procedure, we must bring section #1 all the way down until the cylinder bottoms out. The cylinder does not bottom out if you set the folded boom into the A-frame (travel position). Position the boom so this can be done without hitting the truck, electrical wires, or any other obstacles. 2. Unfold section #2 from section #1 until it is straight. 3. Bring section #1 down until the cylinder is completely bottomed out. Activate the #1 down (retract) hand valve. The boom will not be able to move because the cylinder is already bottomed out. Read the pressure on the gauge that you just installed. It should read 170-bar. If no adjustment is necessary, skip to Step 7. 4. If adjustment is needed, loosen the set screw with the 2.5 mm allen wrench. While you activate #1 down, adjust the relief cartridge with the
screwdriver until the pressure reads just under 170bar. Retightening the set screw will raise the pressure slightly. (If it becomes a problem, hold the cartridge adjustment with the screwdriver while you tighten the set screw.) Recheck the pressure, and readjust if needed. 5. When the pressure is set at 170-bar, remove the whip hose gauge and replace the cap on the gauge port. 6. The boom pressure setting sequence is complete. If you are finished with the boom, slew it back into the transport position, and lower #1 into the Aframe cradle. Reattach the boom strap.
Setting water pump pressure The agitator/water pump-compressor circuit has a maximum pressure of 200-bar (2900 PSI), limited by the relief valve located in the water pump-compressor hand valve. There is a gauge port for checking or setting the pressure in this circuit. The port is located on the water pump-compressor hand valve.
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To set the water pump circuit pressure perform the following steps: 1. Stop the unit, and put the key in your pocket. 2. Connect the whip hose of a 0-400 or 0-600 bar gauge to the gauge port on the water pump hand valve. 3. If your unit does not have a compressor, skip to Step 6. 4. If your unit has a compressor remove one of the hoses from the water pump motor and plug the hose and the open fitting with approved hydraulic dead plugs. Do not improvise on these plugs. If you don’t have any, contact Schwing’s Spare Parts Department and order them before continuing with this procedure. You will need: • Qty 2 VS-16S locking plugs, part number 10016803 • Qty 1 GS-16S straight fitting, part number 10008088 • Qty 2 16S capnuts, part number 10001743 • All of these fittings and many, many more extremely useful items are included in the Troubleshooting Kit, part number 30308553. We highly recommend purchase of this kit. It will pay for itself many times over. 5. Be sure that one of the locking plugs and capnuts are tightened on the straight fitting and that the dead plugs are securely tightened to the hose and the open motor fitting. 6. Locate the relief valve on the water pump hand valve. It comes out of the valve body toward the ground, and it is the smaller of the two cartridges that you’ll see. 7. Be sure that any personnel are clear, and restart the engine. 8. Activate the water hand valve by pushing or pulling the handle. This will send the oil against the high pressure plug. The oil will have nowhere to go, so it will return to the tank over the relief valve in the water pump hand valve. The pressure at which it relieves can be seen on the gauge. It should read 200-bar. If no adjustment is needed, skip to Step 10.
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Pressure Settings Turn body of valve to adjust. Higher Lower
200 bar Relief Valve
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Figure 97 Water pump relief valve 9. If adjustment is needed, turn the outside body of the relief valve that is located at the bottom of the water pump/compressor hand valve. Turn in to raise pressure, turn out to lower pressure. 10. When the pressure is set to 200-bar, stop the engine and remove the key. 11. Remove the dead plugs and store in a clean area or in a plastic bag or something similar to keep dirt from entering the fittings. Re-attach the hose to the water pump motor fitting and tighten securely. (Torque is correct if you make one complete revolution after feeling initial resistance increase.) 12. Remove the whip hose and pressure gauge. Replace the gauge port cover.
Setting the agitator pressure The agitator circuit has a maximum pressure of 150bar (2175 PSI), limited by the relief valve located in the agitator hand valve (Figure 98). There is a gauge port for checking or setting the pressure. The port is located on the agitator hand valve. 1. Stop the unit, and put the key in your pocket. 2. Connect the whip hose of 0-400 or a 0–600-bar gauge to the gauge port on the agitator hand valve. 3. If your unit is equipped with a agitator shut off valve, close it (Figure 98). Skip to Step 6.
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Pressure Settings
Figure 98 Agitator shutoff valve
4. If your unit is not equipped with an agitator shut off valve, remove one of the hoses from the agitator motor and plug the hose and the open fitting with approved hydraulic dead plugs. Do not improvise on these plugs. If you don’t have any, contact the Schwing’s Spare Parts Department and order them before continuing with this procedure. All of these fittings and many, many more extremely useful items are included in the Troubleshooting Kit, part number 30308553. We highly recommend purchase of this kit. It will pay for itself many times over. You will need: 5. - Qty 2 VS-16S locking plugs, part number 10016803 6. - Qty 1 GS-16S straight fitting, part number 10008088 7. - Qty 2 16S capnuts, part number 10001743 8. Be sure that one of the locking plugs and capnuts are tightened on the straight fitting and that the dead plugs are securely tightened to the hose and the open motor fitting. 9. Locate the relief valve on the agitator hand valve. It comes out of the valve body toward the ground, and it is the smaller of the two cartridges that you’ll see. 10. Be sure that any personnel are clear, and restart the engine. 11. Activate the agitator hand valve by pushing or pulling the handle. This will send the oil against the high pressure plug. The oil will have nowhere to go, so it will return to the tank over the relief
valve in the agitator hand valve. The pressure at which it relieves can be seen on the gauge. It should read 150-bar. 12. If adjustment is needed, turn the outside body of the relief valve that is located at the back of the agitator hand valve. Turn in to raise pressure, turn out to lower pressure. 13. When the pressure is set at 150-bar, stop the engine and remove the key. Open the shut off valve or remove the dead plugs and store in a clean area or in a plastic bag or something similar to keep dirt from entering the fittings. Reattach the hose to the agitator motor fitting and tighten securely. (Torque is correct if you make one complete revolution after feeling initial resistance increase.) 14. Remove the whip hose and pressure gauge. Replace the gauge port cover.
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KVM 28X
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Pressure Settings NOTE!
Check hydraulic pressure Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components.
NOTE! Hydraulic pressure settings shown in the following procedures are for a 2023 twin circuit pump kit. However, because different pump kits may be used in this unit, all pressure settings should be verified with the pressure settings shown on the applicable hydraulic schematic. The hydraulic schematics for your pump kit are in the Appendix of this manual. Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when checking or setting pressures. Be sure that the waterbox covers are installed on the waterbox.
If your unit does not have a shutoff valve, order one using part #10004680 (valve) and #30303432 (tube). Contact the Schwing Service Department for installation instructions. If you can’t wait for a shutoff valve, you will need to remove one of the hoses from the agitator motor, and plug the hose and the open fitting with approved hydraulic dead plugs. Do not substitute other plugs, such as a steel bearing, inside a cap fitting. 2. Position the agitator lever in the forward or reverse position. The agitator will not be able to turn, and the oil will be forced over the relief valve. 3. At idle speed (about 600 RPM), about 4.5 horsepower is being converted to heat. Position the agitator lever to the off (center) position when the temperature gauge on the rear control panel indicates 50°C. 4. Open the agitator shutoff valve or remove the plug, and reconnect the hose to the agitator motor.
We do not recommend using the remote control box for the following procedures.
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Wear safety glasses when setting pressures. Position the “remote/local” switch on the rear control panel to the “local” position. Pressure settings must be made with the oil at normal operating temperatures (40°C – 60°C). The agitator circuit must be used to heat the hydraulic oil. Do not jam the paddles to force the oil over relief by stopping the movement of the agitator. To preheat the hydraulic oil using the agitator circuit, follow these instructions. 1. Locate the agitator shutoff valve, and close it (Figure 99). The general location of the agitator shutoff valve is shown in Figure 99.
Shown in the open position Figure 99 Agitator shutoff valve
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Pressure Settings The general location of the components used to check or set hydraulic pressures in shown in Figure 100.
NOTE! Depending on the type of pumpkit and original or current production, your concrete pump unit may or may not have all the components shown in Figure 100
Boom (Section #1) Down Pressure Relief Valve and Gauge Port
Boom Hand Valves and Gauge Port
Water Pump/Compressor Hand Valve and Gauge Port
E-Stop Manifold Valves and Gauge Ports
Electric Stroke Limiter and Pressure Reducing Control Block(s)
Boon/Outrigger Hand Valve and Gauge Port
Soft Switch Shutoff Valve (twin circuit)
Concrete pump forward/reverse and agitator hand valves
Dampener Valve (single circuit)
Soft Switch and Concrete Pump Relief Valves
Concrete Pump Shutoff Valve
Outrigger Hand Valve Outrigger Hand Valve and Gauge Port Concrete Pump Pressure Gauge Accumulator Unloading Manifold Valve and Gauge (twin circuit)
Manual Stroke Limiter
Agitator Hand Valve and Gauge Port
Electric agitator switch
Agitator Shutoff Valve
Accumulator Pressure Gauge (twin circuit)
Rear Control Panel
Figure 100 General location of components used to set hydraulic pressures
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Set the concrete pump main relief valve (single- circuit). The BPL 1200 concrete pump is designed to operated at a maximum pressure of 300 bar (4350 PSI). It is controlled by the main relief valve (Figure 101), The main relief valve is located at the front of the control block (towards the truck cab). To check or set the main relief pressure perform the following steps:
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Pressure Settings
8. Use the concrete pump “forward/neutral/reverse” switch to put the pump into the “forward” position. The unit will stroke only once, then the rock cylinder will retract. Oil will have nowhere to go except over the concrete pump main relief valve. 9. Read the pressure on the concrete pump pressure gauge, located on the main control block. It should read 300 bar. Position the throttle switch to the “neutral” position. If no adjustment is needed, skip to Step 12. Mount bolt and washer removed for illustration
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Lower pressure
Grooves in handle should line up with grooves in valve shaft
Raise pressure
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Figure 101 Main relief valve (single circuit) 1. Be sure that the waterbox covers are installed on the waterbox. We do not recommend using the remote control box for the following procedure. 2. Wear safety glasses when setting pressures. 3. Close the concrete pump shutoff valve (Figure 71) 4. Position the “remote/local” switch, on the rear control panel, to the “local” position. 5. Use the throttle switch, on the rear control panel, to rev the engine up to full RPM. 6. Make sure the manual stroke limiter valve and the dampener valve are turned, counter-clockwise, all the way out. 7. If the unit is equipped with an electric stroke limiter, turn the control knob clockwise to the maximum output (+) position.
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Figure 102 Concrete pump shutoff valve (single circuit 10. If adjustment is required, loosen the jam nut on the relief valve adjusting screw with a 13-mm spanner wrench (Figure 101). 11. Turn the adjustment knob on the relief valve to adjust the pressure. Turn the adjustment knob in (clockwise) to raise pressure, out (counter clockwise) to lower the pressure. 12. Retighten the jam nut. (Tightening the jam nut tends to raise the pressure. If this happens, hold the adjustment knob while tightening the jam nut.)
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Pressure Settings 13. Put the concrete pump into the “forward” position again. The machine will not stroke this time, but will develop maximum pressure. Read the pressure on the control block pressure gauge. If more adjustment is needed, return the pump to “neutral,” then repeat Steps 8 through 11. until the pressure is at 300 bar. Position the throttle switch to the “neutral” position. 14. Open the shutoff valve. The unit will not stroke with the shutoff valve closed.
NOTE! If you cannot adjust the pressure up to 300 bar, you have a problem. In this case, turn the adjustment knob out by several turns so that your pressure isn’t too high once the problem is found. Contact Schwing America’s service department for advice on how to continue. •
Set the concrete pump main relief valve (twin circuit)
The main relief valve is the primary pressure control device on units equipped with Rexroth A7VO hydraulic pumps. This pump is designed to operate at a maximum pressure of 350 bar (5075 PSI).
Hot oil expulsion hazard. Stand away from pumpkit when checking hydraulic pressures.
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The main relief valve is set to very high pressure (at least 350 bar). Use the controls on the rear control panel when checking the pressure of the main relief valve, so you will be out of the way if a hose or a fitting malfunctions. Refer to Figure 103 for the location of the components used to set the concrete pump pressures. Use the following steps to set the main relief valve pressure: 1. Be sure that the waterbox covers are installed on the waterbox. We do not recommend using the remote control box for the following procedure. 2. Wear safety glasses when setting pressures. 3. Close the concrete pump shutoff and soft switch shutoff valves (Figure 103).
4. Position the “remote / local” switch on the rear control panel to the “local” position. 5. Use the throttle switch on the rear control panel to rev the engine up to full RPM. 6. Use the concrete pump “forward/neutral/reverse” switch to put the pump into the “forward” position. The unit will stroke only once, then the rock cylinder will retract. Oil will have no where to go except over the concrete pump main relief valve. 7. Read the pressure on the concrete pump pressure gauge located on the main control block. It should read 350 bar. Position the concrete pump switch to the off (neutral) position. If no adjustment is needed, skip to Step 11. 8. If adjustment is needed, use a 9/16 inch spanner wrench, loosen the jam nut on the main relief valve adjusting screw (Figure 103). 9. Insert a 5/32 inch allen wrench in the adjustment screw. Turn the screw in to raise pressure or out to lower the pressure. 10. Once the pressure is correct (350 bar) retighten the jam nut. Tightening the nut tends to raise the pressure, so check pressure again after tightening. Verify the correct pressure setting (350 bar). 11. Open the concrete pump shutoff valve and soft switch shutoff valves. The unit will not stroke with these valves closed.
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Pressure Settings
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Gauge port
Hif lrv vw .ep s
Main relief valve Soft switch relief valve
Soft switch shutoff valve
Mount bolt and washer removed for illustration
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Concrete pump shutoff valve
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Grooves in handle should line up with grooves in valve shaft
Figure 103 Location of the main relief valve
Setting the soft switch circuit relief pressure To check or adjust the soft switch pressure setting, proceed as follows: 1. Close the concrete pump shutoff valve. Open the soft switch shutoff valve. The rest of the unit should still be set up as though you were going to check concrete pump pressure. 2. Increase the engine RPMs to high pressure the concrete pump. The pressure gauge should read 80 bar (check your schematic). If no adjustment is needed, skip to Step 4.
3. If adjustment is needed, loosen the jam nut on the soft switch relief valve with a 9/16 inch spanner wrench. Adjust the pressure up or down, as needed, using a 5/32 inch Allen wrench. When the correct pressure is achieved, re-lock the jam nut. Be sure to open the concrete pump shutoff valve when you are finished. The unit cannot stroke with this valve closed.
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Pressure Settings Set accumulator circuit hydraulic oil pressure (units with a pressurecompensated pump) You will need an assistant for parts of this procedure. To check or adjust the hydraulic pressure in the accumulator circuit, perform the following steps: 1. Stop the truck, put the key in your pocket, and place a “Do Not Operate” sign on the windshield. 2. Loosen the jam nut on the pressure regulator of the accumulator hydraulic pump. Turn the screw in two-and-a-half turns. This will raise the regulator pressure above 300 bar (Figure 74).
NOTE! If your unit is a current production model Figure 104, skip Steps 3,4, and 8 of this procedure.
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Accumulator pump pressure regulator
Figure 105 Accumulator pump pressure regulator
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3. Connect the whip hose of a 0-600 bar gauge into the gauge port of the E-Stop manifold (Figure 75). 4. Loosen the jam nut on the accumulator circuit relief valve, located on the E-Stop manifold. Turn the screw in two turns. This will raise the relief setting above 300 bar (Figure 75).
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Figure 104 E-Stop manifold (current production)
Relief Valve and Gauge Port
Figure 106 E-Stop manifold relief valve accumulator circuit (original production) 5. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring the engine RPM to maximum.
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6. Read the pressure on the accumulator circuit gauge (Figure 107). Pressure should read 300 bar (4350 PSI). If no adjustment is needed, skip to Step 8.
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Pressure Settings
8. You will need an assistant for this step. With the engine still running, adjust the relief valve on the E-Stop manifold. Back out the adjustment screw until pressure reads 260 bar (3771 PSI) on the gauge connected to the E-Stop manifold.
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Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
Figure 107 Accumulator pressure gauge
7. If additional pressure adjustment is needed, locate the accumulator manifold pressure relief valve (Figure 76). Loosen the jam nut, and turn the screw in to increase pressure or out to decrease pressure. Tighten the jam nut when pressure is at 300 bar. 45s3blck.epsL
Relief Valve Figure 108 Accumulator manifold pressure relief valve
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WARNING
9. After the truck engine is stopped, back out the accumulator circuit hydraulic pump pressure regulator two-and-a-half-turns. This restores the pressure regulator to its original setting (Figure 74). 10. Clear all personnel from the drive line area, start the truck, and rev the engine RPM to maximum. 11. Read the pressure on the accumulator gauge. It should read 200 bar (2900 PSI). 12. If additional adjustment is needed, you must stop the truck engine each time you approach the accumulator circuit hydraulic pump (Figure 74). Adjust the accumulator pump pressure regulator screw in to increase pressure or out to decrease pressure. Lock the jam nut when pressure is correct (200 bar).
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Pressure Settings Setting the outrigger pressure With a seven place hand valve, the boom/outrigger selector valve is inside the boom control block. This valve is activated when the outrigger enable push button is pushed. There is not a separate relief for this circuit, and therefore nothing that must be set. The outrigger circuit is set to a maximum of 280-bar (4060 PSI) by the relief valve located on the passenger side outrigger hand valve assembly (Figure 109). The valve routes the oil to the two outrigger hand valve banks, one on each side of the unit. A relief valve inside the passenger side bank limits the entire outrigger circuit to 280-bar.
NOTE! On some pump units the relief valve may be in a slightly different location (opposite side) than shown in Figure 109.
Lower
280 bar Relief Valve
NOTE! You cannot use the extend position for this adjustment because extend has a nonadjustable secondary relief functions built into the valve. 5. Turn the outside body of the relief valve cartridge that is located at the back of the passenger side outrigger hand valve (Figure 109). Turn in (clockwise) to raise pressure, turn out (counter clockwise) to lower pressure. 6. When the pressure on the gauge connected to the outrigger hand valve is 280-bar, release the enable push button and the outrigger hand valve. 7. Remove the whip hose and gauge from the outrigger handvalve, and replace the cap on the gauge port. • Pressure reducing valve This valve is preset at the factory. Contact Schwing America’s Service Department at (651) 429-0999 for information on checking or setting this valve. • Electric stroke limiter
Higher Turn body of valve to adjust.
This valve is preset at the factory. Contact Schwing America’s Service Department at (651) 429-0999 for information on checking or setting this valve. • Load-sensing boom pressures (7 place proportional circuit)
Figure 109 Outrigger hand valve 1. Connect the whip hose of a 0–400 or 0–600 bar to the gauge port on the back or side of the passenger side outrigger hand valve (Figure 109). 2. If this is not already done, start the truck engine and set the transmission and PTO as you would for a pumping job.
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WARNING Tipping hazard. Never set outrigger pressures with the boom unfolded. Pressure setting procedure requires retraction of an outrigger jacking cylinder.
3. Set the engine RPM to maximum. 4. Push the outrigger enable pushbutton located next to the outrigger handvalve (passenger side). Hold an outrigger hand valve lever in the jacking-retract position. The oil coming from the pump has nowhere to go but over the outrigger relief valve.
If your unit has a load-sensing proportional system, it will have different pressure adjustments than if it is equipped with a black and white boom system. The following instructions are for load-sensing proportional systems. If you have a unit equipped with a black and white boom system, contact Schwing Service Department for the correct instruction pages. In a black and white boom system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain a 20 bar higher pressure at the pump than what the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic
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Pressure Settings
pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting Q-min and ∆P.
fine tuned at the factory, and should not be adjusted unless absolutely necessary.
The general locations of the components used to set boom hydraulic pressures is shown in Figure 110.
Entanglement hazard. Stop drive shafts before adjusting Q-min.
NOTE! Do not adjust ∆P or Q-min if your boom is operating as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned from there. It was Boom Hand Valves
E-Stop Manifold
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Each time the Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning. ∆P Regulator
Q-min Adjust Screw
Figure 110 Location of components used to check or set boom pressures
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WARNING
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Pressure Settings
140 bar gauge port (use 0-400 bar gauge when checking)
140 bar downside relief cartridge
0-400 bar gauge port
0-60 bar gauge port boom control block relief valve ps v.e itprd ap
15 bar pretension adjustment screw
Figure 111 Boom hand valves
Check or set ∆P To check or set ∆P follow these steps: 1. Stop the truck engine and place a “Do Not Operate” sign on the truck windshield. Caution! When checking Delta-P, it is important to note that you be installing a low pressure gauge into a high pressure port. Any activation of a boom function or activation of an E-stop button will damage the low pressure gauge. 2. Install a 0-100 bar gauge in the 0-400 bar gauge port of the manual boom handvalves. Take care not to accidently install the gauge in the 0-60 bar port. (Figure 111).
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7.
Entanglement hazard. Stop drive shafts before adjusting Q-min.
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WARNING
3. To ensure that the pump is putting out only enough oil needed to maintain ∆P, we need to change the setting of the Q-min adjustment screw. Q-min is
adjusted by a screw on the boom hydraulic pump (Figure 112). Turn the Q-min adjustment screw out (counter clockwise) three full turns. Check that all personnel are clear of the truck, then restart the engine, engage the pumps, and leave the engine at an idle. Pressure should read 20 (±1) bar. Increase the throttle RPM and the ∆P pressure should remain the same. If the pressure fluctuates with a change in engine RPM you are probably still reading Q-min. The Q-min adjustment screw will need to be turned out more. If no adjustment is needed, turn the Q-min adjustment screw in (clockwise) three full turns or what ever amount it was turned out. If adjustment is needed, continue to Step 8.
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Pressure Settings
Check or set Q-min
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Q-max
Figure 112 Q-min adjust screw 8. Delta P is adjusted by the ∆P screw on the ∆P regulator (Figure 112). The location of the ∆P regulator valve is shown in Figure 110. Loosen the jam nut and adjust the screw in to increase pressure, or out to decrease pressure until it is set at 20 bar (±1). Contact Schwing America’s Service Department if you are unable to adjust the pressure to specification.
NOTE!
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If the boom does not operate smoothly at 20 bar, you must fine tune the adjustment. 9. Remove the gauge, and adjust ∆P until the boom is responsive and smooth. When done, the gauge (reinstalled) must read between 14 and 25 bar. The electronics in the control system can also affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 20 bar and check the electrical settings. Once electrical settings are verified, you could again refine the boom action with the ∆P adjustment. Caution! Do not operate any functions while setting ∆P. 10. When ∆P has been set remove the 0-100 gauge.
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Figure 113 ∆P regulator valve
∆P adjust screw
Q-min pressure is checked when the engine is at the maximum specified RPM, but must adjust with the engine stopped. To check or set the Q-min follow these steps: 1. Install a 0-600 bar gauge in the 0-400 bar gauge port of the manual boom handvalves. Take care not to accidently install the gauge in the 0-60 bar port. (Figure 111). 2. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to max. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). 3.
WARNING Entanglement hazard. Stop drive shafts before adjusting Q-min.
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Q-min adjustment screw
4. Read the pressure on the 0 - 600 gauge. If the pressure reads less than 100 bar, return the engine RPM to idle speed and install a 0-100 bar gauge.If the pressure reads more than 100 bar, stop the drive shafts from tuning and turn the Q-min adjustment screw in until the pressure is below 100 bar. 5. Bring the engine RPM to maximum. Q-min pressure should read 40 - 45 bar. 6. If no adjustment is needed, stop the drive lines from turning. Tighten the jam nut on the Q-min adjustment screw. Remove the 0-100 gauge. 7. If adjustment is needed, continue to Step 17. 8. Turn the Q-min screw in to raise the pressure (Figure 112). Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When pressure is correct (40-45 bar), tighten the jam nut on the Q-min adjustment screw. Remove the 0-100 bar gauge.
Set boom pressures (load sensing proportional booms) Now that ∆P and Q-min are set, you can check or set the boom valve pressures. There are three pressure settings on the boom circuit (Figure 114).
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Pressure Settings Pressure regulator (the high-pressure adjustment screw on the ∆P regulator valve), set at 290 bar (4205 PSI).
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•
The redundant relief valve located in the emergency stop manifold, set at 320 bar (4640 PSI). The boom control block relief valve, set at 350 bar (5075 PSI).
∆P Regulator Valve (high pressure adjustment screw)
0-400 bar gauge port 0-60 bar gauge port
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boom control block relief valve
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E-Stop Manifold Redundant Relief Valve
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Original Production
Current Production
Figure 114 Boom hydraulic pressure adjustment components
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To check the setting of the valve with the highest pressure, you must first raise the pressure of the lower two: 1. Loosen the jam nut of the high pressure adjustment screw of the ∆P regulator. Turn the screw in twoand-a-half turns. This will raise the pressure on the ∆P regulator above 350 bar. 2. Loosen the jam nut of the adjustment screw on the E-stop manifold redundant relief valve. Turn the screw in one-and-a-half turns. This will raise the pressure setting of the relief valve to above 350 bar. 3. Pressure out any boom cylinder except #1 down by pushing or pulling the control handle. To pressure out a cylinder, retract a fully retracted cylinder or extend a fully extended cylinder. The oil is forced over the relief valve. 4. The tell tale hiss of an open relief valve should be coming from the Apitech control block relief valve now. If it isn’t, raise the setting of the other pressure devices until the hiss originates at the Apitech control block relief valve. Read the pressure on the gauge connected to the 0-400 bar gauge port on the boom hand valve block. It should read 350 bar. If pressure is correct, proceed to Step 5.
NOTE! Although the pressure specification for the Apitech relief valve is 350 bar, you may continue to use the relief valve as long as the cartridge maintains at least 330 bar. If you must replace the valve, proceed to Step 5 before using the concrete pump again, and re-do this entire procedure when you have installed the new valve. If pressure on the Apitech relief valve is below 290 bar, you should not use the concrete pump until the valve is replaced. 5. Screw out the E-Stop manifold redundant relief valve adjustment screw one-and-a-half turns. Pressure out any boom cylinder except #1 down, and read the gauge. Pressure should read 320 bar. If it does not, turn the screw in to raise pressure, or out to lower pressure until it is set at 320 bar. If the location of this valve causes you to be near the drive lines, be sure to stop them from turning before accessing the valve. 6. You will need a helper for this step. While pressuring out any boom cylinder except #1 down, have your helper adjust the high pressure screw of
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Pressure Settings
the ∆P regulator out (lowering the pressure) until the gauge reads 290 bar. Release the pressurized function and lock the jam nut. The boom pressures are now set. If you did not get the readings specified after following the instructions, contact Schwing America’s Service Department at (651) 429-0999 for advice on how to continue.
Set the down side relief valve pressure This valve is a secondary relief valve for #1 cylinder retract function (Figure 115). Proper adjustment ensures that the #1 boom and the A-frame won’t be damaged by putting the boom in the cradle. To adjust this valve (requires a 2.5 mm Allen wrench and a standard screwdriver). Set the pressure of the 140 bar down side relief valve using the following steps: 1. Install a 0 - 400 bar or 0 - 600 bar gauge into the 140 bar gauge port (Figure 115). 2. Unfold the #2 section from #1 until it is straight. For the following procedure we must bring #1 all the way down until the cylinder bottoms out. Position the boom so this can be done without hitting the truck or any other obstacle. 3. Bring #1 down until the cylinder is completely bottomed out. The cylinder does NOT bottom out if you are setting the folded boom into the A-frame (travel position). 4. Activate the #1 down (retract) handvalve The boom will not be able to move because the cylinder is already bottomed out. Read the pressure on the gauge that you just installed. It should read 140 bar (2030 PSI). If no adjustment is necessary, skip to Step 6. 5. If adjustment is needed, loosen the set screw of the 140 bar relief valve with the 2.5 mm allen wrench. While you activate #1 down, adjust the relief cartridge with the screwdriver until the pressure reads just under 140 bar. Retighten the set screw. The pressure may raise slightly. Recheck the pressure, and readjust if needed. 6. When the pressure is set at 140 bar with the set screw tight, you can remove the whip hose gauge and replace the cap on the gauge port. 7. The boom pressure setting sequence is complete. If you are done with the boom, slew it back into the transport position, and lower #1 into the cradle and attach the boom transport strap.
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Pressure Settings
140 bar gauge port
140 bar relief valve
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Figure 115 140 bar relief valve and gauge port
Pretension gauge port
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Pretension adjustment screw Figure 116 Pretension adjustment screw and gauge port
Set 15 bar pretension To check or set pretension, follow these steps: 1. Stop the truck engine. Plug the 0 - 40 bar gauge into the pretension check port of the Apitech handvalve (Figure 116).
2. Start the truck engine, but leave it at an idle. Pretension adjustment is made at an idle to establish the minimum pressure setting. (Note: As RPM is increased, pretension pressure will rise.) Read the pressure on the gauge. If it reads 15 bar ± 1 bar, the pressure is set correctly.
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3. If adjustment is needed, loosen the jam nut on the pretension valve (Figure 116). Turn the screw in to raise pressure, and out to lower pressure. When the pressure is correct, retighten the jam nut. 4. Stop the engine, and remove the 0 - 40 bar gauge. Pretension setting is complete.
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Pressure Settings
Agitator Relief Valve Turn body of valve Gauge port
Higher
to adjust
Lower
Set water pump pressure With a seven place hand valve, the water pump hydraulic control is inside the boom control block. There is not a separate relief valve for this circuit and, therefore nothing that must be set.
Set the agitator pressure
pres rel valv agit.wpsL
The agitator circuit has a maximum pressure of 200 bar (2900 PSI), limited by the relief valve located on the back of the agitator hand valve (Figure 117). The current production agitator handvalve is located on the passenger side of the main control block (Figure 118).
Gauge Port
Relief Valve
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Figure 118 Agitator hand valve (current productions) 1. Stop the unit, and put the key in your pocket. 2. Connect the whip hose of 0-400 or a 0–600-bar gauge to the gauge port on the agitator hand valve (Figure 117). 3. If your unit is equipped with an agitator shutoff valve, close it (Figure 119). Skip to Step 5. 52qrttrn.epsL
Closed
Shown in the open position
Figure 117 Agitator hand valve (original production)
Figure 119 Agitator shutoff valve 4. If your unit is not equipped with an agitator shutoff valve, remove one of the hoses from the agitator motor and plug the hose and the open fitting with approved hydraulic dead plugs. Do not improvise on these plugs. If you don’t have any, contact
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Pressure Settings 5. Schwing’s Spare Parts Department and order them before continuing with this procedure. All of these fittings and many, many more extremely useful items are included in the Troubleshooting Kit, part number 30308553. We highly recommend purchase of this kit. It will pay for itself many times over. You will need: • Qty 2 VS-16S locking plugs, part number 10016803 • Qty 1 GS-16S straight fitting, part number 10008088 • Qty 2 16S capnuts, part number 10001743 6. Be sure that one of the locking plugs and capnuts are tightened on the straight fitting and that the dead plugs are securely tightened to the hose and the open motor fitting. 7. Locate the relief valve on the back of the agitator hand valve. 8. Be sure that all personnel are clear, and restart the engine. 9. Activate the agitator hand valve by pushing or pulling the handle. This will send the oil against the high pressure plug. The oil will have nowhere to go, so it will return to the tank over the relief valve in the agitator hand valve. The pressure at which it relieves can be seen on the gauge. It should read 200-bar. 10. If adjustment is needed, turn the outside body of the relief valve that is located at the back of the agitator hand valve. Turn in to raise pressure or turn out to lower pressure. 11. When the pressure is set at 200-bar, stop the engine and remove the key. Open the shutoff valve or remove the dead plugs and store them in a clean area or in a plastic bag or something similar in order to keep dirt from entering the fittings. Reattach the hose to the agitator motor fitting and tighten securely. (Torque is correct if you make one complete revolution after feeling initial resistance increase.) 12. Remove the whip hose and pressure gauge. Replace the gauge port cover.
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31 EZ Check all hydraulic pressures Changes in pressure can indicate trouble in one or more components and will serve as early warning indicators if you check them on a regular basis. The specifications for each circuit are shown on the hydraulic schematics found in the Appendix section of this manual. The hydraulic schematics are the only documents in this manual that have been updated specifically for your unit, by the serial number, so in each of the following procedures you will be told to refer to the schematic for the pressure required.
Preheat the hydraulic oil Pressure settings must be made with the oil at normal operating temperatures (50° to 60° C). In the past we could pressure out a function in the boom or outrigger system to create heat, but today, load sensing systems no longer allow maximum oil flow to be forced over relief. Because of this, the agitator circuit must be used to heat the hydraulic oil. To heat the oil to operating temperature: 1. Locate the agitator shutoff valve (Figure 120), and close it. The quarter turn shutoff valve has a grooved line on the shaft or pivot point of the
Pressure Settings
handle as well as on the handle itself, which will indicate the open or closed configuration of the valve (Figure 120). If the handle is removed from the agitator shutoff valve (Figure 120) or the concrete pump shutoff valve (Figure 122) and replaced in a different configuration, the grooves in the handle may no longer indicate the proper open/ closed orientation of the valve. The grooves in the shaft give the only true indication of the valve’s position.
NOTE! If your unit is an early production model and does not have an agitator shutoff valve, order one from the Schwing Spare Parts Department, using part number 10004680 (valve) and number 30303432 (tube). Contact the Service Department for installation instructions. 2. Activate the agitator. With the valve closed, the agitator will not be able to turn and the oil will be forced over the relief valve. At an idle (about 600 RPM) you will be converting 4.5 horsepower to heat. 3. When the oil temperature gauge shows 50˚ C, open the shutoff valve.
Grooves in handle Agitator quarter turn shutoff valve (open position)
Closed
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Grooves in shaft
Motor
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Open Mounting screw and washer removed for illustration
Figure 120 Agitator shutoff valve (left) and Open/closed orientation of shutoff valve (right)
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Pressure Settings Check the concrete pump pressure -4 pumpkits
Wear safety glasses any time you check or set pressures. Oil expulsion hazard!
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WARNING
Because the Hi-flow pumpkits have the ability to create high pressure on the concrete, the pressure settings have to be tailored specifically for each model. This means that we cannot simply list a pressure specification for all units. The correct pressure specifications for your unit are shown on the hydraulic schematic in the Appendix, section of this manual.
NOTE! Do not use the remote control box for the following pressure setting procedure. To check or set the concrete pump pressure adjustments, follow these steps:
1. Be sure that the waterbox covers and guards are installed on the waterbox. 2. Start the truck engine, and put the PTO and transmission into gear just as you would to pump a job. 3. Locate and close the concrete pump shutoff valve and the soft switch shutoff valve (Figure 122). (These valves are also known as quarter turn valves). 4. If your concrete pump pressure gauge is not already plumbed into the gauge port (Figure 218), install a 0 - 400 or 0 - 600 bar gauge in the gauge port. 5. The “remote / local” switch located on the rear control panel must be in the “local” position. 6. Be sure that all emergency stop switches are in the up (not activated) position. Reset the E-stop circuit. 7. Using the throttle switch on the rear control panel, bring the truck engine up to full RPM. The main relief valve (Figure 123) is set to very high pressure (at least 350 bar). Use the rear control panel switch when checking the pressure of the main relief valve, so you will be out of the way if a hose or fitting blows.
8. Place the concrete pump “forward / neutral / reverse” switch on the rear control panel into the “forward” position. The unit will stroke no more than once, then the rock cylinder will retract. Oil leaving the hydraulic pumps will be blocked in the brain. This is called high-pressuring the concrete pump. 9. Read the pressure on the gauge. The target pressure for the concrete pump circuit main relief valve is shown on the hydraulic schematic in the Appendix section of this manual. Return the pump control to “neutral” whether the pressure needs adjustment or not. If no adjustment is needed, skip to step 5. If adjustment is needed, proceed to next paragraph.
Setting the main relief valve The main relief valve is the primary pressure control device on units equipped with Rexroth A7VO hydraulic pumps. If the main relief valve needs adjustment, proceed as follows: 1. Wear safety glasses when checking or adjusting pressures. 2. Using a 9/16” spanner wrench, loosen the jam nut on the main relief valve adjusting screw (Figure 123). Gauge port
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Main relief valve Soft switch relief valve
Figure 121 Location of the concrete pump circuit main relief valve and soft switch relief valve 3. Insert a 5/32” Allen wrench in the adjustment screw. Turn the screw in to raise pressure and out to lower the pressure. Always go back to the rear panel before checking the pressure.
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4. Once the pressure is correct to the hydraulic schematic, retighten the jam nut. Tightening the nut tends to raise the pressure, so check pressure again after tightening.
Pressure Settings
5. If you will not be setting the soft switch pressure, open the shutoff valves. The unit will not stroke with closed shutoff valves.
Soft switch shutoff valve Main Pressure Gauge port
Concrete pump shutoff valve
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Figure 122 Showing the concrete pump and soft switch shutoff valves
Grooves in handle
Closed
Open
Main relief cartridge
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Grooves in shaft
Closed
Open Mounting screw and washer removed for illustration
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soft switch relief cartridge 9/16" jam nut
5/32" Allen head 9/16" jam nut
Figure 123 Shutoff valve open / closed orientation
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Pressure Settings Setting the soft switch circuit relief pressure Gauge port
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Figure 124 Location of the main relief valve
Main relief valve Soft switch relief valve
To check or adjust the soft switch pressure setting, proceed as follows:
1. Open the soft switch shutoff valve (Figure 123). The rest of the unit should still be set up as though you were going to check concrete pump pressure. 2. High pressure the concrete pump. The pressure gauge should read 60 or 80 bar (check your schematic). If adjustment is needed, proceed to step (3). If no adjustment is needed, skip to step (). 3. Loosen the jam nut on the soft switch relief valve (Figure 103) with a 9/16” spanner wrench. Adjust the pressure up or down, as needed, using a 5/32” Allen wrench. When the correct pressure is achieved, tighten the jam nut. 4. Be sure to open the concrete pump shutoff valve (Figure 123) on the side of the brain when you are finished. The unit cannot stroke with this valve closed.
Setting pressures on load-sensing booms If your unit has a load-sensing proportional system, it will have different pressure adjustments than if it is equipped with a black and white boom system. The following instructions are for seven place, load-sensing proportional systems. If you have a unit equipped with a black and white boom system, contact Schwing Service for the correct instruction pages.
Preheat the oil When you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (40° - 60° C). Instructions for heating the hydraulic oil are found on page 495.
About proportional boom systems In a black and white boom system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain a 20 bar higher pressure at the pump than what the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting Q-min and ∆P. Read all of the instructions before beginning any pressure settings. General locations of the components for the following procedures are shown in Figure 125. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when checking or setting pressures.
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Pressure Settings
Manual boom hand valves, Delta P adjustment and E-Stop manifold
Figure 125 Locations of components used to check and set boom pressures
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Q-min adjustment screw
Setting ∆P
1. Stop the truck engine and place a “Do Not Operate” sign on the truck windshield. 2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar gauge port (Figure 126) of the manual boom handvalves. Take care not to accidently install the gauge in the 0-60 bar port.
NOTE! Do not adjust ∆P or Q-min if your boom is running as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned from there. It was fine tuned at the factory and should not be adjusted unless absolutely necessary. If it becomes necessary, do not adjust Q-min with the drive shafts turning! Each time the Q-min screw is adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drive lines stop turning. To check or set ∆P, follow these steps:
0-400 bar gauge port
0-60 bar gauge port
Do not operate any function during this procedure. Gauge damage possible!
Boom control block relief valve (non-adjustable)
15 bar pretension adjusment screw
30 bar pilot pressure relief cartridge
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140 bar downside relief cartridge (non-adjustable) Figure 126 Location of the boom circuit pressure devices (Hoses removed for clarity.)
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CAUTION
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Pressure Settings
Q-min adjustment screw
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Q-max
Figure 127 Location of the Q-min adjustment screw on A11VO (left) and A7VO (right) 3. To be sure that the pump is putting out only enough oil to maintain ∆P, we need to change the setting of the Q-min screw. Q-min is adjusted by a screw on the boom hydraulic pump (Figure 127). Unscrew the Q-min screw three full turns. Make sure that all emergency stop switches are in the up (not activated) position. Check that all personnel are clear of the truck; then restart the engine, engage the pumps, and leave the engine at an idle. Pressure can be read on the 0 - 40 bar gauge that you installed. Pressure should read 20 bar. If no adjustment is needed, simply reset the Q-min screw as described on page 357. If adjustment is needed, continue to step (4). 4. Delta P is adjusted on the bottom (smaller) screw of the pressure regulator shown in Figure 225 below. If your unit has an A7VO boom pump, you can do so by loosening the jam nut (10mm open
end wrench) and adjusting the screw (3mm Allen wrench) clockwise to increase pressure or counter clockwise to decrease it. 5. The delta P adjustment screw on the A11VO boom pump, also shown in Figure 225 below, requires a 13mm open end wrench and a 4mm allen wrench.
NOTE! If the boom is not smooth at 20 bar, you must fine tune the adjustment. In that case, REMOVE THE GAUGE and adjust ∆P until the boom is responsive and smooth. The gauge (reinstalled) must now read between 14 and 25 bar. The electronics in the control system can also affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 20 bar and check the electrical settings. Once electrical settings are verified, you could again refine the boom action with the ∆P adjustment.
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Delta-p
T
P adjustment screw 000281.eps
Figure 128 Location of the delta P adjustment screw for a unit with A7VO pump (left) and A11VO pump (right)
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Setting Q-min Check Q-min pressure when the engine is at the maximum specified RPM, but the engine must be stopped to adjust the screw. 1. If you unscrewed the Q-min screw as the first step of ∆P adjustment, begin by returning the screw to its original position (Figure 127). 2. Remove the 0 - 40 bar gauge from the 0 - 400 bar gauge port, and install the 0 - 600 bar gauge in its place. 3. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to max. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). 4. Read the pressure on the 0 - 600 bar gauge. Pressure should be at 40 - 45 bar. If no adjustment is needed, stop the drive lines from turning, be sure the jam nut on the Q-min screw is tight, and proceed to Setting boom pressures. If adjustment is needed, continue to the next step. 5. Turn the Q-min screw in to raise the pressure (Figure 127). Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning
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Pressure Settings
each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures.
Setting boom pressures (Load sensing proportional booms) Now that ∆P and Q-min are set, you can check or set the boom valve pressures. There are several devices on the boom circuit which control boom pressure (Figure 226):
1. Pressure regulator (the high-pressure adjustment screw on the ∆P regulator valve on units with A7VO boom pumps), set at 300 bar. 2. Pressure cut-off on units with A11VO pumps. 3. The boom control block relief valve, pre-set at 350 bar.
NOTE! This relief valve is nonadjustable. If pressure is not maintained with the specification limits, the valve must be replaced.
Boom control block relief valve (non-adjustable)
0-400 bar gauge port T
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High pressure adjustment screw
0-60 bar gauge port
15 bar pretension adjusment screw
30 bar pilot pressure relief cartridge
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140 bar downside relief cartridge (non-adjustable) Figure 129 The boom pressure devices
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Pressure Settings Raise the pressure of the lowest circuit
Setting the outrigger pressures
To check the setting of the valve with the highest pressure, you must first raise the pressure of the lower: 1. Loosen the jam nut of the high pressure adjustment screw (Figure 129) of the ∆P regulator. Turn the screw in two-and-a-half turns. This will raise the pressure on the regulator above 350 bar. 2. Pressure out any boom cylinder except #1 down by activating the control handle. To pressure out a cylinder, retract a fully retracted cylinder or extend a fully extended cylinder. The oil is then forced over the relief valve. The telltale hiss of an open relief valve should be coming from the Apitech control block relief valve now. If it isn’t, raise the setting of the delta P regulator a little more until the hiss originates at the Apitech control block relief valve. Read the pressure on the gauge. It should read 350 bar. If pressure is correct, proceed to the next step.
After the boom pressures are set, you can set the outrigger pressure.
Although the pressure specification for the Apitech relief valve is 350 bar, you may continue to use the relief valve as long as the cartridge maintains at least 330 bar. If you must replace the valve and don’t have one on hand, proceed to the next step before using the machine again. Redo this entire procedure when you have installed the new valve. If pressure on the Apitech relief valve is below 290 bar, you should not use the machine until the valve is replaced. 3. You will need a helper for this step. While pressuring out any boom cylinder except #1 down, have your helper adjust the high pressure screw of the ∆P regulator out (lowering the pressure) until the gauge reads 300 bar. Release the pressurized function, and lock the jam nut. The boom pressures are now set. If you did not get the readings specified after following the instructions, contact Schwing America’s Service Department at (651) 429-0999 for advice on how to continue.
To set the 280 bar relief valve for the outrigger circuit:
WARNING Wear safety glasses any time you check or set pressures. Oil expulsion hazard!
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NOTE!
The boom, outriggers, water pump, and compressor circuits have all been put together in the boom valve manifold. When the outrigger selector push button is pushed, the boom/outrigger control handle is activated (Figure 129), which routes oil to the two outrigger hand valve banks (one on each side of the unit). A relief valve inside the passenger side bank limits the entire outrigger circuit to 280 bar (4060 PSI) instead of the 300 bar (4350 PSI) of the boom relief valve.
1. Plug the whip hose of a 0-400 or 0-600 bar gauge (Figure 227) into the gauge port. 2. If not already done, start the truck engine and set the transmission and PTO as you would for a pumping job. 3. Locate the 280 bar relief valve (Figure 130) on the back of the outrigger valve. 4. Set the engine RPM to maximum. 5. Select “outrigger” with the outrigger push button. This will route oil to the outrigger handvalves. 6. With the outriggers folded into the travel position, activate the passenger side hand valve “jacking cylinder retract” for either the front or rear outrigger.
NOTE! You will get an incorrect reading if you select any other outrigger function. The handles are spring loaded and will return to neutral as soon as you let go.
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Pressure Settings 000452.eps
0-400 bar gauge port
Boom/Outrigger control handle
AGITATOR
CONCRETE PUMP
Boom 1
Boom 2
Boom 3
Boom 4
Boom 1 Telescope
Slewing Boom / Outrigger
Water / Compressor
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DANGER
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Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
WARNING Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
Figure 130 Position of the 0-400 bar gauge port and boom/outrigger control handle 7. Read the pressure on the gauge. It should read 280 bar (4060 PSI). If no adjustment is needed, skip to step 4. 8. If adjustment is needed, turn the outside body of the relief valve that is located at the back of the outrigger valve. Turn in to raise pressure and out to lower pressure. There is no jam nut on this valve. 9. Activate the outrigger “jacking retract” hand valve, and read the pressure on the gauge again. Repeat steps (8) and (9) until the gauge reads 280 bar. 000453.eps
AGITATOR
10. When the pressure is correct, either go on to other pressure settings or remove the whip hose and gauge, and cap the gauge port with the attached cap. 11. Return the RPM of the truck to an idle, take the transmission and PTO out of gear, and shut off the truck, or go on to the other pressure settings as required.
280 bar Relief valve
CONCRETE PUMP
Boom 1
Boom 2
Boom 3
Boom 4
Boom 1 Telescope
Slewing Boom / Outrigger
Water / Compressor
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DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
4 1
3
Outrigger control block
WARNING Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
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WARNING Clear area before activating outriggers
REAR EXTEND
REAR JACKING
FRONT JACKING
FRONT EXTEND
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Figure 131 Location of the 280 bar outrigger pressure relief valve (Hoses removed for clarity)
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Pressure Settings Setting 15 bar pretension
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Truck engine must be at idle to set pretension. Gauge damage possible!
To check or set pretension, follow these steps: 1. Stop the truck engine. Plug the 0 - 40 bar gauge into the 0-60 bar pretension check port of the Apitech hand valve (Figure 130).
2. Start the truck engine, but leave it at an idle. (Pretension adjustment is made at an idle to establish the minimum pressure setting. As RPM is increased, pressure will rise. Damage to the 0 - 40 bar gauge is possible if RPM is raised while the gauge is connected.) 3. If the pressure reads 15 bar ± 1 bar, the pressure is set correctly. If adjustment is needed, proceed to the next step. 4. Loosen the jam nut on the pretension valve. Turn the screw in to raise pressure and out to lower pressure. When the pressure is correct, retighten the jam nut. 5. Stop the engine, and remove the 0 - 40 bar gauge. Pretension setting is complete.
15 bar pretension adjustment screw
0-60 bar gauge port
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Figure 132 Pretension adjustment screw and gauge port
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Pressure Settings
Setting the agitator circuit pressure 000447.eps
Agitator Relief Valve Gauge port
Turn body of valve Higher to adjust. Lower AGITATOR
CONCRETE PUMP
Agitatior Hand Valve Boom 1
Boom 2
Boom 3
Boom 4
Boom 1 Telescope
Slewing Boom / Outrigger
Water / Compressor
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DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
1
3
4
Agitator Fwd/Reverse
WARNING Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
2
WARNING Clear area before activating outriggers
Concrete pump Fwd/Reverse
REAR EXTEND
FRONT JACKING
FRONT EXTEND
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REAR JACKING
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Figure 133 Agitator hand valve (location right, blowup left) The agitator relief valve is located in the agitator forward / neutral / reverse hand valve block. The agitator relief valve limits the pressure in the agitator circuit to 200 bar (2900 PSI). There is a gauge port for checking or setting the pressure in this circuit. The port is located on the agitator hand valve block and shown on top in Figure 230. The gauge port may be mounted on the side of the block on some units. To check or set the agitator pressure, follow these steps: 1. Unscrew the cover from the gauge port. Plug in the 0-600 bar gauge and whip hose that came in the toolbox. 2. Start the engine if it’s not already running. 3. Close the agitator shutoff valve (Figure 53).
NOTE! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and part number 30303432 (tube). Contact Schwing America’s Service Department at (651) 4290999 for installation instructions.
Agitator quarter turn shutoff valve (open position)
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Figure 134 The agitator shutoff valve 4. Activate the agitator, and read the pressure on the gauge. 5. If adjustment is needed, put your wrench on the body of the relief valve (Figure 230), which is located on the back of the agitator hand valve. While reading the gauge, turn the body in to raise pressure or out to lower pressure until 200 bar is achieved. 6. Put the agitator handle in neutral. 7. Remove the whip hose and pressure gauge. Replace the gauge port cover.
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Pressure Settings Setting accumulator circuit pressure To check or adjust the hydraulic pressure in the accumulator circuit: 1. Stop the truck, put the key in your pocket, and place a “Do Not Operate” sign on the windshield. 2. Loosen the jam nut on the pressure regulator of the accumulator hydraulic pump (Figure 135). Turn the screw in two-and-one-half turns. This will raise the regulator pressure above 300 bar. 3. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring the engine RPM to maximum.
4. Read the pressure on the accumulator circuit pressure gauge (Figure 136). The pressure should read the value shown on the hydraulic schematic. If no adjustment is needed, skip to step (7). If additional pressure adjustment is needed, continue with step (5).
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Figure 136 Accumulator circuit pressure gauge 000289.eps
Accumulator pump pressure regulator
5. Locate the accumulator manifold pressure relief cartridge (Figure 137). Loosen the jam nut, and turn the screw clockwise to increase the pressure or counter clockwise to decrease the pressure. Tighten the jam nut when the pressure reaches the value required, and shut off the truck engine. 000449.eps
Figure 135 Accumulator pump pressure regulator for A7VO (above) and for A11VO (below)
Manual bleed valve
Boom Pump Accumulator Pump
Pressure relief cartridge Accumulator Pump Pressure Regulator Standby Pressure Screw
000446.eps hgacugc.psd
Figure 137 Accumulator manifold pressure relief cartridge and manual bleed valve
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SERVICE TRAINING
Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
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WARNING
6. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 136), and turn the screw back out two-and-one-half turns. This restores it to its original setting. 7. Clear all personnel from the drive line area, start the truck, and bring the engine RPM up to maximum. 8. Read the pressure on the accumulator gauge. It should now read the proper accumulator system pressure. 9. If adjustment is needed, you must stop the truck engine, or a least stop the drive lines from turning, each and every time you approach the accumulator circuit hydraulic pump. Turn the screw in to increase the pressure or out to decrease pressure. Lock the jam nut when the pressure is correct.
NOTE! The accumulator circuit hydraulic pump pressure regulator is sometimes referred to as the pressure cut-off.
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Pressure Settings
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Pressure Settings
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SERVICE TRAINING
32XL Single Circuit Check hydraulic pressures Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components. Pressure settings must be made with the oil at normal operating temperatures (40° to 60° C).The specifications for all circuit pressures are found on the hydraulic schematics in the appendix section of this manual.
Preheat the hydraulic oil
Pressure Settings
2. Turn on the agitator. The agitator will not be able to turn, and the oil will be forced over the relief valve. 3. At an idle (approx. 600 rpm), about 5.4 horsepower is being converted to heat. Shut off the concrete pump when the temperature gauge on the rear control panel shows 40° C.
Check the concrete pump pressure (900 or 1200) The Schwing concrete pump circuit on the BPL 900 or 1200, KVM 32 XL is designed to be operated at a maximum pressure of 300 bar (4350 PSI). Pressure is limited by the main relief valve which is located on the forward (towards the truck cab) end of the main control block. To check or set the main relief pressure: (See Figure 138).
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Because of the new load sensing and pressure cutoff regulated hydraulic systems, you can’t use the concrete pump or boom circuit to preheat the hydraulic oil (they stop putting out oil if you try). To heat the oil to operating temperature: 1. Locate the agitator shutoff valve and close it. Note! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and part number 30303432 (tube). Install as shown in figure 231 on page 6-362.
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Pressure gauge Main relief valve
Jam nut Lower pressure
Raise pressure
Adjustment handle Figure 138 The main relief valve, concrete pump
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Pressure Settings 1. Be sure that the waterbox covers are installed on the waterbox. Use of the remote control box for the following procedure is NOT recommended. 2. Wear safety glasses when checking or setting pressures.
3. Start the truck engine, and put the PTO and transmission into gear just as you would to pump a job. 4. See figure 139. Close the shutoff valve (also known as the ball cock or quarter turn valve).
Figure 139 Showing the concrete pump shutoff valve
5. Put the rear control panel switch “remote / local” into the “local” position. 6. Using the switch on the rear control panel, rev the truck engine up to full RPM. 7. Using the concrete pump “forward / neutral / reverse” switch on the rear control panel, put the concrete pump into the “forward” position. The unit will stroke no more than once, then the rock cylinder will retract. Oil will have nowhere to go except over the main relief valve. 8. Read the pressure on the gauge, as shown. It should read 300 bar. Return the pump to “neutral” whether in needs adjustment or not. If no adjustment is needed, skip to step 14. 9. Loosen the jam nut on the relief valve adjusting screw (requires a 13 mm spanner wrench). 10. Turn the knob on the relief valve to adjust the pressure. Screw the handle in to raise pressure, out to lower the pressure. 11. Retighten the jam nut. (This step is necessary because tightening the nut tends to raise the pressure. If it becomes a problem, hold the knob while tightening the jam nut). 12. Put the concrete pump into the “forward” position again. The machine will not stroke this time, but will again develop maximum pressure. Read the pressure on the gauge. If more adjustment is needed, return the pump to “neutral”, then repeat steps 8. thru 12. until the pressure is at 300 bar. NOTE! If you cannot adjust the pressure up to 300
bar, there is a hydraulic problem. In this case, unscrew the adjustment knob by several turns so that your pressure isn’t too high once the problem is found. Contact Schwing America’s Service Department at (651) 429-0999 for advice on how to continue. 13. Return the pump to the “neutral” position. 14. Open the shutoff valve. 15. Return the RPM of the truck to an idle, take the transmission and PTO out of gear, and shut off the truck, or go on to the other pressure settings, as required.
Setting boom pressures (7 place proportional circuit) If your unit has a loadsensing proportional system, it will have different pressure adjustments than if it is equipped with a black and white boom system. The following instructions are for load-sensing proportional systems. If your unit is equipped with a black and white boom system, these instructions will be wrong. Contact Schwing America’s Service Department to obtain correct instructions. Preheat the oil
NOTE! Whenever you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (40° - 60° C). Instructions for heating he hydraulic oil are found in section on page 6-285.
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SERVICE TRAINING About proportional boom systems
Q-min adjustment screw
P regulator
CONCRETE PUMP
FWD
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Figure 140 Locations of components used to check and set boom pressures
Pressure Settings
called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting Q-min and ∆P. See figure 142.
In a black and white boom system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain a 20 bar higher pressure at the pump than what the cylinders actually require. This 20 bar is Manual boom handvalves
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E-Stop manifold
Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when checking or setting pressures.
Setting ∆P Note! Do not adjust ∆P or Q-min if your boom is running as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned from there. It was fine tuned at the factory, and should not be adjusted unless absolutely necessary. You must not adjust Q-min with the drive shafts turning! Each time the Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning. To check or set ∆P, follow these steps: 1. Stop the truck engine and place a “Do Not Operate” sign on the truck windshield. 2. Install a 0 - 40 or 0 - 60 bar gauge in the 0 - 400 bar gauge port of the manual boom handvalves. Take care not to accidently install the gauge in the 0 - 60 bar port. (See Figure 141.) 3. To be sure that the pump is putting out only enough oil needed to maintain ∆P, we need to change the setting of the Q-min screw. Q-min is adjusted by a screw on the boom hydraulic pump (see Figure 142). Unscrew the Q-min screw three full turns.
Check that all personnel are clear of the truck, then restart the engine, engage the pumps, and leave the engine at an idle. CAUTION! If you activate any boom or outrigger functions, you will damage the 0 - 40 bar gauge. Make sure that all emergency stop switches are in the up (not activated) position. Pressure can be read on the 0 40 bar gauge that you installed. Pressure should read 20 bar. If no adjustment is needed, simply reset the Q-min screw as described in . If adjustment is needed, continue to step (2.). 4. Delta P is adjusted by the ∆P screw on the ∆P regulator (see Figure 143). Loosen the jam nut and adjust the screw inward to increase pressure, or outward to decrease pressure until it is set at 20 bar (±1). Contact Schwing America’s Service Department at (651) 429-0999 if you are unable to adjust the pressure to spec. NOTE! If the boom is not smooth at 20 bar, you must fine tune the adjustment. In that case, REMOVE THE GAUGE, and adjust ∆P until the boom is responsive and smooth. When done, the gauge (reinstalled) must read between 14 and 25 bar. The electronics in the control system can also affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 20 bar and check the electrical settings. Once electrical settings are verified, you could again refine the boom action with the ∆P adjustment.
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Pressure Settings
140 bar gauge port (use 0-400 bar gauge when checking)
140 bar downside relief cartridge
0-400 bar gauge port
0-60 bar gauge port boom control block relief valve s
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15 bar pretension adjustment screw
Figure 141 Showing the location of the boom circuit pressure devices (Hoses removed for clarity.)
Q-min adjustment screw
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Q-max
Figure 142 Location of the Q-min adjustment screw
Setting Q-min You must check Q-min pressure when the engine is at the maximum specified RPM, but you must adjust it with the engine stopped. 1. If you unscrewed the Q-min screw as the first step of ∆P adjustment, begin by returning the screw to its original position (see Figure 142).Remove the 0 - 40 bar gauge from the 0 - 400 bar gauge port, and install the 0 - 600 bar gauge in its place.
2. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to max. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). 3. Read the pressure on the 0 - 600 gauge. Pressure should be at 40 - 45 bar. If no adjustment is needed, stop the drivelines from turning, be sure the jam nut on the Q-min screw is tight, then continue to
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Pressure Settings
CAUTION Do not operate any functions while setting ∆P.
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∆P adjustment screw
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paragraph to check the rest of the boom and outrigger pressures. If adjustment is needed, continue to step (5.). 4. Turn the Q-min screw in to raise the pressure (Figure 142). Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures.
Setting boom pressures (Load sensing proportional booms.) Now that ∆P and Q-min are set, you can check or set the boom valve pressures. There are three pressure settings on the boom circuit: (see Figure 144) 1. Pressure regulator (the high-pressure adjustment screw on the ∆P regulator valve), set at 300 bar. 2. The redundant relief valve located in the emergency stop manifold, set at 330 bar. 3. The boom control block relief valve, set at 350 bar. NOTE! This relief valve is nonadjustable. If pressure is not maintained with the specification limits, the valve must be replaced. • To check the setting of the valve with the highest pressure, you must first raise the pressure of the lower two: 4. Loosen the jam nut of the high pressure adjustment screw of the ∆P regulator. Turn the screw in twoand-a-half turns. This will raise the pressure on the regulator above 350 bar.
Figure 143 The ∆P regulator valve 5. Loosen the jam nut of the adjustment screw of the redundant relief valve in the emergency stop manifold. Turn the screw in one-and-a-half turns. This will raise the pressure setting of the relief valve to above 350 bar. 6. Pressure out any boom cylinder except #1 down by pushing or pulling the control handle. To pressure out a cylinder, retract a fully retracted cylinder or extend a fully extended cylinder. The oil is forced over the relief valve. The telltale hiss of an open relief valve should be coming from the Apitech control block relief valve now. If it isn’t, raise the setting of the other pressure devices until the hiss originates at the Apitech control block relief valve. Read the pressure on the gauge. It should read 350 bar. If pressure is correct, proceed to step (4.). NOTE! Although the pressure specification for the Apitech relief valve is 350 bar, you may continue to use the relief valve as long as the cartridge maintains at least 330 bar. If you must replace the valve, proceed to step (4.) before using the machine again, and redo this entire procedure when you have installed the new valve. If pressure on the Apitech relief valve is below 290 bar, you should not use the machine until the valve is replaced. 7. Screw out the e-stop manifold redundant relief valve adjustment screw one-and-a-half turns. Pressure out any boom cylinder except #1 down, and read the gauge. Pressure should read 330 bar. If it does not, turn the screw in to raise pressure, or out to lower pressure until it is set at 330 bar. If the location of this valve causes you to be near the drivelines, be sure to stop them from turning before accessing the valve.
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Pressure Settings
Redundant relief valve
High pressure adjustment screw T
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0-400 bar gauge port 0-60 bar gauge port
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boom control block relief valve
8. You will need a helper for this step. While pressuring out any boom cylinder except #1 down, have your helper adjust the high pressure screw of the ∆P regulator out (lowering the pressure) until the gauge reads 300 bar. Release the pressurized function and lock the jam nut. The boom pressures are now set. If you did not get the readings specified after following the instructions it is possible that there is a problem with the emergency stop manifold (see Figure 145). You can plumb the malfunctioning circuit out of the system to test it. Use only approved hydraulic dead plugs to plug the inlet hose to the malfunctioning circuit. If pressure can now be achieved, the e-stop manifold is the source of the problem. If pressure still cannot be achieved, the problem is elsewhere. Contact Schwing America’s Service Department for advice
Figure 144 The three boom pressure
on how to continue. If the problem was found to be the e-stop manifold, repair it before using the unit again. Remember, the emergency stop switches do nothing if the e-stop manifold is plumbed out of the system. 9. Remove the whip hose from the 300 bar gauge port. Before folding up the boom, proceed to the instructions for setting the 140 bar down side relief valve.
Setting the 140 bar down side relief valve pressure Set the pressure of the 140 bar down side relief valve. This valve is a secondary relief valve for #1 cylinder retract function. Proper adjustment ensures that the #1 boom and the A-frame won’t be damaged by putting
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Concrete pump dump valve
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Pressure Settings
Boom dump valve
Outlet to tank
Boom / Outriggers Pilot drain
Concrete pump
Accumulator
Water pump / compressor / agitator estophartbm.eps
MP
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Boom/outrigger circuit dump valve
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Boom override button Boom/outrigger inlet port
Figure 145 Emergency stop manifold original production (top), current production
the boom in the cradle. (See figure 146.) To adjust this valve (requires a 2.5 mm Allen wrench and a standard screwdriver): 1. Install a 0 - 400 bar or 0 - 600 bar gauge into the 140 bar gauge port (shown in Figure 146).
2. Unfold the #2 section from #1 until it is straight. For the following procedure we must bring #1 all the way down until the cylinder bottoms out. Position the boom so this can be done without hitting the truck or any other obstacle.
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Pressure Settings 3. Bring #1 down until the cylinder is completely bottomed out. The cylinder does NOT bottom out if you are setting the folded boom into the A-frame (travel position). 4. Activate the #1 down (retract) handvalve The boom will not be able to move because the cylinder is already bottomed out. Read the pressure on the gauge that you just installed. It should read 140 bar. If no adjustment is necessary, skip to step 6. 5. If adjustment is needed, loosen the set screw of the 140 bar relief valve with the 2.5 mm Allen wrench. While you activate #1 down, adjust the relief
cartridge with the screwdriver until the pressure reads just under 140 bar. Retightening the set screw will raise the pressure slightly. Recheck the pressure, and readjust if needed. 6. When the pressure is set at 140 bar with the set screw tight, you can remove the whip hose gauge and replace the cap on the gauge port. 7. The boom pressure setting sequence is complete. If you are done with the boom, slew it back into the transport position, and lower #1 into the cradle. Reattach the boom strap.
140 bar gauge port
140 bar relief valve
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Figure 146 location of the 140 bar relief valve and gauge port
Setting the outrigger pressures (7 place boom valve systems)
•
After the boom pressures are set, you can set the outrigger pressure. • In this system, the boom, outriggers, water pump, and compressor circuits have all been put together in the boom valve manifold. (See Figure 227). When the outrigger selector push-button is activated, the outrigger valve routes oil to the two outrigger handvalve banks, one on each side of the unit. A relief valve inside the passenger side bank limits the entire outrigger circuit to 280 bar (4060 PSI) instead of the 300 bar (4350 PSI) of the boom relief valve.
1. 2.
3.
4. 5.
To set the 280 bar relief valve for the outrigger circuit: (See Figure 227 and Figure 228). Wear safety glasses whenever you check or set pressures. Plug the whip hose of a 0 - 400 or 0 - 600 bar gauge into the gauge port. Location is shown in figure 227. If not already done, start the truck engine and set the transmission and PTO as you would for a pumping job. Locate the 280 bar relief valve on the back of the outrigger valve, as shown in Figure 228. Set the engine RPM to maximum.
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Pressure Settings
Gauge port
Figure 147 Position of the outrigger selector valve
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Outrigger handle
6. Select “outrigger” with the outrigger pushbutton. This will route oil to the outrigger handvalves.
280 bar Relief Valve
Lower
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Turn body of valve to adjust.
7. Assuming that the outriggers are folded into the travel position, activate the passenger side handvalve “jacking cylinder retract” for either the front or rear outrigger. Note! You will get an incorrect reading if you select “extension cylinder retract” by mistake. If you select “extend” by mistake, the outriggers will extend instead of reading the relief valve setting. The handles are spring loaded and will return to neutral as soon as you let go.
Figure 149 Location of the outrigger circuit relief valve 8. Read the pressure on the gauge. It should read 280 bar (4060 PSI). If no adjustment is needed, skip to step 4. 9. If adjustment is needed, turn the outside body of the relief valve that is located at the back of the outrigger valve. Turn in to raise pressure, turn out to lower pressure. There is no jam nut on this valve. 10. Activate the outrigger “jacking retract” handvalve and read the pressure on the gauge again. Repeat steps 8. and 9. until the gauge reads 280 bar.
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Pressure Settings
32Porct5.eps
REAR EXTEND
FRONT EXTEND
REAR FOOT
FRONT FOOT
Figure 148 Location of the passenger side outrigger control block 11. When the pressure is correct, either go on to other pressure settings, or remove the whip hose and gauge, and cap the gauge port with the attached cap. 12. Return the RPM of the truck to an idle, take the transmission and PTO out of gear, and shut off the truck, or go on to the other pressure settings, as required.
Setting 15 bar pretension • To check or set pretension, follow these steps: 1. Stop the truck engine. Plug the 0 - 40 bar gauge into the pretension check port of the Apitech handvalve (Figure 150). 2. Start the truck engine, but leave it at an idle. (Pretension adjustment is made at an idle to establish the minimum pressure setting. As RPM is increased, pressure will rise. Damage to the 0 - 40 bar gauge is possible if RPM is raised while the gauge is connected.)
3. Read the pressure on the gauge. If it reads 15 bar ± 1 bar, the pressure is set correctly. If adjustment is needed, proceed to step (4.). 4. Loosen the jam nut on the pretension valve. Turn the screw in to raise pressure, and out to lower pressure. When the pressure is correct, retighten the jam nut. 5. Stop the engine, and remove the 0 - 40 bar gauge. Pretension setting is complete.
To set the agitator circuit pressure: The agitator relief valve is located in the agitator forward / neutral / reverse handvalve, at the rear of the unit on the driver’s side. The relief valve limits the pressure in the agitator circuit to 200 bar (2900 PSI). (See Figure 230). There is a gauge port for checking or setting the pressure in this circuit. The port is located on the agitator handvalve. To check or set the agitator pressure, follow these steps: 1. Remove the aluminum diamond plate cover from over the agitator handvalve.
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Pressure Settings
CAUTION Truck engine must be at an idle while setting pretension.
Pretension gauge port
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Pretension adjustment screw
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Figure 150 Pretension adjustment screw and gauge
Relief valve on this side (not visible from this angle).
Gauge port
Figure 151 Showing the agitator handvalve and gauge port (Diamond plate removed for this illustration.) 2. Unscrew the cover from the gauge port. Plug in the 0 - 600 bar gauge and whip hose that came in the toolbox. 3. Start the engine, if not already running. 4. Close the agitator shutoff valve. (See Figure 152.) Note! If your unit does not have a shutoff valve, you can order one using part number 10004680
(valve) and part number 30303432 (tube). Contact Schwing’s Service Department at (651) 429-0999 for installation instructions. 5. Activate the agitator in forward. Read the pressure on the gauge.
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Pressure Settings
ag its o. ep s
closed
Figure 152 The agitator shutoff valve
open
6. If adjustment is needed, put your wrench on the body of the relief valve, which is located on the back of the agitator handvalve. While reading the gauge, turn the body in to raise pressure, or out to lower pressure until 200 bar is achieved. 7. Put the agitator handle in neutral. 8. Remove the whip hose and pressure gauge. Replace the gauge port cover. 9. Replace the aluminum diamond plate over the agitator handvalve.
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32 XL Twin Circuit
Pressure Settings
off, and the key in your pocket, remove the plug (item 2). The oil should be at the level of the bottom of the hole in the case. If oil is needed, add by removing the breather (item 1) and pouring in through the top. This gearcase uses 90W gearlube.
Units up to 450 l/m
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Check the fluid level of the distribution gearcase. (See Figure 153). Be sure the truck is on reasonably level ground. With the truck engine
1
2 4194.e ps
Figure 153 Check, drain and fill ports of the Stiebel 4194 •
Check the mounting hardware of the subframe, the oil and water tanks, the delivery pipeline, the pumpkit, the differential cylinders, the material cylinders and the driveline hardware. Check for bolt tightness, cracks and other abnormalities.
Check hydraulic pressures •
Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components. Pressure settings must be made with the oil at normal operating temperatures (40° to 60° C).The specifications for all circuit pressures are found on the hydraulic schematics in the appendix section of this manual.
Preheat the hydraulic oil
•
Because of the new load sensing and pressure cutoff regulated hydraulic systems, you can’t use the concrete pump or boom circuit to preheat the hydraulic oil (they stop putting out oil if you try). To heat the oil to operating temperature:
1. Locate the agitator shutoff valve and close it. There is a picture of the location on page 6-362. Note! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and part number 30303432 (tube). Contact Schwing’s Service Department at (651) 429-0999 for installation instructions. 2. Turn on the agitator. The agitator will not be able to turn, and the oil will be forced over the relief valve. 3. At an idle (approx. 600 rpm), about 5.4 horsepower is being converted to heat. Shut off the agitator when the temperature gauge on the rear control panel shows 40° C. Don’t forget to open the shutoff valve when the procedure is finished.
Check the concrete pump pressure (9001200 - MPS pumpkits) Schwing concrete pumps with MPS pumpkits are designed to be operated at a maximum pressure of 320 bar (4640 PSI). Pressure is limited by the main relief valve which is located on the forward end (towards the
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Pressure Settings truck cab) of the main control block. (See Figure 154). To check or set the concrete pump relief pressure, follow these steps: 1. Wear safety glasses when checking or setting pressures. 2. Be sure that the waterbox covers and guards are installed on the waterbox. Use of the remote control box for the following pressure setting procedure is NOT recommended. 3. Start the truck engine, and put the PTO and transmission into gear just as you would to pump a job. 4. See Figure 139. Close the concrete pump shutoff valve, and the soft switch shutoff valve. (These valves are also known as quarter turn valves). 5. Put the rear control panel switch “remote / local” into the “local” position. 6. Be sure that all emergency stop switches are in the up (not activated) position. Reset the e-stop circuit. 7. Using the switch on the rear control panel, rev the truck engine up to full RPM. 8. Put the concrete pump “forward / neutral / reverse” switch on the rear control panel into the “forward” position. The unit will stroke no more than once, then the rock cylinder will retract. Oil leaving the hydraulic pumps will be forced over the main relief valve. This is called high-pressuring the concrete pump.
9. Read the pressure on the gauge, located as shown in figure 154. It should read 320 bar. Return the pump control to “neutral” whether the pressure needs adjustment or not. If no adjustment is needed, skip to step 5. 10. Using a 13 mm spanner wrench, loosen the jam nut on the relief valve adjusting screw (Figure 154). 11. Turn the knob on the relief valve to adjust the pressure. Screw the handle in to raise pressure, out to lower the pressure. 12. Retighten the jam nut. Tightening the nut tends to raise the pressure. If the pressure rise becomes a problem, hold the knob while tightening the jam nut. 13. High pressure the concrete pump again. Read the pressure on the gauge. If more adjustment is needed, return the pump control to “neutral”, then repeat steps (8.) thru (13.) until the pressure is correct. NOTE! If you cannot adjust the pressure up to specification, there is a hydraulic problem. In this case, unscrew the adjustment knob several turns so your pressure isn’t too high when you find the problem. Contact Schwing America’s Service Department for advice on how to continue. 14. If you will not be setting the soft switch pressure, open the shutoff valves. The unit will not stroke with closed shutoff valves.
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Main relief valve Pressure Gauge
Jam Nut Lower pressure
Raise pressure
Adjustment Handle
gray valve.eps L
Figure 154 The main relief valve, concrete pump circuit.
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Pressure Settings soft switch.epsL
Figure 155 Showing the concrete pump shut-off valve (left) and soft switch shutoff valve (right)
Groove lined up with ports - open grooves.eps
Groove at 90° to ports - closed
Figure 156 Shutoff valve orientation
Setting the soft switch circuit relief pressure •
To check or adjust the soft switch pressure setting, proceed as follows: 1. Open the soft switch shutoff valve, as shown in figures 155 and 156. The rest of the unit should still be set up as though you were going to check concrete pump pressure. 2. High pressure the concrete pump. The pressure gauge should read 80 bar (1160 PSI) instead of 320 bar. If adjustment is needed, loosen the set screw on the face of the relief valve cartridge with a 2.5 mm allen wrench. Using a screwdriver, adjust the pressure up or down as needed, and lock the set screw into place with the 2.5 mm allen wrench. Recheck. Use a screwdriver, if necessary, to prevent the cartridge from turning while tightening the allen screw.
3. Be sure to open the concrete pump shutoff valve on the side of the brain (shown in Figure 155) when you are finished. The unit cannot stroke with this valve closed.
Setting the boom pressures (7 place black and white circuit) If your unit has a black and white boom system, it will have different pressure adjustments than if it is equipped with a loadsensing proportional system. The following instructions are for black and white systems. If you have a proportional unit, skip to page 6- 355. To set the 300 bar boom circuit relief valve proceed as follows: (See Figure 157) 1. We have to raise the boom and rotate it 180° for this procedure, so you must set the outriggers as you would to pump a job. Be sure that you set up well away from electrical wires and other obstructions.
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Pressure Settings 7plcpres.eps
140 bar port
Use #2, 3, or 4
3 140 bar relief
300 bar port
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SLEWING
DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
AIR / WATER
BOOM / OUTRIG.
Higher
WARNING SAFETY
MANUAL
Turn body of valve to adjust.
Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
300 bar Relief Valve
Figure 157 Showing the location of the boom circuit pressure devices. (Hoses removed for clarity.)
2. Once the outriggers are set, unlock the boom strap, and raise the #1 boom far enough that you won’t hit anything on the truck. Leave the rest of the boom folded. Rotate the boom so that you have safe and easy access to the boom control valves. 3. Remove the control block cover, held on by 2 M6 screws. 4. Install the whip hose of a 0-400 or 0-600 bar gauge in the 300 bar gauge port (Item 1 in Figure 157). 5. Assuming that your boom is completely folded up (except for #1), select a handle, and retract #2, #3 or #4 section. Do NOT use #1 retract, slewing left right, outrigger, water pump, or any extend function. (Again, when you try to retract a fully retracted cylinder, the oil has no where to go except over the relief valve - this allows us to read the relief valve setting on a gauge). Read the pressure on the whip gauge that you installed in step 4, above. It should read 300 bar. If no adjustment is necessary, skip to step 7.
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6. If adjustment is needed, put your wrench on the 300 bar relief valve at the back of the boom control valve bank. While you are holding the function in retract mode, adjust the cartridge in or out until the pressure reads 300 bar. 7. If you cannot achieve 300 bar, it is possible that there is a problem with the emergency stop manifold (see Figure 158). You can plumb the malfunctioning circuit out of the system to test it. Use only approved hydraulic dead plugs to plug the inlet hose to the malfunctioning circuit. If pressure can now be achieved, the e-stop manifold is the source of the problem. Contact Schwing America’s Service Department for advice on repair of the e-stop manifold. Repair the e-stop manifold before using the unit again. Remember, the emergency stop switches do nothing if the e-stop manifold is plumbed out of the system. Remove the whip hose from the 300 bar gauge port. Before folding up the boom, proceed to the instructions for setting the 140 bar down side relief valve.
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Concrete pump dump valve
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Pressure Settings
Boom dump valve
Outlet to tank
Boom / Outriggers Pilot drain
Concrete pump
Accumulator
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Boom/outrigger circuit dump valve
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Figure 158 Emergency stop manifold original production (top), current production (bottom)
Load-sensing boom pressures
Preheat the oil
(7 place proportional circuit) If your unit has a loadsensing proportional system, it will have different pressure adjustments than if it is equipped with a black and white boom system. The following instructions are for load-sensing proportional systems.
Note! Whenever you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (40° - 60° C). Instructions for heating the hydraulic oil are found in section on page 351. About proportional boom systems
In a black and white boom system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions
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Pressure Settings even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting Q-min and ∆P. See figure 161.
with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain a 20 bar higher pressure at the pump than what the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, Manual boom handvalves
Q-min adjustment screw
P regulator
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E-Stop manifold
Figure 159 Locations of components used to check and set boom pressures Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when checking or setting pressures.
Setting ∆P Note! Do not adjust ∆P or Q-min if your boom is running as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned from there. It was fine tuned at the factory, and should not be adjusted unless absolutely necessary. • You must not adjust Q-min with the drive shafts turning! Each time the Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning. To check or set ∆P, follow these steps: 1. Stop the truck engine and place a “Do Not Operate” sign on the truck windshield.
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Pressure Settings
2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar gauge port of the manual boom handvalves. Take care not to accidently install the gauge in the 0-60 bar port. (See Figure 157.)
140 bar gauge port (use 0-400 bar gauge when checking)
140 bar downside relief cartridge
0-400 bar gauge port
0-60 bar gauge port boom control block relief valve s
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15 bar pretension adjustment screw
Figure 160 Showing the location of the boom circuit pressure devices. (Hoses removed for clarity.) boom or outrigger functions, you will damage the 0 - 40 bar gauge. Make sure that all emergency stop switches are in the up (not activated) position. Pressure can be read on the 0 40 bar gauge that you installed. Pressure should read 20 bar. If no adjustment is needed, simply reset the Q-min screw as described in . If adjustment is needed, continue to step (2.).
3. To be sure that the pump is putting out only enough oil needed to maintain ∆P, we need to change the setting of the Q-min screw. Q-min is adjusted by a screw on the boom hydraulic pump (see Figure 161). Unscrew the Q-min screw three full turns. Check that all personnel are clear of the truck, then restart the engine, engage the pumps, and leave the engine at an idle. CAUTION! If you activate any Q-min adjustment screw
Q-minscrew.eps
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Figure 161 Location of the Q-min adjustment screw
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Pressure Settings 4. Delta P is adjusted by the ∆P screw on the ∆P regulator (see Figure 162). Loosen the jam nut and adjust the screw inward to increase pressure, or outward to decrease pressure until it is set at 20 bar (±1). Contact Schwing America’s Service Department if you are unable to adjust the pressure to spec. NOTE! If the boom is not smooth at 20 bar, you must fine tune the adjustment. In that case, REMOVE THE GAUGE, and adjust ∆P until the
boom is responsive and smooth. When done, the gauge (reinstalled) must read between 14 and 25 bar. The electronics in the control system can also affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 20 bar and check the electrical settings. Once electrical settings are verified, you could again refine the boom action with the ∆P adjustment.
CAUTION Do not operate any functions while setting ∆P.
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∆P adjustment screw
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Figure 162 The ∆P regulator valve
Setting Q-min •
1.
1.
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You must check Q-min pressure when the engine is at the maximum specified RPM, but you must adjust it with the engine stopped. If you unscrewed the Q-min screw as the first step of ∆P adjustment, begin by returning the screw to its original position (see Figure 161). Remove the 0 - 40 bar gauge from the 0 - 400 bar gauge port, and install the 0 - 600 bar gauge in its place. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to max. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). Read the pressure on the 0 - 600 gauge. Pressure should be at 40 - 45 bar. If no adjustment is needed, stop the drivelines from turning, be sure the jam nut on the Q-min screw is tight, then continue to paragraph to check the rest of the boom and outrigger pressures. If adjustment is needed, continue to step (5.).
1. Turn the Q-min screw in to raise the pressure (Figure 161). Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures. Setting boom pressures
(Load sensing proportional booms.) Now that ∆P and Q-min are set, you can check or set the boom valve pressures. • There are three pressure settings on the boom circuit: (see Figure 163) 1. Pressure regulator (the high-pressure adjustment screw on the ∆P regulator valve), set at 300 bar. 2. The redundant relief valve located in the emergency stop manifold, set at 330 bar.
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Pressure Settings
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3. The boom control block relief valve, set at 350 bar. NOTE! This relief valve is nonadjustable. If pressure is not maintained with the specification limits, the valve must be replaced.
Redundant relief valve
High pressure adjustment screw T
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To check the setting of the valve with the highest pressure, you must first raise the pressure of the lower two: 1. Loosen the jam nut of the high pressure adjustment screw of the ∆P regulator. Turn the screw in twoand-a-half turns. This will raise the pressure on the regulator above 350 bar. 2. Loosen the jam nut of the adjustment screw of the redundant relief valve in the emergency stop manifold. Turn the screw in one-and-a-half turns. This will raise the pressure setting of the relief valve to above 350 bar. 3. Pressure out any boom cylinder except #1 down by pushing or pulling the control handle. To pressure out a cylinder, retract a fully retracted cylinder or extend a fully extended cylinder. The oil is forced
Figure 163 The three boom pressure devices
over the relief valve. The telltale hiss of an open relief valve should be coming from the Apitech control block relief valve now. If it isn’t, raise the setting of the other pressure devices until the hiss originates at the Apitech control block relief valve. Read the pressure on the gauge. It should read 350 bar. If pressure is correct, proceed to step (4.). NOTE! Although the pressure specification for the Apitech relief valve is 350 bar, you may continue to use the relief valve as long as the cartridge maintains at least 330 bar. If you must replace the valve, proceed to step (4.) before using the machine again, and redo this entire procedure when you have installed the new
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Pressure Settings valve. If pressure on the Apitech relief valve is below 290 bar, you should not use the machine until the valve is replaced. 4. Screw out the e-stop manifold redundant relief valve adjustment screw one-and-a-half turns. Pressure out any boom cylinder except #1 down, and read the gauge. Pressure should read 330 bar. If it does not, turn the screw in to raise pressure, or out to lower pressure until it is set at 330 bar. If the location of this valve causes you to be near the drivelines, be sure to stop them from turning before accessing the valve. 5. You will need a helper for this step. While pressuring out any boom cylinder except #1 down, have your helper adjust the high pressure screw of the ∆P regulator out (lowering the pressure) until the gauge reads 300 bar. Release the pressurized function and lock the jam nut. The boom pressures are now set. If you did not get the readings specified after following the instructions, contact Schwing America’s Service Department at (651) 429-0999 for advice on how to continue.
Setting the 140 bar down side relief valve pressure Set the pressure of the 140 bar down side relief valve. This valve is a secondary relief valve for #1 cylinder retract function. Proper adjustment ensures that the #1 boom and the A-frame won’t be damaged by putting the boom in the cradle. (See figure 146.) To adjust this valve (requires a 2.5 mm Allen wrench and a standard screwdriver): 1. Install a 0 - 400 bar or 0 - 600 bar gauge into the 140 bar gauge port (shown in Figure 164). 2. Unfold the #2 section from #1 until it is straight. For the following procedure we must bring #1 all the way down until the cylinder bottoms out. Position the boom so this can be done without hitting the truck or any other obstacle. 3. Bring #1 down until the cylinder is completely bottomed out. The cylinder does NOT bottom out if you are setting the folded boom into the A-frame (travel position). 4. Activate the #1 down (retract) handvalve The boom will not be able to move because the cylinder is already bottomed out. Read the pressure on the gauge that you just installed. It should read 140 bar. If no adjustment is necessary, skip to step 6.
5. If adjustment is needed, loosen the set screw of the 140 bar relief valve with the 2.5 mm Allen wrench. While you activate #1 down, adjust the relief cartridge with the screwdriver until the pressure reads just under 140 bar. Retightening the set screw will raise the pressure slightly. Recheck the pressure, and readjust if needed. 6. When the pressure is set at 140 bar with the set screw tight, you can remove the whip hose gauge and replace the cap on the gauge port. 7. The boom pressure setting sequence is complete. If you are done with the boom, slew it back into the transport position, and lower #1 into the cradle. Reattach the boom strap.
Setting the outrigger pressures (7 place boom valve system) After the boom pressures are set, you can set the outrigger pressure. • In this system, the boom, outriggers, water pump, and compressor circuits have all been put together in the boom valve manifold. (See Figure 227). When the outrigger selector pushbutton is activated, the outrigger valve routes oil to the two outrigger handvalve banks, one on each side of the unit. A relief valve inside the passenger side bank limits the entire outrigger circuit to 280 bar (4060 PSI) instead of the 300 bar (4350 PSI) of the boom relief valve. • To set the 280 bar relief valve for the outrigger circuit: (See Figure 166).
1. Wear safety glasses whenever you check or set pressures. 2. Plug the whip hose of a 0-400 or 0-600 bar gauge into the gauge port. Location is shown as item 1 in figure 227. 3. If not already done, start the truck engine and set the transmission and PTO as you would for a pumping job. 4. Locate the 280 bar relief valve on the back of the outrigger valve, as shown in Figure 166. 5. Set the engine RPM to maximum. 6. Select “outrigger” with the outrigger pushbutton. This will route oil to the outrigger handvalves.
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Pressure Settings 7plc140.eps
140 bar gauge port
140 bar relief valve SECTION 1
SECTION 2
SECTION 3
SECTION 4
SLEWING
DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
AIR / WATER
BOOM / OUTRIG.
WARNING SAFETY
MANUAL
Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
140 bar gauge port
140 bar relief valve
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Figure 164 location of the 140 bar relief valves and gauge ports. - B & W (top) proportional (bottom)
7. Assuming that the outriggers are folded into the travel position, activate the passenger side handvalve “jacking cylinder retract” for either the front or rear outrigger. Note! You will get an incorrect reading if you select “extension cylinder retract” by mistake. If you select “extend” by mistake, the outriggers will extend instead of reading the relief valve setting. The handles are spring loaded and will return to neutral as soon as you let go.
8. Read the pressure on the gauge. It should read 280 bar (4060 PSI). If no adjustment is needed, skip to step 4. 9. If adjustment is needed, turn the outside body of the relief valve that is located at the back of the outrigger valve. Turn in to raise pressure, turn out to lower pressure. There is no jam nut on this valve.
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Outrigger handle
1 Gauge port
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SLEWING
DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
AIR / WATER
BOOM / OUTRIG.
WARNING SAFETY
MANUAL
Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
1 Gauge port
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10. Activate the outrigger “jacking retract” handvalve and read the pressure on the gauge again. Repeat steps 8. and 9. until the gauge reads 280 bar. 11. When the pressure is correct, either go on to other pressure settings, or remove the whip hose and gauge, and cap the gauge port with the attached cap. 12. Return the RPM of the truck to an idle, take the transmission and PTO out of gear, and shut off the truck, or go on to the other pressure settings, as required.
Setting the water pump hyd. pressure •
With a seven place handvalve, the water pump hydraulic control is inside the boom control block. There is not a separate relief for this circuit.
To set the agitator circuit pressure: The agitator relief valve is located in the agitator forward / neutral / reverse handvalve, at the rear of the unit on the driver’s side. The relief valve limits the
Figure 165 Position of the outrigger selector valve Monsun-Tyson black & white (top right) Apitech proportional (bottom left)
pressure in the agitator circuit to 200 bar (2900 PSI). (See Figure 167). There is a gauge port for checking or setting the pressure in this circuit. The port is located on the agitator handvalve. To check or set the agitator pressure, follow these steps: 1. Remove the aluminum diamond plate cover from over the agitator handvalve. 2. Unscrew the cover from the gauge port. Plug in the 0-600 bar gauge and whip hose that came in the toolbox. 3. Start the engine, if not already running. 4. Close the agitator shutoff valve. (See Figure 168.) Note! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and part number 30303432 (tube). Contact Schwing’s Service Dept. for installation instructions. 5. Activate the agitator in forward. Read the pressure on the gauge.
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32Porct5.eps
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Higher
Pressure Settings
280 bar Relief Valve
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Figure 166 Location of the 280 bar outrigger pressure relief valve. (Hoses removed for clarity).
Gauge port Figure 167 Showing the agitator handvalve and gauge port. (Diamond plate removed for this illustration.)
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Relief valve on this side (not visible from this angle).
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Pressure Settings
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Figure 168 The agitator shutoff valve
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6. If adjustment is needed, put your wrench on the body of the relief valve, which is located on the back of the agitator handvalve. While reading the gauge, turn the body in to raise pressure, or out to lower pressure until 200 bar is achieved. 7. Put the agitator handle in neutral. 8. Remove the whip hose and pressure gauge. Replace the gauge port cover. 9. Replace the aluminum diamond plate over the agitator handvalve.
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32 XL Hi-Flow B&W
Pressure Settings
off, and the key in your pocket, remove the plug (item 2). The oil should be at the level of the bottom of the hole in the case. If oil is needed, add by removing the breather (item 1) and pouring in through the top. This gearcase uses 90W gearlube.
Units up to 450 l/m •
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Check the fluid level of the distribution gearcase. (See Figure 153). Be sure the truck is on reasonably level ground. With the truck engine
Breather filter 1 filler spout
Drain plug
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4194 gearcase scan.eps
Oil check plug
Figure 169 Check, drain and fill ports of the Stiebel 4194 gearcase. •
Check the mounting hardware of the subframe, the oil and water tanks, the delivery pipeline, the pumpkit, the differential cylinders, the material cylinders and the driveline hardware. Check for bolt tightness, cracks and other abnormalities.
Check hydraulic pressures •
Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components. Pressure settings must be made with the oil at normal operating temperatures (40° to 60° C).The specifications for all circuit pressures are found on the hydraulic schematics in the appendix section of this manual.
Preheat the hydraulic oil
• To heat the oil to operating temperature: 1. Locate the agitator shutoff valve and close it. There is a picture of the location on page 6-362. Note! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and
part number 30303432 (tube). Contact Schwing’s Service Department at (651) 429-0999 for installation instructions. 2. Turn on the agitator. The agitator will not be able to turn, and the oil will be forced over the relief valve. 3. At an idle (approx. 600 rpm), about 5.4 horsepower is being converted to heat. Shut off the agitator when the temperature gauge on the rear control panel shows 40° C. Don’t forget to open the shutoff valve when the procedure is finished.
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Pressure Settings Location of pressure setting/checking devices
eral location of the devices needed to check pressures on the concrete pump, boom, and outriggers,
See Figure 170. The illustration below shows the gen-
Boom control block
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E-Stop manifold Soft Switch ball cock
Agitator control valve
FWD
Driver's side outrigger controls
REV
Outrigger pushbutton
CONCRETE PUMP
Ball cock (quarter-turn valve)
Outrigger pushbutton Passenger side outrigger controls
Control panel
Agitator shutoff valve
Figure 170 Location of the pressure setting devices
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Check the concrete pump pressure (2020, 2023, 2525 pumpkits) •
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Pressure Settings
model. This means that we cannot simply list a pressure specification for all units. The correct pressure specifications for your unit are shown on the hydraulic schematic in section 7 of this manual..
Because the Hi-flo pumpkits have the ability to create high pressure on the concrete the pressure settings have to be tailored specifically for each
Gauge port
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Figure 171 Location of the concrete pump circuit main relief valve and soft switch relief valve
To check or set the concrete pump pressure adjustments, follow these steps: 1. Wear safety glasses when checking or setting pressures. 2. Be sure that the waterbox covers and guards are installed on the waterbox. Use of the remote control box for the following pressure setting procedure is NOT recommended. 3. Start the truck engine, and put the PTO and transmission into gear just as you would to pump a job. 4. See figures 219, 173, and 174. Locate and close the concrete pump shutoff valve, and the soft switch shutoff valve. (These valves are also known as quarter turn valves).
5. Install a 0 - 400 or 0 - 600 bar gauge in the gauge port. 6. Put the rear control panel switch “remote / local” into the “local” position. 7. Be sure that all emergency stop switches are in the up (not activated) position. Reset the e-stop circuit. 8. Using the switch on the rear control panel, rev the truck engine up to full RPM. 9. Put the concrete pump “forward / neutral / reverse” switch on the rear control panel into the “forward” position. The unit will stroke no more than once, then the rock cylinder will retract. Oil leaving the hydraulic pumps will be blocked in the brain. This is called high-pressuring the concrete pump.
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Pressure Settings
Soft switch shutoff valve
Concrete pump shutoff valve hif lob r2. ep s
Figure 172 Showing the concrete pump and soft switch shutoff valves
Groove lined up with ports - open grooves.eps
Groove at 90° to ports - closed
Figure 173 Orientation of the concrete pump shutoff valve open/closed positions 10. Read the pressure on the gauge. Pressure shown on the gauge should be the same as the specification for the concrete pump circuit on the hydraulic schematic. Return the pump control to “neutral” whether the pressure needs adjustment or not. If no adjustment is needed, skip to step (5.) on page 6352. If adjustment is needed, proceed to step (1.).
Setting the main relief valve The main relief valve is the primary pressure control device on units equipped with Rexroth A7VO hydraulic pumps. CAUTION! The main relief valve is set to very high pressure (at least 350 bar). Use the rear control panel switch when checking the pressure of the main relief
valve so you will be out of the way if a hose or fitting blows. See Figure 174. If the main relief valve needs adjustment, proceed as follows: 1. Always wear eye protection when checking or setting pressures. 2. Using a 9/16” spanner wrench, loosen the jam nut on the main relief valve adjusting screw (Figure 174). 3. Insert a 5/32” Allen wrench in the adjustment screw. Turn the screw in to raise pressure, out to lower the pressure. Always go back to the rear panel before checking the pressure.
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open Main relief valve Soft switch relief valve Figure 174 Orientation of the soft switch valve open/closed positions
4. Once the pressure is correct to the hydraulic schematic, retighten the jam nut. Tightening the nut tends to raise the pressure, so check pressure again after tightening. 5. If you will not be setting the soft switch pressure, open the shutoff valves. The unit will not stroke with closed shutoff valves.
Setting the soft switch circuit relief pressure •
To check or adjust the soft switch pressure setting, proceed as follows: 1. Open the soft switch shutoff valve, as shown in figure 174. The rest of the unit should still be set up as though you were going to check concrete pump pressure. 2. High pressure the concrete pump. The pressure gauge should read 60 or 80 bar (check your schematic). If adjustment is needed, proceed to step (3), below. If no adjustment is needed, skip to step (.). 3. Loosen the jam nut on the soft switch relief valve with a 9/16” spanner wrench. Adjust the pressure up or down, as needed, using a 5/32” Allen wrench. When the correct pressure is achieved, re-lock the jam nut.
4. Be sure to open the concrete pump shutoff valve on the side of the brain (shown in Figure 175) when you are finished. The unit cannot stroke with this valve closed.
Setting the boom pressures (7 place black and white circuit) If your unit has a black and white boom system, it will have different pressure adjustments than if it is equipped with a loadsensing proportional system. The following instructions are for black and white systems. If you have a proportional unit, contact Schwing American’s Service Department at (651) 429-0999 for correct instructions. To set the 300 bar boom circuit relief valve proceed as follows: (See Figure 176) 1. The boom must be raised and rotated 180° for this procedure, so you must set the outriggers as you would to pump a job. Be sure that you set up well away from electrical wires and other obstructions. 2. Once the outriggers are set, unlock the boom strap, and raise the #1 boom far enough that you won’t hit anything on the truck. Leave the rest of the boom folded. Rotate the boom so that you have safe and easy access to the boom control valves. 3. Remove the control block cover, held on by 2 M6 screws.
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Main relief valve Soft switch relief valve
Figure 175 Location of the main relief valve
4. Install the whip hose of a 0 - 400 or 0 - 600 bar gauge in the 300 bar gauge port (see Figure 177). 5. Assuming that your boom is completely folded up (except for #1), select a handle, and retract #2, #3 or #4 section. Do NOT use #1 retract, slewing left right, outrigger, water pump, or any extend function. (Again, when you try to retract a fully retracted cylinder, the oil has no where to go except over the relief valve; this allows the relief valve setting to be read on a gauge). Read the pressure on the whip gauge that you installed in step 4, above. It should read 300 bar. If no adjustment is necessary, skip to step 8. 6. If adjustment is needed, put your wrench on the 300 bar relief valve at the back of the boom control valve bank. While you are holding the function in retract mode, adjust the cartridge in or out until the pressure reads 300 bar.
7. If you cannot achieve 300 bar, it is possible that there is a problem with the emergency stop manifold (see Figure 178). You can plumb the malfunctioning circuit out of the system to test it. Use only approved hydraulic dead plugs to plug the inlet hose to the malfunctioning circuit. If pressure can now be achieved, the e-stop manifold is the source of the problem. Contact Schwing America’s Service Department for advice on repair of the e-stop manifold. Repair the e-stop manifold before using the unit again. Remember, the emergency stop switches do nothing if the e-stop manifold is plumbed out of the system.
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7plcpres.eps
140 bar port
Use #2, 3, or 4
140 bar relief
300 bar port
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SLEWING
DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
AIR / WATER
BOOM / OUTRIG.
WARNING SAFETY
MANUAL
Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
Figure 176 Showing the location of the boom circuit pressure devices. (Hoses removed for clarity.)
Higher
300 bar Relief Valve
Turn body of valve to adjust. Lower
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Figure 177 Location of the boom relief valve
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Pressure Settings 8. Remove the whip hose from the 300 bar gauge port. Before folding up the boom, proceed to the instructions for setting the 140 bar down side relief valve on page 318.
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Boom/outrigger circuit dump valve
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Boom override button
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Boom/outrigger inlet port Figure 178 Emergency stop manifold
Setting the 140 bar down side relief valve pressure Set the pressure of the 140 bar down side relief valve. This valve is a secondary relief valve for #1 cylinder retract function. Proper adjustment ensures that the #1 boom and the A-frame won’t be damaged by putting the boom in the cradle. (See figure 179.) To adjust this valve (requires a 2.5 mm Allen wrench and a standard screwdriver): 1. Install a 0 - 400 bar or 0 - 600 bar gauge into the 140 bar gauge port (shown in Figure 146). 2. Unfold the #2 section from #1 until it is straight. For the following procedure we must bring #1 all the way down until the cylinder bottoms out. Position the boom so this can be done without hitting the truck or any other obstacle.
3. Bring #1 down until the cylinder is completely bottomed out. The cylinder does NOT bottom out if you are setting the folded boom into the A-frame (travel position). 4. Activate the #1 down (retract) handvalve The boom will not be able to move because the cylinder is already bottomed out. Read the pressure on the gauge that you just installed. It should read 140 bar. If no adjustment is necessary, skip to step 6. 5. If adjustment is needed, loosen the set screw of the 140 bar relief valve with the 2.5 mm Allen wrench. While you activate #1 down, adjust the relief cartridge with the screwdriver until the pressure reads just under 140 bar. Retightening the set screw will raise the pressure slightly. Recheck the pressure, and readjust if needed.
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6. When the pressure is set at 140 bar with the set screw tight, you can remove the whip hose gauge and replace the cap on the gauge port.
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Pressure Settings
7. The boom pressure setting sequence is complete. If you are done with the boom, slew it back into the transport position, and lower #1 into the cradle. Reattach the boom strap.
7plc140.eps
140 bar gauge port
140 bar relief valve SECTION 1
SECTION 2
SECTION 3
SECTION 4
SLEWING
DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
AIR / WATER
BOOM / OUTRIG.
WARNING SAFETY
MANUAL
Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
Figure 179 location of the 140 bar relief valve and gauge port
Setting the outrigger pressures (7 place boom valve systems) After the boom pressures are set, you can set the outrigger pressure. • In this system, the boom, outriggers, water pump, and compressor circuits have all been put together in the boom valve manifold. (See Figure 227). When the outrigger selector pushbutton is activated, the outrigger valve routes oil to the two outrigger handvalve banks, one on each side of the unit. A relief valve inside the passenger side bank limits the entire outrigger circuit to 280 bar (4060 PSI) instead of the 300 bar (4350 PSI) of the boom relief valve. • To set the 280 bar relief valve for the outrigger circuit: (See Figure 182).
1. Wear safety glasses whenever you check or set pressures.
2. Plug the whip hose of a 0 - 400 or 0 - 600 bar gauge into the gauge port. Location is shown in figure 227. 3. If not already done, start the truck engine and set the transmission and PTO as you would for a pumping job. 4. Locate the 280 bar relief valve on the back of the outrigger valve, as shown in Figure 228. 5. Set the engine RPM to maximum. 6. Select “outrigger” with the outrigger pushbutton. This will route oil to the outrigger handvalves. 7. Assuming that the outriggers are folded into the travel position, activate the passenger side handvalve “jacking cylinder retract” for either the front or rear outrigger. Note! You will get an incorrect reading if you select “extension cylinder retract” by mistake. If you select “extend” by mistake, the outriggers will extend instead of reading the relief valve setting. The handles are spring loaded and will return to neutral as soon as you let go.
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Pressure Settings
7plcORhndl.eps
Outrigger handle
Gauge port
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SLEWING
DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
AIR / WATER
BOOM / OUTRIG.
WARNING SAFETY
MANUAL
Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
Figure 180 Position of the outrigger selector valve
32Porct5.eps
REAR EXTEND
FRONT EXTEND
REAR FOOT
FRONT FOOT
Figure 181 Location of the passenger side outrigger control block
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SERVICE TRAINING
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Pressure Settings
280 bar Relief Valve
Lower
PS
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Higher
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Turn body of valve to adjust. Figure 182 Location of the outrigger relief valve 8. Read the pressure on the gauge. It should read 280 bar (4060 PSI). If no adjustment is needed, skip to step 4. 9. If adjustment is needed, turn the outside body of the relief valve that is located at the back of the outrigger valve. Turn in to raise pressure, turn out to lower pressure. There is no jam nut on this valve. 10. Activate the outrigger “jacking retract” handvalve and read the pressure on the gauge again. Repeat steps 8. and 9. until the gauge reads 280 bar. 11. When the pressure is correct, either go on to other pressure settings, or remove the whip hose and gauge, and cap the gauge port with the attached cap. 12. Return the RPM of the truck to an idle, take the transmission and PTO out of gear, and shut off the truck, or go on to the other pressure settings, as required.
To set the agitator circuit pressure: The agitator relief valve is located in the agitator forward / neutral / reverse handvalve, at the rear of the unit on the driver’s side. The relief valve limits the pressure in the agitator circuit to 200 bar (2900 PSI). (See Figure 183). There is a gauge port for checking or setting the pressure in this circuit. The port is located on the agitator handvalve. To check or set the agitator pressure, follow these steps: 1. Remove the aluminum diamond plate cover from over the agitator handvalve.
2. Unscrew the cover from the gauge port. Plug in the 0 - 600 bar gauge and whip hose that came in the toolbox. 3. Start the engine, if not already running. 4. Close the agitator shutoff valve. (See Figure 184.) Note! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and part number 30303432 (tube). Contact Schwing’s Service Dept. for installation instructions. 5. Activate the agitator in forward. Read the pressure on the gauge. 6. If adjustment is needed, put your wrench on the body of the relief valve, which is located on the back of the agitator handvalve. While reading the gauge, turn the body in to raise pressure, or out to lower pressure until 200 bar is achieved. 7. Put the agitator handle in neutral. 8. Remove the whip hose and pressure gauge. Replace the gauge port cover. 9. Replace the aluminum diamond plate over the agitator handvalve.
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agitator pressure check.eps L
Pressure Settings
Relief valve on this side (not visible from this angle).
Gauge port
Figure 183 Showing the agitator handvalve and gauge port. (Diamond plate removed for this illustration.)
ag its o. ep s
closed
open
Figure 184 The agitator shutoff valve
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SERVICE TRAINING
32 XL High Flow Proportional
Pressure Settings
engine off, and the key in your pocket, remove the plug (item 2). The oil should be at the level of the bottom of the hole in the case. If oil is needed, add by removing the breather (item 1) and pouring in through the top. This gearcase uses 90W gearlube.
Units up to 450 l/m 5.3-6
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Check the fluid level of the distribution gearcase. (See Figure 185). Be sure the truck is on reasonably level ground. With the truck
1
2 4194.e ps
Figure 185 Check, drain and fill ports of the Stiebel 4194 gearcase •
Check the mounting hardware of the subframe, the oil and water tanks, the delivery pipeline, the pumpkit, the differential cylinders, the material cylinders and the driveline hardware. Check for bolt tightness, cracks and other abnormalities.
Check hydraulic pressures •
Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components. Pressure settings must be made with the oil at normal operating temperatures (40° to 60° C).The specifications for all circuit pressures are found on the hydraulic schematics in the appendix section of this manual.
Preheat the hydraulic oil
•
Because of the new load sensing and pressure cutoff regulated hydraulic systems, you can’t use the concrete pump or boom circuit to preheat the hydraulic oil (they stop putting out oil if you try). To heat the oil to operating temperature:
1. Locate the agitator shutoff valve and close it. There is a picture of the location on page 6-362. Note! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and part number 30303432 (tube). Contact Schwing’s Service Department at (651) 429-0999 for installation instructions. 2. Turn on the agitator. The agitator will not be able to turn, and the oil will be forced over the relief valve. 3. At an idle (approx. 600 rpm), about 5.4 horsepower is being converted to heat. Shut off the agitator when the temperature gauge on the rear control panel shows 40° C. Don’t forget to open the shutoff valve when the procedure is finished.
Check the concrete pump pressure (2020, 2023, 2525 pumpkits) •
Because the Hi-flow pumpkits have the ability to create high pressure on the concrete the pressure settings have to be tailored specifically for each model. This means that we cannot simply list a
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Pressure Settings pressure specification for all units. The correct pressure specifications for your unit are shown on the hydraulic schematic in Section 7 of this
manual. (See Figure 218).
Gauge port
Hif
lrv
vw
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Main relief valve Soft switch relief valve
Figure 186 Location of the concrete pump circuit main relief valve and soft switch relief valve
To check or set the concrete pump pressure adjustments, follow these steps: 1. Wear safety glasses when checking or setting pressures. 2. Be sure that the waterbox covers and guards are installed on the waterbox. Use of the remote control box for the following pressure setting procedure is NOT recommended. 3. Start the truck engine, and put the PTO and transmission into gear just as you would to pump a job. 4. See Figure 186. Locate and close the concrete pump shutoff valve, and the soft switch shutoff valve. (These valves are also known as quarter turn valves). 5. Install a 0 - 400 or 0 - 600 bar gauge in the gauge port. 6. Put the rear control panel switch “remote / local” into the “local” position. 7. Be sure that all emergency stop switches are in the up (not activated) position. Reset the e-stop circuit. 8. Using the switch on the rear control panel, rev the truck engine up to full RPM.
9. Put the concrete pump “forward / neutral / reverse” switch on the rear control panel into the “forward” position. The unit will stroke no more than once, then the rock cylinder will retract. Oil leaving the hydraulic pumps will be blocked in the brain. This is called high-pressuring the concrete pump. 10. Read the pressure on the gauge. Pressure should read as shown for the concrete pump circuit main relief valve setting on the hydraulic schematic. Return the pump control to “neutral” whether the pressure needs adjustment or not. If no adjustment is needed, skip to step (5.) on page 6-352. If adjustment is needed, proceed to step (1.).
Setting the main relief valve The main relief valve is the primary pressure control device on units equipped with Rexroth A7VO hydraulic pumps. CAUTION! The main relief valve is set to very high pressure (at least 350 bar). Use the rear control panel switch when checking the pressure of the main relief valve so you will be out of the way if a hose or fitting blows. See Figure 103. If the main relief valve needs adjustment, proceed as follows:
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SERVICE TRAINING
Pressure Settings
Figure 187 Showing the concrete pump and soft switch shutoff
closed
Groove lined up with ports - open
open grooves.eps
Groove at 90° to ports - closed op
n-c
lsd
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Figure 188 Shutoff valve open / closed orientation
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Pressure Settings
Gauge port
Hif
lrv
vw
.ep
s
Main relief valve Soft switch relief valve
Figure 189 Location of the main relief valve
1. Wear safety glasses when checking or adjusting pressures. 2. Using a 9/16” spanner wrench, loosen the jam nut on the main relief valve adjusting screw (Figure 189). 3. Insert a 5/32” allen wrench in the adjustment screw. Turn the screw in to raise pressure, out to lower the pressure. Always go back to the rear panel before checking the pressure. 4. Once the pressure is correct to the hydraulic schematic, retighten the jam nut. Tightening the nut tends to raise the pressure, so check pressure again after tightening. Don’t forget to turn the pressure cut-off adjustment screws back out 1 turn each and verify the correct pressure setting before unplugging the gauge. 5. If you will not be setting the soft switch pressure, open the shutoff valves. The unit will not stroke with closed shutoff valves.
Setting the soft switch circuit relief pressure •
To check or adjust the soft switch pressure setting, proceed as follows:
1. Open the soft switch shutoff valve, as shown in Figure 188. The rest of the unit should still be set up as though you were going to check concrete pump pressure. 2. High pressure the concrete pump. The pressure gauge should read 60 or 80 bar (check your schematic). If adjustment is needed, proceed to step (), below. If no adjustment is needed, skip to step (.). 3. Loosen the jam nut on the soft switch relief valve with a 9/16” spanner wrench. Adjust the pressure up or down, as needed, using a 5/32” Allen wrench. When the correct pressure is achieved, re-lock the jam nut. 4. Be sure to open the concrete pump shutoff valve on the side of the brain (shown in Figure 188) when you are finished. The unit cannot stroke with this valve closed.
Load-sensing boom pressures (7 place proportional circuit) If your unit has a loadsensing proportional system, it will have different pressure adjustments than if it is equipped with a black and white boom system. The following instructions are for load-sensing proportional systems. If you have a unit equipped with a black and white boom system, contact Schwing Service for the correct instruction pages.
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SERVICE TRAINING Preheat the oil
About proportional boom systems
In a black and white boom system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the
Q-min adjustment screw
P regulator
CONCRETE PUMP
FWD
32
XL
loc
.ep
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REV
Figure 190 Locations of components used to check and set boom pressures
Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when checking or setting pressures.
Setting ∆P Note! Do not adjust ∆P or Q-min if your boom is running as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned from there. It was fine tuned at the factory, and should not be adjusted unless absolutely necessary. • You must not adjust Q-min with the drive shafts turning! Each time the Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning. To check or set ∆P, follow these steps: 1. Stop the truck engine and place a “Do Not Operate” sign on the truck windshield. 2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar gauge port of the manual boom handvalves. Take care not to accidently install the gauge in the 0-60 bar port. (See Figure 191.)
Pressure Settings
system. Generally, the pump puts out enough oil to maintain a 20 bar higher pressure at the pump than what the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting Q-min and ∆P. See figure 192.
Note! Whenever you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (40° - 60° C). Instructions for heating the hydraulic oil are found in section on page 351.
Manual boom handvalves
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E-Stop manifold
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Pressure Settings
140 bar gauge port (use 0-400 bar gauge when checking)
140 bar downside relief cartridge
0-400 bar gauge port
0-60 bar gauge port boom control block relief valve s
ep dv.
itpr
ap
15 bar pretension adjustment screw
Figure 191 Location of the boom circuit pressure devices (Hoses removed for clarity.) boom or outrigger functions, you will damage the 0 - 40 bar gauge. Make sure that all emergency stop switches are in the up (not activated) position. Pressure can be read on the 0 40 bar gauge that you installed. Pressure should read 20 bar. If no adjustment is needed, simply reset the Q-min screw as described in . If adjustment is needed, continue to step (2.).
3. To be sure that the pump is putting out only enough oil needed to maintain ∆P, we need to change the setting of the Q-min screw. Q-min is adjusted by a screw on the boom hydraulic pump (see Figure 192). Unscrew the Q-min screw three full turns. Check that all personnel are clear of the truck, then restart the engine, engage the pumps, and leave the engine at an idle. CAUTION! If you activate any Q-min adjustment screw
Q-minscrew.eps
Q-max
Figure 192 Location of the Q-min adjustment screw 4. Delta P is adjusted by the ∆P screw on the ∆P regulator (see Figure 193). Loosen the jam nut and adjust the screw inward to increase pressure, or
outward to decrease pressure until it is set at 20 bar (±1). Contact Schwing America’s Service Department if you are unable to adjust the pressure
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SERVICE TRAINING
to spec. NOTE! If the boom is not smooth at 20 bar, you must fine tune the adjustment. In that case, REMOVE THE GAUGE, and adjust ∆P until the boom is responsive and smooth. When done, the gauge (reinstalled) must read between 14 and 25 bar. The electronics in the control system can also
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Pressure Settings
affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 20 bar and check the electrical settings. Once electrical settings are verified, you could again refine the boom action with the ∆P adjustment.
CAUTION Do not operate any functions while setting ∆P.
deltaPvlv.eps
∆P adjustment screw
T
Figure 193 The ∆P regulator valve
Setting Q-min
Setting boom pressures
•
(Load sensing proportional booms.) Now that ∆P and Q-min are set, you can check or set the boom valve pressures. • There are three pressure settings on the boom circuit: (see Figure 194) 1. Pressure regulator (the high-pressure adjustment screw on the ∆P regulator valve), set at 300 bar. 2. The redundant relief valve located in the emergency stop manifold, set at 330 bar.
1.
2.
3.
4.
5.
You must check Q-min pressure when the engine is at the maximum specified RPM, but you must adjust it with the engine stopped. If you unscrewed the Q-min screw as the first step of ∆P adjustment, begin by returning the screw to its original position (see Figure 192). Remove the 0 - 40 bar gauge from the 0 - 400 bar gauge port, and install the 0 - 600 bar gauge in its place. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to max. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). Read the pressure on the 0 - 600 gauge. Pressure should be at 40 - 45 bar. If no adjustment is needed, stop the drivelines from turning, be sure the jam nut on the Q-min screw is tight, then continue to paragraph to check the rest of the boom and outrigger pressures. If adjustment is needed, continue to step (5.). Turn the Q-min screw in to raise the pressure (Figure 192). Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures.
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Pressure Settings
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3. The boom control block relief valve, set at 350 bar. NOTE! This relief valve is nonadjustable. If pressure is not maintained with the specification limits, the valve must be replaced.
Redundant relief valve
High pressure adjustment screw T
MP
1
10
16
78
92
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P2
P3
P4
P1
M
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0-400 bar gauge port 0-60 bar gauge port
ap
•
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boom control block relief valve
To check the setting of the valve with the highest pressure, you must first raise the pressure of the lower two: 4. Loosen the jam nut of the high pressure adjustment screw of the ∆P regulator. Turn the screw in twoand-a-half turns. This will raise the pressure on the regulator above 350 bar. 5. Loosen the jam nut of the adjustment screw of the redundant relief valve in the emergency stop manifold. Turn the screw in one-and-a-half turns. This will raise the pressure setting of the relief valve to above 350 bar. 6. Pressure out any boom cylinder except #1 down by pushing or pulling the control handle. To pressure out a cylinder, retract a fully retracted cylinder or extend a fully extended cylinder. The oil is forced
Figure 194 The three boom pressure devices
over the relief valve. The telltale hiss of an open relief valve should be coming from the Apitech control block relief valve now. If it isn’t, raise the setting of the other pressure devices until the hiss originates at the Apitech control block relief valve. Read the pressure on the gauge. It should read 350 bar. If pressure is correct, proceed to step (4.). NOTE! Although the pressure specification for the Apitech relief valve is 350 bar, you may continue to use the relief valve as long as the cartridge maintains at least 330 bar. If you must replace the valve, proceed to step (4.) before using the machine again, and redo this entire procedure
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SERVICE TRAINING
when you have installed the new valve. If pressure on the Apitech relief valve is below 290 bar, you should not use the machine until the valve is replaced. 7. Screw out the e-stop manifold redundant relief valve adjustment screw one-and-a-half turns. Pressure out any boom cylinder except #1 down, and read the gauge. Pressure should read 330 bar. If it does not, turn the screw in to raise pressure, or out to lower pressure until it is set at 330 bar. If the location of this valve causes you to be near the drivelines, be sure to stop them from turning before accessing the valve. 8. You will need a helper for this step. While pressuring out any boom cylinder except #1 down, have your helper adjust the high pressure screw of the ∆P regulator out (lowering the pressure) until the gauge reads 300 bar. Release the pressurized function and lock the jam nut. The boom pressures are now set. If you did not get the readings specified after following the instructions, contact Schwing America’s Service Department at (651) 429-0999 for advice on how to continue.
Setting the 140 bar down side relief valve pressure Set the pressure of the 140 bar down side relief valve. This valve is a secondary relief valve for #1 cylinder retract function. Proper adjustment ensures that the #1 boom and the A-frame won’t be damaged by putting the boom in the cradle. (See figure 195.) To adjust this valve (requires a 2.5 mm Allen wrench and a standard screwdriver): 1. Install a 0 - 400 bar or 0 - 600 bar gauge into the 140 bar gauge port (shown in Figure 195). 2. Unfold the #2 section from #1 until it is straight. For the following procedure we must bring #1 all the way down until the cylinder bottoms out. Position the boom so this can be done without hitting the truck or any other obstacle. 3. Bring #1 down until the cylinder is completely bottomed out. The cylinder does NOT bottom out if you are setting the folded boom into the A-frame (travel position). 4. Activate the #1 down (retract) handvalve The boom will not be able to move because the cylinder is already bottomed out. Read the pressure on the gauge that you just installed. It should read 140 bar. If no adjustment is necessary, skip to step 6.
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Pressure Settings
5. If adjustment is needed, loosen the set screw of the 140 bar relief valve with the 2.5 mm allen wrench. While you activate #1 down, adjust the relief cartridge with the screwdriver until the pressure reads just under 140 bar. Retightening the set screw will raise the pressure slightly. Recheck the pressure, and readjust if needed. 6. When the pressure is set at 140 bar with the set screw tight, you can remove the whip hose gauge and replace the cap on the gauge port. 7. The boom pressure setting sequence is complete. If you are done with the boom, slew it back into the transport position, and lower #1 into the cradle. Reattach the boom strap.
Setting the outrigger pressures After the boom pressures are set, you can set the outrigger pressure. • In this system, the boom, outriggers, water pump, and compressor circuits have all been put together in the boom valve manifold. (See Figure 227). When the outrigger selector pushbutton is activated, the outrigger valve routes oil to the two outrigger handvalve banks, one on each side of the unit. A relief valve inside the passenger side bank limits the entire outrigger circuit to 280 bar (4060 PSI) instead of the 300 bar (4350 PSI) of the boom relief valve. • To set the 280 bar relief valve for the outrigger circuit: (See Figure 227 & Figure 228).
1. Wear safety glasses whenever you check or set pressures. 2. Plug the whip hose of a 0-400 or 0-600 bar gauge into the gauge port. Location is shown as item 1 in figure 227. 3. If not already done, start the truck engine and set the transmission and PTO as you would for a pumping job. 4. Locate the 280 bar relief valve on the back of the outrigger valve, as shown in Figure 197. 5. Set the engine RPM to maximum. 6. Select “outrigger” with the outrigger pushbutton. This will route oil to the outrigger handvalves.
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Pressure Settings
140 bar gauge port
140 bar relief valve
ap
it14
0.e
ps
Figure 195 Location of the 140 bar relief valve and gauge port
1 Gauge port
s
.ep
hd
itor
ap
Outrigger handle
Figure 196 Position of the outrigger selector valve on units equipped with Apitech proportional valves
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SERVICE TRAINING
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Pressure Settings
280 bar Relief Valve
Lower
32Porct5.eps
PS
oc
Higher
bb
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Turn body of valve to adjust.
REAR EXTEND
FRONT EXTEND
REAR FOOT
FRONT FOOT
Figure 197 Location of the 280 bar outrigger pressure relief valve. (Hoses removed for clarity).
7. Assuming that the outriggers are folded into the travel position, activate the passenger side handvalve “jacking cylinder retract” for either the front or rear outrigger. Note! You will get an incorrect reading if you select “extension cylinder retract” by mistake. If you select “extend” by mistake, the outriggers will extend instead of reading the relief valve setting. The handles are spring loaded and will return to neutral as soon as you let go. 8. Read the pressure on the gauge. It should read 280 bar (4060 PSI). If no adjustment is needed, skip to step 4. 9. If adjustment is needed, turn the outside body of the relief valve that is located at the back of the outrigger valve. Turn in to raise pressure, turn out to lower pressure. There is no jam nut on this valve. 10. Activate the outrigger “jacking retract” handvalve and read the pressure on the gauge again. Repeat steps 8. and 9. until the gauge reads 280 bar.
11. When the pressure is correct, either go on to other pressure settings, or remove the whip hose and gauge, and cap the gauge port with the attached cap. 12. Return the RPM of the truck to an idle, take the transmission and PTO out of gear, and shut off the truck, or go on to the other pressure settings, as required.
Setting the water pump hyd. pressure With a seven place handvalve, the water pump hydraulic control is inside the boom control block. There is not a separate relief for this circuit, and therefore nothing that must be set.
Setting 15 bar pretension • To check or set pretension, follow these steps: 1. Stop the truck engine. Plug the 0 - 40 bar gauge into the pretension check port of the Apitech handvalve (Figure 195). 2. Start the truck engine, but leave it at an idle. (Pretension adjustment is made at an idle to establish the minimum pressure setting. As RPM is
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Pressure Settings
CAUTION Truck engine must be at an idle while setting pretension.
increased, pressure will rise. Damage to the 0 - 40 bar gauge is possible if RPM is raised while the gauge is connected.)
3. Read the pressure on the gauge. If it reads 15 bar ± 1 bar, the pressure is set correctly. If adjustment is needed, proceed to step (4.).
Pretension gauge port
s
.ep
rtn
itp
ap
Pretension adjustment screw Figure 198 Pretension adjustment screw and gauge port 4. Loosen the jam nut on the pretension valve. Turn the screw in to raise pressure, and out to lower pressure. When the pressure is correct, retighten the jam nut. 5. Stop the engine, and remove the 0 - 40 bar gauge. Pretension setting is complete.
To set the agitator circuit pressure: The agitator relief valve is located in the agitator forward / neutral / reverse handvalve, at the rear of the unit on the driver’s side. The relief valve limits the pressure in the agitator circuit to 200 bar (2900 PSI). (See Figure 199). There is a gauge port for checking or setting the pressure in this circuit. The port is located on the agitator handvalve. To check or set the agitator pressure, follow these steps: 1. Remove the aluminum diamond plate cover from over the agitator handvalve.
2. Unscrew the cover from the gauge port. Plug in the 0-600 bar gauge and whip hose that came in the toolbox. 3. Start the engine, if not already running. 4. Close the agitator shutoff valve. (See Figure 200.) Note! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and part number 30303432 (tube). Contact Schwing America’s Service Department at (651) 429-0999 for installation instructions. 5. Activate the agitator in forward. Read the pressure on the gauge. 6. If adjustment is needed, put your wrench on the body of the relief valve, which is located on the back of the agitator handvalve. While reading the gauge, turn the body in to raise pressure, or out to lower pressure until 200 bar is achieved. 7. Put the agitator handle in neutral. 8. Remove the whip hose and pressure gauge. Replace the gauge port cover.
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agitator pressure check.eps L
SERVICE TRAINING
Gauge port
Pressure Settings
Relief valve on this side (not visible from this angle).
Figure 199 Showing the agitator handvalve and gauge port. (Diamond plate removed for this illustration.)
ag its o. ep s
closed
Figure 200 The agitator shutoff valve
open
9. Replace the aluminum diamond plate over the agitator handvalve.
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Pressure Settings
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SERVICE TRAINING
32 XL Hi-Flow Prop, A11VO Units above 450 l/m (-5 and -6 units) •
Check the fluid level of the distribution gearcase. (See Figure 201). Be sure the truck is on reasonably level ground. With the truck engine Breather / filler
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Pressure Settings
off, and the key in your pocket, remove the plug (item 2). The oil should be at the level of the bottom of the hole in the case. If oil is needed, add by removing the breather (item 1) and pouring in through the top. This gearcase uses 90W gearlube.
TOP VIEW
Spline flange breather/filler
grbx-5-6.eps
Check port
Oil check plug inlinoil.eps
Drain port
•
Check the mounting hardware of the subframe, the oil and water tanks, the delivery pipeline, the pumpkit, the differential cylinders, the material cylinders and the driveline hardware. Check for bolt tightness, cracks and other abnormalities.
Check hydraulic pressures •
Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components. Pressure settings must be made with the oil at normal operating temperatures (40° to 60° C).The specifications for all circuit pressures are found on the hydraulic schematics in the appendix section of this manual.
Preheat the hydraulic oil •
Because of the new load sensing and pressure cutoff regulated hydraulic systems, you can’t use the concrete pump or boom circuit to preheat the hydraulic oil (they stop putting out oil if you try). To heat the oil to operating temperature: 1. Locate the agitator shutoff valve and close it. There is a picture of the location on page 6-362. Note! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and
Figure 201 Check, drain and fill ports of the Stiebel gearcase. Main ports (left illustration) Spline flange ports (right illustration) part number 30303432 (tube). Contact Schwing’s Service Department at (651) 429-0999 for installation instructions. 2. Turn on the agitator. The agitator will not be able to turn, and the oil will be forced over the relief valve. 3. At an idle (approx. 600 rpm), about 5.4 horsepower is being converted to heat. Shut off the agitator when the temperature gauge on the rear control panel shows 40° C. Don’t forget to open the shutoff valve when the procedure is finished.
Check the concrete pump pressure (2020, 2023, 2525 pumpkits) Because the Hi-flow pumpkits have the ability to create high pressure on the concrete the pressure settings have to be tailored specifically for each model. This means that we cannot simply list a pressure specification for all units. The correct pressure specifications for your unit are shown on the hydraulic schematic in section 7 of this manual. (See Figure 218). Additionally, the pressure is not limited by the main relief valve, but rather by a pressure cutoff adjustment on the concrete
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Pressure Settings pump circuit hydraulic pumps. To check or set the concrete pump pressure adjustments, follow these steps:
Gauge port
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Main relief valve Soft switch relief valve
Figure 202 Location of the concrete pump circuit main relief valve and soft switch relief
1. Wear safety glasses when checking or setting pressures. 2. Be sure that the waterbox covers and guards are installed on the waterbox. Use of the remote control box for the following pressure setting procedure is NOT recommended. 3. Start the truck engine, and put the PTO and transmission into gear just as you would to pump a job. 4. See Figure 219. Locate and close the concrete pump shutoff valve, and the soft switch shutoff valve. (These valves are also known as quarter turn valves). 5. Install a 0 - 400 or 0 - 600 bar gauge in the gauge port. 6. Put the rear control panel switch “remote / local” into the “local” position. 7. Be sure that all emergency stop switches are in the up (not activated) position. Reset the e-stop circuit. 8. Using the switch on the rear control panel, rev the truck engine up to full RPM. 9. Put the concrete pump “forward / neutral / reverse” switch on the rear control panel into the “forward” position. The unit will stroke no more than once,
then the rock cylinder will retract. Oil leaving the hydraulic pumps will be blocked in the brain. This is called high-pressuring the concrete pump. 10. Read the pressure on the gauge. Pressure shown on the gauge is actually the hydraulic pump cutoff pressure, because it is set to the lowest setting. Pressure should be as shown for the concrete pump circuit hydraulic pumps on the hydraulic schematic. Return the pump control to “neutral” whether the pressure needs adjustment or not. If no adjustment is needed, skip to step (5.) on page 6352. If adjustment is needed, proceed to step (11.). 11. Shut off the truck, put the key in your pocket, and put a “Do not operate” sign on the truck windshield. 12. See Figure 204. Loosen the jam nut (13mm spanner wrench) on both pressure cutoff adjustment screws. Using a 4mm Allen wrench, turn the screw in to raise pressure, or out to lower
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Pressure Settings
Groove lined up with ports - open grooves.eps
closed
Groove at 90° to ports - closed
open
Figure 203 Showing the concrete pump and soft switch shutoff valves Soft switch and their open/closed orientation
shutoff valve
pressure. Turn the screw on each pump an equal amount. On these screws, very small adjustments make a big pressure difference. Pressure cut-off adjustment screws
A11ctoff.eps
Figure 204 Location of the pressure cutoff adjustment screws
13. Clear the area around the drivelines, then restart the truck. Repeat steps (7.) through (12.) until the pressure is as specified on the hydraulic schematic.
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Setting the main relief valve The main relief valve is not the primary pressure control device on units with Hi-flo pumpkits. CAUTION! The main relief valve is set to very high pressure (at least 350 bar). Use the rear control panel switch when checking the pressure of the main relief valve so you will be out of the way if a hose or fitting blows. Always wear eye protection when setting pressures! See Figure 103. If the main relief valve needs adjustment, proceed as follows: 1. If you ever need to check or adjust the main relief valve, you must first screw in the pressure cut-off screws on the hydraulic pumps by 1 turn each. Then, when you high pressure the concrete pump, you will be reading the setting of the main relief valve.
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Pressure Settings
Gauge port
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Main relief valve Soft switch relief valve
Figure 205 Location of the main relief valve 2. Using a 9/16” spanner wrench, loosen the jam nut on the main relief valve adjusting screw (Figure 205). 3. Insert a 5/32” allen wrench in the adjustment screw. Turn the screw in to raise pressure, out to lower the pressure. Always go back to the rear panel before checking the pressure. 4. Once the pressure is correct to the hydraulic schematic, retighten the jam nut. Tightening the nut tends to raise the pressure, so check pressure again after tightening. Don’t forget to turn the pressure cut-off adjustment screws back out 1 turn each and verify the correct pressure setting before unplugging the gauge. 5. If you will not be setting the soft switch pressure, open the shutoff valves. The unit will not stroke with closed shutoff valves.
Setting the soft switch circuit relief pressure •
To check or adjust the soft switch pressure setting, proceed as follows: 1. Open the soft switch shutoff valve, as shown in figure 203. The rest of the unit should still be set up as though you were going to check concrete pump pressure.
2. High pressure the concrete pump. The pressure gauge should read 60 or 80 bar (check your schematic). If adjustment is needed, proceed to step (), below. If no adjustment is needed, skip to step (.). 3. Loosen the jam nut on the soft switch relief valve with a 9/16” spanner wrench. Adjust the pressure up or down, as needed, using a 5/32” allen wrench. When the correct pressure is achieved, re-lock the jam nut. 4. Be sure to open the concrete pump shutoff valve on the side of the brain (shown in Figure 203) when you are finished. The unit cannot stroke with this valve closed.
Setting boom pressures (7 place proportional circuit) If your unit has a loadsensing proportional system, it will have different pressure adjustments than if it is equipped with a black and white boom system. The following instructions are for load-sensing proportional systems. If your unit is equipped with a black and white boom system, these instructions will be wrong. Contact Schwing America’s Service Department at (651) 429-0999 to obtain correct instructions.
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SERVICE TRAINING Preheat the oil
Note! Whenever you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (40° - 60° C). Instructions for heating the hydraulic oil are found in section on page 6-351. About proportional boom systems
In a black and white boom system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts Manual boom handvalves
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Pressure Settings
out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain a 20 bar higher pressure at the pump than what the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting Q-min and ∆P. See figure 222. P regulator Q-min adjustment screw
CONCRETE PUMP
REV
FWD
Figure 206 Locations of components used to check and set boom pressures
32XLHF+.eps
E-Stop manifold
Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when checking or setting pressures.
Setting ∆P Note! Do not adjust ∆P or Q-min if your boom is running as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned from there. It was fine tuned at the factory, and should not be adjusted unless absolutely necessary. • You must not adjust ∆P or Q-min with the drive shafts turning! Each time the ∆P or Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning. To check or set ∆P, follow these steps: 1. Stop the truck engine and place a “Do Not Operate” sign on the truck windshield. 2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar gauge port of the manual boom handvalves. Take care not to accidently install the gauge in the 0-60 bar port. (See Figure 207.)
3. To be sure that the pump is putting out only enough oil needed to maintain ∆P, we need to change the setting of the Q-min screw. Q-min is adjusted by a screw on the boom hydraulic pump (see Figure 207). Unscrew the Q-min screw three full turns. Check that all personnel are clear of the truck, then restart the engine, engage the pumps, and leave the engine at an idle. CAUTION! If you activate any boom or outrigger functions, you will damage the 0 - 40 bar gauge. Make sure that all emergency stop switches are in the up (not activated) position. Pressure can be read on the 0 40 bar gauge that you installed. Pressure should read 20 bar. If no adjustment is needed, simply reset the Q-min screw as described in . If adjustment is needed, continue to step (2.). 4. Delta P is adjusted by the ∆P screw on the boom pump regulator (see Figure 207). Loosen the jam nut and adjust the screw inward to increase pressure, or outward to decrease pressure until it is set at 20 bar (±1). Contact Schwing America’s Service Department if you are unable to adjust the pressure to spec. NOTE! If the boom is not smooth at 20 bar, you must fine tune the adjustment. In that case, REMOVE THE GAUGE, and adjust ∆P until the boom is responsive and smooth. When done,
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Pressure Settings and check the electrical settings. Once electrical settings are verified, you could again refine the boom action with the ∆P adjustment.
the gauge (reinstalled) must read between 14 and 25 bar. The electronics in the control system can also affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 20 bar
P adjustment screw
Pressure Cut-off adjustment screw
Q-min. adjustment screw
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Figure 207 Boom pump adjustment screws
CAUTION Do not operate any functions while setting ∆P.
140 bar gauge port (use 0-400 bar gauge when checking)
140 bar downside relief cartridge
0-400 bar gauge port
0-60 bar gauge port boom control block relief valve ps
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itpr
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15 bar pretension adjustment screw
Figure 208 Showing the location of the boom circuit pressure devices. (Hoses removed for clarity.)
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SERVICE TRAINING
Setting Q-min •
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2.
3.
4.
5.
You must check Q-min pressure when the engine is at the maximum specified RPM, but you must adjust it with the engine stopped. If you unscrewed the Q-min screw as the first step of ∆P adjustment, begin by returning the screw to its original position (see Figure 207). Remove the 0 - 40 bar gauge from the 0 - 400 bar gauge port, and install the 0 - 600 bar gauge in its place. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to max. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). Read the pressure on the 0 - 600 gauge. Pressure should be at 40 - 45 bar. If no adjustment is needed, stop the drivelines from turning, be sure the jam nut on the Q-min screw is tight, then continue to paragraph to check the rest of the boom and outrigger pressures. If adjustment is needed, continue to step (5.). Turn the Q-min screw in to raise the pressure (Figure 225). Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures.
Setting boom pressures (Load sensing proportional booms.) Now that ∆P and Q-min are set, you can check or set the boom valve pressures. • There are three pressure settings on the boom circuit: (see Figure 209) 1. Pressure regulator (the high-pressure adjustment screw on the boom hydraulic pump), set at 300 bar. 2. The redundant relief valve located in the emergency stop manifold, set at 330 bar. 3. The boom control block relief valve, set at 350 bar. NOTE! This relief valve is nonadjustable. If pressure is not maintained with the specification limits, the cartridge valve must be replaced. • To check the setting of the valve with the highest pressure, you must first raise the pressure of the lower two:
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Pressure Settings
4. With the drive shafts stopped, loosen the jam nut of the high pressure adjustment screw of the boom hydraulic pump pressure regulator. Turn the screw in two-and-a-half turns. This will raise the pressure of the regulator above 350 bar. 5. Loosen the jam nut of the adjustment screw of the redundant relief valve in the emergency stop manifold. Turn the screw in one-and-a-half turns. This will raise the pressure setting of the relief valve to above 350 bar. Pressure out any boom cylinder except #1 down by pushing or pulling the control handle. To pressure out a cylinder, retract a fully retracted cylinder or extend a fully extended cylinder. The oil is forced over the relief valve. The telltale hiss of an open relief valve should be coming from the Apitech control block relief valve now. If it isn’t, raise the setting of the other pressure devices until the hiss originates at the Apitech control block relief valve. Read the pressure on the gauge. It should read 350 bar. If pressure is correct, proceed to step (4.). NOTE! Although the pressure specification for the Apitech relief valve is 350 bar, you may continue to use the relief valve as long as the cartridge maintains at least 330 bar. If you must replace the valve, proceed to step (4.) before using the machine again, and redo this entire procedure when you have installed the new valve. If pressure on the Apitech relief valve is below 290 bar, you should not use the machine until the valve is replaced. 6. Screw out the e-stop manifold redundant relief valve adjustment screw one-and-a-half turns. Pressure out any boom cylinder except #1 down, and read the gauge. Pressure should read 330 bar. If it does not, turn the screw in to raise pressure, or out to lower pressure until it is set at 330 bar. If the location of this valve causes you to be near the drivelines, be sure to stop them from turning before accessing the valve. 7. With the truck engine off, adjust the high pressure screw of the boom hydraulic pump regulator out (lowering the pressure) two-and-a-half turns. Start the engine, pressure out any boom cylinder except #1 down, and read the pressure on the gauge. It should read 300 bar. If not, repeat step (7.), adjusting the screw a small amount each time, until the gauge reads 300 bar when a cylinder is pressured out.
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Pressure Settings Redundant relief valve
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0-400 bar gauge port
Pressure Cut-off adjustment screw
0-60 bar gauge port
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boom control block relief valve
ILbmpmp.eps
Figure 209 The three boom pressure devices 8. With the truck engine off, lock the jam nut on the high pressure screw you were adjusting in step (7.). The boom pressures are now set. If you did not get the readings specified after following the instructions it is possible that there is a problem with the emergency stop manifold (see Figure 210). You can plumb the malfunctioning circuit out of the system to test it. Use only approved hydraulic dead plugs to plug the inlet hose to the malfunctioning circuit. If pressure can now be achieved, the e-stop manifold is the source of the problem. If pressure still cannot be achieved, the problem is elsewhere. Contact Schwing America’s Service Department for advice on how to continue. If the problem was found to be the e-stop manifold, repair it before using the unit again. Remember, the emergency stop switches do nothing if the e-stop
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Pressure Settings
manifold is plumbed out of the system. Remove the whip hose from the 300 bar gauge port. Before folding up the boom, proceed to the instructions for setting the 140 bar down side relief valve.
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Boom/outrigger circuit dump valve
T MP
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Boom override button
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Boom/outrigger inlet port Setting the 140 bar down side relief valve pressure Set the pressure of the 140 bar down side relief valve. This valve is a secondary relief valve for #1 cylinder retract function. Proper adjustment ensures that the #1 boom and the A-frame won’t be damaged by putting the boom in the cradle. (See figure 211.) To adjust this valve (requires a 2.5 mm Allen wrench and a standard screwdriver): 1. Install a 0 - 400 bar or 0 - 600 bar gauge into the 140 bar gauge port (shown in Figure 211). 2. Unfold the #2 section from #1 until it is straight. For the following procedure we must bring #1 all the way down until the cylinder bottoms out. Position the boom so this can be done without hitting the truck or any other obstacle. 3. Bring #1 down until the cylinder is completely bottomed out. The cylinder does NOT bottom out if you are setting the folded boom into the A-frame (travel position). 4. Activate the #1 down (retract) handvalve The boom will not be able to move because the cylinder is already bottomed out. Read the pressure on the gauge that you just installed. It should read 140 bar. If no adjustment is necessary, skip to step 6.
Figure 210 Emergency stop manifold
5. If adjustment is needed, loosen the set screw of the 140 bar relief valve with the 2.5 mm allen wrench. While you activate #1 down, adjust the relief cartridge with the screwdriver until the pressure reads just under 140 bar. Retightening the set screw will raise the pressure slightly. Recheck the pressure, and readjust if needed. 6. When the pressure is set at 140 bar with the set screw tight, you can remove the whip hose gauge and replace the cap on the gauge port. 7. The boom pressure setting sequence is complete. If you are done with the boom, slew it back into the transport position, and lower #1 into the cradle. Attach the boom strap.
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Pressure Settings
140 bar gauge port
140 bar relief valve
ap
it14
0.e
ps
Figure 211 location of the 140 bar relief valve and gauge port.
Setting the outrigger pressures (7 place boom valve systems) After the boom pressures are set, you can set the outrigger pressure. • In this system, the boom, outriggers, water pump, and compressor circuits have all been put together in the boom valve manifold. (See Figure 211). When the outrigger selector push-button is activated, the outrigger valve routes oil to the two outrigger handvalve banks, one on each side of the unit. A relief valve inside the passenger side bank limits the entire outrigger circuit to 280 bar (4060 PSI) instead of the 300 bar (4350 PSI) of the boom relief valve. • To set the 280 bar relief valve for the outrigger circuit: (See Figure 213).
1. Wear safety glasses whenever you check or set pressures. 2. Plug the whip hose of a 0-400 or 0-600 bar gauge into the gauge port. Location is shown as item 1 in figure 213.
3. If not already done, start the truck engine and set the transmission and PTO as you would for a pumping job. 4. Locate the 280 bar relief valve on the back of the outrigger valve, as shown in Figure 213. 5. Set the engine RPM to maximum. 6. Select “outrigger” with the outrigger pushbutton. This will route oil to the outrigger handvalves. 7. Assuming that the outriggers are folded into the travel position, activate the passenger side handvalve “jacking cylinder retract” for either the front or rear outrigger. Note! You will get an incorrect reading if you select “extension cylinder retract” by mistake. If you select “extend” by mistake, the outriggers will extend instead of reading the relief valve setting. The handles are spring loaded and will return to neutral as soon as you let go. 8. Read the pressure on the gauge. It should read 280 bar (4060 PSI). If no adjustment is needed, skip to step 4.
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Pressure Settings 7plcORhndl.eps
Outrigger handle
Gauge port
1 Gauge port
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SLEWING
DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
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Outrigger handle
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AIR / WATER
BOOM / OUTRIG.
WARNING SAFETY
MANUAL
Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
Figure 212 Position of the outrigger selector valve Monsun-Tyson black & white (right) Apitech proportional (left)
280 bar Relief Valve
Lower 32Porct5.eps
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Turn body of valve to adjust.
REAR EXTEND
FRONT EXTEND
REAR FOOT
FRONT FOOT
Figure 213 Location of the 280 bar outrigger pressure relief valve. (Hoses removed for clarity).
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Pressure Settings 9. If adjustment is needed, turn the outside body of the relief valve that is located at the back of the outrigger valve. Turn in to raise pressure, turn out to lower pressure. There is no jam nut on this valve. 10. Activate the outrigger “jacking retract” handvalve and read the pressure on the gauge again. Repeat steps 8. and 9. until the gauge reads 280 bar. 11. When the pressure is correct, either go on to other pressure settings, or remove the whip hose and gauge, and cap the gauge port with the attached cap. 12. Return the RPM of the truck to an idle, take the transmission and PTO out of gear, and shut off the truck, or go on to the other pressure settings, as required.
Setting 15 bar pretension
• To check or set pretension, follow these steps: 1. Stop the truck engine. Plug the 0 - 40 bar gauge into the pretension check port of the Apitech handvalve (Figure 214). 2. Start the truck engine, but leave it at an idle. (Pretension adjustment is made at an idle to establish the minimum pressure setting. As RPM is increased, pressure will rise. Damage to the 0 - 40 bar gauge is possible if RPM is raised while the gauge is connected.) 3. Read the pressure on the gauge. If it reads 15 bar ± 1 bar, the pressure is set correctly. If adjustment is needed, proceed to step (4.).
CAUTION Truck engine must be at an idle while setting pretension.
Pretension gauge port
Figure 214 Pretension adjustment screw and gauge port 4. Loosen the jam nut on the pretension valve. Turn the screw in to raise pressure, and out to lower pressure. When the pressure is correct, retighten the jam nut. 5. Stop the engine, and remove the 0 - 40 bar gauge. Pretension setting is complete.
To set the agitator circuit pressure: The agitator relief valve is located in the agitator forward / neutral / reverse handvalve, at the rear of the unit on the driver’s side. The relief valve limits the pressure in the agitator circuit to 200 bar (2900 PSI). (See Figure 215). There is a gauge port for checking or
s
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Pretension adjustment screw setting the pressure in this circuit. The port is located on the agitator handvalve. To check or set the agitator pressure, follow these steps: 1. Remove the aluminum diamond plate cover from over the agitator handvalve. 2. Unscrew the cover from the gauge port. Plug in the 0-600 bar gauge and whip hose that came in the toolbox. 3. Start the engine, if not already running. 4. Close the agitator shutoff valve. (See Figure 216.) Note! If your unit does not have a shutoff valve, you can order one using part number 10004680
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agitator pressure check.eps L
SERVICE TRAINING
Figure 215 Showing the agitator handvalve and gauge port. (Diamond plate removed for this illustration.) (valve) and part number 30303432 (tube). Contact Schwing’s Service Dept. for installation instructions.
ag
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Figure 216 The agitator shutoff valve
open
5. Activate the agitator in forward. Read the pressure on the gauge. 6. If adjustment is needed, put your wrench on the body of the relief valve, which is located on the back of the agitator handvalve. While reading the gauge, turn the body in to raise pressure, or out to lower pressure until 200 bar is achieved. 7. Put the agitator handle in neutral. 8. Remove the whip hose and pressure gauge. Replace the gauge port cover. 9. Replace the aluminum diamond plate over the agitator handvalve.
Pressure Settings
Relief valve on this side (not visible from this angle).
Gauge port
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Pressure Settings
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Pressure Settings
KVM 34X
Check the concrete pump pressure (2020, 2023, 2525 pumpkits)
Check hydraulic pressures
Because the Hi-flow pumpkits have the ability to create high pressure on the concrete, the pressure settings have to be tailored specifically for each model. This means that we cannot simply list a pressure specification for all units. The correct pressure specifications for your unit are shown on the hydraulic schematic in Appendix, Section 7 of this manual.
The following pages provide the proper techniques for checking and setting hydraulic pressures of each system included on units up to 450 l/m. Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components. Pressure settings must be made with the oil at normal operating temperatures (40° to 60° C). The specifications for all circuit pressures are found on the hydraulic schematics in the Appendix section of this manual.
NOTE: Use of the remote control box for the following pressure setting procedure is NOT recommended. To check or set the concrete pump pressure adjustments, follow these steps:
Preheat the hydraulic oil Because of the new load-sensing hydraulic systems regulated by pressure cut-off, you can’t use the concrete pump or boom circuit to preheat the hydraulic oil (they stop putting out oil rather than send it over relief). To heat the oil to operating temperature: 1. Locate the agitator shutoff valve (Figure 217) and close it. Note! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and part number 30303432 (tube). Contact the Schwing Service Department at (651) 429-0999 for installation instructions. 2. Turn on the agitator. The agitator will not be able to turn, and the oil will be forced over the relief valve. 3. At an idle (approximately 600 rpm), about 5.4 horsepower is being converted to heat. Shut off the agitator when the temperature gauge on the rear control panel shows 40° C. Don’t forget to open the shutoff valve when the procedure is finished. agitoff.eps
Agitator quarter turn shutoff valve (open position)
Motor
Figure 217 Agitator shutoff valve
WARNING Always wear safety glasses when checking or setting pressures. 1. Be sure that the waterbox covers and guards are installed on the waterbox. 2. Start the truck engine, and put the PTO and transmission into gear just as you would to pump a job. 3. Locate and close the concrete pump shutoff valve and the soft switch shutoff valve (Figure 219). (These valves are also known as quarter turn valves). 4. If your concrete pump pressure gauge is not already plumbed into the gauge port (Figure 218), install a 0 - 400 or 0 - 600 bar gauge in the gauge port. 5. The “remote / local” switch located on the rear control panel must be in the “local” position. 6. Be sure that all emergency stop switches are in the up (not activated) position. Reset the E-stop circuit. 7. Using the throttle switch on the rear control panel, bring the truck engine up to full RPM. CAUTION! The main relief valve (Figure 220) is set to very high pressure (at least 350 bar). Use the rear control panel switch when checking the pressure of the main relief valve, so you will be out of the way if a hose or fitting blows. 8. Place the concrete pump “forward / neutral / reverse” switch on the rear control panel into the “forward” position. The unit will stroke no more than once, then the rock cylinder will retract. Oil
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Pressure Settings leaving the hydraulic pumps will be blocked in the brain. This is called high-pressuring the concrete pump. 9. Read the pressure on the gauge. The target pressure for the concrete pump circuit main relief valve is shown on the hydraulic schematic in the Appendix section of this manual. Return the pump control to “neutral” whether the pressure needs adjustment or not. If no adjustment is needed, skip to step 5. If adjustment is needed, proceed to next paragraph.
Setting the main relief valve The main relief valve is the primary pressure control device on units equipped with Rexroth A7VO hydraulic pumps. If the main relief valve needs adjustment, proceed as follows:
1. Wear safety glasses when checking or adjusting pressures. 2. Using a 9/16” spanner wrench, loosen the jam nut on the main relief valve adjusting screw (Figure 218). 3. Insert a 5/32” allen wrench in the adjustment screw. Turn the screw in to raise pressure and out to lower the pressure. Always go back to the rear panel before checking the pressure. 4. Once the pressure is correct to the hydraulic schematic, retighten the jam nut. Tightening the nut tends to raise the pressure, so check pressure again after tightening. 5. If you will not be setting the soft switch pressure, open the shutoff valves. The unit will not stroke with closed shutoff valves.
Gauge port
Hif lo_ 4.e ps
Main relief valve Soft switch relief valve
Figure 218 Location of the concrete pump circuit main relief valve and soft switch relief valve
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SERVICE TRAINING
Pressure Settings
Soft switch shutoff valve Main Pressure Gauge port
Concrete pump shutoff valve
hif
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Figure 219 Showing the concrete pump and soft switch shutoff valves
Grooves in handle
Closed
Open
Main relief cartridge
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Grooves in shaft
Closed
Open Mounting screw and washer removed for illustration
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soft switch relief cartridge 9/16" jam nut
5/32" Allen head 9/16" jam nut
Figure 220 Shutoff valve open / closed orientation
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Pressure Settings Setting the soft switch circuit relief pressure
3. Loosen the jam nut on the soft switch relief valve (Figure 103) with a 9/16” spanner wrench. Adjust
To check or adjust the soft switch pressure setting, proceed as follows: 1. Open the soft switch shutoff valve (Figure 219). The rest of the unit should still be set up as though you were going to check concrete pump pressure. 2. High pressure the concrete pump. The pressure gauge should read 60 or 80 bar (check your schematic). If adjustment is needed, proceed to step (3) below. If no adjustment is needed, skip to step ().
the pressure up or down, as needed, using a 5/32” Allen wrench. When the correct pressure is achieved, tighten the jam nut. 4. Be sure to open the concrete pump shutoff valve (Figure 219) on the side of the brain when you are finished. The unit cannot stroke with this valve closed.
Gauge port
Hif lo_ 4.e ps
Main relief valve Soft switch relief valve
Figure 221 Location of the main relief valve
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Load-sensing boom pressures If your unit has a load-sensing proportional system, it will have different pressure adjustments than if it is equipped with a black and white boom system. The following instructions are for seven place, load-sensing proportional systems. If you have a unit equipped with a black and white boom system, contact Schwing Service for the correct instruction pages.
Preheat the oil Note! Whenever you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (40° - 60° C). Instructions for heating the hydraulic oil are found on page 351. About proportional boom systems
In a black and white boom system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain a 20 bar higher pressure at the pump than what the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting Q-min and ∆P. Read all of the instructions before beginning any pressure settings. General locations of the components for the following procedures are shown in Figure 222.
Pressure Settings
You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when checking or setting pressures.
Setting ∆P Note! Do not adjust ∆P or Q-min if your boom is running as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned from there. It was fine tuned at the factory and should not be adjusted unless absolutely necessary. Do not adjust Q-min with the drive shafts turning! Each time the Q-min screw is adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning. To check or set ∆P, follow these steps: 1. Stop the truck engine and place a “Do Not Operate” sign on the truck windshield. 2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar gauge port (Figure 223) of the manual boom handvalves. Take care not to accidently install the gauge in the 0-60 bar port. CAUTION! If you activate any boom or outrigger functions, you will damage the 0 - 40 bar gauge. 1. To be sure that the pump is putting out only enough oil to maintain ∆P, we need to change the setting of the Q-min screw. Q-min is adjusted by a screw on the boom hydraulic pump (Figure 224). Unscrew the Q-min screw three full turns. Make sure that all emergency stop switches are in the up (not activated) position. Check that all personnel are clear of the truck, then restart the engine, engage the pumps, and leave the engine at an idle. Pressure can be read on the 0 - 40 bar gauge that you installed. Pressure should read 20 bar. If no adjustment is needed, simply reset the Q-min screw as described on page 357. If adjustment is needed, continue to step (4). Manual boom handvalves, Delta P adjustment and E-Stop manifold
Figure 222 Locations of components used to check and set boom pressures
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Q-min adjustment screw
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Pressure Settings
15 bar pretension adjustment screw
140 bar gauge port (use 0-400 bar gauge when checking)
0-60 bar gauge port
0-400 bar gauge port
Figure 223 Location of the boom circuit pressure devices (Hoses removed for clarity.)
boom control block relief valve
140 bar downside relief cartridge
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Q-min adjustment screw
CAUTION Do not operate any functions while setting Delta P.
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Q-max
Figure 224 Location of the Q-min adjustment screw
∆P adjustment screw
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2. Delta P is adjusted by the ∆P screw on the ∆P regulator (Figure 225). Loosen the jam nut, and adjust the screw inward to increase pressure or outward to decrease pressure, until it is set at 20 bar (±1). Contact Schwing America’s Service Department if you are unable to adjust the pressure to specification. NOTE! If the boom is not smooth at 20 bar, you must fine tune the adjustment. In that case, REMOVE THE GAUGE, and adjust ∆P until the boom is responsive and smooth. When done, the gauge (reinstalled) must read between 14 and 25 bar. The electronics in the control system can also affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 20 bar and check the electrical settings. Once electrical settings are verified, you could again refine the boom action with the ∆P adjustment.
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Figure 225 The ∆P regulator valve
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Setting Q-min
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Check Q-min pressure when the engine is at the maximum specified RPM, but the engine must be stopped to adjust the pressure. 1. If you unscrewed the Q-min screw as the first step of ∆P adjustment, begin by returning the screw to its original position (Figure 224). 2. Remove the 0 - 40 bar gauge from the 0 - 400 bar gauge port, and install the 0 - 600 bar gauge in its place. 3. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to max. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). 4. Read the pressure on the 0 - 600 bar gauge. Pressure should be at 40 - 45 bar. If no adjustment is needed, stop the drivelines from turning, be sure the jam nut on the Q-min screw is tight, and proceed to Setting boom pressures. If adjustment is needed, continue to the next step.
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Pressure Settings
5. Turn the Q-min screw in to raise the pressure (Figure 224). Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures.
Setting boom pressures (Load sensing proportional booms.) Now that ∆P and Q-min are set, you can check or set the boom valve pressures. There are three pressure settings (Figure 226) on the boom circuit: 1. Pressure regulator (the high-pressure adjustment screw on the ∆P regulator valve), set at 300 bar. 2. The redundant relief valve located in the emergency stop manifold, set at 330 bar. 3. The boom control block relief valve, set at 350 bar. NOTE! This relief valve is nonadjustable. If pressure is not maintained with the specification limits, the valve must be replaced.
Redundant relief valve
High pressure adjustment screw T
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TT
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140 bar gauge port (use 0-400 bar gauge when checking)
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P2
P3
P4
P1
15 bar pretension adjustment screw
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0-60 bar gauge port
0-400 bar gauge port
boom control block relief valve
140 bar downside relief cartridge
Figure 226 The three boom pressure devices 34blck.eps
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Pressure Settings To check the setting of the valve with the highest pressure, you must first raise the pressure of the lower two: 1. Loosen the jam nut of the high pressure adjustment screw (Figure 226) of the ∆P regulator. Turn the screw in two-and-a-half turns. This will raise the pressure on the regulator above 350 bar. 2. Loosen the jam nut of the adjustment screw of the redundant relief valve (Figure 226) in the emergency stop manifold. Turn the screw in oneand-a-half turns. This will raise the pressure setting of the relief valve to above 350 bar. 3. Pressure out any boom cylinder except #1 down by activating the control handle. To pressure out a cylinder, retract a fully retracted cylinder or extend a fully extended cylinder. The oil is then forced over the relief valve. The telltale hiss of an open relief valve should be coming from the Apitech control block relief valve now. If it isn’t, raise the setting of the other pressure devices until the hiss originates at the Apitech control block relief valve. Read the pressure on the gauge. It should read 350 bar. If pressure is correct, proceed to the next step. NOTE! Although the pressure specification for the Apitech relief valve is 350 bar, you may continue to use the relief valve as long as the cartridge maintains at least 330 bar. If you must replace the valve and don’t have one on hand, proceed to the next step before using the machine again. Redo this entire procedure when you have installed the new valve. If pressure on the Apitech relief valve is below 290 bar, you should not use the machine until the valve is replaced. 4. Screw out the e-stop manifold redundant relief valve (Figure 226) adjustment screw one-and-ahalf turns. Pressure out any boom cylinder except #1 down, and read the gauge. Pressure should read 330 bar. If it does not, turn the screw in to raise pressure or out to lower pressure until it is set at 330 bar. If the location of this valve causes you to be near the drivelines, be sure to stop them from turning before accessing the valve. 5. You will need a helper for this step. While pressuring out any boom cylinder except #1 down, have your helper adjust the high pressure screw of the ∆P regulator out (lowering the pressure) until the gauge reads 300 bar. Release the pressurized
function, and lock the jam nut. The boom pressures are now set. If you did not get the readings specified after following the instructions, contact Schwing America’s Service Department at (651) 429-0999 for advice on how to continue.
Setting the 140 bar down side relief valve pressure Set the pressure of the 140 bar (Figure 226) down side relief valve. Down side relief is a secondary relief valve for #1 cylinder retract function. Proper adjustment ensures that the #1 boom and the A-frame won’t be damaged by putting the boom in the cradle. To adjust this valve (requires a 2.5 mm Allen wrench and a standard screwdriver): 1. Install a 0 - 400 bar or 0 - 600 bar gauge into the 140 bar gauge port shown in Figure 226. 2. Unfold the #2 section from #1 until it is fully extended. For the following procedure we must bring #1 all the way down until the cylinder bottoms out. Position the boom so this can be done without hitting the truck or any other obstacle. 3. Bring #1 down until the cylinder is completely bottomed out. The cylinder does NOT bottom out if you are setting the folded boom into the A-frame (travel position). 4. Activate the #1 down (retract) handvalve. The boom will not be able to move because the cylinder is already bottomed out. Read the pressure on the gauge that you just installed. It should read 140 bar. If no adjustment is necessary, skip to step 6. 5. If adjustment is needed, loosen the set screw of the 140 bar relief valve (Figure 226) with the 2.5 mm Allen wrench. While you activate #1 down, adjust the relief cartridge with the screwdriver until the pressure reads just under 140 bar. Retightening the set screw will raise the pressure slightly. Recheck the pressure, and readjust if needed. 6. When the pressure is set at 140 bar with the set screw tight, you can remove the whip hose gauge and replace the cap on the gauge port. 7. The boom pressure setting sequence is complete. If you are done with the boom, fold it back into the transport position, and reattach the boom strap.
Setting the outrigger pressures After the boom pressures are set, you can set the outrigger pressure.
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Pressure Settings
Outrigger handle
0-400 bar gauge port
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Figure 227 Position of the outrigger selector valve on units equipped with Apitech proportional valves In this system, the boom, outriggers, water pump, and compressor circuits have all been put together in the boom valve manifold. When the outrigger selector pushbutton is pushed, the outrigger valve handle is activated, which routes oil to the two outrigger handvalve banks (one on each side of the unit). A relief valve inside the passenger side bank limits the entire outrigger circuit to 280 bar (4060 PSI) instead of the 300 bar (4350 PSI) of the boom relief valve. To set the 280 bar relief valve for the outrigger circuit:
WARNING Always wear safety glasses when checking or setting pressures. 1. Plug the whip hose of a 0-400 or 0-600 bar gauge (Figure 227) into the gauge port. 2. If not already done, start the truck engine and set the transmission and PTO as you would for a pumping job. 3. Locate the 280 bar relief valve (Figure 228) on the back of the outrigger valve. 4. Set the engine RPM to maximum. 5. Select “outrigger” with the outrigger pushbutton. This will route oil to the outrigger handvalves.
6. Assuming that the outriggers are folded into the travel position, activate the passenger side handvalve “jacking cylinder retract” for either the front or rear outrigger. Note! You will get an incorrect reading if you select any other outrigger function. The handles are spring loaded and will return to neutral as soon as you let go. 7. Read the pressure on the gauge. It should read 280 bar (4060 PSI). If no adjustment is needed, skip to step 4. 8. If adjustment is needed, turn the outside body of the relief valve that is located at the back of the outrigger valve. Turn in to raise pressure, turn out to lower pressure. There is no jam nut on this valve. 9. Activate the outrigger “jacking retract” handvalve and read the pressure on the gauge again. Repeat steps (8) and (9) until the gauge reads 280 bar. 4. When the pressure is correct, either go on to other pressure settings, or remove the whip hose and gauge and cap the gauge port with the attached cap. 5. Return the RPM of the truck to an idle, take the transmission and PTO out of gear, and shut off the truck, or go on to the other pressure settings as required.
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Pressure Settings
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10
280 bar Relief valve
9 4
2 3 AGITATOR
6 5
SECTION 1
SECTION 2
SECTION 3
DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
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SECTION 4
SLEWING
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CONCRETE PUMP
AIR / WATER
BOOM / OUTRIG.
WARNING Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
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WARNING Clear area before activating outriggers
REAR EXTEND
REAR JACKING
FRONT JACKING
FRONT EXTEND
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300 bar
400
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Figure 228 Location of the 280 bar outrigger pressure relief valve. (Hoses removed for clarity).
Setting the water pump hydraulic pressure With a seven place handvalve, the water pump hydraulic control is inside the boom control block. There is not a separate relief for this circuit, and therefore nothing that must be set.
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Pressure Settings
Setting 15 bar pretension
CAUTION Truck engine must be at an idle while setting pretension.
To check or set pretension, follow these steps: 1. Stop the truck engine. Plug the 0 - 40 bar gauge into the pretension check port of the Apitech handvalve (Figure 229). 2. Start the truck engine, but leave it at an idle. (Pretension adjustment is made at an idle to establish the minimum pressure setting. As RPM is increased, pressure will rise. Damage to the 0 - 40 bar gauge is possible if RPM is raised while the gauge is connected.) 3. If the pressure reads 15 bar ± 1 bar, the pressure is set correctly. If adjustment is needed, proceed to the next step. 4. Loosen the jam nut on the pretension valve. Turn the screw in to raise pressure, and out to lower pressure. When the pressure is correct, retighten the jam nut.
5. Stop the engine, and remove the 0 - 40 bar gauge. Pretension setting is complete.
Setting the agitator circuit pressure The agitator relief valve is located in the agitator forward / neutral / reverse handvalve (Figure 230). The relief valve (not completely visible in Figure 230) limits the pressure in the agitator circuit to 200 bar (2900 PSI). There is a gauge port (not visible in Figure 230) for checking or setting the pressure in this circuit. The port is located on the agitator handvalve. To check or set the agitator pressure, follow these steps: 1. Unscrew the cover from the gauge port. Plug in the 0-600 bar gauge and whip hose that came in the toolbox. 2. Start the engine, if it’s not already running.
15 bar pretension adjustment screw
0-60 bar gauge port
Figure 229 Pretension adjustment screw and gauge port pretnsn.eps
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Pressure Settings 3. Close the agitator shutoff valve (Figure 231). 34manco3.eps
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agitator handvalve
10
9 4
2 3
Gauge port Relief valve
AGITATOR
6 5
SECTION 1
SECTION 2
SECTION 3
SECTION 4
DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
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3
4
SLEWING
8 7
CONCRETE PUMP
AIR / WATER
BOOM / OUTRIG.
WARNING Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
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WARNING
AGITATOR forward/reverse
Clear area before activating outriggers
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REAR JACKING
FRONT JACKING
FRONT EXTEND
CONCRETE PUMP forward/reverse 200
Figure 230 Agitator handvalve
100
300 bar
400
WIKA
Note! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and part number 30303432 (tube). Contact Schwing America’s Service Department at (651) 429-0999 for installation instructions. 4. Activate the agitator, and read the pressure on the gauge.
5. If adjustment is needed, put your wrench on the body of the relief valve (Figure 230), which is located on the back of the agitator handvalve. While reading the gauge, turn the body in to raise pressure or out to lower pressure until 200 bar is achieved. 6. Put the agitator handle in neutral. 7. Remove the whip hose and pressure gauge. Replace the gauge port cover. agitoff.eps
Figure 231 The agitator shutoff valve
Agitator quarter turn shutoff valve (open position)
Motor
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Pressure Settings
Setting accumulator circuit pressure
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Accumulator pump pressure regulator
Figure 232 Accumulator pump pressure regulator for A7VO (above) and for A11VO (below) You will need an assistant for parts of this procedure. There are three relief settings for the accumulator circuit. To check or adjust the hydraulic pressure in the accumulator circuit: 1. Stop the truck, put the key in your pocket, and place a “Do Not Operate” sign on the windshield. 2. Loosen the jam nut on the pressure regulator of the accumulator hydraulic pump (Figure 232). Turn the screw in two-and-one-half turns. This will raise the regulator pressure above 300 bar. 3. Loosen the jam nut (Figure 233) on the accumulator redundant relief cartridge, located on the emergency stop manifold. Turn the screw in two turns. This will raise the relief setting above 300 bar.
P4
P1
Redundant relief cartridge
Figure 233 Accumulator redundant relief cartridge
4. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring the engine RPM to maximum. 5. Read the pressure on the accumulator circuit pressure gauge (Figure 234). The pressure should read the value shown on the hydraulic schematic. If no adjustment is needed, skip to step (7). If additional pressure adjustment is needed, continue with step (6).
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Figure 234 Accumulator circuit pressure gauge
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Pressure Settings
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Pressure Relief Cartridge Manual bleed valve
8. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 232) and turn the screw back out two-and-one-half turns. This restores it to its original setting. 9. Clear all personnel from the drive line area, start the truck, and bring the engine RPM up to maximum. 10. Read the pressure on the accumulator gauge. It should read the proper accumulator system pressure. 11. If adjustment is needed, you must stop the truck engine, or a least stop the drive lines from turning, each and every time you approach the accumulator circuit hydraulic pump. Turn the screw in to increase the pressure or out to decrease pressure. Lock the jam nut when the pressure is correct. Note: The accumulator circuit hydraulic pump pressure regulator is sometimes referred to as the pressure cutoff.
Figure 235 Accumulator manifold pressure relief cartridge 6. Locate the accumulator manifold pressure relief cartridge (Figure 235). Loosen the jam nut, and turn the screw clockwise to increase the pressure or counter clockwise to decrease the pressure. Tighten the jam nut when the pressure reaches the value required. 7. You will need an assistant for this step. With the engine still running, one person must go to the redundant relief valve on the emergency stop manifold (Figure 233) and back out the adjustment screw while the other person stands by the pressure gauge to let him know when the pressure reads the value shown on the schematic for accumulator redundant relief.
WARNING Stop the engine before proceeding to the next step. Entanglement hazard.
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KVM 36X-42M (pre-1998) Pressure Settings for KVM 36X Proportional Load Sensing NOTE! NOTE:All pressure settings must be done when the hydraulic oil is at 50 to 70 degrees Celsius. Please read all instructions before attempting to check or set pressures. There is a pressure limit valve and two different relief valves in the KVM 36X boom circuit. Before checking or setting these 3 valves, you should make sure that the Delta-P setting on the pressure regulator and the Q minimum setting on the hydraulic pump are properly set. In order to help you better understand this, we will describe the functions of each valve and the hydraulic pump before attempting to set or check pressures. Refer to Illustration 1on Page- D2 for the location of each item as it is mounted on the unit. Figure 1 of this page, is called the pressure regulator. Adjusting screw (item 4) is the pressure limit function of the pressure regulator. Adjusting screw (item 3) is the Delta-P function of the regulator. The Delta-P function senses pressure on both sides of the boom handvalve, and adjusts the output flow of the hydraulic pump. Figure 2 of this page is the "normally open" relief valve. (Normally open denotes that unless the coil is energized, the relief valve will not develop any pressure). This is the valve that opens and vents your boom circuit to tank when you hit the red emergency shut off button on your remote control box or operations panel. Figure 3 of this page is the boom handvalve. (Item 10) is pointing to the relief valve located on the handvalve. It's function is to protect the handvalves from any pressure spikes that might be in the system. (Item G2) is a gauge port. Figure 4 of this page is the boom circuit hydraulic pump. This style of hydraulic pump has a variable output depending on the requirements of the boom, which is controlled by the pressure regulator described in Figure 1 (above).
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Pressure Settings
As mentioned earlier before we check or adjusts settings of the pressure limit valve or the two relief valves, we must make sure the Delta-P and Qminimum settings are correct.
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Pressure Settings Component Location Guide KVM 36 X W/ Rexroth Handvalves FIGURE 1
FIGURE 2
FIGURE 4
FIGURE 3
1200 / 36 X
Illustration 1 item 4 item 3 T
FIGURE 1
STOP for Q min
item 2
item 1
STOP for Qmax
FIGURE 2
24V
FIGURE 4
item 10
24V
item G2
FIGURE 3
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Pressure Settings for KVM 36X Proportional Load Sensing 1. 1.Delta-P setting on the pressure regulator. (Figure 1, Item 3) With all boom functions in the neutral position, emergency stop buttons up, the engine at minimum RPM's (idle), the pressure that will be read on both the pretension gauge and the main pressure gauge is either Delta-P or an idle Q-minimum. To determine what indeed is creating this pressure, we must do at least ONE of the three following procedures: a. A.Back off the Q-min. screw at least 3 turns on the hydraulic pump to insure that it is only producing the amount of flow that the regulator is requiring to maintain Delta-P pressure. Now read an accurate Delta-P pressure on either the pretension gauge or the main pressure gauge. This requires that the Q-min. be re-adjusted; (refer to paragraph 2. for Q minimum setting). b. B.While observing the pretension or the main pressure gauge you increase the engine RPM by 300 RPM in 3 increments of 100 RPM each, making sure that the pressure does not increase. This will assure that you are indeed observing accurate Delta-P. If the pressure does increase, then the pressure observed is an idle Q-min. and not a true Delta-P. You should then follow the procedures in paragraph 1. A. c. C.Install a high pressure (0-600 Bar) gauge in the X port of the regulator with a "T" fitting. While operating a boom function, monitor the pressure between the main pressure gauge and the gauge at the X port of the regulator. There should be exactly 20 Bar less pressure at the X port continuously. Adjusting Delta-P: The Delta-P pressure should be 20 Bar plus or minus 1 Bar; (this is the same for KVM 32, KVM 36X, KVM 42 and KVM 52 machines). If the Delta-P pressure is incorrect, then the regulator must be adjusted accordingly. Turn the small screw (Figure 1, item 3) on the regulator inward to increase or outward to decrease the Delta-P pressure. If the DeltaP pressure cannot be adjusted to proper pressure, then the regulator is probably defective. Do not replace the regulator until the orifices in the base plate have been checked to make sure they are not obstructed or improperly sized. Refer to Figure 5 on Page - D4 for proper orifice sizes.
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Pressure Settings
2. Q Minimum setting: the Q minimum stop on the hydraulic pump, (Figure 4, item 1). With all boom functions in the neutral position, emergency stop buttons up, the engine at maximum specified RPM's, the pressure on the main gauge (0-600 bar) should be:
a) . . . KVM 32 & 36 = 40 Bar; b) . . . KVM 42 = 40-45 Bar; c) . . . KVM 52 = 50-55 Bar. If the pressure is incorrect, the Q-min. screw on the hydraulic pump must be adjusted accordingly. Turn the Q-min screw inward to increase the pressure and outward to decrease the pressure.
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Pressure Settings Pressure Regulator Cutaway
Pressure Regulator
P Regulator
A
T P
ORIFICE KVM 36X . . . . 1.6 mm KVM 36 LW . . 1.6 mm KVM 42 . . . . . .1.6 mm KVM 52 . . . . . .not used Figure 236
0.8 mm
X
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Pressure Settings for Regulator and Releif Valves Now that we know our delta-P and Q-minimum are set correct we can check and reset the pressure limit and two relief valves. The correct pressure settings are as follows: 1. PRESSURE REGULATOR (Figure 1, item 4)310 Bar 2. NORMALLY OPEN BYPASS VALVE (Figure 2, item 2)330 Bar 3. HANDVALVE RELIEF (Figure 3, item 10)340 Bar In order to reset the valve with the highest pressure, we must first raise the pressure of the other two valves. a. A.Install a 0-600 Bar gauge in the gauge port (Figure 3, item G2) of the handvalve. b. B.To set the pressure regulator (Figure 1), loosen the lock nut (Item 4), and turn the adjusting screw inward approximately two turns. This will raise the pressure of this valve higher than 340 bar. c. C.To set the normally open bypass valve (Figure 2), loosen the lock nut (Item 2), and turn the adjusting screw inward approximately one turn. This will raise the pressure of this valve higher than 340 bar. d. D.Pressure out any boom section except main down. The pressure can now be read on the 0600 Bar gauge that you have installed on the handvalves. The gauge should read 340 Bar. If it does not, adjust the relief valve on the boom handvalves (Figure 3, item 10). After you have this relief set to 340 Bar you can lock the locknut and move on to the normally open bypass valve. e. E.While you continue to hold a function pressured out you can adjust the normally open bypass valve (Figure 2, item 2), until the pressure gauge now reads 330 Bar. After this pressure is set and the locknut is locked, proceed to the pressure regulator. f. F.While still holding a function pressured out you can now adjust the pressure regulator (Fig. 1, Item 4), until the pressure gauge reads 310 Bar. When this pressure has been set and the locknut is locked, you are finished setting the main circuit pressures on the boom.
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Pressure Settings
10
11
8
G2 - HIGH PRESS. GAUGE PORT
G1 - PRETENTION GAUGE PORT
11 - SECTION COMPENSATORS
10 - HIGH PRESS. RELIEF (340 Bar)
9 - PRETENTION RELIEF
8 - PRETENTION VALVE
7 - OUTRIGGER SPEED
6 - COMPRESSOR RPM
5 - WATERPUMP RPM
4 - SWING LEFT SPEED
3 - SWING RIGHT SPEED
2 - BOOM RETRACT SPEED
1 - BOOM EXTEND SPEED
(Waterpump/Compressor & Outrigger)
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24V 24V
BOOM HANDVALVE KVM 36LW & 36X
OUTRIG
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WTR CMP
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SLEW R&L
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O-ring
Filter
O-ring
Orifice
G2
G1
2
1
BOOM 4
2
1
BOOM 3
2
1
BOOM 2
2
1
BOOM 1
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Pressure Settings KVM 36 LW & 36 X W/Rexroth Boom Handvalve
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Pressure Settings for KVM 42 (B&W Load sensing and Proportional Load Sensing NOTE! NOTE:All pressure settings must be done when the hydraulic oil is at 50 to 70 degrees Celsius. Please read all instructions before attempting to check or set pressures. There is a pressure limit valve and two different relief valves in the KVM 42 boom circuit. Before checking or setting these 3 valves, you should make sure that the Delta-P setting on the pressure regulator and the Q minimum setting on the hydraulic pump are properly set. In order to help you better understand this, we will describe the functions of each valve and the hydraulic pump before attempting to set or check pressures. Refer to Illustration 2 on Page- D8 for the location of each item as it is mounted on the unit. Figure 1 of this page, is called the pressure regulator. Adjusting screw (item 4) is the pressure limit function of the pressure regulator. Adjusting screw (item 3) is the Delta-P function of the regulator. The Delta-P function senses pressure on both sides of the boom handvalve, and adjusts the output flow of the hydraulic pump. Figure 2 of this page is the "normally open" relief valve. (Normally open denotes that unless the coil is energized, the relief valve will not develop any pressure). This is the valve that opens and vents your boom circuit to tank when you hit the red emergency shut off button on your remote control box or operations panel. Figure 3 of this page is the boom handvalve. (Item 9) designates the main pressure relief valve located on the handvalve. It's function is to protect the handvalves from any pressure spikes that might be in the system. (Item 11) designates the relief valve for the main section down. Figure 4 of this page is the boom circuit hydraulic pump. This style of hydraulic pump has a variable output depending on the requirements of the boom, which is controlled by the pressure regulator described in Figure 1 (above). As mentioned earlier before we check or adjusts settings of the pressure limit valve or the two relief valves, we must make sure the Delta-P and Qminimum settings are correct.
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Pressure Settings
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Pressure Settings Component Location Guide KVM 42 W/ Rexroth Handvalves FIGURE 1
FIGURE 2 FIGURE 3
FIGURE 4
Illustration 2 item 4 item 3 T
FIGURE 1
STOP for Q min
item 2
item 1
STOP for Qmax
FIGURE 2
FIGURE 4
item 11
item 9
FIGURE 3
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Pressure Settings for KVM 42LW Proportional Load Sensing 1. Delta-P setting on the pressure regulator. (Figure 1, Item 3) With all boom functions in the neutral position, emergency stop buttons up, the engine at minimum RPM's (idle), the pressure that will be read on both the pretension gauge and the main pressure gauge is either Delta-P or an idle Q-minimum. To determine what indeed is creating this pressure, we must do at least ONE of the three following procedures: a. A.Back off the Q-min. screw at least 3 turns on the hydraulic pump to insure that it is only producing the amount of flow that the regulator is requiring to maintain Delta-P pressure. Now read an accurate Delta-P pressure on either the pretension gauge or the main pressure gauge. This requires that the Q-min. be re-adjusted; (refer to paragraph 2. for Q minimum setting). b. B.While observing the pretension or the main pressure gauge you increase the engine RPM by 300 RPM in 3 increments of 100 RPM each, making sure that the pressure does not increase. This will assure that you are indeed observing accurate Delta-P. If the pressure does increase, then the pressure observed is an idle Q-min. and not a true Delta-P. You should then follow the procedures in paragraph 1. A. c. C.Install a high pressure (0-600 Bar) gauge in the X port of the regulator with a "T" fitting. While operating a boom function, monitor the pressure between the main pressure gauge and the gauge at the X port of the regulator. There should be exactly 20 Bar less pressure at the X port continuously. Adjusting Delta-P: The Delta-P pressure should be 20 Bar plus or minus 1 Bar; (this is the same for KVM 32, KVM 36X, KVM 42 and KVM 52 machines). If the Delta-P pressure is incorrect, then the regulator must be adjusted accordingly. Turn the small screw (Figure 1, item 3) on the regulator inward to increase or outward to decrease the Delta-P pressure. If the DeltaP pressure cannot be adjusted to proper pressure, then the regulator is probably defective. Do not replace the regulator until the orifices in the base plate have been checked to make sure they are not obstructed or improperly sized. Refer to Figure 5 on Page - D10 for proper orifice sizes.
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Pressure Settings
2. Q Minimum setting: the Q minimum stop on the hydraulic pump, (Figure 4, item 1). With all boom functions in the neutral position, emergency stop buttons up, the engine at maximum specified RPM's, the pressure on the main gauge (0-600 bar) should be:
a) . . . KVM 32 & 36 = 40 Bar; b) . . . KVM 42 = 40-45 Bar; c) . . . KVM 52 = 50-55 Bar. If the pressure is incorrect, the Q-min. screw on the hydraulic pump must be adjusted accordingly. Turn the Q-min screw inward to increase the pressure and outward to decrease the pressure.
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Pressure Settings Pressure Regulator Cutaway
Pressure Regulator
P Regulator
A
T P
0.8 mm
ORIFICE KVM 36X . . . . 1.6 mm KVM 36 LW . . 1.6 mm KVM 42 . . . . . .1.6 mm KVM 52 . . . . . .not used Figure 237 Regulator Valve
X
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Pressure Settings for Regulator and Relief Valves KVM 42 Now that we know our delta-P and Q-minimum are set correct we can check and reset the pressure limit and two relief valves. The correct pressure settings are as follows:
1) PRESSURE REGULATOR (Figure 1, item 4): KVM 42 B&W KVM 42 Prop.
310 Bar 290 Bar
2) NORMALLY OPEN BYPASS VALVE (Figure 3, item 2): All 42 Meters 3)
320 Bar
HANDVALVE HIGH PRESSURE RELIEF (Figure 3, item 9):
All 42 Meters
330 Bar
In order to reset the valve with the highest pressure, we must first raise the pressure of the other two valves. a. To set the pressure regulator (Figure 1), loosen the lock nut (Item 4), and turn the adjusting screw inward approximately two turns. This will raise the pressure of this valve higher than 330 bar. b. To set the normally open bypass valve (Figure 2), loosen the lock nut (Item 2), and turn the adjusting screw inward approximately one turn. This will raise the pressure of this valve higher than 330 bar. c. Pressure out any boom section except the main down. The pressure can now be read on the 0600 Bar gauge that is near the handvalves. The gauge should read 330 Bar. If it does not, adjust the relief valve on the boom handvalves (Figure 3, item 9). After you have this relief set to 330 Bar you can lock the locknut and move on to the normally open bypass valve. d. While you continue to hold a function pressured out you can adjust the normally open bypass valve (Figure 2, item 2), until the pressure gauge now reads 320 Bar. After this pressure is set and the locknut is locked, proceed to the pressure regulator.
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Pressure Settings
e. While still holding a function pressured out you can now adjust the pressure regulator (Figure 1, Item 4), until the pressure gauge reads 310 Bar on Black & White units or 290 Bar on Proportional units. When this pressure has been set and the locknut is locked, you are finished setting the main circuit pressures on the boom. f. There is also a relief valve for the main boom down function (Figure 3, item 11); (this relief valve is either located in the handvalve housing directly in front of the manual hand lever for the main section), or: (is T’d into the steel tube that comes out of the "A" port on the frontside of the main section handvalve). Before setting the downside relief valve, you must bring the boom to it’s fully retracted position. This is best accomplished with the boom swung off to the side of the truck with the outriggers fully extended. While holding the main section pressured out in the fully retracted position, you can now adjust the downside relief cartridge until you read 100 Bar on the 0-600 Bar gauge.
10
7
11
8 Orifice
O-ring
Filter
O-ring
8
9
- BOOM EXTEND SPEED - BOOM RETRACT SPEED - SWING RIGHT SPEED - SWING LEFT SPEED - WATERPUMP RPM - COMPRESSOR RPM - OUTRIGGER SPEED - PRETENTION VALVE - HIGH PRESS. RELIEF (330 Bar) - SECTION COMPENSATORS - DOWN-SIDE RELIEF VALVE
24V 24V
1 2 3 4 5 6 7 8 9 10 11
(Waterpump/Compressor,Throttle, & Outrigger)
KVM 42LW BOOM HANDVALVE
BOOM 2
24V
2
2
24V
1
24V
2
2
24V
24V
24V
1
4
24V
24V
3
BOOM SWING 4 R/L
1
BOOM 3
24V
24V
1
BOOM 1
RPM
24V
24V
6
24V
24V
5
WTR/ OUTCOMP. RIGGER
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Pressure Settings KVM 42 LW, W/Rexroth BoomHandvalve
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KKVM 36X Check hydraulic pressure Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components.
NOTE! Hydraulic pressures setting shown in the following procedures are for a 1200 single circuit pump kit and a 2023 twin circuit pump kit. However, because different pump kits may be used in this unit, all pressure settings should be verified with the pressure settings shown on the applicable hydraulic schematic. The hydraulic schematics for your pump kit are in the Appendix of this manual.
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Pressure Settings
such as a steel bearing, inside a cap fitting. 2. Position the agitator lever in the forward or reverse position The agitator will not be able to turn, and the oil will be forced over the relief valve. 3. At idle speed (about 600 RPM), about 4.5 horsepower is being converted to heat. Position the agitator lever to the off (center) position when the temperature gauge on the main control panel indicates 50°C. 4. Open the agitator shutoff valve or remove the plug, and reconnect the hose to the agitator motor.
OFF
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Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when checking or setting pressures. Be sure that the waterbox covers are installed on the waterbox. We do not recommend using the remote control box for the following procedures. Wear safety glasses when setting pressures. Position the “remote/local” switch on the main control panel to the “local” position. Pressure settings must be made with the oil at normal operating temperatures (40°C – 60°C). The agitator circuit must be used to heat the hydraulic oil. Do not jam the paddles to force the oil over relief by stopping the movement of the agitator. To preheat the hydraulic oil using the agitator circuit, follow these instructions. 1. Locate the agitator shutoff valve, and close it (Figure 238). The general location of the agitator shutoff valve is shown in Figure 239.
NOTE! If your unit does not have a shutoff valve, order one using part #10004680 (valve) and #30303432 (tube). Contact the Schwing Service Department for installation instructions. If you can’t wait for a shutoff valve, you will need to remove one of the hoses from the agitator motor, and plug the hose and the open fitting with approved hydraulic dead plugs. Do not substitute other plugs,
Figure 238 Agitator shutoff valve The general location of the components used to check or set hydraulic pressures in shown in Figure 239.
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Pressure Settings 36Xdside.eps
Boom (Section #1) Down Pressure Relief Valve and Gauge Port
Boom Hand Valves and Gauge Port
Concrete Pump Shutoff Valve Concrete Gauge
Soft Switch Shutoff Valve (twin circuit)
Pump
Pressure
Side panel box Main Relief Valve
•
Concrete pump forward/ reverse hand valve
•
Outrigger hand valves and gauge port
•
E-Stop Manifold and Gauge
Accumulator Unloading Manifold Valve and Gauge (twin circuit)
•
Remote Control Connector
Agitator Shutoff Valve
Rear Control Panel
Outrigger Hand Valves t
Agitator Hand Valve and Gauge Port
Figure 239 General location of components used to set hydraulic pressures
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Set the concrete pump main relief valve (singlecircuit)
The BPL 1200 concrete pump is designed to operated at a maximum pressure of 300 bar (4350 PSI). It is controlled by the main relief valve (Figure 240), which valve is located at the front of the control block (towards the truck cab). To check or set the main relief pressure perform the following steps:
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Pressure Settings
Mount bolt and washer removed for illustration
grooves2.eps
Grooves in handle should line up with grooves in valve shaft Lower pressure
Raise pressure
gray valve.eps L
Figure 240 Concrete pump main relief valve 1. Close the concrete pump shutoff valve (Figure 241) 2. Use the throttle switch on the main control panel to rev the engine up to full RPM. 3. Use the concrete pump “forward/neutral/reverse” switch to put the pump into the “forward” position. The unit will stroke only once, then the rock cylinder will retract. Oil will have nowhere to go except over the concrete pump main relief valve. 4. Read the pressure on the concrete pump pressure gauge, located on the main control block. It should read 300 bar. Position the concrete pump switch to the off (neutral) position. If no adjustment is needed, skip to Step 8.
quarter turn.eps
Figure 241 Concrete pump shutoff valve 5. If adjustment is required, loosen the jam nut on the relief valve adjusting screw with a 13-mm spanner wrench (Figure 242). 6. Turn the adjustment knob on the relief valve to adjust the pressure. Turn the adjustment knob in to raise pressure or out to lower the pressure. 7. Retighten the jam nut. (Tightening the jam nut tends to raise the pressure. If this happens, hold the adjustment knob while tightening the jam nut.) 8. Put the concrete pump into the “forward” position again. The machine will not stroke this time, but will develop maximum pressure. Read the pressure on the control block pressure gauge. If more adjustment is needed, return the pump to “neutral,” then repeat Steps 5 through Step 8 until the pressure is at 300 bar. 9. Open the shutoff valve. The unit will not stroke with the shutoff valve closed. 10.
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Pressure Settings NOTE!
•
If you cannot adjust the pressure up to 300 bar, you have a problem. In this case, turn the adjustment knob out by several turns so that your pressure isn’t too high once the problem is found. Contact Schwing America’s Service Department for advice on how to continue. Set the concrete pump main relief valve (twin circuit)
The main relief valve is the primary pressure control device on units equipped with Rexroth A7VO hydraulic pumps. This pump is designed to operate at a maximum pressure of 350 bar (5075 PSI).
Hot oil expulsion hazard. stand away from pumpkit when checking hydraulic pressures.
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WARNING
The main relief valve is set to very high pressure (at least 350 bar). Use the controls on the rear control panel when checking the pressure of the main relief valve, so you will be out of the way if a hose or a fitting malfunctions. Refer to Figure 248 for the location of the components used to set the concrete pump pressures. Use the following steps to set the main relief valve pressure: 1. Be sure that the waterbox covers are installed on the waterbox. We do not recommend using the remote control box for the following procedure. 2. Wear safety glasses when setting pressures. 3. Close the concrete pump shutoff and soft switch valves (Figure 242). 4. Position the “remote / local” switch on the main control panel to the “local” position. 5. Use the throttle switch on the main control panel to rev the engine up to full RPM. 6. Use the concrete pump “forward/neutral/reverse” switch to put the pump into the “forward” position. The unit will stroke only once, then the rock cylinder will retract. Oil will have no where to go except over the concrete pump main relief valve.
7. Read the pressure on the concrete pump pressure gauge located on the main control block. It should read 350 bar. Position the concrete pump switch to the off (neutral) position. If no adjustment is needed, skip to Step 11. 8. If adjustment is needed, use a 9/16 inch spanner wrench, loosen the jam nut on the main relief valve adjusting screw (Figure 242). 9. Insert a 5/32 inch allen wrench in the adjustment screw. Turn the screw in to raise pressure or out to lower the pressure. 10. Once the pressure is correct (350) bar retighten the jam nut. Tightening the nut tends to raise the pressure, so check pressure again after tightening. Verify the correct pressure setting (350 bar). 11. Open the concrete pump shutoff and soft switch valves. The unit will not stroke with theses valves closed.
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Pressure Settings
w
Gauge port
39 hif lw1 .ep s
Main relief valve Soft switch relief valve
Mount bolt and washer removed for illustration
Soft switch shutoff valve
grooves2.eps
Concrete pump shutoff valve
39
hif
low
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s
Grooves in handle should line up with grooves in valve shaft
Figure 242 Location of the main relief valve
Set the soft switch circuit relief pressure To check or adjust the soft switch pressure setting, proceed as follows: 1. Close the concrete pump shutoff valve. Open the soft switch shutoff valve. The rest of the unit should still be set up as though you were going to check concrete pump pressure.
2. High pressure the concrete pump. The pressure gauge should read 60 or 80 bar (check your schematic). If no adjustment is needed, skip to Step 4. 3. If adjustment is needed, loosen the jam nut on the soft switch relief valve with a 9/16 inch spanner wrench. Adjust the pressure up or down, as needed, using a 5/32 inch Allen wrench. When the correct pressure is achieved, re-lock the jam nut.
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Pressure Settings 4. Be sure to open the concrete pump shutoff valve when you are finished. The unit cannot stroke with this valve closed.
e-stop/left.epsL
Relief Valve and Gauge Port
Set accumulator circuit hydraulic oil pressure (units with a pressurecompensated pump) You will need an assistant for parts of this procedure. To check or adjust the hydraulic pressure in the accumulator circuit, perform the following steps: 1. Stop the truck, put the key in your pocket, and place a “Do Not Operate” sign on the windshield. 2. Loosen the jam nut on the pressure regulator of the accumulator hydraulic pump. Turn the screw in two-and-a-half turns. This will raise the regulator pressure above 300 bar (Figure 243). .
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Accumulator pump pressure regulator
Figure 243 Accumulator pump pressure regulator 3. Connect the whip hose of a 0-600 bar gauge into the gauge port of the E-Stop manifold (Figure 244). 4. Loosen the jam nut on the accumulator relief valve, located on the E-Stop manifold. Turn the screw in two turns. This will raise the relief setting above 300 bar (Figure 243).
Figure 244 E-Stop manifold accumulator
5. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring the engine RPM to maximum. 6. Read the pressure on the accumulator circuit gauge located on the accumulator manifold block (Figure 76). Pressure should read 300 bar (4350 PSI). If no adjustment is needed, skip to (Step 8). 7. If additional pressure adjustment is needed, locate the accumulator manifold pressure relief valve (Figure 244). Loosen the jam nut, and turn the screw in to increase pressure or out to decrease pressure. Tighten the jam nut when pressure is at 300 bar.
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Pressure Settings
Setting the outrigger pressure SAFETY INSTRUCTIONS Accumulator Safety Rules
of oil pressure. the system is relieved 1. Never assume that hydraulic system of pressure before 2. Always relieve the out, repair, or maintenance. to verify zero dis-assembly for clean circuit pressure gauge 3. Check accumulator in the concrete system pressure. it is safe to put your hands 4. Never assume that system pressure. valve. does not guarantee zero 5. Stopping the engine pump electrically does not de-pressurize 6. Stopping the concrete the accumulator circuit.compressed air to charge the accumulator! or pressure 7. NEVER use oxygen without the correct nitrogen machine the of 8. Operation Before charging the accumulator, could damage the accumulator. Read the operation manual. understand the procedure.
With a seven place hand valve, the boom/outrigger selector valve is inside the boom control block. This valve is activated when the outrigger enable push button is pushed. There is not a separate relief for this circuit and, therefore nothing that must be set.
WARNING Stored hydraulic energy. Release all hydraulic pressure and verify zero pressure on gauge before servicing.
The outrigger circuit is set to a maximum of 280-bar (4060 PSI) by the relief valve located on the passenger side outrigger hand valve assembly (Figure 246). The valve routes the oil to the two outrigger hand valve banks, one on each side of the unit. A relief valve inside the passenger side bank limits the entire outrigger circuit to 280-bar.
Relief Valve 36accum.eps
Figure 245 Accumulator manifold pressure relief valve
Lower Higher
8. You will need an assistant for this step. With the engine still running, adjust the relief valve of the EStop manifold. Back out the adjustment screw until pressure reads 260 bar (3770 PSI) on the gauge connected to the E-Stop manifold.
Turn body of valve to adjust.
280 bar Relief Valve
Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
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WARNING
9. After the truck engine is stopped, back out the accumulator circuit hydraulic pump pressure regulator two-and-a-half-turns. This restores the pressure regulator to its original setting (Figure 243). 10. Clear all personnel from the drive line area, start the truck, and rev the engine RPM to maximum. 11. Read the pressure on the accumulator gauge. It should read 200 bar (2900 PSI). 12. If additional adjustment is needed, you must stop the truck engine each time you approach the accumulator circuit hydraulic pump (Figure 243). Adjust the accumulator pump pressure regulator screw in to increase pressure or out to decrease pressure. Lock the jam nut when pressure is correct (200 bar).
Figure 246 Outrigger hand valve
1. Connect the whip hose of a 0–400 or 0–600 bar to the gauge port on the right side of the outrigger hand valve. 2. If it is not already done, start the truck engine and set the transmission and PTO as you would for a pumping job. 3. Set the engine RPM to maximum. 4. Push the outrigger enable pushbutton located next to the outrigger hand valve (passenger side). Hold one of the outrigger hand valve levers in the jacking-retract position. The oil coming from the pump has nowhere to go but over the outrigger relief valve.
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Pressure Settings You cannot use the extend position for this adjustment because extend has a nonadjustable secondary relief functions built into the valve. 5. Turn the outside body of the relief valve that is located at the back of the passenger side outrigger hand valve (Figure 246). Turn in to raise pressure or turn out to lower pressure. 6. When the pressure on the gauge connected to the outrigger hand valve is 280-bar, release the enable push button and the outrigger hand valve. 7. Remove the whip hose and gauge from the outrigger handvalve, and replace the cap on the gauge port • Pressure reducing valve This valve is preset at the factory. Contact Schwing America’s Service Department at (651) 429-0999 for information on checking or setting this valve. • Electric stroke limiter This valve is preset at the factory. Contact Schwing America’s Service Department at (651) 429-0999 for information on checking or setting this valve • Load-sensing boom pressures (7 place proportional circuit) If your unit has a load-sensing proportional system, it will have different pressure adjustments than if it is equipped with a black and white boom system. The following instructions are for load-sensing proportional systems. If you have a unit equipped with a black and white boom system, contact Schwing Service Department for the correct instruction pages. In a black and white boom system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain a 20 bar higher pressure at the pump than what the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting Q-min and ∆P. The general locations of the components used to set
boom hydraulic pressures is shown in Figure 247.
NOTE! Do not adjust ∆P or Q-min if your boom is running as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned from there. It was fine tuned at the factory and should not be adjusted unless absolutely necessary.
WARNING Entanglement hazard. Stop drive shafts before adjusting Q-min.
Each time the Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning.
W009.eps
NOTE!
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Boom Hand Valves
∆P Regulator
Q-min Adjust Screw
Pressure Settings E-Stop Manifold
36Xdside.eps
Figure 247 Location of components used to check or set boom pressures
0-400 bar gauge port 0-60 bar gauge port boom control block relief valve 36
ap
itpr
ep
dv.
s
15 bar pretension adjustment screw
Figure 248 Boom hand valves
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Pressure Settings Check or set ∆P
NOTE!
Q-min adjustment screw
Q-minscrew.eps
Q-max
Figure 249 Q-min adjust screw
4. Delta P is adjusted by the ∆P screw on the ∆P regulator (Figure 250). Loosen the jam nut, and adjust the screw inward to increase pressure or outward to decrease pressure until it is set at 20 bar (±1). Contact Schwing America’s Service Department if you are unable to adjust the pressure to specification.
Remove the gauge, and adjust ∆P until the boom is responsive and smooth. When done, the gauge (reinstalled) must read between 14 and 25 bar. The electronics in the control system can also affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 20 bar and check the electrical settings. Once electrical settings are verified, you could again refine the boom action with the ∆P adjustment. CAUTION! Do not operate any functions while setting ∆P.
deltaPvlv.eps
To check or set ∆P follow these steps: 1. Stop the truck engine, and place a “Do Not Operate” sign on the truck windshield. 2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar gauge port of the manual boom handvalves. Take care not to accidently install the gauge in the 0-60 bar port (Figure 248). 3. To be sure that the pump is putting out only enough oil needed to maintain ∆P, we need to change the setting of the Q-min screw. Q-min is adjusted by a screw on the boom hydraulic pump (Figure 249). Unscrew the Q-min screw three full turns. Check that all personnel are clear of the truck, then restart the engine, engage the pumps, and leave the engine at an idle. CAUTION! If you activate any boom or outrigger functions, you will damage the 0 40 bar gauge. Make sure that all emergency stop switches are in the up (not activated) position. Pressure can be read on the 0 - 40 bar gauge that you installed. Pressure should read 20 bar. If no adjustment is needed, simply reset the Q-min screw as described in the Check or set Q-min steps. If adjustment is needed, continue to Step 2.
If the boom does not operate smoothly at 20 bar, you must fine tune the adjustment.
T
∆P adjust screw
Figure 250 ∆P regulator valve •
Check or set Q-min
You must check Q-min pressure when the engine is at the maximum specified RPM, but you must adjust it with the engine stopped. To check or set the Q-min follow these steps: 1. If you unscrewed the Q-min screw as the first step of ∆P adjustment, begin by returning the screw to its original position (Figure 249). 2. Remove the 0 - 40 bar gauge from the 0 - 400 bar gauge port, and install the 0 - 600 bar gauge in its place (Figure 248). 3. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to max. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). 4. Read the pressure on the 0 - 600 gauge. Pressure should be at 40 - 45 bar. If no adjustment is needed, stop the drive lines from turning, be sure the jam nut on the Q-min screw is tight, then continue to Set boom pressures to check the rest of the boom pressures. 5. If adjustment is needed, turn the Q-min screw in to raise the pressure (Figure 249). Turn it out to lower the pressure. Be sure that you stop the drive shafts
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Pressure Settings
from turning each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures.
Set boom pressures (load sensing proportional booms) Now that ∆P and Q-min are set, you can check or set
0-400 bar gauge port
the boom valve pressures.There are three pressure settings on the boom circuit (Figure 251). 1. Pressure regulator (the high-pressure adjustment screw on the ∆P regulator valve), set at 290 bar (4205 PSI). 2. The redundant relief valve located in the emergency stop manifold, set at 320 bar (4640 PSI). 3. The boom control block relief valve, set at 350 bar (5075 PSI).
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0-60 bar gauge port boom control block relief valve ps
.e Va
om
Bo
36
15 bar pretension adjustment screw
∆P Regulator Valve (high pressure adjustment screw)
NOTE!
deltaPvlv.eps
The boom control block relief valve is nonadjustable. If pressure is not maintained within the specification limits, the valve must be replaced.
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e-stop/right.epsL
E-Stop Manifold Redundant Relief Valve
Figure 251 Boom hydraulic pressure adjustment components
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Pressure Settings To check the setting of the valve with the highest pressure, you must first raise the pressure of the lower two: 1. Loosen the jam nut of the high pressure adjustment screw of the ∆P regulator. Turn the screw in twoand-a-half turns. This will raise the pressure on the ∆P regulator above 350 bar. 2. Loosen the jam nut of the adjustment screw on the E-stop manifold redundant relief valve. Turn the screw in one-and-a-half turns. This will raise the pressure setting of the relief valve to above 350 bar. 3. Pressure out any boom cylinder except #1 down by pushing or pulling the control handle. To pressure out a cylinder, retract a fully retracted cylinder or extend a fully extended cylinder. The oil is forced over the relief valve. 4. The tell tale hiss of an open relief valve should be coming from the Apitech control block relief valve now. If it isn’t, raise the setting of the other pressure devices until the hiss originates at the Apitech control block relief valve. Read the pressure on the gauge connected to the 0-400 bar gauge port on the boom hand valve block. It should read 350 bar. If pressure is correct, proceed to Step 5.
NOTE! Although the pressure specification for the Apitech relief valve is 350 bar, you may con-
tinue to use the relief valve as long as the cartridge maintains at least 330 bar. If you must replace the valve, proceed to Step 5 before using the concrete pump again, and redo this entire procedure when you have installed the new valve. If pressure on the Apitech relief valve is below 290 bar, you should not use the concrete pump until the valve is replaced. 5. Screw out the E-Stop manifold redundant relief valve adjustment screw one-and-a-half turns. Pressure out any boom cylinder except #1 down, and read the gauge. Pressure should read 320 bar. If it does not, turn the screw in to raise pressure or out to lower pressure until it is set at 320 bar. If the location of this valve causes you to be near the drive lines, be sure to stop them from turning before accessing the valve. 6. You will need a helper for this step. While pressuring out any boom cylinder (except #1 down) have your helper adjust the high pressure screw of the ∆P regulator out (lowering the pressure) until the gauge reads 290 bar. Release the pressurized function and lock the jam nut. The boom pressures are now set. If you did not get the readings specified after following the instructions, contact Schwing America’s Service Department at (651) 429-0999 for advice on how to continue.
0-400 bar gauge port 0-60 bar gauge port boom control block relief valve s
ep dv.
itpr
ap
36
15 bar pretension adjustment screw
Figure 252 Pretension adjustment screw and gauge port
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•
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Pressure Settings
Set 15 bar pretension
AgitHdVl.eps
To check or set pretension, follow these steps: 1. Stop the truck engine. Plug the 0 - 40 bar gauge into the 0-60 bar gauge port of the Apitech hand valve (Figure 252). 2. Start the truck engine, but leave it at an idle. (Pretension adjustment is made at an idle to establish the minimum pressure setting. As RPM is increased, pressure will rise. Read the pressure on the gauge. If it reads 15 bar ± 1 bar, the pressure is set correctly.
Relief Valve
Gauge Port
NOTE! Damage to the 0 - 40 bar gauge is possible if RPM is raised while the gauge is connected. 3. If adjustment is needed, loosen the jam nut on the pretension valve (Figure 252). Turn the screw in to raise pressure and out to lower pressure. When the pressure is correct, retighten the jam nut. 4. Stop the engine, and remove the 0 - 40 bar gauge. #1 boom down - brake valve With a seven place hand valve, the #1 down brake valve is inside the boom control block. There is not a separate relief valve for this circuit and, therefore, nothing that must be set.
Set water pump pressure With a seven place hand valve, the water pump hydraulic control is inside the boom control block. There is not a separate relief valve for this circuit and, therefore nothing that must be set.
Figure 253 Agitator hand valve 1. Stop the unit, and put the key in your pocket. 2. Connect the whip hose of 0-400 or a 0–600-bar gauge to the gauge port on the agitator hand valve (Figure 117). 3. If your unit is equipped with an 4. agitator shut off valve, close it (Figure 119). Skip to Step 6. 52qrttrn.epsL
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Set the agitator pressure The agitator circuit has a maximum pressure of 200 bar (2900 PSI), limited by the relief valve located in the agitator hand valve (Figure 117). The gauge port for checking or setting the agitator pressure is located on the agitator hand valve.
Shown in the open position
Figure 254 Agitator shutoff valve 5. If your unit is not equipped with an agitator shut off valve, remove one of the hoses from the agitator motor and plug the hose and the open fitting with approved hydraulic dead plugs. Do not improvise on these plugs. If you don’t have any, contact the Schwing’s Spare Parts Department and order them before continuing with this procedure.
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Pressure Settings
6.
7. 8. 9.
10.
11.
12.
All of these fittings and many, many more extremely useful items are included in the Troubleshooting Kit, part number 30308553. We highly recommend purchase of this kit. It will pay for itself many times over. You will need: - Qty 2 VS-16S locking plugs, part number 10016803 - Qty 1 GS-16S straight fitting, part number 10008088 - Qty 2 16S capnuts, part number 10001743 Be sure that one of the locking plugs and capnuts are tightened on the straight fitting and that the dead plugs are securely tightened to the hose and the open motor fitting. Locate the relief valve on the agitator hand valve. Be sure that all personnel are clear, and restart the engine. Activate the agitator hand valve by pushing or pulling the handle. This will send the oil against the high pressure plug. The oil will have nowhere to go, so it will return to the tank over the relief valve in the agitator hand valve. The pressure at which it relieves can be seen on the gauge. It should read 200-bar. If adjustment is needed, turn the outside body of the relief valve that is located at the back of the agitator hand valve. Turn in to raise pressure or turn out to lower pressure. When the pressure is set at 200-bar, stop the engine and remove the key. Open the shut off valve or remove the dead plugs and store them in a clean area or in a plastic bag or something similar to keep dirt from entering the fittings. Reattach the hose to the agitator motor fitting and tighten securely. (Torque is correct if you make one complete revolution after feeling initial resistance increase.) Remove the whip hose and pressure gauge. Replace the gauge port cover.
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KVM 39X
Pressure Settings Closed
Check hydraulic pressures Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components.
NOTE! Hydraulic pressure settings shown in the following procedures are for a 2023 twin circuit pump kit. However, because different pump kits may be used in this unit, all pressure settings should be verified with the pressure settings shown on the applicable hydraulic schematic. The hydraulic schematics for your pump kit are in the Appendix of this manual. Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when checking or setting pressures. Be sure that the waterbox covers are installed on the waterbox. We do not recommend using the remote control box for the following procedures. Wear safety glasses when setting pressures. Position the “remote/local” switch on the rear control panel to the “local” position. Pressure settings must be made with the oil at normal operating temperatures (40°C – 60°C). The agitator circuit must be used to heat the hydraulic oil. Do not jam the paddles to force the oil over relief by stopping the movement of the agitator. To preheat the hydraulic oil using the agitator circuit, follow these instructions. 1. Locate the agitator shutoff valve, and close it (Figure 255). The general location of the agitator shutoff valve is shown in Figure 257. 2. Position the agitator lever in the forward or reverse position. The agitator will not be able to turn, and the oil will be forced over the relief valve. 3. At idle speed (about 600 RPM), about 4.5 horsepower is being converted to heat. Position the agitator lever to the off (center) position when the temperature gauge on the rear control panel indicates 50°C. 4. Open the agitator shutoff valve or remove the plug, and reconnect the hose to the agitator motor.
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Shown in the open position Figure 255 Agitator shutoff valve
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Pressure Settings The general location of the components used to check or set hydraulic pressures in shown in Figure 256.
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Hydraulic Controls Enclosure •
Boom Hand Valves and Gauge Port
•
Forward/Reverse Hand Valve
•
Agitator Hand Valve and Gauge Port
•
E-Stop Manifold and Gauge port
•
Pilot Air Regulator
Concrete Pump Shutoff Valve
•
Stroke Limiter
Outrigger Hand Valves
Outrigger Hand Valves and Gauge Port
Soft Switch Shutoff Valve (twin circuit)
Main Relief Valve Soft Switch Relief Valve
Accumulator Unloading Manifold Valve (twin circuit)
Rear Control Panel Accumulator Gauge
Agitator Shutoff Valve Concrete Pump Pressure Gauge
Figure 256 General location of components used to set hydraulic pressures
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•
Set the concrete pump main relief valve (twin circuit)
The main relief valve is the primary pressure control device on units equipped with Rexroth A7VO hydraulic pumps. This pump is designed to operate at a maximum pressure of 350 bar (5075 PSI).
Hot oil expulsion hazard. Stand away from pumpkit when checking hydraulic pressures.
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WARNING
The main relief valve is set to very high pressure (at least 350 bar). Use the controls on the rear control panel when checking the pressure of the main relief valve, so you will be out of the way if a hose or a fitting malfunctions. Refer to Figure 256 for the location of the components used to set the concrete pump pressures. Use the following steps to set the main relief valve pressure: 1. Be sure that the waterbox covers are installed on the waterbox. We do not recommend using the remote control box for the following procedure. 2. Wear safety glasses when setting pressures. 3. Close the concrete pump shutoff and soft switch shutoff valves (Figure 257). 4. Position the “remote / local” switch on the rear control panel to the “local” position. 5. Use the throttle switch on the rear control panel to rev the engine up to full RPM. 6. Use the concrete pump “forward/neutral/reverse” switch to put the pump into the “forward” position. The unit will stroke only once, then the rock cylinder will retract. Oil will have no where to go except over the concrete pump main relief valve. 7. Read the pressure on the concrete pump pressure gauge located on the main control block. It should read 350 bar. Position the concrete pump switch to the off (neutral) position. If no adjustment is needed, skip to Step 11. 8. If adjustment is needed, use a 9/16 inch spanner wrench, loosen the jam nut on the main relief valve adjusting screw (Figure 257).
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Pressure Settings
9. Insert a 5/32 inch allen wrench in the adjustment screw. Turn the screw in to raise pressure or out to lower the pressure. 10. Once the pressure is correct (350 bar) retighten the jam nut. Tightening the nut tends to raise the pressure, so check pressure again after tightening. Verify the correct pressure setting (350 bar). 11. Open the concrete pump shutoff valve and soft switch shutoff valve. The unit will not stroke with these valves closed.
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Pressure Settings w
Gauge port
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Main relief valve Soft switch relief valve
Soft switch shutoff valve
Mount bolt and washer removed for illustration
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Concrete pump shutoff valve
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Grooves in handle should line up with grooves in valve shaft
Figure 257 Location of the main relief valve
Set the soft switch circuit relief pressure To check or adjust the soft switch pressure setting, proceed as follows: 1. Close the concrete pump shutoff valve. Open the soft switch shutoff valve. The rest of the unit should still be set up as though you were going to check concrete pump pressure.
2. Increase the engine RPM to high pressure the concrete pump. The pressure gauge should read 80 bar (check your schematic). If no adjustment is needed, skip to Step 4. 3. If adjustment is needed, loosen the jam nut on the soft switch relief valve with a 9/16 inch spanner wrench. Adjust the pressure up or down, as needed, using a 5/32 inch Allen wrench. When the correct pressure is achieved, re-lock the jam nut.
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4. Be sure to open the concrete pump shutoff valve when you are finished. The unit cannot stroke with this valve closed.
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Pressure Settings
.
Set accumulator circuit hydraulic oil pressure (units with a pressurecompensated pump) You will need an assistant for parts of this procedure. To check or adjust the hydraulic pressure in the accumulator circuit, perform the following steps: 1. Stop the truck, put the key in your pocket, and place a “Do Not Operate” sign on the windshield. 2. Loosen the jam nut on the pressure regulator of the accumulator hydraulic pump. Turn the screw in two-and-a-half turns. This will raise the regulator pressure above 300 bar (Figure 259).
NOTE! If your unit is a current production model Figure 104, skip Steps 3,4, and 8 of this procedure.
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Accumulator pump pressure regulator
Figure 259 Accumulator pump pressure regulator 3. Connect the whip hose of a 0-600 bar gauge into the gauge port of the E-Stop manifold (Figure 260). 4. Loosen the jam nut on the accumulator circuit relief valve, located on the E-Stop manifold. Turn the screw in two turns. This will raise the relief setting above 300 bar (Figure 260).
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Relief Valve and Gauge Port Figure 258 E-Stop manifold (current production)
Figure 260 E-Stop manifold relief valve, accumulator circuit (original production)
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Pressure Settings 5. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring the engine RPM to maximum. 6. Read the pressure on the accumulator circuit gauge located below the rear control panel. Pressure should read 300 bar (4350 PSI). If no adjustment is needed, skip to Step 8. 7. If additional pressure adjustment is needed, locate the accumulator manifold pressure relief valve (Figure 261). Loosen the jam nut, and turn the screw in to increase pressure or out to decrease pressure. Tighten the jam nut when pressure is at 300 bar. 45s3blck.epsL
9. After the truck engine is stopped, back out the accumulator circuit hydraulic pump pressure regulator two-and-a-half-turns. This restores the pressure regulator to its original setting (Figure 74). 10. Clear all personnel from the drive line area, start the truck, and rev the engine RPM to maximum. 11. Read the pressure on the accumulator gauge. It should read 200 bar (2900 PSI). 12. If additional adjustment is needed, you must stop the truck engine each time you approach the accumulator circuit hydraulic pump (Figure 259). Adjust the accumulator pump pressure regulator screw in to increase pressure or out to decrease pressure. Lock the jam nut when pressure is correct (200 bar).
Set the outrigger pressure With a seven place hand valve, the boom/outrigger selector valve is inside the boom control block. This valve is activated when the outrigger enable push button is pushed. There is not a separate relief for this circuit and, therefore, nothing that must be set. The outrigger circuit is set to a maximum of 280-bar (4060 PSI) by the relief valve located on the passenger side outrigger hand valve assembly (Figure 262). The valve routes the oil to the two outrigger hand valve banks, one on each side of the unit. A relief valve inside the passenger side bank limits the entire outrigger circuit to 280-bar.
Relief Valve
Figure 261 Accumulator manifold pressure relief valve
Lower 8. You will need an assistant for this step. With the engine still running, adjust the relief valve on the E-Stop manifold. Back out the adjustment screw until pressure reads 260 bar (3771 PSI) on the gauge connected to the E-Stop manifold.
Higher
Turn body of valve to adjust.
280 bar Relief Valve
Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
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WARNING
Figure 262 Outrigger hand valve
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Pressure Settings
If your unit has a load-sensing proportional system, it will have different pressure adjustments than if it is equipped with a black and white boom system. The following instructions are for load-sensing proportional systems. If you have a unit equipped with a black and white boom system, contact Schwing Service Department for the correct instruction pages.
WARNING Tipping hazard. Never set outrigger pressures with the boom unfolded. Pressure setting procedure requires retraction of an outrigger jacking cylinder.
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NOTE!
The general locations of the components used to set boom hydraulic pressures is shown in Figure 247.
You cannot use the extend position for this adjustment because extend has nonadjustable secondary relief functions built into the valve. 5. Turn the outside body of the relief valve that is located at the back of the passenger side outrigger hand valve (Figure 262). Turn in to raise pressure or turn out to lower pressure. 6. When the pressure on the gauge connected to the outrigger hand valve is 280-bar, release the enable push button and the outrigger hand valve. 7. Remove the whip hose and gauge from the outrigger handvalve, and replace the cap on the gauge port. • Pressure reducing valve This valve is preset at the factory. Contact Schwing America’s Service Department at (651) 429-0999 for information on checking or setting this valve. • Electric stroke limiter The stroke limiter valve is preset at the factory. Contact Schwing America’s Service Department at (651) 4290999 for information on checking or setting this valve. • Load-sensing boom pressures (7 place proportional circuit)
NOTE! Do not adjust ∆P or Q-min if your boom is running as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned from there. It was fine tuned at the factory and should not be adjusted unless absolutely necessary.
WARNING Entanglement hazard. Stop drive shafts before adjusting Q-min.
Each time the Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning.
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1. Connect the whip hose of a 0–400 or 0–600 bar to the gauge port on the right side of the outrigger hand valve. 2. If it is not already done, start the truck engine and set the transmission and PTO as you would for a pumping job. 3. Set the engine RPM to maximum. 4. Push the outrigger enable pushbutton located next to the outrigger hand valve (passenger side). Hold one of the outrigger hand valve levers in the jacking-retract position. The oil coming from the pump has nowhere to go but over the outrigger relief valve.
In a black and white boom system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain a 20 bar higher pressure at the pump than what the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting Q-min and ∆P.
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Pressure Settings Boom Hand Valves
∆P Regulator
E-Stop Manifold
Q-min Adjust Screw
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Figure 263 Location of components used to check or set boom pressures
0-400 bar gauge port 0-60 bar gauge port boom control block relief valve 36
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15 bar pretension adjustment screw
Figure 264 Boom hand valves
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To check or set ∆P follow these steps: 1. Stop the truck engine, and place a “Do Not Operate” sign on the truck windshield. 2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar gauge port of the manual boom handvalves. Take care not to accidently install the gauge in the 0-60 bar port (Figure 264). 3. To be sure that the pump is putting out only enough oil needed to maintain ∆P, we need to change the setting of the Q-min screw. Q-min is adjusted by a screw on the boom hydraulic pump (Figure 265). Unscrew the Q-min screw three full turns. Check that all personnel are clear of the truck, then restart the engine, engage the pumps, and leave the engine at an idle. CAUTION! If you activate any boom or outrigger functions, you will damage the 0 40 bar gauge. Make sure that all emergency stop switches are in the up (not activated) position. Pressure can be read on the 0 - 40 bar gauge that you installed. Pressure should read 20 bar. If no adjustment is needed, simply reset the Q-min screw as described in the Check or set Q-min steps. If adjustment is needed, continue to Step 2. Q-min adjustment screw
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Q-max
Figure 265 Q-min adjust screw 4. Delta P is adjusted by the ∆P screw on the ∆P regulator (Figure 266). Loosen the jam nut, and adjust the screw inward to increase pressure or outward to decrease pressure until it is set at 20 bar (±1). Contact Schwing America’s Service Department if you are unable to adjust the pressure to specification.
NOTE! If the boom does not operate smoothly at 20 bar, you must fine tune the adjustment.
Pressure Settings
Remove the gauge, and adjust ∆P until the boom is responsive and smooth. When done, the gauge (reinstalled) must read between 14 and 25 bar. The electronics in the control system can also affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 20 bar and check the electrical settings. Once electrical settings are verified, you could again refine the boom action with the ∆P adjustment. CAUTION! Do not operate any functions while setting ∆P.
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Check or set ∆P
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∆P adjust screw
Figure 266 ∆P regulator valve
Check or set Q-min You must check Q-min pressure when the engine is at the maximum specified RPM, but you must adjust it with the engine stopped. To check or set the Q-min follow these steps: 1. If you unscrewed the Q-min screw as the first step of ∆P adjustment, begin by returning the screw to its original position (Figure 265). 2. Remove the 0 - 40 bar gauge from the 0 - 400 bar gauge port, and install the 0 - 600 bar gauge in its place (Figure 264). 3. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to max. All boom functions must be in neutral, and all emergency stop buttons must be up (not engaged). 4. Read the pressure on the 0 - 600 gauge. Pressure should be at 40 - 45 bar. If no adjustment is needed, stop the drive lines from turning, be sure the jam nut on the Q-min screw is tight, then continue to Set boom pressures to check the rest of the boom pressures. 5. If adjustment is needed, turn the Q-min screw in to raise the pressure (Figure 265). Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures.
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Pressure Settings Set boom pressures (load sensing proportional booms) Now that ∆P and Q-min are set, you can check or set the boom valve pressures. There are three pressure settings on the boom circuit (Figure 267 and Figure 251). 1. The boom control block relief valve, set at 350 bar (5075 PSI). 2. Pressure regulator (the high-pressure adjustment screw on the ∆P regulator valve), set at 300 bar (4350 PSI).
3. The redundant relief valve located in the emergency stop manifold, set at 330 bar (4786 PSI).
NOTE! The boom control block relief valve is nonadjustable. If pressure is not maintained within the specification limits, the valve must be replaced.
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E-Stop manifold redundant relief valve
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E-Stop manifold redundant relief valve
Figure 267 E-Stop manifold (current production left - original production right
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0-400 bar gauge port 0-60 bar gauge port boom control block relief valve ps
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Bo
36
15 bar pretension adjustment screw
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∆P Regulator Valve (high pressure adjustment screw)
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Figure 268 Boom hydraulic pressure adjustment components To check the setting of the valve with the highest pressure, you must first raise the pressure of the lower two: 1. Loosen the jam nut of the high pressure adjustment screw of the ∆P regulator. Turn the screw in twoand-a-half turns. This will raise the pressure on the ∆P regulator above 350 bar. 2. Loosen the jam nut of the adjustment screw on the E-stop manifold redundant relief valve. Turn the screw in one-and-a-half turns. This will raise the pressure setting of the relief valve to above 350 bar. 3. Pressure out any boom cylinder except #1 down by pushing or pulling the control handle. To pressure out a cylinder, retract a fully retracted cylinder or extend a fully extended cylinder. The oil is forced over the relief valve.
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Pressure Settings
4. The tell tale hiss of an open relief valve should be coming from the Apitech control block relief valve now. If it isn’t, raise the setting of the other pressure devices until the hiss originates at the Apitech control block relief valve. Read the pressure on the gauge connected to the 0-400 bar gauge port on the boom hand valve block. It should read 350 bar. If pressure is correct, proceed to Step 5.
NOTE! Although the pressure specification for the Apitech control block relief valve is 350 bar, you may continue to use the concrete pump as long as the relief valve cartridge maintains at least 330 bar. If pressure on the relief valve is below 290 bar, you should not use the concrete pump until the relief valve is replaced. If you need to replace the relief valve, repeat this entire procedure before using the concrete pump again. 5. Screw out the E-Stop manifold redundant relief valve adjustment screw one-and-a-half turns. Pressure out any boom cylinder except #1 down, and read the gauge. Pressure should read 330 bar. If it does not, turn the screw in to raise pressure or out to lower pressure until it is set at 330 bar. If the location of this valve causes you to be near the drive lines, be sure to stop them from turning before accessing the valve. 6. You will need a helper for this step. While pressuring out any boom cylinder (except #1 down) have your helper adjust the high pressure screw of the ∆P regulator out (lowering the pressure) until the gauge reads 300 bar. Release the pressurized function, and lock the jam nut. The boom pressures are now set. If you did not get the readings specified after following the instructions, contact Schwing America’s Service Department at (651) 429-0999 for advice on how to continue. • Boom holding valves The boom holding valves are adjusted at the factory. Never adjust a holding valve while it is on the boom. If you suspect that a holding valve is not functioning properly contact Schwing America’s Service Department at (651) 429-0999.
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Pressure Settings
0-400 bar gauge port 0-60 bar gauge port boom control block relief valve 36
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15 bar pretension adjustment screw Figure 269 Pretension adjustment screw and gauge port
Set 15 bar pretension To check or set pretension, follow these steps: 1. Stop the truck engine. Plug the 0 - 40 bar gauge into the 0-60 bar gauge port of the Apitech hand valve (Figure 269). 2. Start the truck engine, but leave it at an idle. (Pretension adjustment is made at an idle to establish the minimum pressure setting. As RPM is increased, pressure will rise. Read the pressure on the gauge. If it reads 15 bar ± 1 bar, the pressure is set correctly.
NOTE! Damage to the 0 - 40 bar gauge is possible if RPM is raised while the gauge is connected. 3. If adjustment is needed, loosen the jam nut on the pretension adjustment screw (Figure 269). Turn the screw in to raise pressure and out to lower pressure. When the pressure is correct, retighten the jam nut.
4. Stop the engine, and remove the 0 - 40 bar gauge. With a seven place hand valve, the #1 down brake valve is inside the boom control block. There is not a separate relief valve for this circuit and, therefore, nothing that must be set.
Set water pump pressure With a seven place hand valve, the water pump hydraulic control is inside the boom control block. There is not a separate relief valve for this circuit and, therefore nothing that must be set.
Set the agitator pressure The agitator circuit has a maximum pressure of 200 bar (2900 PSI), limited by the relief valve located on the back of the agitator hand valve (Figure 270). The gauge port for checking or setting the agitator pressure is located on top of the agitator hand valve.
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Pressure Settings 52qrttrn.epsL
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Closed
Shown in the open position
Figure 271 Agitator shutoff valve Agitator Hand Valve 39Xcontr.eps
SECTION 1 AGITATOR
SECTION 2
SECTION 3
SECTION 4
SLEWING
AIR / WATER
BOOM / OUTRIG.
CONCRETE PUMP
WARNING
DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
SAFETY
MANUAL
Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
Figure 270 Agitator hand valve (current production top and original production bottom) 1. Stop the unit, and put the key in your pocket. 2. Connect the whip hose of 0-400 or a 0–600-bar gauge to the gauge port on the agitator hand valve (Figure 272). 3. If your unit is equipped with an agitator shutoff valve, close it (Figure 271). Skip to Step 5.
4. Be sure that one of the locking plugs and capnuts are tightened on the straight fitting and that the dead plugs are securely tightened to the hose and the open motor fitting. 5. Locate the relief valve on the back of the agitator hand valve. 6. Be sure that all personnel are clear, and restart the engine. 7. Activate the agitator hand valve by pushing or pulling the handle. This will send the oil against the high pressure plug. The oil will have nowhere to go, so it will return to the tank over the relief valve in the agitator hand valve. The pressure at which it relieves can be seen on the gauge. It should read 200-bar. 8. If adjustment is needed, turn the outside body of the relief valve that is located at the back of the agitator hand valve. Turn in to raise pressure or turn out to lower pressure (Figure 272).
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Pressure Settings
Agitator Relief Valve Turn body of valve Gauge port
Higher
to adjust.
Lower
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Figure 272 Agitator relief valve 9. When the pressure is set at 200-bar, stop the engine and remove the key. Open the shutoff valve or remove the dead plugs and store them in a clean area or in a plastic bag or something similar in order to keep dirt from entering the fittings. Reattach the hose to the agitator motor fitting and tighten securely. (Torque is correct if you make one complete revolution after feeling initial resistance increase.) 10. Remove the whip hose and pressure gauge. Replace the gauge port cover.
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KVM 42SX Setting Pressures The following pages provide the proper techniques for checking and setting hydraulic pressures of each system included on your unit.
Check all hydraulic pressures Changes in pressures can indicate trouble in one or more components. The specifications for each circuit are shown on the hydraulic schematics found in the Appendix of this manual. The hydraulic schematics are the only documents in this manual that have been updated specifically for your unit, by the serial number, so in each of the following procedures you will be told to refer to the schematic for the pressure required. If you wish to order a CD ROM which explains the pressure setting procedure for a specific model (all pumpkits), call SAI Spare Parts Department at (800) 328 - 9635 and request the CD using the following part numbers: • 61/58 meter. . . . . . . . . . . . . . . . . . . . . . . 30365860 • 52 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30354732 • 45/47 meter. . . . . . . . . . . . . . . . . . . . . . . 30356770 • 42 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30355485 • 39 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30365861 • 34 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30356772 • 32 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30355486 • 31 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30365862 Preheat the hydraulic oil
Pressure settings must be made with the oil at normal operating temperatures (40°− 60° C). In the past we could pressure out a function in the boom or outrigger system to create heat, but load sensing systems no longer allow maximum oil flow to be forced over relief. Because of this the agitator circuit must be used to heat the hydraulic oil. To preheat the hydraulic oil: 1. Locate the agitator shutoff valve (Figure 319) and close it.
NOTE! If your unit does not have a shutoff valve, order one from the Schwing Spare Parts Department using part number 10004680 (valve), and number 30303432 (tube). Contact the Service Department for installation instructions.
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Pressure Settings
2. Activate the agitator. With the valve closed, the agitator will not be able to turn, and the oil will be forced over the relief valve. At an idle (about 600 RPM), 4.5 horsepower is being converted to heat.
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Figure 1 Agitator shutoff valve
3. When the oil temperature gauge shows 50˚C, open the shutoff valve.
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Pressure Settings Setting pressures on Hi-flo -6 pumpkits To set the pressure of the main relief valve on Hi-flo pumpkits, you must first disable the soft switch circuit. Simply locate the ball cock for the soft switch circuit (Figure 320) and close it by rotating the handle 90 degrees. The quarter turn shutoff valve for the concrete pump (Figure 320) will also need to be closed during this procedure.
NOTE! Main system adjustments are preset at the factory. The following procedure begins with adjustment of the main relief cartridge and pressure cutoff. If proper pressures can not be obtained through these steps, contact the Schwing Service Department for specific instructions on the adjustment of flow, horsepower, beginning of stroke regulation, and Q-min. Pressure setting procedure: Soft switch shutoff valve
Concrete pump shutoff valve
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Figure 2 Concrete pump and Soft switch shutoff valves 1. Be sure that the waterbox covers and guards are in place any time you will be working in the area around the main control block. 2. Wear safety glasses when working around a concrete pump.
NOTE! It is vital that each adjustment screw be properly identified prior to making any adjustment. All screw adjustments for the system relief must be made with the pumpkit in the neutral position and adjustments for pressure cutoff must be made with the engine shut off. 3. Start the truck engine, and put the PTO in gear just as you would to pump a job.
4. If you have not already closed the soft switch shutoff valve and the concrete pump shutoff valve (Figure 320) do so at this time. 5. At the rear panel, select “local” control with the “local/remote” switch and turn the electric stroke limiter knob clockwise to maximum strokes per minute. 6. The main system control block pressure must be set first to properly set the pressure cutoff on both pumps. Begin by backing off the jam nut of the main relief cartridge (Figure 322) with a 9/16 inch wrench. 7. Using a 5/32 inch allen wrench, turn the adjustment screw out (counterclockwise) until you can feel no spring tension on the adjustment screw. 8. Now, turn the screw back in (clockwise) two or three full turns to give you a proper starting point and tighten the jam nut. 9. Stop the truck engine and put the key in your pocket. Adjust the pressure cutoff screw (Figure 321) on each pump, by backing off the jam nut with a 13mm wrench. Using a 4mm allen wrench, turn the adjustment screw in (clockwise) one full turn and tighten the jam nut. Restart the truck engine. 10. Adjust the engine RPM to maximum specification. (See decal in truck cab) 11. Pressure out the system by activating the concrete pump forward switch on the rear panel. Using the rear panel controls will allow you to read the concrete pump main system pressure gauge, near the e-stop manifold, from a safe distance.
NOTE! Because you turned out the pressure relief cartridge in step 7, the system pressure should read low at this time. If it does not and the gauge spikes to 320 bar or more, disengage the pump immediately. Turn the relief cartridge out (counterclockwise) more. For safety, it is important to adjust the pressure up from below the specified target pressure rather than down from a pressure which exceeds the target. Continue this procedure until the main system pressure gauge reads lower than the specified target. 12. To increase the pressure put the pump in the neutral position and adjust the relief cartridge by turning it in (clockwise). When increasing the pressure, the adjustments should be made in quarter turn increments. If you make adjustments
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to increase the pressure but the pressure does not come up, you are probably reading the pressure cutoff of the pumps, if so proceed to the next step otherwise skip to step 15.Turn the relief cartridge adjustment screw back out (counterclockwise) until you can no longer see a pressure drop and tighten the jam nut. 13. Stop the truck engine, put the key in your pocket. 14. Go to the pressure cutoff screw on both hydraulic pumps (Figure 321) and back off the jam nut with a 13mm wrench. Turn the adjustment screws in with a 4mm allen wrench one or two more turns, restart the engine and check the pressure again. Repeat this procedure until the main system relief can be set to the target pressure. 15. When the proper main relief pressure is achieved, pressure cutoff can be set. Shut off the engine, put the key in your pocket and install 0-600 bar gauges with whip hoses to the “M1” gauge ports on the bottom of the two hydraulic pumps (Figure 321). You must be able to read both gauges simultaneously to ensure that one pump is not more dominant than the other.
NOTE! The gauges in the M1 ports will read considerably less than the cutoff pressure of the pump. On a -6 (190/130 pump combination) the 190 will usually read 85 to 90 bar while the 130 reads about 110 bar. They could read the same however, at approximately 110 bar, but the 190 must never read higher than the 130. The actual cutoff pressure will be read on the concrete pump main system pressure gauge near the e-stop manifold. 16. Activate concrete pump forward to pressure out the pump and read the pressure on the two gauges in the “M1” ports. 17. Always stop the truck engine and put the key in your pocket before making any adjustment on the hydraulic pump. If the cutoff on one pump is set higher than the other, that pump will be more dominant. The pressure gauge in the M1 port of the dominant pump will however, read lower than the other. To equalize the two pumps you must either adjust the cutoff screw in (clockwise) to increase the pressure of the pump showing the higher reading or adjust the cutoff screw of the dominant pump showing the lower reading out
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Pressure Settings
(counterclockwise) to reduce the pressure. These adjustments must be made until the two gauges in the M1 ports are reading approximately the same. 18. When you have achieved the same pressure on the M1 port gauges, you can begin to adjust the pressure cutoff screws in or out simultaneously until you achieve the desired pressure setting of 350 bar (again, confirm the pressure specification with the hydraulic schematic). After pressure cutoff is set, return the pump to neutral, bring engine RPM to idle, open the soft switch quarter turn valve, and either proceed to other pressure settings or take the transmission and PTO out of gear and shut off the truck.
2 PRESSURE CUT OFF 4 Q-MIN
1 STROKE REGULATION 3 HORSE POWER 2
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M1 GAUGE PORT (BOTTOM OF EACH PUMP) 130ajst.eps
Figure 3 A11VO adjustment screws for Hi-flo – 6 units 190/130
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Pressure Settings Soft switch shutoff valve
Closed
Open
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soft switch relief valve
Concrete pump shutoff valve
Main relief valve 5/32" Allen head
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Figure 4 Soft switch components
Setting the soft switch relief pressure
Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure 322, right) that you closed in the previous procedure. The rest of the unit should still be set up as if you were going to check the main relief valve pressure (concrete pump shutoff valve still closed). When you put the pump in forward now, the main concrete pump pressure gauge should read the pressure shown on the schematic for soft switch. If adjustment is needed, loosen the soft switch relief valve jam nut (Figure 322, right) with a 9/16 open end wrench, and use a 5/32 allen wrench to adjust the pressure. Turn the adjustment screw in (clockwise) to raise the pressure or out (counter clockwise) to lower the pressure. When you attain the required pressure, tighten the jam nut while holding the allen wrench to keep the pressure from rising. Be sure to open the concrete pump shutoff valve on the side of the brain (Figure 322, left) when you are finished. The unit will not stroke with this valve closed.
This unit is equipped with a load-sensing, proportional boom hydraulic system. In a black-and-white system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain 20 bar higher pressure at the pump than the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting ∆P and Q-min.
NOTE! Any time you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (40°–60° C). Instructions on heating the hydraulic oil are found in the first step of this “checking hydraulic pressures” segment. Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when setting pressures.
WARNING Entanglement hazard. Stop drive shafts before adjusting Delta P on A11VO pump.
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Setting boom circuit pressures
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Pressure Settings
0-600 bar gauge port ps
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pretension only 33-35 bar
Boom pressure relief cartridge
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Figure 5 (Left) The 0–60 bar gauge port is located at the top of the boom control block, and the 0-600 bar port is at the bottom. (Right) A 0–600 bar gauge port is located on the E-stop manifold.
Do not adjust ∆P or Q-min if your boom is running as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned from that point. The pressure was fine tuned at the factory and should not be adjusted unless absolutely necessary. 1. Start by turning off the engine and putting the key in your pocket; then place a “Do Not Operate” sign on the windshield of the truck. 2. Install a 0-100 bar gauge in the high pressure test port at the bottom of the boom control block (Figure 279).
NOTE! Do not activate any boom/outrigger functions or release any e-stops with a low pressure gauge attached to a high pressure port. 3. Delta P is adjusted on the pressure regulator (Figure 307, top) if your unit has an A7VO pump or (Figure 307, bottom) if your unit has an A11VO boom pump. When all personnel are clear of the truck, restart the engine, engage the pumps, and leave the engine at an idle. ∆P pressure should read 17 bar, which is the standard starting point. 4. There are two adjustment screws on the pressure regulator (Figure 307, top) for A7VO pumps. The smaller screw is used in this procedure to adjust ∆P. On the A11VO pumps there is only one ∆P screw (Figure 307, bottom). 5. If adjustment is required, loosen the jam nut, and adjust the screw inward to increase pressure or outward to decrease pressure until it is set at 20
bar. After achieving proper ∆P, tighten the jam nut and bring the engine RPM up. If the pressure gauge continues to read 20 bar, you are reading the true ∆P pressure and may move on to setting the Qmin. If the pressure rises with the RPM, however, you may be reading the Q-min pressure instead of true ∆P. If that happens, stop the engine, put the key in your pocket, and place a “Do Not Operate” sign on the windshield of the truck before proceeding.
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Setting delta P pressure
Regulator pressure adjustment T
Adjustment for P pressure
Delta-P
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Figure 6 Pressure regulator for A7VO boom pumps (top) and A11VO pumps (bottom)
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Q-min adjustment screw
Delta-P
Pressure cut-off
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Q-min
Q max
Q-max (bottom of pump)
If pressure cannot be set correctly, there is a problem either with the orifices in the base of the regulator or with the regulator itself. Contact the Schwing Service Department to determine how to continue. If the boom does not run smoothly at 17 bar, you must fine tune the adjustment. Remove the gauge, and turn the ∆P adjustment screw until the boom is responsive and smooth. After adjusting, the gauge (reinstalled) must read between 14-25 bar. The electronics in the control system can also affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 17 bar and check the electrical settings. Once electrical settings are verified, you could again try to refine the boom action with the ∆P adjustment.
NOTE! The pressure regulator (Figure 326) is usually mounted on the inside of the subframe, near the cab end of the differential cylinders.
Regulator pressure adjustment T
Adjustment for P pressure
Figure 8 Boom pressure regulator for units with A7VO pumps
WARNING Entanglement hazard. Stop drive shafts before adjusting Q-min.
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6. Unscrew the Q-min screw (Figure 325) three full turns. This step will help ensure that the pump produces only the amount of flow needed to maintain ∆P pressure. Once all personnel are clear of the truck, restart the engine, engage the pumps, and recheck at an idle. Pressure should now read 17 bar. If it does not, go back and adjust ∆P until it does.
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Figure 7 Location of Q-min screw on the A7VO (left) and all adjustment screws of the A11VO (right)
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Setting Q-min Check Q-min when the engine is at maximum specified RPM. You must not adjust Q-min with the drive shafts turning! Each time the Q-min screw must be adjusted, the engine must be stopped or, at least, the transmission must be taken out of gear so that the drivelines stop turning. 1. If you unscrewed the Q-min screw as part of the ∆P adjustment, begin by returning the screw to its original position. 2. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). Clear away all personnel, start the truck engine, engage the pumps and bring engine RPM to max. Read the pressure at the 0–600 bar main boom gauge port (Figure 327) with a 0-100 bar gauge. Pressure should be at 30 bar. If no adjustment is needed, be sure the jam nut on the Q-min screw is tight; then continue to set the rest of the boom and outrigger pressures. If adjustment is needed, continue to the next step. 3. Turn the Q-min screw (Figure 325) in to raise the pressure. Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures; then recheck ∆P to make sure that it hasn’t changed during the Q-min adjustment.
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Pressure Settings
4. Identify the main boom pressure relief cartridge on the boom control block (Figure 328) and loosen the jam nut. Then unscrew the adjustment two full turns. 5. Take engine RPM to full throttle and activate boom retract for any boom section except #1. 6. Now adjust pressure, which is read at the main boom gauge port, to the setting found on the schematic by turning the boom pressure relief cartridge in, or clockwise, using no more than 1/4 turn increments. 7. When desired pressure is achieved, lock down the jam nut.
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NOTE! If you don’t have a 0-100 bar gauge you can order one from Schwing Spare Parts Department at (800) 328-9635, part # 10004659.
Setting boom pressures Now that ∆P and Q-min are set, you can remove the 0100 bar pressure gauge and proceed to check and adjust the main boom pressures. 1. Loosen jam nut of the boom pressure relief cartridge (Figure 327) with a 30mm open end wrench. 2. Turn the adjustment cartridge clockwise all the way in with a 32mm wrench. 3. Loosen the jam nut on the pressure relief screw of the regulator (Figure 326) or the pressure cut-off (Figure 325), and tighten the screw all the way down.
Figure 9 Boom pressure relief cartridge 8. The next step is to return to the e-stop manifold boom pressure relief cartridge (Figure 327) and back off the jam nut (30 mm). Turn the relief cartridge (32mm) out, or counter clockwise, until you achieve the pressure shown on the schematic, for the boom pressure relief cartridge. When the proper pressure is achieved, lock the jam nut.
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Pressure Settings Setting outrigger pressure mainrlf.eps
After the boom circuit is properly set, you can set the outrigger pressure. Find the relief cartridge located on the front of the passenger side outrigger control valve (Figure 312).
Main boom pressure relief cartridge
Figure 10 Main boom pressure adjustment and piston side relief
9. The next pressure setting is the regulator pressure. Locate the regulator adjustment screw (Figure 325) or pressure cut-off screw (Figure 326). Back off the jam nut, and turn the screw counterclockwise until you achieve the pressure shown on the schematic; then lock the jam nut. 10. The final boom pressure setting is the #1 boom rod side relief setting. This relief cartridge is in close proximity to the main boom relief (Figure 328), so be sure to locate the proper adjustment. This procedure should be performed with the outriggers extended and the boom unfolded over the cab. Disconnect all gauges from gauge ports prior to operating any boom or outrigger functions. Bring section #1 all the way down until the cylinder bottoms out. Install a 0-600 bar gauge in the main boom gauge port of the e-stop manifold (Figure 327), and activate boom #1 down. The pressure should read the setting shown on the schematic. If adjustment is required, back off the jam nut and turn the relief cartridge in or out as required until the desired pressure is achieved; then lock down the jam nut.
Tipping hazard. Never set outrigger pressures with the boom unfolded. Pressure setting procedure requires retraction of an outrigger jacking cylinder.
1. Attach 0-600 bar whip gauge to the gauge port (Figure 312) below the outrigger valve bank. 2. Push the outrigger enable button. 3. Activate an outrigger jacking cylinder to retract. By retracting a fully retracted cylinder, the oil coming from the pump has nowhere to go but over the relief valve. You cannot use an extension or slewing cylinder because they have secondary relief functions (nonadjustable) built into the valve. While holding the handle to retract, read the pressure gauge. 4. The pressure should read the bar value shown on the hydraulic schematic. Adjust by loosening the jam nut with a 9/16” open end wrench and turning the cartridge (Figure 312) in or out with 5/32 allen wrench. When the proper pressure is achieved, let go of the handle and release the outrigger enable button. testport.eps
REAR SLEW
REAR JACKING
FRONT JACKING
FRONT EXTEND
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#1 down side relief cartridge
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Relief Cartridge Gauge Port
Figure 11 Outrigger valve bank relief cartridge and gauge port
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CONCRETE PUMP FORWARD/REVERSE
AGITATOR
Relief valve
Gauge port
Figure 12 Agitator component location
Setting the agitator pressure The agitator circuit has a maximum pressure shown on the hydraulic schematic, which is limited by the relief cartridge (Figure 314) in the agitator hand valve. The relief cartridge is located on the back side of the agitator manual control handle (Figure 314). The cartridge is adjustable with just an 19mm open end wrench. 1. Plug the 0–600 bar whip gauge into the gauge port (Figure 314) for checking or setting agitator pressure. 2. Locate the agitator shutoff (Figure 331) valve and close it. If your unit does not have a shutoff valve, order one from the Schwing Spare Parts Department using part numbers 10004680 (valve) and 30303432 (tube). Contact the Service Department for installation instructions, or if you can’t wait for a shutoff valve, you will need to remove one of the hoses from the agitator motor and plug the hose and open fitting with approved hydraulic dead plugs (Figure 332).
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Figure 13 Agitator shutoff valve
Plugs Straight Fitting Figure 14 Approved hydraulic dead plugs
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NOTE! Do not jam the paddles to force the oil over relief by stopping the movement of the agitator.
Cap Nuts 3. Increase the throttle to any speed above idle. Activate the agitator valve handle in either forward or reverse, and read the gauge. If it does not read
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Pressure Settings the specified pressure, adjustment is required. Turn the entire valve body (Figure 314) in to increase pressure or out to decrease pressure. 4. When the pressure is set, deactivate the agitator by placing the manual control handle in the neutral position. 5. Remove the whip gauge. 6. Reopen the shutoff valve or remove the dead plugs and reconnect the capped hydraulic line.
Setting accumulator circuit pressure
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Accumulator pump pressure regulator
January 1, 2000, it will have an emergency stop manifold similar to the illustration shown in the bottom of Figure 233, which no longer has a redundant relief cartridge, and you must skip steps 3. and 7. in the following procedure. To check or adjust the hydraulic pressure in the accumulator circuit: 1. Stop the truck, put the key in your pocket, and place a “Do Not Operate” sign on the windshield. 2. Loosen the jam nut on the pressure regulator of the accumulator hydraulic pump (Figure 232). Turn the screw in two-and-one-half turns. This will raise the regulator pressure above 300 bar. 3. Loosen the jam nut (Figure 233) on the accumulator redundant relief cartridge located on the emergency stop manifold. Turn the screw in two turns. This will raise the relief setting above 300 bar. accurlf2.eps
Accumulator redunant relief cartridge
Figure 15 Accumulator pump pressure regulator for A7VO (above) and for A11VO (below) Boom Pump
Figure 16 Accumulator redundant relief cartridge (above) is only present on early production models. New e-stop (below) has no redundant relief cartridge.
Accumulator Pump Pressure Regulator
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You will need an assistant for parts of this procedure. There are three relief settings for the accumulator circuit if your unit is equipped with an accumulator redundant relief cartridge in the emergency stop manifold(Figure 233, top). If your pump was built after
4. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring the engine RPM to maximum.
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@@@@@@@@ ;;;;;;;; QQQQQQQQ @@@@@@@@ ;;;;;;;; QQQQQQQQ @@@@@@@@ ;;;;;;;; QQQQQQQQ @@@@@@@@ ;;;;;;;; QQQQQQQQ ;;;;;;;; @@@@@@@@ QQQQQQQQ @@@@@@@@ ;;;;;;;; QQQQQQQQ ;;;;;;;; @@@@@@@@ QQQQQQQQ ;;;;;;;; @@@@@@@@ QQQQQQQQ 45acumpr.epsL
Figure 17 Accumulator circuit pressure gauge
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Pressure Settings
screw while the other person stands by the pressure gauge to let him know when the pressure reads the value shown on the schematic for accumulator redundant relief.
WARNING Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
8. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 232), and turn the screw back out two-and-one-half turns. This restores it to its original setting. 9. Clear all personnel from the drive line area, start the truck, and bring the engine RPM up to maximum. 10. Read the pressure on the accumulator gauge. It should read the proper accumulator system pressure. 11. If adjustment is needed, you must stop the truck engine, or a least stop the drive lines from turning, each and every time you approach the accumulator circuit hydraulic pump. Turn the screw in to increase the pressure or out to decrease pressure. Lock the jam nut when the pressure is correct.
NOTE! The accumulator circuit hydraulic pump pressure regulator is referred to as the pressure cut-off. Figure 18 Accumulator manifold pressure relief cartridge 6. Locate the accumulator manifold pressure relief cartridge (Figure 235). Loosen the jam nut, and turn the screw clockwise to increase the pressure or counterclockwise to decrease the pressure. Tighten the jam nut when the pressure reaches the value required. 7. You will need an assistant for this step. With the engine still running, one person must go to the redundant relief valve on the emergency stop manifold (Figure 233) and back out the adjustment
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5. Read the pressure on the accumulator circuit pressure gauge (Figure 234). The pressure should read the value shown on the hydraulic schematic. If no adjustment is needed, skip to step number 7. If additional pressure adjustment is needed, continue with step number 6.
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KVM 42M - Proportional (Apitech) Single Circuit Check the fluid level of the distribution gearcase (Figure 273). Be sure the truck is on reasonably level ground. With the truck engine off and the key in your
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Pressure Settings
pocket, remove the check plug from the check port. The oil should be at the level of the bottom of the hole in the case. If oil is needed, add it by removing the breather and pouring the oil through the top of the fill port. This gearcase uses 90W gear lube.
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Breather (fill port)
Check port
Drain port
Figure 273 Fill, check, and drain ports of Stiebel 4194 gearcase Check the mounting hardware of the subframe, the oil and water tanks, the delivery pipeline, the pumpkit, the differential cylinders, the material cylinders, and the driveline hardware. Check for bolt tightness, cracks, and other abnormalities.
Check hydraulic pressures Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components. Pressure settings must be made with the oil at normal operating temperature (40°–60°C). The specifications for all circuits are shown on the hydraulic schematics in the appendix of this manual.
Preheat the hydraulic oil Pressure settings must be made with the oil at normal operating temperatures (40°– 60°C). Because the system is load-sensing, the boom circuit cannot be used to heat the hydraulic oil. The agitator circuit must be used instead. To preheat the hydraulic oil using the agitator circuit, follow these instructions:
1. Place a 4-by-4 in front of the agitator paddle. 2. Turn on the agitator. The agitator will not be able to turn, and the oil will be forced over the relief valve. At an idle (about 600 RPM), you are converting about 4.5 horsepower to heat, which is a good-sized heater. Shut off the concrete pump when the oil shows 40°C on the temperature gauge of the operator’s panel.
Setting concrete pump pressure (singlecircuit units) Schwing single-circuit pumpkits are designed to be operated at a maximum pressure of 300 bar (4350 PSI). The pressure in the system is controlled by the main relief valve on the forward end (toward the truck cab) of the main control block (Figure 274).
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Jam nut
Lower pressure
Raise pressure
Adjustment handle
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Figure 274 Concrete pump circuit main relief valve To check or set the main relief pressure:
1. When setting pressures, always wear safety glasses. 2. Be sure that the waterbox covers and guards are installed on the waterbox. Schwing does not recommend using the remote control box when setting the main relief pressure.
3. Start the truck engine, and put the PTO and transmission into gear, just as you would to pump a job. 4. Close the shutoff valve (also known as the “ballcock” or “quarter-turn valve”)(Figures 275).
Shutoff valve
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Figure 275 Concrete pump shutoff valve 5. Put the main operator’s panel “remote / local” switch into the “local” position. 6. Using the switch on the main operator’s panel, rev the truck engine up to full RPM. 7. Put the operator’s panel “forward / neutral / reverse” switch into the “forward” position. The unit will stroke only once; then the rock cylinder
will retract. Oil will be forced over the main relief valve. This procedure is called high-pressuring the concrete pump.
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Groove at 90° to ports— Closed
Groove lined up with ports— Open Ball cock grooves.eps
Figure 276 Open/closed orientation of concrete pump shutoff valve 8. Read the pressure on the gauge. It should read 300 bar. Return the pump to “neutral” whether it needs adjustment or not. If no adjustment is needed, skip to step (n). 9. Using a 13-mm spanner wrench, loosen the jam nut on the relief valve adjusting screw (Figure 274). 10. Turn the knob on the relief valve to adjust the pressure. Screw the handle in to raise pressure, and out to lower pressure. 11. Retighten the jam nut. Tightening the nut tends to raise the pressure setting. If the rise in pressure becomes a problem, hold the knob while tightening the jam nut.
12. Put the concrete pump into the “forward” position again. The machine will not stroke this time, but it will high-pressure again. Read the pressure on the gauge. If more adjustment is needed, return the pump to “neutral,” then repeat steps (i) through (l) until the pressure is correct. Note! If you cannot adjust the pressure up to specification, you have a problem. In this case, unscrew the adjustment handle several turns so that your pressure is not too high when you find the problem. Contact Schwing America’s Service Department for advice on how to continue. 13. Return the pump to the “neutral” position. 14. Open the concrete pump shutoff valve (Figure 277).
Shutoff valve
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Figure 277 Concrete pump shutoff valve
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Pressure Settings 15. Return the RPM of the truck to idle, take the transmission and PTO out of gear, and shut off the truck, or go on to other pressure settings.
Setting boom circuit pressures Note! Whenever you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (40°–60°C). Instructions on preheating the hydraulic oil for this procedure are in section • on page 6-243. Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when setting pressures.
Figure 283
Load-sensing boom hydraulic controls This unit is equipped with a load-sensing, proportional boom hydraulic system. In a black-and-white system, the hydraulic pump puts out an unchanging amount of oil, and speed is controlled by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain 20 bar higher pressure at the pump than what the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil ensures that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a loadsensing system, begin by setting Q-min and ∆P (Figure 278).
Figure 281 Figure 280
Figure 279
42 Location Page 1
Component Locations Figure 279—Boom control handvalves Figure 280—Q-min adjustment screw Figure 281—∆P regulator
Figure 278 Locations of components used to check boom pressures
Setting ∆P You must not adjust Q-min with the drive shafts turning! Each time the Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning. To check or set ∆P, follow these steps: 1. Stop the truck engine and place a “Do Not Operate” sign on the windshield of the truck.
2. Install a 0–40 bar gauge in the pressure check port of the boom handvalve. Take care not to accidently install the gauge in the pretension check port (Figure 279).
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Adjustment screw (15 bar pretension)
Pretension check port (0–40)
Pressure check port (except pretension) 0-40 and 0-600
Figure 279 Boom control handvalve (Apitech) 3. To be sure that the pump is only putting out the oil needed to maintain ∆P, we need to change the setting of the Q-min screw. Q-min is adjusted by a screw on the boom hydraulic pump (Figure 280).
Q-min adjustment screw
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Q-max
Figure 280 Location of the Q-min adjustment screws
CAUTION Do not operate any functions while setting ∆P. 4. Unscrew the Q-min screw three full turns. Check that all personnel are clear of the truck, then restart the engine, engage the pumps, and leave the engine at an idle. If you activate any boom or outrigger functions, you will damage the 0–40 bar gauge.
Make sure that all emergency stop switches are in the up (not engaged) position. Pressure can be read on the 0–40 bar gauge that you installed. Pressure should read 20 bar. If no adjustment is needed,
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pressreg.eps deltaPvlv.eps
simply reset the Q-min screw as described in paragraph . If adjustment is needed, continue to step (5).
5. Delta P is adjusted by the ∆P adjustment screw on the boom pump (Figure 281). Loosen the jam nut, and adjust the screw inward to increase pressure, or outward to decrease pressure until it is set at 20 bar ± 1.
Regulator pressure adjustment T
Adjustment for P pressure
Figure 281 ∆P regulator valve
6. If pressure cannot be set correctly, contact the Schwing Service Department to determine how to continue.
each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures.
Setting Q-min You must check Q-min pressure when the engine is at the maximum specified RPM, but you must adjust it with the engine stopped. 1. If you unscrewed the Q-min screw as the first step of ∆P adjustment, begin by returning the screw to its original position (see Figure 280). 2. Remove the 0–40 bar gauge from the pressure check port, and install the 0–600 bar gauge in its place. 3. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to max. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). Read the pressure on the 0– 600 bar gauge. Pressure should be at 40–45 bar. If no adjustment is needed, stop the drivelines, be sure the jam nut on the Q-min screw is tight, then continue to paragraph to check the rest of the boom and outrigger pressures. If adjustment is needed, continue to step (4). 4. Turn the Q-min screw in to raise the pressure (see Figure 280). Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning
Setting boom pressure Now that ∆P and Q-min are set, you can check or set the main boom pressures. There are three pressure settings:
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Pressure Settings
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1. Pressure regulator (the high-pressure adjustment screw on the ∆P regulator valve), set at 290 bar (Figure 281)
Regulator pressure adjustment T
Adjustment for P pressure
Figure 282 ∆P regulator valve 2. Redundant relief valve located in the emergency stop manifold, set at 320 bar (Figure 283). 10167892-3.eps
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Figure 283 Emergency stop manifold, and boom redundant relief
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Pressure Settings 3. Boom control block relief, set at 350 bar. NOTE! This relief valve is nonadjustable. If pressure is not maintained within the specification limits, the valve must be replaced (Figure 284).
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350 bar relief
30 bar relief
Figure 284 Apitech boom control block relief To check the setting of the valve with the highest pressure, you must first raise the pressure of the lower two: 1. Loosen the jam nut of the high-pressure adjustment screw of the ∆P regulator (see Figure 281). Turn the screw in two-and-a-half turns. This will raise the pressure on the regulator above 350 bar. 2. Loosen the jam nut of the adjustment screw of the redundant relief valve in the emergency stop manifold (see Figure 283). Turn the screw in oneand-a-half turns. This will raise the pressure on the relief valve to above 350 bar. 3. Pressure out any boom cylinder except #1 down by pushing or pulling the control handle. To pressure out a cylinder, retract a fully retracted cylinder or extend a fully extended cylinder. The oil is forced over the relief valve. The telltale hiss of an open relief valve should be coming from the Apitech control block relief valve now. If it isn’t, raise the setting of the other pressure devices until the hiss originates at the Apitech control block relief valve. Read the pressure on the gauge. It should read 350 bar. If pressure is correct, proceed to step (4).
NOTE! Although the pressure specification for the Apitech relief valve is 350 bar, you may continue to use the relief valve as long as the cartridge maintains at least 330 bar. If you must replace the valve, proceed to step (4) before using the machine again, and redo this entire procedure when you have installed the new valve. If pressure on the Apitech relief valve is below 290 bar, you should not use the machine until the valve is replaced. 4. Screw out the redundant relief valve adjustment screw (see Figure 283) one-and-a-half turns. Pressure out any boom cylinder except #1 down, and read the gauge. Pressure should read 320 bar. If does not, turn the screw in to raise pressure, or out to lower pressure until it is at 320 bar. If the location of this valve causes you to be near the drivelines, be sure to stop them from turning before accessing the valve. 5. You will need a helper for this step. While pressuring out any boom cylinder except #1 down, have your helper adjust the high-pressure screw of the ∆P regulator out (lowering the pressure) until the gauge reads 290 bar (see Figure 281). Release the pressurized function and lock the jam nut. The boom pressures are now set. If you did not get the
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readings specified after following the instructions, contact Schwing’s Service Department for advice on how to continue.
Setting pretension To check or set pretension follow these steps: 1. Remember that the oil must be at normal operating temperature (40°–60°C). See point • for information about preheating the oil.
Pressure Settings
2. Stop the truck engine. Plug the 0–40 bar gauge into the pretension gauge port of the Apitech handvalve (Figure 285). 3. Start the truck engine, but leave it at an idle. Read the pressure on the gauge. If it reads 15 bar ± 1 bar, the pressure is set correctly. If the pressure is not set correctly, continue to point (4.)
CAUTION Truck engine must be at idle when pretension is set.
4. Loosen the jam nut on the pretension valve. Turn the screw in to raise pressure, and out to lower pressure. When the pressure is correct, retighten the jam nut (Figure 285).
Adjustment screw Apitech pretnscrw.eps
Gauge port
Figure 285 Pretension adjustment screw and gauge port 5. Stop the engine, and remove the 0–40 bar pressure gauge. Pretension setting is now complete.
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Pressure Settings
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KVM 42M - Proportional (Apitech) Twin Circuit Check the fluid level of the distribution gearcase (Figure 286). Be sure the truck is on reasonably level ground. With the truck engine off and the key in your
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Pressure Settings
pocket, remove the check plug from the check port. The oil should be at the level of the bottom of the hole in the case. If oil is needed, add it by removing the breather and pouring in the oil through the top. This gearcase uses 90W gear lube.
Check port
4194 gearcase scan.eps
Breather (fill port)
Drain port
Figure 286 Fill, check, and drain ports of Stiebel 4194 gear Check the mounting hardware of the subframe, the oil and water tanks, the delivery pipeline, the pumpkit, the differential cylinders, the material cylinders, and the driveline hardware. Check for bolt tightness, cracks, and other abnormalities.
Check hydraulic pressures Check all hydraulic pressures. The specifications for each circuit are shown on the hydraulic schematics in the appendix of this manual. Changes in pressures can indicate trouble in one or more components.
Preheat the hydraulic oil Pressure settings must be made with the oil at normal operating temperatures (40°– 60°C). Because the system is load-sensing, the boom circuit cannot be used to heat the hydraulic oil. The agitator circuit must be used instead. To preheat the hydraulic oil using the agitator circuit, follow these instructions: 1. Place a 4-by-4 in front of the agitator paddle.
2. Turn on the agitator. The agitator will not be able to turn, and the oil will be forced over the relief valve. 3. At an idle (about 600 RPM), you are converting about 4.5 horsepower to heat, which is a pretty good-sized heater. Shut off the concrete pump when the oil shows 40°C on the temperature gauge of the operator’s panel.
Setting concrete pump pressure (Highflow pumpkits) Schwing units with high-flow pumpkits are designed to be operated at a maximum pressure of 320 bar (4640 PSI). The pressure in the system is limited by the relief valve located on the forward end (toward the truck cab) of the main control block (Figure 287). In addition, the hydraulic pumps have a pressure cutoff function, set at 350 bar. To check or set concrete pump circuit pressures, follow these steps: 1. Wear safety glasses when setting pressures.
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Pressure Settings 9. Loosen the jam nut on the relief valve adjusting screw (Figure 287). 10. Insert a hex key (allen) wrench into the screw, and turn the screw to adjust the pressure. Turn the screw in to raise pressure, out to lower pressure. 11. Retighten the jam nut. (Tightening the nut tends to raise the pressure. If the rise in pressure becomes a problem, hold the hex key wrench while tightening the jam nut.) 12. High-pressure the concrete pump again. Read the pressure on the gauge. If more adjustment is needed, return the concrete pump switch to “neutral,” then repeat steps (i) through (l) until the pressure is correct. Note! If you cannot adjust the pressure up to specification, you have a problem. In this case, unscrew the adjustment knob several turns so that your pressure is not too high when you find the problem. Contact Schwing America’s Service Department at (612) 429-0999 for advice on how to continue. 13. If you will not be setting the soft switch pressure, open the shutoff valves. The unit will not stroke with closed shutoff valves.
Soft switch shutoff valve Main Pressure Gauge port
Closed
Concrete pump shutoff valve
hif
lob
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Open
2. Be sure that the waterbox covers and guards are installed on the waterbox. Schwing does not recommend using the remote control box when setting the main relief pressure. 3. Start the truck engine, and put the PTO and transmission into gear, just as you would to pump a job. 4. Locate and close the concrete pump shutoff valve (quarter-turn valve), and the soft switch shutoff valve (quarter-turn valve) (Figures 288 and 289). 5. Put the operator’s panel “remote / local” switch into the “local” position. 6. Using the switch on the operator’s panel, rev the truck engine up to full RPM. 7. Put the operator’s panel “forward / neutral / reverse” switch into the “forward” position. The unit will stroke only once, then the rock cylinder will retract. The oil leaving the hydraulic pumps will be forced over the main relief valve. This procedure is called high-pressuring the concrete pump. 8. Read the pressure on the gauge, as shown. It should read 320 bar. Return the pump control to “neutral,” whether it needs adjustment or not. If no adjustment is needed, skip to step (13).
Figure 287 Locations of the concrete pump and soft switch relief valves
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Pressure Settings
Soft switch shutoff valve Main Pressure Gauge port
Concrete pump shutoff valve
hif
lob
rn
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ps
Figure 288 Locations of the concrete pump and soft switch shutoff valves
Groove lined up with ports - open
Closed
Open
openclsd.eps
grooves.eps
Groove at 90° to ports - closed
Figure 289 Open/closed orientation of the concrete pump shutoff valve (left) and the soft switch shutoff valve (right)
Setting the soft switch circuit relief pressure To check or adjust the soft switch pressure setting, proceed as follows: 1. Open the soft switch shutoff valve. The rest of the unit should still be set up as if you were going to check concrete pump pressure (Figure 290). 2. High-pressure the concrete pump. The pressure gauge should read 80 bar (1160 PSI) instead of 320 bar. If adjustment is needed, loosen the jam nut of the relief valve cartridge. Using the hex key wrench, adjust the pressure up or down as needed, and lock into place with the jam nut. Recheck. Hold the screw with the hex key wrench, if necessary, to prevent the screw from turning while tightening the jam nut. Be sure to open up the
concrete pump shutoff valve on the side of the brain (shown in Figure 288) when you are finished. The unit will not stroke with this valve closed.
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Pressure Settings
Soft switch shutoff valve
Open
sftopen.eps
Main Pressure Gauge port
Soft switch relief valve
Concrete pump shutoff valve
hif
lob
rn
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reheat the oil to check pressures Note! Any time you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (40°–60°C). Instructions on heating the hydraulic oil for this procedure are found in section • on page 6-243. Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when setting pressures.
Load-sensing boom hydraulic controls This unit is equipped with a load-sensing, proportional boom hydraulic system. In a black-and-white system such as the 28X, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain 20 bar higher pressure at the pump than what the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting Q-min and ∆P (Figure 278).
Figure 290 Soft switch circuit components
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SERVICE TRAINING
Figure 283
Figure 281
Figure 280
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Pressure Settings Figure 279
42 Location Page 1
Component Locations Figure 279—Boom control handvalves Figure 280—Q-min adjustment screw Figure 281—∆P regulator
Figure 291 Locations of components used to check boom pressures
Setting ∆P You must not adjust Q-min with the drive shafts turning! Each time the Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drive lines stop turning. To check or set ∆P, follow these steps:
1. Stop the truck engine and place a “Do Not Operate” sign on the windshield of the truck. 2. Install a 0–40 bar gauge in the pressure check port of the boom handvalve. Take care not to accidently install the gauge in the pretension check port (Figure 292).
42 apitech back.epsL
Adjustment screw (15 bar pretension)
Pretension check port (0–40)
Pressure check port (except pretension) 0-40 and 0-600
Figure 292 Boom control handvalve (Apitech)
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Pressure Settings 3. To be sure that the pump is only putting out the oil needed to maintain ∆P, we need to change the setting of the Q-min screw. Q-min is adjusted by a screw on the boom hydraulic pump (Figure 293). Q-min adjustment screw
Q-minscrew.eps
Q-max
Figure 293 Locations of the Q-min adjustment screws
CAUTION Do not operate any functions while setting 20 bar ∆P.
pressreg.eps deltaPvlv.eps
4. Unscrew the Q-min screw three full turns. Check that all personnel are clear of the truck, then restart the engine, engage the pumps, and leave the engine at an idle. If you activate any boom or outrigger functions, you will damage the 0–40 bar gauge. Make sure that all emergency stop switches are in the up (not engaged) position. Pressure can be read on the 0–40 bar gauge that you installed. Pressure should read 20 bar. If no adjustment is needed,
simply reset the Q-min screw as described in paragraph . If adjustment is needed, continue to step (5). 5. Delta P is adjusted by the ∆P adjustment screw on the ∆P regulator (Figure 294). Loosen the jam nut, and adjust the screw inward to increase pressure, or outward to decrease pressure until it is set at 20 bar ± 1.
Regulator pressure adjustment T
Adjustment for P pressure
Figure 294 Delta P regulator valve 6. If pressure cannot be set correctly, contact the Schwing Service Department to determine how to
continue.
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Setting Q-min
pressreg.eps deltaPvlv.eps
You must check Q-min pressure when the engine is at the maximum specified RPM, but you must adjust it with the engine stopped. 1. If you unscrewed the Q-min screw as the first step of ∆P adjustment, begin by returning the screw to its original position (see Figure 293). 2. Remove the 0–40 bar gauge from the pressure check port, and install the 0–600 bar gauge in its place. 3. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to max. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). Read the pressure on the 0– 600 bar gauge. Pressure should be at 40–45 bar. If no adjustment is needed, stop the drive lines, be sure the jam nut on the Q-min screw is tight, then
Pressure Settings
continue to paragraph to check the rest of the boom and outrigger pressures. If adjustment is needed, continue to step (4). 4. Turn the Q-min screw in to raise the pressure (see Figure 293). Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures.
Setting boom pressure Now that ∆P and Q-min are set, you can check or set the main boom pressures. There are three pressure settings: 1. Pressure regulator (the large adjustment screw on the ∆P regulator valve), set at 290 bar (Figure 295).
Regulator pressure adjustment T
Adjustment for P pressure
Figure 295 ∆P regulator valve 2. Redundant relief valve located in the emergency stop manifold, set at 320 bar (Figure 296). 10167892-3.eps
P3
P2 P4 P1
M
TT MP
1
Figure 296 Emergency stop manifold, and boom redundant relief valve
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Pressure Settings 3. Boom control block relief, set at 350 bar. NOTE! This relief valve is nonadjustable. If pressure is not maintained within the specification limits, the valve must be replaced (Figure 297).
42 apitech relief.eps
350 bar relief
30 bar relief
Figure 297 Apitech boom control block relief valve To check the setting of the valve with the highest pressure, you must first raise the pressure of the lower two: 1. Loosen the jam nut of the high-pressure adjustment screw of the ∆P regulator (see Figure 295). Turn the screw in two-and-a-half turns. This will raise the pressure on the regulator above 350 bar. 2. Loosen the jam nut of the adjustment screw of the redundant relief valve in the emergency stop manifold (see Figure 283). Turn the screw in oneand-a-half turns. This will raise the pressure on the relief valve to above 350 bar. 3. Pressure out any boom cylinder except #1 down by pushing or pulling the control handle. To pressure out a cylinder, retract a fully retracted cylinder or extend a fully extended cylinder. The oil is forced over the relief valve. The telltale hiss of an open relief valve should be coming from the Apitech control block relief valve now. If it is not, raise the setting of the other pressure devices until the hiss originates at the Apitech control block relief valve. Read the pressure on the gauge. It should read 350 bar. If pressure is correct, proceed to step (4).
NOTE! Although the pressure specification for the Apitech relief valve is 350 bar, you may continue to use the relief valve as long as the cartridge maintains at least 330 bar. If you must replace the valve, proceed to step (4) before using the machine again, and redo this entire procedure when you have installed the new valve. If pressure on the Apitech relief valve is below 290 bar, you should not use the machine until the valve is replaced. 4. Screw out the redundant relief valve adjustment screw one-and-a-half turns (see Figure 298). Pressure out any boom cylinder except #1 down, and read the gauge. Pressure should read 320 bar. If does not, turn the screw in to raise pressure, or out to lower pressure until it is at 320 bar. If the location of this valve causes you to be near the drive lines, be sure to stop them from turning before accessing the valve. 5. You will need a helper for this step. While pressuring out any boom cylinder except #1 down, have your helper adjust the high-pressure screw (see Figure 284) of the ∆P regulator out (lowering the pressure) until the gauge reads 290 bar. Release
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SERVICE TRAINING
the pressurized function and lock the jam nut. The boom pressures are now set. If you did not get the readings specified after following the instructions, contact Schwing’s Service Department for advice on how to continue.
Setting 15 bar pretension
Pressure Settings
1. Stop the truck engine. Plug the 0–40 bar gauge into the pretension check port of the Apitech handvalve (Figure 297). 2. Start the truck engine, but leave it at an idle. Read the pressure on the gauge. If it reads 15 bar ± 1 bar, the pressure is set correctly. If the pressure is not set correctly, continue to point (4.)
To check or set pretension follow these steps:
CAUTION Truck engine must be at idle when pretension is set.
3. Loosen the jam nut on the pretension valve. Turn the screw in to raise pressure, and out to lower pressure. When the pressure is correct, retighten the jam nut (Figure 298).
Apitech pretnscrw.eps
Figure 298 Pretension adjustment screw and check port
4. Stop the engine, and remove the 0–40 bar pressure gauge. Pretension setting is now complete.
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Pressure Settings
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KVM 42M - Proportional (Rexroth) Check the fluid level of the distribution gearcase (Figure 299). Be sure the truck is on reasonably level ground. With the truck engine off and the key in your
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Pressure Settings
pocket, remove the check plug from the check port. The oil should be at the level of the bottom of the hole in the case. If oil is needed, add it by removing the breather and pouring the oil through the top of the fill port. This gearcase uses 90W gear lube.
Check port
4194 gearcase scan.eps
Breather (fill port)
Drain port
Figure 299 Check, drain, and fill ports of Stiebel 4194 gearcase •
Check the mounting hardware of the subframe, the oil and water tanks, the delivery pipeline, the pumpkit, the differential cylinders, the material cylinders, and the driveline hardware. Check for bolt tightness, cracks, and other abnormalities.
Check hydraulic pressures Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components. The specifications for all circuits are shown on the hydraulic schematics in the appendix of this manual.
number 30303432 (tube). Contact the Schwing America Service Department for installation instructions. 2. Turn on the agitator. The agitator will not be able to turn, and the oil will be forced over the relief valve. At an idle (about 600 RPM), about 4.5 horsepower is being converted to heat. Shut off the concrete pump when the oil temperature gauge on the operator’s panel shows 40°C.
Preheat the hydraulic oil
Setting concrete pump pressure (singlecircuit units)
Pressure settings must be made with the oil at normal operating temperature (40°– 60°C). The agitator circuit must be used to heat the hydraulic oil. To preheat the hydraulic oil using the agitator circuit, follow these instructions: 1. Locate the agitator shutoff valve and close it.
Schwing single-circuit pumpkits are designed to be operated at a maximum pressure of 300 bar (4350 PSI). The pressure in the system is controlled by the main relief valve on the forward end (toward the truck cab) of the main control block (Figure 300).
NOTE! If your unit does not have a shutoff valve, order one, using part number 10004680 (valve) and
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Pressure Settings
Jam nut
Lower pressure
Raise pressure
Adjustment handle
gray valve.eps L
Figure 300 Concrete pump circuit main relief valve To check or set the main relief pressure:
1. When setting pressures, always wear safety glasses. 2. Be sure that the waterbox covers and guards are installed on the waterbox. Schwing does not recommend using the remote control box when setting the main relief pressure.
3. Start the truck engine, and put the PTO and transmission into gear, just as you would to pump a job. 4. Close the shutoff valve (also known as the “ballcock” or “quarter-turn valve”) (Figures 301 and 302).
Shutoff valve
quarter turn.eps
Figure 301 Concrete pump shutoff valve 5. Put the rear operation panel “remote / local” switch into the “local” position. 6. Using the switch on the rear operation panel, rev the truck engine up to full RPM. 7. This procedure is called high-pressuring the concrete pump. Put the main operation panel “forward / neutral / reverse” switch into the
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“forward” position. The unit will stroke only once; then the rock cylinder will retract. Oil will be forced over the main relief valve.
Groove at 90° to ports— Closed
Groove lined up with ports— Open Ball cock grooves.eps
Figure 302 Open/closed orientation of concrete pump shutoff valve 8. Read the pressure on the gauge. It should read 300 bar. Return the pump to “neutral,” whether it needs adjustment or not. If no adjustment is needed, skip to step (14). 9. Using a 13-mm spanner wrench, loosen the jam nut on the relief valve adjusting screw (see Figure 13). 10. Turn the knob on the relief valve to adjust the pressure. Screw the handle in to raise pressure, and out to lower pressure. 11. Retighten the jam nut. Tightening the nut tends to raise the pressure setting. If the rise in pressure becomes a problem, hold the knob while tightening the jam nut. 12. Put the concrete pump into the “forward” position again. The machine will not stroke this time, but it will high-pressure again. Read the pressure on the gauge. If more adjustment is needed, return the pump to “neutral,” then repeat steps (9) through (11) until the pressure is correct. IMPORTANT! If you cannot adjust the pressure up to specification, you have a problem. In this case, unscrew the adjustment handle several turns so that your pressure is not too high when you find the problem. Contact Schwing America’s Service Department for advice on how to continue. 13. Return the pump to the “neutral” position.
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Pressure Settings
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Pressure Settings 14. Open the concrete pump shutoff valve (Figure 303).
Shutoff valve
quarter turn.eps
Figure 303 Concrete pump shutoff valve 15. Return the RPM of the truck to idle, take the transmission and PTO out of gear, and shut off the truck, or go on to other pressure settings.
Setting boom circuit pressures NOTE! Any time you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (40°–60° C). Instructions on heating the hydraulic oil for this procedure are found on page 6-243. Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when setting pressures.
Load-sensing boom hydraulic controls This unit is equipped with a load-sensing, proportional boom hydraulic system. In a black-and-white system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain 20 bar higher pressure at the pump than what the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”).
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Pressure Settings
To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting Q-min and ∆P (Figure 306).
Figure 307
Figure 281
Figure 309
Figure 279
42 Location Page 1
Component Locations Figure 279—Boom control handvalves Figure 281—Q-min adjustment screw Figure 307—∆P regulator (original location—inside frame; current location—outside frame) Figure 309—Normally open bypass valve
Figure 304 Locations of components used to check boom pressures
Setting ∆P You must not adjust Q-min with the drive shafts turning! Each time the Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning. To check or set ∆P, follow these steps: 1. Stop the truck engine, put the key in your pocket, and place a “Do Not Operate” sign on the windshield of the truck. 2. Install a 0-600 bar gauge and a 0-40 bar gauge in the boom control hand valve (Figure 305).
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Pressure Settings
SECTION 1
FORWARD / REV.
SECTION 2
SECTION 3
SECTION 4
SLEWING
OUTPUT + / -
AC / WP
BOOM / OUTRIG.
WARNING
DANGER
Do not operate at pressures exceeding the rating of the entire material delivery system.
Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
WARNING Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
0-40 42 rexman.epsL
0-600 Figure 305 Boom control handvalve (Rexroth) 3. To be sure that the pump is putting out only enough oil to maintain ∆P, we need to change the setting of the Q-min screw. Q-min is adjusted by a screw on
the boom hydraulic pump (Figure 306).
Q-min adjustment screw
Q max
Figure 306 Location of Q-min screw
CAUTION Do not operate any functions when setting ∆P.
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Unscrew the Q-min screw three full turns. Check that all personnel are clear of the truck, then restart the engine, engage the pumps, and leave the engine at an idle. If you activate any boom or outrigger functions, you will damage the 0–40 bar gauge. Make sure that all emergency stop switches are in the up (not engaged) position. Pressure can be read on either the main boom gauge (0–600 bar) or the pretension (0–40 bar) gauge. Pressure should read
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Pressure Settings
20 bar. If no adjustment is needed, simply reset the Q-min screw. If adjustment is needed, continue with step (5). 4. Delta P is adjusted on the ∆P adjustment screw of the ∆P regulator (Figure 307). There are two adjustment screws on the ∆P regulator. The smaller screw is used to adjust ∆P. Loosen the jam nut, and adjust the screw inward to increase pressure, or outward to decrease pressure, until it is set at 20 bar (±1). High-pressure adjustment screw
∆P T
Figure 307 Delta P regulator. 5. If pressure cannot be set correctly, contact the Schwing Service Department to determine how to continue.
Setting Q-min You must check Q-min pressure when the engine is at the maximum specified RPM, but you must adjust it with the engine stopped. 1. If you unscrewed the Q-min screw as the first step of ∆P adjustment, begin by returning the screw to its original position (Figure 308).
Q-min adjustment screw
Q-minscrew.eps
Q-max
Figure 308 Q-min screw no adjustment is needed, stop the drivelines, be 2. Clear all personnel away from the drivelines, start sure the jam nut on the Q-min screw is tight, then the truck engine, engage the pumps and bring continue to “Setting boom pressure” to set the rest engine RPM to max. All boom functions must be of the boom and outrigger pressures. If adjustment in neutral, and all emergency stop buttons should is needed, continue to step 3. be up (not engaged). Read the pressure on the 0– 600 bar gauge. Pressure should be at 40–45 bar. If
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Pressure Settings 3. Turn the Q-min screw in to raise the pressure. Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures.
Setting boom pressure Now that ∆P and Q-min are set, you can check or adjust the boom circuit high pressure settings. NOTE! These instructions apply to units built before January, 1997.
High-pressure adjustment screw of the ∆P regulator (the large adjustment screw on the ∆P regulator), set at 290 bar (see Figure 307). • Normally open bypass valve (the valve that opens when an E-stop switch is activated), set at 320 bar (see Figure 309). • Handvalve relief (located in the boom control block), set at 330 bar (Figure 310). To check or adjust the high pressure settings on the boom circuit, follow these steps: 1. Loosen the jam nut of the large adjustment screw of the ∆P regulator. (see Figure 307). Turn the screw in two full turns. This will raise the pressure on the regulator above 330 bar. •
There are three pressure settings on the boom circuit:
WARNING If the ∆P regulator is located inside the frame, stop the drivelines from turning before making adjustments. 2. Loosen the jam nut on the normally open bypass valve adjustment screw (see Figure 309). Turn the
adjusting screw in one full turn. This will raise the pressure of this valve above 330 bar.
Jam nut
nP age
3
Adjustment screw
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Protective cover
Figure 309 Normally open bypass valve 3. Pressure out any boom cylinder except #1 down, by pushing or pulling the control handle. To pressure out a cylinder, retract a fully retracted cylinder or extend a fully extended cylinder. The oil is forced over the relief valve. The telltale hiss of an open relief valve should be coming from the control block relief valve now. If it isn’t, raise the set-
tings of the other pressure devices until the hiss originates at the boom control block relief valve. Read the pressure on the gauge. It should read 330 bar. If no adjustment is needed, skip to step (4). If adjustment is needed, proceed to step (4).
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4. Adjust the pressure by turning the adjustment screw on the boom handvalve relief valve (Figure 310). Screw in to raise pressure, or out to lower
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Pressure Settings
pressure. When pressure is correct, lock the jam nut, and continue to step (4).
Handvalve relief valve is located here.
rxboomblk.eps
Front view
Side view
Figure 310 Boom hand valve relief valve
5. You will need a helper for this step. Pressure out any boom cylinder except #1 down, as described in (3) above. Read the gauge while your helper turns the adjustment screw of the normally open bypass valve out (lowering the pressure). Continue adjusting until the pressure reads 320 bar. Lock the jam nut before proceeding. 6. While pressuring out any boom cylinder except #1 down, have your helper turn the high-pressure adjustment screw of the pressure regulator out (lowering the pressure) until the gauge reads 290 bar. Lock the jam nut. The boom pressures are now set. If you did not get the readings specified after following the instructions, contact Schwing’s Service Department for advice on how to continue.
Set the #1 down side pressure Because gravity pulls the boom down, high pressure is not needed to bring section #1 down. Allowing high pressure to be available leaves open the possibility of an inattentive operator causing damage to the boom or
the A-frame when the boom is being folded into the transport position. To prevent this, there is a secondary relief valve that regulates only the pressure on the #1 retract function (Figure 311).
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Pressure Settings
Down side relief valve is located behind this section.
rxdnside.eps
Front view
Side view
Figure 311 Down side relief valve 1. Set up the unit as if to pump a job. Put down the outriggers, avoiding overhead wires and other obstructions. 2. Bottom out the #1 cylinders completely. No position can allow the boom to do this without hitting something unless the boom is unfolded. Unfold sections #2, #3, and #4 away from section #1. 3. Slew the boom to a position that will allow section #1 to come all the way down without hitting anything, then bring section #1 down. 4. When the #1 cylinders have completely bottomed out, the oil coming from the pump will have nowhere to go except over the relief valve. Read the gauge; it should say 100 bar. (Although pressure is specified as 80 bar, the gauge will read 100 bar because of the 20 bar ∆P that we set earlier.) If no adjustment is needed, skip to step (6). If adjustment is needed, proceed to step (5). 5. Loosen the jam nut on the down side relief cartridge. Adjust the pressure by turning the screw in to increase pressure, or out to decrease pressure. When the gauge reads 100 bar, retighten the jam nut. 6. Fold up the boom, stow the outriggers, and refasten the tie-down strap, or move on to other maintenance procedures.
7. Stop the truck engine. Remove the gauges from the boom control block. The job is now complete.
Setting outrigger pressure After the boom circuit is properly set, you can set the outrigger pressure. Find the relief valve on the back side of the passenger side outrigger control bank relief valve (Figure 312).
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280 Bar relief valve
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Pressure Settings
280 Bar relief valve
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Manitrol valve system
Pushbutton system
Figure 312 Outrigger valve bank relief valves To check the pressure, follow these steps: 1. On original units, pull the outrigger/boom selector valve to the outrigger position. On units in current production, push the outrigger enable button (Figure 26).
Outrigger enable button
EXTEND REAR
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FOLD REAR
FOLD FRONT
FOOT REAR
FOOT FRONT
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Figure 313 Passenger side outrigger enable button (current production) 2. Pressure out an outrigger jacking cylinder. Pressure out by retracting a retracted cylinder. The oil from the pump will be forced over the relief valve. You cannot use an extension cylinder, because these have secondary, nonadjustable relief functions built
into the valve. While holding the handle, have your helper read the pressure gauge installed on the boom control block.
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Pressure Settings Set agitator pressure The agitator circuit has a maximum pressure of 200 bar (2900 PSI), which is limited by the relief valve in the agitator handvalve (Figure 314). 1. There is a gauge port for checking or setting agitator pressure. Plug the 0–600 bar whip gauge into the port.
3. The pressure should read 280 bar. Adjust by turning the body of the valve in or out. When 280 bar is reached, let go of the handle. 4. On original units, restore the outrigger/boom selector valve to the boom position. On units in current production, release the pushbutton.
AGITATOR FORWARD
REVERSE
Gauge port behind here
Relief valve 42 E Stop & PS Agit Lever.eps
Figure 314 Agitator relief valve 2. With the engine shut off and the key in your pocket, remove one of the hoses from the agitator motor and plug the hose and the open fitting with approved hydraulic dead plugs. Do not substitute other plugs. If you have no hydraulic dead plugs, contact the Schwing America Spare Parts Department and order them before continuing with this procedure. You will need: • • • • •
Qty. 2 VS-16S locking plugs, part number 10016803 Qty. 1 GS-16S straight fitting, part number 10008088 Qty. 2 16S cap nuts, part number 10001743 or Qty. 1 size 16 shutoff valve, part number 10004680 Qty. 1 size 16 tube, part number 30303432. If you install the shutoff valve, you can leave it installed for future use. All of these fittings and many more useful items are included in the troubleshooting kit, part
number 30308553. Schwing recommends that you purchase this kit. It will pay for itself many times over. Be sure that one of the locking plugs and cap nuts are tightened on the straight fitting, and that the dead plugs are securely tightened to the hose and the open motor fitting. 3. Restart the engine, engage the pumps, and bring the throttle anywhere above idle. Activate the agitator valve handle in either forward or reverse. Read the gauge. If adjustment is needed, turn the entire valve body in to increase pressure, or out to decrease pressure. 4. When the pressure is set, stop the engine and remove the key. Remove the dead plugs and store in a clean area or in a plastic bag or another container to keep dirt out of the fittings. Reattach the hose to the agitator motor fitting and tighten securely. (Torque is correct if you make one complete revolution after initial resistance increases.)
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SERVICE TRAINING
5. Remove the whip gauge. Restart the engine, if necessary.
Set accumulator circuit hydraulic oil pressure (units with accumulator unloading valves)
Pressure Settings
b. Loosen the jam nut on the accumulator unloading valve. Turn the accumulator unloading valve adjustment screw in two-and-a-half turns. This will raise the pressure above 300 bar (Figure 77).
5.3-7
You will need an assistant for parts of this procedure. To check or adjust the hydraulic pressure in the accumulator circuit, follow these steps: a. Stop the truck, put the key in your pocket, and place a “Do Not Operate” sign on the windshield.
Jam nut
Accumulator unloading valve adjustment screw
Figure 315 Accumulator unloading valve
c. Loosen the jam nut on the accumulator redundant relief valve. (This valve is located on the emergency stop manifold.) NOTE: The emergency stop manifold was added to units built after January 1, 1997.) Turn the screw in two turns. This will raise the relief setting above 300 bar (Figure 316).
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Pressure Settings
Accumulator relief valve P2
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Figure 316 Accumulator redundant relief valve d. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring engine RPM to maximum. e. Read the pressure on the accumulator circuit gauge located just between the hopper and the A-frame. Pressure should read 300 bar (4350 PSI). If no
f.
adjustment is needed, skip to (g). If additional pressure adjustment is needed, continue to (f). Locate the accumulator manifold pressure relief valve (Figure 317). Loosen the jam nut, and turn the screw in to increase pressure, or out to decrease pressure. Tighten the jam nut when pressure is at 300 bar.
Pressure relief valve
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Figure 317 Accumulator manifold pressure relief
g. You will need an assistant for this step. With the engine still running, one person must go to the
redundant relief valve on the emergency stop manifold and back out the adjustment screw. The other
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person should stand by the pressure gauge to let him know when pressure reads 260 bar (3770 PSI). h. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator and the turn the screw back out two-and-onehalf turns. This restores it to its original setting. i. Read the pressure on the accumulator gauge. It should read 200 bar (2900 PSI). j. If adjustment is needed, you must stop the truck engine, or at least stop the drivelines from turning each and every time you approach the accumulator circuit hydraulic pump. Turn the screw in to increase pressure, or out to decrease pressure. Lock the jam nut when the pressure is correct.
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Pressure Settings
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Pressure Settings
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Pressure Settings
KVM 45/47SX
Spline flange breather
Figure 318 Oil check plug for spline flange cavity (4400 gearcase)
Setting Pressures The following pages provide the proper techniques for checking and setting hydraulic pressures of each system included on your unit.
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Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components. The specifications for each circuit are shown on the hydraulic schematics found in the Appendix of this manual. The hydraulic schematics are the only documents in this manual that have been updated specifically for your unit, by the serial number, so in each of the following procedures you will be told to refer to the schematic for the pressure required. • Preheat the hydraulic oil Pressure settings must be made with the oil at normal operating temperatures (40°− 60° C). In the past we could pressure out a function in the boom or outrigger system to create heat, but load sensing systems no longer allow maximum oil flow to be forced over relief. Because of this the agitator circuit must be used to heat the hydraulic oil. To preheat the hydraulic oil: 1. Locate the agitator shutoff valve (Figure 319) and close it. NOTE! If your unit does not have a shutoff valve, order one from the Schwing Spare Parts Department using part number 10004680 (valve), and number 30303432 (tube). Contact the Service Department for installation instructions. 2. Activate the agitator. With the valve closed the agitator will not be able to turn and the oil will be forced over the relief valve. At an idle (about 600 RPM), 4.5 horsepower is being converted to heat.
Figure 319 Agitator shutoff valve 3. When the oil temperature gauge shows 50˚C, open the shutoff valve.
Setting pressures on Hi-flo -6 pumpkits a. To set the pressure of the main relief valve on Hi-flo pumpkits, you must first disable the soft switch circuit. Simply locate the ball cock for the soft switch circuit (Figure 320) and close it by rotating the handle 90 degrees. b. The quarter turn shutoff valve for the concrete pump (Figure 320) will also need to be closed during this procedure. Note: Main system adjustments are preset at the factory. The following procedure begins with adjustment of the main relief cartridge and pressure cutoff. If proper pressures can not be obtained through these steps, contact the Schwing Service Department for specific instructions on the adjustment of flow, horsepower, beginning of stroke regulation and Q-min. Pressure setting procedure:
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Pressure Settings Soft switch shutoff valve Main Pressure Gauge port
Concrete pump shutoff valve
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turn the adjustment screw in (clockwise) one full turn and tighten the jam nut. Restart the truck engine. 10. Adjust the engine RPM to maximum specification. (See decal in truck cab) 11. Pressure out the system by activating the concrete pump forward switch on the rear panel. Using the rear panel controls will allow you to read the concrete pump main system pressure gauge, near the e-stop manifold, from a safe distance.
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Figure 320 Concrete pump and Soft switch shutoff valves 1. Be sure that the waterbox covers and guards are in place any time you will be working in the area around the main control block. 2. Wear safety glasses when working around a concrete pump. Note! It is vital that each adjustment screw be properly identified prior to making any adjustment. All screw adjustments for the system relief must be made with the pumpkit in the neutral position and adjustments for pressure cutoff must be made with the engine shut off. 3. Start the truck engine, and put the PTO in gear just as you would to pump a job. 4. If you have not already closed the soft switch shutoff valve and the concrete pump shutoff valve (Figure 320) do so at this time. 5. At the rear panel, select “local” control with the “local/remote” switch and turn the electric stroke limiter knob clockwise to maximum strokes per minute. 6. The main system control block pressure must be set first to properly set the pressure cutoff on both pumps. Begin by backing off the jam nut of the main relief cartridge (Figure 322) with a 9/16 inch wrench. 7. Using a 5/32 inch allen wrench, turn the adjustment screw out (counterclockwise) until you can feel no spring tension on the adjustment screw. 8. Now, turn the screw back in (clockwise) two or three full turns to give you a proper starting point and tighten the jam nut. 9. Stop the truck engine and put the key in your pocket. Adjust the pressure cutoff screw (Figure 321) on each pump, by backing off the jam nut with a 13mm wrench. Using a 4mm allen wrench,
Note: Because you turned out the pressure relief cartridge in step 7, the system pressure should read low at this time. If it does not and the gauge spikes to 320 bar or more, disengage the pump immediately. Turn the relief cartridge out (counterclockwise) more. For safety, it is important to adjust the pressure up from below the specified target pressure rather than down from a pressure which exceeds the target. Continue this procedure until the main system pressure gauge reads lower than the specified target. 12. To increase the pressure put the pump in the neutral position and adjust the relief cartridge by turning it in (clockwise). When increasing the pressure, the adjustments should be made in quarter turn increments. If you make adjustments to increase the pressure but the pressure does not come up, you are probably reading the pressure cutoff of the pumps, if so proceed to the next step otherwise skip to step 15.Turn the relief cartridge adjustment screw back out (counterclockwise) until you can no longer see a pressure drop and tighten the jam nut. 13. Stop the truck engine, put the key in your pocket. 14. Go to the pressure cutoff screw on both hydraulic pumps (Figure 321) and back off the jam nut with a 13mm wrench. Turn the adjustment screws in with a 4mm allen wrench one or two more turns, restart the engine and check the pressure again. Repeat this procedure until the main system relief can be set to the target pressure. 15. When the proper main relief pressure is achieved, pressure cutoff can be set. Shut off the engine, put the key in your pocket and install 0-600 bar gauges with whip hoses to the “M1” gauge ports on the bottom of the two hydraulic pumps (Figure 321). You must be able to read both gauges simultaneously to ensure that one pump is not more dominant than the other.
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Note: The gauges in the M1 ports will read considerably less than the cutoff pressure of the pump. On a -6 (190/130 pump combination) the 190 will usually read 85 to 90 bar while the 130 reads about 110 bar. They could read the same however, at approximately 110 bar, but the 190 must never read higher than the 130. The actual cutoff pressure will be read on the concrete pump main system pressure gauge near the e-stop manifold. 16. Activate concrete pump forward to pressure out the pump and read the pressure on the two gauges in the “M1” ports. 17. Always stop the truck engine and put the key in your pocket before making any adjustment on the hydraulic pump. If the cutoff on one pump is set higher than the other, that pump will be more dominant. The pressure gauge in the M1 port of the dominant pump will however, read lower than the other. To equalize the two pumps you must either adjust the cutoff screw in (clockwise) to increase the pressure of the pump showing the higher reading or adjust the cutoff screw of the dominant pump showing the lower reading out (counterclockwise) to reduce the pressure. These adjustments must be made until the two gauges in the M1 ports are reading approximately the same. 18. When you have achieved the same pressure on the M1 port gauges, you can begin to adjust the pressure cutoff screws in or out simultaneously until you achieve the desired pressure setting of 350 bar (again, confirm the pressure specification with the hydraulic schematic).
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Pressure Settings
After pressure cutoff is set, return the pump to neutral, bring engine RPM to idle, open the soft switch quarter turn valve, and either proceed to other pressure settings or take the transmission and PTO out of gear and shut off the truck. 2 PRESSURE CUT OFF 4 Q-MIN
1 STROKE REGULATION 3 HORSE POWER 2
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M1 GAUGE PORT (BOTTOM OF EACH PUMP) 130ajst.eps
Figure 321 A11VO adjustment screws for Hi-flo – 6 units 190/130
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Pressure Settings
Soft switch shutoff valve
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Main Pressure Gauge port
Concrete pump shutoff valve
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Figure 322 Soft switch components
Setting the soft switch relief pressure
Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure 322 right) that you closed in the previous procedure. The rest of the unit should still be set up as if you were going to check the main relief valve pressure (concrete pump shutoff valve still closed). When you put the pump in forward now, the main concrete pump pressure gauge should read the pressure shown on the schematic for soft switch. If adjustment is needed, loosen soft switch relief valve jam nut (Figure 322 right) with a 9/16 open end wrench, and use a 5/32 allen wrench to adjust the pressure. Turn the adjustment screw in (clockwise) to raise the pressure or out (counter clockwise), to lower the pressure. When you attain the required pressure, tighten the jam nut while holding the allen wrench to keep the pressure from rising. Be sure to open the concrete pump shutoff valve on the side of the brain (Figure 322 left) when you are finished. The unit will not stroke with this valve closed.
This unit is equipped with a load-sensing, proportional boom hydraulic system. In a black-and-white system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain 20 bar higher pressure at the pump than the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting ∆P and Q-min. Note: The illustration in Figure 323 shows a gauge port in the center of the main control block. Your main concrete pump pressure gauge should be plumbed to that port.
Note! Any time you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (40°–60° C). Instructions on heating the hydraulic oil are found in the first step of this “checking hydraulic pressures” segment. Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when setting pressures.
WARNING Entanglement hazard. Stop drive shafts before adjusting Delta P on A11VO pump.
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Setting boom circuit pressures
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Pressure Settings
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Figure 323 (Left) The 0–60 bar gauge port is located at the top of the boom control block, and the 0-600 bar port is at the bottom. (Right) A 0–600 bar gauge port is located on the E-stop manifold.
Note! Do not adjust ∆P or Q-min if your boom is running as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned from that point. The pressure was fine tuned at the factory and should not be adjusted unless absolutely necessary. 1. Start by turning off the engine and putting the key in your pocket; then place a “Do Not Operate” sign on the windshield of the truck. 2. Install a 0-100 bar gauge in the high pressure test port at the bottom of the boom control block (Figure 323). NOTE! Do not activate any boom/ outrigger functions or release any e-stops with a low pressure gauge attached to a high pressure port. 3. Delta P is adjusted on the pressure regulator (Figure 324 top) if your unit has an A7VO pump or (Figure 324 bottom) if your unit has an A11VO boom pump. When all personnel are clear of the truck, restart the engine, engage the pumps, and leave the engine at an idle. ∆P pressure should read 20 bar, which is the standard starting point. 4. There are two adjustment screws on the pressure regulator (Figure 324 top) for A7VO pumps. The smaller screw is used in this procedure to adjust ∆P. On the A11VO pumps there is only one ∆P screw (Figure 307 bottom).
5. If adjustment is required, loosen the jam nut, and adjust the screw inward to increase pressure or outward to decrease pressure until it is set at 20 bar. After achieving proper ∆P, tighten the jam nut and bring the engine RPM up. If the pressure gauge continues to read 20 bar, you are reading the true ∆P pressure and may move on to setting the Qmin. If the pressure rises with the RPM however, you may be reading the Q-min pressure instead of true ∆P. If that happens, stop the engine, put the key in your pocket, and place a “Do Not Operate” sign on the windshield of the truck before proceeding .
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Setting delta P pressure
Regulator pressure adjustment T
Adjustment for P pressure Delta-p
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Figure 324 Pressure regulator for A7VO boom pumps (top) and A11VO pumps (bottom)
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Pressure Settings
Q-min adjustment screw
Delta-p
Pressure Cut-off
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Q max
Q-min
Q-max (Bottom Of Pump)
If pressure cannot be set correctly, there is a problem either with the orifices in the base of the regulator or with the regulator itself. Contact the Schwing Service Department to determine how to continue. Note: If the boom does not run smoothly at 20 bar, you must fine tune the adjustment. Remove the gauge, and turn the ∆P adjustment screw until the boom is responsive and smooth. After adjusting, the gauge (reinstalled) must read between 14-25 bar. The electronics in the control system can also affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 20 bar and check the electrical settings. Once electrical settings are verified, you could again try to refine the boom action with the ∆P adjustment. Note: The pressure regulator (Figure 326) is usually mounted on the inside of the subframe, near the cab end of the differential cylinders.
Regulator pressure adjustment T
Adjustment for P pressure
Figure 326 Boom pressure regulator for units with A7VO pumps
WARNING Entanglement hazard. Stop drive shafts before adjusting Q-min.
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6. Unscrew the Q-min screw (Figure 325) three full turns. This step will help ensure that the pump produces only the amount of flow needed to maintain ∆P pressure. Once all personnel are clear of the truck, restart the engine, engage the pumps, and recheck at an idle. Pressure should now read 20 bar. If it does not, go back and adjust ∆P until it does.
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Figure 325 Location of Q-min screw on the A7VO (left) and all adjustment screws of the A11VO (right)
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Setting Q-min Check Q-min when the engine is at maximum specified RPM. You must not adjust Q-min with the drive shafts turning! Each time the Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning. 1. If you unscrewed the Q-min screw as part of the ∆P adjustment, begin by returning the screw to its original position. 2. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). Clear away all personnel, start the truck engine, engage the pumps and bring engine RPM to max. Read the pressure at the 0–600 bar main boom gauge port (Figure 327) with a 0-100 bar gauge. Pressure should be at 40–45 bar. If no adjustment is needed, be sure the jam nut on the Q-min screw is tight, then continue to set the rest of the boom and outrigger pressures. If adjustment is needed, continue to the next step. 3. Turn the Q-min screw (Figure 325) in to raise the pressure. Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures, then recheck ∆P to make sure that it hasn’t changed during the Q-min adjustment. Note: If you don’t have a 0-100 bar gauge you can order one from Schwing Spare Parts Department at (800) 328-9635, part # 10004659.
Setting boom pressures Now that ∆P and Q-min are set, you can remove the 0100 bar pressure gauge and proceed to check and adjust the main boom pressures. 1. Loosen jam nut of the boom pressure relief cartridge (Figure 327) with a 30mm open end wrench. 2. Turn the adjustment cartridge clockwise all the way in with a 32mm wrench. 3. Loosen the jam nut on the pressure relief screw of the regulator (Figure 326) or the pressure cut-off (Figure 325), and tighten the screw all the way down. 4.
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Pressure Settings
5. Identify the main boom pressure relief cartridge on the boom control block (Figure 328) and loosen the jam nut. Then unscrew the adjustment two full turns. 6. Take engine RPM to full throttle and activate boom retract for any boom section except #1. 7. Now adjust pressure, which is read at the main boom gauge port, to the setting found on the schematic by turning the boom pressure relief cartridge in, or clockwise, using no more than 1/4 turn increments. 8. When desired pressure is achieved, lock down the jam nut.
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Figure 327 Boom pressure relief cartridge 9. The next step is to return to the e-stop manifold boom pressure relief cartridge (Figure 327), and back off the jam nut (30 mm), and turn the relief cartridge (32mm) out, or counter clockwise, until the pressure shown on the schematic, for the boom pressure relief cartridge, is achieved. When the proper pressure is achieved, lock the jam nut.
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Pressure Settings Setting outrigger pressure mainrlf.eps
After the boom circuit is properly set, you can set the outrigger pressure. Find the relief cartridge located on the front of the passenger side outrigger control valve (Figure 312).
Figure 328 Main boom pressure adjustment and piston side relief 10. The next pressure setting is the regulator pressure. Locate the regulator adjustment screw (Figure 325) or pressure cut-off screw (Figure 326). Back off the jam nut, and turn the screw counter clockwise until you achieve the pressure shown on the schematic; then lock the jam nut. 11. The final boom pressure setting is the #1 boom piston side relief setting. This relief cartridge is in close proximity to the main boom relief (Figure 328), so be sure to locate the proper adjustment. This procedure should be performed with the outriggers extended and the boom unfolded over the cab. Disconnect all gauges from gauge ports prior to operating any boom or outrigger functions. Bring section #1 all the way down until the cylinder bottoms out. Install a 0-600 bar gauge in the main boom gauge port of the e-stop manifold (Figure 327), and activate boom #1 down. The pressure should read the setting shown on the schematic. If adjustment is required, back off the jam nut and turn the relief cartridge in or out as required until the desired pressure is achieved; then lock down the jam nut.
Tipping hazard. Never set outrigger pressures with the boom unfolded. Pressure setting procedure requires retraction of an outrigger jacking cylinder.
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Main boom pressure relief cartridge
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1. Attach 0-600 bar whip gauge to the gauge port (Figure 312) below the outrigger valve bank. 2. Push the outrigger enable button. 3. Activate an outrigger jacking cylinder to retract. By retracting a fully retracted cylinder, the oil coming from the pump has nowhere to go but over the relief valve. You cannot use an extension or slewing cylinder because they have secondary relief functions (nonadjustable) built into the valve. While holding the handle to retract, read the pressure gauge. 4. The pressure should read the bar value shown on the hydraulic schematic. Adjust by loosening the jam nut with a 9/16” open end wrench and turning the cartridge (Figure 329) in or out with 5/32 allen wrench. When the proper pressure is achieved, let go of the handle and release the outrigger enable button. testport.eps
REAR SLEW
REAR JACKING
FRONT JACKING
FRONT EXTEND
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#1 down side relief cartridge
Relief Valve Gauge Port
Figure 329 Outrigger valve bank relief cartridge and gauge port
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Pressure Settings
CONCRETE PUMP FORWARD/REVERSE
AGITATOR
Relief valve
Gauge port
Figure 330 Agitator component location
Set the agitator pressure The agitator circuit has a maximum pressure shown on the hydraulic schematic, which is limited by the relief cartridge (Figure 330) in the agitator hand valve. The relief cartridge is located on the back side of the agitator manual control handle (Figure 331). The cartridge is adjustable with just an 19mm open end wrench. 1. Plug the 0–600 bar whip gauge into the gauge port (Figure 330) for checking or setting agitator pressure. 2. Locate the agitator shutoff (Figure 331) valve and close it. If your unit does not have a shutoff valve, order one from the Schwing Spare Parts Department using part numbers 10004680 (valve) and 30303432 (tube). Contact the Service Department for installation instructions, or if you can’t wait for a shutoff valve, you will need to remove one of the hoses from the agitator motor and plug the hose and open fitting with approved hydraulic dead plugs (Figure 332). NOTE! Do not jam the paddles to force the oil over relief by stopping the movement of the agitator.
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Figure 331 Agitator shutoff valve
Plugs Straight Fitting Figure 332 Approved hydraulic dead plugs
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Cap Nuts
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Pressure Settings 3. Increase the throttle to any speed above idle. Activate the agitator valve handle in either forward or reverse, and read the gauge. If it does not read the specified pressure, adjustment is required. Turn the entire valve body (Figure 330) in to increase pressure or out to decrease pressure. 4. When the pressure is set, deactivate the agitator by placing the manual control handle in the neutral position. 5. Remove the whip gauge. 6. Reopen the shutoff valve or remove the dead plugs and reconnect the capped hydraulic line.
Set accumulator circuit pressure
redundant relief cartridge in the emergency stop manifold(Figure 233 top). If your pump was built after January 1, 2000. It will have an emergency stop manifold similar to the illustration shown in the bottom of Figure 233 which no longer has a redundant relief cartridge and you must skip steps 3. and 7. in the following procedure. To check or adjust the hydraulic pressure in the accumulator circuit: 1. Stop the truck, put the key in your pocket, and place a “Do Not Operate” sign on the windshield. 2. Loosen the jam nut on the pressure regulator of the accumulator hydraulic pump (Figure 333). Turn the screw in two-and-one-half turns. This will raise the regulator pressure above 300 bar. 3. Loosen the jam nut (Figure 334) on the accumulator redundant relief cartridge located on the emergency stop manifold. Turn the screw in two turns. This will raise the relief setting above 300 bar.
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Accumulator pump pressure regulator
Figure 333 Accumulator pump pressure regulator for A7VO (above) and for A11VO (below) Boom Pump Accumulator Pump
Standby Pressure Screw Accumulator Pump Pressure Regulator
Accumulator redunant relief cartridge
Figure 334 Accumulator redundant relief cartridge (above) is only present on early production models. New e-stop (below) has no redundant relief cartridge.
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You will need an assistant for parts of this procedure. There are three relief settings for the accumulator circuit if your unit is equipped with an accumulator,
4. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring the engine RPM to maximum.
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SERVICE TRAINING
5. Read the pressure on the accumulator circuit pressure gauge (Figure 335). The pressure should read the value shown on the hydraulic schematic. If no adjustment is needed, skip to step number 7. If additional pressure adjustment is needed, continue with step number 6.
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Pressure Settings
counter clockwise to decrease the pressure. Tighten the jam nut when the pressure reaches the value required. 7. You will need an assistant for this step. With the engine still running, one person must go to the redundant relief valve on the emergency stop manifold (Figure 334) and back out the adjustment screw while the other person stands by the pressure gauge to let him know when the pressure reads the value shown on the schematic for accumulator redundant relief.
Figure 335 Accumulator circuit pressure gauge
Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
acumrlf.epsL
Figure 336 Accumulator manifold pressure relief cartridge
6. Locate the accumulator manifold pressure relief cartridge (Figure 336). Loosen the jam nut, and turn the screw clockwise to increase the pressure or
W010.eps
WARNING
8. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 333), and turn the screw back out two-and-one-half turns. This restores it to its original setting. 9. Clear all personnel from the drive line area, start the truck, and bring the engine RPM up to maximum. 10. Read the pressure on the accumulator gauge. It should read the proper accumulator system pressure. 11. If adjustment is needed, you must stop the truck engine, or a least stop the drive lines from turning, each and every time you approach the accumulator circuit hydraulic pump. Turn the screw in to increase the pressure or out to decrease pressure. Lock the jam nut when the pressure is correct. Note: The accumulator circuit hydraulic pump pressure regulator is referred to as the pressure cut-off.
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Pressure Settings
KVM 45SX Hi-Flow - 6 Breather
Breather filter filler spout
grbx-5-6.eps
Oil check plug
Oil Check Plug
Drain plug
4194 gearcase scan.eps
Oil Drain Plug
Figure 337 Check fluid level of distribution gearcase Stiebel box 4194 (left) or 4400 (right)
Spline flange breather
Figure 338 Oil check plug for spline flange cavity (4400 gearcase)
Setting Pressures The following pages provide the proper techniques for checking and setting hydraulic pressures of each system included on your unit.
Check all hydraulic pressures. Changes in pressures can indicate trouble in one or more components. The specifications for each circuit are shown on the hydraulic schematics found in the Appendix of this manual. The hydraulic schematics are the only documents in this manual that have been updated specifically for your unit, by the serial number, so in each of the following procedures you will be told to refer to the schematic for the pressure required. • Preheat the hydraulic oil
Oil check plug flange.eps
Pressure settings must be made with the oil at normal operating temperatures (40°− 60° C). In the past we could pressure out a function in the boom or outrigger system to create heat, but load sensing systems no longer allow maximum oil flow to be forced over relief. Because of this the agitator circuit must be used to heat the hydraulic oil. To preheat the hydraulic oil: 1. Locate the agitator shutoff valve (Figure 319) and close it. NOTE! If your unit does not have a shutoff valve, order one from the Schwing Spare Parts Department using part number 10004680 (valve), and number 30303432 (tube). Contact the Service Department for installation instructions.
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Pressure Settings 2. Activate the agitator. With the valve closed the agitator will not be able to turn and the oil will be forced over the relief valve. At an idle (about 600 RPM), 4.5 horsepower is being converted to heat.
agitoff2.eps
Figure 339 Agitator shutoff valve 3. When the oil temperature gauge shows 50˚C, open the shutoff valve.
Setting the main relief pressure and pressure cutoff on Hi-flo -6 pumpkits a. To set the pressure of the main relief valve on Hi-flo pumpkits, you must first disable the soft switch circuit. Simply locate the ball cock for the soft switch circuit (Figure 340) and close it by rotating the handle 90 degrees. b. The quarter turn shutoff valve for the concrete pump (Figure 340) will also need to be closed during this procedure. Note: Main system adjustments are preset at the factory. The following procedure begins with adjustment of the main relief cartridge and pressure cutoff. If proper pressures can not be obtained through these steps, contact the Schwing Service Department for specific instructions on the adjustment of flow, horsepower, beginning of stroke regulation and Q-min. Pressure setting procedure: Soft switch shutoff valve Main Pressure Gauge port
Concrete pump shutoff valve
hif
lob
rn.
ep
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Figure 340 Concrete pump, Soft switch shutoff valves
1. Be sure that the waterbox covers and guards are in place any time you will be working in the area around the main control block. 2. Wear safety glasses when working around a concrete pump. Note! It is vital that each adjustment screw be properly identified prior to making any adjustment. All screw adjustments for the system relief must be made with the pumpkit in the neutral position and adjustments for pressure cutoff must be made with the engine shut off. 3. Start the truck engine, and put the PTO in gear just as you would to pump a job. 4. If you have not already closed the soft switch shutoff valve and the concrete pump shutoff valve (Figure 320) do so at this time. 5. At the rear panel, select “local” control with the “local/remote” switch and turn the electric stroke limiter knob clockwise to maximum strokes per minute. 6. The main system control block pressure must be set first to properly set the pressure cutoff on both pumps. Begin by backing off the jam nut of the main relief cartridge (Figure 342) with a 9/16 inch wrench. 7. Using a 5/32 inch allen wrench, turn the adjustment screw out (counterclockwise) until you can feel no spring tension on the adjustment screw. 8. Now, turn the screw back in (clockwise) two or three full turns to give you a proper starting point and tighten the jam nut. 9. Stop the truck engine and put the key in your pocket. Adjust the pressure cutoff screw (Figure 321) on each pump, by backing off the jam nut with a 13mm wrench. Using a 4mm allen wrench, turn the adjustment screw in (clockwise) one full turn and tighten the jam nut. Restart the truck engine. 10. Adjust the engine RPM to maximum specification. (See decal in truck cab) 11. Pressure out the system by activating the concrete pump forward switch on the rear panel. Using the rear panel controls will allow you to read the concrete pump main system pressure gauge, near the e-stop manifold, from a safe distance. Note: Because you turned out the pressure relief cartridge in step 7, the system pressure should read low at this time. If it does not and the gauge spikes to 320 bar or more, disengage the pump immediately. Turn the relief cartridge out (counterclockwise) more. For
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safety, it is important to adjust the pressure up from below the specified target pressure rather than down from a pressure which exceeds the target. Continue this procedure until the main system pressure gauge reads lower than the specified target. 12. To increase the pressure put the pump in the neutral position and adjust the relief cartridge by turning it in (clockwise). When increasing the pressure, the adjustments should be made in quarter turn increments. If you make adjustments to increase the pressure but the pressure does not come up, you are probably reading the pressure cutoff of the pumps, if so proceed to the next step otherwise skip to step 15.Turn the relief cartridge adjustment screw back out (counterclockwise) until you can no longer see a pressure drop and tighten the jam nut. 13. Stop the truck engine, put the key in your pocket. 14. Go to the pressure cutoff screw on both hydraulic pumps (Figure 341) and back off the jam nut with a 13mm wrench. Turn the adjustment screws in with a 4mm allen wrench one or two more turns, restart the engine and check the pressure again. Repeat this procedure until the main system relief can be set to the target pressure. 15. When the proper main relief pressure is achieved, pressure cutoff can be set. Shut off the engine, put the key in your pocket and install 0-600 bar gauges with whip hoses to the “M1” gauge ports on the bottom of the two hydraulic pumps (Figure 341). You must be able to read both gauges simultaneously to ensure that one pump is not more dominant than the other. Note: The gauges in the M1 ports will read considerably less than the cutoff pressure of the pump. On a -6 (190/130 pump combination) the 190 will usually read 85 to 90 bar while the 130 reads about 110 bar. They could read the same however, at approximately 110 bar, but the 190 must never read higher than the 130. The actual cutoff pressure will be read on the concrete pump main system pressure gauge near the e-stop manifold. 16. Activate concrete pump forward to pressure out the pump and read the pressure on the two gauges in the “M1” ports. 17. Always stop the truck engine and put the key in your pocket before making any adjustment on the hydraulic pump. If the cutoff on one pump is set higher than the other, that pump will be more dominant. The pressure gauge in the M1 port of the
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Pressure Settings
dominant pump will however, read lower than the other. To equalize the two pumps you must either adjust the cutoff screw in (clockwise) to increase the pressure of the pump showing the higher reading or adjust the cutoff screw of the dominant pump showing the lower reading out (counterclockwise) to reduce the pressure. These adjustments must be made until the two gauges in the M1 ports are reading approximately the same. 18. When you have achieved the same pressure on the M1 port gauges, you can begin to adjust the pressure cutoff screws in or out simultaneously until you achieve the desired pressure setting of 350 bar (again, confirm the pressure specification with the hydraulic schematic). After pressure cutoff is set, return the pump to neutral, bring engine RPM to idle, open the soft switch quarter turn valve, and either proceed to other pressure settings or take the transmission and PTO out of gear and shut off the truck.
-6adjust.eps
Figure 341 A11VO adjustment screws for Hi-flo – 6 units 190/130
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Pressure Settings
Concrete pump gauge port
Closed
NOTE: The main control block (brain) of a 2525 pumpkit will be rotated 180 degrees from the illustration shown
Open
Main relief cartridge opencls.eps
Main and soft switch relief cartridges
soft switch relief cartridge 9/16" jam nut
5/32" Allen head ga
ug
pr
t.e
ps
9/16" jam nut
Figure 342 Location of soft switch shutoff and relief cartridges
Setting the soft switch relief pressure
Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure 342 right) that you closed in the previous procedure. The rest of the unit should still be set up as if you were going to check the main relief valve pressure (concrete pump shutoff valve still closed). When you put the pump in forward now, the main concrete pump pressure gauge should read the pressure shown on the schematic for soft switch. If adjustment is needed, loosen Soft switch relief valve jam nut (Figure 342 right) 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 require pressure, tighten the jam nut while holding the allen wrench, to keep the pressure from rising. Be sure to open the concrete pump shutoff valve on the side of the brain (Figure 342 left) when you are finished. The unit will not stroke with this valve closed.
This unit is equipped with a load-sensing, proportional boom hydraulic system. In a black-and-white system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain 20 bar higher pressure at the pump than the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting ∆P and Q-min. Note: The illustration in Figure 342 shows a gauge port in the center of the main control block. Your main concrete pump pressure gauge should be plumbed to that port
Setting boom circuit pressures Note! Any time you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (40°–60° C). Instructions on heating the hydraulic oil are found in the first step of this “checking hydraulic pressures” segment. Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when setting pressures.
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KVM 52M (pre-1998) Pressure Settings for KVM 52 Proportional Load Sensing NOTE! NOTE:All pressure settings must be done when the hydraulic oil is at 50 to 70 degrees Celsius. Please read all instructions before attempting to check or set pressures. There is a pressure limit valve and two different relief valves in the KVM 52 boom circuit. Before checking or setting these 3 valves, you should make sure that the Delta-P setting on the pressure regulator and the Q minimum setting on the hydraulic pump are properly set. In order to help you better understand this, we will describe the functions of each valve and the hydraulic pump before attempting to set or check pressures. Refer to Illustration 3 on Page- E2 for the location of each item as it is mounted on the unit. Figure 1 of this page, is called the pressure regulator. Adjusting screw (item 4) is the pressure limit function of the pressure regulator. Adjusting screw (item 3) is the Delta-P function of the regulator. The Delta-P function senses pressure on both sides of the boom control blocks, and adjusts the output flow of the hydraulic pumps. Figure 2 of this page is the "normally open" relief valve. (Normally open denotes that unless the coil is energized, the relief valve will not develop any pressure). This is the valve that opens and vents your boom circuit to tank when you hit the red emergency shut off button on your remote control box or operations panel. Figure 3 of this page shows one of the two boom control blocks. (Item 5) is pointing to the primary relief valve located on the control block. It's function is to protect the block from any pressure spikes that might be in the system. Figure 4 of this page is the boom circuit hydraulic pump. This style of hydraulic pump has a variable output depending on the requirements of the boom, which is controlled by the pressure regulator described in Figure 1 (above). Figure 5 of this page is the pre-control block. (Item 6) designates the gauge port. (Item 7) designates the 34 Bar pressure reducing valve. (Item 8) designates the 50 Bar pretension relief valve.
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Pressure Settings
As mentioned earlier before we check or adjusts settings of the pressure limit valve or the two relief valves, we must make sure the Delta-P and Qminimum settings are correct.
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Pressure Settings Component Location Guide- KVM 52 FIGURE 2
FIGURE 1
FIGURE 4
FIGURE 3
FIGURE 5
KVM 52M
Illustration 3
item 5
item 4 item 3
a6
b6
A6 T
FIGURE 1
a5
item 2
A4
B4
b4
FIGURE 3
FIGURE 2
STOP for Q min
B5
a4 24V
item 1
b5
A5
item 8
L
P
item 6
STOP for Qmax
FIGURE 4
item 7
Pressure Settings for KVM 52 Proportional Load Sensing 1. .Delta-P setting on the pressure regulator. (Figure 1, Item 3) With all boom functions in the neutral position, emergency stop buttons up, the engine at minimum RPM's (idle), the pressure that will be read on both the pretension gauge and the main pressure gauge
FIGURE 5
is either Delta-P or an idle Q-minimum. To determine what indeed is creating this pressure, we must do at least ONE of the three following procedures: a. .Back off the Q-min. screw at least 3 turns on the hydraulic pump to insure that it is only producing the amount of flow that the regulator is requiring to maintain Delta-P pressure. Now
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read an accurate Delta-P pressure on either the pretension gauge or the main pressure gauge. This requires that the Q-min. be re-adjusted; (refer to paragraph 2. for Q minimum setting). b. While observing the pretension or the main pressure gauge you increase the engine RPM by 300 RPM in 3 increments of 100 RPM each, making sure that the pressure does not increase. This will assure that you are indeed observing accurate Delta-P. If the pressure does increase, then the pressure observed is an idle Q-min. and not a true Delta-P. You should then follow the procedures in paragraph 1. A. c. Install a high pressure (0-600 Bar) gauge in the X port of the regulator with a "T" fitting. While operating a boom function, monitor the pressure between the main pressure gauge and the gauge at the X port of the regulator. There should be exactly 20 Bar less pressure at the X port continuously. Adjusting Delta-P: The Delta-P pressure should be 20 Bar, plus or minus 1 Bar; (this is the same for KVM 32, KVM 36 X, KVM 42 and KVM 52 machines). If the Delta-P pressure is incorrect, then the regulator must be adjusted accordingly. Turn the small screw (Figure 1, item 3) on the regulator inward to increase or outward to decrease the Delta-P pressure. If Delta-P pressure cannot be adjusted to proper pressure, the regulator may be defective. 2. Q Minimum setting: the Q minimum stop on the hydraulic pump, (Figure 4, item 1). With all boom functions in the neutral position, emergency stop buttons up, the engine at maximum specified RPM's, the pressure on the main gauge (0-600 bar) should be: a)
KVM 32 & 36 = 40 Bar;
b)
KVM 42 = 40-45 Bar;
c)
KVM 52 = 50-55 Bar.
If the pressure is incorrect, the Q-min. screw on the hydraulic pump must be adjusted accordingly. Turn the Q-min screw inward to increase the pressure and outward to decrease the pressure.
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Pressure Settings Pressure Regulator Cutaway KVM 52
Pressure Regulator
P Regulator
A
T P NOTE: NO ORIFICE USED ON KVM 52
0.8 mm
X
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Pressure Settings for Regulator and Releif Valves KVM 52 Now that we know our delta-P and Q-minimum are set correct we can check and reset the pressure limit and two relief valves. The correct pressure settings are as follows:
1) PRESSURE REGULATOR (Figure 1, item 4)320 Bar 2) CONTROL BLOCK RELIEF (Figure 3, item 5)350 Bar 3) NORMALLY OPEN BYPASS VALVE (Figure 2, item 2)360 Bar In order to reset the valve with the highest pressure, we must first raise the pressure of the other two valves. a. To set the pressure regulator (Figure 1), loosen the lock nut (Item 4), and turn the adjusting screw inward approximately two turns. This will raise the pressure of this valve higher than 360 bar. b. To set the control block (Figure 3), loosen the lock nut (item 5), and turn the adjusting screw inward approximately one turn. This will raise the relief pressure higher than 360 Bar. c. Pressure out any boom section. The pressure can now be read on the 0-600 Bar gauge that is near the control blocks. The gauge should read 360 Bar. If not, adjust the normally open bypass valve, (Figure 2, item 2). After you have this relief set to 360 Bar, you can lock the locknut and move on to the control block relief. (Be careful not break off the electrical connections or over-torque the locknuts on this valve. d. While you continue to hold a function pressured out you can adjust the control block relief valve (Figure 3, item 5), until the pressure gauge now reads 350 Bar. After this pressure is set and the locknut is locked, proceed to the pressure regulator. e. While still holding a function pressured out you can now adjust the pressure regulator (Fig. 1, Item 4), until the pressure gauge reads 320 Bar. When this pressure has been set and the locknut is locked, you are finished setting the main circuit pressures on the boom.
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Pressure Settings
Setting Pretension Pressure(Refer to Figure 5) a. To set the pretension pressure, install a 0-250 Bar gauge and connection hose on the gauge port (item 6). Loosen the locknut on the pressure reducing valve (item 7), and turn the adjusting screw inward approximately two turns. This will raise the valve’s pressure higher than 50 Bar. b. While holding a function pressured out, adjust the pretension relief valve (item 8), until the gauge reads 50 Bar. c. Remove 0-250 Bar gauge, and install a 0-40 Bar gauge. With all boom functions in neutral and engine at full rpm’s (this provides Q-Min), adjust the pressure reducing valve (item 7), until the gauge reads 34 Bar. (CAUTION!!! - do not activate any boom functions during this operation or damage to the 0-40 Bar gauge will result).
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Pressure Settings Control Block 1 for KVM 52 Boom 3, Boom 4, & Slewing
52 METER CONTROL BLOCK 1 BOOM 3, BOOM 4, SLEWING
a3
BOOM DOWN TIME SPEED ADJUSTMENT
b3
A3
B3
A2
B2
A1
B1
BOOM #3
a2
b2
BOOM #4
a1
b1
SLEWING
BOOM UP TIME SPEED ADJUSTMENT
A1-A3
B1-B3
SLEWING RELIEF-190 BAR
SLEWING RELIEF-190 BAR
BLEED SCREW
BLEED SCREW T a1-a3 P
b1-b3
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Pressure Settings
Control Block 2 for KVM 52 Boom 1, Boom 2, & Outriggers
52 METER CONTROL BLOCK 2 BOOM 1, BOOM 2, OUTRIGGER 350 BAR PRIMARY RELIEF
a6
b6
A6
OUTRIGGER
a5
b5
A5
B5
A4
B4
BOOM #1
a4
BOOM DOWN TIME SPEED ADJUSTMENT
b4
BOOM #2
BOOM UP TIME SPEED ADJUSTMENT
A4-A6
B4-B6
BLEED SCREW
BLEED SCREW T a4-a6 P
b4-b6
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Pressure Settings Pre-Control Block 1-A for KVM 52
52 PRE-CONTROL BLOCK 1-A FILTER PRETENSION RELIEF 50 Bar
O-ring
Filter O-ring
L
P
24V
Orifice NOT USED
24V
PV (PST)
NOTE:
PRESSURE REDUCING 34 Bar
GAUGE PORT FOR CHECKING THESE PRESSURES IS ON THE PRE-CONTROL BLOCK 2-A.
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Pressure Settings
Pre-Control block 1-B for KVM 52
52 PRE-CONTROL BLOCK 1-B
24V
24V
24V
L
TOP VIEW
a1- #3 Boom Extend b1- #3 Boom Retract a2- #4 Boom Extend b2- #4 Boom Retract a3- #1 Boom Extend b3- #1 Boom Retract
b3
b2
b1
b3 INPUT
b2 INPUT
b1 INPUT
24V
24V
24V
a1
a2
a3
a1 INPUT
a2 INPUT
a3 INPUT
PV
BOTTOM VIEW REXROTH M10-100S
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PV (PST)
P
34 BAR
50 BAR
L
b1
b1
a1
a1
b2
b2
a2
a2
PART # 995 120 002 651 (Complete)
b3
52 PRE-CONTROL BLOCK 1-C
b3
a3
a3 HOME
Pressure Settings Pre-Control Block 1-C for KVM 52
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L
PV (PST)
24V
SIDE VIEW
Quick Gauge Port b4 INPUT
b4
24V
a4 INPUT
a4
24V
b4- #2 Boom retract b5- Slewing - Right b6- Outriggers
b5 INPUT
REXROTH M10-1006
b5
24V
TOP VIEW
a5 INPUT
a5
24V
b6 INPUT
b6
24V
a4- #2 Boom Extend a5- Slewing Left
L
PV (PST)
24V
SIDE VIEW
52 PRE-CONTROL BLOCK 2-A
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Pressure Settings
Pre-Control Block 2-A for KVM 52
L
PV (PST)
b4
b4
a4
a4
b5
b5
a5
a5
b6
PART #995 120 003 651 (Complete)
b6
52 PRE-CONTROL BLOCK 2-B
X
L
PV (PST) GAUGE PORT
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Pressure Settings Pre-Control Block 2-B for KVM 52
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Pressure Settings
Electric Bypass Valve for KVM 52
52 METER ELECTRIC BYPASS 360 Bar RELIEF A
A 360 Bar
B CAUTION: OVER TIGHTENING WILL CAUSE DAMAGE TO THE VALVE! 24V
TORQUE VALUES:
24V
PRESSURE ADJUSTMENT 15 FT.LBS. LOCK NUT 7.5 FT.LBS. CARTRIDGE(COMPLETE) 37 FT.LBS.
Y
X
A
A
B
A SAI ITEM# (Cartridge Only) 10055188
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KVM 52M Preheat the hydraulic oil. Pressure settings must be made with the oil at normal operating temperatures (50° to 60° C). In the past we could pressure out a function in the boom or outrigger system to create heat, but today, load sensing systems no longer allow maximum oil flow to be forced over relief. Because of this, the agitator circuit must be used to heat the hydraulic oil. To heat the oil to operating temperature: 1. Locate the agitator shutoff valve (Figure 343) and close it. The quarter turn shutoff valve has a grooved line (Figure 343) on the shaft or pivot point of the handle as well as on the handle itself, which will indicate the open or closed configuration of the valve. If the handle is removed from the agitator shutoff valve (Figure 343) or the concrete pump shutoff valve (Figure 344) and
agitoff.eps
Motor
Pressure Settings
replaced in a different configuration the grooves in the handle may no longer indicate the proper open/ closed orientation of the valve. The grooves in the shaft give the only true indication of the valves position. Note! If your unit is an early production model, and does not have an agitator shutoff valve, order one from the Schwing Spare Parts Department, using part number 10004680 (valve) and number 30303432 (tube). Contact the Service Department for installation instructions. 2. Activate the agitator. With the valve closed, the agitator will not be able to turn and the oil will be forced over the relief valve. At an idle (about 600 RPM) you will be converting 4.5 horsepower to heat. 3. When the oil temperature gauge shows 50˚ C, open the shutoff valve.
Grooves in handle
Grooves in shaft
Agitator quarter turn shutoff valve (open position)
Closed
grooves2.eps
Open Mounting screw and washer removed for illustration
Figure 343 Agitator shutoff valve (left) and Open/closed orientation of shutoff valve (right)
Setting relief pressure and pressure cutoff on Hi-flo -6 pumpkits a. To set the pressure of the main relief valve on Hi-flo pumpkits, you must first disable the soft switch circuit. Simply locate the ball cock for the soft switch circuit (Figure 320) and close it by rotating the handle 90 degrees. b. The quarter turn shutoff valve for the concrete pump (Figure 344) will also need to be closed during this procedure.
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Pressure Settings Soft switch shutoff valve Main Pressure Gauge port
Figure 344 Concrete pump and Soft switch shutoff valves
Concrete pump shutoff valve
Note: Main system adjustments are preset at the factory. The following procedure begins with adjustment of the main relief cartridge and pressure cutoff. If proper pressures can not be obtained through these steps, contact the Schwing Service Department for specific instructions on the adjustment of flow, horsepower, beginning of stroke regulation and Q-min. Pressure setting procedure: 1. Be sure that the waterbox covers and guards are in place any time you will be working in the area around the main control block. 2. Wear safety glasses when working around a concrete pump. Note! It is vital that each adjustment screw be properly identified prior to making any adjustment. All screw adjustments for the system relief must be made with the pumpkit in the neutral position and adjustments for pressure cutoff must be made with the engine shut off. 3. Start the truck engine, and put the PTO in gear just as you would to pump a job. 4. If you have not already closed the soft switch shutoff valve and the concrete pump shutoff valve (Figure 344) do so at this time. 5. At the rear panel, select “local” control with the “local/remote” switch and turn the electric stroke limiter knob clockwise to maximum strokes per minute. 6. The main system control block pressure must be set first to properly set the pressure cutoff on both pumps. Begin by backing off the jam nut of the main relief cartridge (Figure 345) with a 9/16 inch wrench. 7. Using a 5/32 inch allen wrench, turn the adjustment screw out (counterclockwise) until you can feel no spring tension on the adjustment screw.
hif
low
br
n.
ep
s
8. Now, turn the screw back in (clockwise) two or three full turns to give you a proper starting point and tighten the jam nut. 9. Stop the truck engine, put the key in your pocket and adjust the pressure cutoff screw (Figure 345) on each pump, by backing off the jam nut with a 13mm wrench. Using a 4mm allen wrench, turn the adjustment screw in (clockwise) one full turn and tighten the jam nut. Restart the truck engine. 10. Adjust the engine RPM to maximum specification. (See decal in truck cab) 11. Pressure out the system by activating the concrete pump forward switch on the rear panel. Using the rear panel controls will allow you to read the concrete pump main system pressure gauge, near the e-stop manifold, from a safe distance. Note: Because you turned out the pressure relief cartridge in step 7, the system pressure should read low at this time. If it does not and the gauge spikes to 320 bar or more, disengage the pump immediately. Turn the relief cartridge out (counterclockwise) more. For safety, it is important to adjust the pressure up from below the specified target pressure rather than down from a pressure which exceeds the target. Continue this procedure until the main system pressure gauge reads lower than the specified target. 12. To increase the pressure put the pump in the neutral position and adjust the relief cartridge by turning it in (clockwise). When increasing the pressure, the adjustments should be made in quarter turn increments. If you make adjustments to increase the pressure but the pressure does not come up, you are probably reading the pressure cutoff of the pumps, if so proceed to the next step otherwise skip to step 15.Turn the relief cartridge
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adjustment screw back out (counterclockwise) until you can no longer see a pressure drop and tighten the jam nut. 13. Stop the truck engine, put the key in your pocket. 14. Go to the pressure cutoff screw on both hydraulic pumps and back off the jam nut with a 13mm wrench. Turn the adjustment screws in with a 4mm allen wrench one or two more turns, restart the engine and check the pressure again. Repeat this procedure until the main system relief can be set to the target pressure. 15. When the proper main relief pressure is achieved, pressure cutoff can be set. Shut off the engine, put the key in your pocket and install 0-600 bar gauges with whip hoses to the “M1” gauge ports on the bottom of the two hydraulic pumps (Figure 346). You must be able to read both gauges simultaneously to ensure that one pump is not more dominant than the other. Note: The gauges in the M1 ports will read considerably less than the cutoff pressure of the pump. On a -6 (190/130 pump combination) the 190 will usually read 85 to 90 bar while the 130 reads about 110 bar. They could read the same however, at approximately 110 bar, but the 190 must never read higher than the 130. The actual cutoff pressure will be read on the concrete pump main system pressure gauge near the e-stop manifold. Main and soft switch relief cartridges
Pressure Settings
16. Activate concrete pump forward to pressure out the pump and read the pressure on the two gauges in the “M1” ports. 17. Always stop the truck engine and put the key in your pocket before making any adjustment on the hydraulic pump. If the cutoff on one pump is set higher than the other, that pump will be more dominant. The pressure gauge in the M1 port of the dominant pump will however, read lower than the other. To equalize the two pumps you must either adjust the cutoff screw in (clockwise) to increase the pressure of the pump showing the higher reading or adjust the cutoff screw of the dominant pump showing the lower reading out (counterclockwise) to reduce the pressure. These adjustments must be made until the two gauges in the M1 ports are reading approximately the same. 18. When you have achieved the same pressure on the M1 port gauges, you can begin to adjust the pressure cutoff screws in or out simultaneously until you achieve the desired pressure setting of 350 bar (again, confirm the pressure specification with the hydraulic schematic). After pressure cutoff is set, return the pump to neutral, bring engine RPM to idle, open the soft switch quarter turn valve, and either proceed to other pressure settings or take the transmission and PTO out of gear and shut off the truck.
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Concrete pump gauge port
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Main relief cartridge
soft switch relief cartridge 9/16" jam nut
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9/16" jam nut
Figure 345 Location of soft switch shutoff and relief cartridges
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Pressure Settings
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1 Stroke Regulation
2 Pressure Cut Off
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M1 GAUGE PORT (BOTTOM OF EACH PUMP) Figure 346 A11VO adjustment screws for Hi-flo – 6 units 190/130 NOTE: The main control block (brain) of a 2525 pumpkit will be rotated 180 degrees from the illustration shown in Figure 321.
Setting the soft switch circuit relief pressure a. If you haven’t already done so, open the soft switch quarter turn valve (Figure 345). The rest of the unit should still be set up as though you were going to check the main relief valve pressure (concrete pump shutoff valve still closed). b. When you put the pump in forward now, the pressure gauge should read the pressure shown on the schematic for soft switch. If adjustment is needed, loosen the jam nut of the soft switch relief cartridge (Figure 321) with a 9/16 inch open end wrench, and use a 5/32 inch allen wrench to adjust the pressure. Turn the adjustment screw in (clockwise) to raise the pressure or out (counter clockwise) to lower the pressure. When you attain the required pressure, tighten the jam nut while holding the allen wrench, to keep the pressure from rising. Be sure to open the concrete pump quarter turn valve on the side of the brain (Figure 321) when you are finished. The unit will not stroke with this valve closed.
Set boom circuit pressures NOTE! Any time you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (50 to 60° C). Instructions on heating the hydraulic oil for this procedure are found in step on page 6-483. Please read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the following procedure. You and any assistants should wear eye protection when setting pressures. Current production model 52 meter pumps are equipped with a load sensing, proportional boom hydraulic system. If the system were black and white, the hydraulic pump would put out an unchanging amount of oil and speed control is done by restricting the oil to certain functions with orifices. With a load sensing system, the pumps put out more or less oil to respond to the needs of the system. Generally, the pump always puts out enough oil to maintain 20 bar higher pressure at the pump than the boom cylinders actually require. This 20 bar is called delta P. You may see it referred to by a symbol (∆ P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if none is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced
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SERVICE TRAINING
“cue min”). To set the boom or outrigger hydraulic pressures on a load sensing system, begin by checking ∆ P and Q-min.t
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Pressure Settings
CAUTION! When checking Delta P, it is important to note that you will be installing a low pressure gauge into a high pressure port. Any activation of a boom function or activation of an e-stop, while this gauge is attached will destroy your gauge. On Comfort control units, always center the boom speed switch on the remote box to prevent accidental activation of a joy stick.
Checking and Setting ∆P pressure Note! Do not adjust delta P or Q-min if your boom is running as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned from that point. The pressure was fine tuned at the factory, and should not be adjusted unless absolutely necessary.
1. Install a 0-100 bar whip gauge in the high pressure test port (Figure 347) located on the inside of the right boom control block as you face the three valve blocks. rtblock2.eps
Figure 347 The high pressure gauge port is located between the blocks on the inside edge of the right boom control High pressure gauge port
2. With the engine at idle, turn the adjustable relief cartridge (Figure 348) on the boom pilot control valve, out (counter clockwise) approximately three
turns. Remember exactly how much you move this cartridge because it will need to be returned to the original position.
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preset pressure reducing valve gauge port
Figure 348 Location of adjustable relief cartridge on the boom pilot control valve 3. With the engine running and the relief cartridge backed out, the gauge (Figure 279) should be
showing Delta P. The pressure could be anywhere from 16-25 bar.
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Pressure Settings 4. Increase the throttle RPM and the pressure should remain the same. If the pressure fluctuates with engine RPM you are probably still reading Q-min, and the adjustable relief cartridge (Figure 349) will need to be turned out more. 5. If no further adjustment is needed, return the pilot valve relief cartridge to its original position. If adjustment is required, proceed to the next step. 6. Delta P is adjusted on the bottom (smaller) screw of the pressure regulator shown in Figure 349 below, if your unit has an A7VO boom pump, by loosening the jam nut (10mm open end wrench),
and adjusting the screw (3mm allen wrench) clockwise to increase pressure or counter clockwise to decrease it. 7. The delta P adjustment screw on the A11VO boom pump also shown in Figure 307 below, requires a 13mm open end wrench and a 4mm allen wrench. 8. If no further adjustment is needed, return the pilot valve relief cartridge to its original position, and proceed to Q-min. 9. If pressure cannot be correctly set, there is a problem, contact Schwing Service Department to determine how to continue.
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Figure 349 Location of the delta P adjustment screw for a unit with A7VO pump (left) and A11VO pump (right)
Set Q-min
WARNING Stop the engine before adjusting the Q-min screw or Delta P on A11. Driveline entanglement hazard! Check Q-min with the engine at maximum specified RPM. Each time the Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning. 1. Before proceeding, remove the 0-100 bar whip gauge from the high pressure gauge port (Figure 279) and install a 0-400 or 0-600 bar gauge to the same port, to make certain that the higher pressure won’t destroy your 0-100 bar gauge.
2. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). Clear away all personnel, start the truck engine, engage the pumps and bring engine RPM to maximum specification. 3. Read the pressure. If the pressure reads less than 100 bar, remove the high pressure gauge and reinstall the 0-100 bar gauge. Pressure should be at 50-55 bar. If adjustment is needed, continue to point 4. 4. Stop the engine and turn the Q-min screw (Figure 350) in (clockwise) to raise the pressure, or out (counter-clockwise) to lower the pressure. Be sure that you stop the drive shafts from turning each
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SERVICE TRAINING
time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures. Delta-p
Pressure Cut-off
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Pressure Settings
Note! If you don’t have a 0-100 bar gauge you can order one from Schwing Spare Parts Department at (800) 328-9635, part #10004659.
Q-min adjustment screw
A7VX section min.top.eps
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Q-min
Q-max (Bottom Of Pump)
Q max
Figure 350 Location of Q-min screw on A11VO (left) and A7VO (right)
Checking boom pressures After the Delta P and Q-min are set, remove the 0-100 bar gauge and proceed to check and adjust, if necessary, the main boom pressures. 1. To check the boom pressure, install a 0-600 bar gauge in the boom circuit high pressure gauge port (Called out but not visible in Figure 351). 2. With the engine at full RPM and the boom folded, activate boom #2, #3, or #4 to the in position, which will pressure out the function. A function must be pressured out each time you want to check the pressure.
3. Read the gauge. It should be showing the lowest relief pressure setting of the boom circuit (pressure regulator or cutoff) + or - 5 bar (See schematic). If it does not, a minor adjustment can be made by going to the pressure regulator (large screw) for units with A7VO pumps or after stopping the engine, the pressure cutoff screw for units with A11VO pumps, backing off the jam nut and turning the adjustment screw to achieve the desired pressure. If the pressure can not be reached, return the screw to the original setting and proceed to Setting boom circuit pressures. Down side dynamic gauge port Main boom pressure gauge port (Hidden)
Figure 351 Main boom circuit high pressure gauge port (not visible on illustration) Main relief cartridge
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Pressure Settings Setting main boom circuit pressures 1. Review the hydraulic schematic and identify the three different pressure settings involved in this circuit. 1) Boom block main relief, 2) e-stop manifold relief, and 3) pressure regulator.
2. Since the gauge will always show you the lowest of the three settings, it is necessary to raise the two lowest pressures enough to allow us to see the highest one, which will be the main relief at the boom block (Figure 352).
Down side dynamic gauge port Main boom pressure gauge port (Hidden)
Figure 352 Main relief adjustment screw and gauge ports
Main relief cartridge
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3. Loosen the jam nut on the large screw of the pressure regulator or the pressure cutoff screw (Figure 353), depending which one your unit has, and turn the adjustment screw clockwise, all the way in.
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Delta-p
Pressure Cut-off
Regulator pressure adjustment T
Adjustment for P pressure hifloreg.eps
Q-min
Q-max (Bottom Of Pump)
Figure 353 Pressure regulator adjustment (A7VO left) and Pressure cutoff screw (A11VO right) 4. Loosen the jam nut on the boom circuit relief cartridge located on the e-stop manifold (Figure 354) using a 9/16 wrench and turn the adjustment screw using a 5/32 allen wrench in until you can see the maximum pressure of the boom block main relief showing on the gauge while pressuring out a boom function.
If the pressure reading is still lower than the maximum shown on the schematic, loosen the jam nut on the control block main relief (Figure 352) adjustment screw and turn the adjusting screw in. This will raise the pressure of the main relief valve until the desired pressure is achieved. Tighten the jam nut to secure the adjustment screw.
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Pressure Settings
@@;; ;; @@;; @@;@ ;;;; @@ @@ @@ ;; @@ ;; @@ ;; @@;; ;; @@ @@ ;; @@ ;; @@ ;; @@;; ;; @@;; @@;; @@;; @@ @@;; ;; @@ @@ ;; @@ ;; @@ ;; @@;; ;; @@;; @@;; @@;; @@ @@;; ;; @@ @@ ;; @@ ;; @@ ;; @@ ;; @@ ;; @@ ;; @@ ;; @@ ;; Figure 354 @@ ;; QQ @@ ;; QQ @@ ;; QQ @@ ;; QQ Q;@ @@ ;; Boom circuit relief cartridge on e-stop @@ ;; QQ @@ ;; QQ QQ @@ ;; QQ @ ; Q @@ ;; @@ ;; @@ ;; QQ @@ ;; QQ @@ ;; QQ @@ ;; QQ manifold Q;@ @@ ;; @@ ;; QQ @@ ;; QQ @@ ;; QQ @@ ;; QQ @ ; Q @@ ;; @@ ;; @@ ;; @@ ;; @@ ;; ;@ @@;; ;; QQ @@;; ;; QQ @@ ;; QQ @@ ;; QQ @ ; Q @@ ;; @@ @@ @@ ;; @@ ;; @ ; @@ ;; QQ @@ ;; QQ @@;; ;; QQ @@;; ;; QQ Q;@ ;@ @@ ;; @@ ;; @@ ;; @@ @@ @@ ;; QQ @@ ;; QQ @@ ;; QQ @@ ;; QQ @ ; Q @@ ;; Boom circuit @@ ;; @@ ;; @@ ;; @@ ;; ;@ @@relief ;; QQ @@;; ;; QQ @@ ;; QQ @@;; ;; QQ @ ; Q @@ ;; @@ ;; @@ @@ ;; @@ @ ; cartridge @@ ;; QQ @@ ;; QQ @@ ;; QQ @@ ;; QQ @@ ;; @@ ;; @@ ;; @@ ;; @@ ;; @@;; ;; QQ @@;; ;; QQ @@;; ;; QQ @@;; ;; QQ Q;@Q;@ ;@;@ @@ ;; @@ @@ @@ @@ Now return to the boom circuit relief cartridge Checking pretension pressure 52estp1.eps
5.
(Figure 354) and turn the adjustment screw back out (counter-clockwise) until the second highest pressure on the boom circuit schematic is achieved, and tighten the jam nut to secure the adjustment screw. 6. Finally, return to the pressure regulator or pressure cutoff (Figure 353) and turn the adjustment screw out until the lowest pressure on the schematic is achieved, and lock the jam nut.
This procedure is to check the pretension pressure only. The pressure you will be reading is from the factory preset pressure reducing valve (Figure 355) which can not be adjusted. 1. Install a 0-60 bar whip gauge on the gauge port of the precontrol block (Figure 355) and bring the engine RPM to full throttle. The gauge should read 33-35 bar. If the pressure reading is different than that, contact the Schwing Service Department for instructions on how to proceed.
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preset pressure reducing valve
gauge port Figure 355 Showing the precontrol valve gauge port and adjustment points
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Pressure Settings Set the outrigger pressure To set the outrigger pressure. Find the relief cartridge (Figure 356) located on the passenger side outrigger control valve. 1. Attach 0-600 bar whip gauge to gauge port shown in Figure 312. 2. Push the outrigger button. 3. Activate an outrigger jacking cylinder to retract. By attempting to retract a cylinder which is already retracted the oil coming from the pump has no where to go but over the relief valve. You cannot
use an extension cylinder because they have secondary relief functions (non-adjustable) built into the valve. While holding the push-button and activating either handle number 4 or 5 Figure 312, to retract position, read the pressure on the gauge. 4. Check the schematic to see what the pressure should read. Adjust by loosening the jam nut with a 9/16 open end wrench and turning the cartridge with a 5/32 allen wrench. When the desired pressure is reached, let go of the handle and the push-button. 5. Remove the whip gauge when the job is complete. PScntrl#.eps
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Relief cartridge
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Outrigger controls after mid 1999 1. 2. 3. 4. 5.
Front extend Rear fold Front fold Rear foot Front foot
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Outrigger controls prior to mid 1999 1. 2. 3. 4.
Front extend Rear fold Front fold Foot
Figure 356 Passenger side outrigger valve bank for units built after mid 1999 (left) and prior to mid 1999 (right)
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Set the agitator pressure The agitator circuit has a maximum pressure, shown on the schematic, which is limited by the relief cartridge (Figure 357) in the agitator hand valve. The cartridge is adjustable with a 19mm socket or wrench.
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Pressure Settings
1. Plug the 0 - 600 bar whip gauge into the gauge port which is located on the front of the agitator hand valve (not shown in this illustration).
Relief cartridge
Figure 357 Location of the agitator relief cartridge
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2. Locate the agitator shutoff valve (Figure 358) and close it. If your unit does not have a shutoff valve, order one from the Schwing Spare Parts Department using part number 10004680 (valve), and number 30303432 (tube). Contact the Service Department for installation instructions. If you can’t wait for a shutoff valve, you will need to shut off the engine and place the key in your pocket as you remove one of the hoses from the agitator motor and plug the hose and open fitting with approved hydraulic dead plugs (Figure 358). • qty 2 VS-16S locking plugs, part number 10016803
• •
qty 1 GS-16S straight fitting, part number 10008088 qty 2 16S capnuts, part number 10001743.
All of these fittings and many, many more extremely useful items are included in the trouble shooting kit, part number 30308553. 3. Be sure that one of the locking plugs and capnuts are tightened on the straight fitting, and that the dead plugs are securely tightened to the hose and the open motor fitting. 4. Be sure that all personnel are clear, and restart the engine.
WARNING Do not jam agitator paddles to force oil over relief. Entanglement hazard!
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Pressure Settings agitoff.eps
Plugs Straight Fitting
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Agitator quarter turn shutoff valve (open position)
Cap Nuts Motor
Figure 358 Agitator shutoff valve and approved hydraulic dead plugs 5. Increase the engine RPM to full throttle and activate the agitator hand valve in either forward or reverse and read the gauge. If it does not read the specified pressure, turn the body of the relief valve using a 19mm socket or wrench. The cartridge should be turned in (clockwise) to increase pressure or out (counterclockwise) to decrease pressure. 6. After the pressure is set, deactivate the agitator system by placing the manual control handle in the neutral position. 7. Remove the whip gauge. Reopen the shutoff valve or stop the engine and remove the key. Remove the dead plugs and store them in a clean area. Re-attach the hose to the agitator motor fitting and tighten securely. (Torque is correct if you make one complete revolution after feeling initial resistance increase).
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SERVICE TRAINING
KVM 55M Check all hydraulic pressures Changes in pressure can indicate trouble in one or more components and will serve as early warning indicators if you check them on a regular basis. The specifications for each circuit are shown on the hydraulic schematics found in the Appendix section of this manual. The hydraulic schematics are the only documents in this manual that have been updated specifically for your unit, by the serial number, so in each of the following procedures you will be told to refer to the schematic for the pressure required.
Preheat the hydraulic oil Pressure settings must be made with the oil at normal operating temperatures (50° to 60° C). In the past we could pressure out a function in the boom or outrigger system to create heat, but today, load sensing systems no longer allow maximum oil flow to be forced over relief. Because of this, the agitator circuit must be used to heat the hydraulic oil. To heat the oil to operating temperature: 1. Locate the agitator shutoff valve (Figure 359), and close it. The quarter turn shutoff valve has a grooved line (Figure 359) on the shaft or pivot
Pressure Settings
point of the handle as well as on the handle itself, which will indicate the open or closed configuration of the valve. If the handle is removed from the agitator shutoff valve (Figure 359) or the concrete pump shutoff valve (Figure 360) and replaced in a different configuration, the grooves in the handle may no longer indicate the proper open/ closed orientation of the valve. The grooves in the shaft give the only true indication of the valves position. NOTE: If your unit is an early production model and does not have an agitator shutoff valve, order one from the Schwing Spare Parts Department, using part number 10004680 (valve) and number 30303432 (tube). Contact the Service Department for installation instructions. 2. Activate the agitator. With the valve closed, the agitator will not be able to turn and the oil will be forced over the relief valve. At an idle (about 600 RPM) you will be converting 4.5 horsepower to heat. 3. When the oil temperature gauge shows 50˚ C, open the shutoff valve.
Grooves in handle Agitator quarter turn shutoff valve (open position)
Closed
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Grooves in shaft
Motor
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Open Mounting screw and washer removed for illustration
Figure 359 Agitator shutoff valve (left) and Open/closed orientation of shutoff valve (right)
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Pressure Settings
Soft switch shutoff valve Main Pressure Gauge port
Figure 360 Concrete pump and Soft switch shutoff valves
Concrete pump shutoff valve
Setting relief pressure and pressure cutoff on Hi-flo -6 pumpkits 1. To set the pressure of the main relief valve on Hiflo pumpkits, you must first disable the soft switch circuit. Simply locate the ball cock for the soft switch circuit (Figure 360), and close it by rotating the handle 90 degrees. 2. The quarter turn shutoff valve for the concrete pump (Figure 360) will also need to be closed during this procedure. Note: Main system adjustments are preset at the factory. The following procedure begins with adjustment of the main relief cartridge and pressure cutoff. If proper pressures cannot be obtained through these steps, contact the Schwing Service Department for specific instructions on the adjustment of flow, horsepower, beginning of stroke regulation, and Q-min. Pressure setting procedure: 3. Be sure that the waterbox covers and guards are in place any time you will be working in the area around the main control block. 4. Wear safety glasses when working around a concrete pump. Note! It is vital that each adjustment screw be properly identified prior to making any adjustment. All screw adjustments for the system relief must be made with the pumpkit in the neutral position, and adjustments for pressure cutoff must be made with the engine shut off. 5. Start the truck engine, and put the PTO in gear just as you would to pump a job.
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6. If you have not already closed the soft switch shutoff valve and the concrete pump shutoff valve (Figure 360), do so at this time. 7. At the rear panel, select “local” control with the “local/remote” switch, and turn the electric stroke limiter knob clockwise to maximum strokes per minute. 8. The main system control block pressure must be set first to properly set the pressure cutoff on both pumps. Begin by backing off the jam nut of the main relief cartridge (Figure 361) with a 9/16 inch wrench. 9. Using a 5/32 inch allen wrench, turn the adjustment screw out (counterclockwise) until you can feel no spring tension on the adjustment screw. 10. Now, turn the screw back in (clockwise) two or three full turns to give you a proper starting point, and tighten the jam nut. 11. Stop the truck engine, put the key in your pocket, and adjust the pressure cutoff screw (Figure 321) on each pump, by backing off the jam nut with a 13mm wrench. Using a 4mm allen wrench, turn the adjustment screw in (clockwise) one full turn, and tighten the jam nut. Restart the truck engine. 12. Adjust the engine RPM to maximum specification. (See decal in truck cab) 13. Pressure out the system by activating the concrete pump forward switch on the rear panel. Using the rear panel controls will allow you to read the concrete pump main system pressure gauge, near the e-stop manifold, from a safe distance.
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NOTE: Because you turned out the pressure relief cartridge in step 7, the system pressure should read low at this time. If it does not and the gauge spikes to 320 bar or more, disengage the pump immediately. Turn the relief cartridge out (counterclockwise) more. For safety, it is important to adjust the pressure up from below the specified target pressure rather than down from a pressure which exceeds the target. Continue this procedure until the main system pressure gauge reads lower than the specified target. 14. To increase the pressure, put the pump in the neutral position and adjust the relief cartridge by turning it in (clockwise). When increasing the pressure, the adjustments should be made in quarter turn increments. If you make adjustments to increase the pressure but the pressure does not come up, you are probably reading the pressure cutoff of the pumps. If so, proceed to the next step; otherwise skip to step 15. • Turn the relief cartridge adjustment screw back out (counterclockwise) until you can no longer see a pressure drop, and tighten the jam nut. • Stop the truck engine, and put the key in your pocket. • Go to the pressure cutoff screw on both hydraulic pumps, and back off the jam nut with a 13mm wrench. Turn the adjustment screws in with a 4mm allen wrench one or two more turns, restart the engine, and check the pressure again. Repeat this procedure until the main system relief can be set to the target pressure. 15. When the proper main relief pressure is achieved, pressure cutoff can be set. Shut off the engine, put the key in your pocket, and install 0-600 bar gauges with whip hoses to the M1 gauge ports on the bottom of the two hydraulic pumps (Figure 321). You must be able to read both gauges simultaneously to ensure that one pump is not more dominant than the other. NOTE: The gauges in the M1 ports will read considerably less than the cutoff pressure of the pump. On a -6 (190/130 pump combination) the 190 will usually read 85 to 90 bar while the 130 reads about 110 bar. They could read the same at approximately 110 bar, but the 190 must never read higher than the 130. The actual cutoff pressure will be read on the concrete pump main system pressure gauge near the e-stop manifold.
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Pressure Settings
16. Activate the concrete pump forward to pressure out the pump and read the pressure on the two gauges in the M1 ports. 17. Always stop the truck engine, and put the key in your pocket before making any adjustment on the hydraulic pump. If the cutoff on one pump is set higher than the other, that pump will be more dominant. The pressure gauge in the M1 port of the dominant pump will, however, read lower than the other. To equalize the two pumps, you must either adjust the cutoff screw in (clockwise) to increase the pressure of the pump showing the higher reading, or adjust the cutoff screw of the dominant pump showing the lower reading out (counterclockwise) to reduce the pressure. These adjustments must be made until the two gauges in the M1 ports are reading approximately the same. 18. When you have achieved the same pressure on the M1 port gauges, you can begin to adjust the pressure cutoff screws in or out simultaneously until you achieve the desired pressure setting of 350 bar (again, confirm the pressure specification with the hydraulic schematic). After pressure cutoff is set, return the pump to neutral, bring engine RPM to idle, open the soft switch quarter turn valve, and either proceed to other pressure settings or take the transmission and PTO out of gear; then shut off the truck.
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Pressure Settings Main and soft switch relief cartridges
Closed
Open
Concrete pump gauge port
soft switch relief cartridge
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Main relief cartridge
9/16" jam nut
5/32" Allen head ga
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9/16" jam nut
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Figure 361 Location of soft switch shutoff and relief cartridges
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1 Stroke Regulation
2 Pressure Cut Off
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M1 GAUGE PORT (BOTTOM OF EACH PUMP)
Figure 362 A11VO adjustment screws for Hi-flo – 6 units 190/130
NOTE: The main control block (brain) of a 2525 pumpkit will be rotated 180 degrees from the illustration shown in Figure 361.
Setting the soft switch circuit relief pressure 1. If you haven’t already done so, open the soft switch quarter turn valve (Figure 361). The rest of the unit should still be set up as though you were going to check the main relief valve pressure (concrete pump shutoff valve still closed).
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Setting boom circuit pressures NOTE! Any time you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (50 to 60° C). Instructions on heating the hydraulic oil for this procedure are found on page 495. Please read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the following procedure. You and any assistants should wear eye protection when setting pressures. Current production model 55 meter pumps are equipped with a load sensing, proportional boom hydraulic system. If the system were black and white, the hydraulic pump would put out an unchanging amount of oil, and speed control would be done by restricting the oil to certain functions with orifices. With a load sensing system, the pumps put out more or less oil to respond to the needs of the system. Generally, the pump always puts out enough oil to maintain 20 bar higher pressure at the pump than the boom cylinders actually require. This 20 bar is called delta P. You may see it referred to by a symbol (∆ P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if none is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load sensing system, begin by checking ∆ P and Q-min.
Checking and setting ∆P pressure NOTE: Do not adjust delta P or Q-min if your boom is running as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned
Pressure Settings
from that point. The pressure was fine tuned at the factory and should not be adjusted unless absolutely necessary. rtblock2.eps
High pressure gauge port
Figure 363 The high pressure gauge port is located between the blocks on the inside edge of the right boom control block. CAUTION! When checking delta P, it is important to note that you will be installing a low pressure gauge into a high pressure port. Any activation of a boom function or activation of an e-stop while this gauge is attached will destroy your gauge. On Comfort Control units, always center the boom speed switch on the remote box to prevent accidental activation of a joy stick.
WARNING Entanglement hazard. Stop drive shafts before adjusting Delta P on A11VO pump.
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2. When you put the pump in forward now, the pressure gauge should read the pressure shown on the schematic for soft switch. If adjustment is needed, loosen the jam nut of the soft switch relief cartridge (Figure 321) with a 9/16 inch open end wrench, and use a 5/32 inch allen wrench to adjust the pressure. Turn the adjustment screw in (clockwise) to raise the pressure or out (counter clockwise) to lower the pressure. When you attain the required pressure, tighten the jam nut while holding the allen wrench to keep the pressure from rising. Be sure to open the concrete pump quarter turn valve on the side of the brain (Figure 359) when you are finished. The unit will not stroke with this valve closed.
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1. Install a 0-100 bar whip gauge in the high pressure test port (Figure 363), located on the inside of the right boom control block as you face the three valve blocks.
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Pressure Settings 2. With the engine at idle, turn the adjustable relief cartridge (Figure 364) on the boom pilot control valve out (counter clockwise) approximately three turns. Remember exactly how much you move this cartridge, because it will need to be returned to the original position.
adjustable relief cartridge L
P
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preset pressure reducing valve gauge port Figure 364 Location of adjustable relief cartridge on the boom pilot control valve 3. With the engine running and the relief cartridge backed out, the gauge (Figure 365) should be showing delta P. The pressure could be anywhere from 16-25 bar.
4. Increase the throttle RPM, and the pressure should remain the same. If the pressure fluctuates with engine RPM, you are probably still reading Q-min, and the adjustable relief cartridge (Figure 365) will need to be turned out more. 5. If no further adjustment is needed, return the pilot valve relief cartridge to its original position. If adjustment is required, proceed to the next step. 6. Delta P is adjusted on the bottom (smaller) screw of the pressure regulator shown in Figure 365 below, if your unit has an A7VO boom pump you can do so by loosening the jam nut (10mm open end wrench) and adjusting the screw (3mm allen wrench) clockwise to increase pressure or counter clockwise to decrease it. 7. The delta P adjustment screw on the A11VO boom pump, also shown in Figure 307 below, requires a 13mm open end wrench and a 4mm allen wrench. 8. If no further adjustment is needed, return the pilot valve relief cartridge to its original position, and proceed to Q-min. 9. If pressure cannot be correctly set, there is a problem; contact Schwing Service Department to determine how to continue.
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Regulator pressure adjustment T
Adjustment for P pressure smdeltap.eps
Figure 365 Location of the delta P adjustment screw for a unit with A7VO pump (left) and A11VO pump (right)
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Pressure Settings
Setting Q-min Delta-p
Q-min adjustment screw
Pressure Cut-off
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Figure 366 Location of Q-min screw on A11VO (left) and A7VO (right) Check Q-min with the engine at maximum specified RPM. Each time the Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning.
Entanglement hazard. Stop drive shafts before adjusting Q-min.
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1. Before proceeding, remove the 0-100 bar whip gauge from the high pressure gauge port (Figure 364), and install a 0-400 or 0-600 bar gauge to the same port to make certain that the higher pressure won’t destroy your 0-100 bar gauge. 2. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). Clear away all personnel, start the truck engine, engage the pumps, and bring engine RPM to maximum specification. 3. Read the pressure. If the pressure reads less than 100 bar, remove the high pressure gauge and reinstall the 0-100 bar gauge. Pressure should be at 50-55 bar. If adjustment is needed, continue to point 4. 4. Stop the engine, and turn the Q-min screw (Figure 365) in (clockwise) to raise the pressure or out (counter-clockwise) to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures.
NOTE: If you don’t have a 0-100 bar gauge, you can order one from Schwing Spare Parts Department at (800) 328-9635, part #10004659.
Checking boom pressures After the delta P and Q-min are set, remove the 0-100 bar gauge, and proceed to check and adjust the main boom pressures, if necessary. 1. To check the boom pressure, install a 0-600 bar gauge in the boom circuit high pressure gauge port (called out but not visible in Figure 367). 2. With the engine at full RPM and the boom folded, activate boom #2, #3, or #4 to the in position, which will pressure out the function. A function must be pressured out each time you want to check the pressure. Read the gauge. It should be showing the lowest relief pressure setting of the boom circuit (pressure regulator or cutoff) + or - 5 bar (see schematic). If it does not, a minor adjustment can be made by going to the pressure regulator (large screw) for units with A7VO pumps (Figure 368), backing off the jam nut and turning the adjustment screw to achieve the desired pressure. For units with A11VO pumps, after stopping the engine, back off the jam nut on the pressure cutoff screw (Figure 368) and make the adjustment. If the pressure cannot be reached, return the screw to the original setting, and proceed to Setting boom circuit pressures.
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Pressure Settings
Down side dynamic gauge port Main boom pressure gauge port (Hidden)
Figure 367 Main relief adjustment screw and gauge ports. (High pressure gauge port not visible on illustration)
Main relief cartridge
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1. Review the hydraulic schematic, and identify the three different pressure settings involved in this circuit. 1) boom block main relief, 2) e-stop manifold relief, and 3) pressure regulator. 2. Since the gauge will always show you the lowest of the three settings, it is necessary to raise the two lowest pressures enough to allow us to see the highest one, which will be the main relief at the boom block (Figure 367).
3. Loosen the jam nut on the large screw of the pressure regulator or the pressure cutoff screw (Figure 368), depending which one your unit has, and turn the adjustment screw clockwise, all the way in.
WARNING Entanglement hazard. Stop drive shafts before adjusting Pressure cut-off on A11VO pump.
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Pressure Cut-off
Regulator pressure adjustment T
Adjustment for P pressure hifloreg.eps
Q-min
Q-max (Bottom Of Pump)
Figure 368 Pressure regulator adjustment (A7VO left) and Pressure cutoff screw (A11VO right)
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Setting main boom circuit pressures
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Pressure Settings
Boom circuit relief cartridge s ep trl. crc bm
Figure 369 Boom circuit relief cartridge on e-stop manifold
4. Loosen the jam nut on the boom circuit relief cartridge located on the e-stop manifold (Figure 369) using a 9/16 wrench, and turn the adjustment screw in using a 5/32 allen wrench until you can see the maximum pressure of the boom block main relief showing on the gauge while pressuring out a boom function. 5. If the pressure reading is still lower than the maximum shown on the schematic, loosen the jam nut on the control block main relief adjustment screw, (Figure 352) and turn the adjusting screw in. This will raise the pressure of the main relief valve until the desired pressure is achieved. Tighten the jam nut to secure the adjustment screw. 6. Now return to the boom circuit relief cartridge (Figure 369), and turn the adjustment screw back out (counter-clockwise) until the second highest pressure on the boom circuit schematic is achieved. Tighten the jam nut to secure the adjustment screw.
7. Finally, return to the pressure regulator or pressure cutoff (Figure 368), and turn the adjustment screw out until the lowest pressure on the schematic is achieved. Lock the jam nut.
Checking pretension pressure This procedure is to check the pretension pressure only. The pressure you will be reading is from the factory preset pressure reducing valve (Figure 370), which can not be adjusted. 1. Install a 0-60 bar whip gauge on the gauge port of the precontrol block (Figure 370), and bring the engine RPM to full throttle. The gauge should read 33-35 bar. If the pressure reading is different than that, contact the Schwing Service Department for instructions on how to proceed.
adjustable relief cartridge L
P
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preset pressure reducing valve
Figure 370 The precontrol valve gauge port and adjustment points
gauge port
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Pressure Settings Setting the outrigger pressure To set the outrigger pressure, find the relief cartridge (Figure 371) located on the passenger side outrigger control valve. 1. Attach a 0-600 bar whip gauge to the gauge port shown in Figure 371. 2. Push the outrigger button. 3. Activate an outrigger jacking cylinder to retract. By attempting to retract a cylinder which is already retracted, the oil coming from the pump has no where to go but over the relief valve. You cannot
use an extension cylinder because they have secondary relief functions (non-adjustable) built into the valve. While holding the push-button and activating handle number 4 (Figure 371) to retract position, read the pressure on the gauge. 4. Check the schematic to see what the pressure should read. Adjust by loosening the jam nut with a 9/16 open end wrench and turning the cartridge with a 5/32 allen wrench. When the desired pressure is reached, let go of the handle and the push-button. 5. Remove the whip gauge when the job is complete.
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Outrigger controls on units built in U.S. prior to 2000
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1. Front extend 2. Rear fold
Relief cartridge
3. Front fold 4. Foot (jacking)
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Gauge port
Figure 371 Passenger side outrigger valve bank
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Pressure Settings
Agitator Relief Valve Turn body of valve Gauge port
Higher
to adjust.
Lower
Figure 372 Location of the agitator relief cartridge and gauge port
Set the agitator pressure The agitator circuit has a maximum pressure, shown on the schematic, which is limited by the relief cartridge (Figure 372) in the agitator hand valve. The cartridge is adjustable with a 19mm socket or wrench. 1. Plug the 0 - 600 bar whip gauge into the gauge port, which is located on the top of the agitator hand valve. 2. Locate the agitator shutoff valve (Figure 372), and close it. If your unit does not have a shutoff valve, order one from the Schwing Spare Parts Department using part number 10004680 (valve) and number 30303432 (tube). Contact the Service Department for installation instructions. If you can’t wait for a shutoff valve, you will need to shut off the engine and place the key in your pocket as
Agitator quarter turn shutoff valve (open position)
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you remove one of the hoses from the agitator motor and plug the hose and open fitting with approved hydraulic dead plugs (Figure 373). • Qty 2 VS-16S locking plugs, part number 10016803 • Qty 1 GS-16S straight fitting, part number 10008088 • Qty 2 16S capnuts, part number 10001743 3. All of these fittings and many, many more extremely useful items are included in the trouble shooting kit, part number 30308553. 4. Be sure that one of the locking plugs and capnuts are tightened on the straight fitting, and that the dead plugs are securely tightened to the hose and the open motor fitting. 5. Be sure that all personnel are clear, and restart the engine.
Plugs Straight Fitting
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Figure 373 Agitator shutoff valve and approved hydraulic dead plugs
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Pressure Settings 6. Increase the engine RPM to full throttle, activate the agitator hand valve in either forward or reverse, and read the gauge. If it does not read the specified pressure, turn the body of the relief valve using a 19mm socket or wrench. The cartridge should be turned in (clockwise) to increase pressure or out (counterclockwise) to decrease pressure. 7. After the pressure is set, deactivate the agitator system by placing the manual control handle in the neutral position. 8. Remove the whip gauge. 9. Reopen the shutoff valve or stop the engine and remove the key. Remove the dead plugs and store them in a clean area. Re-attach the hose to the agitator motor fitting and tighten securely. (Torque is correct if you make one complete revolution after feeling initial resistance increase).
Set accumulator circuit pressure You will need an assistant for parts of this procedure. There are three relief settings for the accumulator circuit if your unit is equipped with an accumulator redundant relief cartridge in the emergency stop manifold (Figure 375). If your pump was built after January 1, 2000. It will have an emergency stop manifold which no longer has a redundant relief cartridge. In that case, you must skip steps 3 and 7 in the following procedure. To check or adjust the hydraulic pressure in the accumulator circuit: 1. Stop the truck, put the key in your pocket, and place a “Do Not Operate” sign on the windshield. 2. Loosen the jam nut on the pressure regulator of the accumulator hydraulic pump (Figure 374). Turn the screw in two-and-one-half turns. This will raise the regulator pressure above 300 bar. 3. Loosen the jam nut (Figure 375) on the accumulator redundant relief cartridge located on the emergency stop manifold. Turn the screw in two turns. This will raise the relief setting above 300 bar.
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Accumulator pump pressure regulator
Figure 374 Accumulator pump pressure regulator for A7VO (above) and for A11VO (below) Boom Pump Accumulator Pump
Standby Pressure Screw Accumulator Pump Pressure Regulator
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Accumulator redunant relief cartridge
Figure 375 Accumulator redundant relief cartridge
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Pressure Settings
4. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring the engine RPM to maximum. 5. Read the pressure on the accumulator circuit pressure gauge (Figure 376). The pressure should read the value shown on the hydraulic schematic. If no adjustment is needed, skip to step number 7. If additional pressure adjustment is needed, continue with step number 6.
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Figure 376 Accumulator circuit pressure gauge 6. Locate the accumulator manifold pressure relief cartridge (Figure 377). Loosen the jam nut, and turn the screw clockwise to increase the pressure or counter clockwise to decrease the pressure. Tighten the jam nut when the pressure reaches the value required. 7. You will need an assistant for this step. With the engine still running, one person must go to the redundant relief valve on the emergency stop manifold (Figure 375) and back out the adjustment screw while the other person stands by the pressure gauge to let him know when the pressure reads the value shown on the schematic for accumulator redundant relief.
Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
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Figure 377 Accumulator manifold pressure relief cartridge 8. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 374), and turn the screw back out two-and-one-half turns. This restores it to its original setting. 9. Clear all personnel from the drive line area, start the truck, and bring the engine RPM up to maximum. 10. Read the pressure on the accumulator gauge. It should read the proper accumulator system pressure. 11. If adjustment is needed, you must stop the truck engine, or a least stop the drive lines from turning, each and every time you approach the accumulator circuit hydraulic pump. Turn the screw in to increase the pressure or out to decrease pressure. Lock the jam nut when the pressure is correct. NOTE: The accumulator circuit hydraulic pump pressure regulator is referred to as the pressure cut-off.
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Pressure Settings
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S 58/61SX The following pages provide the proper techniques for checking and setting hydraulic pressures of each system included on your unit.
Check all hydraulic pressures Changes in pressures can indicate trouble in one or more components. The specifications for each circuit are shown on the hydraulic schematics found in the Appendix of this manual. The hydraulic schematics are the only documents in this manual that have been updated specifically for your unit by the serial number, so in each of the following procedures you will be told to refer to the schematic for the pressure required. If you wish to order a CD ROM which explains the pressure setting procedure for a specific model (All pumpkits), call SAI Spare Parts Department at (800) 328 - 9635 and request the CD using the following part numbers: • 61/58 meter. . . . . . . . . . . . . . . . . . . . . . . 30365860 • 52 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30354732 • 45/47 meter. . . . . . . . . . . . . . . . . . . . . . . 30356770 • 42 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30355485 • 39 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30365861 • 34 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30356772 • 32 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30355486 • 31 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30365862 Preheat the hydraulic oil
Pressure Settings
RPM), 4.5 horsepower is being converted to heat. 3. When the oil temperature gauge shows 50˚C, open the shutoff valve. Agitator quarter turn shutoff valve (open position)
Figure 378 Agitator shutoff valve
NOTE! If your unit does not have a shutoff valve, order one from the Schwing Spare Parts Department using part number 10004680 (valve) and number 30303432 (tube). Contact the Service Department for installation instructions. 2. Activate the agitator. With the valve closed, the agitator will not be able to turn and the oil will be forced over the relief valve. At an idle (about 600
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Setting pressures on Hi-flo -6 pumpkits •
•
To set the pressure of the main relief valve on Hi-flo pumpkits, you must first disable the soft switch circuit. Simply locate the ball cock shutoff for the soft switch circuit (Figure 320), and close it by rotating the handle 90 degrees. The quarter turn shutoff valve for the concrete pump (Figure 320) will also need to be closed during this procedure.
NOTE! Main system adjustments are preset at the factory. The following procedure begins with adjustment of the main relief cartridge and pressure cutoff. If proper pressures can not be obtained through these steps, contact the Schwing Service Department for specific instructions on the adjustment of flow, horsepower, beginning of stroke regulation and Q-min. Pressure setting procedure:
Pressure settings must be made with the oil at normal operating temperatures (40°− 60° C). In the past we could pressure out a function in the boom or outrigger system to create heat, but load sensing systems no longer allow maximum oil flow to be forced over relief. Because of this the agitator circuit must be used to heat the hydraulic oil. To preheat the hydraulic oil: 1. Locate the agitator shutoff valve (Figure 319) and close it.
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Soft switch shutoff valve Main Pressure Gauge port
Concrete pump shutoff valve
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Figure 379 Concrete pump and Soft switch shutoff 1. Be sure that the waterbox covers and guards are in place any time you will be working in the area around the main control block. 2. Wear safety glasses when working around a concrete pump.
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Pressure Settings NOTE!
3. 4.
5.
6.
7.
8.
9.
10. 11.
It is vital that each adjustment screw be properly identified prior to making any adjustment. All screw adjustments for the system relief must be made with the pumpkit in the neutral position, and adjustments for pressure cutoff must be made with the engine shut off. Start the truck engine, and put the PTO in gear just as you would to pump a job. If you have not already closed the soft switch shutoff valve and the concrete pump shutoff valve (Figure 320), do so at this time. At the Vector controller, select “local” control with the “local/remote” switch, and activate the electric stroke limiter switch to maximum strokes per minute. The main system control block pressure must be set first to properly set the pressure cutoff on both pumps. Begin by backing off the jam nut of the main relief cartridge (Figure 322) with a 9/16 inch wrench. Using a 5/32 inch allen key, turn the adjustment screw out (counterclockwise) until you can feel no spring tension on the adjustment screw. Now, turn the screw back in (clockwise) two or three full turns to give you a proper starting point, and tighten the jam nut. Stop the truck engine, and put the key in your pocket. Adjust the pressure cutoff screw (Figure 321) on each pump by backing off the jam nut with a 13mm wrench. Using a 4mm allen key, turn the adjustment screw in (clockwise) one full turn, and tighten the jam nut. Restart the truck engine. Adjust the engine RPM to maximum specification. (See decal in truck cab) Pressure out the system by activating the concrete pump forward switch on the rear panel. Using the rear panel controls will allow you to read the concrete pump main system pressure gauge, near the e-stop manifold, from a safe distance.
NOTE! Because you turned out the pressure relief cartridge in step 7, the system pressure should read low at this time. If it does not, and the gauge spikes to 320 bar or more, disengage the pump immediately. Turn the relief cartridge out (counterclockwise) more. For safety, it is important to adjust the pressure up from below the specified target pressure rather than down from a
12.
13. 14.
15.
pressure which exceeds the target. Continue this procedure until the main system pressure gauge reads lower than the specified target. To increase the pressure put the pump in the neutral position, and adjust the relief cartridge by turning it in (clockwise). When increasing the pressure, the adjustments should be made in quarter turn increments. If you make adjustments to increase the pressure but the pressure does not come up, you are probably reading the pressure cutoff of the pumps. If so, proceed to the next step; otherwise skip to step 15. Turn the relief cartridge adjustment screw back out (counterclockwise) until you can no longer see a pressure drop, and tighten the jam nut. Stop the truck engine and put the key in your pocket. Go to the pressure cutoff screw on both hydraulic pumps (Figure 321), and back off the jam nut with a 13mm wrench. Turn the adjustment screws in with a 4mm allen key one or two more turns, restart the engine, and check the pressure again. Repeat this procedure until the main system relief can be set to the target pressure. When the proper main relief pressure is achieved, pressure cutoff can be set. Shut off the engine, put the key in your pocket, and install 0-600 bar gauges with whip hoses to the “M1” gauge ports on the bottom of the two hydraulic pumps (Figure 321). You must be able to read both gauges simultaneously to ensure that one pump is not more dominant than the other.
NOTE! The gauges in the M1 ports will read considerably less than the cutoff pressure of the pump. On a -6 (190/130 pump combination), the 190 will usually read 85 to 90 bar, while the 130 reads about 110 bar. They could read the same, however, at approximately 110 bar, but the 190 must never read higher than the 130. The actual cutoff pressure will be read on the concrete pump main system pressure gauge near the e-stop manifold. 16. Activate concrete pump forward to pressure out the pump, and read the pressure on the two gauges in the “M1” ports. 17. Always stop the truck engine and put the key in your pocket before making any adjustment on the hydraulic pump. If the cutoff on one pump is set higher than the other, that pump will be more
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dominant. The pressure gauge in the M1 port of the dominant pump will, however, read lower than the other. To equalize the two pumps, you must either adjust the cutoff screw in (clockwise) to increase the pressure of the pump showing the higher reading or adjust the cutoff screw of the dominant pump showing the lower reading out (counterclockwise) to reduce the pressure. These adjustments must be made until the two gauges in the M1 ports are reading approximately the same. 18. When you have achieved the same pressure on the M1 port gauges, you can begin to adjust the
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Pressure Settings
pressure cutoff screws in or out simultaneously until you achieve the desired pressure setting of 350 bar (again, confirm the pressure specification with the hydraulic schematic). After pressure cutoff is set, return the pump to neutral, bring engine RPM to idle, open the soft switch quarter turn valve, and either proceed to other pressure settings or take the transmission and PTO out of gear and shut off the truck.
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1 Stroke Regulation
2 Pressure Cut Off
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Horse Power 2
Q-Min 2 3
1 4
Figure 380 A11VO adjustment screws for Hi-flo – 6 units 190/130
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M1 GAUGE PORT (BOTTOM OF EACH PUMP)
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Pressure Settings
Soft switch shutoff valve
Open
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Main Pressure Gauge port
Closed
Concrete pump shutoff valve
soft switch relief cartridge 9/16" jam nut
5/32" Allen head 00
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Figure 381 Soft switch components
Setting the soft switch relief pressure
Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure 322, right) that you closed in the previous procedure. The rest of the unit should still be set up as if you were going to check the main relief valve pressure (concrete pump shutoff valve still closed). When you put the pump in forward now, the main concrete pump pressure gauge should read the pressure shown on the schematic for soft switch. If adjustment is needed, loosen soft switch relief valve jam nut (Figure 322 right) with a 9/16 open end wrench, and use a 5/32 allen key to adjust the pressure. Turn the adjustment screw in (clockwise) to raise the pressure or out (counterclockwise) to lower the pressure. When you attain the required pressure, tighten the jam nut while holding the allen key to keep the pressure from rising. Be sure to open the concrete pump shutoff valve on the side of the brain (Figure 322, left) when you are finished. The unit will not stroke with this valve closed.
This unit is equipped with a load-sensing, proportional boom hydraulic system. In a black-and-white system, the hydraulic pump puts out an unchanging amount of oil, and speed control is done by restricting the oil to certain functions with orifices. In a load-sensing system, the pump puts out more or less oil to respond to the needs of the system. Generally, the pump puts out enough oil to maintain 20 bar higher pressure at the pump than the cylinders actually require. This 20 bar is called delta P (∆P). Additionally, we set the hydraulic pump so that it always puts out a small amount of oil, even if no oil is needed for the system. This oil is used to ensure that you have control when you need it. The setting to maintain this minimum amount of oil is called Q-min (pronounced “cue min”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting ∆P and Q-min.
Read all of the instructions before beginning any pressure settings. You will need an assistant for parts of the procedure. You and any assistants should wear eye protection when setting pressures.
NOTE!
Any time you set pressures for any circuit on any unit, the hydraulic oil should be at normal operating temperature (40°–60° C). Instructions on heating the hydraulic oil are found in the first step of this “checking hydraulic pressures” segment.
WARNING Entanglement hazard. Stop drive shafts before adjusting Delta P on A11VO pump.
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Setting boom circuit pressures
Note: The illustration in Figure 322 shows a gauge port in the center of the main control block. Your main concrete pump pressure gauge should be plumbed to that port.
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Pressure Settings gauge ports for Delta P
Figure 382 Gauge ports for setting Delta P delta/p.eps
Setting Delta P pressure NOTE!
1.
2.
3. 4.
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6.
Do not adjust Delta P or Q-min if your boom is running as you like it. The pressure setting procedure uses a standard starting point and must be fine tuned from that point. The pressure was fine tuned at the factory and should not be adjusted unless absolutely necessary. Start by turning off the engine and putting the key in your pocket; then place a “Do Not Operate” sign on the windshield of the truck. Install a 0-400 bar gauge in the high pressure test port at the bottom of the boom control block (Figure 279). Install a second 0-400 bar gauge (Figure 279) in the port marked “LS” (load-sensing). Delta P is adjusted on the pressure regulator (Figure 307) if your unit has an A11VO boom pump. When all personnel are clear of the truck, restart the engine, engage the pumps, and increase the engine speed to max RPM. Activate any boom cylinder to maximum speed and read both gauges as the boom section moves. The difference between the two pressures should be 20 bar + or - 5. If adjustment is required, loosen the jam nut, and adjust the screw inward to increase pressure or outward to decrease pressure until the boom runs smoothly.
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Figure 383 Pressure regulator for A11VO pumps 7. When the proper Delta P is achieved, use the following spaces to document the pressure.
NOTE! Remember that the documented Delta P pressure applies only to the unit with the serial number shown in the front of this book. Date__________________ ∆P__________bar Date__________________ ∆P__________bar Date__________________ ∆P__________bar Date__________________ ∆P__________bar Date__________________ ∆P__________bar
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Pressure Settings If pressure cannot be set correctly, there is a problem with the regulator itself. Contact the Schwing Service Department to determine how to continue. If the boom does not run smoothly at 20 bar, you must fine tune the adjustment. Remove the gauge, and turn the ∆P adjustment screw until the boom is responsive and smooth. After adjusting, the difference between the gauges (reinstalled) must read between 14-25 bar. The electronics in the control system can also affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 20 bar and check the electrical settings. When the electrical settings are verified, you could again try to refine the boom action with the ∆P adjustment.
NOTE! If you don’t have a 0-100 bar gauge, you can order one from Schwing Spare Parts Department at (800) 328-9635, part # 10004659.
Boom pressure relief cartridge
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Wear safety glasses any time you check or set pressures. Oil expulsion hazard!
Figure 384 0-600 bar gauge port
Setting Q-min Check Q-min when the engine is at maximum specified RPM. You must not adjust Q-min with the drive shafts turning! Each time the Q-min screw must be adjusted, the engine must be stopped, or at least the transmission must be taken out of gear so that the drivelines stop turning. 1. All boom functions must be in neutral, and all emergency stop buttons should be up (not engaged). Clear away all personnel, start the truck engine, engage the pumps, and bring engine RPM to max. Read the pressure at the 0–600 bar main boom gauge port (Figure 384) with a 0-100 bar gauge. Pressure should be at 40–45 bar. If no adjustment is needed, be sure the jam nut on the Q-min screw is tight, then continue to set the rest of the boom and outrigger pressures. If adjustment is needed, continue to the next step. 2. Turn the Q-min screw (Figure 385) in to raise the pressure. Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures; then, recheck ∆P to make sure that it hasn’t changed during the Q-min adjustment.
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Pressure Cut-off
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Q-min
Q-max (Bottom Of Pump)
Figure 385 Location of Q-min screw
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Pressure Settings
Setting boom pressures Now that ∆P and Q-min are set, you can remove the 0100 bar pressure gauge and proceed to check and adjust the main boom pressures. Setting main pressure
1. The main pressure is the highest pressure of the three boom system settings. The only way you will be able to see the main pressure on the gauge is to turn the pressure of the two lower systems up to a level which is higher than that of the main pressure relief valve. 2. Loosen the jam nut of the boom pressure relief cartridge (Figure 386) with a 30mm open end wrench, turn the adjustment cartridge in all the way with a 32mm wrench, and lock the jam nut back down.
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Figure 387 Hose for boom section number two
Plugs Straight Fitting Boom pressure relief cartridge
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0-600 bar gauge port
Figure 386 Boom pressure relief cartridge on the e-stop manifold 3. Loosen the jam nut on the pressure cut-off screw (Figure 391), tighten the screw all the way down, and tighten the jam nut back down. 4. Identify the main boom pressure relief cartridge on the control block (Figure 389), loosen the jam nut with a 12mm wrench, then unscrew the adjustment two full turns with a 4mm allen key. 5. Setting the main pressure will require disconnecting a hose for boom section number two (Figure 387) and installing an approved dead plug on each of the open fittings.
Figure 388 Approved dead plugs
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Cap Nuts
6. Install a 0 - 600 bar gauge in the main pressure gauge port (Figure 389). 7. Increase the engine speed to maximum RPM, and activate the manual control handle for boom number two in the direction that will pressurize the disconnected and plugged hose. 8. Now adjust the pressure to the setting found on the schematic by turning the main boom pressure relief cartridge on the boom control block (Figure 389) with a 4mm allen key. Read the pressure on the 0600 bar gauge installed in step 6. When desired pressure is achieved, lock down the jam nut with a 12mm wrench. Setting boom pressure (redundant) relief
9. Return to the e-stop manifold boom pressure relief cartridge (Figure 386), and back off the jam nut (30mm). Turn the cartridge (32mm) out, or counter clockwise, until the pressure gauge reads the number shown on the schematic for the boom pressure relief cartridge. Lock down the jam nut.
HOME
Pressure Settings Setting pressure cut-off
10. Return to the pressure cut-off screw (Figure 391). Back off the jam nut, and turn the screw counter clockwise until you achieve the pressure shown on the schematic, then lock the jam nut.
Delta-p
Pressure Cut-off
Setting slewing pressure
11. The slewing function has two relief valves which must be set individually. Since there is no way to block the slewing function, it is also necessary to disconnect the supply hoses which go to the slewing motor one at a time and install an approved dead plug to the open fitting. 12. Install a 0 - 600 bar gauge in line on the open hose.
Gauge port
000282.eps
Q-min
Q-max (Bottom Of Pump) Figure 391 Pressure cut-off screw
14. The final boom pressure setting is the #1 boom piston side relief setting. The relief cartridge is shown in Figure 328. This procedure should be performed with the outriggers extended and the boom unfolded over the cab. Extend section #1 all the way until the cylinder bottoms out. Install a 0600 bar gauge in the gauge port shown in Figure 389. Activate boom #1 extend. The pressure should read 230 bar. If adjustment is required, back off the jam nut with a 12mm wrench, and turn the relief cartridge (Figure 328) in or out using a 4mm allen key as required until the desired pressure is achieved; then, lock down the jam nut.
Main relief
mainrlf.eps
Figure 389 Main boom control block 13. Activate the slewing handle in a direction which will pressurize the disconnected hose and read the gauge. If the pressure is not what the schematic calls for, adjust the appropriate relief valve located directly under the valve (Figure 390).
dwnsdrlf.eps
Figure 392 Piston side relief
NOTE! Figure 390 Boom slewing relief valves
HWslew.eps
Boom Slewing relief valves
If you are unable to achieve 230 bar by adjusting the relief valve in Figure 328, call the Schwing Service Department and ask if the unit has a redundant relief valve.
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Setting outrigger pressure
Pressure Settings
Setting the agitator pressure
000359.eps
WARNING Tipping hazard. Never set outrigger pressures with the boom unfolded. Pressure setting procedure requires retraction of an outrigger jacking cylinder.
After the boom circuit is properly set, you can set the outrigger pressure. Find the relief cartridge located on the front of the passenger side outrigger control valve (Figure 312). 1. Attach 0-600 bar whip gauge to the gauge port below the outrigger valve bank. 2. Push the outrigger enable button. 3. Activate an outrigger jacking cylinder to retract. By retracting a fully retracted cylinder, the oil coming from the pump has nowhere to go but over the relief valve. You cannot use an extension or slewing cylinder because they have secondary relief functions (nonadjustable) built into the valve. While holding the handle to retract, read the pressure gauge. 4. The pressure should read the bar value shown on the hydraulic schematic. Adjust by loosening the jam nut and turning the cartridge (Figure 312) in or out. When the proper pressure is achieved, let go of the handle, and release the outrigger enable button.
Outrigger valve relief cartridge
The agitator circuit has a maximum pressure shown on the hydraulic schematic, which is limited by the relief cartridge (Figure 314) in the agitator hand valve. The relief cartridge is located on the back side of the agitator manual control handle (Figure 314). The cartridge is adjustable with just a 19mm open end wrench. 1. Plug the 0–600 bar whip gauge into the gauge port (Figure 314) for checking or setting agitator pressure. 2. Locate the agitator shutoff valve (Figure 331), and close it. If your unit does not have a shutoff valve, order one from the Schwing Spare Parts Department using part numbers 10004680 (valve) and 30303432 (tube). Contact the Service Department for installation instructions. If you can’t wait for a shutoff valve, you will need to remove one of the hoses from the agitator motor and plug the hose and open fitting with approved hydraulic dead plugs (Figure 332).
NOTE! Do not jam the paddles to force the oil over relief by stopping the movement of the agitator. 3. Increase the throttle to any speed above idle. Activate the agitator valve handle in either forward or reverse, and read the gauge. If it does not read the specified pressure, adjustment is required. Turn the entire relief valve cartridge (Figure 314) in to increase pressure or out to decrease pressure. 4. When the pressure is set, deactivate the agitator by placing the manual control handle in the neutral position. 5. Remove the whip gauge. 6. Reopen the shutoff valve or remove the dead plugs, and reconnect the capped hydraulic line. Agitator Relief Valve
otrigrlf.eps
Figure 393 Outrigger valve bank relief cartridge
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Figure 394 Agitator relief cartridge located on back side hand valve
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Pressure Settings Agitator quarter turn shutoff valve (open position)
000174.eps
000289.eps
Motor
Accumulator pump pressure regulator
Figure 395 Agitator shutoff valve
Plugs Straight Fitting Figure 396 Approved hydraulic dead plugs
Figure 397 Accumulator pump pressure regulator for A7VO (above) and for A11VO on a unit with a stiebel gearcase (below) Boom Pump
000257.eps
Accumulator Pump
Cap Nuts Setting accumulator circuit pressure To check or adjust the hydraulic pressure in the accumulator circuit: 1. Stop the truck, put the key in your pocket, and place a “Do Not Operate” sign on the windshield. 2. Loosen the jam nut on the pressure regulator of the accumulator hydraulic pump (Figure 232). Turn the screw in two-and-one-half turns. This will raise the regulator pressure above 300 bar.
Accumulator Pump Pressure Regulator Standby Pressure Screw
000446.eps hgacugc.psd
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Pressure Settings
000449.eps
Manual bleed valve
Boom pressure relief cartridge
ps
lf.e
ssr
pre
Pressure relief cartridge
0-600 bar gauge port
Figure 398 New e-stop has no redundant relief cartridge.
Figure 400 Accumulator manifold pressure relief cartridge
3. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring the engine RPM to maximum. 4. Read the pressure on the accumulator circuit pressure gauge (Figure 234). The pressure should read the value shown on the hydraulic schematic. If no adjustment is needed, skip to step number 7. If additional pressure adjustment is needed, continue with step number 5.
5. Locate the accumulator manifold pressure relief cartridge (Figure 235). Loosen the jam nut, and turn the screw clockwise to increase the pressure or counterclockwise to decrease the pressure. Tighten the jam nut when the pressure reaches the value required.
000292.eps
Figure 399 Accumulator circuit pressure gauge
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Pressure Settings
Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
000075.eps
WARNING
6. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 232), and turn the screw back out two-and-one-half turns. This restores it to its original setting. 7. Clear all personnel from the drive line area, start the truck, and bring the engine RPM up to maximum. 8. Read the pressure on the accumulator gauge. It should read the proper accumulator system pressure. 9. If adjustment is needed, you must stop the truck engine, or a least stop the drive lines from turning, each and every time you approach the accumulator circuit hydraulic pump. Turn the screw in to increase the pressure or out to decrease pressure. Lock the jam nut when the pressure is correct. Note: The accumulator circuit hydraulic pump pressure regulator is referred to as the pressure cut-off.
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Electrical
Electrical Information Boom Control Systems and the Advantages of Each Manual Controls Manual Black and White (On-Off) System: • Totally, completely reliable. • Electrical malfunctions are impossible.
Cable Remote Controls Remote Controlled Black and White System: • Operator can go to the location with the best possible view of the boom and job. • Allows mobility to move around the unit. Analog Proportional Remote Control System: • Infinitely variable speed control. • No need to use the “feathering” technique of speed control. • Start and stop the boom with smooth acceleration and deceleration. • Hydraulic stroke limiter can be adjusted from the remote box. Digital Proportional Remote Control System: • Less susceptible to external noise interference (from radio transmitters, for example). • Cable requires only 6 wires, instead of 25. One for power, one for ground, two for the emergency stop circuit, and two for data transfer. • More precise adjustment of boom speed than previous systems. • Troubleshooting a non-working system can be done in minutes via a hand held test device. • Increased safety because of numeric operating principles. (Cannot go out of adjustment). • A digital system can be updated or expanded by E-prom replacement or reprogramming. (Analog systems are not possible to improve without hardware replacement). • The proportional valve amplifiers are self diagnosing via L.E.D.’s. • The boom can go slower before shut-off than with an analog system. • Digital system has built in ramp functions, which makes it impossible to accidentally go to full speed by bumping a joystick. Comfort Proportional Remote Control System • Has the Schwing information system 1. Pumped volume determination by means of stroke counter and pumped volume calculation. 2. Extensive operational data acquisition and display. 3. Safely stored malfunction list of last 100 malfuction messages. 4. Manual operation of lubricating cycles. 5. Status display of all signals of the electronic control. 6. Password-protected parameter setting for the central lubricating system 7. Password-protected parameter setting for the proportional boom fuctions. • Has the Schwing diagnostic system. 1. The diagnosis system monitors the control unit, the machine and partly also the vehicle for malfunctions or inadmissible states of operation. 2. The system recognizes e.g. parting of cables or short-circuits in electric lines of solenoids, Fault sensors, contaminated oil filters or critical hydraulic oil or diesel engine temperatures and displays different operating conditions. 3. The system is to assist the concrete pump operator in his work on site and to inform him about the possible causes of malfunctions when they occur.
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The malfunction messages are displayed as continuous text in the form of an easily understandable plain language message with additional fault code.
Radio Remote Controls Digital Black and White Radio Remote Control System FW 16: • Operator doesn’t have to drag around a cable when moving. • The operator is not connected to the unit if a power line is contacted. (This does not protect others around the unit if contact is made). Digital Radio Remote Control System FW18: • Quicker response time than FW 16. • Greater safety than FW16, because of binary code transmissions. • Higher power output gives greater range than FW16. Digital Radio Remote Control System FW 20/24: • Radio receiver is built into the digital proportional system (no separate receiver) • Radio receiver has 2 separate frequency drivers, selectable by the operator with a switch. If interference is shutting down the system, just switch to the other frequency. • The receiver has many indicating lamps that tell the status of the radio systems. • Higher power output gives greater range and fewer interference shut-downs than FW 18. • Advanced filtration circuits cut down on interference shut-downs versus FW 18. • The antenna is internal to the remote box. Nothing external to get broken. Spread Spectrum Radio Remote System • The Schwing Spread Radio system employ frequency hopping spread spectrum technology to provide the optimum performance allowable under present FCC and ISC regulations. This technology provides a unigue performance advantage compared to conventional fixed frequency systems. The major benefits are listed below: 1. Interference Free: It cannot be jammed by other RF transmitters or extraneous noise source. 2. Coordination Free: All Schwing-spread spectrum transmitters are factory coded. The user does not need to worry about which frequency the unit is operating on. It operates as if there ia s unique frequency for each unit in existence. Any number of these units can be operated in the same location at the same time. 3. License Free: These radios are certified by the U.S. and Canadian governments to meet their criteria for license-free operation. With Spread Spectrum Technology, these radios are allowed to transmit as much power and sometimes more than conventional licensed products. This makes for very high performance reliable RF links through many types of material and over very great distances should the application require it. 4. Security: Combine the Spread Spectrum robustness with the added 16-bit address space and CRC16 error-detection code built into the data protocol, and these units provide extremely reliable, error-free control.
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Electrical
Boom Control Systems
A
MANUAL - BLACK AND WHITE
vo lts
TO BOOM
12
B
REMOTE CONTROL BLACK AND WHITE
Switches
+
s +12 volt
Relay Box
TO BOOM
to
1000 mA 20 0
C
Proportional Amplifiers
0 01
0 101 1
D
DIGITAL PROPORTIONAL Radio
A/D Converters
TO BOOM
0 1 1 0100 1 1 0 1 1 0 0 1 0
lt s
0 10
6 to 9 vo
011 0
Potentiometers
0 1 0 10 0 1 0
ANALOG PROPORTIONAL
D
DIGITAL PROPORTIONAL Cable
20 0
to
1000 mA
A/D Converters
D/A Converter 01010010 & Proportional Amplifiers
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Electrical
Introduction to Proportional Controls The difference between the proportional and the black and white control is the function performed from the signal. With the black and white control, the signal will be either on or off only. With the proportional control, the function will vary according to the movement given to the potentiometer by the Joystick. The proportional system can be broken down into 3 major components. They are as follows:
A. The Joystick with the Potentiometer. B. The Proportional amplifier C. The Solenoid valves. The Joystick with Potentiometer There is a 15 volt supply at connection 1 of the potentiometer (See Figure). If you tilt the Joystick up and down, the voltage going into the amplifier will be changed (input signal - connection 2 of the potentiometer). Simultaneously, when the N.O. micro-switch is closed the relay on the power supply card is switched and the circuit is activated.
BOOM FUNCTION UP
7.5 VOLTS
DOWN
+ 1.5 VOLTS -
MICROSWITCH OPEN
CLOSED I
DOWN TO 6 VOLTS (BOOM DOWN)
CLOSED
I MIN
I MIN
UP TO 9 VOLTS (BOOM UP)
I MAX
MAX
1
3
2 7.5 VOLTS
7.5 VOLTS
V
V
V 15 VOLTS 1
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Electrical
The Proportional Amplifier The proportional amplifier receives a voltage signal from the potentiometer and amplifies the input voltage signal to the desired output current (See Figure). 24 VOLTS
MICROSWITCH
7.5 VOLTS
15 VOLTS
0 VOLTS
PROPORTIONAL AMPLIFIER CARD
SIGNAL BOOM UP
COMMON GROUND
SIGNAL BOOM DOWN
RELAY
GROUND
PILOT VALVES BOOM UP
BOOM DOWN
The Solenoid Valves Schematic of a proportional valve with a current to pressure ratio diagram. PRESSURE RANGE UP TO 30 BAR
30 28 26 24
PRESSURE AT PORT "A" IN BAR
22 20 18
A
16
T
14 12 10 8
P
6 4 2 0 0
0.1
0.2
0.3
0.4 0.5 0.6 CURRENT IN AMPS
0.7
0.8
0.9
1.0
More current = More pressure at port “A.” More pressure at port “A” = Increase the hydraulic flow at the slave valve. Increased hydraulic flow = Boom acceleration
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The Proportional Amplifier in Use with the Radio The signal from the radio remote control to the proportional amplifier is 12 V±6 V, instead of 7.5 V± with the cable remote control. For instance:
1.5 V as
• Boom up 12 V → 6V
• Boom down 12 V → 18 V In order to make the proportional controls work with these input voltages, we need to switch relays on the proportional amplifier cards. This is accomplished with a bridge wired into the connecting cable for the radio remote, from the receiver to the operator’s control panel. The bridge is wired in the plug that connects to the control panel. It is because of this bridge that two different cables are required.
TRANSMITTER MICROSWITCH
RADIO SIGNAL
CONNECTING CABLE RELAY
RECEIVER BRIDGE FOR RADIO REMOTE
12
PROPORTIONAL CARD
PILOT VALVES
BOOM UP
526
BOOM DOWN
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22
24
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Electrical
Motherboard for Proportional Units POWER SUPPLY CARD (PART# BEFORE 1992 10074135 AFTER 1992 10023316)
PROPORTIONAL AMPLIFIER CARD (PART# BEFORE 1992 10074136 AFTER 1992 10023317)
PROPORTIONAL AMPLIFIER CARD (PART# BEFORE 1992 10074136 AFTER 1992 10023317)
PROPORTIONAL AMPLIFIER CARD (PART# BEFORE 1992 10074136 AFTER 1992 10023317)
ADAPTER CARD FOR TEST METER (PART# BEFORE 1992 10074136 AFTER 1992 10023317)
EMPTY SLOT
9
1
2
3
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5
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Electrical
Power Supply - Slot 9
CARD 9
LED
Voltage
1
7.5 V
Must be on at all times.
2
15 V
Must be on at all times.
3
18 V
Must be on at all times.
4
24 V
Emergency Stop. Must be on when the Emergency Stop has been activated.
LED 1 LED 2
5
LED 3 LED 4
LED 5
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Function
Fuse for voltage regulation. It should be off. When it is on, check the fuse.
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Electrical
Proportional Amplifier - Slot 1,2,3
CARD 1, 2, 3
MIN MAX LED
LED 1
Channel 1
Function
1
Illuminates when the corresponding function has been activated.
2
Illuminates when the corresponding function has been activated.
MIN MAX
3
Illuminates when the corresponding function has been activated.
LED 3
4
Illuminates when the corresponding function has been activated.
5
Should be off. If it illuminates when a channel 1 function has been activated, check fuse.
6
Should be off. If it illuminates when a channel 1 function has been activated, check fuse.
MIN MAX LED 2
MIN MAX LED 4 LED 5
Channel 2
LED 6
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Electrical
Calibration of Proportional Amplifier Cards Note: The average Proportional solenoid valve operates between 300 and 800 mA. 1. Push the emergency stop button (Only if not using the Schwing proportional card test meter). 2. Connect Amp meter in the circuit of the proportional function that is to be calibrated. The most convenient way to measure the current is using the Schwing proportional card test meter (ID 77706). 3. Release the Emergency Stop button. 4. Tilt the Joystick to the point that the micro-switch is in the closed position (trigger point is at I min). The circuit is now in a closed position, the LED on the proportional amplifier card is illuminated, and the current can be read on the test meter. 5. Adjust the minimum current (at the min potentiometer) to the point where the boom section just starts to move (approximately 300 - 450 mA). 6. Tilt the Joystick all the way (I max.). Adjust your maximum current (at the max potentiometer) on the proportional amplifier card (approximately 700 - 800 mA).
After adjusting the maximum current, repeat steps 4 though 6 until the correct result has been achieved. The reason for this is because as the min or max is adjusted, the other is effected. CARD 1, 2, 3 BOOM FUNCTION UP
DOWN MICROSWITCH OPEN
CLOSED
CLOSED
I MIN I
I MIN I MAX
MAX
MIN MAX LED 1 MIN MAX
Channel 1
LED 2 MIN MAX LED 3 MIN MAX LED 4 LED 5 LED 6 1
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Electrical
Linear Signal Diagram
MAXIMUM CURRENT OUTPUT (mA)
1000 900 MAX
800 700 600 500
MIN 400 300 200 100 0 0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
MIN MAX PRETENSION PRESSURE (Bar) The optimum adjustment makes full use of the joystick’s range of travel. Other adjustments result in poor response and on/off switching of valves, which in turn causes jerky motion of the bomm and possible structure damage.
MAX
MIN 5¡ 0¡
0¡
MIN
36¡
36¡
1
2
MAX 36¡
3
36¡
1
IMPROPERLY ADJUSTED
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3
PROPERLY ADJUSTED
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Electrical
Decal of Proportional Motherboard POSITIONING OF THE CIRCUIT BOARDS IN THE BASE PALTE
6
8
PN 327524
10 12 14 16 18 20 22
9 SLOT 1
2
3
4
5
SERVICE CARD SLOT
4
EMPTY SLOT
2
MIN MAX Slew RIGHT
Boom 2 DOWN
Boom 4 DOWN
Slew LEFT
Boom 2 UP
Boom 4 UP
Main DOWN
Boom 3 DOWN
Output volume CABLE
Main UP
Boom 3 UP
FUSE 1
FUSE 1
Output volume RADIO FUSE 1
FUSE 2
FUSE 2
FUSE 2
7.5v 15v 18v 24v ES FU
+ + - -
532
20 18 16 14 12 10
8
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Electrical
Wiring Diagram - DUVAC II 12V / 24V Transformer
Truck batteries GND
IGN. 12v
24v 30A
30A
+ 12V -
+ 12V -
+ 12V -
+ 12V -
Ignition switch (on) PTO switch
(on)
12V ACTUATED
12V ACTUATED
24v solenoid
12v solenoid 24v output to Schwing unit
12v output to Schwing unit
DUVAC II . . . . . . . . . . . . . . Part #319438 SOLENOID . . . . . . . . . . . . .Part #302563 (continuous duty) PTO SWITCH . . . . . . . . . . .Part #302178 (cam type)
Service Manual
01/26/95 GRP
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Wiring Diagram - DUVAC II 12V / 24V Transformer Truck batteries GND
IGN. 12v
24v 30A
30A
A
C
+ 12V -
+ 12V -
+ 12V -
+ 12V -
B
D
Ignition switch (on) PTO switch
(on)
12V ACTUATED
12V ACTUATED
12v solenoid
24v solenoid 24v output to Schwing unit
12v output to Schwing unit
01/26/95 GRP
1. Determine which battery doesn’t have any accessary power leads. This will be the battery used to create the 24V power. 2. Disconnect the truck cables from that battery (BE CERTAIN THERE ISN’T ANY OTHER WIRES CONNECTED TO THE 24V BATTERY OR SEVERE DAMAGE COULD RESULT TO OTHER CIRCUITS ON THE UNIT). 3. Connect jumper from Battery "A" (+ positive) to Battery "B" (- negative) and then connect Battery "B" (+ positive) to the 24V wire disconnected from the Duvac’s 24V post. 4. It may be required to swap Battery "B" with Battery "D" if operated in this mode for an extended period of time because the battery used to create 24V isn’t being charged.
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Electrical
Digital Proportional - Overview (1 of 5) Overview The term DigiProp is used to describe Schwing Americas digital proportional control system. Proportional refers to the fact that the boom adjusts it's speed in response to the movement of the joysticks. The farther the joystick is moved, the faster the boom moves. Digital means that the movement of the joystick is translated (by an analog to digital converter) to numbers (zeros and ones). Once translated to numbers the signal moves into a processor not unlike a computer. The processor responds to the joystick movements and compares them to a set of values that are preprogrammed into memory. It then translates the numbers into a signal that is fed to the coils of the hydraulic valves. See Figure 1.
15 volts
6 to 9 v olts
Proportional Amplifiers TO BOOM
DIGITAL PROPORTIONAL A/D Converters
010 01010
1000 mA 20 0t o
Potentiometers
1000 mA 20 0t o
ANALOG PROPORTIONAL
Digital control system
1 10 1 0 110
TO BOOM
Figure 1
ana/digi compare.eps
Digital systems have definite advantages over the analog proportional system found on older machines. Because everything is translated into numbers, there can be no mis-adjustments. Instead of adjusting a trim pot to fine tune the response, you simply enter in the parameters that you want, and the processor takes care of the rest. In addition, the zeros and ones (referred to as “bits”) travel to the processor in groups (referred to as “bytes”). Each bit in the byte tells the processor something about the condition of the machine. If you could translate one of the bytes into plain English, it would look something like this: “I am a Schwing with an ID number of 7. Emergency stop is not activated. Concrete pump is activated in forward. Boom #3 retract joystick is activated to 48% travel. Boom #2 extend joystick is activated to 85% travel.”
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The processor updates these signals many times per second. The byte always starts with the identification of the system (“I am a Schwing”) so that electrical “noise” from the surrounding area cannot activate a function. Some types of noise that could send a false signal are cellular phones, garage door openers, police radar, etc. Because of the identification process, however, these false signals are ignored. See Figure 2. Digital Code
10101110011000010100100011000100101010010100010
11010001
Identifier
SCHWING NG UF UE1 UCC1 UE2 UCC2 NOT1 K1
A/D Converters
NF K1 K2
F W 20 MC2 TEL
T2
K28
V24
MC1 ST 1 ST 2 REL PROP TEL TST 3 TST 2 TST 1
T1
RADIO CONTROL FW20 FCC ID. DA87G6 FW20RL SCHWING AMERICA INC. GERMANY SERIAL NR 003 143 FREQ. 456.962S (mHZ) 457.762S
Figure 2
M.A.T. The M.A.T. is a hand held programmer that can be plugged into the digital controller. It consists of an 8 digit alphanumeric display and a 4 button keypad. Its used to access information and program the system. This is important because you can’t troubleshoot a digital system with a test light. However, the advantage of a digital system is that in most cases the processor already knows what is wrong by the time you notice a problem. See Figure 3. *scv
P C M.A.T.
Figure 3
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Electrical
Processor Unit The digital control system is housed in the device called the Processor unit. The processor unit replaces the relay enclosure found on analog systems. This processor unit contains various types of electronic function cards and the optional radio receiver. The SCV9 card is the master card in the system. Its function is to coordinate the entire system by decoding instructions from the operator control panels, then sending commands to the appropriate slave cards. The SCV9 card holds all the programmed settings. It has been programmed at the factory for your specific machine. Replacement cards contain generic settings. In an emergency, they can be used as is, but they should be programmed to match the hydraulic system on your machine. The HC2 and DG8 cards are known as slave cards because they receive commands from the master card, SCV9. See Figure 4
+ .A12 REC 2
+ A11 SCV
+ .A10 HC2L-1
+ .A9 + .A8 HC2L-1 HC2L-1
+ .A7 HC2L-1
+ .A6 HC2L-1
+ .A5 HC2L-1
+ .A4 DG8-1
+ .A3 DG8-1
M.A.T. CONNECTOR
SCV 9
HC 2
(master card)
(slave card
DG 8 (slave card
Figure 4
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The HC2 cards provide proportional control of the placing boom and concrete pump output. The HC2 cards send a 50 milliamp diagnostic signal, generated by the SCV9 card, which continuously tests the various proportional electrical circuits. The DG8 cards provide on/off control of the concrete pump, horns, motors and other accessories. Each of the slave cards control specific functions which are determined by their location in the digital processor unit. The card positions (numbered horizontally) are also used when troubleshooting with the M.A.T. to indicate the location of communication errors. The vertical numbers on the right of the drawing indicate the output channels for the slave card functions. See Figure 5.
1 + .A12 REC 2
+ A11 SCV
+ .A10 HC2L-1
2
3
+ .A9 + .A8 HC2L-1 HC2L-1
4 + .A7 HC2L-1
5
6
+ .A6 HC2L-1
+ .A5 HC2L-1
7 + .A4 DG8-1
8 + .A3 DG8-1
1 2 3 M.A.T. CONNECTOR
DIGITAL INPUTS
+
MIN
RES.
MOTOR
Figure 5
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Control System Arrangement The arrangement of the control systems is shown in Figure 6 below. You can see that the control system is made up of individual function blocks. Each block is an electronic card. Data is transferred between the cards via the RS485 bus shown in the diagram. The entire coordination of the system is performed by the SCV card which is the “MASTER” of the control system. The HC2 and DG8 cards are “SLAVE” cards that receive commands from the MASTER and pass them on to the machine. All parameters, i.e. machine-specific settings and functions are stored in and managed by the MASTER, which is the SCV card, therefore, it is possible to exchange any SLAVE card for another SLAVE card of the same type without altering any functions or settings in the control system. All parameters can only be adjusted or changed in the SCV card. All external control instructions are sent by either the BDI-F (cable remote control), the BDI-A (rear panel control), or radio remote interface in the SCV card to the SCV MASTER via the bus system. The SCV master card accepts these control instructions, and based on the parameters stored, sends them via the RS 485 bus to the appropriate slave card (HC2 or DG8). The slave cards then send an acknowledgment back to the SCV card as to whether or not they can properly follow the control instruction . Digital Control Unit Proportional Control
On/Off Control
Boom 1
Boom 2
Boom 3
Boom 4
Slewing
Stroke Limiter
Throttle Etc.
HC2 1
HC2 2
HC2 3
HC2 4
HC2 5
HC2 6
DG8 7
Con pump Machines with For/Rev Etc. Agitators only
DG8 8
DG8 12
RS 485 BUS SCV 9
Relay Board
M.A.T.
Push Buttons
BDI_A
RS232/V24
BDI_F
FW 20/RC Radio Reciever
FW 20/R Transmitter
SBP BUS____Motherboard (p/n 126390) REC____Relay card (p/n 126442) FW20RC____Radio control receiver HC2____Prop. output, 2 function (p/n 125849) (36X, 42 p/n 130877) FW20TR____Radio control transmitter DG8 ____Digital output, 8 function (p/n 125848) (52 p/n 147676) MAT____Manual adjustment terminal (p/n132426) SCV____Interface converter and central processing Cable remote control box complete (p/n 13539) unit (p/n 125851) Cable remote control cable (p/n 124956) BDI_S____(can be programmed for either BDI_A or BDI_F) BDI_A____Rear operators panel interface card (p/n 125846) BDI_F____Cable remote control interface card (p/n 125847)
Figure 6
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Digital Proportional - Programming Programming To get the most from the programming and self-diagnostic capabilities of the system, you must be able to use the hand-held M.A.T. and menu survey to navigate to specific locations. See Figure 7. Think of the menu survey as a road map that allows you to navigate through the system software and the M.A.T. as the vehicle that takes you from place to place.
CUSTOMER MENU
*scv Controller
Main Menu
Submenus
Software Version 2.4X
Display
Translation
1H1 200 1H2 300 1H3 900 1S1 200 1S2 300 1S3 900 2H1 200 2H2 300 2H3 900 2S1 200 2S2 300 2S3 900 3H1 200 3H2 300 3H3 900 3S1 200 3S2 300 3S3 900 4H1 200 4H2 300 4H3 900 4S1 200 4S2 300 4S3 900
Min. stop current (mA.)
ML1 200 ML2 300 ML3 900 MR1 200 MR2 300 MR3 900 FM1 200 FM2 300 FM3 900
Min. stop current (mA.)
To cable remote & back panel
P
*SCV 9
?AUSL 1H
?AUSL
?PAR
?AUSL 1S To slave cards
C
?AUSL 2H
M.A.T.
?AUSL 2S
?AUSL 3H
?AUSL 3S
?AUSL 4H
?AUSL 4S
?MAST L
?MAST R
?F.MENGE
Figure 7
Min. start current (mA.)
Boom up Section 1
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom down Section 1
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom up Section 2
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom down Section 2
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom up Section 3
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom down Section 3
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom up Section 4
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom down Section 4
Max. current (mA.)
Min. start current (mA.) Max. current (mA.)
Slew left
Min. stop current (mA.) Min. start current (mA.)
Slew right
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Stroke limiter
Max. current (mA.)
(PG-1)
MAT Operation The MAT (Manual Adjustment Terminal) is the setting and diagnostic unit for the digital proportional control system.When plugged into the 9 pin front panel connector it goes through an initializing phase, then “*SCV 9” or ”? SCV 9” appears in the 8-digit, alphanumeric display. There are 4 keys on the M.A.T. which allow you to scroll through the menu structure in order to set system parameters to there required values, observe the non-adjustable entries, or perform well aimed signal tracing while troubleshooting.
The symbols on the keys stand for the following:
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P
= Program
= Up
C
= Clear
= Down
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Menu Structure Looking at the menu structure you can see it is laid out in columns. This was done to make it easier to follow the multitude of existing parameters and entries, that are combined into the submenus and main menus. See Figure 8. The menu system consists of: • • • • •
Controller Selection Main Menu Submenus Parameters Entries
The controller selection is marked by an asterisk (*) in the first digit of the M.A.T. display when using software version 2.4. In software versions 2.2 and 2.3, a question mark will display in the first digit. Menus have a question mark (?) displayed in the first digit. Entries are information from the system that cannot be externally changed (similar to measured values obtained by the connection of instruments). Parameters are adjustable values which must be set to the conditions found on the machine (e.g., valve currents).
MENU STRUCTURE Controller
Main Menu
Submenus
Software Version 2.4X
Display
Translation
1H1 200 1H2 300 1H3 900 1S1 200 1S2 300 1S3 900 2H1 200 2H2 300 2H3 900 2S1 200 2S2 300 2S3 900 3H1 200 3H2 300 3H3 900 3S1 200 3S2 300 3S3 900 4H1 200 4H2 300 4H3 900 4S1 200 4S2 300 4S3 900
Min. stop current (mA.)
ML1 200 ML2 300 ML3 900 MR1 200 MR2 300 MR3 900 FM1 200 FM2 300 FM3 900
Min. stop current (mA.)
To cable remote & back panel
*SCV 9
?PAR
?AUSL
?AUSL 1H
?AUSL 1S To slave cards ?AUSL 2H
?AUSL 2S
?AUSL 3H
?AUSL 3S
?AUSL 4H
?AUSL 4S
?MAST L
?MAST R
?F.MENGE
Service Manual
Min. start current (mA.)
Boom up Section 1
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom down Section 1
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom up Section 2
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom down Section 2
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom up Section 3
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom down Section 3
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom up Section 4
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom down Section 4
Max. current (mA.)
Min. start current (mA.) Max. current (mA.)
Slew left
Min. stop current (mA.) Min. start current (mA.)
Slew right
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Stroke limiter
Max. current (mA.)
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Using the M.A.T. to navigate through the menu survey is simply a matter of pressing the buttons on the key pad and noting your location with the alphanumeric display. See Figures 9, 10, & 11.
To scroll to the right, press the “P” or program key. ?PAR
?AUSL
?AUSL 1H
?AUSL 1S Figure 9
1H1 200 1H2 300 1H3 900 1S1 200 1S2 300 1S3 900
To scroll to the left, press the “C” or clear key once. To return to the SCV 9 starting point, press “C” twice. ?PAR
?AUSL
?AUSL 1H
?AUSL 1S Figure 10
1H1 200 1H2 300 1H3 900 1S1 200 1S2 300 1S3 900
Use the arrow keys to scroll up and down. ?PAR
?AUSL
?AUSL 1H
?AUSL 1S
?AUSL 2H Figure 11
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1H1 200 1H2 300 1H3 900 1S1 200 1S2 300 1S3 900 2H1 200 2H2 300
M M M M M M
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Access The Service Menu Versions 2.4 and later have two levels of menu access. Connecting the M.A.T. automatically brings you to the customer menu. The second menu level called the service menu, is hidden. See Figure 12. To access the service menu: • • •
Press the letter “P” to enter main menu Scroll down the main menu to “system” Then, press “P” again
The M.A.T. display now reads SCV S. Press the “P” key once, the “C” key once, and the “up arrow” key once. The display will now read NR500. Press the “P” key again; a dotted line will appear in the display. Use the “up arrow” key to change the value in the display to 530. Press “P” again, a dashed line will replace the dotted line meaning the setting has been saved. You now have access to the service menu items.
?RAMPE
?RAMP UP
?RAMP DN
Customer Menu (White) ?INS
?V24
?TELEGR.
Service Menu (Gray)
?SELECT
T1LU T1RU T2LU T2RU T3LU T3RU
1.0 1.0 1.0 1.0 1.0 1.0
T1LD T1RD T2LD T2RD T3LD T3RD
0.5 0.5 0.5 0.5 0.5 0.5
RP1 RP2 RP3
25 50 75
OK CE FE PE OE VE
0 0 0 0 0 0
W0 W1 W2 W3 W4 W5 CRC
0000 0000 0000 0000 0000 0000 00
A1Hs A1Ss A2Hs A2Ss A3Hs A3Ss A4Hs A4Ss MLs MRs FMs
ON ON ON ON ON ON ON ON ON ON ON
CERR NA_F OFF NA_C OFF (PG-2)
STOER 0 PERR
Figure 12
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Each entry or parameter is shown in the 8-digit display of the MAT. The left side shows an alphanumerical abbreviation with a maximum of four digits which serves to explain the value shown on the right. Within this abbreviation, lower case letters are used to describe the origin or the type of representation of the value. The individual letters stand for the following: a f r s p
Signal from the rear panel Signal from remote control (radio or cable) Signal from the rack Function selection (this parameter serves to activate or deactivate certain functions) Display value in percent
“SCV” Card Main Menus Note: Some of the definitions listed are common to both menu structures, while others are specific to the 2.4 menu. After selecting the “*SCV 9” controller, you can scroll the individual main menu items with the “⇑” and “⇓” keys. The following main menus can be found in the “*SCV
9” controller:
“?PAR”
= “Parameter Setting” main menu display or selection.
“?INS”
= “Installation or Start-Up Auxiliary Functions” submenu display or selection.
“?DIN”
= “Digital Input Data” submenu display or selection.
“?SOUT1” = “First Menu Digital Switching Outputs” submenu display or selection. “?SOUT2” = “Second Menu Digital Switching Outputs” submenu display or selection. “?POUT1” = “First Menu Proportional Valve Outputs” submenu display or selection. “?POUT2” = “Second Menu Proportional Valve Outputs” submenu display or selection. “?DIAG”
= “Diagnostic Information” submenu display or selection.
“?SYSTEM”= “System Control” submenu display or selection. “?GERAET”= “Unit Control” submenu display or selection.
“?PAR” Main Menu After selecting the “?PAR” main menu, you can scroll the individual submenus with the “⇑” and “⇓” keys. The following submenus can be found in the “?PAR” main menu: “?AUSL”= “Boom Settings” submenu display or selection including: “?AUSL_H”=
“Boom 1 Up Current Value Settings” submenu display or selection.
“?AUSL_S”=
“Boom 1 Down Current Value Settings” submenu display or selection “Boom 2 Up Current Value Settings” submenu display or selection.
“?AUSL_H”=
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“?AUSL_S”= “Boom 2 Down Current Value Settings” submenu display or selection. “?AUSL_H”= “Boom 3 Up Current Value Settings” submenu display or selection. “?AUSL_S”= “Boom 3 Down Current Value Settings” submenu display or selection. “?AUSL_H”= “Boom 4 Up Current Value Settings” submenu display or selection. “?MAST_L”
=
“Slewing Left Current Value Settings” submenu display or selection.
“?MAST_R”
=
“Slewing Right Current Value Settings” submenu display or selection.
“?F.MENGE”
=
“Stroke Limiter Current Value Settings” submenu display or selection.
“?RAMPE”
=
“Ramp Value and Time Settings” submenu display or selection (for “R_A2”)
Submenus Functions and Parameters “?AUSL_XY”
=
Settings the XY boom current values, where: X = 1 - 4; Y = H or S The individual parameters are:
“XY1 200” =Here, the jump-out or minimum stop current can be set within the range from 50 to 1100 mA. Default 200 mA. “XY2 300”=Here, the jump-in or minimum start current can be set within the range from 50 to 1100mA. Default 300 mA. “XY3 900” = Here, the maximum current can be set within the range from 50 to 1100 mA. Default 900 mA. “?MAST_X ” = Setting the current values for boom slewing X, where: X = L (left) or R (eight). The individual parameters are: “MX1 200” = Here, the jump-out or minimum stop current can be set within the range from 50 to 1100 mA. Default 200 mA. “MX2 300” = Here, the jump-in or minimum start current can be set within the range from 50 to 1100 mA. Default 300 mA. “MX3 900” = Here, the jump-in or minimum start current can be set within the range from 50 to 1100 mA. Default 900 mA. “F.MENGE” = Setting the stroke limiter current values The individual parameters are: “FM1 200” = Here, the jump-out or minimum stop current can be set within the range from 50 to 1100 mA. Default 200 mA. “FM2 300” = Here, the jump-out or minimum stop current can be set within the range from 50 to 1100 mA.
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SERVICE TRAINING Default 300 mA. 900” = Here, the jump-out or minimum stop current can be set within the range from 50 to 1100 mA. Default 900 mA.
“RAMPE”
= Setting ramp control data (For “R_A2” or “R_MD” types only.) including: “?RAMP_UP”= Submenu with the ramp-uptimes (when push-button is belong pressed, or when changing over from low ramp value to higher one while push-button is being held depressed). The individual parameters are: “TXYU 1.0” = Here, the ramp-up time for speed step X, triggered by control switch Y, can be set within the range from 0.1 to 5.0 sec/100%. Default 1.0. Where: X = 1 - 3; Y = L (left)(/ R (ight). “?RAMP_DN”= Submenu with the ramp-down times (when push-button is being released, or when changing over from high ramp value to lower one while push-button is being held depressed). The individual parameters are: “TXYD 1.0”= Here, the ramp- time for speed step X, triggered by control switch Y, can be set within the range from 0.1 to 5.0 sec/100%. Default 1.0. Where: X = 1 - 3; Y = L (eft)( / R (ight).
“RP1
25”
= Here, the speed step 1 ramp value can be set within the range from 0 to 99%. Default: 25.
“RP2
50”
= Here, the speed step 2 ramp value can be set within the range from 0 to 99%. Default: 50.
“RP2
75”
= Here, the speed step 3 ramp value can be set within the range from 0 to 99%. Default: 75.
“?SELECT ” Submenu Functions and Parameters (In Service Menu Only!) “?SELECT” = Submenu for locking or unlocking prop channels (In service menu only!). The individual parameters are: “AXYsON” = Parameter, by means of which the prop output for boom XY (X = 1 - 4; Y = U/D) can be activated or deactivated.
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“MX
ON”= Parameter, by means of which the prop output for boom slewing X (X = L/R) can be activated or deactivated.
“FM
ON”= Parameter, by means of which the prop output for the stroke limiter can be activated or deactivated.
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“?V24” Submenu Functions and Parameters “?V24” = “OK “CE
“FE
“PE
“OE
“VE
V 24 (radio remote) interface state display submenu. The individual displays are: 00” = Indicating the number of correctly received data blocks. For proper operation, this number must continuously grow. 00” = Indicating the number of errors determined when the checksum was checked (Checksum Error). For proper operation, this number must not grow or may only grow slowly. 00” = Indicating the number of errors determined when the length of a data block was checked (Framing Error). For proper operation, this number must not grow or may only grow slowly. 00” = Indicating the number of errors determined when the parity was checked (Parity Error). For proper operation, this number must not grow or may only grow slowly. 00” = Indicating the number of errors caused by telegram buffer overflow (Overflow Error). For proper operation, this number must not grow or may only grow slowly. 00” = Indicating the number of errors caused by software telegram buffer overflow buffer Overflow Error). For proper operation, this number must not grow or may only grow slowly.
“?TELEGR.”=“RS 232 Interface Original Telegram” submenus display or selection (In service menu only!) “W0 0000”= Original data word 0 in hexadecimal representation. Start and mode ID. “W1
0000”=
Original data word 1 in hexadecimal representation. Pulse channels 16 - 1.
“W2
0000”=
Original data word 2 in hexadecimal representation. Pulse channels 32 - 17.
“W3
0000”=
Original data word 3 in hexadecimal representation. Prop channels 1 + 2.
“W4
0000”=
Original data word 4 in hexadecimal representation. Prop channels 3 + 4.
“W5
0000”=
Original data word 5 in hexadecimal representation. Prop channels 5 + 6.
“CRC 00”=
Original data byte 13 in hexadecimal representation. Checksum.
“?DIN” Main Menu After selecting the “?DIN” main menu, you can scroll the individual entries with the “⇑” and “⇓” keys. In the “?DIN” main menu, all the input signals recognized by the system are represented. They are divided into submenus assigned to the individual signal sources.
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Electrical The following submenus can be found: “?BDI_A”=
“Input Date from BDI_A (Rear Panel) Display” submenu display or selection.
“?BDI_F”=
“Input Date from BDI_F (Cable or Radio Remote Control) Display” submenu display or selection.
“?RACK”=
“Input Date from Rack Display” submenu display or selection.
“?RACK” Submenu Functions and Parameters “?RACK”= Submenu for the display of input date from the rack. The individual displays are: “LDK O/F” = Entry indicating how the system recognized the “alternator (D+)” input nstruction.
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“UMSO/F”=
Entry indicating how the system recognized the “outrigger” input instruction.
“DWLO/F”=
Entry indicating how the system recognized the “limit switch slewing left” input instruction.
“DWRO/F”=
Entry indicating how the system recognized the “limit switch slewing right” input instruction.
“BPVO/F”=
Entry indicating how the system recognized the “concrete pump forward” input instruction from site control.
“BRPO/F”=
Entry indicating how the system recognized the “concrete pump reverse”input instruction from site control.
“WMNrO/F”=
Entry indicating how the system recognized the “water level minimum”input instruction.
“RWKO/F” =
Entry indicating how the system recognized the “agitator ON” input instruction. (Input active for AGRs = 1 function.)
“REPO/F”=
Entry indicating how the system recognized the “Maintenance ON” input instruction. (Input active for MTNs = ON function.
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“?BDI A” Submenu Functions and Parameters “?BDI_A”=
Submenu for the display of the input data from the rear panel. The individual displays are: “Sxa 0000”= Entry indicating the hexadecimal code of the rear panel input ports. (In service menu only!) Detailed hardware knowledge is necessary to understand this entry. One can determine the following guideline for servicing: Each actuation of a switching element must cause a digit in the display to change.
“?DIGa” =
“Digital Inputs from BDI_A (Rear Panel)” submenu display or selection. The individual displays are: “ASWO/F”= Entry indicating how the system recognized the “spotlight ON” input instruction. “HUPaO/F”=
Entry indicating how the system recognized the “horn” (communication) input instruction.
“RTHaO/F”=
Entry indicating how the system recognized the “vibrator manual” input instruction.
“RTAaO/F”=
Entry indicating how the system recognized the “vibrator automatic” input instruction. “KPRaO/F”= Entry indicating how the system recognized the “compressor ON” input instruction. “WPEaO/F”= Entry indicating how the system recognized the “water pump ON” input instruction. “BPVaO/F”= Entry indicating how the system recognized the “concrete pump forward” input instruction. “BPRaO/F”= Entry indicating how the system recognized the “concrete pump reverse” input instruction. “MONaO/F”= Entry indicating how the system recognized the “motor ON” input instruction. “MOFaO/F”= Entry indicating how the system recognized the “motor OFF” input instruction. “MUPaO/F”= Entry indicating how the system recognized the “rpm +” input instruction. “MDNaO/F”= Entry indicating how the system recognized the “rpm -” input instruction. “FSTaO/F”= Entry indicating how the system recognized the “remote control OFF” input instruction. “REiaO/F”= Entry indicating how the system recognized the “spare X” input instruction. Where X = 1 to 3. “FMpaO” = Entry representing the “stroke limiter” potentiometer setting recognized. 0...99 = MIN...MAX potentiometer setting in %.
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“?BDI F” Submenu Functions and Parameters “?BDI_F”
= Submenu for the display of the remote control input data (cable or radio). The individual displays are: “Sxf 0000”=Entry indicating the hexadecimal code of the remote control input ports. (In service menu only!) Detailed hardware knowledge is necessary to understand this entry. One can determine the following guideline for servicing: Each actuation of a switching element must cause a digit in the display to change. “DIGf” = “Digital inputs from BDI_A (Remote Control)” submenu display or selection. The individual displays are: “MSTS”= “M1 O/F”=
“Switches from Joystick” submenu display or selection. Entry indicating how the system recognized the “boom 1” input instruction. “M23O/F”= Entry indicating how the system recognized the “boom 2/3” input instruction. “M4 O/F”= Entry indicating how the system recognized the “boom 4” input instruction. “MMO/F”= Entry indicating how the system recognized the “slewing” input instruction. “DSLO/F”= Entry indicating how the system recognized the “push-button left” input instruction. “DSRO/F”= Entry indicating how the system recognized the “push-button right” input instruction. “HUPO/F”= Entry indicating how the system recognized the “horn” (communication) input instruction. “BPVO/F” = Entry indicating how the system recognized the “concrete pump forward” input instruction. “BPRO/F” = Entry indicating how the system recognized the “concrete pump reverse” input instruction. “MONfO/F”= Entry indicating how the system recognized the “motor ON” input instruction. “MOFfO/F”= Entry indicating how the system recognized the “motor ON” input instruction. “MUPfO/F”= Entry indicating how the system recognized the “rpm +” input instruction. “MDNfO/F”= Entry indicating how the system recognized the “rpm -” input instruction. “RTAfO/F”= Entry indicating how the system recognized the “vibrator automatic” input instruction. “RP1fO/F”= Entry indicating how the system recognized the “ramp 1” input instruction. For the “FBP” type, this entry is substituted by: “SP2fO/F”= Entry indicating how the system recognized the “drum speed 2” input instruction. “RP3fO/F”=
Entry indicating how the system recognized the “ramp 3” input instruction. For the “FBP” type, this entry is substituted by: “AUTfO/F”= Entry indicating how the system recognized the “automatic” input instruction. “RWVfO/F”= Entry indicating how the system recognized the “agitator forward” input instruction.
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“RWRfO/F”= “A1p
0”=
“A2p
0”=
“A3p
0”=
“A4p
0”=
“MDp
0”=
“FMpf
0”=
Entry indicating how the system recognized the “agitator reverse” input instruction. Entry representing the “boom 1” control switch actuation converted into percent. 0... 99 = Control switch “up” actuation. 0...-99 = Control switch “down” actuation. Entry representing the “boom 2” control switch actuation converted into percent. 0... 99 = Control switch “up” actuation. 0...-99 = Control switch “down” actuation. Entry representing the “boom 3” control switch actuation converted into percent. 0... 99 = Control switch “up” actuation. 0...-99 = Control switch “down” actuation. Entry representing the “boom 4” control switch actuation converted into percent. 0... 99 = Control switch “up” actuation. 0...-99 = Control switch “down” actuation. Entry representing the “slewing” control switch actuation converted into percent. 0... 99 = Control switch “right” actuation. 0...-99 = Control switch “left” actuation. Entry representing the “stroke limiter” potentiometer setting converted into percent. 0... 99 = MIN...MAX potentiometer setting.
“?SOUT" Main Menu After selecting the “?SOUT_1” main menu, you can scroll the individual entries with the “⇑” and “⇓” keys. In the “?SOUT_1” main menu, the first group of the digital outputs as to be given out by the system is represented. The following individual entries can be found: “MOF O/F” = Entry indicating whether the system wants to give out the “motor OFF” output instruction. “MON O/F” = Entry indicating whether the system wants to give out the “motor ON” output instruction. “MDN O/F” = Entry indicating whether the system wants to give out the “rms -” output instruction. “MUP O/F” = Entry indicating whether the system wants to give out the “rms +” output instruction. “HP1 O/F” = Entry indicating whether the system wants to give out the “horn 1” (communication) output instruction. “HP2 O/F” = Entry indicating whether the system wants to give out the “horn 2” (slewing mechanism end position) output instruction. “ASW O/F” = Entry indicating whether the system wants to give out the “spotlight” output instruction. “RTE O/F” = Entry indicating whether the system wants to give out the “vibrator” output instruction. After selecting the “?SOUT_2” main menu, you can scroll the individual entries with the “⇑” and “⇓” keys. In the “?SOUT_2” main menu, the second group of the digital outputs as to be given out by the system is represented. The following individual entries can be found:
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“BPR
O/F” = Entry indicating whether the system wants to give out the “concrete pump reverse”output instruction. “BPV O/F” = Entry indicating whether the system wants to give out the “concrete pump forward”output instruction. “UMS O/F” = Entry indicating whether the system wants to give out the “outrigger” output instruction. “WPE O/F” = Entry indicating whether the system wants to give out the “water pump” output instruction. “KPR O/F” = Entry indicating whether the system wants to give out the “compressor” output instruction. “RWK O/F” = Entry indicating whether the system wants to give out the “agitator” output instruction. “MFU O/F” = Entry indicating whether the system wants to give out the “boom movement” output instruction. “BPK O/F” = Entry indicating whether the system wants to give out the “oil cooler” output instruction.
“?POUT” Main Menu After selecting the “?POUT_1” main menu, you can scroll the individual entries with the “⇑” and “⇓” keys. In the “?POUT_1” main menu, the first group of the proportional outputs as to be given out by the system is represented. The following individual entries can be found: “A1H “A1S “A2H “A2S “A3H “A3S “A4H “A4S
XXX” = Entry indicating what current the system wants to drive through the “boom 1 up” valve. XXX” = Entry indicating what current the system wants to drive through the “boom 1 down” valve. XXX” = Entry indicating what current the system wants to drive through the “boom 2 up” valve. XXX” = Entry indicating what current the system wants to drive through the “boom 2 down” valve. XXX” = Entry indicating what current the system wants to drive through the “boom 3 up” valve. XXX” = Entry indicating what current the system wants to drive through the “boom 3 down” valve. XXX” = Entry indicating what current the system wants to drive through the “boom 4 up” valve. XXX” = Entry indicating what current the system wants to drive through the “boom 4 down” valve.
After selecting the “?POUT_2” main menu, you can scroll the individual entries with the “⇑” and “⇓” keys. In the “?POUT_2” main menu, the second group of the proportional outputs as to be given out by the system is represented. The following individual entries can be found: “MR “ML “FM
552
XXX” = Entry indicating what current the system wants to drive through the “slewing right” valve. XXX” = Entry indicating what current the system wants to drive through the “slewing left” valve. XXX” = Entry indicating what current the system wants to drive through the “stroke limiter” valve.
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“?DIAG” Main Menu After selecting the “?DIAG ” main menu, you can scroll the individual submenus and entries with the “⇑” and “⇓” keys. In the “?DIAG ” main menu, a few entries can be found for easier diagnosing. The following individual entries can be found: “WAS
O/F”
=
“NAH “FERN “REPB
O/F” O/F” O/F”
= = =
“MAST
O/F”
=
“DWL
O/F”
=
“DWR
O/F”
=
“LDK
O/F”
=
“WMH
O/F”
=
This entry indicates whether the control system is under restart protection for the time being, i.e. no output signal is given unless all instruction sources of the newly selected mode (LOCAL or REMOTE) are at their neutral positions. Entry indicating whether the control system is in “LOCAL” mode. Entry indicating whether the control system is in “REMOTE” mode. Entry indicating whether the control system is in “maintenance” mode. (On-site control active!) Entry indicating whether the control system wants to five out the “boom active” output instruction. Entry indicating how the system recognized the “limit switch slewing left” input instruction. Entry indicating how the system recognized the “limit switch slewing right” input instruction. Entry indicating how the system recognized the “alternator (D+)” input instruction. Entry indicating how the system recognized the “water level minimum” input instruction.
“?SYSTEM” Main Menu After selecting the “?SYSTEM” main menu, you can scroll the individual submenus and entries with the aid of the “⇑” and “⇓” keys. In the “?SYSTEM” main menu, some system information and setting aids can be found. This menu should only be used by especially trained personnel as system data can be changed here that may result in system failure when entered in the wrong way!!! The following individual entries can be found: “SCV_S” = This entry indicates which hardware (which card) and which software (program) can be found. This entry allows for opening the service menu: 1.Pressing key “P” once: “SCV_S menu” 2.Pressing key “C” once: “SCV_S menu” 3.Pressing key “⇑” once: “NO500” 4.Enter and save the code number (530) as for normal parameters “V2.4x” = This entry indicates what software version is found. (See Explanation of Different Software Versions). “TYPXXX” = This entry indicates what type of unit the card is currently programmed to. No re-programming is possible here! Types of units which can be indicated:NORMBoom 2 / 3 changeover R_A2Boom 2 ramp control “hh : mm : ss” = This entry indicates the time of operation since the last reset or restart. “USAGE XX” = This entry indicates the current usage of the bus system in percent (0...99). “!RESET” = By selecting this item, a so-called warm start can be initiated, i.e. the system is brought to the same condition as after turning on the supply voltage. ! N E W”
= Selecting this item brings all parameters in the system to factory-set default.
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Electrical
SERVICE TRAINING In such case, the system will request you to acknowledge by the same keys if you really want to change the parameters.
“?GERAET” Main Menu (In Service Menu Only!) After selecting the “?GERAET” main menu, you can scroll the individual submenus and entries with the “⇑” and “⇓” keys. In the “?GERAET” main menu, all unit-specific settings are concentrated. The following individual entries can be found: “TYP
XXX” = The type of equipment can be selected here: NORM Boom 2 / 3 changeover R_A2 Boom 2 ramp control Default: NORM
“REP
OFF”
= This serves to select the concrete pump on-site control mode. If on-site control is to be activated by a release switch, this parameter must be programmed “ON”. Default: OFG
“RWK 0”
= This switches off the optional agitator (0), and activates it for simple functioning forward only / 1), or for extended functioning (forward and reverse / 2). Default: 0
“FHYS 2.0”
= This serves to set the hysteresis compensation factory within the range from 1.0 to 10.0. Default 2.0
“IVOR 50”
= This serves to set the driver current within the range from 0 to 200mA. Default: 50 mA
V2.4 Menus The V2.4x software version has two different levels of access, the customer menu and the service menu. The customer menu has the parameter settings for the current that is used for driving the hydraulic valves. These settings are changeable from the customer menu in the “?PAR” portion of the main menu. The customer menu also allows you to view non-changeable entries such as inputs to and outputs from the “SCV” card. The customer menu only allows you access to the “SCV” card. The service menu allows you to access some extra troubleshooting entries in the “SCV” card along with all HCL and DG cards. Along with this, you can also view the BDI_A (rear operators panel card and the BDI_F (cable remote) card. On the following pages containing the 2.4 menu structure, the service menu entries are all the entries in the shaded boxes. All the entries in the unshaded boxes can be accessed from the customer or the service menu. To access the service menu, do the following: 1. From the “SCV” entry in the controller column, you press the “P” button. This will bring up the “?PAR” entry in the main menu column. 2. Press the arrow key down “⇓” until the “?SYSTEM” entry is displayed on the mat. 3. Press “P” to display “SCV_S”. 4. Press the “P” key one, then the “C” key once, and finally the arrow up “⇑” key once. The display should now read NR500. 5. Press the “P” key and a dotted line will appear under the NR500. 6. Press the arrow up “⇑” key until the display reads NR530. 7. Press the “P” key and a dashed line will appear under the NR530. You now have access to all entries in the customer and service entries. Every time the unit is reset, either by shutting off the power and turning it back on, or my using the reset function in the mat, you will automatically be in the customer menu and must re-enter the code to access the service menu.
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Electrical
Software Versions There are a few different software versions used on the digital proportional units. The SCV cards have versions 2.2x, 2.3x and 2.4x. The x denotes that there could be another digit in that location, for example 2.46 or 2.48. The earlier versions (2.2x and 2.3x) have a ? in front of the SCV display on the MAT. The 2.4x version will have a * in front of the SCV displayed on the MAT. You can also see what version software you have by scrolling to the “system” entry in the main menu column. Version 2.3x and 2.4x can be used in place of a version 2.2x. The 2.2x and 2.3x version cannot be used in a unit that has ramp functions for boom controls or remote agitator control, as used in the 52m’s. The 2.2x and 2.3x also cannot be used in units that have on site activation switches. On the following pages there is one menu structure for the 2.2x and 2.3x version and one menu structure for the 2.4x version. The BDI cards or the cards used for the rear panel and remote control box can also have various versions. The versions are either 1.xx or 2.xx. In the 1.xx version the cards were specific to their location, ie., the BDIA card was used for the rear panel and the BDIF card was used for the remote box. The 2.xx version is called BDI S and it can be programmed to be used in the rear panel or remote box. The versions are interchangeable, however the 1.xx version cannot be used in systems with remote agitator controls as used in the 52m. The HCL and DG cards have different versions and they are interchangeable and compatible with all SCV card version
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MENU STRUCTURE Controller
Main Menu
Submenus
Software Version 2.4X
Display
Translation
1H1 200 1H2 300 1H3 900 1S1 200 1S2 300 1S3 900 2H1 200 2H2 300 2H3 900 2S1 200 2S2 300 2S3 900 3H1 200 3H2 300 3H3 900 3S1 200 3S2 300 3S3 900 4H1 200 4H2 300 4H3 900 4S1 200 4S2 300 4S3 900
Min. stop current (mA.)
ML1 200 ML2 300 ML3 900 MR1 200 MR2 300 MR3 900 FM1 200 FM2 300 FM3 900
Min. stop current (mA.)
To cable remote & back panel
*SCV 9
?PAR
?AUSL
?AUSL 1H
?AUSL 1S To slave cards ?AUSL 2H
?AUSL 2S
?AUSL 3H
?AUSL 3S
?AUSL 4H
?AUSL 4S
?MAST L
?MAST R
?F.MENGE
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Min. start current (mA.)
Boom up Section 1
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom down Section 1
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom up Section 2
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom down Section 2
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom up Section 3
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom down Section 3
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom up Section 4
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.)
Boom down Section 4
Max. current (mA.)
Min. start current (mA.) Max. current (mA.)
Slew left
Min. stop current (mA.) Min. start current (mA.)
Slew right
Max. current (mA.) Min. stop current (mA.) Min. start current (mA.) Max. current (mA.)
Stroke limiter
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Controller
Main Menu
Submenus ?RAMPE
?RAMP UP
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Electrical
Display T1LU 1.0 T1RU 1.0 T2LU 1.0
Translation Only when ramp function is activated
T2RU 1.0 T3RU 1.0 T3RU 1.0 ?RAMP DN
T1LD 0.5 T1RD 0.5 T2LD 0.5 T2RD 0.5 T3LD 0.5 T3RD 0.5
?INS
?V24
?TELEGR.
?SELECT
RP1 RP2 RP3
25 50 75
OK CE FE PE OE VE
0 0 0 0 0 0
W0 W1 W2 W3 W4 W5 CRC
0000 0000 0000 0000 0000 0000 00
A1Hs A1Ss A2Hs A2Ss A3Hs A3Ss A4Hs A4Ss MLs MRs FMs
ON ON ON ON ON ON ON ON ON ON ON
CERR NA_F OFF NA_C OFF STOER 0 PERR
Version 2.4X
Service Manual
No. of correctly received data blocks. For proper operation, no. must cont. grow. No. of errors determined when the checksum was checked. No. must not grow/grow slowly. No. of errors determined when lengh of a data block checked. No. must not grow/grow slowly. No. of errors determined when parity was checked. No. must not grow/grow slowly. No. of errors caused by telegram buffer overflow. No. must not grow/grow slowly. No. of errors caused by software telegram buffer overflow. No. must not grow/grow slowly.
Lock/Unlock Proportional Outputs
Communication error (See Pg. 4 )
---------------------Prop. output Hardware error
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Electrical
Controller
Main Menu
Submenus
Display
Sxa 0000
?DIN
Translation Rear panel all functions Hexidecimal code
?BDI-A ?DIGa
ASWa O/F HUPa O/F RTHa O/F RTAa KPRa WPEa BPVa BPRa
O/F O/F O/F O/F O/F
MONa O/F MOFa O/F MUPa MDNa FSTa RE1a RE2a
O/F O/F O/F O/F O/F
RE3a O/F FMpa Sxf
O
Spotlight Horn Vibrator Manual Vibrator Automatic Compressor Water Pump Concrete Pump Forward Concrete Pump Reverse Engine Start Engine Stop RPM Up RPM Down Local (on)/Remote (off) Spare Spare Spare Stroke Limiter Remote control all functions hexidecimal code
0000
?BDI_F ?DIGf
?MSTS
Version 2.4X
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M 1 M 23 M 4 MM DSL
O/F O/F O/F O/F O/F
Boom 1 Joystick Microswitch
DSR
O/F
Push button Right
Boom 2/3 Joystick Microswitch Boom 4 Joystick Microswitch Slewing Push button Left
HUPf O/F BPV f O/F BPRf O/F MON f O/F MOF f O/F MUPf O/F MDN f O/F RTAf O/F
Horn
RP1f RP3f
Ramp 1
O/F O/F
Concrete Pump Forward Concrete Pump Reverse Engine Start Engine Stop RPM Up RPM Down Vibrator Automatic
Ramp 3
RWVf O/F RWRf O/F
Agitator Forward
A1p A2p A3p A4p MDp FMpfs
Boom 1 Potentiometer
0 0 0 0 0 0
Agitator Reverse
Boom 2 Potentiometer Boom 3 Potentiometer Boom 4 Potentiometer Slewing Potentiometer Stroke Limiter Potentiometer
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Controller
Main Menu
Submenus ?RACK
Electrical
Display
Translation
LDKr O/F Alternator D+ UMSr O/F Outrigger DWLr O/F Slew Left Limit Switch DWRr BPVr BPRr WMNr RWKr REPr
?SOUT 1
PRINT
O/F O/F O/F O/F O/F O/F
Slew Right Limit Switch Concrete Pump Forward Concrete Pump Reverse Water Level Min Agitator Maintenance On
MOFo O/F Engine Stop MONo O/F Engine Start MDNo O/F RPM Down MUPo O/F RPM Up HP1o O/F Horn 1 HP2o O/F Horn 2 ASWo O/F Spotlight RTEo O/F Vibrator
?SOUT 2
BPRo O/F Concrete Pump Reverse BPVo O/F Concrete Pump Forward UMSo O/F Outrigger WPEo O/F Water Pump KPRo O/F Compressor RWKo O/F Agitator MFUo O/F Boom Movement BPK o O/F Oil Cooler RWVo O/F Agitator Forward RWRo O/F Agitator Reverse
?POUT 1
?POUT 2
A1Ho A1So A2Ho
0 0 0
Boom 1 Up Prog. Output Current
A2So A3Ho A3So A4Ho A4So
0 0 0 0 0
Boom 2 Dn Prog. Output Current
MR o ML o FM o
0 0 0
Slewing R. Programmed Current
Boom 1 Dn Prog. Output Current Boom 2 Up Prog. Output Current
Boom 3 Up Prog. Output Current Boom 3 Dn Prog. Output Current Boom 4 Up Prog. Output Current Boom 4 Dn Prog. Output Current
Slewing L. Programmed Current Stroke Limiter Progammed Current
Version 2.4X
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Electrical
Controller
Main Menu
Submenus
?DIAG
?SYSTEM
?GERAET
Display
WAS ON NAH O/F FERN O/F REPB O/F MAST O/F DWL r O/F DWR r O/F LDK r O/F
Restart Protection
WMH r O/F
Water Level Min
SCVS V2.48 TYP NORM
Hardware Version
HH:MM:SS USAGE XX ! RESET ! NEW
Time of Operation Since Last Reset
TYP NORM REPs ON RWKs 2 FHYs 2.0 IVOR 50
Version 2.4X
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Service Manual
Translation
Local Mode Remote Mode Maintenance Mode Boom Slewing Limit Switch Left Slewing Limit Switch Right Alternator
Software Version Type of Unit
Current Usage by Bus System in % Reset the System Return to Factory Setting
Norm R_A2 Boom 2/3 Change Boom 2 Ramp
Agitator For/Rev mode Refer to balancing valve currents Refer to balancing valve currents
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Software Version 2.1X Controller
Electrical
Rear Panel Card - Controller No. 10 Main Menu
Submenus
?BD12 10
PRINT
Display
BDI - s Card Menu Translation
SWH HHHH All functional hexadecimal code
?DIGITAL ASW HUP RTH RTA RPR WPE BPV BPR MON MOF MUP MDH FST RE1 RE2 RE3
O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F
FMpa XX
Spotlight Horn Vibrator manual Vibrator automatic Compressor Water pump Concrete pump forward Concrete pump reverse Engine start Engine stop RPM up RPM down Remote control/Manual Spare Spare
Stroke limiter set value
"System information" Main Menus
?SYS
Service Manual
BDI S V2.10 hh:mm:ss USP XX !RESET !N E W
Card type/hardware
TYP A 10
Type selection parameter
Software version Time of operation since last RESET Percentage bus employment Reset system / warm start Reset parameter to default
561
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Electrical Software Version 1.30 Controller
Rear Panel Card - Controller No. 10 Main Menu
Submenus
?BD12 10
Display
BDI - A Card Menu Translation
SWH HHHH All functional hexadecimal code
% FM XX
Stroke limiter set value
ASW HUP RTH RTA RPR WPE BPV BPR MON MOF MUP MDH FST RE1 RE2 RE3
Spotlight
?DIGITAL O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F
Horn Vibrator manual Vibrator automatic Compressor Water pump Concrete pump forward Concrete pump reverse Engine start Engine stop RPM up RPM down Remote control/Manual Spare Spare Spare
?SYS USP XX TAS XX BDI A V1.30 hh:mm:ss
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Percentage bus employment Task posed by bus communication Card type/hardware Software version Time of operation since last RESET
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Controller *BDI
Electrical
Remote Control Panel Controller No. 11
Software Version 2.1x Main Menu
Submenus
11
PRINT
BDI - S Card Menu Programmed Type: F11
Display
Translation
SWH HHHH All functional hexadecimal code
?DIGITAL ?MSTS M1 M23 M4 MM DSL DSR
O/F O/F O/F O/F O/F O/F
Boom 1 microswitch
HUPf BPVf BPRf MONf MOFf MUPf MDHf RTAf RP1f RP3f RWVf RWRf
O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F
Horn
A1p A2p A3p A4p MDp FMp
XX XX XX XX XX XX
Boom 1 potentiometer (-99 to 99%)
Boom 2/3 microswitch Boom 4 microswitch Slewing microswitch Lt-hand pushbutton Rt-hand pushbutton
Concrete pump forward Concrete pump reverse Engine start Engine stop RPM up RPM down Vibrator automatic input Ramp step 1 Ramp step 3 Agitator forward Agitator reverse
?ANALOG Boom 2 potentiometer (-99 to 99%) Boom 3 potentiometer (-99 to 99%) Boom 4 potentiometer (-99 to 99%) Slewing potentiometer (-99 to 99%) Stroke limiter potentiometer (0 - 99%)
?HEXIN A1x HHH A23xHHH A4x HHH MDx HHH FMx HHH
?CALIB
Boom 1 input value Boom 2/3 input value Boom 4 input value Slewing input value Stroke limiter input value "Calibration" Main Menu
!C START !C STOP
Start automatic calibration Stop automatic calibration
OFS HHHH ADC offset setting
To be continued on next page ...
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Electrical
Remote Control Panel Controller No. 11
Software Version 2.1x Controller
Main Menu
Submenus
Continued
Display
BDI - S Card Menu Programmed Type: F11
Translation
?PARM1 1PN HHHH Calibration (do not change) 1PX HHHH Calibration (do not change) 1NN HHHH Calibration (do not change) 1NX HHHH Calibration (do not change) 2PN HHHH Calibration (do not change) 2PX HHHH Calibration (do not change) 2NN HHHH Calibration (do not change) 2NX HHHH Calibration (do not change) 4PN HHHH Calibration (do not change) 4PX HHHH Calibration (do not change) 4NN HHHH Calibration (do not change) 4NX HHHH Calibration (do not change)
?PARM2 MPN HHHH Calibration (do not change) MPX HHHH Calibration (do not change) MNN HHHH Calibration (do not change) MNX HHHH Calibration (do not change) FPN HHHH Calibration (do not change) FPX HHHH Calibration (do not change) FNN HHHH Calibration (do not change) FNX HHHH Calibration (do not change) MI1 HHHH Calibration (do not change) MI2 HHHH Calibration (do not change) MI4 HHHH Calibration (do not change) MIM HHHH Calibration (do not change) MF1 HHHH Calibration (do not change)
?SYSTEM
"System Information" Main Menu
BDI S V2.10 hh:mm:ss USAGE XX !RESET ! NEW
TYP F 11
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Service Manual
Version/ hardware Software version Time of operation since last RESET Percent bus usage Reset system / warm start Reset parameter to default
Type selection parameter
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Controller ?BDI1
Electrical
Remote Control Panel Controller No. 11
Software Version 1.30 Main Menu
Submenus
PRINT
BDI - F Card Menu
Display
Translation
11 ?ANALOG %A1 %A2 %A3 %A4 %MD %FM
XX XX XX XX XX XX
Boom 1 potentiometer (-99% - 99%) Boom 2 potentiometer (-99% - 99%) Boom 3 potentiometer (-99% - 99%) Boom 4 potentiometer (-99% - 99%) Slewing potentiometer (-99% - 99%) Strk lmtr potentiometer (-99% - 99%)
?HEXIN A1 A23 A4 MD FM
HHH HHH HHH HHH HHH
Boom 1 (Hexidecimal code) Boom 2/3 (Hexidecimal code) Boom 4 (Hexidecimal code) Slewing (Hexidecimal code) Stroke limiter (Hexidecimal code)
?DIGITAL SWH HHHH All function hexadecimal code
M1 M23 M4 MM U23 HUP BPV BPR MON MOF MUP MDN RTA RE1 RE2 RE3
O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F O/F
Boom 1 microswitch Boom 2/3 Boom 4 Boom slewing Boom 2/3 pushbutton Horn Concrete pump forward Concrete pump reverse Engine start Engine stop RPM up RPM down Vibrator automatic Spare 1 Spare 2 Spare 3
To be continued on next page ...
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Electrical
Remote Control Panel Controller No. 11
Software Version 1.30 Controller
Main Menu
Submenus
BDI - F Card Menu
Display
Translation
Continued
?CALIB
?PARMS 1PN HHHH Calibration (don’t change) 1PX HHHH Calibration (don’t change) 1NN HHHH Calibration (don’t change) 1NX HHHH Calibration (don’t change)
BDI
11
!C START !C STOP
Calibration (don’t change) Calibration (don’t change)
OFS HHHH Calibration (don’t change)
?SYS USP XX TASK XX BDI F V1.30 hh:mm:ss ?NEW P
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Percentage bus usage Task posed by bus communication Version type / hardware Software version Time of operation since last RESET Reset parameter to default
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Electrical
.
Software Version 1.1x Controller *HC2 X
Proportional Current Output Card Controller Nos. 1 ... 6 Main Menu
Submenus
?DATA
?CONFIG
?SYSTEM
Display
HC2L Card Menu Translation
I1
XXXX
Current 1 output
I2
XXXX
Current 2 output
S14
::::
Inputs S1, S2, S3, S4
S58
::::
Inputs S5, S6, S7, S8
ER EOK
Error message
DFQ XXX
Dither frequency in Hz
RPV XXX
Solenoid coil initial resistance
HC2
Card type / hardware
S
V1.10
Software version
HH:MM:SS Time of operation since last RESET USP
Service Manual
XX
Percent bus usage
! RESET
Reset system / warm start
! NEW
Set parameter to default
567
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Electrical Software Version 1.0x Controller ?HC2 X
Proportional Current Output Card Controller Nos. 1 ... 6 Main Menu
Submenus
?SERV
Display
HC2L Card Menu Translation
HH:MM:SS Time of operation since last RESET HC2L
S Hardware version Software version
V1.0x
USAGE XX Percent bus usage
TASK XX
?CALIB
Task posed by bus communication
I1L HHHH (Don’t change) I1H HHHH (Don’t change) I2L HHHH (Don’t change) I2H HHHH (Don’t change)
PV TN
3.0 ---------------0.06 ----------------
!NEW ENA ----------------
?VARI
?ALLG
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Service Manual
!NEW
Return to factory setting
I1 XXXX I2 XXXX S41 S85 ER EOK
Real current 1
DF
Frequency setting (Hz)
XXX
Real current 2 Digital input (4-1) Digital input (8-5) Error indication
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Switching Valve Output Card Controller Nos. 7, 8 and 12. Resp. (For Agitator FWD/REV Only)
Software Version 1.0x Controller
Main Menu
Submenus
Display
PRINT
Electrical DG8 Card Menu
Translation
?DG8 X ?SERV
"Service Data" Main Menu
hh:mm:ss
Time of operation since last RESET
DG8 S
Card type / hardware
V1.0x
Software version
USAGE XX Percent bus usage
TASK XX
?VARI
Task posed by bus communication
"Variables" Main Menu
Service Manual
V41 - - - -
Outputs V4, V3, V2, V1
V85 - - - -
Outputs V8, V7, V6, V5
S41 : : : :
Inputs S4, S3, S2, S1
S85 : : : :
Inputs S8, S7, S6, S5
ER EOK
Error message
569
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Electrical
Switching Valve Output Card Controller Nos. 7, 8 and 12. Resp. (For Agitator FWD/REV Only)
Software Version 1.1x Controller
Main Menu
Submenus
DG8 Card Menu
Display
*DG8 X
Controller type w/ network no. (7, 8 or 12)
?VARI
"Data" Main Menu
V14 - - - -
Outputs V1, V2, V3, V4
V58 - - - -
Outputs V5, V6, V7, V8
S14 : : : :
Inputs S1, S2, S3, S4
S58 : : : :
Inputs S5, S6, S7, S8
?SYSTEM
"System Information" Main Menu
DG8
S
V1.1X
Card type / hardware Software version
hh:mm:ss
Time of operation since last RESET
USP
Percent bus usage
XX
! RESET
?TEST
570
Translation
Reset system / warm start "Output Test" Main Menu
Service Manual
TFREE
Teset enable
TEST 0/1
Activate test output
TV1
0/1
Act. or deact. V1 output test
TV2
0/1
Act. or deact. V2 output test
TV3
0/1
Act. or deact. V3 output test
TV4
0/1
Act. or deact. V4 output test
TV5
0/1
Act. or deact. V5 output test
TV6
0/1
Act. or deact. V6 output test
TV7
0/1
Act. or deact. V7 output test
TV8
0/1
Act. or deact. V8 output test
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Electrical
MENU STRUCTURE Controller
Main Menu
Submenus
Display
PRINT
Software Version 2.2X & 2.3X
Translation
To cable remote & back panel ?SCV 9
To slave cards
?PAR
?ALLGEM.
?AUSL.1H
?AUSL.1S
?AUSL.2H
?AUSL.2S
?AUSL.3H
?AUSL.3S
?AUSL.4H
?AUSL.4S
?MAST L
?MAST R
?F.MENGE
Service Manual
Fhys 2.0 IVOR 50 RWK RAMP
Refer to balancing valve current Refer to balancing valve current Software version 2.3 only Software version 2.3 only
1H1 200 1H2 300 1H3 900
Min. stop current (mA.)
1S1 200 1S2 300 1S3 900
Min. stop current (mA.)
2H1 200 2H2 300 2H3 900
Min. stop current (mA.)
2S1 200 2S2 300 2S3 900
Min. stop current (mA.)
3H1 200 3H2 300 3H3 900
Min. stop current (mA.)
3S1 200 3S2 300 3S3 900
Min. stop current (mA.)
4H1 200 4H2 300 4H3 900
Min. stop current (mA.)
4S1 200 4S2 300 4S3 900
Min. stop current (mA.)
ML1 200 ML2 300 ML3 900
Min. stop current (mA.)
MR1 200 MR2 300 MR3 900
Min. stop current (mA.)
FM1 200 FM2 300 FM3 900
Min. stop current (mA.)
Min. start current (mA.)
Boom up Section 1
Max. current (mA.)
Min. start current (mA.)
Boom down Section 1
Max. current (mA.)
Min. start current (mA.)
Boom up Section 2
Max. current (mA.)
Min. start current (mA.)
Boom down Section 2
Max. current (mA.)
Min. start current (mA.)
Boom up Section 3
Max. current (mA.)
Min. start current (mA.)
Boom down Section 3
Max. current (mA.)
Min. start current (mA.)
Boom up Section 4
Max. current (mA.)
Min. start current (mA.)
Boom down Section 4
Max. current (mA.)
Min. start current (mA.)
Slew left
Max. current (mA.)
Min. start current (mA.)
Slew right
Max. current (mA.)
Min. start current (mA.)
Stroke limiter
Max. current (mA.)
571
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Electrical
Controller
Main Menu ?INS
Submenus ?V24
Display INTS 0 OK 0 PY 00 OV 00 FR 00 W0 0000 W1 0000 W2 0000 W3 0000 W4 0000 W5 0000 CRC 00 CERR 0 NA_F AUS NA_C AUS STOER 0 PERR 0
?DIN
Version 2.2X & 2.3X
572
Service Manual
Translation Data received from radio. bytes. Data received from radio. received data. Data received from radio. faults. Data received from radio. faults. Data received from radio. faults. Data received from radio.
Amount of received Amount of correctly Amount of partity Amount of reoccuring Amount of format
Data received from radio. Data received from radio. Original data bytes. Data received from radio. Data received from radio. Check overall sum Communication error (See Pg. 4)
---------------------Proportional output. Hardware error.
A1H A1S A2H A2S A3H
EIN EIN EIN EIN EIN
A3S A4H A4S ML MR FM
EIN EIN EIN EIN EIN EIN
Lock/unlock proportional output
AS FB A1
0000 0000 0
Hexidecimal code from rear panel Hexidecimal code from remote box Boom 1 Potentiometer (-99 ... 99)
A2 A3
0 0
Boom 2 Potentiometer (-99 ... 99)
A4 A5 FM
0 0 0
Boom 4 Potentiometer (-99 ... 99)
Boom 3 Potentiometer (-99 ... 99)
Slewing Potentiometer (-99 ... 99) Strk. Limt. Potentiometer (0 ... 99)
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Controller
Main Menu
Submenus
?SOUT
Electrical
Display MOF AUS MON AUS MDN AUS MUP AUS HP1 AUS HP2 AUS ASW AUS RTE AUS BPR AUS BPV AUS UMS AUS
?POUT
?SYS
PRINT
Translation Engine stop Engine start RPM Down RPM Up Boom horn Slewing horn Spot light Vibrator Concrete Pump Reverse Concrete pump forward Boom/outrigger
WPE AUS KRP AUS
Water pump
RS1 AUS RS2 AUS BPK AUS
Spare
A1H A1S A2H A2S A3H A3S A4H A4S MR ML FM
Boom 1 Up Prog. Output Current
0 0 0 0 0 0 0 0 0 0 0
Compressor
Spare Oil cooler
Boom 1 Down Prog. Output Current Boom 2 Up Prog. Output Current Boom 2 Down Prog. Output Current Boom 3 Up Prog. Output Current Boom 3 Down Prog. Output Current Boom 4 Up Prog. Output Current Boom 4 Down Prog. Output Current Slew Rt. Prog. Output Current Slew Lft. Prog. Output Current Strk. Limit. Prog. Output Current Reset system (power off)
!RESET USP XX TASK XX SCV_S V2.21 HH:MM:SS ? NEW P
------------------------Hardware Version Software Version Time since last reset Return to the factory setting
Version 2.2X & 2.3X
Service Manual
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Electrical
Controller
?DG8
8
Main Menu
Submenus
?SERV
?VARI
?DG8
7
?HC2
6
Display
Translation
HH:MM:SS DG8_S V1.00 USAGE XX TASK XX
Time since last reset
V41 V85 S41
Output transistor status (4-1)
S85 ER
Digital input (8-5)
Software version --------------------------
Output transistor status (8-5) Digital input (4-1)
EOK
Error indication
(SAME AS THE "DG8 8")
?SERV
?CALIB
HH:MM:SS HC2L_S V1.00 USAGE XX TASK XX
Time of operation since last reset
I1L I1H I2L I2H
(Don’t change)
XXXX XXXX XXX XXXX
PV 3.0 TN 0.06 !NEW ENA !NEW
?VARI
?ALLG ?HC2
5
(SAME AS THE "HC2 6")
?HC2
4
(SAME AS THE "HC2 6")
?HC2
3
(SAME AS THE "HC2 6")
?HC2
2
(SAME AS THE "HC2 6")
?HC2
1
(SAME AS THE "HC2 6")
Version 2.2X & 2.3X
574
Hardware version
Service Manual
Hardware version Software version Percent of bus usage Task passed by bus comm.
(Don’t change) (Don’t change) (Don’t change) ---------------------------------------Return to factory setting
I1 XXXX I2 XXXX S41 S85 ER EOK
Real current 1
DF
Frequency setting (Hz)
200
Real current 2 Digital input (4-1) Digital input (8-5) Error indication
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Controller ?BDI1
11
Main Menu
Submenus
?ANALOG
?HEXIN
A1 A23 A4 MD FM
?DIGITAL
?CALIB
?PRAMS
?SYS
Electrical
Display %A1 %A2 %A3 %A4 %MD %FM
PRINT
XX XX XX XX XX XX HHH HHH HHH HHH HHH
Translation Boom 1 Potentiometer (-99% = 99) Boom 2 Potentiometer (-99% = 99) Boom 3 Potentiometer (-99% = 99) Boom 4 Potentiometer (-99% = 99) Slewing Potentiometer (-99% = 99) StrkLimiter Pot (-99% = 99) Boom 1 (Hexidecimal code) Boom 2/3 (Hexidecimal code) Boom 4 (Hexidecimal code) Slewing (Hexidecimal code) Strk. Limit. (Hexidecimal code)
SWH HHHH M1 OFF M23 OFF
All functions (Hexidecimal code)
M4 MM U23 HUP
OFF OFF OFF OFF
Boom 4 Microswitch
BPV BPR
OFF OFF
MON MOF MUP MDN RTA RE1 RE2 RE3
OFF OFF OFF OFF OFF OFF OFF OFF
Boom 1 Microswitch Boom 2/3 Microswitch
Slewing Microswitch Boom 2/3 Pushbutton Horn Concrete pump forward Concrete pump reverse Engine start Engine stop RPM Up RPM Down Vibrator Automatic Spare Spare Spare
1PN HHHH 1PX HHHH 1NN HHHH 1NX HHH BDI 11
Calibration (don’t change)
!C_START !C_STOP OFS HHHH
Calibration (don’t change)
USP XX TASK XX BDI_F V1.30 HH:MM:SS ?NEW P
----------------
Calibration (don’t change) Calibration (don’t change) Calibration (don’t change) Calibration (don’t change)
Calibration (don’t change) Calibration (don’t change)
---------------Hardware Version Software Version Time since last reset Return to factory setting
Version 2.2X & 2.3X
Service Manual
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Electrical
Controller
?BDI2
Main Menu
Submenus
10
%FM
?DIGITAL
?SYS
XX
Service Manual
Translation Stroke Limiter (%)
SWH HHHH ASW OFF HUP OFF RTH OFF RTA OFF KPR OFF WPE OFF BPV OFF
All Functions (Hexidecimal code)
BPR OFF MON OFF MOF OFF MUP OFF MDN OFF
Concrete Pump Reverse
FST RE1 RE2 RE3
Remote Control/Manual
OFF OFF OFF OFF
USP XX TASK XX BDI_A V1.30 HH:MM:SS
Version 2.2X & 2.3X
576
Display
Spotlight Horn Vibrator Manual Vibrator Automatic Compressor Water Pump Concrete Pump Forward
Engine Start Engine Stop RPM Up RPM Down
Spare Spare Spare
----------------------------Hardware version Software version Time since last reset
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Electrical
Digital Proportional - Balancing Valve Currents Balancing The Valve Currents With the digital proportional control system, you no longer have to adjust trim pots to fine tune control response. You can now simply enter the parameters you want and the microprocessor takes care of the rest. This is called balancing the valve currents, and it is necessary to provide precise synchronization between joystick control and boom movement. Incorrect valve current settings will have an adverse affect on the proportionality of the boom. There are three adjustments or parameters to set for each boom section as well as for slewing and concrete output. They are the: • • •
Minimum start current. Minimum stop current. And maximum driver current.
The minimum start current controls how the boom reacts as the joystick is moved from the neutral position. It is the lowest level of driver current required to start the boom moving. Moving the joystick from the neutral position activates a micro switch. Immediately after the micro switch is activated the current should be at the minimum start level. This will provide linear proportional control when setting the boom in motion. See Figure 13.
MINIMUM START CURRENT
mA
MAXIMUM CURRENT OUTPUT
1000 900 800
MAX
700 600 500
MIN 400 300 200 100 0 0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
MIN MAX PRETENSION PRESSURE (BAR)
MAX
MIN
MICROSWITCH CLOSED
Figure 13
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Electrical
If the minimum start current is set too low, the boom will not move with the joystick. This results in a “dead spot” as the joystick is moved off the neutral position and the micro switch is activated. Setting the minimum start current too high will cause the boom to start abruptly and bounce after the micro switch has been activated. The minimum stop current controls how the boom slows to a stop as the joystick is moved to the neutral position. It is the precise point at which the driver current falls below the level necessary to keep the boom in motion. When the driver current reaches this setting, the micro switch should open. This causes the system to go to the 50 milliamp diagnostic level. If the minimum stop current is set too high, the boom will be moving too fast when the micro switch closes, causing it to stop abruptly and bounce. If it is set too low, the boom will stop before the micro switch closes, and you will have an increased dead area.
MINIMUM START CURRENT
mA
MAXIMUM CURRENT OUTPUT
1000 900 800
MAX
700 600 500
MIN 400 300 200
MIN, START 100 SETTING 0 0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
MIN MAX PRETENSION PRESSURE (BAR)
MAX
MIN "DEAD" AREA
MICROSWITCH CLOSED
Figure 14 The maximum current setting controls the amount of driver current available. When properly adjusted, the hydraulic valve should just contact the mechanical stop as the joystick reaches the 100% position. See Figure 15.
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Electrical
MINIMUM START CURRENT
mA
MAXIMUM CURRENT OUTPUT
1000 900 800
MAX
700 600 500
MIN 400 300 200 100 0 0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
MIN MAX PRETENSION PRESSURE (BAR)
MAX
MIN
MICROSWITCH CLOSED
Figure 15
Hysteresis Because of the inertia generated by the weight of the boom, the system responds differently when increasing the driver current (accelerating the boom) than it does to decreasing driver current (slowing the boom). This difference in response is referred to as hysteresis. To provide smooth transitions when controlling boom speed, a hysteresis compensation factor is programmed into the system. This setting is located in the “FHYS 2.0” submenu, but the value should not be changed.
Diagnostic Signal Part of the systems self diagnostic ability is a result of a 50 mA driver current programmed into the system. This diagnostic current is applied to both values on axis at the same time. This small amount of current is not enough to run the boom; however, it does allow the system to detect an open circuit such as a broken wire or faulty solenoid.
Setting Valve Currents The procedure for setting the valve currents requires the use of the M.A.T. and menu survey. First, find the value you want to adjust in the display column of the menu survey. These are located in the P-A-R section of the main menu.Then chart a course back to the SCV9 starting point. Use the M.A.T. to scroll to the desired location and observe the current value. Use the following procedure to change the setting: 7.
press the program key once. A dotted line appears under the alpha numeric display, the
Service Manual
value can now be changed.
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Electrical 8. 9.
Press the arrow keys to adjust the value up or down to the desired setting. If you make a mistake, press the “C” key to start over. When the parameter is set to the desired value, press the program key again. The dotted line changes to a dashed line indicating the change has been saved.
After setting the driver currents, check the operation of the hydraulic valve by watching the boom and the handle on the hydraulic valve as you move the joy stick. The boom should just start to move as you move the joy stick off neutral and you hear the micro switch activate. Then move the joy stick to the 100% position, the handle on the hydraulic valve should just contact the maximum stop. Correctly balancing the valve currents precisely tailors the digital controller to the hydraulic system on your unit. This provides smooth proportional control of boom functions and concrete output. The initial settings that were programmed into your machine are located on a decal near the digital processor. See Figure 16.
CURRENT MEASUREMENT DATA PROPORTIONAL BOOM - DIGITAL MODEL: SERIAL NO. FUNCTION
MIN STOPPING CURRENT (mA)
MIN STARTING CURRENT (mA)
1H1
1H2
1H3
1S1
1S2
1S3
2H1
2H2
2H3
2H1
2H2
2H3
3H1
3H2
3H3
3S1
3S2
3S3
4H1
4H2
4H3
4S1
4S2
4S3
ML1
ML2
ML3
MR1
MR2
MR3
FM1
FM2
FM3
HYSTERESIS COMPENSATION: DRIVER CURRENT:
Figure 16
580
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Electrical
Digital Proportional - Troubleshooting The digital proportional control is designed with self-diagnostic capabilities built-in to help you quickly and efficiently locate faults in the system. When the unit is activated, it continuously monitors the systems and communicates their status using LED’s located on the digital processor. See Figure 17.
Troubleshooting LED’s
+ .A12 REC 2
+ A11 SCV
+ .A10 HC2L-1
+ .A9 + .A8 HC2L-1 HC2L-1
+ .A7 HC2L-1
+ .A6 HC2L-1
+ .A5 HC2L-1
+ .A4 DG8-1
+ .A3 DG8-1
M.A.T. CONNECTOR
Figure 17 If a problem exists, the first step is to check the status of the LED’s on the digital controller. Use the charts to interpret the messages communicated by the LED’s, then follow the appropriate troubleshooting (T.S.) procedure on the following page.
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Electrical
Message
Meaning
Troubleshooting procedure
All LED’s steady green
No faults, system ready
None (If a boom function is inoperative see T. S. procedure 1)
All LED’s off
No power to unit
“E” Stop pressed, Main power switch off
SCV 9 steady green all others off
Communication error
T. S. procedure 2
SCV 9 & HC 2 flashing
Hardware fault
T. S. procedure 3
SCV 9 flashing
Intermit hardware fault
T. S. procedure 4
SCV Red
M.A.T. plugged in
None
Rear panel card off (inside rear panel)
No faults
None
Rear panel blinking (inside rear panel)
Matching blinking error from SCV card
T. S. procedure 4
Red LED on cable remote box or LED on card inside cable remote box blinking.
Matching blinking error from SCV card
T. S. procedure 4
Problem in card
Replace card
Rear card or cable card steady red
NOTE: The rear panel board will light for approximately 1 second on system activation or restart. Note: The troubleshooting procedures listed below pertain to the electrical system. Make sure that there are no problems with the hydraulic system before performing any of these procedures.
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Electrical
Troubleshooting procedure 1 If one boom function is not working and the LED’s are steady green, you’ll need to use the M.A.T. and menu survey to pinpoint the problem. To do this, first connect the M.A.T. and scroll to the P-A-R main menu, then to the affected boom display. Check the minimum start, stop and max current parameters. They should approximate the values written on the decal. If not, reprogram the function to the correct values. If the parameters are set correctly, scroll to the P-OUT main menu, then to the affected boom display. Move the joystick and watch the value. When the joystick is at the neutral position, the reading should be 50, indicating the 50 milliamp diagnostic current. As the joystick is moved towards the 100% position, the reading should rise to the max current setting. If these functions are not correct, try using the other remote control panel. If that doesn’t help or the readings are correct but the boom function still is not working, check the output current of the affected HC 2 card.
Troubleshooting procedure 2 If none of the control functions are working and the SCV9 card is steady green, but the other cards are off, it indicates a communication error between SCV9 and one or more of the slave cards. To locate the problem, connect the M.A.T. and scroll to the INS main menu. Then scroll to the C-E-R-R display which is the entry for communication errors. The number in the display indicates the position to the right of the SCV 9 card where the first error occurred. To determine if the problem is on the card, swap it into another position of the same card type and reset the system. If the error follows to the new position, the board is defective. If the error is still in the same position, call Schwing Service for assistance.
Troubleshooting procedure 3 If the card that controls the problem function is flashing, along with the SCV9 card, there is a hardware fault somewhere between the output of the digital processor and the hydraulic valve. To determine if the problem is the solenoid or the wiring, swap the solenoid caps. If the problem is unchanged, replace the solenoid. If the problem follows the solenoid caps, the problem is in the wiring. If this is the case, you should consult the electrical schematics to track the faulty wire.
Troubleshooting procedure 4 If the SCV9 is the only card flashing, it means the problem is intermittent, possibly a bad connection. It continues to flash because it stores fault information in its memory until the system is reset. Because of the sensitivity of the system the SCV light may blink for various reasons, if resetting the system does not clear the problem refer to troubleshooting procedure 3. Resetting the system can be accomplished either by turning the power off and on, or by using the M.A.T.
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Electrical Troubleshooting The Radio
The radio remote consists of a transmitter built into the battery powered remote control and a receiver built into the digital processing unit. All commands transmitted are safety coded, that is they contain an identifier, so that the unit will only respond to commands from the correct remote control. The receiver checks the command and passes it on only if it is complete and correct. If there is interference, the unit will automatically shut down, however, there are two frequencies available that can be switched at the remote control. See Figure 18. When using the radio remote, it is important to stay within a safe operating range, always knowing where the boom is.
Low Battery LED
Communications LED
Frequency Selector
Emergency Stop
Figure 18
E- stop LED
There are 3 LED’s on the radio remote. The one on the left warns you when the radio battery voltage is getting low. The center LED indicates when a digital message is being sent. The E-stop LED lights when the emergency stop on the transmitter has been pressed. The rechargeable transmitter battery will operate the system for about 8 hours, depending on the age of the batteries and the operating conditions. When the battery warning light starts to flash, you have about thirty minutes operating time left before the unit shuts down due to low battery voltage. The battery charger is located in the cab of the truck. See Figure 19.
POWER
Figure 19
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Electrical
The other half of the radio remote control is the receiver, which is located in the truck mounted digital processor. It receives the digital code from the transmitter, checks to make sure the instructions are correct and complete, then passes them on to the digital processor. See Figure 20.
SCHWING NG
NF
UF UE1 UCC1 UE2 UCC2 NOT1 K1
K1 K2
20
MC2 TEL
T 2
K28
MC1 ST 1 ST 2 REL PROP TEL TST 3 TST 2 TST 1
T 1
RADIO CONTROL FCC ID. DA87G6 FW SCHWING AMERICA . GERMANY SERIAL NR 003 143 FREQ. 456.962S (mHZ) 457.762S
Radio Receiver
Figure 20
Operation With the Local/Remote switch located on the rear operators panel in the local mode: 1.
Connect the Funk plug or cable remote to the remote receptacle (one or the other must be connected to operate a digital machine). See Figure 21.
2.
Properly set the machine, as described in the operators manual, then turn the mode switch back to the remote position.
FUNK
Figure 3.
Make sure all the function switches on the remote control transmitter are in the neutral position.
4.
Turn the remote control power supply on. (the LED on the right should start flashing)
5.
Turn the power switch located on the transmitter to the “on” position. (the E-stop LED should flash faster) See Figure 22.
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Electrical 6.
Pull the emergency stop button. (the communication LED should now be on)
7.
Activate one of the control functions. (the communication LED should start flashing, indicating messages are being sent)
Low Battery LED
Communications LED
Emergency Stop
E- stop LED
Frequency Selector
Figure 22
Emergency Stop Pushing the emergency stop button stops the main functions of the machine.
Automatic Shut down The unit will automatically shut down in case of: • • • •
Low battery voltage Message errors. Electronic module failure. No command messages sent for 30 minutes.
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Electrical
Trouble-shooting Many problems with the radio remote control can be identified by interpreting the LED’s on the radio receiver. The following is a brief explanation of the LED’s: NG= power supply UF= vehicle system voltage UE 1= controller 1 supply UCC 1= controller 1 supply (+5V) UE 2= controller 2 supply UCC 2= controller 2 supply (+5V) NOT 1= EMERGENCY STOP circuit of controller 1 for controller MC 1 NOT 2 = EMERGENCY STOP circuit of controller 1 for controller MC 2 HF= receiver K1= RF-channel 1 selected K2= RF-channel 2 selected MC 2= controller 2
data message reception TEL= data message recepton
MC 1= controller 1 ST 1= controller 1 failure ST 2= controller 2 failure REL= relay output defective PROP= proportional control output defective TEL= data message recepton TST3= data message error 3 TST2= data message error 2 TST1= data message error1
SCHWING NG UF UE1 UCC1 UE2 UCC2 NOT1 NOT2
HF K1 K2
F W 20 MC2 TEL
T2
K28
V24
MC1 ST 1 ST 2 REL PROP TEL TST 3 TST 2 TST 1
T1
RADIO CONTROL FW20 FCC ID. DA87G6 FW20RL SCHWING AMERICA INC. GERMANY SERIAL NR 003 143 FREQ. 456.962S (mHZ) 457.762S
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Electrical Troubleshooting tables
LED
DISPLAY
MESSAGE
REMEDIAL ACTION
UF, UE1, UCC1, UE2, UCC2
None lit
Machine power failure
Switch in, check power supply
UF, UE1, UCC1, UE2, UCC2
On One off
Power supply failure, shortcircuit in receiver
Call Schwing Service
NOT1, NOT2
ON
Emergency stop activated Fault detected by electronic system
Unlock “E” stop See MC1
NOT1, NOT2
Off but no function
Fuse defective
Replace fuse
LED
DISPLAY
MESSAGE
REMEDIAL ACTION
K1, K2
Alternately flashing
Transmitter scan, no radio contact Message format error
Switch on transmitter, choose better transmitter location, check antenna See MC1
LED
DISPLAY
MESSAGE
REMEDIAL ACTION
TEL
Irregular flashing
Transmitter off, no radio contact Transmitter defective, RF section defective
Switch on transmitter, choose better transmitter location, check antenna Call Schwing Service
LED
DISPLAY
MESSAGE
REMEDIAL ACTION
ST1
On
Failure in MC1 or in periphery module, e.g. REL, NG, PROP
Call after Schwing Service
ST2
On
Failure in MC2, no exchange of data
Call after Schwing Service
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DISPLAY
MESSAGE
REMEDIAL ACTION
PROP
On
Vehicle power supply voltage 28V
Check vehicle power supply
No radio reception Transmitter off or defective Antenna not installed or defective
Check transmitter and antenna Call Schwing Service
Irregular flashing
TST2
TST 2
❍ ❍
On
TST 1
MESSAGE
REMEDIAL ACTION
●
No empty message after switch-on emergency shut-off activated HF interference3
Set control element to “0” position Unlock “E” stop Call Schwing Service
Format error in pulse-coded message
Change frequency if fault cannot be rectified Call Schwing Service
Format error in proportional message
Change frequency if fault cannot be rectified Call Schwing Service
Another transmitter with the same frequency nearby, message affected by address error
Change frequency if fault cannot be rectified Call Schwing Service
Message affected by mode error, encoder switch in wrong position
Change frequency check encoder switch. Call Schwing Service
Message affected by cyclic redundancy check error
Change frequency if fault cannot be rectified Call Schwing Service
Emergency stop message
Rectify fault, unlock “E” stop
❍ ● ❍ ❍ ● ● ✸ ✸ ❍ ✸ ✸ ✸ ● ● ❍ ●
Electrical
LED
TEL
TST 3
PRINT
●
●
● = LED ON
❍ = LED OFF
✸ = LED Flashing
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Comfort Control Manual Chp.
Contents
1.0
Working with the info & diagnosis system
2.0
3.0
4.0
5.0
Page
1.1
Introduction into the info & diagnosis system
2
1.2
Menu structure of the info & diagnosis system / Operation data display
4
Parameter setting concrete pump efficiency / Central lubricating system / Prop characteristics 2.1
Password entry and parameter selection menu
9
2.2 2.3 2.4
Setting the concrete pump efficiency for pumped volume determination Setting the central lubricating system Setting proportional parameters for boom functions
10 11 12
I/O status display signals & references 3.1
Machine control
15
3.2 3.3 3.4 3.5
Concrete pump control Boom control Rear panel Extension module (central lubricating system)
17 18 20 22
Fault messages and fault causes 4.1
Introduction / Structure of error codes
4.2 4.3 4.4 4.5 4.6 4.7 4.8
Control diagnosis electronic modules Remote control system diagnosis Machine diagnosis - General Diesel engine diagnosis / P.T.O. Concrete pumpe diagnosis Boom control diagnosis Central lubricating system diagnosis / Extension
23 (fault code S) (fault code F) (fault code A) (fault code D) (fault code B) (fault code M)
24 25 26 28 30 31
(fault code Z / E)
34
Interdependence list of most important output signals
35
Annex :Overview info center menu Vers.: 1.2
Status:02.10.97
Service Manual
U.Weber (TEW)
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1.0 Working with the info & diagnosis system 1.1 Introduction into the info & diagnosis system
The SCHWING info & diagnosis system for truck-mounted concrete pumps is located in the rear panel unit at the rear step-ladder of the machine and is operated with the display and the 6 function buttons below.
The info system offers the following functions : -Pumped volume determination by means of stroke counter and pumped volume calculation (cf. 1.2.3) -Extensive operational data acquisition and display (cf. 1.2.4) -Safely stored malfunction list of the last 100 malfunction messages (cf. 1.2.5) -Manual operation of lubricating cycles (cf. 1.2.6) -Status display of all signals of the electric control (cf. 1.2.7 & 3.0) -Password-protected efficiency adjustment for the pumped volume determination of the concrete pump (cf. 2.0) -Password-protected parameter setting for the central lubricating system (cf. 2.0) -Password-protected parameter setting for the proportional boom functions (cf. 2.0)
The diagnosis system monitors the control unit, the machine and partly also the vehicle for malfunctions or inadmissible states of operation. The system recognizes e.g. parting of cables or short-circuits in electric lines of solenoids, Fault sensors, contaminated oil filters or critical hydraulic oil or diesel engine temperatures and displays different operating conditions. The system is to assist the concrete pump operator in his work on site and to inform him about the possible causes of malfunctions when they occur. The malfunction messages are displayed as continuous text in the form of an easily understandable plain language message with additional fault code. The manual contains a detailed description of the faults for each fault code (cf 4.0) In case of recognized malfunctions, the diagnosis system distinguishes between minor faults and severe faults. Minor faults do not require immediate elimination of the fault cause and the machine can be used - possibly with some restrictions - until the job is finished A severe fault bears the risk that the machine or the vehicle may be severely damaged. An immediate elimination of the fault cause is therefore necessary. If the integrated diagnosis system recognizes a malfunction or an inadmissible state of operation of the machine, a horn sounds intermittently and a fault message appears on the display of the rear panel unit. Moreover, the last 100 recognized malfunctions are stored safely in a malfunction list together with date and time. They can be recalled at any time.
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In case of a minor fault, the horn signal and the fault message can be switched off by means of the "Hupe / quitt" button on the remote control box or the cable control box. Switching off the horn does not delete the fault message. To prevent fault messages from getting lost, a fault message is recalled whenever one of the two "hydraulic on outriggers" buttons (at the outrigger control block) is recalled and displayed, and until the operator has read the fault message displayed and acknowledged the message at the rear panel stand with the [QUITT] button below the display. Pressing the [QUITT] button once only shuts off the horn signal with the fault message still being displayed. Only after the [QUITT] button has been depressed a second time, the fault message is deleted from the display. In the event of severe faults, the horn signal cannot be cancelled with the buttons on the remote control box. The operator can therefore recognize severe faults by the fact that the horn signal continues to sound although the [Hupe / quitt] button on the remote control box or the cable control box has been actuated. Since severe faults cause considerable damage of the machine, the concrete pump operator must inform himself at the display of the diagnosis system on the machine about the fault occurred. In the event of severe faults, the horn signal can be cancelled and the fault message be deleted only with the [QUITT] button below the diagnosis display. Fault messages are also definitely cancelled when the electric control system is switched off. The operator himself is responsible for the elimination of indicated faults in order to prevent the machine from being damaged. If the message of a fault that has not been eliminated is being cancelled, there is no new fault indication. A persistant fault will however be recognized and reported again by the diagnosis system after the machine has been de-activated with the EMERGENCY SHUT-OFF button on the machine or on the remote control box. SCHWING is not responsible for damage caused by non-eliminated faults of the machine !
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1.2 Menu structure info & diagnosis system / Operation data display The SCHWING diagnosis system is operated with 6 buttons below the display at the rear panel stand. The diagnosis system is based on an easily understandable menu system in form of a so-called tree structure. Depressing the [ENTER] button always branches into the next menu level or recalls the displayed function. The [CLEAR] button returns to the previous menu level. If further branching into another sub-menu is possible, the second line in the display shows " ↓ / ↑ / ENTER / CLEAR ". Depressing [ENTER] switches the info & diagnosis system on, displaying the main menu after the standard window. (cf. annex : Overview info center menu)
The buttons on the display have the following functions : [ ↓ ] or [ ↑ ]menu up or down [ENTER]menu item selection / confirmation / activation of next menu level [CLEAR]interrupt actual function and back to previous level in menu system [QUITT]fault message acknowledge / horn shut-off [START]start of a function (pumped volume counter / manual lubrication)
The operation of the diagnosis system on all menu levels is explained on the following pages. The message displayed is shown in a frame. The menu functions and the selection of special functions is described by the key symbols in brackets and the pertaining explanantions.
1.2.1 Standard display & malfunction messages
INFO SYSTEM ENTER = On
[ ENTER ] → Call up main menu (cf. 1.2.2)
When the diagnosis system recognizes a malfunction of the machine or the electrical system, the actual message on the display is overwritten with the actual fault message.
MALFUNCTION (CODE) FAULT MESSAGE
1. x [ QUITT ] → Shut off horn signal 2. x [ QUITT ] → Fault message cancel / acknowledge !
Please observe also the detailed description of fault acknowledgement in 1.1.
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1.2.2 Main menu
[ ENTER ] → Sub-menu "Pump Volume" for
PUMPED VOLUME ↓ / ENTER / CLEAR [↓]
[ CLEAR ]
pump volume calculation (cf. 1.2.3) →
[ ENTER ] → Call up "Operation Data" sub-menu
OPERATION DATA ↓ / ↑ / ENTER / CLEAR [ ↓ ] [ ↑ ] [ CLEAR ]
(cf. 1.2.4) →
(cf. 1.2.5) →
(cf. 1.2.6) →
(cf. 1.2.7) →
(CLEAR = back) →
(cf. 1.2.8) →
Back to start window [ ENTER ] → Call up "Parameter" menu
PARAMETERS ↑ / ENTER / CLEAR [ ↑ ] [ CLEAR ]
Back to start window [ ENTER ] → Scrolling rate fault message adjust
SCROLLING ↓ / ↑ / ENTER / CLEAR [ ↓ ] [ ↑ ] [ CLEAR ]
Back to start window [ ENTER ] → Display of date and time of internal timer
INTERNAL TIMER ↓ / ↑ / ENTER / CLEAR [ ↓ ] [ ↑ ] [ CLEAR ]
Back to start window [ ENTER ] → Call up "I/O display" sub-menu
I/O STATUS DISPL ↓ / ↑ / ENTER / CLEAR [ ↓ ] [ ↑ ] [ CLEAR ]
Back to start window [ ENTER ] → Call up "Central Lubrication" sub-menu
LUBRICATION-UNIT ↓ / ↑ / ENTER / CLEAR [ ↓ ] [ ↑ ] [ CLEAR ]
Back to start window [ ENTER ] → Call up "Malfunction List" sub-menu
MALFUNCTION LIST ↓ / ↑ / ENTER / CLEAR [ ↓ ] [ ↑ ] [ CLEAR ]
Back to start window
(cf. 2.0) →
Back to start window
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Electrical 1.2.3 "PUMP VPUME" sub-menu
[ START ] → Start new pump volume determination &
PUMPED ON JOB (S) ≈ 1723.5 cbm [ CLEAR ]
delete old value (cf. 2.2) →
Back to main menu
1.2.4 "OPERATION DATA" sub-menu
HYD OIL TEMP 062 ßC [↓]
Display of actual oil temperature in hydraulic oil reservoir [ CLEAR ]
→
PTO SHAFT RPM 1270 rpm [↓] [↑]
[ CLEAR ]
Display of actual rpm of PTO. →
[ CLEAR ]
→
CONCR-PUMP HOURS 328.3 h [↓] [↑]
[ CLEAR ]
→
placing boom [ CLEAR ]
→
PTO. [ CLEAR ]
→
[ CLEAR ]
[ CLEAR ]
→
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[ CLEAR ]
Back to main menu
Display of stored total pumped quantity of concrete pump →
STROKES PER MIN 21.4 S/min [↑]
Back to main menu
Display of stored total number of strokes of concrete pump
TOTAL VOL. PUMPED 1491258 cbm [↓] [↑]
Back to main menu
Display of stored operating hors
TOTAL STROKES CP 18529417 strokes [↓] [↑]
Back to main menu
Display of stored operating hours
PTO HOURS 469.8 h [↓] [↑]
Back to main menu
Display of stored operating hours concrete pump
BOOM HOURS 406.1 h [↓] [↑]
Back to main menu
Display of actual oil pressure in concrete pump circuit
HYD PRESSURE CP 159 bars [↓] [↑]
Back to main menu
Back to main menu
Display of actual number of strokes of concrete pump in strokes/ min →
Back to main menu
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1.2.5 "MALFUNCTION LIST" sub-menu
16.03.93 / 12:34
[ ↓ ] / [ ↑ ] → Scrolling up & down malfunction list
(CODE) FAULT TEXT
(cf. 4.0)
[ CLEAR ]
→
Back to main menu
1.2.6 "LUBRICATION-UNIT" sub-menu
[ START ] → Manual lubrication starts
MANUAL LUBRIC. CP & Agitator [↓]
[ CLEAR ]
→
[ START ] → Manual lubrication starts
MANUAL LUBRIC. Boom [↓] [↑]
[ CLEAR ]
→
[ CLEAR ]
Back to main menu
[ START ] → Manual lubrication starts
MANUAL LUBRIC. Outriggers [↑]
Back to main menu
→
Back to main menu
1.2.7 "I/O DISPLAY" sub-menu
[ ENTER ] → Call up I/O display for machine control module (cf.
MACHINE-CONTROL ↓ / ENTER / CLEAR [↓]
[ CLEAR ]
3.1) →
[ ENTER ] → Call up I/O display for concrete pump control mod-
CP-CONTROL ↓ / ↑ / ENTER / CLEAR [↓] [↑]
[ CLEAR ]
ule (cf. 3.2) →
[ CLEAR ]
3.3) →
[ CLEAR ]
→
[ CLEAR ]
Back to main menu
[ ENTER ] → Call up I/O display for extension module
EXTENSION I/O ↑ / ENTER / CLEAR [↑]
Back to main menu
[ ENTER ] → Call up I/O display for rear panel module (cf. 3.4)
REAR PANEL ↓ / ↑ / ENTER / CLEAR [↓] [↑]
Back to main menu
[ ENTER ] → Call up I/O display for boom control module (cf.
BOOM-CONTROL ↓ / ↑ / ENTER / CLEAR [↓] [↑]
Back to main menu
(cf. 3.5) →
Back to main menu
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Electrical 1.2.8 SCROLLING" sub-menu
This sub-menu can be used to adjust the so-called "SCROLLING rate" (running speed) of fault message texts in the display. For easier checking during adjustment, the "SCROLL-speed" text always moves through the first line of the display at the actually set speed. Depressing [ ENTER ] activates the adjusting mode for the scrolling rate. The activation of the adjusting mode is indicated by a flashing scrolling rate (300 ms) in the display. By depressing the [ ↓ ] [ ↑ ] keys, the scrolling-speed rate can be changed by 50 ms at a time. Depressing [ ENTER ] stores the set value and quits the adjusting mode. [ ENTER ] → Activate adjusting mode
Scrolling speed 300 ms
[ ENTER ] ← Store set value [ CLEAR ]
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2.0 Concrete pump efficiency parameter setting / Central lubrication / Prop characteristics 2.1 Password entry and parameter selection menu
Unintentional or unauthorized access to the adjustment of set values (parameters) for the pumped volume determination of the concrete pump for the central lubrication and the prop current characteristics of the boom functions is protected by a password. After selecting "PARAMETER" in the main menu, the password must be entered first. [ ↓ ] [ ↑ ] → Enter password and then press
PASSWORD **** ↓ / ↑ / ENTER / CLEAR [ CLEAR ]
[ ENTER ] →
Back to main menu
Explanation : The password can be entered with the [ ↓ ] [ ↑ ] keys. If one of the keys is kept depressed, the password display starts incrementing slowly. After abt. 5 seconds, the display starts incrementing faster and after further 5 seconds, the speed increases once again. After pressing [ ENTER ] and after the correct password has been selected, the display shows "Password OK" and jumps to the parameter selection menu. In the event of a wrong password, the display shows "Password wrong" and the diagnosis system goes back to the standard display. [ ENTER ] → Parameter setting for pumped volume calculation
CP EFFICIENCY ↓ / / ENTER / CLEAR
of concrete pump (cf. 2.2)
[↓]
[ CLEAR ]
→
[ ENTER ] → Call up parameter menu for central lubrication (cf.
LUBRIC. PARAM ↓ / ↑ / ENTER / CLEAR [↓]
[ CLEAR ]
2.3) →
[ CLEAR ]
→
[ CLEAR ]
Back to PASSWORD entry
[ ENTER ] → Select parameter setting for boom function BOOM
PROP-CUR BOOM 1 ↓ / ↑ / ENTER / CLEAR [↓] [↑]
Back to PASSWORD entry
[ ENTER ] → Select parameter setting for BOOM SLEW function
PROP-CUR SLEW ↓ / ↑ / ENTER / CLEAR [↓]
Back to PASSWORD entry
1 →
Back to PASSWORD entry
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[ ENTER ] → Select parameter setting for boom function BOOM
PROP-CUR BOOM 2 ↓ / ↑ / ENTER / CLEAR [↓] [↑]
[ CLEAR ]
2 →
[ ENTER ] → Select parameter setting for boom function BOOM
PROP-CUR BOOM 3 ↓ / ↑ / ENTER / CLEAR [↓] [↑]
[ CLEAR ]
3 →
[ CLEAR ]
4 →
[ CLEAR ]
Back to PASSWORD entry
[ ENTER ] → Select parameter setting for boom function BOOM
PROP-CUR BOOM 5 / ↑ / ENTER / CLEAR [↑]
Back to PASSWORD entry
[ ENTER ] → Select parameter setting for boom function BOOM
PROP-CUR BOOM 4 ↓ / ↑ / ENTER / CLEAR [↓] [↑]
Back to PASSWORD entry
5 →
Back to PASSWORD entry
2.2 Setting the concrete pump efficiency for pumped volume determination
The volumetric efficiency of the pumped volume calculation (efficiency CP) of the concrete pump can be set in this parameter menu. The setting acts on the pumped volume counter (PUMPED VOLUME) and on the total pumped quantity of the concrete pump (TOTAL VOL. PUMPED). The pumping volume of the concrete pump is determined by counting the pump strokes and by calculating the delivery rate by means of the pumped volume of the pumping cylinder and the CP EFFICIENCY: EFFICIENCY CP should therefore be an average value for the pump efficiency of the concrete pump depending on the most often pumped concrete qualities. [ ENTER ] activates the setting mode for the "Concrete pump efficiency" parameter. The activation of the adjusting mode is indicated by a flashing percentage for the pumped quantity efficiency in the display. The efficiency concrete pump value can then be changed in steps of 1% by pressing the [ ↓ ] [ ↑ ] keys. Depressing [ ENTER ] stores the set value and quits the adjusting mode.
[ ENTER ] → Activate adjusting mode
EFFICIENCY CP 92 % [ CLEAR ]
600
[ ENTER ] ← Store set value →
Back to parameter selection menu
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2.3 Adjusting the central lubrication The lubricant amount of the individual circuits of the central lubrication system can be set individually by presetting the number of greasing cycles if the supplementary module for intelligent central lubrication is installed. [ ENTER ] activates the adjusting mode for one lubricating circuit. The activation of the adjusting mode is indicated by a flashing lubricating cycle number in the display. The number of lubricating cycles can be re-adjusted for the selected lubricating circuit within a range of 0 and 20 greasing cycles by depressing the [ ↓ ] [ ↑ ] keys. Depressing [ ENTER ] stores the set value and quits the adjusting mode. If "0" lubricating cycles have been preset, the corresponding lubricating circuit is shut off.
[ ENTER ] → Activate parameter setting for placing boom greas-
LUBRIC. CYCLE BOOM 09 [↓]
[ CLEAR ]
ing circuit →
[ ENTER ] → Activate parameter setting for concrete pump/agita-
LUBRIC. CYCLE CP/AGITATOR 12 [ ↓ ] [ ↑ ] [ CLEAR ]
tor greasing circuit →
Back to parameter selection menu [ ENTER ] → Activate parameter setting for outrigger greasing
LUBRIC. CYCLE OUTRIGGERS 07 [ ↑ ] [ CLEAR ]
Back to parameter selection menu
circuit →
Back to parameter selection menu
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2.4 Adjusting the proportional parameters for boom functions The electrical characteristics of the proportional valves can be individually adjusted for each boom function. The correct adjustment of a proportional characteristics curve requires profound machine knowledge and should only be carried out by specially trained personnel. Since a machine with wrong settings may get into unsafe operating states, SCHWING GMBH assumes no liability for events occurring as a consequence of proportional characteristics settings modified by the customer. After selection of a boom function, 4 parameters can be adjusted for each axis. For each direction (extend / retract or slew right / left) the pertaining MIN and MAX value of the proportional characteristics curve can be set. Depending on the proportional valves installed in the machine, there are two different methods of setting the prop value parameters. For prop-current-controlled valves (e.g. REXROTH) the characteristic values are set as current values in mA (valve type: PROP). For PWM-controlled valves (e.g. APITECH) the characteristic values are set as percentages of the PWM ratio (valve type: PULSAR). [ ENTER ] activates the adjusting mode for a prop parameter. The activation of the adjusting mode is indicated by a flashing prop parameter value in the display. The set value can then be changed by depressing [ ↓ ] [ ↑ ] by 10 mA resp. 1 % for the selected prop parameter. Depressing [ ENTER ] stores the set value and quits the adjusting mode.
The adjusting ranges of the prop current values are limited as follows : - Current value for "I min" within 250 mA to 1000 mA. (The set value must be less than the value for "I max") - Current value for "I max" within 500 mA to 1500 mA. (The set value must be greater than the value for "I min")
The adjusting ranges of the PWM percentages are limited as follows : - Value for "PWM min" in a range of 20 % to 60 %. (The set value must be less than the value for "PWM max") - Value for "PWM max" in a range of 40 % to 100 %. (The set value must be greater than the value for "PWM min")
The following examples illustrate changes of the proportional values for the BOOM SLEWING MECHANISM for valves of the PROP type and for BOOM SECTION 1 for valves of the PULSAR type.
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Proportional characteristics adjustment for the BOOM SLEW function with PROP valve types : → Display of actual value for proportional current boom slew
BOOM SLEW RIGHT I act 510 mA [↓]
[ CLEAR ]
right ! →
[ ENTER ] → Activate parameter adjustment for MIN current of
BOOM SLEW RIGHT I min 340 mA [ ↓ ] [ ↑ ] [ CLEAR ]
boom slew right function →
boom slew right function →
→
boom slew left function →
Back to boom functions selection menu [ ENTER ] → Activate parameter adjustment for MAX current of
BOOM SLEW LEFT I max 850 mA [ ↑ ] [ CLEAR ]
Back to boom functions selection menu [ ENTER ] → Activate parameter adjustment for MIN current of
BOOM SLEW LEFT I min 340 mA [ ↓ ] [ ↑ ] [ CLEAR ]
Back to boom functions selection menu → Display of actual value for proportional current boom slew left
BOOM SLEW LEFT I act 470 mA [ ↓ ] [ ↑ ] [ CLEAR ]
Back to boom functions selection menu [ ENTER ] → Activate parameter adjustment for MAX current of
BOOM SLEW RIGHT I max 850 mA [ ↓ ] [ ↑ ] [ CLEAR ]
Back to boom functions selection menu
boom slew left function →
Back to boom functions selection menu
etc. for all boom sections
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Proportional characteristics adjustment for the BOOM 1 function with PULSAR valve types : → Display of actual value for the actual PWM boom 1 extend
BOOM 1 EXTEND PWM act 43 % [↓]
[ CLEAR ]
value →
[ ENTER ] → Activate parameter adjustment for MIN value of
BOOM 1 EXTEND PWM min 31 % [ ↓ ] [ ↑ ] [ CLEAR ]
boom 1 extend function →
boom 1 extend function →
value →
boom 1 retract function →
Back to boom functions selection menu [ ENTER ] → Activate parameter adjustment for MAX value of
BOOM 1 RETRACT PWM max 67 % [ ↑ ] [ CLEAR ]
Back to boom functions selection menu [ ENTER ] → Activate parameter adjustment for MIN value of
BOOM 1 RETRACT PWM min 23 % [ ↓ ] [ ↑ ] [ CLEAR ]
Back to boom functions selection menu → Display of actual value for the actual PWM boom 1 retract
BOOM 1 RETRACT PWM act 49 % [ ↓ ] [ ↑ ] [ CLEAR ]
Back to boom functions selection menu [ ENTER ] → Activate parameter adjustment for MAX value of
BOOM 1 EXTEND PWM max 87 % [ ↓ ] [ ↑ ] [ CLEAR ]
Back to boom functions selection menu
boom 1 retract function →
Back to boom functions selection menmu
etc. for all boom sections
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3.0 I/O status display - signals & references The status display of all inputs & outputs shows the real state of the respective input or output! ( ■ = high = +24 V / ❏ = Low = 0 V ) The arrow keys [ ↓ ] [ ↑ ] are used to move between the status displays ! [ CLEAR ] returns to the module selection of the I/O displays ! 3.1 Machine control
INP MACHINE-C1 1■2❏3❏4■5■6❏7❏8■ LED
Signal
Module / Assembly
Connector / Pin
1 2 3 4 5 6 7 8
??? Gearbox in neutral position Battery charge monitor (signal at D+) Pushbutton "Hydraulic on outriggers" Signal "High truck coolant temperature" Signal "Engine safety stop" Signal "Low truck oil pressure" Reserve Prox-switch PTO RPM
Machine control 1 (-A231) Machine control 1 (-A231) Machine control 1 (-A231) Machine control 1 (-A231) Machine control 1 (-A231) Machine control 1 (-A231) Machine control 1 (-A231) Machine control 1 (-A231)
-X231 / 05 -X231 / 17 -X231 / 19 -X231 / 28 -X231 / 10 -X231 / 23 -X231 / 21 -X231 / 13
OUTP MACHINE-C1 1■2❏3❏4■5■6❏7❏8■ LED
Signal
Module / Assembly
Connector / Pin
1 2 3 4 5 6 7 8
Engine Start Engine Stop Engine RPM speed up Engine RPM speed down Solenoid "Agitator forwards" Solenoid "Agitator backwards" Solenoid "Hydraulic on outriggers" Relay oil cooler on
Machine control 1 (-A231) Machine control 1 (-A231) Machine control 1 (-A231) Machine control 1 (-A231) Machine control 1 (-A231) Machine control 1 (-A231) Machine control 1 (-A231) Machine control 1 (-A231)
-X231 / 04 -X231 / 16 -X231 / 06 -X231 / 15 -X231 / 08 -X231 / 18 -X231 / 27 -X231 / 07
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Electrical INP MACHINE-C2 1■2❏3❏4■5■6❏7❏8■ LED
Signal
Module / Assembly
Connector / Pin
1 2 3 4 5 6 7 8
Level switch water reservoir Signal "PTO engaged" Oil filter monitor concrete pump Oil filter monitor boom hydraulics Level switch hydraulic reservoir Over-temperature switch compressor Engine Start ch. pump rams Engine Stop ch. pump rams
Machine control 2 (-A251) Machine control 2 (-A251) Machine control 2 (-A251) Machine control 2 (-A251) Machine control 2 (-A251) Machine control 2 (-A251) Machine control 2 (-A251) Machine control 2 (-A251)
-X251 / 05 -X251 / 17 -X251 / 19 -X251 / 28 -X251 / 10 -X251 / 23 -X251 / 21 -X251 / 13
OUTP MACHINE-C2 1■2❏3❏4■5■6❏7❏8■ LED
Signal
Module / Assembly
Connector / Pin
1 2 3 4 5 6 7 8
Relay "Agitator on" Solenoid "Water pump on" Relay "Boom horn" Relay "Slewing-gear horn" Solenoid "Compressor on" Solenoid "High-pressure water pump" Solenoid "End-hose unlock" Alarm output (optional !)
Machine control 2 (-A251) Machine control 2 (-A251) Machine control 2 (-A251) Machine control 2 (-A251) Machine control 2 (-A251) Machine control 2 (-A251) Machine control 2 (-A251) Machine control 2 (-A251)
-X251 / 04 -X251 / 16 -X251 / 06 -X251 / 15 -X251 / 08 -X251 / 18 -X251 / 27 -X251 / 07
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3.2 Concrete pump control
INP CP-CONTROL 1■2❏3❏4■5■6❏7❏8■ LED
Signal
Module / Assembly
1 2 3 4 5 6 7 8
Local switch concrete pump on Local switch concrete pump forwards Local switch concrete pump reverse ??? Hopper-grate limit switch Soft-start limit switch on Soft-start limit switch off CP stroke count limit switch Reserve
_____ Connector / Pin
Concrete-pump control (-A201) Concrete-pump control(-A201) Concrete-pump control(-A201) Concrete-pump control (-A201) Concrete-pump control (-A201) Concrete-pump control (-A201) Concrete-pump control (-A201) Concrete-pump control (-A201)
-X201 / 05 -X201 / 17 -X201 / 19 -X201 / 28 -X201 / 10 -X201 / 23 -X201 / 21 -X201 / 13
OUTP CP-CONTROL 1■2❏ LED
Signal
Module / Assembly
Connector / Pin
1 2
Switch valve CP forwards ON Switch valve CP reverse ON
Concrete-pump control (-A201) Concrete-pump control (-A201)
-X201 / 04 -X201 / 16
STROKE LIMITER ■■■■■■■
Tendency display prop current stroke limiter adjustment for concrete pump!
[↓]
PRESS LIMITER CP ■■■■■■
Tendency display prop current pressure limiting valve! (at present not relevant)
[↓]
HYD PRESSURE CP ■■■■■
Tendency display for pressure pick-up signal concrete pump hydraulics!
[↓]
HYD OIL TEMP ■■■■■■■■■■ Signal
Tendency display temperature sensor signal hydraulic reservoir! Module / Assembly
Output pressure-regulating valve stroke lim. CP Output pressure-regulating valve soft-start Analog input oil pressure concrete pump Analog input oil temperature hydraulics
Concrete pump control (-A201) Concrete pump control (-A201) Concrete pump control (-A201) Concrete pump control (-A201)
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Connector / Pin -X201 / 11 -X201 / 02 -X201 / 25 -X201 / 14
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Electrical 3.3 Boom control
INP BOOM-C1 1■2❏3❏4■5■6❏ LED
Signal
Module / Assembly
Connector/Pin
1 2 3 4 5 6
Cam switch boom-slew right 1 Cam switch boom-slew right 2 Cam switch boom-slew left 1 Cam switch boom-slew left 2 Boom-slew cab protection switch 1 Boom-slew cab protection switch 2
Boom control 1 (-A161) Boom control 1 (-A161) Boom control 1 (-A161) Boom control 1 (-A161) Boom control 1 (-A161) Boom control 1 (-A161)
-X161 / 07 -X161 / 17 -X161 / 26 -X161 / 08 -X161 / 25 -X161 / 27
INP BOOM-C2 1■2❏3❏4■5■6❏ LED
Signal
Module / Assembly
Connector/Pin
1 2 3 4 5 6
Cab protection switch boom 1 < 50 grd 1 Cab protection switch boom 1 < 50 grd 2 Cab protection switch boom 2 < 20 grd 1 Cab protection switch boom 2 < 20 grd 2 Cab protection switch boom 1 > 180 grd 1 Cab protection switch boom 1 > 180 grd 2
Boom control 2 (-A181) Boom control 2 (-A181) Boom control 2 (-A181) Boom control 2 (-A181) Boom control 2 (-A181) Boom control 2 (-A181)
-X181 / 07 -X181 / 17 -X181 / 26 -X181 / 08 -X181 / 25 -X181 / 27
BOOM-SLEW RIGHT ■■■■■■■■■■
Tendency display prop output value boom-
[↓] BOOM-SLEW LEFT ■■■■■ [↓] BOOM 1 EXTEND ■■■■■■■■■■
Tendency display prop output value boom 1
[↓] BOOM 1 RETRACT ■■■■ [↓] BOOM 2 EXTEND ■■■■■■■■■■
Tendency display prop output value boom 2!
[↓]
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BOOM 2 RETRACT ■■■■■■ [↓]
BOOM 3 EXTEND ■■■■
Tendency display prop output value boom 3!
[↓]
BOOM 3 RETRACT ■■■■■■■■■■ [↓]
BOOM 4 EXTEND ■■■■■
Tendency display prop output value boom 4!
[↓]
BOOM 4 RETRACT ■■■■■ [↓]
BOOM 5 EXTEND ■■
Tendency display prop output value boom 5
[↓]
BOOM 5 RETRACT ■■■■■■■ Signal
Module / Assembly
Connector / Pin
Output "boom-slew right" solenoid Output "boom-slew left" solenoid Output "boom 1 extend" solenoid Output "boom 1 retract" solenoid Output "boom 2 extend" solenoid Output "boom 2 retract" solenoid Output "boom 3 extend" solenoid Output "boom 3 retract" solenoid Output "boom 4 extend" solenoid Output "boom 4 retract" solenoid Output "boom 5 extend" solenoid Output "boom 5 retract" solenoid
Boom control (-A161) Boom control 1 (-A161) Boom control 1 (-A161) Boom control 1 (-A161) Boom control 1 (-A161) Boom control 1 (-A161) Boom control 2 (-A181) Boom control 2 (-A181) Boom control 2 (-A181) Boom control 2 (-A181) Boom control 2 (-A181) Boom control 2 (-A181)
-X161 / 21 -X161 / 12 -X161 / 03 -X161 / 13 -X161 / 04 -X161 / 09 -X181 / 21 -X181 / 12 -X181 / 03 -X181 / 13 -X181 / 04 -X181 / 09
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Electrical 3.4 Rear panel
INP REAR PANEL 1 1■2❏3❏4■5■6❏7❏8■ LED
Signal
Module / Assembly
Connector / Pin
1 2 3 4 5 6 7 8
Switch signal "Rear panel" Pushbutton signal "Engine start" Pushbutton signal "Engine stop" Pushbutton signal "r.p.m.speed up" Pushbutton signal "r.p.m. speed down" Switch signal "CP forwards" Switch signal "CP backwards" Switch signal "Agitator forwards"
Panel at step-ladder (-A1) Panel at step-ladder (-A1) Panel at step-ladder (-A1) Panel at step-ladder (-A1) Panel at step-ladder (-A1) Panel at step-ladder (-A1) Panel at step-ladder (-A1) Panel at step-ladder (-A1)
-1X / 01 -1X / 02 -1X / 03 -1X / 04 -1X / 05 -1X / 06 -1X / 07 -1X / 08
INP REAR PANEL 2 1■2❏3❏4■5■6❏7❏8■ LED
Signal
Module / Assembly
Connector / Pin
1 2 3 4 5 6 7 8
Switch signal "Agitator backwards" Switch signal "Agitator manual ON" Switch signal "Agitator automatic ON" Pushbutton signal"Boom-horn ON" Switch signal "Water pump ON" Switch signal "Compressor ON" Switch signal "High-pressure WP ON" Pushbutton signal "End-hose unlock"
Panel at step-ladder (-A1) Panel at step-ladder (-A1) Panel at step-ladder (-A1) Panel at step-ladder (-A1) Panel at step-ladder (-A1) Panel at step-ladder (-A1) Panel at step-ladder (-A1) Panel at step-ladder (-A1)
-1X / 09 -1X / 10 -1X / 11 -1X / 12 -1X / 13 -1X / 14 -1X / 15 -1X / 16
INP REAR PANEL 3 1■2❏3❏4■ LED
Signal
Module / Assembly
Connector / Pin
1 2-4
Agitator reverse Reserve
Panel at step-ladder (-A1) Panel at step-ladder (-A1)
-1X / 17 -1X / 18 - 20
OUTP REAR PANEL 1■2❏3❏4■ LED
Signal
Module / Assembly
Connector / Pin
1 2-4
Cab protection warning lamp Reserve
Panel at step-ladder (-A1) Panel at step-ladder (-A1)
-1X / 21 -1X / 22 - 24
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POT REAR PAN SL ■■■■■■■
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Tendency display potentiometer input signal stroke limiter concrete pump !
Signal
Module / Assembly
Connector / Pin
Potentiometer input "Stroke limiter CP"
Panel at step-ladder (-A1)
-1X / 25
3.5 Extension module
INP EXTENSION 1■2❏3❏4■5■6❏7❏8■ LED
Signal
Module / Assembly
Connector / Pin
1 2 3 4 5 6 7 8
Cycle switch lubric. circuit 1 (boom) Cycle switch lubric. circuit 2 (CP) Cycle switch lubric. circuit 3 (outriggers) Input "Central lubrication inhibit" Free digital input 1 Free digital input 2 Free digital input 3 Free digital input 4
Machine control 3 (-A271) Machine control 3 (-A271) Machine control 3 (-A271) Machine control 3 (-A271) Machine control 3 (-A271) Machine control 3 (-A271) Machine control 3 (-A271) Machine control 3 (-A271)
-X271 / 05 -X271 / 17 -X271 / 19 -X271 / 28 -X271 / 10 -X271 / 23 -X271 / 21 -X271 / 13
OUTP EXTENSION 1■2❏3❏4■5■6❏7❏8■ LED
Signal
Module / Assembly
Connector / Pin
1 2 3 4 5 6 7 8
Lubricating pump on Lubric. distrib. valve circuit 1 (boom) Lubric. distrib. valve circuit 2 (CP) Lubric. distrib. valve circuit 3 (outriggers) Free digital output 1 Free digital output 2 Free digital output 3 Free digital output 4
Machine control 3 (-A271) Machine control 3 (-A271) Machine control 3 (-A271) Machine control 3 (-A271) Machine control 3 (-A271) Machine control 3 (-A271) Machine control 3 (-A271) Machine control 3 (-A271)
-X271 / 04 -X271 / 16 -X271 / 06 -X271 / 15 -X271 / 08 -X271 / 18 -X271 / 27 -X271 / 07
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Electrical 4.0 Fault messages and fault causes 4.1Introduction
Each fault message has its own fault code permitting to obtain further information about a special fault from this list. This fault code consists of the machine section identification, a number and the fault category ! A fault message is shown on the rear panel display as follows : MALFUNCTION !!! (CODE) FAULT MESSAGE
"MALFUNCTION" flashing Fault code and continuous malfunction message text !
The following letters identify the machine section: S = System F = Remote control A = General machine D = Truck engine or PTO
B = Concrete pump M = Boom control Z = Central lubrication E = Extensions
Three fault categories can be displayed: L = minor fault, horn cancelling from control box possible. (rectification of fault cause required only upon completion of job !) S = severe fault, horn cancelling from control box not possible. (immediate rectification of fault cause required !) M = operating fault, only message displayed, cancelling not required. (no storage of fault in diagnosis system !)
Example : B01S
B 01 S
= machine section "concrete pump" = number 01 = fault category "severe"
Meaning of the "Disconnected" or "Overload" fault messages The "Disconnected" fault is reported when the cable from this output to the relay / solenoid is broken. This fault can only be detected when the output is not activated ! The cause of this fault is either a broken cable or a disconnected solenoid connector ! The "Overload" fault is reported when an inadmissibly high current has been detected for this output. This fault can only be detected when the output is activated! The cause of this fault is either a short-circuit in the electric cable to the relay / solenoid or a defect of the solenoid coil (charred) ! This applies to all following faults reported as "Disconnected" or "Overload" faults !!!
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4.2 Control diagnosis electronic modules(fault code S !)
Code
Message / source of fault message / fault detection time
S01L
Boom-Control Board 1 Fault
(system fault !)
Module monitoring by central board ! S02L
Boom-Control Board 2 Fault Module monitoring by central board !
(system fault !)
S03L
Machine-Control Board 1 Fault Module monitoring by central board !
(system fault !)
S04L
Machine-Control Board 2 Fault Module monitoring by central board !
(system fault !)
S05L
Machine-Control Board 3 Fault Module monitoring by central board !
(system fault !)
S06L
Concrete-Pump Control Board Fault Module monitoring by central board !
(system fault !)
S07L
Rear Panel Board Fault Module monitoring by central board !
(system fault !)
S08L
Info-Center Board Fault Module monitoring by central board !
(system fault !)
S09L
Network-Fault / Central-Board Fault When network monitor on central board detects
(system fault !)
a malfunction of the CAN network ! S10L
Network-Fault Central Board - Info-Center Detected by Info-Center if CAN communication with
(system fault !)
Central Board cannot be established ! System faults are reported when the module in question does not work perfectly. All modules are regularly checked by the central module ! In the event of a system fault, the electric control of the truck-mounted concrete pump should be switched off once for ca. 5 secs. with the key-operated switch in the driver's cab. This fault message may have the following causes: - power supply to one of the modules interrupted (check fuse !) - electronic components on module Fault, e.g. storage defect(replace module !) - communication fault with central module(replace module!)
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Electrical 4.3 Remote-control system diagnosis (fault code F!)
Code
Message / source of fault message / fault detection time
F01M
Emergency-Stop on Radio Control Box active Source: REMOTE-CONTROL DIAGNOSIS Indicated when emergency shut-off button on radio control box has been actuated !
F02M
Actuator Switches on Control Box out of Neutral Position Source: REMOTE-CONTROL DIAGNOSIS Indicated when control box actuators after activation of radio control box have not been once in neutral position !
F03M
No Radio Control Transmission Source: REMOTE-CONTROL DIAGNOSIS Indicated when radio control box is off or when - for other reasons - there is no radio contact between transmitter and revceiver.
F05L
Joy-Stick 1 from Remote-Control Fault Source: REMOTE-CONTROL DIAGNOSIS Indicated when control box has detected a fault at joy-stick 1 !
F06L
Joy-Stick 2 from Remote-Control Fault Source: REMOTE-CONTROL DIAGNOSIS Indicated when control box has detected a fault at joy-stick 2 !
F07L
Joy-Stick 3 from Remote-Control Fault Source: REMOTE-CONTROL DIAGNOSIS Indicated when control box has detected a fault at joy-stick 3 !
F08M
CAN-Transmission with Remote-Control Fault Source: REMOTE-CONTROL DIAGNOSIS Indicated after 30 seconds when CAN data transmission between control unit and remote-control system is interrupted
F09L
Emergency-Stop Switch on Radio Control Box Fault Source: REMOTE-CONTROL DIAGNOSIS Indicated when control box has detected a fault at emergency-stop button !
F10M
Radio Control Signal with Faulty Address received Source: REMOTE-CONTROL DIAGNOSIS Indicated when radio receiver has received a radio data telegram from another radio control box or from a wrongly adjusted radio control box.
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4.4 Machine diagnosis-General (fault code A!)
Code
Message / source of fault message / fault detection time
A01M
Emergency-Stop on Machine active Source: DIAGNOSIS SYSTEMfault detection time :20 sec.! Indicated when central board detects that all electronic modules except the central module, operating panel at step-ladder and Info-Center have been shut off !
A02S
Hydraulic Oil Temperature exceeded Source: HYD OIL TEMP / CPfault detection time:5 sec.! Indicated when oil temperature sensor detects that the maximum oil temperature hzas been exceeded (set value CP module) !
A03L
Temperatur Transmitter Hydraulic Oil Fault Source: HYD OIL TEMP / CP inputfault detection time:30 sec.! Indicated when monitor detects sensor oil temperature outside the valid range ( 500 - 2000 ohms ) !
A04L
Exchange Hydraulic Oil Filter Boom Source: Input 4 / INP MACHINE-C2fault detection time :10 Sek.! Indicated when pressure filter monitor (differential pressure switch in oil filter) detects excessive pressure drop in hydraulic oil filter at an oil temperature above 30˚ C !
A05L
Exchange Hydraulic Oil Filter Concrete Pump Source: Input 3 / INP MACHINE-C2fault detection time :10 Sek.! Indicated when pressure filter monitor (differential pressure switch in oil filter) detects excessive pressure drop in hydraulic oil filter at an oil temperature above 30˚ C !
A06L
Low Level Hydraulic Oil Source: Input 5 / INP MACHINE-C2fault detection time :3 Sek.! Indicated when level switch in hydraulic oil reservoir (option !) detects insufficient oil level !
A07M
Low Level Water Reservoir Source: Input 1 / INP MACHINE-C2fault detection time :3 Sek.! Indicated when level switch in water tank (option !) detects insufficient level in tank for cleaning water (dry-run protection) !
A08L
High Temperature Air-Compressor Source: Input 6 / INP MACHINE-C2fault detection time :3 Sek.!
Indicated when over-temperature protection in compressor (bi-metal switch) responds !
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Code
Message / source of fault message / fault detection time
A09M
Operating Mode for Changing Pump Rams active Source: Input 1 / INP CONCRETE PUMPoperating mode display ! Indicated when "ram change" mode has been selected at separate controls for "CP inching" !
A10M
Actuator Switches on Rear Panel out of Neutral Position Source: DIAGNOSIS SYSTEM Indicated when actuators on rear panel have not been at least once in neutral position after an EMERGENCY SHUT-OFF or after switching over from REMOTE to LOCAL (rear panel!) control.
A30L A31L A32L A33L A34L A35L A36L A37L A38L A39L
Disconnected Oil-Cooler Relay Overload Oil-Cooler Relay Disconnected Vibrator Relay Overload Vibrator Relay Disconnected Boom-Horn Relay Overload Boom Horn Relay Disconnected Slew-Horn Relay Overload Slew-Horn Relay Disconnected Alarm Output Overload Alarm Output
A40L A41L A42L A43L A44L A45L A46L A47L A48L A49L
Disconnected Waterpump Solenoid Overload Waterpump Solenoid Disconnected Compressor Solenoid Overload Compressor Solenoid Disconnected Agitator Forwards Solenoid Overload Agitator Forwards Solenoid Disconnected Agitator Reverse Solenoid Overload Agitator Reverse Solenoid Disconnected Hydraulic-on-Outriggers Solenoid Overload Hydraulic-on-Outriggers Solenoid
A50L A51L A52L
Disconnected High-Pressure Waterpump Solenoid Overload High-Pressure Waterpump Solenoid Disconnected End-Hose unlocking Solenoid
A53L
Overload End-Hose unlocking Solenoid
For "Disconnected" and "Overload" faults cf. "Introduction" (4.1) !
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4.5 Engine/PTO Diagnosis (fault code D!)
Code
Message / source of fault message / fault detection time
D01S
Engine Safety Stop / High Coolant Temperature Source: Input 4 / INP MACHINE-C1fault detection time:5 sec.! Indicated when engine saftety stop (option !) has occurred because of excessive temperature of vehicle engine (cooling-water temperature switch) !
D02S
Engine Safety Stop Source: Input 5 / INP MACHINE-C1fault detection time:5 sec.! Indicated when engine safety stop has occurred from customer-specific option (e.g. hydraulic oil levelfalling)
D03S
Engine Safety Stop / Low Truck Oil Pressure Source: Input 6 / INP MACHINE-C1fault detection time:5 sec.! Indicated when engine safety stop (option !) has occurred from insufficient vehicle engine oil pressure (oil pressure switch) !
D04L
PTO is not working or Prox-Switch PTO-RPM Fault Source: DIAGNOSIS SYSTEMfault detection time:120 sec.! Indicated when - in spite of engine running (D+ signal) and PTO engaged (PTO limit switch) - no pulses are transmitted from RPM sensor at pump transfer gearbox (inductive proximity switch) for more than 30 seconds.
D05L
PTO RPM Exceeded Source: DIAGNOSIS SYSTEMfault detection time:5 sec.! Indicated when PTO RPM exceeds the set maximum limit (set value machine control 1 module) !
D06S
Battery Charging on Truck Fault Source: DIAGNOSIS SYSTEMfault detection time:120 sec.! Indicated when - in spite of PTO RPM detected (pulses from prox-switch and PTO engaged) - there is no D+ signal (alternator running) !
D07L
Indicator switch PTO=ON/OFF Fault Source: DIAGNOSIS SYSTEMfault detection time:120 sec.! Indicated when - in spite of engine running (D+ signal) and PTO RPM detected (pulses from proxswitch) - there is no signal from "PTO engaged" indicator switch.
D30L D31L D32L D33L D34L D35L D36L D37L
Disconnected Engine Start Relay Overload Engine Start Relay Disconnected Engine Stop Relay Overload Engine Stop Relay Disconnected Engine Speed-Up Relay Overload Engine Speed-Up Relay Disconnected Engine Speed-Down Relay Overload Engine Speed-Down Relay
For "Disconnected" and "Overload" faults cf. "Introduction" (4.1) !
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Electrical 4.6 Concrete pump diagnosis (fault code B!)
Code
Message / source of fault message / fault 0detection time
B01L
Power Limiter Concrete Pump active Source: Input HYD OIL TEMPfault detection time:5 sec.! Indicated when the temperature of the hydraulic oil in the reservoir has exceeded the set limit (set value CP module) and after the concrete pump power limiter has been activated !
B02L
Pressure Limiter Concrete Pump active Source: Input CP OIL PRESSUREfault detection time:15 sec.! Indicated when the pressure of the concrete pump hydraulic oil has exceeded the set limit (set value CP module) and after the electronic pressure limiter has been activated !
B03L
Pressure Transmitter CP Hydraulics Fault Source: Input CP OIL PRESSUREfault detection time:30 sec.! Indicated when monitor detects that measured value of hydraulic oil pressure transmitter is out of valid range ( 4 - 20 mA ) !
B04L
Prox-Switch Soft-Start / Pumped Volume Fault Quelle : DIAGNOSIS SYSTEMfault detection time:120 sec.! Indicated when - within 120 seconds of concrete pump operation (engine running, PTO engaged and CP forwards or backwards ON) no pulses from the soft-start / pump volume proximity switches are being detected !
B05L
Hopper Grate open / CP jammed / Prox-Switch Stroke Counter Fault Source: DIAGNOSIS SYSTEMfault detection time:120 sec.! Indicated when - within 120 seconds of concrete pump operation (engine running, PTO engaged and CP forwards or backwards ON) no pulses from the stroke counter proximity switch on the concrete pump are being detected! ATTENTION, hopper grate must be closed and CP must not be jammed !
B30L B31L B32L B33L B34L B35L B36L B37L
Disconnected CP Forwards Solenoid Overload CP Forwards Solenoid Disconnected CP Reverse Solenoid Overload CP Reverse Solenoid Disconnected CP Stroke Limiter Solenoid Overload CP Stroke Limiter Solenoid Disconnected CP Pressure Limiter CP Solenoid Overload CP Pressure Limiter CP Solenoid
For "Disconnected" and "Overload" faults cf. "Introduction" (4.1) !
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4.7 Boom control diagnosis (fault code M!)
Code
Message / source of fault message / fault detection time
M01L
Limit Switch Boom Slewing Right 1 Fault Source: Input 1 / INP BOOM-C1statistical function: (5 x 5 sec.!) Indicated when limit switch monitor detects that the redundant limit switches "boom-slew right" 1 & 2 are in different signal states.
M02L
Limit Switch Boom Slewing Right 2 Fault Source: Input 2 / INP BOOM-C1statistical function: (5 x 5 sec.!) Indicated when limit switch monitor detects that the redundant limit switches "boom-slew right" 1 & 2 are in different signal states.
M03L
Limit Switch Boom Slewing Left 1 Fault Source: Input 3 / INP BOOM-C1statistical function: (5 x 5 sec.!) Indicated when limit switch monitor detects that the redundant limit switches "boom-slew left" 1 & 2 are in different signal states.
M04L
Limit Switch Boom Slewing Left 2 Fault Source: Input 4 / INP BOOM-C1statistical function : (5 x 5 sec.!) Indicated when limit switch monitor detects that the redundant limit switches "boom-slew left" 1 & 2 are in different signal states.
M05L
Truck Cab Protection Switch 1 Boom 2 < 20 Degree Fault (cab protection) Source: Input 3 / INP BOOM-C2statistical function: (5 x 5 sec.!) Indicated when limit switch monitor detects that the redundant limit switches "boom 2 < 20 degrees" 1 & 2 are in different signal states.
M06L
Truck Cab Protection Switch 2 Boom 2 < 20 Degree Fault (cab protection) Source: Input 4 / INP BOOM-C2statistical function: (5 x 5 sec.!) Indicated when limit switch monitor detects that the redundant limit switches "boom 2 < 20 degrees" 1 & 2 are in different signal states.
M07L
Truck Cab Protection Switch 1 Boom 1 < 50 Degree Fault (cab protection) Source: Input 1 / INP BOOM-C2statistical function: (5 x 5 sec.!) Indicated when limit switch monitor detects that the redundant limit switches "boom 1 < 50 degrees" 1 & 2 are in different signal states.
M08L
Truck Cab protection Switch 2 Boom 1 < 50 Degree Fault (cab protection) Source: Input 2 / INP BOOM-C2statistical function: (5 x 5 sec.!) Indicated when limit switch monitor detects that the redundant limit switches "boom 1 < 50 degrees" 1 & 2 are in different signal states.
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Electrical Code
Message / source of fault message / fault detection time
M09L
Truck Cab Protection Switch 1 Boom 1 > 180 Degree Fault (cab protection) Source: Input 5 / INP BOOM-C2statistical function : (5 x 5 sec.!) Indicated when limit switch monitor detects that the redundant limit switches "boom 1 > 180 degrees" 1 & 2 are in different signal states.
M10L
Truck Cab Protection Switch 2 Boom 1 > 180 Degree Fault (cab protection) Source: Input 6 / INP BOOM-C2statistical function: (5 x 5 sec.!) Indicated when limit switch monitor detects that the redundant limit switches "boom 1 > 180 degrees" 1 & 2 are in different signal states.
M11L
Truck Cab Protection Switch 1 Boom Slewing Fault (cab protection) Source: Input 5 / INP BOOM-C1statistical function: (5 x 5 sec.!) Indicated when limit switch monitor detects that the redundant limit switches "cab protection boom slewing" 1 & 2 are in different signal states.
M12L
Truck Cab Protection Switch 2 Boom Slewing Fault (cab protection) Source: Input 6 / INP BOOM-C1statistical function: (5 x 5 sec.!) Indicated when limit switch monitor detects that the redundant limit switches "cab protection boom slewing" 1 & 2 are in different signal states.
Code
Message / source of fault message / fault detection time
M30L M31L M32L M33L M34L M35L M36L M37L M38L M39L M40L M41L M42L M43L M44L M45L M46L M47L M48L M49L M50L M51L M52L M53L
Disconnected Boom Slewing Right Solenoid Overload Boom Slewing Right Solenoid Disconnected Boom Slewing Left Solenoid Overload Boom Slewing Left Solenoid Disconnected Boom 1 Extend Solenoid Overload Boom 1 Extend Solenoid Disconnected Boom 1 Retract Solenoid Overload Boom 1 Retract Solenoid Disconnected Boom 2 Extend Solenoid Overload Boom 2 Extend Solenoid Disconnected Boom 2 Retract Solenoid Overload Boom 2 Retract Solenoid Disconnected Boom 3 Extend Solenoid Overload Boom 3 Extend Solenoid Disconnected Boom 3 Retract Solenoid Overload Boom 3 Retract Solenoid Disconnected Boom 4 Extend Solenoid Overload Boom 4 Extend Solenoid Disconnected Boom 4 Retract Solenoid Overload Boom 4 Retract Solenoid Disconnected Boom 5 Extend Solenoid Overload Boom 5 Extend Solenoid Disconnected Boom 5 Retract Solenoid Overload Boom 5 Retract Solenoid
For "Disconnected" and "Overload" faults cf. "Introduction" (4.1) !
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4.8 Central lubrication/extension diagnosis (fault code Z/E!)
Code
Message / source of fault message / fault detection time
Z01L
Malfunction Lubrication Boom / Slewing Gear Source: Input 1 / INP EXTENSIONfault detection time : Parameter ! Indicated when - after activation of the "boom / slewing gear" greasing circuit - there are no pulses coming from the corresponding cycle switch in the progressive distributor after a certain time.
Z02L
Malfunction Lubrication CP / Agitator Source: Input 2 / INP EXTENSIONfault detection time : Parameter ! Indicated when - after activation of the "CP / agitator" greasing circuit - there are no pulses coming from the corresponding cycle switch in the progressive distributor after a certain time.
Z03L
Malfunction Lubrication Outriggers Source: Input 3 / INP EXTENSIONfault detection time : Parameter ! Indicated when - after activation of the "outrigger" greasing circuit - there are no pulses coming from the corresponding cycle switch in the progressive distributor after a certain time.
Z04L
Lubrication Switched OFF Source: Input 4 / INP EXTENSIONfault detection time :5 sec.! Indicated when central lubrication has been switched off with the service switch.
Z30L Z31L Z32L Z33L
Disconnected Lubrication Pump Relay Overload Lubrication Pump Relay Disconnected Lubrication Boom Solenoid Overload Lubrication Boom Solenoid Disconnected Lubrication CP / Agitator
Z34L Z35L
Solenoid Overload Lubrication CP / Agitator Solenoid
Z36L Z37L
Disconnected Lubrication Outriggers Solenoid Overload Lubrication Outriggers Solenoid
E30L E31L E32L E33L E34L E35L E36L E37L
Disconnected PLC-Outp 1 Overload PLC-Outp 1 Disconnected PLC-Outp 2 Overload PLC-Outp 2 Disconnected PLC-Outp 3 Overload PLC-Outp 3 Disconnected PLC-Outp 4 Overload PLC-Outp 4
For "Disconnected" and "Overload" faults cf. "Introduction" (4.1) !
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Electrical 5.0 Output signal interdependence list
The present list supplies information about the input signals and control states governing the most important output signals !
Boom control Boom-slewing right / left (prop. or switched output !)depends on : - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of Local / Remote mode of operation ! - Slewing gear limit switch 1 or 2 on slewing ring not actuated ! - Boom limiting (cab protection at KVM 52 & S 45 SX) not active ! - REMOTE mode selected and RAM CHANGE mode not activated ! - Slewing function on remote-control box activated, [HARE/SNAIL] switch not in "0" position ! Boom 1/2 retract/extend (prop. or switched output !)depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of Local / Remote mode of operation ! - Boom limiting (cab protection at KVM 52 & S 45 SX) not active ! - REMOTE mode selected and RAM CHANGE mode not activated ! - Boom function 1/2 on remote-control box activated, [HARE/SNAIL] switch not in "0" position ! Boom 3/4/5 retract/extend (prop. or switched output !)depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of Local / Remote mode of operation ! - REMOTE mode selected and RAM CHANGE mode not activated ! - Boom function 3/4/5 on remote-control box activated, [HARE/SNAIL] switch not in "0" position !
Concrete pump control Concrete pump forwards/backwards ON (switched output !) depends on: - Emergency-stop not actuated ! - Limit switch at hopper grate not actuated and CP not blocked at control block ! - Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation ! - Correct mode of operation LOCAL / REMOTE selected and RAM CHANGE mode not activated ! - Concrete pump FORWARDS or BACKWARDS activated on remote-control box or at rear panel ! CP stroke limiting (prop. output !) depends on: - Emergency-stop not actuated ! - Correct mode of operation LOCAL / REMOTE selected and RAM CHANGE mode not activated ! - Concrete pump FORWARDS or BACKWARDS activated ! - Stroke limiter adjustment on remote-control box or at rear panel ! - Limiting functions and soft-start / automatic pumping rate increase, if activated ! Agitator ON (switched output !) depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation ! - Limit switch at hopper grate not actuated ! - Correct mode of operation LOCAL / REMOTE selected ! - Agitator activated on remote-control box or at rear panel ! - Momentary contact functions "Agitator reversing" ! Vibrator ON (switched output !) depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation !
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Electrical
- Correct mode of operation LOCAL / REMOTE selected ! - Vibrator activated on remote-control box or at rear panel in MANUAL mode or vibrator in AUTO mode and CP FORWARDS activated at the same time !
Cleaning systems Water pump ON (switched output !) depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation ! - Correct mode of operation LOCAL / REMOTE selected ! - Water tank level switch indicates sufficient amounts of water in tank ! (dry running protection for water pump !) - Water pump activated on remote-control box or at rear panel ! Compressor ON (switched output !) depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation! - Correct mode of operation LOCAL / REMOTE selected ! - Compressor activated on remote-control box or at rear panel!
Truck engine control Engine Start (switched output !) depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation ! - Correct mode of operation LOCAL / REMOTE selected and RAM CHANGE mode not activated ! - Gearbox in neutral position ! - Engine not yet running (D+ signal) ! - Safety delay of "Engine Stop" command (ca. 5 seconds) already elapsed ! - Engine Start activated on remote-control box or at rear panel ! Engine Stop (switched output !) depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation ! - Correct mode of operation LOCAL / REMOTE selected and RAM CHANGE mode not activated ! - Gearbox in neutral position ! - Engine Stop activated on remote-control box or at rear panel! Engine RPM +/- adjust (switched output !) depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation! - Correct mode of operation LOCAL / REMOTE selected and RAM CHANGE mode not activated! - Engine RPM +/- adjust activated on remote-control box or at rear panel!
Service Manual
623
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Electrical
Info-Center Menu Overview
Status: 03.02.97
INFO-SYSTEM Enter=On
[ ... ] = key !
[ENTER]
PUMPED VOLUME ↓/ /Enter/Clear [↓] [↑]
OPERATION DATA ↓/↑/Enter/Clear
→ [ENTER] → ← [CLEAR] ←
PUMPED ON JOB ~ 1752.3 cbm
(S !)
→ [START] →
Restart delivery-rate measurement!
------------------------------------------------------------------------------------------------------------------------
→ [ENTER] → ← [CLEAR] ←
HYD OIL TEMP 62 ß C
Display temperature of oil in hydraulic reservoir !
[↓] [↑]
PTO SHAFT RPM 1270 rpm
Display RPM of PTO shaft !
[↓] [↑]
HYD PRESSURE CP 159 bars
Display concrete pump hydraulic oil pressure !
[↓] [↑]
CONCR-PUMP HOURS 328.3 h
Concrete pump operating hours !
[↓] [↑]
BOOM HOURS 406.1 h [↓] [↑]
Placing boom operating hours !
[↓] [↑]
PTO HOURS 469.8 h
PTO operating hours !
[↓] [↑]
TOTAL STROKES CP 1398743 strokes
Total number of concrete pump strokes !
[↓] [↑]
TOTAL VOL. PUMPED 109125 cbm
Total pumped volume of concrete pump !
[↓] [↑]
STROKES PER MIN 21 strokes/min
Actual number of strokes of concrete pump unit !
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MALFUNCTION LIST ↓/↑/Enter/Clear
→ [ENTER] → ← [CLEAR] ←
16.03.95 / 12:34 (Code) fault text
PRINT
Electrical Display of last stored fault message !
[↓] [↑] 14.02.95 / 10:17 (Code) fault text [↓] [↑]
LUBRICATION-UNIT ↓/↑/Enter/Clear
Display of previous fault message !
[↓] [↑] etc ! ------------------------------------------------------------------------------------------------------------------------
→ [ENTER] → ← [CLEAR] ←
MANUAL LUBRIC. CP & Agitator
→ [START] →
Manual lubrication of concrete pump and agitator !
[↓] [↑]
MANUAL LUBRIC. Boom [↓] [↑]
Manual lubrication of boom and slewing gear !
[↓] [↑]
MANUAL LUBRIC. Outriggers
Manual lubrication of outriggers!
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I/O-STATUS DISPL ↓/↑/Enter/Clear
→ [ENTER] → ← [CLEAR] ←
MACHINE-CONTROL ↓/ /Enter/Clear
Display of I/O status of individual control modules
[↓] [↑]
CP-CONTROL ↓/↑/ENTER/CLEAR
Cf. page 3 I/O display sub-menu
[↓] [↑]
BOOM-CONTROL ↓/↑/ENTER/CLEAR [↓] [↑]
[↓] [↑]
REAR PANEL ↓/↑/ENTER/CLEAR [↓] [↑]
EXTENSION I/O /↑/ENTER/CLEAR -----------------------------------------------------------------------------------------------------------------------INTERNAL TIMER ↓/↑/Enter/Clear [↓] [↑] SCROLLING ↓/↑/Enter/Clear [↓] [↑]
→ [ENTER] → ← [CLEAR] ←
DATE 23.08.95 TIME 16:32
Display of date & time
-----------------------------------------------------------------------------------------------------------------------→ [ENTER] → ← [CLEAR] ←
Scroll rate 400 ms
→ [ENTER] → ← [ENTER] ←
Setting of scroll rate with ↓ & ↑ keys
------------------------------------------------------------------------------------------------------------------------
Service Manual
625
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Electrical PARAMETER /↑/Enter/Clear
→ [ENTER] → ← [CLEAR] ←
PASSWORD **** ↓/↑/Enter/Clear
Password entry for parameter adjustment
[↓] [↑]
EFFICIENCY CP ↓/↑/Enter/Clear [↓] [↑]
LUBRIC. PARAM ↓/↑/Enter/Clear [↓] [↑]
PROP-CUR SLEW ↓/↑/Enter/Clear [↓] [↑]
PROP-CUR BOOM 1 ↓/↑/Enter/Clear [↓] [↑]
PROP-CUR BOOM 2 ↓/↑/Enter/Clear [↓] [↑]
PROP-CUR BOOM 3 ↓/↑/Enter/Clear [↓] [↑]
PROP-CUR BOOM 4 ↓/↑/Enter/Clear [↓] [↑]
PROP-CUR BOOM 5 ↓/↑/Enter/Clear
626
Service Manual
Cf. page 5 Parameter adjustment menu
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Sub-menu I/O display overview MACHINE-CONTROL ↓/ /ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
PRINT
Electrical Status : 03.02.97
INP MACHINE-C1
1■2❏3■4❏5❏6■7■8❏
Machine-control 1 Digital-inputs
[↓] [↑]
OUTP MACHINE-C1
1■2❏3■4❏5❏6■7■8❏ [↓] [↑]
Machine-control 1 Digital-outputs
[↓] [↑]
INP MACHINE-C2
1■2❏3■4❏5❏6■7■8❏
Machine-control 2 Digital-inputs
[↓] [↑]
OUTP MACHINE-C2
1■2❏3■4❏5❏6■7■8❏
Machine-control 2 Digital-outputs
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CP-CONTROL ↓/↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
INP CP-CONTROL
1■2❏3■4❏5❏6■7■8❏
Concrete pump control Digital-inputs
[↓] [↑]
OUTP CP-CONTROL
1■2❏
Concrete pump control Digital-outputs
[↓] [↑]
STROKE LIMITER
■■■■■■■ [↓] [↑]
Concrete pump control Prop-output stroke limiter CP
[↓] [↑]
PRESS LIMITER CP
■■
Concrete pump control Prop-output pressure limiting
[↓] [↑]
HYD PRESSURE CP
■■■■■■
Concrete pump control Analogue-input oil pressure CP
[↓] [↑]
HYD OIL TEMP
■■■
Concrete pump control Analogue-input hydraulic oil temperature
------------------------------------------------------------------------------------------------------------------------
Service Manual
627
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SERVICE TRAINING
Electrical BOOM-CONTROL ↓/↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
INP BOOM-C1
1■2❏3■4❏5❏6■
Boom-control 1 Digital-inputs
[↓] [↑] INP BOOM-C2
1■2❏3❏4■5❏6❏
Boom-control 2 Digital-inputs
[↓] [↑] BOOM-SLEW RIGHT
■■
Boom-control 1 Prop-output boom-slew right
[↓] [↑]
BOOM-SLEW LEFT
■■■■■■■
Boom-control 1 Prop-output boom-slew left
[↓] [↑]
BOOM 1 EXTEND
■■■■■■■
Boom-control 1 Prop-output boom 1 extend
[↓] [↑]
BOOM 1 RETRACT
■■■■■■■
Boom-control 1 Prop-output boom 1 retract
[↓] [↑]
BOOM 2 EXTEND
■■■■■
[↓] [↑]
Boom-control 1 Prop-output boom 2 extend
[↓] [↑]
BOOM 2 RETRACT
■■■■■
Boom-control 1 Prop-output boom 2 retract
[↓] [↑]
BOOM 3 EXTEND
■■■■■■
Boom-control 2 Prop-output boom 3 extend
[↓] [↑]
BOOM 3 RETRACT
■■■
Boom-control 2 Prop-output boom 3 retract
[↓] [↑]
BOOM 4 EXTEND
■■■■■■
Boom-control 2 Prop-output boom 4 extend
[↓] [↑]
BOOM 4 RETRACT
■■■■■■
[↓] [↑]
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Service Manual
Boom-control 2 Prop-output boom 4 retract
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BOOM 5 EXTEND
■■■■■■■
PRINT
Electrical Boom-control 2 Prop-output boom 5 extend
[↓] [↑]
BOOM 5 RETRACT
■■■■
Boom-control 2 Prop-output boom 5 retract
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REAR PANEL ↓/↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
INP REAR PANEL 1
1■2❏3■4❏5❏6■7■8❏
Rear panel Digital-inputs 1
[↓] [↑]
INP REAR PANEL 2
1■2❏3■4❏5❏6■7■8❏
Rear panel Digital-inputs 2
[↓] [↑]
INP REAR PANEL 3
1■2❏3■4❏ [↓] [↑]
Rear panel Digital-inputs 3
[↓] [↑]
OUTP REAR PANEL
1■2❏3❏4❏
Rear panel Digital-outputs
[↓] [↑]
POT REAR PAN SL
■■■■■■■
Rear panel Analogue-input stroke limiter CP
------------------------------------------------------------------------------------------------------------------------
EXTENSION I/O /↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
INP EXTENSION
1■2❏3■4❏5❏6■7■8❏
Machine-control 3 Digital-inputs
[↓] [↑]
OUTP EXTENSION
1■2❏3■4❏5❏6■7■8❏
Service Manual
Machine-control 3 Digital-outputs
629
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Electrical
Parameter adjustment menu overview
Status : 03.02.97
Entry of PASSWORD and access to parameter adjustment menu PARAMETER /↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
PASSWORD **** ↓/↑/ENTER/CLEAR
Enter password with [↓] [↑] keys
[↓] [↑]
PASSWORD 1234 ↓/↑/ENTER/CLEAR [↓] [↑]
End password entry with [ENTER] key
[ENTER]
PASSWORD 1234 Password OK
Correct password entry confirmed
[↓] [↑]
EFFICIENCY CP ↓/↑/ENTER/CLEAR
Display of PARAMETER ADJUSTMENT MENU
Parameter adjustment menu for EFFICIENCY concrete pump / Central lubrication / Prop current values
EFFICIENCY CP ↓/↑/ENTER/CLEAR
[↓] [↑]
LUBRIC. PARAM ↓/↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
EFFICIENCY CP 94 %
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] change EFFICIENCY CP
------------------------------------------------------------------------------------------------------------------------
→ [ENTER] → ← [CLEAR] ←
LUBRIC. CYCLES BOOM 07
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] change number of cycles
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] change number of cycles
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] change number of cycles
[↓] [↑]
LUBRIC. CYCLES CP / AGITATOR 09 [↓] [↑]
[↓] [↑]
LUBRIC. CYCLES OUTRIGGERS 12
------------------------------------------------------------------------------------------------------------------------
The parameter adjustment menu for prop current values of the current control (Rexroth valves) please turn over
630
Service Manual
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PROP-CUR SLEW ↓/↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
BOOM-SLEW RIGHT I act 530 mA
PRINT
Electrical Online-display of effective prop-current
[↓] [↑]
BOOM-SLEW RIGHT I min 450 mA
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MIN-current
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MAX-current
[↓] [↑]
BOOM-SLEW RIGHT I max 820 mA [↓] [↑]
[↓] [↑]
BOOM-SLEW LEFT I act 610 mA
Online-display of effective prop-current
[↓] [↑]
BOOM-SLEW LEFT I min 520 mA
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MIN-current
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MAX-current
[↓] [↑]
BOOM-SLEW LEFT I max 810 mA
------------------------------------------------------------------------------------------------------------------------
PROP-CUR BOOM 1 ↓/↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
BOOM 1 EXTEND I act 530 mA
Online-display of effective prop-current
[↓] [↑]
BOOM 1 EXTEND I min 450 mA
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MIN-current
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MAX-current
[↓] [↑]
BOOM 1 EXTEND I max 820 mA [↓] [↑]
BOOM 1 RETRACT I act 610 mA [↓] [↑]
Online-display of effective prop-current
[↓] [↑] BOOM 1 RETRACT I min 520 mA
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MIN-current
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MAX-current
[↓] [↑] BOOM 1 RETRACT I max 810 mA
------------------------------------------------------------------------------------------------------------------------
Service Manual
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Electrical PROP-CUR BOOM 2 ↓/↑/ENTER/CLEAR [↓] [↑]
PROP-CUR BOOM 3 ↓/↑/ENTER/CLEAR [↓] [↑]
PROP-CUR BOOM 4 ↓/↑/ENTER/CLEAR [↓] [↑]
PROP-CUR BOOM 5 ↓/↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
Cf. boom section 1!
------------------------------------------------------------------------------------------------------------------------
→ [ENTER] → ← [CLEAR] ←
Cf. boom section 1
------------------------------------------------------------------------------------------------------------------------
→ [ENTER] → ← [CLEAR] ←
Cf. boom section 1
------------------------------------------------------------------------------------------------------------------------
→ [ENTER] → ← [CLEAR] ←
Cf. boom section 1
The parameter adjustment menu for prop-current values PWM-controlled (Apitech valves) please turnover PROP-CUR SLEW ↓/↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
SLEW RIGHT PWM act 33 %
Online-display of effective current value of valve
[↓] [↑]
SLEW RIGHT PWM min 10 %
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MIN-value
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MAX-value
[↓] [↑]
SLEW RIGHT PWM max 95 % [↓] [↑]
[↓] [↑]
SLEW LEFT PWM act 48 %
Online-display of effective current value of valve
[↓] [↑]
SLEW LEFT PWM min 10 %
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MIN-value
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MAX-value
[↓] [↑]
SLEW LEFT PWM max 93 %
------------------------------------------------------------------------------------------------------------------------
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PROP-CUR BOOM 1 ↓/↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
BOOM 1 EXTEND PWM act 29 %
PRINT
Electrical Online-display of effective current value of valve
[↓] [↑]
BOOM 1 EXTEND PWM min 14 %
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MIN-value
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MAX-value
[↓] [↑]
BOOM 1 EXTEND PWM max 92 % [↓] [↑]
BOOM 1 RETRACT PWM IST 63 % [↓] [↑]
Online-display of effective current value of valve
[↓] [↑]
BOOM 1 RETRACT PWM min 15 %
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MIN-value
→ [ENTER] → ← [ENTER] ←
Parameter adjustment ON [↓] [↑] adjust MAX-value
[↓] [↑]
BOOM 1 RETRACT PWM max 97 %
------------------------------------------------------------------------------------------------------------------------
PROP-CUR BOOM 2 ↓/↑/ENTER/CLEAR [↓] [↑]
PROP-CUR BOOM 3 ↓/↑/ENTER/CLEAR [↓] [↑]
PROP-CUR BOOM 4 ↓/↑/ENTER/CLEAR [↓] [↑]
PROP-CUR BOOM 5 ↓/↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
Cf. boom section 1
------------------------------------------------------------------------------------------------------------------------
→ [ENTER] → ← [CLEAR] ←
Cf. boom section 1!
------------------------------------------------------------------------------------------------------------------------
→ [ENTER] → ← [CLEAR] ←
Cf. boom section 1
------------------------------------------------------------------------------------------------------------------------
→ [ENTER] → ← [CLEAR] ←
Cf. boom section 1
Service Manual
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634
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Service Manual
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SCHWING Control system “VECTOR”
SERVICE MANUAL
OK
2
1
0 PTO 1500
OFF
x1000 3
rpm
62˚C
Menu: [ENTER]=ON
HOME
+
HELP
START
CLEAR
-
ENTER
QUIT
PART 1: OPERATION PART 2: TEACH MODE PART 3: EASY OPERATION 5900 Centerville Road White Bear, Mn. 55127 Tel. (651) 429-0999 Fax (651) 429-3464 www.schwing.com
Copyright © 2005, Schwing America, Inc. All rights reserved VECTOR CONTROLLER-SERVICE MANUAL
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START SCREEN: Control status Oil cooler "On" PTO Speed Hydraulic oil temperature
OK System is running Start
OK
2
1
Off?
STOP!
x1000 3 0 PTO 1350 rpm 62˚C
Start up control unit Control switches not in neutral position Emergency stop activated Entry expected
Modes of operation Remote mode
Menu: [ENTER]=ON
Local mode
Menu bar for further screens
Concrete pump delivery rate
Ram change mode Teach mode!
Teach mode StartScreen.eps
636
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual
PART 1
SCHWING control system 'VECTOR'
OPERATION The present instructions are intended to serve as a 'memory aid'. They do not refer to any particular type of machine and do not relieve the user of familiarizing himself with the operating manual of the machine in question.
CONTENTS
Commissioning .......................................................................................638 Selecting local control .............................................................................639 Selecting remote control .........................................................................640 Ram change mode:.................................................................................641 Emergency stop buttons .........................................................................642 Override of the E-stop manifold ..............................................................642 Options box .............................................................................................643 Control and monitoring components .......................................................644 Menu control ...........................................................................................645 Local control............................................................................................646 Remote control........................................................................................647 Menu overview - Main menu ...................................................................648 Menu overview - submenus ....................................................................652 Menu operation - Example: .....................................................................653 Diagnostic system/”Fault handling” .........................................................654 Acknowledging faults ..............................................................................656 Fault definition.........................................................................................656 Summary of messages ...........................................................................664 Heat the oil first .......................................................................................676
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual
Part 1 Operation
•
Commissioning The electrical machine control system can only be activated if the drive configuration has been properly selected: • Parking brake set • Ignition key on, engine running at idle. • Transmission in neutral • Activate the PTO switch • When Indicator light comes on, put transmission in proper pumping gear. •
Select the desired mode of operation with the switch in the lower right corner of the vector cover. The mode will then be indicated in the display window at the right side, center of the start screen (Figure 1).
vectorramchange.eps
•
When the control mode is selected, the display will indicate that with a picture (Figure 2).
A bar graph on the display will indicate that the system is being initialized. The start screen (Figure 1) will be displayed after initialization.
localcontrol.eps
remotecontrol.eps
1
2 Start
OFF
x1000 3
0
NA 1760 U/min
52˚C
Menu: [ENTER]=ON
HOME
+
HELP
START
CLEAR
-
ENTER
QUIT
Figure 2 Vector control mode display, local (top) remote (center) ram change (bottom)
commissionart2.eps
1
2 Start
x1000 3 0 PTO 1760 rpm 52˚C
Menu: [ENTER]=ON vectornormal.eps
Figure 1 Vector start screen
638
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Selecting local control 1
1
OK
2
x1000 3 0 PTO 1500 rpm 62˚C
2
Menu: [ENTER]=ON
Figure 3 Vector display window This symbol is displayed in section #2 of Figure 3 when local control is selected.
Start up the system by activating the “I” switch on the front panel of the controller (Figure 1).
localcontrol.eps Iswitch.eps
This symbol will flash in section 1 of Figure 3 when any E-stop on the machine is activated. Check that all E-stop buttons are released.
Starting is confirmed by a brief beep and the symbol below is displayed in section 1 of Figure 3.
OK STOP! estop.eps
This symbol flashes in section 1 when a switch on the rear operaors panel is on. Set all switches to neutral.
This symbol flashes in section 1 of Figure 3 when the system is ready for start-up.
Start Istart.eps
VECTOR CONTROLLER-SERVICE MANUAL
639
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Service Manual Selecting remote control 1 1
OK
2
30356 534 C
2 3
303 623
48 4
6
3
2
8
1
9
0
remotebox.eps
This symbol is displayed in section 2 of the screen (Figure 4). remotecontrol.eps
STOP! estop.eps
This symbol flashes in section 1 (Figure 4) when an emergency stop button on the machine or on the remote control box has been pressed. The symbol flashes also when the remote control box is off. Unlock all E-stops or turn on the remote. This symbol flashes in section 1 (Figure 4) when a switch on the remote control box is on. Set all switches to neutral.
Start Istart.eps
This symbol flashes in section 1 (Figure 4) when the system is ready for start-up:
Start up the control with this switch on the remote control box. activate"I".eps
OK
The starting is confirmed by a brief beep and the symbol on the left is displayed in section 1(Figure 4). VECTOR CONTROLLER-SERVICE MANUAL
10
Menu: [ENTER]=ON
Figure 4 Display screen for remote control
640
5
7
displayID.eps
1
2
x1000 3 0 PTO 1500 rpm 62˚C
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Service Manual Ram change mode:
vectorramchange.eps
This symbol is displayed in section 2 of the screen (Figure 4).
STOP! estop.eps
The ram change position disables both local (rear panel) and remote control, brings the engine to idle, reduces the stroke limiter to minimum output, and gives complete concrete pump control to the concrete pump fwd/rev switch located at the ram change station (Figure 6). See the Maintenance section of the operation manual for ram change instructions.
This symbol flashes in section 1 (Figure 4) when any E-stop on the machine is pushed. Unlock all E-stops.
1
OK
2
OFF
x1000 3 0 PTO 1500 rpm 62˚C
Menu: [ENTER]=ON
Start
This symbol flashes in section 1 (Figure 4) when the system is ready for start-up.
Istart.eps
HOME
+
HELP
START
CLEAR
-
ENTER
QUIT
panelID.eps
Start up the controller with the “I” switch in (Figure 5). Iswitch.eps
OK
“ ” switch
Figure 5 Vector control panel
Starting is confirmed by a brief beep and the symbol on the left is displayed in section 1 (Figure 4).
32ramchange.eps
Figure 6 Ram change station
VECTOR CONTROLLER-SERVICE MANUAL
641
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Service Manual Emergency stop buttons BY-PASS NORM. BY-PASS
E_Stopbutton.eps
Figure 7 E-stop button
by-pass2.eps
When and E-stop is pushed, all hydraulic functions of the machine will stop. Do not use the emergency stop for an on/off switch. It is for emergencies only. In normal operating conditions, always stop the machine functions with the controls provided for that purpose.
If the problem is actually a bad solenoid, the pilot signal to the dump valve can be overridden by having one person push and hold the override handle on the Estop manifold while the other person activates the manual controls for the nonworking system.
Override of the E-stop manifold Bypass Key
Bypass mode 1
WARNING
OK
2
OFF
x1000 3 0 PTO 1500 rpm 62˚C
Emergency stop switches are disabled when manual override is activated. Use the by-pass key switch only for folding the boom in an emergency and for clean out
• •
000360.eps
Menu: [ENTER]=ON
Use override only for emergency fold-up and cleaning. Emergency stop buttons do not function when the bypass mode is used.
HOME
+
HELP
START
CLEAR
-
ENTER
QUIT
bypasskeyswitch.eps
Figure 8 Bypass key switch location
If there is a malfunction in the E-stop circuit and the dump valves (in the E-stop manifold) open, oil will be routed from the hydraulic pump directly back to the tank. The dump valves also open when any emergency stop button is pushed. If the dump valves open and the machine cannot be repaired immediately, the power supply to the dump valves can be reactivated by using the bypass switch (Figure 8). By activating the bypass key switch to the bypass position, you send power to the solenoid of the normally open dump valve. If the solenoid is functional the dump valve will close and you should be able to fold up the boom and outriggers with the manual controls. 642
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Options box
The bottom of the two switches (Figure 11) is used to control the function of the optional concrete shut-off valve. The three position switch allows the operator to control the function of the valve in three different modes: • Position number “1” is “Auto-mode”. This mode should be used for normal operation. The shut-off valve will work in relationship to the concrete pump on-off switch. When the machine is pumping, the concrete shut-off valve is open and when the pump is stopped, power is removed from the solenoid and the valve inflates to stop concrete from draining out of the boom. The valve can be overridden via the remote box. If you are standing near the boom with the remote box and wish to drain the concrete from the boom, activate the switch in Figure 12 to the down position which is the concrete shut-off icon and the valve will open. The switch is located to the left of the E-stop button on the remote box. Concrete shut-off valve disable switch
optionsbox.eps
Figure 9 Electrical options box for Vector units
shutoffswtch.eps
Night light switch 1 3035653 4 C
2 3
3036 2348 4
5
6
3
7
2
8
1
9 10
0
switchlocation.eps
valveicon.eps
Figure 10 Switch to activate the night light kit
Figure 12 Switch on the remote box (left) shut-off valve icon (right)
The switch shown in Figure 10 is used to activate the optional night light kit.
•
Position number “2” closes the valve full time.
NOTE! Concrete shut-off valve switch
Do not activate the concrete pump in this mode with full air pressure on the valve. Damage could occur! •
Figure 11 Concrete shut-off valve switch
Position number three supplies power to the concrete shut-off valve full time and disables the valve. This position can be used instead of the disable switch shown in Figure 12, to allow the boom to drain prior to inserting a cleanout ball, or any time the concrete needs to be removed from the boom by gravity.
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Control and monitoring components Controller cabinet (Figure 13)
6 1 5 1
OK
2
OFF
x1000 3 0 PTO 1500 rpm 62˚C
On start-up the following data is displayed on screen (Figure 14): 1. PTO speed 2. Hydraulic oil temperature 3. Oil cooler “ON” 4. Control status 5. Selected mode of operation 6. Concrete pump delivery rate 7. Menu options
Menu: [ENTER]=ON
NOTE!
2 HOME
+
HELP
START
CLEAR
-
ENTER
QUIT
After pressing arrow down key on the menu control panel, further operational data will be displayed:
4 3
- Concrete pump hydraulic oil pressure
panelID.eps
Figure 13 Component locations on the controller cabinet
- Hydraulic oil level indication (optional equipment)
1. Display window 2. Key: menu control 3. Operating mode selector • Local mode • Remote mode • Ram change mode 4. Momentary contact “I” switch (Start switch) 5. Key switch: E-stop bypass 6. Connector: radio or remote control
2
allcallouts.eps
Section 4 (Figure 14) of the screen displays the following conditions:
OK
Control system is running
System ready for start up.
4
3
Starting not possible: switches not in neutral position.
OK 5
x1000 3 0 PTO 1500 rpm 62˚C
STOP!
Starting not possible: emergency stop activated
estop.eps
Operating mode display
Section 5 (Figure 14) of the screen displays one of these modes of operation: Local-Remote-Ram change
Menu: [ENTER]=ON
7
6
Figure 14 Display window data information
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Control status indications
Istart.eps
2
1
- Engine load factor (optional equipment.)
Start
Display window (Figure 14)
1
menuarrowdwn.eps
localcontrol.eps
VECTOR CONTROLLER-SERVICE MANUAL
remotecontrol.eps
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Service Manual Menu control
Fast selection/abbreviated function keys (shortcuts):
Basic functions of the keys (Figure 15)
Press the following keys at the same time: HOME
HOME
+
HELP
START
-
ENTER
QUIT
•
CLEAR
+
and
home.eps
•
menubuttons.eps
Figure 15 Menu Keys
down.eps
To set the contrast of the LCD display manually. During setting, the contrast is indicated on display between 0 and 99%. HOME
and
home.eps
•
or
HELP help.eps
To go to the manual language selection for all displays.
Each key performs a different function as follows: Full return to start screen
HOME home.eps
Up one item in the menu selection list
+
-
Down one item in the menu selection list
down.eps
Supplementary information for certain screens of the diagnostic function. Presently not implemented. Execution of certain actions, e.g. resetting of the concrete pump delivery rate counter.
HELP help.eps
S TAR T start.eps
CLEAR
One step back in menu.
clear.eps
Select indicated menu item or activate change.
E NTE R enter.eps
Confirmation and reset of diagnostic messages.
QUIT quit.eps
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Local control
HP
R
P
RPM engine (-) (+)
Compressor
= down = up
Concrete pump delivery rate Vehicle engine (0)
= stop
(I)
= start
(-) (+)
= decrease = increase
Agitator Work light (0) = off (I)
(R) = reverse (suction)
R
= on
Agitator
Water pump
(P) = forwards (pumping)
(T)= momentary (special control) (0) = off (I) = locked (continuous)
P
Concrete pump reverse (suction)
Vibrator
Concrete pump forwards (pumping) Ball injection system
High-pressure water pump
646
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Remote control
1 30356534 C
2 3
303623
48 4
5
6
3
7
2
8
1
9 10
0
RPM engine (-)
= down
(+)
= up
Water pump
Agitator in: ( ) = forward ( ) = reverse
Vehicle engine (0)
= off (stopping)
(I)
= on (starting)
Concrete pump forwards (pumping)
Control on Diagnostic horn signal confirm (shut-off)
Concrete pump reverse (suction)
Vehicle signal horn on
boom speed slow (placing operations)
End hose shutoff valve
(0)
Radio remote control only:
Ball injection system
Concrete pump delivery rate (-) (+)
boom functions off boom speed fast (set-up and take-down)
= decrease = increase
LED: charge condition of transmitter battery
LED: tansmitter state of operation: continuously on = transmitter ready
Vibrator in automatic mode(on)
flashing
VECTOR CONTROLLER-SERVICE MANUAL
= transmitting control signals
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Service Manual Menu overview - Main menu
OK
2
1
x1000 3 0 PTO 1500 rpm
Engine CP Hydraulic 2 100 100 3
2
OK
50
75
4 0 0 bar ---%
50 ---%
Status-Screen?
OK On On On
OK
Function: E-Stop
Oil Temp. Hydr. Diesel Engine
84˚C Off
Output
0
0%
0˚C
A: 0 C: 0 DW: 0
Function: Concrete Pump Switch/Command Water Tank
0 OK
Valve Output
0
Switch/Command Water Tank
0 close
Output
0
33 h C
Function: Vibrator
OK
Truck Data
OK
Main
0
Switch/Command Overheating
0 No
Valve Output
0
Switch/Command Output Switch/Command Output
Remote Manufact.
0 h C
OK
0 0 0 0
Function: Diesel Engine
Mach.-Nr. Mach.Type CP-Type Hyd.-Type Hotline
: : : : : :
OK
OK
VECTOR CONTROLLER-SERVICE MANUAL
OK
C
:TEST SHE :03.09.001 :LS :.-.-.-.-.-.-
OK
1-888-292-0262 C
interPTOl clock!!! cond. batt. :OK date time
33 h C
C
03.09.002 V01.10 03.09.002 V01.10 PROTOTYP OX
Machine Data
Pumped Volume?
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ID SW ID SW ID
System Data
O h C
Function: Compressor
0 h C
Truck Serial Number KFZ.-NR
0 OK
Function: HP-Water Pump
OK
Manufacturer/Type KFZ.-TYP
MMI Valve Output
OK 0 h C
Switch Command Hopper Grate
0 h C
Function: Water Pump
0 h C
Function: Agitator
OK
OK
OFF close No OFF
Switch Command Hopper Grate Rever. Station Valve Output
0 h C OFF CLOSE 0% OFF
0 0 0 0
Function: Outrigger
OK
B: 0 D: 0 E: 0
Function: Boom Switch/Command Hopper Grate Stroke Limiter Valve Output
Outrigger Station Brakes Lim-Sw right Brakes Lim-Sw left Valve Output
0 h C
Function: Radio Remote Command Valve Valve Valve
OK
OK 33 h C
Function: Oilcooler
C
Active :Radio Error :No CAN Data! SigPTOl : =OK
OK
p 0
E-Stop Chain Dump Valve BOOM Dump Valve CP Dump Valve MPS
x1000 3 0 PTO 1500 rpm
Menu: [ENTER]=Ein
1
1
OK
d.m.y : h.m.s :
System Clock
C
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Service Manual Menu overview - Main menu (continued) Status-Screen?
2
1
OK
Pumped Volume Counter Start
Pumped on the job: 2.4 cbm 0 PTO 1500
x1000 3
rpm
Reset ? - > [START] Pumped Volume
Pumped Volume?
2
1
0 PTO 1500
OK
n/a
Start
!!
rpm
Malfunct.List?
1
Malfunction List !
x1000 3
C
2
x1000 3 0 PTO 1500 rpm
Oper.Data?
Malfunct.List!
OK
Oil Pressure CP Oil Temperature Oil Tank Level PTO Hours CP Hours Boom Hours
C
69.8 64 ---.33.84 0.09 0.10
Oper. Data! Water Pump Hp-Water Pump Compressor Agitator Oilcooler Vibrator
Hrs Hrs Hrs Hrs Hrs Hrs
C 0.00 0.00 0.00 0.05 33.51 0.00
Oper. Data! Pumped Vol. Pumped Vol. Strokes CP Stroke Rate
Job Ttl Ttl CP
Central Lubr. Hrs
bar ˚C % h h h
h h h h h h
C 2.4 cbm 3.0 cbm 40 00.0 st/m 0.00 h
Oper. Data!
C
! Hours when moving ! Boom Slewing Outrigger Oper. Data!
0.00 h 0.00 h 0.00 h C
I/O-Readout?
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Menu overview - Main menu (continued)
Oper.Data?
1
2
OK Dig. Input?
x1000 3
0
NA 1350 U/min I/O-Readout?
1
0
2
x1000 3
OK
1
OK
x1000 3
0
NA 1350 U/min
2
NA 1350 U/min
Parameters?
Silent Diagn?
1
2
OK
NA 1350 U/min Language MMI?
1
2
--- System-Language --Current: English -----------------------[ENTER] Change? Select Language [ ] [ ] [ENTER] Store?
OK
Language MMI!
OK
x1000 3
0
OK
Silent Diagn!
x1000 3
0
-- Silent Diagnostic ?-Current: No -----------------------Change? [ENTER] Select Y/N [ ] [ ] Store? [ENTER]
NA 1350 U/min
Pumped Volume shown in: Current: cbm -----------------------[ENTER] Change? Select Language [ ] [ ] [ENTER] Store?
OK
Display cbm/cby? Displ cbm/cby! 1
0
2
x1000 3
NA 1350 U/min Password?
650
OK
Please Enter Password **** -----------------------Input Store? Password!
VECTOR CONTROLLER-SERVICE MANUAL
[ ] [ ] [ENTER]
OK
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Service Manual Menu overview - Main menu (continued) I/O-Readout? 1
2
OK
x1000 3
0
NA 1350 U/min Dig. Input?
1
2
OK
x1000 3
0
NA 1350 U/min Dig. Output?
1
0
2
x1000 3
NA 1350 U/min Analog Input?
OK
DI11 DI12 DI13 DI14 DI15 DI16 DI17 DI18
F31 Pwr Supply Dig Out F32 Pwr Supply PropOut F20 Pwr Supply Dig Out F18 Pwr Supply Inputs Dump Valve Boom Dump Valve CP Dump Valve MPS E-STOP Chain
1 1 1 1 1 1 1 1
DI21 DI22 DI23 DI24 DI25 DI26 DI27 DI28
D+ Signal Diesel PTO On Overheating Diesel Oil Press. Diesel LOW Limit Sw Boom A
