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SCHWING SERVICE DEPARTMENT jlkjlkjlkjlkjlkjkj (651) 429-0999
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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 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 Product Data .........................................................................23 Features .................................................................................23 Uses ......................................................................................23 Maintenance of Hydraulic Cylinders ........................................24 To check the piston side holding valves .......................24 To check the rod side holding valve .............................24 Check Outrigger Cylinder for: ......................................25 Check the control block for: .........................................25 Lubrication Specs for Schwing Placing Booms .......................26 Boom Inspections ........................................................................27
Pumpkits Specifications ...............................................................................29 2023-4 ...................................................................................29 2023-5 ...................................................................................29 2023H-6 ................................................................................29 2525H-5 ................................................................................29 2525H-6 ................................................................................29 Change rams ...............................................................................30 Remove the old rams. ...................................................31 Material Cylinder Alignment ....................................................34 Changing the Material Cylinders ..........................................34 Pumping on piston side ..............................................................40 Sealing Gland Replacement .......................................................41 Shimming the Differential Cylinders ........................................42 Determining the proper shim size .........................................42 Dimension A .........................................................................42 Dimension B .........................................................................42 Formula .................................................................................43
Hydraulic Pumps Hydraulic Pump Drive ...............................................................45 Placing boom hydraulic pumps .................................................45 Concrete pump hydraulic pumps ..............................................45 Hydraulic Pump Locations ........................................................46 Fixed Displacement Pump A2FO ..............................................47 Rexroth/Hydromatik Model A7V Series 2 ...............................48 Constant Pressure Control DR ..............................................49 Constant Horsepower Control LV ........................................49 Commencement of control: 50 bar min. ...............................49 Auxiliary Equipment: Stroke Limiter ...................................50 Rexroth/Hydromatik Model A7V Series 6 ...............................51 LR Constant Power Control .................................................52 LRH Constant Power Control With Hydraulic Stroke Limiter .......................................................................52 Variation: Hydraulic Stroke Limiter (H...) ...........................53 H1/H5 (Negative Control Function): Vg max to Vg min .....53 DR Constant Pressure Control ..............................................53 Rexroth/Hydromatik Model A10VO ........................................55 Rexroth/Hydromatik Model A11VO ........................................57 Linde Hydraulik BPR 105 .........................................................60 Constant Power Regulator (LR) ...........................................61
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Table of Contents Power Regulator With Hydraulic Stroke Limiter (LRH) .... 61 Voac Variable Displacement Axial Piston Pump .................... 62
Pressure Settings General ........................................................................................ 63 Stroke Limiter Adjustment .................................................. 63 Check the accumulator Pre-Charge ..................................... 64
Hydraulic Pump Adjustments Main System Pumps A11VO .................................................... 69 Setting the Flow Rate ........................................................... 69 Horsepower Setting .............................................................. 70 Setting Stroke Limitation ..................................................... 70 Q-min Output Flow .............................................................. 70 Check all hydraulic pressures. ............................................. 71 Setting pressures on Hi-flo -6 pumpkits .............................. 71 Pressure setting procedure: .................................................. 72 Setting the soft switch relief pressure .................................. 73 BPL 500 ....................................................................................... 75 BPL 2000 ..................................................................................... 81 BPL 4000 ..................................................................................... 85 KVM 17M ................................................................................... 97 Setting concrete pump pressure ........................................... 98 Setting the soft switch circuit relief pressure ..................... 100 Setting accumulator E-Stop manifold pressure (original production) .......................................................... 100 Setting the accumulator unloading valve (original production) .......................................................... 101 Setting accumulator E-Stop manifold pressure (current production) ........................................................... 101 Setting the accumulator unloading valve (current production) ........................................................... 102 Setting the boom E-Stop manifold pressure ...................... 102 Setting the boom/outrigger pressure .................................. 103 Setting the outrigger pressure ............................................ 103 Setting the boom pressures ................................................ 104 Set boom section #1 down pressure ................................... 105 Setting water pump pressure .............................................. 106 Setting the agitator pressure ............................................... 107 KVM 28X .................................................................................. 109 Check all hydraulic pressures ............................................ 109 Set the concrete pump main relief valve ............................ 111 Set the concrete pump main relief valve ............................ 112
Set the soft switch circuit relief pressure ....113 Set accumulator circuit hydraulic oil pressure ................... 113 Setting the outrigger pressure ............................................ 115 Pressure reducing valve ..................................................... 116 Electric stroke limiter ......................................................... 116 Load-sensing boom pressures ............................................ 116 Check or set ∆P .................................................................. 118 Check or set Q-min ............................................................ 119 Set boom pressures ............................................................ 119 Set the down side relief valve pressure .............................. 121 Set 15 bar pretension .......................................................... 122 Set water pump pressure .................................................... 122
Set the agitator pressure ......................................................123 S 31 XT ......................................................................................125 Check all hydraulic pressures .............................................125 Preheat the hydraulic oil .....................................................125 Check the concrete pump pressure -4 pumpkits .................126 To check or set the concrete pump pressure adjustments, follow these steps: .................................126 Setting the main relief valve ...............................................126 Setting the soft switch circuit relief pressure ......................128 To check or adjust the soft switch pressure setting, proceed as follows: .....................................................128 Setting pressures on load-sensing booms ...........................128 Preheat the oil .....................................................................128 About proportional boom systems ......................................128 Setting DP ...........................................................................129 Setting Q-min .....................................................................131 Setting boom pressures .......................................................131 There are several devices on the boom circuit which control boom pressure (Figure 45): ............................131 Raise the pressure of the lowest circuit ..............................132 Setting the outrigger pressures ...........................................132 To set the 280 bar relief valve for the outrigger circuit: .........................................................................132 Setting 15 bar pretension ....................................................134 To check or set pretension, follow these steps: ..................134 Setting the agitator circuit pressure ....................................135 Setting accumulator circuit pressure ...................................136 32XL Single Circuit ..................................................................139 Check hydraulic pressures ..................................................139 Preheat the hydraulic oil .....................................................139 Check the concrete pump pressure (900 or 1200) ..............139 Setting boom pressures .......................................................140 Preheat the oil .............................................................140 About proportional boom systems ..............................141 Setting DP ...........................................................................141 Setting Q-min .....................................................................142 Setting boom pressures .......................................................143 Setting the 140 bar down side relief valve pressure ...........144 Setting the outrigger pressures (7 place boom valve systems) .............................146 Setting 15 bar pretension ....................................................148 To set the agitator circuit pressure: .....................................148 32 XL Twin Circuit ...................................................................151 Units up to 450 l/m .....................................................151 Check hydraulic pressures ..................................................151 Preheat the hydraulic oil .............................................151 Check the concrete pump pressure (900-1200 - MPS pumpkits) ...............................................151 Setting the soft switch circuit relief pressure ......................153 Setting the boom pressures .................................................153 Load-sensing boom pressures .............................................155 Preheat the oil .............................................................155 About proportional boom systems ..............................155 Setting DP ...........................................................................156 Setting Q-min .....................................................................158 Setting boom pressures ...............................................158 Setting the 140 bar down side relief valve pressure ...........160
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Table of Contents Setting the outrigger pressures (7 place boom valve system) .............................. 160 Setting the water pump hyd. pressure ................................ 162 To set the agitator circuit pressure: .................................... 162 32 XL Hi-Flow B&W ............................................................... 165 Units up to 450 l/m ............................................................ 165 Check hydraulic pressures ................................................. 165 Preheat the hydraulic oil ............................................ 165 Location of pressure setting/checking devices .......... 166 Check the concrete pump pressure (2020, 2023, 2525 pumpkits) ............................................. 167 Setting the main relief valve .............................................. 168 Setting the soft switch circuit relief pressure ..................... 169 Setting the boom pressures ................................................ 169 Setting the 140 bar down side relief valve pressure .......... 172 Setting the outrigger pressures (7 place boom valve systems) ............................................ 173 To set the agitator circuit pressure: .................................... 175 32 XL High Flow Proportional ............................................... 177 Units up to 450 l/m ............................................................ 177 Check hydraulic pressures ................................................. 177 Check the concrete pump pressure (2020, 2023, 2525 pumpkits) ............................................. 177 Setting the main relief valve .............................................. 178 Setting the soft switch circuit relief pressure ..................... 180 Load-sensing boom pressures ............................................ 180 Preheat the oil ............................................................ 181 About proportional boom systems ............................. 181 Setting DP .......................................................................... 181 Setting Q-min ..................................................................... 183 Setting boom pressures ...................................................... 183 Setting the 140 bar down side relief valve pressure .......... 185 Setting the outrigger pressures ........................................... 185 Setting the water pump hyd. pressure ................................ 187 Setting 15 bar pretension ................................................... 187 To set the agitator circuit pressure: .................................... 188 32 XL Hi-Flow Prop, A11VO .................................................. 191 Units above 450 l/m (-5 and -6 units) ................................ 191 Check hydraulic pressures ................................................. 191 Preheat the hydraulic oil .................................................... 191 Check the concrete pump pressure (2020, 2023, 2525 pumpkits) ............................................. 191 Setting the main relief valve .............................................. 193 Setting the soft switch circuit relief pressure ..................... 194 Setting boom pressures ...................................................... 194 Preheat the oil ............................................................ 195 About proportional boom systems ............................. 195 Setting DP .......................................................................... 195 Setting Q-min ..................................................................... 197 Setting boom pressures ...................................................... 197 Setting the 140 bar down side relief valve pressure .......... 199 Setting the outrigger pressures (7 place boom valve systems) 200 Setting 15 bar pretension ........................................... 202 To set the agitator circuit pressure: .................................... 202 KVM 32 XG .............................................................................. 205 Check hydraulic pressures ...................................................... 205 Preheat the hydraulic oil .................................................... 205
Check the concrete pump pressure (2020, 2023, 2525 pumpkits) ..............................................205 Setting the main relief valve on -4 pumpkit .......................206 Setting the soft switch circuit relief pressure ......................208 Setting boom pressures .......................................................209 140 bar down side relief .....................................................209 Setting the outrigger pressures ...........................................209 Setting the water pump hydraulic pressure .........................210 Setting 15 bar pretension ....................................................210 Setting the agitator circuit pressure ....................................211 Setting accumulator circuit pressure ...................................213 S 34 X .........................................................................................217 Check hydraulic pressures ..................................................217 Preheat the hydraulic oil .............................................217 Check the concrete pump pressure (2020, 2023, 2525 pumpkits) ......................................217 Setting the main relief valve .......................................218 Setting the soft switch circuit relief pressure ..............220 Load-sensing boom pressures .....................................221 Preheat the oil .............................................................221 About proportional boom systems ..............................221 Setting DP ...................................................................221 Setting Q-min .............................................................223 Setting boom pressures (Load sensing proportional booms.) ...........................223 Setting the 140 bar down side relief valve pressure ...224 Setting the outrigger pressures ...................................225 Setting the water pump hydraulic pressure .................226 Setting 15 bar pretension ............................................226 Setting the agitator circuit pressure ............................227 Setting accumulator circuit pressure ...........................228 KVM 36X-42M (pre-1998) .......................................................231 Pressure Settings for KVM 36X Proportional Load Sensing .................................................231 Component Location Guide KVM 36 X W/Rexroth Handvalves .......................................................232 Pressure Settings for KVM 36X Proportional Load Sensing ......................................................................233 Pressure Regulator Cutaway ...............................................234 Pressure Settings for Regulator and Releif Valves .............235 KVM 36 LW & 36 X W/Rexroth Boom Handvalve ..........236 Pressure Settings for KVM 42 (B&W Load sensing and Proportional Load Sensing ........237 Component Location Guide KVM 42 W/Rexroth Handvalves .......................................................238 Pressure Settings for KVM 42LW Proportional Load Sensing ......................................................................239 Pressure Regulator Cutaway ...............................................240 Pressure Settings for Regulator and Relief Valves KVM 42 ..............................................................................241 KVM 42 LW, W/Rexroth BoomHandvalve .......................242 KVM 36X ...................................................................................243 Set the concrete pump main relief valve (single- circuit) ...244 Setting the soft switch circuit relief pressure ......................247 Set accumulator circuit .......................................................248 Units with a pressure- compensated pump .................248 Setting the outrigger pressure .............................................249 Check or set ∆P ...................................................................252
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Table of Contents Set boom pressures ............................................................ 253 (load sensing proportional booms) ............................ 253 Set 15 bar pretension .......................................................... 255 Set water pump pressure .................................................... 255 Set the agitator pressure ..................................................... 255 KVM 39X .................................................................................. 257 Check all hydraulic pressures ............................................ 257 Set the concrete pump main relief valve (twin circuit) ...... 259 Setting the soft switch circuit relief pressure ..................... 260 Set accumulator circuit ...................................................... 261 (units with a pressure- compensated pump) .............. 261 Set the outrigger pressure .................................................. 262 Check or set ∆P .................................................................. 265 Check or set Q-min ............................................................ 265 Set boom pressures ............................................................ 266 (load sensing proportional booms) ............................ 266 Boom holding valves ......................................................... 267 Set 15 bar pretension .......................................................... 268 Set water pump pressure .................................................... 268 Set the agitator pressure ..................................................... 268 S 42SX ....................................................................................... 271 Setting Pressures ................................................................ 271 Check all hydraulic pressures ............................................ 271 Preheat the hydraulic oil ............................................ 271 Setting pressures on Hi-flo -6 pumpkits ............................ 272 Setting the soft switch relief pressure ................................ 274 Setting boom circuit pressures ........................................... 274 Load-sensing boom hydraulic controls .............................. 274 Setting delta P pressure ...................................................... 275 Setting Q-min ..................................................................... 277 Setting boom pressures ...................................................... 277 Setting outrigger pressure .................................................. 278 Setting the agitator pressure ............................................... 279 Setting accumulator circuit pressure .................................. 280 KVM 42M - Proportional (Apitech) Single Circuit .............. 283 Check hydraulic pressures ................................................. 283 Preheat the hydraulic oil .................................................... 283 Setting concrete pump pressure (single-circuit units) ........ 283 Setting boom circuit pressures ........................................... 286 Load-sensing boom hydraulic controls .............................. 286 Setting DP .......................................................................... 286 Setting Q-min ..................................................................... 288 Setting boom pressure ........................................................ 288 Setting pretension .............................................................. 291 KVM 42M - Proportional (Apitech) Twin Circuit ............... 293 Check hydraulic pressures ................................................. 293 Preheat the hydraulic oil .................................................... 293 Setting concrete pump pressure (High-flow pumpkits) ..... 293 Setting the soft switch circuit relief pressure ..................... 295 reheat the oil to check pressures ........................................ 296 Load-sensing boom hydraulic controls .............................. 296 Setting DP .......................................................................... 297 Setting Q-min ..................................................................... 299 Setting boom pressure ........................................................ 299 Setting 15 bar pretension ................................................... 301 KVM 42M - Proportional (Rexroth) ...................................... 303 Check hydraulic pressures ................................................. 303 Preheat the hydraulic oil .................................................... 303
Setting concrete pump pressure (single-circuit units) ........303 Setting boom circuit pressures ............................................306 Load-sensing boom hydraulic controls ...............................306 Setting DP ...........................................................................306 Setting Q-min .....................................................................308 Setting boom pressure ........................................................309 Set the #1 down side pressure .............................................310 Setting outrigger pressure ...................................................311 Set accumulator circuit hydraulic oil pressure (units with accumulator unloading valves) .........................314 S 45/47SX ...................................................................................317 Setting Pressures .......................................................................317 Check all hydraulic pressures. ............................................317 Setting pressures on Hi-flo -6 pumpkits .............................317 Setting the soft switch relief pressure .................................320 Setting boom circuit pressures ............................................320 Load-sensing boom hydraulic controls ...............................320 Setting delta P pressure .......................................................321 Setting Q-min .....................................................................323 Setting boom pressures .......................................................323 Setting outrigger pressure ...................................................324 Set the agitator pressure ......................................................325 Set accumulator circuit pressure .........................................326 S 45SX Hi-Flow - 6 ....................................................................329 Setting Pressures .......................................................................329 Check all hydraulic pressures. ............................................329 Setting the main relief pressure and pressure cutoff on Hi-flo -6 pumpkits ..............................................................330 Setting the soft switch relief pressure .................................332 Setting boom circuit pressures ............................................332 Load-sensing boom hydraulic controls ...............................332 KVM 52M (pre-1998) ...............................................................333 Pressure Settings for KVM 52 Proportional Load Sensing ......................................................................333 Component Location Guide- KVM 52 ...............................334 Pressure Settings for KVM 52 Proportional Load Sensing ......................................................................334 Pressure Regulator Cutaway KVM 52 ...............................336 Pressure Settings for Regulator and Releif Valves KVM 52 ..............................................................................337 Setting Pretension Pressure(Refer to Figure 5) ..................337 Control Block 1 for KVM 52 Boom 3, Boom 4, & Slewing 338 Control Block 2 for KVM 52 Boom 1, Boom 2, & Outriggers .......................................................................339 Pre-Control Block 1-A for KVM 52 ..................................340 Pre-Control block 1-B for KVM 52 ..................................341 Pre-Control Block 1-C for KVM 52 ..................................342 Pre-Control Block 2-A for KVM 52 ..................................343 Pre-Control Block 2-B for KVM 52 ..................................344 Electric Bypass Valve for KVM 52 ....................................345 S 52 SX .......................................................................................347 Setting Pressures .......................................................................347 Check and adjust all hydraulic pressures ............................347 Preheat the hydraulic oil .............................................347 Setting pressures on Hi-flo -6 pumpkits .............................348 Pressure setting procedure: .........................................348
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Table of Contents Setting the soft switch relief pressure ................................ 350 Setting boom circuit pressures ........................................... 350 Load-sensing boom hydraulic controls .............................. 350 Setting Delta P pressure ..................................................... 351 Setting Q-min ..................................................................... 352 Setting boom pressures ...................................................... 353 Setting main pressure ................................................. 353 Setting boom pressure (redundant) relief ................... 353 Setting pressure cut-off .............................................. 354 Setting slewing pressure ............................................ 354 Setting outrigger pressure ................................................. 355 Setting the agitator pressure ............................................... 355 Setting accumulator circuit pressure .................................. 356 KVM 52M ................................................................................. 359 Setting relief pressure and pressure cutoff on Hi-flo -6 pumpkits ............................................................. 359 Setting the soft switch circuit relief pressure ..................... 362 Set boom circuit pressures ................................................. 362 Checking and Setting DP pressure ..................................... 363 Set Q-min ........................................................................... 364 Checking boom pressures .................................................. 365 Setting main boom circuit pressures .................................. 366 Checking pretension pressure ............................................ 367 Set the outrigger pressure .................................................. 368 Set the agitator pressure ..................................................... 369 KVM 55M ................................................................................. 371 Check all hydraulic pressures ............................................ 371 Preheat the hydraulic oil .................................................... 371 Setting relief pressure and pressure cutoff on Hi-flo -6 pumpkits ............................................................. 372 Setting the soft switch circuit relief pressure ..................... 375 Setting boom circuit pressures ........................................... 375 Checking and setting DP pressure ..................................... 375 Setting Q-min ..................................................................... 377 Checking boom pressures .................................................. 377 Setting main boom circuit pressures .................................. 378 Checking pretension pressure ............................................ 379 Setting the outrigger pressure ............................................ 380 Set the agitator pressure ..................................................... 381 Set accumulator circuit pressure ........................................ 382 S 58/61SX .................................................................................. 385 Check all hydraulic pressures ............................................ 385 Preheat the hydraulic oil ............................................ 385 Setting pressures on Hi-flo -6 pumpkits ............................ 385 Pressure setting procedure: ........................................ 385 Setting the soft switch relief pressure ................................ 388 Setting boom circuit pressures ........................................... 388 Load-sensing boom hydraulic controls .............................. 388 Setting Delta P pressure ..................................................... 389 Setting Q-min ..................................................................... 390 Setting boom pressures ...................................................... 391 Setting main pressure ................................................. 391 Setting boom pressure (redundant) relief ................... 391 Setting pressure cut-off .............................................. 392 Setting slewing pressure ............................................ 392 Setting outrigger pressure ................................................. 393 Setting the agitator pressure ............................................... 393 Setting accumulator circuit pressure .................................. 394
Electrical Information Boom Control Systems and the Advantages of Each ............397 Boom Control Systems .............................................................399 Introduction to Proportional Controls ...................................400 The Joystick with Potentiometer ........................................400 The Proportional Amplifier ................................................401 The Solenoid Valves ...........................................................401 The Proportional Amplifier in Use with the Radio ...............402 Motherboard for Proportional Units ......................................403 Power Supply - Slot 9 ...............................................................404 Proportional Amplifier - Slot 1,2,3 ..........................................405 Calibration of Proportional Amplifier Cards ........................406 Linear Signal Diagram .............................................................407 Decal of Proportional Motherboard .......................................408 Wiring Diagram - DUVAC II 12V / 24V Transformer .........409 Wiring Diagram - DUVAC II 12V / 24V Transformer .........410 Digital Proportional - Overview (1 of 5) .................................411 Overview ............................................................................411 M.A.T. ................................................................................412 Processor Unit .....................................................................413 Card Functions ....................................................................414 Control System Arrangement .............................................415 Digital Proportional - Programming ......................................416 Programming ......................................................................416 MAT Operation ..................................................................416 Menu Structure ...................................................................417 Moving Through The Menu Survey ...................................418 Access The Service Menu ..................................................419 Identifying the Entries and Parameters ...............................420 “SCV” Card Main Menus ...................................................420 “?PAR” Main Menu ...........................................................420 Submenus Functions and Parameters .................................421 “?SELECT ” Submenu Functions and Parameters (In Service Menu Only!) .....................................................422 “?V24” Submenu Functions and Parameters ......................423 “?DIN” Main Menu ............................................................423 “?RACK” Submenu Functions and Parameters ................424 “?BDI A” Submenu Functions and Parameters .................425 “?BDI F” Submenu Functions and Parameters .................426 “?SOUT" Main Menu .........................................................427 “?POUT” Main Menu .........................................................428 “?DIAG” Main Menu .........................................................429 “?SYSTEM” Main Menu ..................................................429 “?GERAET” Main Menu (In Service Menu Only!) ...........430 V2.4 Menus ........................................................................430 Software Versions ...............................................................431 Digital Proportional - Balancing Valve Currents ..................453 Hysteresis ............................................................................455 Diagnostic Signal ................................................................455 Setting Valve Currents ........................................................455 Digital Proportional - Troubleshooting ..................................457 Troubleshooting procedure 1 ..............................................459 Troubleshooting procedure 2 ..............................................459 Troubleshooting procedure 3 ..............................................459
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Table of Contents Troubleshooting procedure 4 ............................................. 459 Troubleshooting The Radio ............................................... 460 Operation ........................................................................... 461 Emergency Stop ................................................................. 462 Automatic Shut down ........................................................ 462 Trouble-shooting ................................................................ 463 Troubleshooting tables ....................................................... 464
Comfort Control Manual 1.0 Working with the info & diagnosis system ................. 468 1.1 Introduction into the info & diagnosis system ..... 468 1.2 Menu structure info & diagnosis system / Operation data display ....................................................... 470 1.2.1 Standard display & malfunction messages ....... 470 1.2.2 Main menu ........................................................ 471 1.2.3 "PUMP VPUME" sub-menu ............................. 472 1.2.4 "OPERATION DATA" sub-menu .................... 472 1.2.5 "MALFUNCTION LIST" sub-menu ................ 473 1.2.6 "LUBRICATION-UNIT" sub-menu ................ 473 1.2.7 "I/O DISPLAY" sub-menu ............................... 473 1.2.8 SCROLLING" sub-menu .................................. 474 2.0 Concrete pump efficiency parameter setting / Central lubrication / Prop characteristics ........................... 475 2.1 Password entry and parameter selection menu .... 475 2.2 Setting the concrete pump efficiency for pumped volume determination .................................. 476 2.3 Adjusting the central lubrication .................................. 477 2.4 Adjusting the proportional parameters for boom functions ............................................................................. 478 Proportional characteristics adjustment for the BOOM SLEW function with PROP valve types : ............. 479 Proportional characteristics adjustment for the BOOM 1 function with PULSAR valve types : ................ 480 3.0 I/O status display - signals & references ..................... 481 3.1 Machine control ................................................... 481 3.2 Concrete pump control ......................................... 483 3.3 Boom control ....................................................... 484 3.4 Rear panel ............................................................ 486 3.5 Extension module ................................................ 487 4.0 Fault messages and fault causes ................................... 488 4.1Introduction ........................................................... 488 4.2 Control diagnosis electronic modules Fault code S !) ............................................................ 489 4.3 Remote-control system diagnosis (fault code F!) 490 4.5 Engine/PTO Diagnosis (fault code D!) ................ 493 4.6 Concrete pump diagnosis (fault code B!) ............ 494 4.7 Boom control diagnosis (fault code M!) .............. 495 4.8 Central lubrication/extension diagnosis (fault code Z/ E!) 497 5.0 Output signal interdependence list ............................... 498 Part 1 Operation ...................................................................... 514 Commissioning .................................................................. 514 Selecting local control ....................................................... 515 Selecting remote control .................................................... 516 Ram change mode: ............................................................. 517 Emergency stop buttons ..................................................... 518 Override of the E-stop manifold ........................................ 518
Bypass mode ...............................................................518 Options box .........................................................................519 Night light switch .......................................................519 Concrete shut-off valve switch ...................................519 Control and monitoring components ..................................520 Controller cabinet (Figure 13) ....................................520 Display window (Figure 14) .......................................520 Control status indications ...........................................520 Operating mode display ..............................................520 Menu control .......................................................................521 Basic functions of the keys (Figure 15) ......................521 Fast selection/abbreviated function keys (shortcuts): .521 Local control .......................................................................522 Remote control ...................................................................523 Menu overview - Main menu .............................................524 Menu overview - Main menu (continued) ..........................525 Menu overview - submenus ................................................528 Menu operation - Example: ................................................529 Diagnostic system/”Fault handling” ...................................530 Display language ........................................................531 Acknowledging messages ...........................................532 Acknowledging faults .........................................................532 Fault definition ...................................................................532 Low level fault ............................................................532 High level faults ..........................................................532 Silent diagnostic .........................................................533 Reporting and acknowledging of faults ......................534 Acknowledging of several faults ................................539 Switching off the control system ................................539 Summary of messages ........................................................540 Heat the oil first ..................................................................552 Restore original factory settings .................................552 Setting parameters ......................................................553
Radio Remotes Cross Reference Wiring Chart ................................................559
Radio Control FW 18 Table of Contents ......................................................................561 1. Safety and Accident Prevention Regulations .....................561 Safety Regulations - Concrete Pumps with placing booms .....................................................................562 Traveling .............................................................................562 Jacking ................................................................................562 Concrete Pump ...................................................................562 Placing Boom .....................................................................562 Pipelines ..............................................................................563 Remote Controls .................................................................563 Electrical Connections .........................................................563 2. Short Instructions .................................................................564 Preparing the Commissioning ............................................564 Making Ready for Operation ..............................................564 Operating Mode ..................................................................564 Reasons for Automatic Switch-off .....................................564 3. Preface ...................................................................................564
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Table of Contents 4. Extract from the Terms of Warranty ................................ 565 5. Model Plates ......................................................................... 566 6. Technical Data ...................................................................... 566 7. Brief Description .................................................................. 566 Transmitter ......................................................................... 566 Receiver ............................................................................. 567 8. Control and Monitoring Equipment .................................. 568 Radio Remote .................................................................... 568 Receiver ............................................................................. 569 9. Commissioning ..................................................................... 570 Preparations ....................................................................... 570 Ready for operation ........................................................... 570 10. Operating the Radio Remote Control .............................. 571 Transmitter mode ............................................................... 571 Transmitter range ............................................................... 572 Putting out of Operation .................................................... 573 Changeover to Cable Remote Control ............................... 573 12. Safety Facilities .................................................................. 574 Fuses .................................................................................. 574 13. Maintenance Works and Checks ...................................... 575 Changing the transmitter battery ........................................ 575 Charging the transmitter battery ........................................ 575
Radio Control FW 20 Table of Contents ..................................................................... 577 2. Short Operating Instructions .............................................. 578 Preparations ....................................................................... 578 Ready-for-Operation State ................................................. 578 Emergency Shut-Off .......................................................... 578 Automatic Shut-Off ........................................................... 578 Interruptions of Work ........................................................ 578 3. Foreward ............................................................................... 579 4. Designated Use ..................................................................... 579 Non Designated Use ................................................................. 579 Extract from Terms of Warranty ........................................... 580 5. Safety Rules and Accident Prevention Regulations .......... 581 7. Short Description ................................................................. 582 8. Technical Data: .................................................................... 583 Transmitter ......................................................................... 583 Receiver ............................................................................. 584 9. Monitoring-, Warning-, and Control Elements ................ 585 10. Pre-Operational Instructions ............................................ 588 11. Operation ............................................................................ 592 Battery Capacity ................................................................ 592 Disturbances ....................................................................... 593 Frequency Change ............................................................. 593 12. Emergency Shut-Off .......................................................... 593 13. Interruptions of Work/End of Operation ........................ 594 14. Replacing the Battery ........................................................ 595 Recharging of Battery ........................................................ 595 15. Malfunctions ....................................................................... 596 Message Interference ......................................................... 597 Trouble Shooting ...................................................................... 598
Troubleshooting: Receiver LEDs .......................................598 Troubleshooting Controller (MC1) ....................................600 Troubleshooting Table: Transmitter LED’s ......................601 16. Maintenance ........................................................................602 Replacing of Fuses ..............................................................602 17. Repair ..................................................................................603
Radio Control FW 24 Table of Contents ......................................................................605 Safety Instructions ....................................................................606 Scope of Application .................................................................607 Start-Up .....................................................................................608 Operation ...................................................................................611 Charging the Battery ................................................................612 Maintenance ..............................................................................613 Operation Fault Indicators ......................................................614
C32/CPC Radio Remote Spread Spectrum Technology ..................................................617 Mounting the Receiver Antenna: ............................................618 Transmitter Operation .............................................................619 Remote Radio Controller .........................................................622
Omnex Radio Control System 1. Introduction ..........................................................................627 2. Physical Mounting ................................................................628 3. Considerations for Electrowelding ......................................628 4. Receiver Connector Assignments ........................................629 5. Cable Unit Connector Assignments ....................................630 6. Fuses .......................................................................................630 7. Operations .............................................................................631 7.1 Receiver ........................................................................631 7.1.1 Receiver Lights - General Function ...................631 7.1.2 Receiver Lights - Error Conditions ...................631 7.1.3 Operator Adjustments: .......................................632 7.2 Transmitter ....................................................................633 7.2.1 Transmitter Lights .............................................633 7.2.2 Operator Controls: .............................................634 7.3 Cable Unit .....................................................................634 7.3.1 Cable Unit Lights ...............................................634 7.3.2 Operator Controls: .............................................635 8. Troubleshooting Information ..............................................635 8.1 I24-MC Board ...............................................................635 8.2 Receiver TPCB-1527-01 Board ....................................635
Conversion Charts Fluid Power Formulas ..............................................................642 Torque Specifications ...............................................................644 Torque Specification: Slewing Roller Bearing Bolts .............647 WP Number Codes ...................................................................652
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Table of Contents BP Model Number Codes ........................................................ 653 Outrigger Spreads and Loads ................................................. 654 Boom Pin Clearances ............................................................... 655 Nozzle Chart ............................................................................. 665 Boom Times/Without Weights ................................................ 666 Boom Pressures & Nozzle Chart Size .................................... 667 Boom Pressures & Nozzle Chart Size .................................... 668 Rotek Bearing Clearance Instructions - SAIE - 5114 ........... 669
Special Tools Hydraulic Trouble Shooting Kits ........................................... 679 Hydraulic Oil Filter Cart ........................................................ 679 Flow Meters and Accesories .................................................... 680 Flow Meter Y223 Model HT200 ............................... 680 Specifications: ............................................................ 680 Accessories: ............................................................... 680 Material Cylinder Alignment Tool ......................................... 681 Piston Installation Tools for Differential Cylinders ............. 682 Gland Packing Installation Tools ........................................... 683 Seal Replacement Tools ........................................................... 684 Piston Seal Guide Tool ...................................................... 684 Piston Seal Form Tool ....................................................... 684 Bushing Installation Tool ........................................................ 684 Rock Shaft Bushing Installation Tool ................................ 684 Accumulator Charging Kit ..................................................... 685 Adjustment Meters for Analog Proportional Cards ............. 685 Analog Adjustment Meter ................................................. 685 Technition Support Kit ........................................................... 685 Electrical Tools and Accessories ............................................. 686 Spanner Socket Tools for Boom Pins ..................................... 687 Truck Engine Tools ................................................................. 688 Pro-Link 9000 .................................................................... 688 Micellaneous Tools ................................................................... 688 Whip Hose and Fittings ..................................................... 688 Rock Valve Cover Alignment ............................................ 688
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Maintenance
Check hydraulic pressures
√
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
√
As Indicated
Annually
Semi-annually
Quarterly
Monthly
Weekly
Task
Maintenance Chart
Daily
HOME
√
Fill optional auto greaser reservoir Inspect for damage and leaks
√
Check if maintenance is due
√
Grease boom zerks
√
Check pipewall thickness
√
Check oil in optional air compressor
√
Check Rock Valve tension nut
√
Inspect cutting ring/rotate if needed
√
Lubricate mechanical moving parts
√
Check tapered bend wedge bolt
√
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Check boom slewing gearcase oil level
√
Clean slewing gearcase breather cap
√
Check function of mechanical boom brake
√
Clean and repack rollix gear
√
Inspect the turret bolts for tightness
√
Check fluid in distribution gearcase
√
Check unit mounting hardware
√
Check and adjust hydraulic pressures
√
Check hydraulic oil cooler fins
√
Check drive pinion mounting screw
√
Change oil in optional air compressor
√
As Indicated
Annually
√
Change hydraulic oil for temp. reasons Check the accumulator pre-charge
Semi-annually
Quarterly
Monthly
Task
SERVICE TRAINING
Weekly
Daily
Maintenance, Lubrication Schedules, etc.
∆
√
∆
√
Change oil in distribution gearcase - ∆ Change oil in boom slewing gearcase
√
Test dirty filter lamp circuit
√
Change hydraulic oil for age reasons
√
Clean optional compressor
√
Change corrosion inhibitors
√
Periodic - structural inspection
√
Change main return oil filter
√
Change high pressure oil filter
√
Change water system inline filter
√
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Service Manual
Perform post-trip inspection
Check if maintenance is due
Inspect for damage and leaks
Fill optional auto greaser reservoir
Grease boom bearings and hollow pin
Grease rock valve and agitator bearings
Inspect bolts on rock valve and rams
Check differential cylinder rod packings
Bleed moisture from hydraulic tank
Check hydraulic oil
Check tires
Bleed moisture from air tank
Check truck fluid levels
Check hydraulic pressures
Perform DOT pre-trip inspection
Task Mon
Tues
Wed
Thurs
Friday
Comments
Operator’s Checklist for Unit#_________________________ Week Ending_________________________
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Operators Check list for Weekly Maintenance (Ex.)
S0167.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
OUT
β=
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
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.
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)
UPSTREAM
DOWNSTREAM
FLOW
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Fluid Contamination and Control
SERVICE TRAINING
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
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
SERVICE TRAINING
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. 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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Maintenance, Lubrication Schedules, etc. Hydraulic Oils
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
S 17
130 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
S 28 X
98 gallons
S 31 XT
127 gallons
KVM 32M
132 gallons
KVM 32 XL
127 gallons
S 34 X
127 gallons
KVM 36M
147 gallons
KVM 36XL
127 gallons
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Maintenance, Lubrication Schedules, etc. Model
System 1 & 2
System 3
KVM 39X
127 gallons
S 39/41 SX
110 gallons
KVM 42M
147 gallons
S 42 SX
169 gallons
S 45/47 SX
169 gallons
S 52 SX
153 gallons
KVM 52/55 M
206 gallons
S 58/61 SX
153/180 gallons
SPB Power Pack
30 gallons
Slew Drives Schwing Model
Model
Part Number
Liters
S 17
NA
NA
NA
KVM 32 XL
ZHP
10072000
2.25 liters
KVM 36M
ZHP 3.19
10150116
3.0 liters
S 34X/KVM 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
S 45/47 SX
ZHP 3.20
10174104
4.0 liters
KVM 52 M
ZHP 3.25
10154423
3.7 liters
S 52 SX
ZHP 3.25
10188099
9.2 liters
S 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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SERVICE TRAINING
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, be sure that vehicle is on level surface before removing any port plugs.
Remove the level checking plug at position #3, 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
4 - Breather
1 - Oil Filler Plug
2 - Oil Drain Plug
3 - Oil Level Plug (only for models with oil cooler)
2 - Oil Drain Plug 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.
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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 highly recommended prior to the installation of any model/manufacture of hydraulic pump(s) that the drive spline be lubricated with a special pre-assembly grease. Schwing America recommends 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
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. 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. 1. If there is no movement of the cylinder rod, then piston sealing and holding valve are free from internal leakage. 2. If there is movement of the cylinder rod, then piston sealing and/or holding valve on the piston
SERVICE TRAINING
side have internal leakage. a. Remove the hose connections at the holding valve on the piston side. b. 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. c. If oil runs out of the hose connected to the holding valve, then the holding valve on the piston side is defective. 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. 1. If there is no movement of the cylinder rod, then piston sealing and holding valve are free from internal leakage. 2. If there is movement of the cylinder rod, then piston sealing and/or holding valve on the rod side have internal leakage. a. Remove the hose connecting at the holding valve on the piston side. b. 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. c. 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) S0100.ai
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Maintenance, Lubrication Schedules, etc. Check Outrigger Cylinder for:
1. Any missing or damaged parts, then check for leakage of shut-off valves or cylinder seals. 2. 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. 3. 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. Check the control block for:
1. Any missing parts (knobs, symbol of switching levers, etc.), damaged or leaking parts, and cleanliness.
2. 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.) 3. Check the #1 boom down relief - Refer to Service Bulletin G-103-89 for checking this function. 4. Check boom slewing cylinders for: a. Exterior damage of cylinders tubes and mounting flanges. b. Leakage and correct movement. 5. Check the hydraulic tank for: a. Proper oil level and leakage b. Contamination and oil purity. (if necessary, take an oil sample for evaluation). 6. Check boom operation speed (too fast / too slow), with unstressed boom as per Boom Time Chart. 7. Check remote control motions with all switch functions and operation symbols. 8. 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
SERVICE TRAINING
S102.eps
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Boom Inspections The recommended CPMA (Concrete Pump Manufactures Association) Safety Standard boom inspection intervals are as follows: First 5 years; every 2000 working hours, or at least once per year. Five to ten years; every 1000 working hours, or at least once per year. Ten years and older, every 500 working hours, or at least once per year, whichever occurs first.
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.
This schedule must be a planned schedule based on the age of the unit.
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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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
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 • •
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
2525H-5
2023-5 • •
Pumpkits
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.)
29
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Pumpkits
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
• •
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
30
Service Manual
O = Off
tch.e
ps
I = On
Figure 1 Ram change station on rear boom cradle “A” frame (current production)
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Pumpkits
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).
Pumpkits
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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Material Cylinder Alignment The material cylinders are considered worn out when the inside diameter has grown 3 millimeters beyond the specification for new. For example, a 2023 has 230 mm material cylinders. When the inside diameter reaches 233 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 show little or no wear, because that end never experiences concrete. For this reason, the material cylinders were designed to be able to rotate end for end. That way you can move the worn out end to the waterbox and the little-worn end to the concrete valve for double the life. If you notice excessive amounts of grout in the waterbox or accelerated wear on the rams, it may be time to rotate the material cylinders. For units without the Ram Change Station, please reference Schwing Service Bulletin #G-102/88. Contact the Schwing America Service Department at (651) 429-0999 if you need a copy of the bulletin.
Changing the Material Cylinders 1. Extend and jack the outriggers. 2. Lift the placing boom enough to clear an obstructions and slew it off to the side. 3. Remove both rubber rams from the differential cylinders in the normal manner. See “Remove the old rams” on page 31. 4. Retract the first differential cylinder rod completely: a. 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
Concrete Pump “forward”
Concrete Pump “reverse” S0169.eps
Figure 12 Ram Change Mode switch b. Place the Concrete Pump Forward/Reverse switch in the “forward” position. The pistons will move at the slowest possible speed. Hold the switch until the piston reaches bottom dead center (B.D.C.) position.
NOTE! The concrete pump can only be actuated with the Forward/reverse switch to the right of the I O selector switch. For more information see “Select the Ram Change Mode” on page 30.
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Figure 13 B.D.C. position c. The rod will move into the end position and stop. Immediately release the Pump Forward/ ”reverse” switch on the Ram Change mode station. This will place the S1 spool into the neutral position. (otherwise the machine will go into a high pressure situation) d. Stop the engine. Put the key in your pocket.
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5. In order to move the second piston to the bottom dead center position without re-extending the first cylinder, we must drain out the rocking oil.
NOTE! When opening the hydraulic system, which we have to do to drain the rocking oil, make certain of absolutely clean conditions. 6. To drain the rocking oil rod side: a. Disconnect one end of the rocking oil hose and hold the hose into a clean container. b. Start the engine. c. Select I (ON = ram change mode). Put the S1 in reverse mode by holding the Pump Forward/ Reverse switch in the “reverse” position. When the piston reaches bottom dead center (B.D.C.) position. The rocking oil will be expelled, through the hose.
Pumpkits
“Rock Valve” section of this book for rebuilding instructions. 12. Support each material cylinder with the lifting device. Remove the bolts at the waterbox. If an impact wrench is used, you must use an impact socket and wear eye protection. 13. Detach the material cylinders and remove in a downward direction.
NOTE! Take care not to damage hoses and tubes that may be positioned under the material cylinders
\
S0168.eps
7. 8. 9.
10.
Figure 14 Draining the rocking oil Stop the engine Remove the hopper and outlet piping from the concrete valve Carefully support the differential cylinders cylinders to avoid unintentional movement of the pumpkit after the material cylinders have been removed. for example, wedge wooden blocks between the cylinders and across of the subframes. Mark for identification, then remove the hydraulic hoses from the rock slewing cylinder.
Figure 15 Removing bolts at the waterbox 14. Remove the split rings and mounting flanges. If spacing rings are used on the unit, remove them at this time.
NOTE! Plug the open hydraulic lines with dead plugs. 11. Remove the entire rock valve assembly. See the
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S0171
Figure 16 Removing the Split Rings 15. Clean, check and grease the mounting parts and all mounting surfaces at the waterbox and rock housing. 16. Clean the mounting surfaces of the new material cylinders thoroughly, remove primer, and grease. 17. Install mounting flanges and split rings. At this time mount spacing rings removed in step 12, if any
S0172.eps
Figure 17 Grease new o-rings 19. Carefully slide a pre-completed material cylinder into the waterbox, and give a ballpark alignment. 20. Screw in the mounting bolts and washers and tighten crosswise, using the torques specified in the table.
NOTE! Please remember not to interchange the flanges and split rings, and spacing rings from the waterbox to concrete valve end. The cylinder themselves can go either way. 18. Grease the new o-rings and insert into the lead in rings of the waterbox
S0168.eps
Figure 18 Tightening bolts at the waterbox
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Bolt
Step 1
Step 2
M16 8.8
75 ft/lbs
155 ft/lbs
M16 10.8
110 ft/lbs
220 ft/lbs
M24 8.8
260 ft/lbs
525 ft/lbs
Pumpkits
25. 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.
21. After both material cylinders have been installed, the alignment must be checked. 22. Re-attach the rocking oil hose that you removed in step 6. After the rocking oil loop is in place, start the engine. Pump Forward/Reverse switch in the “reverse” position. The passenger side differential cylinder rod should extend as the rocking oil loop is refilled. When the rod stops moving, the loop is filled. Release the Pump Forward/Reverse switch 23. Stop the engine. Put the key in your pocket. 24. Mount alignment tool on a differential cylinder rod. See chart on page 39 for the proper material cylinder alignment tool part number and size.
Figure 20 Putting trouble light in waterbox 26. Put the Pump Forward/Reverse switch in the “forward” position. 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
S0174.eps
Figure 19 Mount the alignment tool, to the differential cylinder rod.
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Even rays around alignment tool
MOUNTING BOLTS
28. 29. Uneven rays around alignment tool
30. Figure 21
NOTE! If the alignment tool should contact the cylinder wall at any time, release the Concrete Pump Forward/Reverse switch immediately! Damage may occur to cylinder wall. 27. 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.
31. 32.
Figure 22 Mounting bolts on waterbox Grease new o-rings and insert in the valve housing. Carefully slide the valve housing onto the material cylinders, and rest the valve housing on the machine frame. Bolt the valve housing and material cylinder flanges together making sure that the alignment is being maintained. Bolt the valve housing to the machine frame. Check alignment with the tool once more, by using the Ram Change Mode switch. NOTE! If a squeaking sound indicates the alignment tool is dragging on the material cylinder, turn off the pump IMMEDIATELY!
33. If there is no dragging, you may proceed to step 36. If dragging does happen, repeat the visual checks. 34. Loosen the bolts on the material cylinders and valve housing, and at the machine frame, and repeat the alignment procedure. 35. Check the mounting and shimming of the pump kit and its mounting to the pump kit frame. 36. Tighten all bolts. 37. Complete the reassembly of valves, and install the rubber rams. 38. Reopen the 1/4” turn valve.
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.
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Pumpkits
Rod Diameter
Material Cylinder Diameter
Ordering Chart Rod Cylinder Item Diameter Diameter Number
Pumpkit Model Number
50 mm
150 mm
30379547
450, 500, BP 750-15
50 mm
180 mm
30339165
WP 750-18, WP 1000-18, BP 1000-18
55 mm
150 mm
30379532
250-15
55 mm
180 mm
30379533
350-18, 500-18, 650-18
63 mm
150 mm
30379534
650-15
63 mm
180 mm
30379535
580-18, 600-18, 650-18, 601-18, 900-18, 901D-18
63 mm
200 mm
30379536
800-20, 801-20, 901-20
80 mm
150 mm
30379541
3000-15, 3001-15, 5000-15
80 mm
150 mm
30379544
5000-15
80 mm
180 mm
30379548
900-18, 2000-18, 3000-18, 3001-18, 4000-18, 5000-18,
80 mm
200 mm
30379542
900-20, 1200-20, 1201-20, 2000-20, 3000-20, 3001-20, 4000-20, 5000-20, 8000-20, 2020
80 mm
230 mm
30379543
1200-23, 1201-23,2000-23, 4000-23, 5000-23, 8000-23, 2023
85 mm
180 mm
30379538
4000-18
90 mm
180 mm
30379549
8000-18HPR, 4000-18
85 mm
200 mm
30379540
1001-20
90 mm
200 mm
30379550
4000-20
85 mm
230 mm
30379539
1001-23, 4000-23
85 mm
250 mm
30364756
2525
S0044.eps
Figure 23 Alignment Tool Chart
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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
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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Sealing Gland Replacement No.: SAIE - 5221
Date: 12-19-95
By: T.A. Rev.: D
1
of 1
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Shimming the Differential Cylinders
Tension Ring
Determining the proper shim size When ever you rebuild differential cylinders, it may be necessary to add shims to the tension ring. Adding shims 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 25 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 24 Measuring for dimension A Figure 26 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 27 Formula for determining shim size In this example, we would need to add 1 - 0.5mm shim 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 shims 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
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
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.
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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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Hydraulic Pumps
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
A (B) Operating pressure PB (bar)
HOME
R
200
G
100
50 0 Flow Q (L/min.)
S
Figure 28 - Pressure Setting Ranges
Figure 30 - 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 29 - 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 31 - 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 32 - Q Min and Q Max Locations on a A7V Variable Displacement Pump
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Rexroth/Hydromatik Model A7V Series 6
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.
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.
Hydraulic Pumps
25ß -
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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 33 - 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 34 - Schematic of a A7VO Variable Displacement Pump
LRH Constant Power Control With Hydraulic Stroke Limiter
X1 Y3 A A1
S
A7VO-107 LR
Figure 35 - Schematic of a A7VO Variable Displacement Pump With Hydraulic Stroke Limiter
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Hydraulic Pumps
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 37 - 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 25
pilot press. PSt in bar setting range
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20 15
Q max
10
Figure 38 - 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 36 - 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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Hydraulic Pumps
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 39 - 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 40 - 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
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
Service Manual
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 41 - Static Operating Curve
Figure 42 - Schematic of A10V0 Variable Displacement Pump
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Rexroth/Hydromatik Model A11VO
Hydraulic Pumps
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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Hydraulic Pumps
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 43 - 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 44 - 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 45 - 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.
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
60
from 3.06 to 15.86 cid. Pressure ratings are 5000 psi intermittent and 3000 psi continuous duty.
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Hydraulic Pumps
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 46 - 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 48 - Schematic of a BPR 105 Variable Displacement Pump With Stroke Limiter
Y
Figure 47 - 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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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
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 49). Use only dry nitrogen, never liquid nitrogen. explwarn.eps
Figure 49 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 50). 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
Pressure Settings
High pressure gas regulator is not included with the kit. These are available from the nitrogen supplier.
45s3blck.epsL
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 50 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 51). Verify zero accumulator pressure on the concrete pump’s accumulator pressure gauge..
acc
um
ma
nifo
ld.e
ps
S0106.eps
Figure 51 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 52 Charge valve assembly
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5. Remove the valve protection cap and the valve seal cap from the accumulator (Figure 53). Leave the valve protection cap on the accumulator until you actually begin the procedure.
Valve Protection Cap
Valve Seal Cap
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 52. 10. Do not open the nitrogen bottle supply valve yet. Turn the regulator adjustment handle on the highpressure regulator (Figure 52) counter clockwise to its minimum setting (closed). 11. Slowly open the nitrogen bottle supply valve (Figure 52). 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!
Valve Stem O-ring
HYDAC bladder Accumulator accum closeup
Figure 53 Detail of accumulator gas valve area 6. On the charge valve assembly (Figure 52, 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 52). 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 52). 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Pressure Settings
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 52) reads the desired pressure of 1450 PSI. Close the nitrogen bottle supply valve. 13. If you overcharge the nitrogen pressure, refer to (Figure 52) 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 52) 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. 54. 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. 55. Replace the gas valve seal cap (tighten to 22 ft/lb), and hand-tighten the valve protection cap. 56. If your concrete pump has two accumulators, repeat this procedure for each accumulator.
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Hydraulic Pump Adjustments
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;
T P T
MG
P MY
Setting the Flow Rate
G Y
Adjustment Knob
Before flow metering the pumps, ensure that the maximum engine Rpm’s are set to the proper specifications. All Schwing units have a metal ID tag located inside the cab displaying the specific RPM settings for that particular unit. Set the supplement system pressure to 0 bar by turning the adjustment knob all the way out on the electric stroke limiter. This will avoid false readings of the flow rate until the maximum flow rate and horsepower break points are set.
Adjustment Knob
Figure 57 Electric Stroke Limiters Install the flow meter. (Consult the operation manual for proper installation and use of the flow meter). Set the engine Rpm’s at maximum and set the maximum flow at the Q max screw to the proper specifications per the output chart. (Check your operators manual for the proper output chart for your specific unit).
A11VO130 / A11VO130
Q-max Screws
A11VO130 / A11VO190
Q-max Screws
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Pressure Settings Horsepower Setting Adjustment Knob
After the flow rate is set, the horsepower setting then must be done. The horsepower break point must be set to the proper specifications per the output chart. CONCRETE PRESSURE
PERFORMANCE CHARACTERISTICS OF THE AXIAL PISTON HYDRAULIC PUMP
ROD SIDE
4500
350 300
4000 3500 3000 2500 2000 1500 1000
250 200
131
117
HYDRAULIC RELIEF VALVE IS SET AT 350 BAR MAX. PRESSURE (5075 PSI).
1600
110
1500
103
P
1400
97
MY
1300
90
1200
83
1100
76
200 Kw
150 100
Break Point 180 Kw = 182 bar 200 KW = 202 bar At 350 bar 180 Kw = 278 l/m 200 Kw = 309 l/m
0
10
20
7.5 15
30 40
50 60
70 80
900
62
800
55
700
48
600
41
500
34
400
27
300
21
200
14
100
7
208 90 100 110 120 130 140 150 160 170 180 190 200 210 220
23 30.5 38 46 53.5 61 69 76.5 84 92 99 107 114 122 130 137 145 153 160 168
cu yd / h cu meters/ h
CONCRETE OUTPUT 5
10 100
15 200
20 300
25 400
30 500
32
535
Number of strokes (stroke / min.) Oil volume (liter / min.)
Break Points
Figure 58 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 59 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.
70
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
Adjustment Knob
Adjustment Knob
Figure 60 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
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 61 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 62) and close it. NOTE! If your unit does not have a shutoff valve, order one from the Schwing Spare
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Figure 62 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 63) 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
lob
rn.
ep
s
Figure 63 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 64) 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.
72
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 63) 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 65) 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 64) 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 64).
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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.
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
130ajst.eps
Figure 64 Adjustment screw locations Soft switch shutoff valve Main Pressure Gauge port
Concrete pump shutoff valve
Closed
hif
lob
rn.
ep
s
Open soft switch relief valve
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Main relief valve 5/32" Allen head 9/16" jam nut Figure 65 Soft switch circuit/Main relief valve
Setting the soft switch relief pressure First, open the soft switch quarter turn valve (Figure 65) 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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Pressure Settings is needed, loosen soft switch relief valve jam nut (Figure 65) 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 65) 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 66 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 67). The general location of the agitator shutoff valve is shown in Figure 66. 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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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
agit.shutoff.eps
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 67 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 68).
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 6-77). 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.
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Jam nut Relief Valve
Figure 68 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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Concrete pump
17valves.epsL
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
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 69). 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 70).
Blckgrvs.eps
open Figure 69 Concrete pump shut off valves
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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
230-bar
17accum.eps
Figure 70 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 71).
17estopman.eps
Relief valve Gauge port
Figure 71 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 71). 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 70).
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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 70). 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 70 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 66). 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 66. 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 66.) 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 67) The general location of the agitator shutoff valve is shown in Figure 66. 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
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 72). Turn the body of the relief valve clockwise to increase or counter clockwise to decrease until 150 bar is showing the pressure gauge.
PS
7.E
lv1
pv
m p/c
pm
wtr
Figure 72 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 67) 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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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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 73). To check or set the main relief pressure:
Lower pressure
Raise pressure
gray valve.eps L
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 74.) 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.
Figure 73 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Pressure Settings
Closed
Ball cock grooves.eps
Open
Figure 74 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 75).
Relief Valve
OU TR IG GE R R ET
RA CT
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XT
EN
D
Figure 75 Outrigger handvalve 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.
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Pressure Settings
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 75) 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. 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
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 76 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 77 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 77). 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.
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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 78 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 79). To check or set the main relief pressure perform the following steps.
relieflocMPS.eps
Main relief valve
Lower pressure
Concrete pump shutoff valve
Raise pressure
gray valve.eps L
Figure 79 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
2. Wear safety glasses when setting pressures.
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Pressure Settings 3. Close the concrete pump shutoff valve (Figure 688) and the soft switch shutoff valve (FigureFigure 81).
Closed
Ball cock grooves.eps
Open
Figure 80 Concrete pump shutoff valve
4Ksoft switch.epsL
Relief valve
Figure 81 Soft switch shutoff valve and relief valve 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.
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7. Read the pressure on the concrete pump pressure gauge, located on the main control block (Figure 79.) 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 jam nut on the relief valve adjusting screw with a 13-mm spanner wrench (Figure 79). 9. 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. 10. 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). 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! 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.
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Pressure Settings
12. 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: 1. Open the soft switch shutoff valve. Close the concrete pump shutoff value. 2. 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 81). 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 79). To check or set the main relief pressure perform the following steps. 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.
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Pressure Settings
Soft switch shutoff valve
Gauge or gauge port
Concrete pump shutoff valve
Pressure control position (closed)
hif
low
brn
.ep
s
Groove lined up with ports - open grooves.eps
Groove at 90° to ports - closed
Jam nut
Main relief valve 4K
op
n-c
lsd
.ep
s
Soft switch relief valve
Allen adjustment screw
Operating position (open)
Figure 82 Concrete pump shutoff valve and soft switch shutoff valve 3. Close the concrete pump shutoff valve and the soft switch shutoff valve (Figure 82). 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.
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7. Read the pressure on the concrete pump pressure gauge, located on the main control block (Figure 82.) 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 82). 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 82.) 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 82). 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 83). .
Accumreg.eps
Accumulator pump pressure regulator
Figure 83 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 84). 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 84).
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Pressure Settings 45s3blck.epsL
e-stop/left.epsL
Relief Valve and Gauge Port
Relief Valve Figure 84 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 85). 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 85 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 83). 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 83). Adjust the accumulator pump pressure regulator
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SERVICE TRAINING
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 87). 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 86).
Pressure Settings
e-stop/left.epsL
Relief Valve and Gauge Port
Figure 87 E-Stop manifold accumulator relief valve
Adjustment Screw
un
.ep lvlv
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 88). 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.
s
Figure 86 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 87).
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Pressure Settings . 45s3blck.epsL
Relief Valve
Figure 88 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 87). 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 66). This hydraulic circuit has a maximum pressure of 210 bar (3045 PSI), limited by the relief valve on the water pump handvalve.
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 66. 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 66.) 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 89) clockwise to increase, or counterclockwise to decrease until 210 bar is showing the pressure gauge.
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.
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SERVICE TRAINING
210 bar Relief Valve
Turn body of valve to adjust. Higher Lower
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 90), clockwise to increase or counter clockwise to decrease until 200 bar is showing the pressure gauge.
;;;;;;;; @@@@@@@@ ;;; @@@ @@@@@@@@ ;;; ;;;;;;;; @@@ @@@ @@@@@@@@ ;;; ;;;;;;;;
4Kpsoutr.eps
WARNING
Clear area before activating outriggers
IN RETRACT OUTRIGGER OUT EXTEND
S
.EP
4K
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/c mp
p
wtr
Outrigger Relief Valve and Gauge Port
Figure 89 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).
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Figure 90 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 91). 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 92). Make sure the whip hose connection is tight.
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agit.shutoff.eps
Pressure Settings WARNING
4Kdshppr.epsL
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
Gauge Port @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; QQQQQQQQQQQQQQQQQQQQ @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; QQQQQQQQQQQQQQQQQQQQ @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; QQQQQQQQQQQQQQQQQQQQ @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; QQQQQQQQQQQQQQQQQQQQ @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;; QQQQQQQQQQQQQQQQQQQQ @@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;
Valve shown in the OPEN position
AMERICA INC. WHITE BEAR, MINNESOTA PHONE 612-429-0999 TWX: 910-563-3539
WEIGHT
Clear area before activating outriggers
Figure 91 Close agitator shutoff valve
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
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
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 92). Turn the body of the relief valve clockwise to increase or counter clockwise to decrease until 200 bar is showing the pressure gauge.
96
SUBSIDIARY OF
U. S. PATENTS: 3.146.721; 3.640.303; 3.409.334;
MODEL
Agitator Relief Valve Figure 92 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
Pressure Settings
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 107). The general location of the agitator shutoff valve is shown in Figure 93.
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 107). 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 93.
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Pressure Settings
•
Boom (Section #1) Down Pressure Relief Valve and Gauge
•
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
•
Main Relief Valve
•
Concrete Pump Pressure Gauge
•
Main Control Panel
•
Outrigger Hand Valve
•
AGITATOR
Soft Switch Shutoff Valve
CONCRETE PUMP
30347529 A
•
Accumulator Unloading Manifold Valve and Gauge EMERGENCY STOP PARO DE EMERGENCIA ARRÉT D'URGENCE
•
Outrigger Hand Valve and Gauge Port
•
Agitator Hand Valve and Gauge Port
•
Agitator Shutoff Valve
Figure 93 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 94).
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17mainreliefvalve.eps
Pressure Settings
8. Read the pressure on the control block pressure gauge, shown in Figure 68. 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.eps
Shutoff valve
Jam nut Relief Valve
Figure 94 Concrete pump main relief valve 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 95). 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.
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closed
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open Figure 95 Concrete pump shut off valves 9. Using a 13-mm spanner wrench, loosen the jam nut on the relief valve adjusting screw (Figure 95). 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 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.
170-bar 138-bar
230-bar 17accum.eps
Figure 96 Accumulator unloading valve (original production)
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 95). 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
1. Locate the accumulator unloading valve (Figure 96). 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 97).
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.
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SERVICE TRAINING
17estopman.eps
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 96). 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 97 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 97). 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 96). 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 96).
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;@Q;@Q;@Q ;@Q;@Q;@Q ;@Q;@Q;@Q ;@Q;@Q;@Q;@Q ;@Q;@Q;@Q;@Q ;@Q;@Q;@Q ;@Q;@Q;@Q
@@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; Gauge @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; 230-bar relief @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; 170-bar relief @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@@@@@@@ ;;;;;;;;;;;;;;;;;;;;;; Figure 98 Accumulator unloading valve (current production
1. Locate the accumulator unloading valve (Figure 98). 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 99.)
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Pressure Settings
Gauge port
Figure 99 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 99). 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.
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 101). 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 101). 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 100). 17e-stop.eps GREASE TOWER BEARINGS 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
Gauge port and relief valve on cab side of
SAFETY INSTRUCTIONS
= =
STOP
WARNING
manifold block.
Emergency stop switches do NOT function when manual bypass is depressed.
AT TE NT IO N!
Relief valve
Setting the boom E-Stop manifold pressure
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17estopman.eps
WARNING Do not operate at pressures exceeding the rating of the entire material delivery system.
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 98.) 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 98.) 4. Tighten the jam nuts on all adjustment screws.
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Figure 100 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 100). 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.
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.
NOTE!
6.
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 101). 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.
7.
8.
9.
300 bar Relief Valve
Turn body of valve to adjust. Higher Lower
Pressure Settings
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 102). 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
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Figure 101 Boom/outrigger hand valve
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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.
Setting the boom pressures
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The boom circuit is set to a maximum of 280-bar (4060 PSI) by the relief valve on the boom hand valve assembly (Figure 103).
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.
REAR FOOT
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Relief Valve
Figure 102 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 102. 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.
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Ele Sta ctro vo y ba cu 17 ltage ck tion fe et wir fromhaza (5 es hi rd m et at le gh . er s) ast .
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Do m not ac tra hi oper ne th inin w ate e m warg. Unithou this an ua ning ders t ls an s in tand d on safe de ty ca ls.
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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 104.
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Turn body of valve to adjust.
Higher
280 bar Relief Valve
Pressure Settings
Lower
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Figure 104 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 104). 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.
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 105.
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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Pressure Settings
170-bar gauge port 170-bar relief valve
;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@ @; @; ;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@ @;@;@;@;@;@;@;@;@;@;@;@; @; ;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@ @;@;@;@;@;@;@;@;@;@;@;@; ;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@ @;@; @;@;@;@;@; @;@; ;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@ @;@;@; @; abbreviated for clarity) @;@;@; @;(Hoses DA
Ele Sta ctr vo y oc 17 ltag bac utio fe e w k fr n h et o a (5 ires m zard h m ete at le igh . rs as ). t
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Figure 105 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
106
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
PS
7.E
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/cm
p rpm
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Figure 106 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 107). 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 107). Skip to Step 6.
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Pressure Settings
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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.
Figure 107 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
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KVM 28X
Pressure Settings
1. Locate the agitator shutoff valve, and close it (Figure 1). The general location of the agitator shutoff valve is shown in Figure 1.
Check all 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. 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
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, 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. Closed
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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.
Shown in the open position
Be sure that the waterbox covers are installed on the waterbox. We do not recommend using the remote control box for the following procedures.
Figure 1 Agitator shutoff valve
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:
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Pressure Settings 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 2
The general location of the components used to check or set hydraulic pressures are shown in Figure 2.
Boom (Section #1) Down Side 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)
Boom/Outrigger Hand Valve and Gauge Port plus Agitator Hand Valve and Gauge Port
Soft Switch Shutoff Valve (twin circuit) Dampener circuit) Concrete Valve
Valve
Pump
Concrete pump forward/reverse and Agitator Hand Valves
(single
Soft Switch and Concrete Pump Relief Valves
Shutoff
Outrigger Hand Valve Outrigger Hand Valve and Gauge Port Concrete Pump Pressure Gauge Accumulator Unloading Manifold Valve and Gauge (twin circuit)
Rear Control Panel Electric Agitator Switch Accumulator Pressure Gauge (twin circuit)
Agitator Shutoff Valve
Figure 2 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 operate at a maximum pressure of 300 bar (4350 PSI). It is controlled by the main relief valve (Figure 3). 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:
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
grooves2.eps
Grooves in handle should line up with grooves in valve shaft Lower pressure
Raise pressure
gray valve.eps
Figure 3 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 80). 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, counterclockwise, 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 4 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 3). 11. Turn the adjustment knob on the relief valve to adjust the pressure. Turn the adjustment knob in (clockwise) to raise pressure and out (counter clockwise) to lower the pressure.
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Pressure Settings 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.) 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).
WARNING
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Hot oil expulsion hazard. Stand away from pumpkit when checking hydraulic pressures.
3. Close the concrete pump shutoff and soft switch shutoff valves (Figure 5). 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, to loosen the jam nut on the main relief valve adjusting screw (Figure 5). 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.
NOTE! 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 5 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.
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SERVICE TRAINING
Pressure Settings
w
Gauge port
Hif
lrv
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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
Grooves in handle should line up with grooves in valve shaft
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Figure 5 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 pressure out the concrete pump. The pressure gauge should read 80 bar (check your schematic). If no adjustment is needed, skip to Step 4. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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. 4. Be sure to open the concrete pump shutoff valve when you are finished. The unit cannot stroke with this valve closed.
Set accumulator circuit hydraulic oil pressure (units with a pressure- compensated pump)
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Pressure Settings 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 83).
.
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NOTE! If your unit is a current production model (Figure 6), skip Steps 3,4, and 8 of this procedure.
Accumulator pump pressure regulator
Figure 7 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 84). 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 84).
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Relief Valve and Gauge Port
Figure 6 E-Stop manifold (current production)
Figure 8 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 9). Pressure should read 300 bar (4350 PSI). If no adjustment is needed, skip to Step 8.
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.
accumgag.eps
WARNING Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
Figure 9 Accumulator pressure gauge 7. If additional pressure adjustment is needed, locate the accumulator manifold pressure relief valve (Figure 85). 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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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 83). 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 83). 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).
Setting the outrigger pressure 45s3blck.eps
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 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 11). 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
NOTE! Figure 10 Accumulator manifold pressure relief valve
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On some pump units the relief valve may be in a slightly different location (opposite side) than shown in Figure 11.
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Pressure Settings
Lower
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 hand valve, and replace the cap on the gauge port.
280 bar Relief Valve
Higher
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.
Turn body of valve to adjust.
Electric stroke limiter Figure 11 Outrigger hand valve 1. Connect the whip hose of a 0–400 or 0–600 bar gauge to the gauge port on the back or side of the passenger side outrigger hand valve (Figure 11). 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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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 hand valve (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.
NOTE! You cannot use the extend position for this adjustment because extend has a nonadjustable secondary relief function 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 11). Turn in (clockwise) to raise pressure; turn out (counter clockwise) to lower pressure.
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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 America 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 12.
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
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Pressure Settings NOTE!
and must be fine tuned from there. It was fine tuned at the factory and should not be adjusted unless absolutely necessary.
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.
WARNING Entanglement hazard. Stop drive shafts before adjusting Q-min.
Boom Hand Valves
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E-Stop Manifold
∆P Regulator
Q-min Adjust Screw
Figure 12 Location of components used to check or set boom pressures
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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
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boom control block relief valve
15 bar pretension adjustment screw
Figure 13 Boom hand valves
Check or set Delta-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.
4.
NOTE! 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 button will damage the low pressure gauge.
5.
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 13).
6.
7.
adjusted by a screw on the boom hydraulic pump (Figure 14). Turn the Q-min adjustment screw out (counterclockwise) 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 whatever amount it was turned out. If adjustment is needed, continue to Step 8.
Entanglement hazard. Stop drive shafts before adjusting Q-min.
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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
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Check or set Q-min
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Figure 14 Q-min adjust screw 8. Delta P is adjusted by the ∆P screw on the ∆P regulator (Figure 15). The location of the ∆P regulator valve is shown in Figure 12. 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.
Q-min pressure is checked when the engine is at the maximum specified RPM, but must be adjusted 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 13). 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).
WARNING Entanglement hazard. Stop drive shafts before adjusting Q-min.
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Q-min adjustment screw
NOTE! 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 15 ∆P regulator valve
∆P adjust screw
3. 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 turning, and turn the Q-min adjustment screw in until the pressure is below 100 bar, then install the 0 - 100 bar gauge. 4. Bring the engine RPM to maximum. Q-min pressure should read 40 - 45 bar. 5. 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. 6. If adjustment is needed, continue to Step 7. 7. Turn the Q-min screw in to raise the pressure (Figure 14). 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.
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Pressure Settings 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 16): 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).
∆P Regulator Valve (high pressure adjustment screw)
0-400 bar gauge port
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E-Stop Manifold Redundant Relief Valve
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Figure 16 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
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1. Loosen the jam nut of the high pressure adjustment screw on 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 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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Pressure Settings
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 the #1 cylinder retract function (Figure 17). 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 17). 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) 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 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. Lower section #1 into the cradle, and attach the boom transport strap.
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Pressure Settings
140 bar gauge port
140 bar relief valve
Figure 17 140 bar relief valve and gauge port
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Pretension gauge port
Figure 18 Pretension adjustment screw and gauge port
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Pretension adjustment screw
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 18). 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 18). 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.
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.
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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 on the passenger side of the main control block (Figure 19).
Agitator Relief Valve Turn body of valve Gauge port
Higher
to adjust
Lower
5.
6. 7.
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8. Figure 19 Agitator hand valve 1. Stop the unit, and put the key in your pocket. 2. Connect the whip hose of a 0-400 or a 0–600-bar gauge to the gauge port on the agitator hand valve (Figure 19). 3. If your unit is equipped with an agitator shutoff valve, close it (Figure 20). Skip to Step 5.
9.
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Shown in the open position 11. Figure 20 Agitator shutoff valve
Pressure Settings
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 back of 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 shutoff valve or remove the dead plugs, and store them in a clean area like 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.) Remove the whip hose and pressure gauge. Replace the gauge port cover.
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 Schwing’s Spare Parts Department and order them before continuing with this procedure. All of these Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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S 31 XT 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 108), 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 108). If the handle is removed from the agitator shutoff valve (Figure 108) or the concrete pump shutoff valve (Figure 110) 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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Open Mounting screw and washer removed for illustration
Motor
Figure 108 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 110). (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 37), 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 111) 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.
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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 14. 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 111). Gauge port
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Main relief valve Soft switch relief valve
Figure 109 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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02
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Figure 110 Showing the concrete pump and soft switch shutoff valves
Grooves in handle
Grooves in shaft
Closed
Closed
Open
Main relief cartridge
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Open Mounting screw and washer removed for illustration
soft switch relief cartridge 9/16" jam nut
5/32" Allen head 9/16" jam nut
Figure 111 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 112 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 111). 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 (4). 3. Loosen the jam nut on the soft switch relief valve (Figure 5) 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 111) 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.
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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 371.
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 113. 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 113 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 114) 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!
CAUTION
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!
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Boom control block relief valve (non-adjustable)
15 bar pretension adjusment screw
30 bar pilot pressure relief cartridge
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Pressure Settings
Q-min adjustment screw
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Figure 115 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 115). 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 223. 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 44 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 44 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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Figure 116 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 115). 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 115). 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 45):
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
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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 117 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 117) 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. 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 117), 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. To set the 280 bar relief valve for the outrigger circuit:
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.
Wear safety glasses any time you check or set pressures. Oil expulsion hazard!
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WARNING
NOTE!
1. Plug the whip hose of a 0-400 or 0-600 bar gauge (Figure 46) 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 118) 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
000
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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 118 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 10. 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.
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.
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AGITATOR
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
00
04
40
.ep
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Figure 119 Location of the 280 bar outrigger pressure relief valve (Hoses removed for clarity)
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Pressure Settings Setting 15 bar pretension
CAUTION 000439.eps
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 118).
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 120 Pretension adjustment screw and gauge port
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Pressure Settings
Setting the agitator circuit pressure 000447.eps
Agitator Relief Valve Turn body of valve Higher to adjust.
Gauge port
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.
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WARNING Clear area before activating outriggers
Concrete pump Fwd/Reverse
REAR EXTEND
FRONT JACKING
FRONT EXTEND
88
02
00
REAR JACKING
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Figure 121 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 49. 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 62).
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.
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Agitator quarter turn shutoff valve (open position)
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Motor
Figure 122 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 49), 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.
4. Read the pressure on the accumulator circuit pressure gauge (Figure 124). 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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2. Loosen the jam nut on the pressure regulator of the accumulator hydraulic pump (Figure 123). 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.
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Figure 124 Accumulator circuit pressure gauge 000289.eps
Accumulator pump pressure regulator
5. Locate the accumulator manifold pressure relief cartridge (Figure 125). 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 123 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
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Figure 125 Accumulator manifold pressure relief cartridge and manual bleed valve
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SERVICE TRAINING
Pressure Settings
WARNING Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
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6. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 124), 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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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
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 126).
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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 50 on page 6-228.
Pressure Settings
Bra
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Pressure gauge Main relief valve
Jam nut Lower pressure
Raise pressure
Adjustment handle
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Figure 126 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 127. Close the shutoff valve (also known as the ball cock or quarter turn valve).
Figure 127 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
140
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 6-139.
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SERVICE TRAINING About proportional boom systems
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 130.
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
Figure 128 Locations of components used to check and set boom pressures
Pressure Settings
Q-min adjustment screw
P regulator
CONCRETE PUMP
FWD
XL
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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 129.) 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 130). Unscrew the Q-min screw three full turns. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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 (4.). 4. Delta P is adjusted by the ∆P screw on the ∆P regulator (see Figure 131). 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
ps v.e itprd
boom control block relief valve
ap
15 bar pretension adjustment screw
Figure 129 Showing the location of the boom circuit pressure devices (Hoses removed for clarity.)
Q-min adjustment screw
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Q-max
Figure 130 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 130).Remove the 0 - 40 bar gauge from the 0 - 400 bar gauge port, and install the 0 - 600 bar gauge in its place.
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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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SERVICE TRAINING
Pressure Settings
CAUTION Do not operate any functions while setting ∆P.
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P adjustment screw
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 130). 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 132) 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. location of this valve causes you to be near the drivelines, be sure to stop them from turning before Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Figure 131 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 accessing the valve.
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Pressure Settings
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Redundant relief valve T
High pressure adjustment screw
MP
1
10
16
78
92
-7.
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P2
P3
P4
P1
M
TT
0-400 bar gauge port 0-60 bar gauge port
ap
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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 133). 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
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Figure 132 The three boom pressure
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 the boom in the cradle. (See figure 134.) 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 134).
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SERVICE TRAINING
Concrete pump dump valve
Pressure Settings
Boom dump valve
Outlet to tank
Boom / Outriggers Pilot drain
Concrete pump
Accumulator
Water pump / compressor / agitator estophartbm.eps
MP
S
Boom/outrigger circuit dump valve
T MP
ps
P3
s.e
pre
op est
S
P2
P4
Boom override button
P1
Boom/outrigger inlet port Figure 133 Emergency stop manifold original production (top), current production
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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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).
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Pressure Settings 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
ap
it14
0.e
ps
Figure 134 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 46). 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 46 and Figure 47).
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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 46. 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 47. 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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SERVICE TRAINING
Pressure Settings
Gauge port
Figure 135 Position of the outrigger selector valve
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ap
Outrigger handle
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REAR EXTEND
FRONT EXTEND
REAR FOOT
FRONT FOOT
Figure 136 Location of the passenger side outrigger control block
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Pressure Settings
280 bar Relief Valve
Lower
PS
oc
Higher
bb
ck.
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Turn body of valve to adjust.
Figure 137 Location of the outrigger circuit relief valve
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 10. 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:
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1. Stop the truck engine. Plug the 0 - 40 bar gauge into the pretension check port of the Apitech handvalve (Figure 138). 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 49). 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.
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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 Figure 138 Pretension adjustment screw and gauge agitator pressure check.eps L
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Relief valve on this side (not visible from this angle).
Gauge port
Figure 139 Showing the agitator handvalve and gauge port (Diamond plate removed for this illustration.) 3. Start the engine, if not already running. 4. Close the agitator shutoff valve. (See Figure 140.) 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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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Pressure Settings
ag its o. ep s
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Figure 140 The agitator shutoff valve
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SERVICE TRAINING
32 XL Twin Circuit
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
•
Pressure Settings
Check the fluid level of the distribution gearcase. (See Figure 141). Be sure the truck is on reasonably level ground. With the truck engine
1
2 4194.e ps
Figure 141 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:
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1. Locate the agitator shutoff valve and close it. There is a picture of the location on page 6-228. 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 142). 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 127. 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 142. 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 14. 10. Using a 13 mm spanner wrench, loosen the jam nut on the relief valve adjusting screw (Figure 142). 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.
relieflocMPS.eps
Main relief valve Pressure Gauge
Jam Nut Adjustment Handle Lower pressure
Raise pressure
gray valve.eps
Figure 142 The main relief valve, concrete pump circuit.
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Pressure Settings soft switch.epsL
Figure 143 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 144 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 143 and 144. 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
3. Be sure to open the concrete pump shutoff valve on the side of the brain (shown in Figure 143) 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- 221. To set the 300 bar boom circuit relief valve proceed as follows: (See Figure 145) 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
Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
300 bar Relief Valve
Figure 145 Showing the location of the boom circuit pressure devices. (Hoses removed for clarity.)
Lower
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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 145). 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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Turn body of valve to adjust.
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 146). 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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SERVICE TRAINING
Concrete pump dump valve
Pressure Settings
Boom dump valve
Outlet to tank
Boom / Outriggers Pilot drain
Concrete pump
Accumulator
Water pump / compressor / agitator estophartbm.eps
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Boom/outrigger circuit dump valve
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Boom override button
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Figure 146 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 217. 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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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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 149.
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
CONCRETE PUMP
FWD
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E-Stop manifold
Figure 147 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 145.)
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
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boom control block relief valve
15 bar pretension adjustment screw
Figure 148 Showing the location of the boom circuit pressure devices. (Hoses removed for clarity.) 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 149). 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 (4.).
Q-min adjustment screw
Qminscrew.eps
Q-max
Figure 149 Location of the Q-min adjustment screw Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Pressure Settings 4. Delta P is adjusted by the ∆P screw on the ∆P regulator (see Figure 150). 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
000435.eps
Do not operate any functions while setting ∆P.
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P adjustment screw
Figure 150 The ∆P regulator valve
Setting Q-min •
1.
1.
1.
1.
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 149). 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.).
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1. Turn the Q-min screw in to raise the pressure (Figure 149). 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 151) 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
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.
000436.eps
Redundant relief valve
MP
High pressure adjustment screw
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0-400 bar gauge port 0-60 bar gauge port
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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: 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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Figure 151 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 134.) 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 152). 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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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 46). 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 154).
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 46. 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 154. 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 152 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
8. Read the pressure on the gauge. It should read 280 bar (4060 PSI). If no adjustment is needed, skip to step 10. 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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Pressure Settings
7plcORhndl.eps
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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Figure 153 Position of the outrigger selector valve Monsun-Tyson black & white (top right) Apitech proportional (bottom left)
Outrigger handle
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:
pressure in the agitator circuit to 200 bar (2900 PSI). (See Figure 155). 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 156.) 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.
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
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32Porct5.eps
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Higher
Pressure Settings
280 bar Relief Valve
Lower
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Turn body of valve to adjust. REAR EXTEND
FRONT EXTEND
REAR FOOT
FRONT FOOT
Figure 154 Location of the 280 bar outrigger pressure relief valve. (Hoses removed for clarity).
agitator pressure check.eps L
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Relief valve on this side (not visible from this angle).
Gauge port Figure 155 Showing the agitator handvalve and gauge port. (Diamond plate removed for this illustration.)
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Pressure Settings
ag its o. ep s
closed
Figure 156 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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SERVICE TRAINING
32 XL Hi-Flow B&W Units up to 450 l/m •
Check the fluid level of the distribution gearcase. (See Figure 141). Be sure the truck is on reasonably level ground. With the truck engine
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.
2
4194 gearcase scan.eps
1
Figure 157 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.
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.
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 6-228. Note! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and
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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 158. The illustration below shows the gen-
Boom control block
32
prs
loc
.ep
s
E-Stop manifold Soft Switch ball cock REV FWD
CONCRETE PUMP
Ball cock (quarter-turn valve)
Outrigger pushbutton
Outrigger pushbutton
Passenger side outrigger controls
Driver's side outrigger controls
Agitator control valve
Control panel
Agitator shutoff valve
Figure 158 Location of the pressure setting devices
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SERVICE TRAINING
Check the concrete pump pressure (2020, 2023, 2525 pumpkits) •
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
Hif
lrv
vw
.ep
s
Main relief valve Soft switch relief valve
Figure 159 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 38, 161, and 162. Locate and close the concrete pump shutoff valve, and the soft switch shutoff valve. (These valves are also known as quarter turn valves). Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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 160 Showing the concrete pump and soft switch shutoff valves
Groove lined up with ports - open grooves.eps
Groove at 90° to ports - closed
Figure 161 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 (14.) on page 6218. 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
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valve so you will be out of the way if a hose or fitting blows. See Figure 162. 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 162). 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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Pressure Settings
op
n-c
lsd
2.e
ps
closed
open Main relief valve Soft switch relief valve Figure 162 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 162. 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 (4.). 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
4. Be sure to open the concrete pump shutoff valve on the side of the brain (shown in Figure 163) 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 164) 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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Pressure Settings
Gauge port
Hif
lrv
2.e
ps
Main relief valve Soft switch relief valve
Figure 163 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 165). 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.
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7. If you cannot achieve 300 bar, it is possible that there is a problem with the emergency stop manifold (see Figure 166). 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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SERVICE TRAINING
Pressure Settings
7plcpres.eps
Use #2, 3, or 4
140 bar port
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 164 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
s
ep
m.
oo
lcb
7p
Figure 165 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 172.
MP
S
Boom/outrigger circuit dump valve
T MP
ps
S
P3
s.e
re opp
est
P2
P4
Boom override button
P1
Boom/outrigger inlet port Figure 166 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 167.) 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 134). 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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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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SERVICE TRAINING
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.
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 167 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 46). 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 170).
1. Wear safety glasses whenever you check or set pressures.
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2. Plug the whip hose of a 0 - 400 or 0 - 600 bar gauge into the gauge port. Location is shown in figure 46. 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 47. 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 168 Position of the outrigger selector valve
32Porct5.eps
REAR EXTEND
FRONT EXTEND
REAR FOOT
FRONT FOOT
Figure 169 Location of the passenger side outrigger control block
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SERVICE TRAINING
Pressure Settings
280 bar Relief Valve
Lower
PS
oc
Higher
bb
ck.
ep
s
Turn body of valve to adjust. Figure 170 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 10. 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 171). 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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 172.) 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 171 Showing the agitator handvalve and gauge port. (Diamond plate removed for this illustration.)
ag its o. ep s
closed
open
Figure 172 The agitator shutoff valve
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SERVICE TRAINING
32 XL High Flow Proportional
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
Pressure Settings
Check the fluid level of the distribution gearcase. (See Figure 173). Be sure the truck is on reasonably level ground. With the truck
1
2 4194.e ps
Figure 173 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:
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1. Locate the agitator shutoff valve and close it. There is a picture of the location on page 6-228. 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 37).
Gauge port
Hif
lrv
vw
.ep
s
Main relief valve Soft switch relief valve
Figure 174 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 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.
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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 (14.) on page 6-218. If adjustment is needed, proceed to step (10.).
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 5. If the main relief valve needs adjustment, proceed as follows:
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Pressure Settings
Soft switch shutoff valve Main pressure gauge port
Concrete pump shutoff valve
hif
low
br
n.
ep
s
Figure 175 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
.ep
s
Figure 176 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 177 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 177). 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:
180
1. Open the soft switch shutoff valve, as shown in Figure 176. 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 (4), below. If no adjustment is needed, skip to step (4.). 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 176) 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
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 180.
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 217. 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
Manual boom handvalves
Pressure Settings
Q-min adjustment screw
P regulator
CONCRETE PUMP
FWD
XL
loc
.ep
s
REV
32
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Figure 178 Locations of components used to check and set boom pressures
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 179.) Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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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
ps v.e itprd ap
boom control block relief valve
15 bar pretension adjustment screw
Figure 179 Location of the boom circuit pressure devices (Hoses removed for clarity.) 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 180). 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 (4.).
Q-min adjustment screw
Q-minscrew.eps
Q-max
Figure 180 Location of the Q-min adjustment screw 4. Delta P is adjusted by the ∆P screw on the ∆P regulator (see Figure 181). Loosen the jam nut and adjust the screw inward to increase pressure, or
182
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
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.
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
CAUTION
000435.eps
Do not operate any functions while setting ∆P.
T
P adjustment screw
Figure 181 The ∆P regulator valve
Setting Q-min •
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 180). 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 180). Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the adjustment. When
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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 182) 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 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
MP
1
10
16
78
92
-7.
ep
s
P2
P3
P4
P1
M
TT
0-400 bar gauge port 0-60 bar gauge port
ap
•
ipo
.ep nly
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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
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Figure 182 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 valve. If pressure
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SERVICE TRAINING
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 183.) 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 183). 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 46). 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 46 & Figure 47).
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 46. 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 185. 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 183 Location of the 140 bar relief valve and gauge port
1 Gauge port
s
.ep
hd
itor
ap
Outrigger handle
Figure 184 Position of the outrigger selector valve on units equipped with Apitech proportional valves
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Pressure Settings
280 bar Relief Valve
Lower
32Porct5.eps
PS
oc
Higher
bb
ck.
ep
s
Turn body of valve to adjust.
REAR EXTEND
FRONT EXTEND
REAR FOOT
FRONT FOOT
Figure 185 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 10. 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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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 183). 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 186 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 187). 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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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 188.) 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
Gauge port
Pressure Settings
Relief valve on this side (not visible from this angle).
Figure 187 Showing the agitator handvalve and gauge port. (Diamond plate removed for this illustration.)
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Figure 188 The agitator shutoff valve
open
9. Replace the aluminum diamond plate over the agitator handvalve.
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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 189). Be sure the truck is on reasonably level ground. With the truck engine
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.
Breather / filler grbx-5-6.eps
Check port 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 6-228. Note! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Figure 189 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 37). 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
Hif
lrv
vw
.ep
s
Main relief valve Soft switch relief valve
Figure 190 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 38. 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,
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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 (14.) on page 6218. 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 192. 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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SERVICE TRAINING
Pressure Settings Soft switch shutoff valve Main pressure gauge port
Concrete pump shutoff valve
hif
low
br
n.
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closed
Groove lined up with ports - open grooves.eps
Groove at 90° to ports - closed
open
Figure 191 Showing the concrete pump and soft switch shutoff valves and their open/closed orientation
op
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lsd
.ep
s
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
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 5. 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.
A11ctoff.eps
Figure 192 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Pressure Settings
Gauge port
Hif
lrv
vw
.ep
s
Main relief valve Soft switch relief valve
Figure 193 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 193). 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 191. The rest of the unit should still be set up as though you were going to check concrete pump pressure.
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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 (4), below. If no adjustment is needed, skip to step (4.). 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 191) 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 6-217. 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
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 41. P regulator Q-min adjustment screw
CONCRETE PUMP
REV
FWD
Figure 194 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 195.) Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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 195). 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 (4.). 4. Delta P is adjusted by the ∆P screw on the boom pump regulator (see Figure 195). 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
Hi
pm
pb
m.
ep
s
Figure 195 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
s
ep
rdv.
boom control block relief valve
itp ap
15 bar pretension adjustment screw
Figure 196 Showing the location of the boom circuit pressure devices. (Hoses removed for clarity.)
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Setting Q-min •
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 195). 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 44). 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 197) 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
MP
1
TT
10
16
78
92
-7.
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0-60 bar gauge port
s
P2
P3
P4
P1
M
0-400 bar gauge port
ap
ipo
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boom control block relief valve
Pressure Cut-off adjustment screw
ILbmpmp.eps
Figure 197 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 198). 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.
MP
S
Boom/outrigger circuit dump valve
T MP
ps
S
P3
s.e
re opp
est
P2
P4
Boom override button
P1
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 199.) 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 199). 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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Figure 198 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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140 bar gauge port
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Figure 199 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 199). 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 201).
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 201.
200
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 201. 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 10.
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Outrigger handle
Gauge port
1 Gauge port
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DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
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Do not operate this machine without training. Understand the warnings in safety manuals and on decals.
Figure 200 Position of the outrigger selector valve Monsun-Tyson black & white (right) Apitech proportional (left)
280 bar Relief Valve
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Figure 201 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 202). 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 202 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 203). There is a gauge port for checking or
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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 204.) Note! If your unit does not have a shutoff valve, you can order one using part number 10004680
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Relief valve on this side (not visible from this angle).
Gauge port
Figure 203 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.
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Figure 204 The agitator shutoff valve
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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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KVM 32 XG
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 the Appendix, section 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.
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 36) 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
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Figure 21 Agitator shutoff valve Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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
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:
WARNING Wear safety glasses any time you check or set pressures. Oil expulsion hazard!
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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 38 next page). (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 37), install a 0 - 400 or 0 - 600 bar gauge in the gauge port.
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Pressure Settings 5. The local/remote switch located on the controller cover 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. 8. CAUTION! The main relief valve (Figure 39) 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. 9. 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. 10. 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 14 of the next procedure. If adjustment is needed, proceed to next paragraph.
If your unit has any pumpkit other than a Hi-flo -4, call SAI Service Department and ask for the proper pressure setting procedures for your specific pumpkit. 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 37). 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.
Setting the main relief valve on -4 pumpkit NOTE!
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Figure 22 Location of the concrete pump circuit main relief valve and soft switch relief valve
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Soft switch shutoff valve Main Pressure Gauge port
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Figure 23 Showing the concrete pump and soft switch shutoff valves
Grooves in handle
Grooves in shaft
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Main relief cartridge
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Open Mounting screw and washer removed for illustration
soft switch relief cartridge 9/16" jam nut
5/32" Allen head 9/16" jam nut
Figure 24 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 5) with a 9/16” spanner wrench. Adjust the
To check or adjust the soft switch pressure setting, proceed as follows: 1. Open the soft switch shutoff valve (Figure 38). 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 (4).
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 38) on the side of the brain when you are finished. The unit cannot stroke with this valve closed.
Gauge port
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Main relief valve Soft switch relief valve
Figure 25 Location of the main relief valve
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0-400 bar gauge port Boom control block relief valve Redundant relief valve
0-60 bar gauge port
15 bar pretension adjusment screw
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140 bar downside relief cartridge (non-adjustable) Figure 26 The boom pressure devices
Setting boom pressures There are two pressure settings on the boom circuit: the redundant relief valve and the boom control block relief (Figure 45). 1. Install 0-400 or 0-600 bar gauge in the 0-400 bar gauge port (Figure 45). 2. The redundant relief valve located in the emergency stop manifold (Figure 45) should first be turned out two turns by loosening the jam nut with a 9/16” open end wrench and turning the cartridge out with a 4 mm Allen wrench. 3. The boom control block relief valve (Figure 45), should then be turned in one turn by using a 1/8” allen wrench to remove the cover guard and a 5/32” allen wrench to turn in the screw. 4. The redundant relief valve, located in the emergency stop manifold, should be set at 330 bar. Activate any boom cylinder, except #1, to the boom in or boom down position. The gauge should be reading lower than the target 330 bar. Turn the screw in until it reaches 330 bar.
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5. The boom control block relief valve can then be turned out with the handle still activated until the gauge reads 300 bar.
NOTE! The gauge will always read the lowest relief setting in the system; therefore, we turn the pressure up on the boom control block in step #3 to assure that it is higher than the 330 bar required for the redundant relief valve.
140 bar down side relief The down side relief is now a non-adjustable, internal valve which is verified at the factory and should not require further attention. If you feel you need to verify the down side relief call Schwing Service Department and ask about the proper procedure for doing so.
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. When the outrigger selector pushbutton is pushed, the outrigger valve handle is activated, which routes oil to the two outrigger
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Pressure Settings 0-400 bar gauge port
Outrigger handle
15 bar pretension adjusment screw
Figure 27 Position of the outrigger selector valve on units equipped with Apitech proportional valves 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:
Wear safety glasses any time you check or set pressures. Oil expulsion hazard!
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WARNING
1. Plug the whip hose of a 0-400 or 0-600 bar gauge into the gauge port shown (Figure 46) or the port on the outrigger hand valve. 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 47) on the bottom of the outrigger valve. 4. Set the engine RPM to maximum. 5. Select “outrigger” with the outrigger pushbutton or manual handle (Figure 46). 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 10.
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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. 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).
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.
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 48 page 211). 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.)
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REAR EXTEND
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Figure 28 Location of the 280 bar outrigger pressure relief valve. (Hoses removed for clarity).
CAUTION Truck engine must be at idle to set pretension. Gauge damage possible!
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.
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Setting the agitator circuit pressure The agitator relief valve is located in the agitator forward / neutral / reverse handvalve (Figure 49). The relief valve (not completely visible in Figure 49) limits the pressure in the agitator circuit to 200 bar (2900 PSI). There is a gauge port (not visible in Figure 49) 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:
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Pressure Settings 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.
0-60 bar gauge port
15 bar pretension adjusment screw
Figure 29 Pretension adjustment screw and gauge port
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Figure 30 Agitator handvalve 3. Close the agitator shutoff valve (Figure 50).
NOTE!
30303432 (tube). Contact Schwing America’s Service Department at (651) 4290999 for installation instructions.
If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and part number
4. Activate the agitator, and read the pressure on the gauge.
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5. If adjustment is needed, put your wrench on the body of the relief valve (Figure 49), 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.
Pressure Settings
6. Put the agitator handle in neutral. 7. Remove the whip hose and pressure gauge. Replace the gauge port cover.
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Figure 31 The agitator shutoff valve
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Agitator quarter turn shutoff valve (open position)
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Pressure Settings Setting accumulator circuit pressure
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Accumulator pump pressure regulator
Redundant Relief cartridge
Figure 32 Accumulator pump pressure regulator for A7VO (above) and for A11VO (below)
Figure 33 Accumulator redundant relief cartridge
Boom Pump Accumulator Pump
Standby Pressure Screw 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.
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 53). 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). 45acumpr.epsL
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 51). Turn the screw in two-and-one-half turns. This will raise the regulator pressure above 300 bar. 3. Loosen the jam nut (Figure 52) 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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Figure 34 Accumulator circuit pressure gauge
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8. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 51), 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.
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Pressure Relief Cartridge Manual bleed valve
NOTE! The accumulator circuit hydraulic pump pressure regulator is sometimes referred to as the pressure cut-off.
Figure 35 Accumulator manifold pressure relief cartridge 6. Locate the accumulator manifold pressure relief cartridge (Figure 54). 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 52) 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 Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
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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. 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 36) 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.
If you wish to order a CD ROM which explains the pressure setting procedure for a specific model (all pumpkits), call Schwing 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
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:
WARNING Wear safety glasses any time you check or set pressures. Oil expulsion hazard!
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Figure 36 Agitator shutoff valve Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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 38). (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 37), install a 0 - 400 or 0 - 600 bar gauge in the gauge port.
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Pressure Settings 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 39) 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, and 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 14. 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: 10. Wear safety glasses when checking or adjusting pressures. 11. Using a 9/16” spanner wrench, loosen the jam nut on the main relief valve adjusting screw (Figure 37). 12. 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. 13. 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. 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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Figure 37 Location of the concrete pump circuit main relief valve and soft switch relief valve
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Pressure Settings
Soft switch shutoff valve Main Pressure Gauge port
Concrete pump shutoff valve
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Figure 38 Showing the concrete pump and soft switch shutoff valves
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Open Mounting screw and washer removed for illustration
soft switch relief cartridge 9/16" jam nut
5/32" Allen head 9/16" jam nut
Figure 39 Shutoff valve open / closed orientation
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Pressure Settings 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 (Figure 38). The rest of the unit should still be set up as though you were going to check concrete pump pressure. 2. Pressure out 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 (4).
3. Loosen the jam nut on the soft switch relief valve (Figure 5) 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 38) on the side of the brain when you are finished. The unit cannot stroke with this valve closed.
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Figure 40 Location of the main relief valve
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SERVICE TRAINING
Pressure Settings
Setting ∆P
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 217. 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 41. You will need an assistant for parts of this procedure. You and any assistants should wear eye protection when checking or setting pressures.
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 42) of the manual boom hand valves. 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. 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 43). 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 223. If adjustment is needed, continue to step (4).
Manual boom handvalves, Delta P adjustment and E-Stop manifold
Figure 41 Locations of components used to check and set boom pressures
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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 42 Location of the boom circuit pressure devices (Hoses removed for clarity.)
boom control block relief valve
CAUTION
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4. Delta P is adjusted by the ∆P screw on the ∆P regulator (Figure 44). 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 43 Location of the Q-min adjustment screw
∆P adjustment screw
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Do not operate any function during this procedure. Gauge damage possible!
140 bar downside relief cartridge
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Figure 44 The ∆P regulator valve
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SERVICE TRAINING 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 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 43). 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.
Pressure Settings
5. Turn the Q-min screw in to raise the pressure (Figure 43). 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 45) 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
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15 bar pretension adjustment screw
140 bar gauge port (use 0-400 bar gauge when checking)
0-60 bar gauge port
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0-400 bar gauge port
boom control block relief valve
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Figure 45 The three boom pressure devices 34blck.eps
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Pressure Settings 1. Loosen the jam nut of the high pressure adjustment screw (Figure 45) 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 45) 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 45) 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
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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 45) 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 45. 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 45) 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.
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SERVICE TRAINING
Pressure Settings
Setting the outrigger pressures
Outrigger handle
0-400 bar gauge port
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Figure 46 Position of the outrigger selector valve on units equipped with Apitech proportional valves 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. 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 Wear safety glasses any time you check or set pressures. Oil expulsion hazard!
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1. Plug the whip hose of a 0-400 or 0-600 bar gauge (Figure 46) 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 47) on the back of the outrigger valve. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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 10. 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 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.
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Pressure Settings
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280 bar Relief valve
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DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).
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SLEWING
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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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Figure 47 Location of the 280 bar outrigger pressure relief valve (Hoses removed for clarity)
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. If there are not other pressure settings required, return the RPM of the truck to an idle, take the transmission and PTO out of gear, and shut off the truck.
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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. 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 (0 - 60 bar) pretension check port of the Apitech handvalve (Figure 48).
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SERVICE TRAINING
Pressure Settings
CAUTION Truck engine must be at idle to set pretension. Gauge damage possible!
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. If not skip to step (5). 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.
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Setting the agitator circuit pressure
The agitator relief valve is located in the agitator “forward / neutral / reverse” handvalve (Figure 49). The relief valve (not completely visible in Figure 49) limits the pressure in the agitator circuit to 200 bar (2900 PSI). There is a gauge port (not visible in Figure 49) 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 48 Pretension adjustment screw and gauge port pretnsn.eps
3. Close the agitator shutoff valve (Figure 50).
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30303432 (tube). Contact Schwing America’s Service Department at (651) 4290999 for installation instructions. 4. Activate the agitator, and read the pressure on the gauge.
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Pressure Settings 34manco3.eps
1 agitator handvalve
10
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Gauge port Relief valve
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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Figure 49 Agitator handvalve
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5. If adjustment is needed, put your wrench on the body of the relief valve (Figure 49), 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.
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Figure 50 The agitator shutoff valve
Agitator quarter turn shutoff valve (open position)
Setting accumulator circuit pressure
You will need an assistant for parts of this procedure. There are three relief settings for the accumulator circuit.
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Motor
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.
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SERVICE TRAINING
Pressure Settings
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Accumulator pump pressure regulator
Redundant Relief cartridge
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Figure 51 Accumulator pump pressure regulator for A7VO (above) and for A11VO (below) 2. Loosen the jam nut on the pressure regulator of the accumulator hydraulic pump (Figure 51). Turn the screw in two-and-one-half turns. This will raise the regulator pressure above 300 bar. 3. Loosen the jam nut (Figure 52) 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.
Figure 52 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 53). 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).
@@@@@@@@ ;;;;;;;; QQQQQQQQ @@@@@@@@ ;;;;;;;; QQQQQQQQ @@@@@@@@ ;;;;;;;; QQQQQQQQ @@@@@@@@ ;;;;;;;; QQQQQQQQ @@@@@@@@ ;;;;;;;; QQQQQQQQ @@@@@@@@ ;;;;;;;; QQQQQQQQ @@@@@@@@ ;;;;;;;; QQQQQQQQ @@@@@@@@ ;;;;;;;; QQQQQQQQ 45acumpr.epsL
Figure 53 Accumulator circuit pressure gauge
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Pressure Settings 8. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 51) 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.
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Pressure Relief Cartridge Manual bleed valve
NOTE! The accumulator circuit hydraulic pump pressure regulator is sometimes referred to as the pressure cut-off.
Figure 54 Accumulator manifold pressure relief cartridge 6. Locate the accumulator manifold pressure relief cartridge (Figure 54). 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 52) 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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SERVICE TRAINING
KVM 36X-42M (pre-1998)
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.
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 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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SERVICE TRAINING
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.
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.
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 Pressure Regulator Cutaway
Pressure Regulator
P Regulator
A
T P
X
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 205
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SERVICE TRAINING
Pressure Settings
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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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)
BOOM HANDVALVE KVM 36LW & 36X
9
7
24V 24V
OUTRIG
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WTR CMP
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3
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SLEW R&L
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Pressure Settings KVM 36 LW & 36 X W/Rexroth Boom Handvalve
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SERVICE TRAINING
Pressure Settings
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 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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SERVICE TRAINING
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.
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.
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 Pressure Regulator Cutaway
Pressure Regulator
P Regulator
A
T P
X
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 206 Regulator Valve
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SERVICE TRAINING
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.
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.
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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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- 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
(Waterpump/Compressor,Throttle, & Outrigger)
KVM 42LW BOOM HANDVALVE
24V
242 24V
BOOM 2
24V
2
2
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1
24V
2
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24V
24V
24V
1
4
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BOOM SWING 4 R/L
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BOOM 3
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BOOM 1
RPM
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24V
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WTR/ OUTCOMP. RIGGER
HOME PRINT
Pressure Settings KVM 42 LW, W/Rexroth BoomHandvalve
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SERVICE TRAINING
KVM 36X
Pressure Settings
1. Locate the agitator shutoff valve, and close it (Figure 10). The general location of the agitator shutoff valve is shown in Figure 93.
Check all hydraulic pressures 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. 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
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, 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.
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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.
Figure 10 Agitator shutoff valve
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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Pressure Settings The general location of the components used to check or set hydraulic pressures in shown in Figure 93. 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
•
Remote Control Connector
Outrigger Hand Valves t Accumulator Unloading Manifold Valve and Gauge (twin circuit)
Rear Control Panel
Agitator Shutoff Valve
Agitator Hand Valve and Gauge Port
Figure 11 General location of components used to set hydraulic pressures
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 79), which
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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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SERVICE TRAINING
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 12 Concrete pump main relief valve 1. Close the concrete pump shutoff valve (Figure 80) 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.
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quarter turn.eps
Figure 13 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 79). 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
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Pressure Settings 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).
WARNING
W008.eps
Hot oil expulsion hazard. stand away from pumpkit when checking hydraulic pressures.
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 5). 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.
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 5 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 5). 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.
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SERVICE TRAINING
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
.ep
Grooves in handle should line up with grooves in valve shaft
s
Figure 14 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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.
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Relief Valve and Gauge Port
Set accumulator circuit Units with a pressure- compensated 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 83). .
Figure 16
Accumreg.eps
Accumulator pump pressure regulator
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 85). 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 85). 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 15 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 84). 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 84).
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SERVICE TRAINING
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 102). 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 17 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
WARNING Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
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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 83). 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 83). 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 18 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
•
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 •
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.
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. •
boom hydraulic pressures is shown in Figure 19.
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.
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
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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 102). 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
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SERVICE TRAINING
Boom Hand Valves
∆P Regulator
Q-min Adjust Screw
Pressure Settings
E-Stop Manifold
36Xdside.eps
Figure 19 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
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dv.
s
15 bar pretension adjustment screw
Figure 20 Boom hand valves
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Pressure Settings 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 20). 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 21). 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 4. Q-min adjustment screw
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Figure 21 Q-min adjust screw 4. Delta P is adjusted by the ∆P screw on the ∆P regulator (Figure 22). 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.
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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 adjust screw
Figure 22 ∆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 21). 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 20). 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 21). 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 23). 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).
0-400 bar gauge port 0-60 bar gauge port boom control block relief valve ps
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15 bar pretension adjustment screw
NOTE! The boom control block relief valve is nonadjustable. If pressure is not maintained within the specification limits, the valve must be replaced.
∆P Regulator Valve (high pressure adjustment screw)
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E-Stop Manifold Redundant Relief Valve
Figure 23 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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Pressure Settings 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.
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.
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 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
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Pressure Settings
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 24 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 24). 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 valve (Figure 24). 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
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 in the agitator hand valve (Figure 117). The gauge port for checking or setting the agitator pressure is located on the agitator hand valve.
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Pressure Settings AgitHdVl.eps
Relief Valve
Gauge Port
6.
7. 8. 9. Figure 25 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 20). Skip to Step 6.
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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.
Figure 26 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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SERVICE TRAINING
Pressure Settings
KVM 39X Closed
Check all hydraulic pressures
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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.
Shown in the open position Figure 27 Agitator shutoff valve
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 10). The general location of the agitator shutoff valve is shown in Figure 93. 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Pressure Settings The general location of the components used to check or set hydraulic pressures is shown in Figure 93. 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
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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 28 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).
WARNING Hot oil expulsion hazard. Stand away from pumpkit when checking hydraulic pressures.
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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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 5 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 5). 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 5). Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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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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Figure 29 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 RPM to high pressure the concrete pump. The pressure gauge should read 80
260
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. 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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SERVICE TRAINING
Set accumulator circuit
Pressure Settings
.
(units with a pressure- compensated 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 83).
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Accumulator pump pressure regulator
If your unit is a current production model Figure 6, skip Steps 3,4, and 8 of this procedure.
Figure 31 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 84). 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 84).
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Relief Valve and Gauge Port
Figure 30 E-Stop manifold (current production)
Figure 32 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Pressure Settings 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 85). 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
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 83). 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 102). 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
Lower
Figure 33 Accumulator manifold pressure relief valve
Higher
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.
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 34 Outrigger hand valve
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 83). 10. Clear all personnel from the drive line area, start the truck, and rev the engine RPM to maximum.
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SERVICE TRAINING
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.
Pressure Settings
NOTE!
The general locations of the components used to set boom hydraulic pressures is shown in Figure 19.
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 102). 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. •
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.
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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.
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.
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)
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Pressure Settings
Boom Hand Valves
∆P Regulator
E-Stop Manifold
Q-min Adjust Screw
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Figure 35 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 a 36
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15 bar pretension adjustment screw Figure 36 Boom hand valves
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Check or set ∆P
Pressure Settings
bar, you must fine tune the adjustment.
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 20). 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 21). 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 4. Q-min adjustment screw
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Figure 37 Q-min adjust screw 4. Delta P is adjusted by the ∆P screw on the ∆P regulator (Figure 22). 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.
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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 adjust screw
Figure 38 ∆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 21). 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 20). 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 21). Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning each time before making the
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Pressure Settings adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures.
Set boom pressures
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!
(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 39 and Figure 23). 1. The boom control block relief valve, set at 350 bar (5075 PSI). 2. Pressure regulator (the high-pressure adjustment
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 39 E-Stop manifold (current production left - original production right
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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.
0-400 bar gauge port
NOTE!
0-60 bar gauge port boom control block relief valve ps
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15 bar pretension adjustment screw
∆P Regulator Valve (high pressure adjustment screw)
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Figure 40 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. 4. The tell tale hiss of an open relief valve should be coming from the Apitech control block relief valve Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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
ap
itpr
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s
15 bar pretension adjustment screw Figure 41 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 24). 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 24). 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 -
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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 117). The gauge port for checking or setting the agitator pressure is located on top of the agitator hand valve.
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SERVICE TRAINING
Pressure Settings
39Xcont3.eps
52qrttrn.epsL
Closed
Shown in the open position
Figure 43 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 42 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 44). 3. If your unit is equipped with an agitator shutoff valve, close it (Figure 20). Skip to Step 5.
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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 44).
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Pressure Settings
Agitator Relief Valve Turn body of valve Gauge port
Higher
to adjust.
Lower
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Figure 44 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.) 3. Remove the whip hose and pressure gauge. Replace the gauge port cover.
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SERVICE TRAINING
S 42SX Setting Pressures The following pages provide the proper techniques for checking and setting hydraulic pressures of each system included on your unit.
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. 3. When the oil temperature gauge shows 50˚C, open the shutoff valve.
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
agitoff2.eps
Figure 55 Agitator shutoff valve
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 55) 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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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 56) and close it by rotating the handle 90 degrees. The quarter turn shutoff valve for the concrete pump (Figure 56) 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 56 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.
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4. If you have not already closed the soft switch shutoff valve and the concrete pump shutoff valve (Figure 56) 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 58) 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 57) 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
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SERVICE TRAINING
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 57) 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 57). You must be able to read both gauges simultaneously to ensure that one pump is not more dominant than the other.
Pressure Settings
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
2
1
1
3
3 4
4
M1 GAUGE PORT (BOTTOM OF EACH PUMP) 130ajst.eps
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.
Figure 57 A11VO adjustment screws for Hi-flo – 6 units 190/130
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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Pressure Settings
Closed
Open
openclsd.eps
soft switch relief valve
Main relief valve 5/32" Allen head 9/16" jam nut Figure 58 Soft switch components
Setting the soft switch relief pressure
Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure 58, 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 58, 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 58, 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.
Entanglement hazard. Stop drive shafts before adjusting Delta P on A11VO pump.
W020.eps
WARNING
Setting boom circuit 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 setting pressures.
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SERVICE TRAINING
Pressure Settings
0-600 bar gauge port ps
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pretension only 33-35 bar
Boom pressure relief cartridge
0-600 bar gauge port 45bmcnbl.epsL
Figure 59 (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.
Setting delta P pressure 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 16).
NOTE!
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.
pressreg.eps
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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 43, top) if your unit has an A7VO pump or (Figure 43, 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 43, 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 43, 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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Regulator pressure adjustment T
Adjustment for P pressure
Delta-P
smdeltap.eps
Figure 60 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
A7VX section min.top.eps
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Q-min
Q max
Q-max (bottom of pump)
6. Unscrew the Q-min screw (Figure 61) 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. 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.
pressreg.eps
Figure 61 Location of Q-min screw on the A7VO (left) and all adjustment screws of the A11VO (right)
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.
Regulator pressure adjustment T
Adjustment for P pressure
Figure 62 Boom pressure regulator for units with A7VO pumps
NOTE! The pressure regulator (Figure 62) is usually mounted on the inside of the subframe, near the cab end of the differential cylinders.
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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 63) 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 61) 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.
Pressure Settings
4. Identify the main boom pressure relief cartridge on the boom control block (Figure 64) 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.
0-600 bar gauge port ps
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Boom pressure relief cartridge
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 63) 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 62) or the pressure cut-off (Figure 61), and tighten the screw all the way down.
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Figure 63 Boom pressure relief cartridge 8. The next step is to return to the e-stop manifold boom pressure relief cartridge (Figure 63) 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 48).
#1 down side relief cartridge Main boom pressure relief cartridge
9. The next pressure setting is the regulator pressure. Locate the regulator adjustment screw (Figure 61) or pressure cut-off screw (Figure 62). 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 64), 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 63), 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.
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REAR SLEW
REAR JACKING
FRONT JACKING
FRONT EXTEND
30354359
Figure 64 Main boom pressure adjustment and piston side relief
1. Attach 0-600 bar whip gauge to the gauge port (Figure 48) 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 48) 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.
Relief Cartridge Gauge Port
Figure 65 Outrigger valve bank relief cartridge and gauge port
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Pressure Settings
CONCRETE PUMP FORWARD/REVERSE
AGITATOR
Relief valve
Gauge port
Figure 66 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 50) in the agitator hand valve. The relief cartridge is located on the back side of the agitator manual control handle (Figure 50). The cartridge is adjustable with just an 19mm open end wrench. 1. Plug the 0–600 bar whip gauge into the gauge port (Figure 50) for checking or setting agitator pressure. 2. Locate the agitator shutoff (Figure 67) 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 68).
agitoff2.eps
Figure 67 Agitator shutoff valve
Plugs Straight Fitting Figure 68 Approved hydraulic dead plugs
capplug.eps
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 50) 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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January 1, 2000, it will have an emergency stop manifold similar to the illustration shown in the bottom of Figure 52, 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 51). Turn the screw in two-and-one-half turns. This will raise the regulator pressure above 300 bar. 3. Loosen the jam nut (Figure 52) 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.
Accumulator pump pressure regulator
accurlf2.eps
Accumulator redunant relief cartridge
Figure 69 Accumulator pump pressure regulator for A7VO (above) and for A11VO (below) Boom Pump
Figure 70 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
Accumulator Pump
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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 52, top). If your pump was built after
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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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5. Read the pressure on the accumulator circuit pressure gauge (Figure 53). 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
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.
45acumpr.epsL
Figure 71 Accumulator circuit pressure gauge
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8. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 51), 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 72 Accumulator manifold pressure relief cartridge 6. Locate the accumulator manifold pressure relief cartridge (Figure 54). 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 52) and back out the adjustment Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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KVM 42M - Proportional (Apitech) Single Circuit Check the fluid level of the distribution gearcase (Figure 10). Be sure the truck is on reasonably level ground. With the truck engine off and the key in your
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.
Breather (fill port)
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Check port
Drain port
Figure 10 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: Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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 11).
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Pressure Settings
Jam nut
Lower pressure
Raise pressure
Adjustment handle
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Figure 11 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 12).
Shutoff valve
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Figure 12 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
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will retract. Oil will be forced over the main relief valve. This procedure is called high-pressuring the concrete pump.
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Pressure Settings
Groove at 90° to ports— Closed
Groove lined up with ports— Open Ball cock grooves.eps
Figure 13 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 11). 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 14).
Shutoff valve
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Figure 14 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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
truck, or go on to other pressure settings.
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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 6-97. 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
Figure 20
Figure 18
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 15).
Figure 17
Figure 16
42 Location Page 1
Component Locations Figure 16—Boom control handvalves Figure 17—Q-min adjustment screw Figure 18—∆P regulator Figure 20—E-stop manifold
Figure 15 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 16).
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Pressure Settings
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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 16 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 17).
Q-min adjustment screw
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Figure 17 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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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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 18). 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 18 ∆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 17). 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 17). Turn it out to lower the pressure. Be sure that you stop the drive shafts from turning
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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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1. Pressure regulator (the high-pressure adjustment screw on the ∆P regulator valve), set at 290 bar (Figure 18)
Regulator pressure adjustment T
Adjustment for P pressure Figure 19 ∆P regulator valve 2. Redundant relief valve located in the emergency stop manifold, set at 320 bar (Figure 20). 10167892-3.eps
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Figure 20 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 21).
42 apitech relief.eps
350 bar relief
30 bar relief
Figure 21 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 18). 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 20). 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).
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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 20) 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 18). 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 22). 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 22).
Adjustment screw Apitech pretnscrw.eps
Gauge port
Figure 22 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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KVM 42M - Proportional (Apitech) Twin Circuit Check the fluid level of the distribution gearcase (Figure 23). Be sure the truck is on reasonably level ground. With the truck engine off and the key in your
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.
Breather (fill port)
Check port
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Drain port
Figure 23 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.
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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 24). 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 24). 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
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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 25 and 26). 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 24 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
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Figure 25 Locations of the concrete pump and soft switch shutoff valves
Groove lined up with ports - open
Closed
Open
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Groove at 90° to ports - closed
Figure 26 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 27). 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
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concrete pump shutoff valve on the side of the brain (shown in Figure 25) when you are finished. The unit will not stroke with this valve closed.
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Pressure Settings
Soft switch shutoff valve
Open
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Main Pressure Gauge port
Soft switch relief valve
Concrete pump shutoff valve
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Figure 27 Soft switch circuit components
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 6-97. 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 15).
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Figure 20
Figure 18
Figure 17
Pressure Settings Figure 16
42 Location Page 1
Component Locations Figure 16—Boom control handvalves Figure 17—Q-min adjustment screw Figure 18—∆P regulator Figure 20—E-stop manifold
Figure 28 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 29).
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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 29 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 30). Q-min adjustment screw
Q-minscrew.eps
Q-max
Figure 30 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 31). 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 31 Delta P regulator valve 6. If pressure cannot be set correctly, contact the Schwing Service Department to determine how to
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continue.
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Setting Q-min
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 30). 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).
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 30). 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
Regulator pressure adjustment T
Adjustment for P pressure Figure 45 ∆P regulator valve
2. Redundant relief valve located in the emergency stop manifold, set at 320 bar (Figure 32). 10167892-3.eps
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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 33).
42 apitech relief.eps
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30 bar relief
Figure 33 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 20). 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).
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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 34). 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 21) of the ∆P regulator out (lowering the pressure) until the gauge reads 290 bar. Release
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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 33). 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 34).
Apitech pretnscrw.eps
Figure 34 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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KVM 42M - Proportional (Rexroth) Check the fluid level of the distribution gearcase (Figure 35). Be sure the truck is on reasonably level ground. With the truck engine off and the key in your
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 35 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 36).
NOTE! If your unit does not have a shutoff valve, order one, using part number 10004680 (valve) and Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Pressure Settings
Jam nut
Raise pressure
Lower pressure
Adjustment handle
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Figure 36 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 37 and 38).
Shutoff valve
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Figure 37 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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SERVICE TRAINING
Pressure Settings
“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 38 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. 14. Open the concrete pump shutoff valve (Figure 39).
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Figure 39 Concrete pump shutoff valve Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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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! 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 6-97. 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 43
Figure 18
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”). To set the boom or outrigger hydraulic pressures on a load-sensing system, begin by setting Q-min and ∆P (Figure 42).
Figure 45
Figure 16
42 Location Page 1
Component Locations Figure 16—Boom control handvalves Figure 18—Q-min adjustment screw Figure 43—∆P regulator (original location—inside frame; current location—outside frame) Figure 45—Normally open bypass valve
Figure 40 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:
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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 41).
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SECTION 1
FORWARD / REV.
SECTION 2
SECTION 3
SECTION 4
SLEWING
OUTPUT + / -
Pressure Settings
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 41 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 42).
Q-min adjustment screw
Q max
Figure 42 Location of Q-min screw
CAUTION Do not operate any functions when setting ∆P.
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Pressure Settings 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
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 43). 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 43 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 44).
Q-min adjustment screw
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Figure 44 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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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.
Pressure Settings
High-pressure adjustment screw of the ∆P regulator (the large adjustment screw on the ∆P regulator), set at 290 bar (see Figure 43). • Normally open bypass valve (the valve that opens when an E-stop switch is activated), set at 320 bar (see Figure 45). • Handvalve relief (located in the boom control block), set at 330 bar (Figure 46). 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 43). 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 45). Turn the
adjusting screw in one full turn. This will raise the pressure of this valve above 330 bar.
Jam nut
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Figure 45 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 setMedia:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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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Pressure Settings 4. Adjust the pressure by turning the adjustment screw on the boom handvalve relief valve (Figure 46). Screw in to raise pressure, or out to lower
pressure. When pressure is correct, lock the jam nut, and continue to step (4).
Handvalve relief valve is located here.
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Front view
Side view
Figure 46 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.
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 47).
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
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Pressure Settings
Down side relief valve is located behind this section.
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Front view
Side view
Figure 47 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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 48).
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Pressure Settings
280 Bar relief valve
280 Bar relief valve
Lower
Lower
Higher
PS
Higher
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Turn body of valve to adjust.
Turn body of valve to adjust.
Manitrol valve system
Pushbutton system
Figure 48 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
EXTEND FRONT
FOLD REAR
FOLD FRONT
FOOT REAR
FOOT FRONT
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Figure 49 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
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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 50). 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 50 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
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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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Pressure Settings 5. Remove the whip gauge. Restart the engine, if necessary.
Set accumulator circuit hydraulic oil pressure (units with accumulator unloading valves)
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 86).
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 51 Accumulator unloading valve
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un
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 52).
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SERVICE TRAINING
Pressure Settings
Accumulator relief valve P2
P1
P4
P3 MP
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Figure 52 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 53). 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 53 Accumulator manifold pressure relief
g. You will need an assistant for this step. With the engine still running, one person must go to the Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
redundant relief valve on the emergency stop manifold and back out the adjustment screw. The other
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Pressure Settings 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
S 45/47SX
Spline flange breather
Figure 54 Oil check plug for spline flange cavity (4400 gearcase)
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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 55) 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.
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Figure 55 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 56) and close it by rotating the handle 90 degrees. b. The quarter turn shutoff valve for the concrete pump (Figure 56) 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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Figure 56 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 56) 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 58) 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 57) on each pump, by backing off the jam nut with
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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 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 57) 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 57). 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
2
1
1
3
3 4
4
M1 GAUGE PORT (BOTTOM OF EACH PUMP) 130ajst.eps
Figure 57 A11VO adjustment screws for Hi-flo – 6 units 190/130
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Pressure Settings
Closed
Soft switch shutoff valve
Open
Main Pressure Gauge port
Concrete pump shutoff valve
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Figure 58 Soft switch components
Setting the soft switch relief pressure
Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure 58 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 58 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 58 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 59 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.
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WARNING Entanglement hazard. Stop drive shafts before adjusting Delta P on A11VO pump.
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Pressure Settings
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Figure 59 (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.
Setting delta P pressure 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 59). 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 60 top) if your unit has an A7VO pump or (Figure 60 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 60 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 43 bottom).
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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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Regulator pressure adjustment T
Adjustment for P pressure Delta-p
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Figure 60 Pressure regulator for A7VO boom pumps (top) and A11VO pumps (bottom)
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Pressure Settings
Q-min adjustment screw
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Pressure Cut-off
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6. Unscrew the Q-min screw (Figure 61) 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. 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.
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Figure 61 Location of Q-min screw on the A7VO (left) and all adjustment screws of the A11VO (right)
Regulator pressure adjustment T
Adjustment for P pressure
Figure 62 Boom pressure regulator for units with A7VO pumps
Note: The pressure regulator (Figure 62) is usually mounted on the inside of the subframe, near the cab end of the differential cylinders.
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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 63) 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 61) 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.
5. Identify the main boom pressure relief cartridge on the boom control block (Figure 64) 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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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 63) 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 62) or the pressure cut-off (Figure 61), and tighten the screw all the way down. 4.
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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
Pressure Settings
Figure 63 Boom pressure relief cartridge 9. The next step is to return to the e-stop manifold boom pressure relief cartridge (Figure 63), 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 48).
#1 down side relief cartridge Main boom pressure relief cartridge
10. The next pressure setting is the regulator pressure. Locate the regulator adjustment screw (Figure 61) or pressure cut-off screw (Figure 62). 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 64), 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 63), 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.
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REAR JACKING
FRONT JACKING
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Figure 64 Main boom pressure adjustment and piston side relief
1. Attach 0-600 bar whip gauge to the gauge port (Figure 48) 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 65) 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.
Relief Valve Gauge Port
Figure 65 Outrigger valve bank relief cartridge and gauge port
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Pressure Settings
CONCRETE PUMP FORWARD/REVERSE
AGITATOR
Relief valve
Gauge port
Figure 66 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 66) in the agitator hand valve. The relief cartridge is located on the back side of the agitator manual control handle (Figure 67). The cartridge is adjustable with just an 19mm open end wrench. 1. Plug the 0–600 bar whip gauge into the gauge port (Figure 66) for checking or setting agitator pressure. 2. Locate the agitator shutoff (Figure 67) 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 68). NOTE! Do not jam the paddles to force the oil over relief by stopping the movement of the agitator.
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Figure 67 Agitator shutoff valve
Plugs Straight Fitting Figure 68 Approved hydraulic dead plugs
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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 66) 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 52 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 52 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 69). Turn the screw in two-and-one-half turns. This will raise the regulator pressure above 300 bar. 3. Loosen the jam nut (Figure 70) 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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Figure 69 Accumulator pump pressure regulator for A7VO (above) and for A11VO (below) Boom Pump Accumulator Pump
Accumulator redunant relief cartridge
Figure 70 Accumulator redundant relief cartridge (above) is only present on early production models. New e-stop (below) has no redundant relief cartridge.
Standby Pressure Screw 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,
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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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5. Read the pressure on the accumulator circuit pressure gauge (Figure 71). 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 70) 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 71 Accumulator circuit pressure gauge
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8. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 69), 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 72 Accumulator manifold pressure relief cartridge
6. Locate the accumulator manifold pressure relief cartridge (Figure 72). Loosen the jam nut, and turn the screw clockwise to increase the pressure or Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Pressure Settings
S 45SX Hi-Flow - 6 Breather
Breather filter filler spout
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Oil check plug
Oil Check Plug Oil Drain Plug
Drain plug
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Figure 73 Check fluid level of distribution gearcase Stiebel box 4194 (left) or 4400 (right)
Spline flange breather
Figure 74 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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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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 55) 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 75 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 76) and close it by rotating the handle 90 degrees. b. The quarter turn shutoff valve for the concrete pump (Figure 76) 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
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Figure 76 Concrete pump, Soft switch shutoff valves
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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 56) 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 78) 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 57) 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
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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 77) 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 77). 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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Pressure Settings
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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Figure 77 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
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Main and soft switch relief cartridges
soft switch relief cartridge 9/16" jam nut
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Figure 78 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 78 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 78 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 78 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 78 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
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.
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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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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
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A6 T
FIGURE 1
a5
item 2
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FIGURE 2
STOP for Q min
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a4 24V
item 1
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item 6
P
STOP for Qmax
FIGURE 4
item 7 FIGURE 5
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
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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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SERVICE TRAINING
Pressure Settings
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
X
0.8 mm
NOTE: NO ORIFICE USED ON KVM 52
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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
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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
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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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SERVICE TRAINING
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)
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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 PRINT
Pressure Settings Pre-Control Block 1-C for KVM 52
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Quick Gauge Port b4 INPUT
b4
24V
a4 INPUT
a4
24V
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
SERVICE TRAINING
L
PV (PST)
24V
SIDE VIEW
b4- #2 Boom retract b5- Slewing - Right b6- Outriggers
52 PRE-CONTROL BLOCK 2-A
HOME PRINT
Pressure Settings
Pre-Control Block 2-A for KVM 52
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344
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
HOME PRINT
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
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A SAI ITEM# (Cartridge Only) 10055188
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Pressure Settings
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S 52 SX Setting Pressures The following pages provide the proper techniques for checking and setting hydraulic pressures of each system included on your unit.
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. 3. When the oil temperature gauge shows 50˚C, open the shutoff valve. Agitator quarter turn shutoff valve (open position)
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Check and adjust all hydraulic pressures Changes in pressures can indicate trouble in one or more components. The specifications for each circuit are shown on the hydraulic schematics found in the Appendix of this manual. The hydraulic schematics are the only documents in this manual that have been updated specifically for your unit by the serial number, so in each of the following procedures you will be told to refer to the schematic for the pressure required.
Figure 79 Agitator shutoff valve
Motor
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 55) 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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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 shutoff for the soft switch circuit (Figure 56), and close it by rotating the handle 90 degrees. The quarter turn shutoff valve for the concrete pump (Figure 56) will also need to be closed during this procedure.
5.
6.
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.
7.
8.
9.
Pressure setting procedure: Soft switch shutoff valve Main Pressure Gauge port
10. 11.
Concrete pump shutoff valve
00 02 74 .e ps
Figure 80 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.
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
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shutoff valve and the concrete pump shutoff valve (Figure 56), 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 58) 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 57) 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 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
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SERVICE TRAINING
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 and put the key in your pocket. 14. Go to the pressure cutoff screw on both hydraulic pumps (Figure 57), 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. 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 57). 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.
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). 19. 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
3
4
Horse Power 2
Q-Min 2 3
1
3
4
Figure 81 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
Closed
Main Pressure Gauge port
Open
000276.eps
Main relief cartridge
soft switch relief cartridge
Concrete pump shutoff valve
9/16" jam nut
5/32" Allen head 00
02
74
.e
ps
9/16" jam nut Figure 82 Soft switch components
Setting the soft switch relief pressure
Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure 58, 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 58 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 58, 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.
WARNING
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.
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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 58 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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SERVICE TRAINING
Pressure Settings gauge ports for Delta P
Figure 83 Gauge ports for setting Delta P delta/p.eps
Setting Delta P pressure Delta-p
NOTE!
1.
2.
3. 4.
5.
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 16). Install a second 0-400 bar gauge (Figure 16) in the port marked “LS” (load-sensing). Delta P is adjusted on the pressure regulator (Figure 43) 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 84 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
ps
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pre
0-600 bar gauge port
Wear safety glasses any time you check or set pressures. Oil expulsion hazard!
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WARNING
Figure 85 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 124) 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 125) 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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Delta-p
Pressure Cut-off
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Q-min
Service Manual
Q-max (Bottom Of Pump)
Figure 86 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 126) 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.
Disconnect hose hose1.eps
Figure 88 Hose for boom section number two
Plugs Straight Fitting Boom pressure relief cartridge
Figure 89 Approved dead plugs ps
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Cap Nuts
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0-600 bar gauge port
Figure 87 Boom pressure relief cartridge 3. Loosen the jam nut on the pressure cut-off screw (Figure 131), 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 129), 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 127) and installing an approved dead plug on each of the open fittings.
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6. Install a 0 - 600 bar gauge in the main pressure gauge port (Figure 129). 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 129) 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 126), 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.
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Pressure Settings Setting pressure cut-off
10. Return to the pressure cut-off screw (Figure 131). 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
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Q-min
Q-max (Bottom Of Pump) Figure 92 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 64. 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 129. 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 64) 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 90 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 130).
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Figure 93 Piston side relief Figure 91 Boom slewing relief valves
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NOTE! HWslew.eps
Boom Slewing relief valves
If you are unable to achieve 230 bar by adjusting the relief valve in Figure 64, 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
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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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 48). 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 48) 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 50) in the agitator hand valve. The relief cartridge is located on the back side of the agitator manual control handle (Figure 50). The cartridge is adjustable with just a 19mm open end wrench. 1. Plug the 0–600 bar whip gauge into the gauge port (Figure 50) for checking or setting agitator pressure. 2. Locate the agitator shutoff valve (Figure 67), 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 68).
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 50) 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 Turn body of valve Gauge port
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Figure 95 Agitator relief cartridge located on back side hand valve
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Pressure Settings Agitator quarter turn shutoff valve (open position)
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Figure 96 Agitator shutoff valve 000289.eps
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Figure 97 Approved hydraulic dead plugs
Accumulator pump pressure regulator
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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 51). Turn the screw in two-and-one-half turns. This will raise the regulator pressure above 300 bar.
Figure 98 Accumulator pump pressure regulator for A7VO (above) and for A11VO on a unit with a stiebel gearcase (below)
Boom Pump Accumulator Pump
Accumulator Pump Pressure Regulator Standby Pressure Screw
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Figure 99 New e-stop has no redundant relief cartridge.
Figure 101 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 53). 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 54). 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.
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Figure 100 Accumulator circuit pressure gauge
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Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
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6. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 51), and turn the screw back out twoand-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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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 102) and close it. The quarter turn shutoff valve has a grooved line (Figure 102) 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 102) or the concrete pump shutoff valve (Figure 103) and
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.
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Agitator quarter turn shutoff valve (open position)
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Figure 102 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 56) and close it by rotating the handle 90 degrees. b. The quarter turn shutoff valve for the concrete pump (Figure 103) will also need to be closed during this procedure. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Pressure Settings Soft switch shutoff valve Main Pressure Gauge port
Figure 103 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 103) 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 104) 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.
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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 104) 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 105). 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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Figure 104 Location of soft switch shutoff and relief cartridges
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M1 GAUGE PORT (BOTTOM OF EACH PUMP) Figure 105 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 57.
Setting the soft switch circuit relief pressure a. If you haven’t already done so, open the soft switch quarter turn valve (Figure 104). 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 57) 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 57) when you are finished. The unit will not stroke with this valve closed.
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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 6-359. 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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“cue min”). To set the boom or outrigger hydraulic pressures on a load sensing system, begin by checking ∆ P and Q-min.t
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 106) located on the inside of the right boom control block as you face the three valve blocks. rtblock2.eps
Figure 106 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 107) 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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Figure 107 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 16) should be Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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 108) 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 108 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 43 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 108 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 16) 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.
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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 109) 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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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 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.
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Figure 109 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 110). 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 110 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 111).
Down side dynamic gauge port Main boom pressure gauge port (Hidden)
Figure 111 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 112), depending which one your unit has, and turn the adjustment screw clockwise, all the way in.
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Figure 112 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 113) 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.
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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 111) 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 113 @@ ;; 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
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(Figure 113) 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 112) 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 114) which can not be adjusted. 1. Install a 0-60 bar whip gauge on the gauge port of the precontrol block (Figure 114) 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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gauge port Figure 114 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 115) located on the passenger side outrigger control valve. 1. Attach 0-600 bar whip gauge to gauge port shown in Figure 48. 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 48, 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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Front extend Rear fold Front fold Foot
Figure 115 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 116) in the agitator hand valve. The cartridge is adjustable with a 19mm socket or wrench.
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).
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Figure 116 Location of the agitator relief cartridge
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2. Locate the agitator shutoff valve (Figure 117) 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 117). • 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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Agitator quarter turn shutoff valve (open position)
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Figure 117 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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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. 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 (50° to 60° C). In the past we
Pressure Settings
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 102), and close it. The quarter turn shutoff valve has a grooved line (Figure 102) 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 102) or the concrete pump shutoff valve (Figure 56) 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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Open Mounting screw and washer removed for illustration
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Figure 46 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 47 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 56), and close it by rotating the handle 90 degrees. 2. The quarter turn shutoff valve for the concrete pump (Figure 56) 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 56), 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 104) 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 57) 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 57). 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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9/16" jam nut
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Figure 48 Location of soft switch shutoff and relief cartridges
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1 Stroke Regulation
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M1 GAUGE PORT (BOTTOM OF EACH PUMP)
Figure 49 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 57.
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Pressure Settings
Setting the soft switch circuit relief pressure
on a load sensing system, begin by checking ∆ P and Q-min.
1. If you haven’t already done so, open the soft switch quarter turn valve (Figure 57). 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). 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 57) 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 57) when you are finished. The unit will not stroke with this valve closed.
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. rtblock2.eps
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 371. 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 52/55 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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
High pressure gauge port
Figure 50 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.
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Pressure Settings
Entanglement hazard. Stop drive shafts before adjusting Delta P on A11VO pump.
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1. Install a 0-100 bar whip gauge in the high pressure test port (Figure 16), located on the inside of the right boom control block as you face the three valve blocks. 2. With the engine at idle, turn the adjustable relief cartridge (Figure 107) 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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3. With the engine running and the relief cartridge backed out, the gauge (Figure 16) 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 107) 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 43 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 43 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.
Figure 51 Location of adjustable relief cartridge on the boom pilot control valve
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Figure 52 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 53 Location of Q-min screw on A11VO (left) and A7VO (right) Check Q-min with the engine at maximum specified NOTE: If you don’t have a 0-100 bar gauge, you can RPM. Each time the Q-min screw must be adjusted, the order one from Schwing Spare Parts Department at engine must be stopped, or at least the transmission (800) 328-9635, part #10004659. must be taken out of gear so that the drivelines stop Checking boom pressures turning.
WARNING 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 16), 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 5055 bar. If adjustment is needed, continue to point 4. 4. Stop the engine, and turn the Q-min screw (Figure 109) 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. Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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 111). 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 (Figure 45), 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 45) 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 54 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 111).
3. Loosen the jam nut on the large screw of the pressure regulator or the pressure cutoff screw (Figure 45), 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 55 Pressure regulator adjustment (A7VO left) and Pressure cutoff screw (A11VO right)
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Pressure Settings
Boom circuit relief cartridge s ep trl. crc bm
Figure 56 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 113) 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 111) 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 113), 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 45), 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 114), which can not be adjusted. 1. Install a 0-60 bar whip gauge on the gauge port of the precontrol block (Figure 114), and bring the engine RPM to full throttle. 2. 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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Figure 57 The precontrol valve gauge port and adjustment points
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gauge port
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Pressure Settings Setting the outrigger pressure To set the outrigger pressure, find the relief cartridge (Figure 48) located on the passenger side outrigger control valve. 1. Attach a 0-600 bar whip gauge to the gauge port shown in Figure 48. 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 48) 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 pushbutton. 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
EXTEND
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1. Front extend 2. Rear fold
Relief cartridge
3. Front fold 4. Foot (jacking)
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Figure 58 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 59 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 50) 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 117), 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 Agitator quarter turn shutoff valve (open position)
ps
2.e
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motor and plug the hose and open fitting with approved hydraulic dead plugs (Figure 117). • 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.
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Plugs Straight Fitting
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Figure 60 Agitator shutoff valve and approved hydraulic dead plugs 6. Increase the engine RPM to full throttle, activate the agitator hand valve in either forward or reverse, Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
and read the gauge. If it does not read the specified pressure, turn the body of the relief valve using a
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Pressure Settings 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 62). 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 61). Turn the screw in two-and-one-half turns. This will raise the regulator pressure above 300 bar. 3. Loosen the jam nut (Figure 62) 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 61 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 62 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 63). 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 63 Accumulator circuit pressure gauge 6. Locate the accumulator manifold pressure relief cartridge (Figure 64). 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 62) 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 Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.
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Figure 64 Accumulator manifold pressure relief cartridge 8. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 61), and turn the screw back out twoand-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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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 118 Agitator shutoff valve
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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 56), and close it by rotating the handle 90 degrees. The quarter turn shutoff valve for the concrete pump (Figure 56) 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.
Soft switch shutoff valve Main Pressure Gauge port
To preheat the hydraulic oil: 1. Locate the agitator shutoff valve (Figure 55) 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 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Figure 119 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.
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Pressure Settings 2. Wear safety glasses when working around a concrete pump.
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 56), 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 58) 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 57) 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)
386
12.
13. 14.
15.
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 and put the key in your pocket. Go to the pressure cutoff screw on both hydraulic pumps (Figure 57), 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 57). 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
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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.
Pressure Settings
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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Figure 120 A11VO adjustment screws for Hi-flo – 6 units 190/130
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Soft switch shutoff valve
Open
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Concrete pump shutoff valve
soft switch relief cartridge 9/16" jam nut
5/32" Allen head 00
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Figure 121 Soft switch components
Setting the soft switch relief pressure
Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure 58, 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 58 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 58, 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.
WARNING
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.
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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 58 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 122 Gauge ports for setting Delta P delta/p.eps
Setting Delta P pressure NOTE!
1.
2.
3. 4.
5.
6.
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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 16). Install a second 0-400 bar gauge (Figure 16) in the port marked “LS” (load-sensing). Delta P is adjusted on the pressure regulator (Figure 43) 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 123 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.
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0-600 bar gauge port 000438.eps
Wear safety glasses any time you check or set pressures. Oil expulsion hazard!
Figure 124 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 124) 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 125) 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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Figure 125 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 126) 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 127 Hose for boom section number two
Plugs Straight Fitting Boom pressure relief cartridge
Figure 128 Approved dead plugs
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Figure 126 Boom pressure relief cartridge on the e-stop manifold 3. Loosen the jam nut on the pressure cut-off screw (Figure 131), 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 129), 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 127) and installing an approved dead plug on each of the open fittings.
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6. Install a 0 - 600 bar gauge in the main pressure gauge port (Figure 129). 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 129) 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 126), 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.
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Pressure Settings Setting pressure cut-off
10. Return to the pressure cut-off screw (Figure 131). 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
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Q-min
Q-max (Bottom Of Pump) Figure 131 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 64. 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 129. 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 64) in or out using a 4mm allen key as required until the desired pressure is achieved; then, lock down the jam nut.
Main relief
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Figure 129 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 130).
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Figure 132 Piston side relief
NOTE! Figure 130 Boom slewing relief valves
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If you are unable to achieve 230 bar by adjusting the relief valve in Figure 64, call the Schwing Service Department and ask if the unit has a redundant relief valve.
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SERVICE TRAINING
Setting outrigger pressure
Pressure Settings
Setting the agitator pressure
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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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 48). 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 48) 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 50) in the agitator hand valve. The relief cartridge is located on the back side of the agitator manual control handle (Figure 50). The cartridge is adjustable with just a 19mm open end wrench. 1. Plug the 0–600 bar whip gauge into the gauge port (Figure 50) for checking or setting agitator pressure. 2. Locate the agitator shutoff valve (Figure 67), 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 68).
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 50) 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
Figure 133 Outrigger valve bank relief cartridge Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
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Figure 134 Agitator relief cartridge located on back side hand valve
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Pressure Settings Agitator quarter turn shutoff valve (open position)
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Figure 135 Agitator shutoff valve 000289.eps
Plugs Straight Fitting Figure 136 Approved hydraulic dead plugs
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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 51). Turn the screw in two-and-one-half turns. This will raise the regulator pressure above 300 bar.
Figure 137 Accumulator pump pressure regulator for A7VO (above) and for A11VO on a unit with a stiebel gearcase (below) Boom Pump Accumulator Pump
Accumulator Pump Pressure Regulator Standby Pressure Screw
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Pressure Settings
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Manual bleed valve
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0-600 bar gauge port
Figure 138 New e-stop has no redundant relief cartridge.
Figure 140 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 53). 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 54). 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.
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Figure 139 Accumulator circuit pressure gauge
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Pressure Settings
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 51), and turn the screw back out twoand-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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Electrical 4.
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
0 101 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
0 01
to
1000 mA
D
DIGITAL PROPORTIONAL Cable
20 0
HOME
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
400
2
3
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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 22 PRESSURE AT PORT "A" IN BAR
HOME
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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Electrical
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
402
BOOM DOWN
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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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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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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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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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Linear Signal Diagram
1000 MAXIMUM CURRENT OUTPUT (mA)
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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
+ + - -
408
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)
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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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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.
Potentiometers
15 volts
6 to 9 v olts
Proportional Amplifiers TO BOOM
DIGITAL PROPORTIONAL A/D Converters
1000 mA 20 0t o
ANALOG PROPORTIONAL
010 01010
1000 mA 20 0t o
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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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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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Electrical Card Functions
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:
416
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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Electrical Moving Through The Menu Survey
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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Electrical Identifying the Entries and Parameters
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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“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
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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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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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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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Main Menu
Submenus ?RAMPE
?RAMP UP
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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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
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
Electrical
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
Service Manual
435
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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
436
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
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
437
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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
438
Service Manual
Percentage bus employment Task posed by bus communication Card type/hardware Software version Time of operation since last RESET
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Remote Control Panel Controller No. 11
Software Version 2.1x Controller *BDI
Electrical
Main Menu
Submenus
11
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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439
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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
440
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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Remote Control Panel Controller No. 11
Software Version 1.30 Controller ?BDI1
Electrical
Main Menu
Submenus
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 ...
Service Manual
441
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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
442
Service Manual
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
443
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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
444
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
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
445
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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
446
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
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.)
447
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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
448
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
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
450
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
A1 A23 A4 MD FM
?DIGITAL
?CALIB
Display %A1 %A2 %A3 %A4 %MD %FM
?HEXIN
?PRAMS
?SYS
Electrical
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
451
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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
452
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
Service Manual
453
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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.
454
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Electrical
MINIMUM START CURRENT
mA 1000
MAXIMUM CURRENT OUTPUT
HOME
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
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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
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MAXIMUM CURRENT (mA)
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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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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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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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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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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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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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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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LED
DISPLAY
MESSAGE
REMEDIAL ACTION
PROP
On
Vehicle power supply voltage <20V resp.>28V
Check vehicle power supply
No radio reception Transmitter off or defective Antenna not installed or defective
Check transmitter and antenna Call Schwing Service
TEL
Irregular flashing
TST2
TST 3
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 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
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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. →
HYD PRESSURE CP 159 bars [↓] [↑]
[ CLEAR ]
[ 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
CONCR-PUMP HOURS 328.3 h [↓] [↑]
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 ]
476
[ 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)
Service Manual
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 ■■■■■■■
Electrical
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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- 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!
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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!
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→ [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
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
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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
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Sub-menu I/O display overview MACHINE-CONTROL ↓/ /ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
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
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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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BOOM 5 EXTEND
■■■■■■■
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
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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
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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
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→ [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
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The parameter adjustment menu for prop current values of the current control (Rexroth valves) please turn over
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PROP-CUR SLEW ↓/↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
BOOM-SLEW RIGHT I act 530 mA
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
507
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SERVICE TRAINING
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 %
------------------------------------------------------------------------------------------------------------------------
508
Service Manual
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SERVICE TRAINING
PROP-CUR BOOM 1 ↓/↑/ENTER/CLEAR
→ [ENTER] → ← [CLEAR] ←
BOOM 1 EXTEND PWM act 29 %
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
509
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Electrical
510
SERVICE TRAINING
Service Manual
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Service Manual
SCHWING Control system “VECTOR”
SERVICE MANUAL Part Number 30100425
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 MODE (SHORT INSTRUCTIONS) 5900 Centerville Road White Bear, Mn. 55127 Tel. (651) 429-0999 Fax (651) 429-3464 www.schwing.com
Copyright © 2007, Schwing America, Inc. All rights reserved VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual
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
512
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 .......................................................................................514 Selecting local control .............................................................................515 Selecting remote control .........................................................................516 Ram change mode:.................................................................................517 Emergency stop buttons .........................................................................518 Override of the E-stop manifold ..............................................................518 Options box .............................................................................................519 Control and monitoring components .......................................................520 Menu control ...........................................................................................521 Local control............................................................................................522 Remote control........................................................................................523 Menu overview - Main menu ...................................................................524 Menu overview - submenus ....................................................................528 Menu operation - Example: .....................................................................529 Diagnostic system/”Fault handling” .........................................................530 Acknowledging faults ..............................................................................532 Fault definition.........................................................................................532 Summary of messages ...........................................................................540 Heat the oil first .......................................................................................552
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
514
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
515
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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
516
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
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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. 518
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
HOME
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
519
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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
520
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
521
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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
522
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
HOME
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
523
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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?
524
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
HOME
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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
525
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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?
526
OK
Please Enter Password **** -----------------------Input Store? Password!
VECTOR CONTROLLER-SERVICE MANUAL
[ ] [ ] [ENTER]
OK
HOME
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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<22˚ Limit Sw Outr. right Limit Sw Outr. left Prox Sw Stroke Counter
0 0 0 0 0 0 0 0
DI31 DI32 DI33 DI34 DI35 DI36 DI37 DI38
Limit Sw Slew 180˚ Limit Sw Boom A<50˚ Limit Sw Boom A<20˚ Boom above the Hopper Limit Sw Slew 0˚ Agitator Rever.Station Horn Station Limit Sw Hopper Grate
0 0 0 0 0 0 0 1
DI41 DI42 DI43 DI44 DI45 DI46 DI47 DI48
Oil Filter Boom Oil Filter CP Limit Sw Slew right Limit Sw Slew left Outrigger Station Water Tank MIN Overheating Compressor PTO rpm Prox Switch
1 1 1 1 0 1 1 0
DI51 DI52 DI53 DI54 DI55 DI56 DI57 DI58
RC Station Eng. Start RC Station Eng. Stop RC Station CP Forw. RC Station CP Rev. Dump Valves Bypassed! Telescope Disabled! Boom disabled! Boom on Rest
0 0 0 0 0 0 0 0
DO11 DO12 DO13 DO14 DO15 DO16 DO17 DO18
Start E-Stop Module BTS Driver Vibrator BTS Driver Oilcooler Relay K01 Power MainB BTS Driver CP Lub.Sys. BTS Driver Horn Boom C BTS Driver Horn Slew Buzzer Power Board
1 0 0 1 0 0 0 0
DO21 DO22 DO23 DO24 DO25 DI26 DI27 DI28
Valve Valve Valve Valve Valve Valve Valve Valve
0 0 0 0 0 0 0 0
DO31 DO32 DO33 DO34 DO35 DO36 DO37 DO38
engine Start Engine Stop rpm (+) rpm (-) Valve Boom Lub. Sys. LED Slew Stowed Pos. Air Cuff Cleaning Ball Injector
AI11 AI12 AI13 AI14 AI15 AI16 AI17 AI18
Agitator Forw. Agitator Rev. CP Forw. CP Rev. Outriggers Water Pump HP-Water Pump Compressor
87 5100 9810 9790 4330 9800 06.8 06.4
1
2
OK
x1000 3
0
NA 1350 U/min Prop. Output?
1
2
OK
x1000 3
0
NA 1350 U/min MMI Input?
PO41 PO42 PO43 PO44 PO45 PO46 PO47 PO48
Slew Slew Boom Boom Boom Boom Boom Boom
right left A extend A retract B extend B retract C extend C retract
0 0 0 0 0 0 0 0
mA mA mA mA mA mA mA mA
PO51 PO52 PO53 PO54
Boom Boom Boom Boom
D D E E
0 0 0 0
mA mA mA mA
PO55 PO56
StrokeLimiter CP Outrigger Prop.
SI11 SI12 SI13 SI14 SI15 SI16 SI17 SI18
Switch Switch Switch Switch Switch Switch Switch Switch
Water Pump CP Forw. BP Rev St. Limiter + St. Limiter Agitator Forw. Agitator Rev. Compressor
0 0 0 0 0 0 0 0
SI21 SI22 SI23 SI24 SI25 SI26 SI27 SI28
Switch Switch Switch Switch Switch Switch Switch Switch
HD-Water Pump Engine Start Engine Stop Cl. Ball Inject Vibrator On rpm (+) rpm (-) Option
0 0 0 0 0 0 0 0
SI31 SI32 SI33 SI34
Rear Panel Detection Switch Control Start Switch Op.Mode Local Switch Op.Mode Ch.rams
0 0 0 0
extend retract extend retract
704 mA 2 mA
Set Valve Stroke Lim. CP 30%
1
0
2
x1000 3
NA 1350 U/min Remote Input?
0 0 0 0 0 0 0 0
OK
0 0 0 0 0 0 0 0
RI11 RI12 RI13 RI14 RI15 RI16 RI17 RI18
Switch Switch Switch Switch Switch Switch Switch Switch
Ctl. Start/Quit Horn CP Reverse CP Forward Vibrator Auto Open Air Cuff Rabbit Snail
RI21 RI22 RI23 RI24 RI25 RI26 RI27 RI28
Switch Switch Switch Switch Switch Switch Switch Switch
rpm (+) 0 rpm (-) 0 Engine Start 0 Engine Stop 0 Agitator Auto 0 C1. Ball Inject.0 0 Compressor 0 Water Pump
RI31 RI32 RI33 RI34 RI35 RI36 RI37 RI38
Prop Prop Prop Prop Prop Prop Prop Prop
Boom A Boom B Boom C Boom D Boom E /Tel. Slew Str. Limiter Option
+000 +000 +000 +000 +000 +000 +000 +000
% % % % % % % %
mV mV mV mV mV mV mV mV
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Menu overview - submenus
Status Screen? Pumped Volume?
E-stop remote control boom concrete pump water pump high-pressure water pump compressor diesel engine oil cooler
pumping volume counter
Fault list?
Oper. data?
I/O readout?
Parameters?
Malfunction list
oil parameters
digital input? - DI11-DI58
silent diagnostic
operating hours: - P.T.O
digital output? - DO11-DO38
language MMI?
- CP
analog input? - AI11-AI22
- boom operating hours: - other
agitator
CP delivery rate: - day / total
vibrator
- strokes
outrigger
machine data
system data
moving hours: - boom
system clock
- slew drive
truck data
- stabilizers
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VECTOR CONTROLLER-SERVICE MANUAL
prop output? - PO41-PO56 MMI input? - SI11-SI34 remote control? - RI11-RI38
display - cbm / cby? password: - limit SR CP
- Efficiency CP?
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Service Manual Menu operation - Example:
RESETTING THE CONCRETE PUMP DAILY DELIVERY RATE ACTION:
RESULT:
menu line on opening screen: Press: •••••
Menu: [ENTER] = ON
next menu line: Press: • • • • Status Screens? • E•• C••
next menu line: Press: • • • • • Pumped Volume?•• E•• C••
Press:
display of daily pumping rate, e.g.: 18.0 m³
Press:
daily pumping rate reset to 0.0 m³
Press:
return to opening screen
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Diagnostic system/”Fault handling”
The integrated diagnostic system informs the operator about certain operating states, displays faults, and indicates the possible causes.
The following message origins are available (1st column): B = Boom (placing boom control)
The corresponding messages are displayed on the screen of the control unit 1 (Fig. 1).
D = Diesel engine (truck diesel engine)
The information displayed is always composed of a code and the corresponding message.
M = Machine (general machine control) 0 = Optional (Optional control functions)
MESSAGE
P = Pump (concrete pump)
CODE R = Remote (remote control system) S = System
CODE The four-digit code is composed as follows: X xx X
The following types of message are existing: M = Message
X............: Origin of message
L = Low-level fault (minor fault)
xx........: Number of message H = High-level fault (severe fault)
X : Type of message
8
Example: 1
P01M 7
P............: Pump (concrete pump)
6
01.......: Number of message
1
OK
2
x1000 3 0 PTO 1500 rpm 62˚C
M.....: Message
OFF
5
Menu: [ENTER]=ON
2 HOME
+
HELP
START
CLEAR
-
ENTER
QUIT
4 3 Fig. 1
530
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Display language
Texts can be displayed in three languages; English, German, and Spanish. The language of text displays can be selected in the "Parameter?" menu under "Language MMI?". If "International" is selected, the messages are displayed without text by means of symbols. The “Summary of Messages” section of this book contains a complete list of the text messages together with the international symbols.
Text messages, as well as international symbols, may include additional information for service personnel. Example 1: Text display Disconnected / Overload Solenoid Slewing Right - PO41 !
Example 2: International display
The messages are sorted by their code in alpabetical order. PO41
Example 1: Text display Message: Pressure Limiter Concrete Pump Activated ! Code:
Proportional Output 41 The following additional information is possible:
P01M
Example 2: International display
Message: Code:
PO41 designates, for instance:
PO
= Proportional Output
DO
= Digital Output
K
= Relay
F
= Fuse
P01M
Important: Since the international display makes multiple use of the various symbols, it is absolutely essential to consult “Summary of Messages” for a clear identification of the message.
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Acknowledging messages
NOTE! CLEAR clear.eps
Messages are not faults! They are announced only visually on the display and can be acknowledged with the “CLEAR” key.
Acknowledging faults Low level faults are announced visually on the screen and acoustically by an intermittent tone from the controller and the warning horn. These faults can be acknowledged via remote control or directly on the control cabinet. High level faults are also announced visually on display and acoustically by an intermittent tone from the controller and the warning horn. They can only be acknowledged on the control cabinet
NOTE! In both cases the acoustic signal can be shut off via remote control.
Fault definition Low level fault
In the event of a low level fault, the job can still be finished even if only with certain restrictions. High level faults
High level faults can cause direct damage to the machine. The control system will go to E-stop mode. The operator must then decide if the fault displayed will affect operational safety.
NOTE! The operator is responsible for rectifying any fault reported as soon as he possible can, in order to prevent possible damage to the machine. After a fault message has been canceled, it will not be repeated. Schwing assumes no liability for damage caused by faults that have not been rectified. When a low level fault is reported, this does not mean that it can be ignored completely, only that the job can be finished with possible restrictions.
532
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Silent diagnostic
m u u d r "Silent a ?" op ra or ca s l c w r a faul is sig all d i "REMOTE" mod of op ra io by or or wi
In the
"Parameter?"
the
e
the
t
n
en
ee t
n e
di g
hethe
e
e
t
t
n
n
the h
MENU OVERVIEW Ð Silent a nostic D splay menu l ne / Key:
,
e
n
n th the
buzzer in the control cabinet.
di g
i
i
• • • • • Menu: [ENTER]
= EIN
[ENTER]
• • • • Status screen? • E• C•
[
]
[
]
[
]
• • • • • Pumped Volume?• E• C• ••••• •••••
Fault l st? i
Oper. [
•••••
]
ata? • E• C•
I/O splay?
• E• C •
Parameter?
• E• C •
di
[
• •••
d
• E• C •
]
[ENTER] >
• • • • Silent diagnostic? • E• C• Current : No
[ENTER]
Change?
[ENTER]
Select y/n
[
Store? • • • Silent Diagn?
[ENTER]
][
]
• E• C •
d
Silent iagnostic: Yes
Ð
m
ssage displayed on the screen
e
Ð acoustic signal from buzzer Silent diagnostic: No
Ð
m
ssage displayed on the screen
e
Ð acoustic signal from horn
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Reporting and acknowledging of faults
The way faults are acknowledged depends on the se lected mode of operation (LOCAL or REMOTE) and on the severity of the fault: 1. Mode of operation
: LOCAL
Silent diagnostic
2. Mode of operation
: LOCAL
Silent diagnostic
: Yes or No
Severe fault
: Yes or No In the LOCAL mode of operation, severe faults are reported and acknowledged in the same manner as described for minor faults.
Minor fault In the LOCAL mode of operation, minor faults are reported and acknowledged in the same way, irrespective of whether Yes or No has been selected for the silent diagnostic:. The fault is displayed on the screen and an nounced by the buzzer in the control cabinet. - Depress the "QUIT" key on the control panel (Fig. 1) once. The buzzer stops sounding. The message continues to be displayed and can be read without hurry. - Depress "QUIT" once more. The fault message is definitely acknowledged.
In addition, the control system goes to e-stop mode. Optional shutdown of the engine is also possible. A severe fault can only be acknowledged from LOCAL. ATTENTION: RISK OF ACCIDENT AND DAMAGE After shut-off by a severe fault, the control system and, if applicable, the drive engine must be restarted. • It is absolutely vital to have a severe fault rectified before restarting. Otherwise there is the risk of irreparable damage to the machine.
The message is deleted from the display and logged in the faults list.
OK
2
1
OFF
x1000 3 0 PTO 1500 rpm 62˚C
Menu: [ENTER]=ON
HOME
+
HELP
START
CLEAR
-
ENTER
QUIT
QUIT key
534
VECTOR CONTROLLER-SERVICE MANUAL
Fig. 1
PRINT
Service Manual
3. Mode of operation
: REMOTE
Silent diagnostic
: No
Minor fault The fault is displayed on the screen and announced by a horn signal. - Activate "QUIT" on the remote control box (Fig. 1) once. The horns stop sounding. The message is deleted from the display.
Important: Minor faults acknowledged immediately with the "QUIT" key on the control cabinet in the REMOTE mode are not reported again when changing modes.
- After switching the mode of operation from Remote to Local, the fault is displayed on the screen and announced by the buzzer in the control cabinet. - Depress the "QUIT" key on the control cabinet (Fig. 2) once.
1
30356534 C
2 3
303623
48
The buzzer stops sounding.
5
6
2
8
3
7
4
1
9
HOME
0
The message continues to be displayed and can be read without hurry.
01
QUIT switch Fig. 1
- Depress "QUIT" once more. The fault message is definitely acknowledged. The message is deleted from the display and logged in the faults list.
1
OK
2
OFF
x1000 3 0 PTO 1500 rpm 62˚C
Menu: [ENTER]=ON
HOME
CLEAR
+
HELP
START
-
ENTER
QUIT
QUIT key
VECTOR CONTROLLER-SERVICE MANUAL
Fig. 2
535
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Service Manual
4. Mode of operation Silent diagnostic
: R E MOTE : Yes
Minor fault T he fault is displayed on the screen and announced by the buzzer in the control cabinet. - Activate "QUIT" on the remote control box (F ig. 1) once. T he buzzer stops sounding (if not switched off manually, the buzzer will be stopped automatically after 60 seconds).
Important: Low- level faults acknowledged immediately with the "QUIT" key on the control cabinet in the R E MOTE mode are not reported again when switching over from LOC AL to R E MOT E mode.
T he message is deleted from the display.
1 30356 534 C
2 3
303623
48
- Depres s the "QUIT" key on the control cabinet (F ig. 2) once.
4
5
6
3
7
2
8
1
9 10
- After switching the mode of operation from R EM O TE to LO CAL, the fault is displayed on the screen and announced by the buzzer in the control cabinet.
0
QUIT switch
T he buzzer stops sounding.
Fig. 1
T he message continues to be displayed and can be read without hurry. - Depress the "QUIT" key on the control cabinet (F ig. 2) once more. 1
T he fault message is definitely acknowledged. T he message is deleted from the display and logged in the faults list.
OK
2
OFF
x1000 3 0 PTO 1500 rpm 62˚C
Menu: [ENTER]=ON
HOME
+
HELP
START
CLEAR
-
ENTER
QUIT
QUIT key
536
VECTOR CONTROLLER-SERVICE MANUAL
Fig. 2
PRINT
Service Manual
5. Mode of operation Silent diagnostic
: REMOTE : No
Severe fault The fault is displayed on the screen and announced by the horns. In addition, the control system goes to e-stop mode. Optional shutdown of the engine is also possible.
Important: High-level faults can only be acknowledged with the "QUIT" key on the control cabinet, irrespective of the selected mode LOCAL or REMOTE.
- Activate "QUIT" on the remote control box (Fig. 1) once. The horns stop sounding. The message continues to be displayed and can be read without hurry.
1 30356 534 C
2 3
303623
48 4
5
6
3
7
- Depress the "QUIT" key on the control cabinet (Fig. 2).
2
8
1
9 10
0
HOME
QUIT switch The fault message is definitely acknowledged.
Fig. 1
The message is deleted from the display and logged in the faults list.
ATTENTION: RISK OF ACCIDENT AND DAMAGE After shut-off by a high- level fault, the control system and, if applicable, the drive engine must be restarted. • It is absolutely vital to have a severe fault rectified before restarting. Otherwise there is the risk of irreparable damage to the machine.
1
OK
2
OFF
x1000 3 0 PTO 1500 rpm 62˚C
Menu: [ENTER]=ON
HOME
+
HELP
START
CLEAR
-
ENTER
QUIT
VECTOR CONTROLLER-SERVICE MANUAL
QUIT key
Fig. 2
537
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Service Manual 6. Mode of operation Silent diagnostic
: REMOTE : Yes
Severe fault
Important: Severe faults can only be acknowledged with the "QUIT" key on the control cabinet irrespective of the selected mode LOCAL or REMOTE.
The fault is displayed on the screen and announced by the buzzer in the control cabinet.
1 303565 34 C
2 3
303 623
48
• Activate "QUIT" on the remote control box (Fig. 1) once.
4
5
6
3
7
2
8
1
9 10
In addition, the control system goes to e-stop mode. Optional shutdown of the engine is also possible.
0
QUIT switch Fig. 1
The buzzer stops sounding (if not switched off manually, the buzzer will be stopped automatically after 60 seconds). 1
The message continues to be displayed and can be read without hurry.
The message is deleted from the display and logged in the faults list. ATTENTION: RISK OF ACCIDENT AND DAMAGE After shut-off by a high- level fault, the control system and, if applicable, the drive engine must be restarted. • It is absolutely vital to have a severe fault rectified before restarting. Otherwise there is the risk of irreparable damage to the machine.
538
OFF
Menu: [ENTER]=ON
HOME
+
HELP
START
CLEAR
-
ENTER
QUIT
• Depress the "QUIT" key on the control cabinet (Fig. 2). The fault message is definitely acknowledged.
OK
2
x1000 3 0 PTO 1500 rpm 62˚C
QUIT key
Fig. 2
VECTOR REMOTE DATA ABBREVIATIONS =
NO DATA SEND
=
HYD. PRESSURE IN BAR
=
PTO RPM (all digits are numbers)
=
STROKES/MINUTE
=
HYD. OIL TEMP (Degrees Celsius)
=
EMERGENCY STOP ACTIVATED
=
START CONTROL SYSTEM
=
MACHINE in LOCAL MODE
=
MACHINE in RAM CHANGE MODE
=
MACHINE in TEACH MODE
=
MACHINE IN CLEANING MODE
=
PUT SWITCHES TO NEUTRAL
=
HOPPER GRATE OPEN
=
WATER TANK LOW
Fig. 3 30364527
• The LCD window on the Radio remote will have abbreviated codes which are explained in Figure 3. NOTE: Cable remote has no LCD window.
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Acknowledging of several faults
ACKNOWLEDGING SEVERAL FAULTS If several messages are existing, a symbol appears in the lower righthand corner of the display: – Acknowledge the first message as usual. The next message appears and the buzzer sounds. – Acknowledge this as well as any following message until no further message is displayed. Switching off the control system
Switching off electrical control to the system, any existing faults will be stored to memory. Any fault will be re-detected and reported again when the diagnostic system is restarted.
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual Summary of messages
Code
international version (symbolic)
plain text messages
B = Boom
Limitation Slewing Gear Activated !
B01M
BOOM Limitation Activated ! B02M
Disconnected / Overload E-Stop Solenoid BOOM ! B04L
PO41
Disconnected / Overload Solenoid Slewing Right - PO41 !
PO42
Disconnected / Overload Solenoid Slewing Left - PO42 !
PO43
Disconnected / Overload Solenoid BOOM A extend - PO43 !
PO44
Disconnected / Overload Solenoid BOOM A retract - PO44 !
PO45
Disconnected / Overload Solenoid BOOM B extend - PO45 !
B05L
B06L
B07L
B08L
B09L
540
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PO46
Disconnected / Overload Solenoid BOOM B retract - PO46 !
PO47
Disconnected / Overload Solenoid BOOM C extend - PO47 !
PO48
Disconnected / Overload Solenoid BOOM C retract - PO48 !
PO51
Disconnected / Overload Solenoid BOOM D extend - PO51 !
PO52
Disconnected / Overload Solenoid BOOM D retract - PO52 !
PO53
Disconnected / Overload Solenoid BOOM E extend - PO53 !
PO54
Disconnected / Overload Solenoid BOOM E retract - PO54 !
B10L
B11L
B12L
B13L
B14L
B15L
B16L
! Machine Safety Stop ! BOOM Control Fault ! B17H
D = Diesel Engine
Some Hydraulic Functions Not In Neutral! Diesel Start Disabled! D01M
Power Limitation Diesel Engine Activated ! D02M
PTO is not working or Prox-Switch PTO-RPM Fault ! D03L
VECTOR CONTROLLER-SERVICE MANUAL
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PTO RPM-Limit exceeded ! D04L
Indicator-Switch PTO = ON/OFF Fault ! D05L
Indicator-Signal Engine Load Fault ! D06L
Indicator Lvel Diesel-Reservoir Fault ! D07L
DO31
Disconnected Truck Interface Diesel Start - D031 !
DO31
Overload Truck Interface Diesel Start - D031 !
DO32
Disconnected Truck Interface Diesel Stop - D032 !
DO32
Overload Truck Interface Diesel Stop - D032 !
DO33
Disconnected Truck Interface RPM (+) - D033 !
DO33
Overload Truck Interface RPM (+) - D033 !
DO34
Disconnected Truck Interface RPM (-) - D034 !
DO34
Overload Truck Interface RPM (-) - D034 !
D08L
D09L
D10L
D11L
D12L
D13L
D14L
D15L
542
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Service Manual
! Machine Safety Stop ! High Truck Coolant Temperature ! D16H
! Machine Safety Stop ! Low Truck Oil Pressure ! D17H
! Machine Safety Stop ! Low Level Hydraulic Oil ! D18H
! Machine Safety Stop ! Battery charging On Truck Fault ! D19H
M = Machine
Ball Injector Activated ! M01M
End-Hose Shut-Off Activated ! M02M
Temperature Transmitter Hydraulic Oil Fault ! M03L
Hydraulic Oil Filter BOOM Contaminated ! Please Exchange Filter! M04L
Hydraulic Oil Filter CP Contaminated ! Please Exchange Filter! M05L
Low Level Hydraulic Oil Reservoir ! M06L
High Temperature Air Compressor ! M07L
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual
Level Transmitter Hydraulic Reservoir Fault ! M08L
Transmitter Oil Pressure Service Fault ! M09L
Transmitter Cleaning Ball Detection Fault ! M10L
DO13
Disconnected PowerOutput Oil Cooler - DO13 !
DO13
Overload / Fuse PowerOutput Oil Cooler - DO13 !
DO12
Disconnected PowerOutput Vibrator - DO12 !
DO12
Overload / Fuse PowerOutput Vibrator - DO12 !
DO16
Disconnected PowerOutput Horn Boom C - DO16 !
DO16
Overload / Fuse PowerOutput Horn Boom C - DO16 !
DO17
Disconnected PowerOutput Horn Slew - DO17 !
DO17
Overload / Fuse PowerOutput Horn Slew - DO17 !
DO38
Disconnected Solenoid Ball-Injector - DO38 !
M11L
M12L
M13L
M14L
M15L
M16L
M17L
M18L
M19L
544
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Service Manual
DO38
Overload Solenoid Ball-Injector - DO38 !
DO26
Disconnected Solenoid Water Pump - DO26 !
DO26
Overload Solenoid Water Pump - DO26 !
M20L
M21L
M22L Kabelbruch Schaltventil Kompressor - DO28 ! DO28 M23L
DO28
Disconnected Solenoid Air-Compressor - DO28 !
DO21
Disconnected Solenoid Agitator Forward - DO21 !
DO21
Overload Solenoid Agitator Forward - DO21 !
DO22
Disconnected Solenoid Agitator Reverse - DO22 !
DO22
Overload Solenoid Agitator Reverse - DO22 !
DO25
Disconnected Solenoid Hydraulic On Outriggers - DO25 !
DO25
Overload Solenoid Hydraulic On Outriggers - DO25 !
DO27
Disconnected Solenoid High Pressure Water Pump - DO27 !
M24L
M25L
M26L
M27L
M28L
M29L
M30L
M31L
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual
DO27
Overload Solenoid High Pressure Water Pump - DO27 !
DO37
Disconnected Solenoid End-Hose Shut-Off - DO37 !
DO37
Overload Solenoid End-Hose Shut-Off - DO37 !
PO56
Disconnected / Overload Solenoid Hydraulic On Outrigger - PO56 !
M32L
M33L
M34L
M35L
! Machine Safety Stop ! Hydraulic Oil Temperature Exceeded ! M36H
O = Optional
DO15
Disconnected PowerOutput Central Lubrication CP active / Pump - DO15!
DO15
Overload PowerOutput Central Lubrication CP active / Pump - DO15!
DO35
Disconnected Output Central Lubrication BOOM active - DO35 !
DO35
Overload Output Central Lubrication BOOM active - DO35 !
DO36
Disconnected LED-Output BOOM above rest - DO36 !
DO36
Overload LED-Output BOOM above rest - DO36 !
O01L
O02L
O03L
O04L
O05L
O06L
546
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual
P = Pump
Pressure Limiter Concrete Pump Activated ! P01M
Stroke Rate Limitation Concrete Pump Activated ! P02M
Hopper Grate Open ! P03M
Low Level Water Reservoir ! P04M
Oil Temperature High, Power Limiter Concrete Pump Activated ! P05L
Transmitter Oil Pressure Concrete Pump Fault ! P06L
Prox-Switch Stroke Counter Fault or CP jammed ! P07L
Disconnected / Overload E-Stop Solenoid CP ! P08L
Disconnected / Overload E-Stop Solenoid MPS ! P09L
DO23
Disconnected Solenoid Concrete Pump Forward - DO23 !
DO23
Overload Solenoid Concrete Pump Forward - DO23 !
P10L
P11L
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual
DO24
Disconnected Solenoid Concrete Pump Reverse - DO24 !
DO24
Overload Solenoid Concrete Pump Reverse - DO24 !
PO55
Disconnected / Overload Solenoid Stroke Limiter - PO55 !
P12L
P13L
P14L
R = Remote
548
R01M
Emergency-Stop On Radio Control Box Activated !
R02M
Low Battery In Radio Control Box !
R03M
CAN-FST / Transmission With Remote Control Fault !
R04M
No Radio Control Transmission !
R05L
Joy-Stick 1 From Remote Control Fault !
R06L
Joy-Stick 2 From Remote Control Fault !
R07L
Joy-Stick 3 From Remote Control Fault !
R08L
Emergency-Stop Switch On Radio Control Box Fault !
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual
Radio Control Signal With Faulty Address Received ! R09L
Disconnected Boom Release Solenoid ! R10L
Overload Boom Release Solenoid ! R11L
! Machine Safety Stop ! Hydraulic Enable Fault! R12H
S = System
Disconnected Rear Panel ! S01M
Power Supply MAIN-Board Fault ! S02L
Power Supply MMI-Board Fault ! S03L
CAN-Communication to MMI or MMI-Board Fault ! S04L
K 13
Relay Contact K 13 Override / Fault !
S05L
Fuse F 18 Fault ! F 18 S06L
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual
Fuse F 20 Fault ! F 20 S07L
Fuse F 16 Fault ! F 16 S08L
Fuse F 31 Fault ! F 31 S09L
Fuse F 32 Fault ! F 32 S10L
MF1
MF1 : Power Supply Diagnosis E-Stop Board DI15 - DI18 Fault !
MF2
MF2 : Power Supply Truck Interface etc. DI21 - DI27 Fault !
MF3
MF3 : Power Supply DI28,DI38,DI46,DI48 Fault !
MF4
MF4 : Power Supply DI31-DI37,DI43,DI44 Fault !
MF5
MF5 : Power Supply DI36,DI37,DI45 Fault !
MF6
MF6 : Power Supply DI41,DI42,DI47,AI21,AI22 Fault !
MF7
MF7 : Power Supply RAM-Change Station DI51-DI54 Fault !
MF8
MF8 : Power Supply DI55 - DI58 Fault !
S11L
S12L
S13L
S14L
S15L
S16L
S17L
S18L
550
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Reference Voltage for analog Sensors AI12, AI13,AI14,AI16 Fault ! S19L
Multi Fuse MMI-Board Fault ! S20L
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual
PART 2
SCHWING control system 'VECTOR'
TEACH MODE NOTE!
Restore original factory settings
Setting the parameters in “Teach Mode” should only be done by persons with a complete understanding of the vector control system.
When setting parameters you will need to take your remote control with you and go to the main controller.
Teach mode offers the user the opportunity to teach the main controller how he or she would prefer to have the boom respond to the remote control joystick movements by setting parameters for minimum and maximum response times of each boom movement. MIN being the amount of signal it takes to start boom movement and MAX is the signal required to make the boom manual control handle travel all the way to the mechanical stop. Setting these parameters requires setting up the unit and unfolding the boom. Be certain that the boom has room to move safely during this procedure.
NOTE!
If your boom parameters have been changed and you would like to have them revert to where they were originally, you can perform a simple procedure to restore the original factory settings. 1. Open the front cover and without activating the “I” switch, insert the “Teach Key” into the connector shown in Figure 17. 2. The display window on the front cover should now be showing you the screen shown in Figure 16.
Restore parameters to factory setting no [CLEAR]
When the unit is in teach mode, the concrete pump and agitator are disabled to prevent the operator from accidentally trying to pump while the teach mode key is installed.
Start
yes [ENTER]
Teach Mode
E C vectorrestore.eps
Figure 16 Vector display window for restoring to factory settings
Improper setup causes job site accidents: • Look for power lines before unfolding • Be sure of unit's stability
W024.eps
WARNING
3. Push the ENTER button to select yes. The controller will then restore the parameters to the values set in the Schwing Test Department. After about 10 seconds the system will reset itself.
NOTE! Heat the oil first When setting the boom parameters the hydraulic oil temperature must be at least 50˚ C and the engine RPM should be increased to normal operating speed.
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When the system restart screen appears after setting the parameters, allow the controller time to complete the process before performing any other system functions to prevent losing your stored information.
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual 4. Select the Remote mode and activate the reset “I” switch on the remote box. 5. Operate each function of the boom to see if it is now responding the way you prefer. If it is, no further action is required.
2
1
Start
NOTE! The boom operates normally while in teach mode so the key can be left in while testing each boom function.
Teach mode!
x1000 3
0
NA 1760 U/min
52˚C
Menu: [ENTER]=ON
6. If the boom is still not performing as you prefer, it will be necessary to continue with setting each parameter individually by completing the steps that follow.
teachmode.eps
Figure 18 Teach mode screen
NOTE! Setting parameters
1. Place controller in Remote mode and activate the “I” switch on the remote box. 2. Open the front cover of the Vector controller and plug in the hardware “Teach Key” to the connector shown in Figure 17.
Vector Teach Key Connector
If the unit is in local control when the teach key is inserted the display will tell you that you must change to remote control to enter the teach mode. Switch the local/remote switch to the remote position and activate the “I” switch on the remote box. If the display again asks the question “Restore the parameters to factory setting?”, Press the Clear button to say no. 4. The display on the radio remote will display the code shown in Figure 19.
1 303565 34 C
2 3
303 623
48 4
5
6
3
7
2
8
1 0
Figure 17 Location of “Teach key” connector 3. The display window on the controller cover will show that the unit is in teach mode and the “I” in the upper right hand corner will be flashing, which indicates that you need to activate the reset “I” switch to start the “teach mode” process (Figure 18).
9
connectorlocation.eps
10
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Teach mode
Figure 19 Teach mode display
VECTOR CONTROLLER-SERVICE MANUAL
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Service Manual 5. After activating the “I” switch, the display window will show you the screen in Figure 20. This chart shows you RPM, Oil temperature, a picture of a boom cylinder, and six different boom options. The far left column is where the boom slewing adjustment will show, while columns A through E represent each boom section A=1, B=2, C=3, D=4, and E=5 if you have a five section boom.
1760 rpm A
B
52 ˚C C
D
E
7. Start by holding down the “I” switch on the remote box while you activate the right hand joystick forward to the extend positon.
activate"I".eps
OK Teach mode!
Teach Mode teachfunctionscreen.eps
Figure 20 Teach mode parameter screen 6. You are now ready to teach the controller what parameters you prefer. We’ll use boom #1 extend as an example. Before you activate the function to be adjusted, you must decide which parameter you want to adjust (MIN or MAX). The selection is made with the “Rabbit/Off/Snail” switch. Choose Rabbit for MAX or Snail for MIN. So to set the #1 boom extend MIN, you must first place the switch to the Snail position (Figure 21).
Figure 22 Activate “I” switch and hold
NOTE! Boom movement is not proportional in “Teach mode” so the joystick can be moved all the way to extend or half way, it doesn’t matter as long as the boom function is activated. 8. When the joystick is activated and the “I” switch is still being held down, the display will show a bar graph like the one shown in Figure 23, at which time the “I” switch can be released. The joystick however, must remain activated or the screen will revert to the one shown in Figure 20 and you will need to start over at the previous step. The percentage shown on the graph indicates the amount of signal to this particular function (45%).
Engine speed (RPM)
1760 rpm
52 ˚C
45
A
snailspeed.eps
Oil temperature
%
15
Figure 21 Choose Snail speed to set MIN
OK Teach mode!
50
45
Teach Mode Cylinder ID
minparameterscreen.eps
Cylinder extend MIN
Figure 23 #1 boom extend MIN screen
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Service Manual 9. If the boom is not moving you should increase the percentage to this function by activating the throttle switch to the “+” position. Each time you tap the switch the duty cycle percentage will increase by 1%.
vectorthrtlpicto.eps
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Figure 24 Throttle switch on remote box
11. If you felt that the boom took off too fast when joystick was activated and the percentage needs to be decreased, tap the throttle switch Figure 24 to the “-” position until the boom responds as you like and store with the horn button as explained in the previous step before releasing the joystick. 12. You should now activate the #1 boom joystick to the retract position and adjust the percentage the same way as you did for extend, and after storing the parameter with the horn switch, the display should look like Figure 26.
1760 rpm A
10. When the boom just begins to move, you have attained the required MIN signal and you will be required to push up on the horn switch Figure 22 to store the number. If you release the joystick before beeping the horn, the percentage will revert to where it was when you began. After you store the information for “#1 boom extend MIN” the screen will display a single mark in the “A” column as shown in Figure 25.
1760 rpm A
B
52 ˚C C
D
E
B
52 ˚C C
D
E
OK Teach mode!
Teach Mode minretractstored.eps
Retract MIN stored Figure 26 Boom #1 retract MIN stored 13. You now have the option of continuing on to set the MIN on the other boom sections or moving the rabbit/snail switch to the rabbit position (Figure 27) and set the MAX for boom #1 as follows.
OK Teach mode!
rabbitspeed.eps
Figure 27 Rabbit speed
Teach Mode
NOTE!
extendstored.eps
Extend MIN stored Figure 25 Boom #1 extend MIN stored
Setting the MAX parameters requires opening the hydraulic enclosure to gain access to the boom hand valve (Figure 28). This procedure applies to all units except the 45/47 meter units which have no visible hand valve handles to view. The MAX parameter on those units must be set by checking the boom times found in the Specification section of the operation manual and operating each boom section to monitor those times.
VECTOR CONTROLLER-SERVICE MANUAL
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1760 rpm
52 ˚C
80
A
%
60
95
OK Teach mode!
80
Teach Mode 42s xbm vlvR V.ep s
maxparameterscreen.eps
Figure 28 Manual boom control handles
14. Activate the “I” switch on the remote box and hold it down. Move the right hand joystick to the extend position.
NOTE! Boom movement is not proportional in “Teach mode” so the joystick can be moved all the way to extend or half way, it doesn’t matter as long as the boom function is activated. 15. When the joystick is activated (Figure 28) and the “I” switch is still being held down, the display will show a bar graph like the one shown in Figure 29, at which time the “I” switch can be released. The joystick however, must remain activated or the screen will revert to the one shown in Figure 26 and you will need to start over at the previous step.
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Figure 29 MAX parameter screen
16. The handle on the boom valve should now have moved to the full extend position. Grab the handle and pull or push it in the same direction it has already moved. If the handle will not move any further, it has reached the mechanical stop. If you feel it is solidly against the stop and should be backed off slightly, tap the throttle switch to the “-” position until the pressure is relieved from the mechanical stop. If on the other hand the handle moves freely and is not in contact with the mechanical stop, tap the throttle switch to the “+” position until the handle comes in light contact with the stop. When you feel that the handle is properly adjusted activate the horn button to store the parameter and release the joystick. The display should now look like the one in Figure 30.
NOTE! With the apitech hand valve it is necessary to have pulsation in the handle after MAX parameter is set. If pulsation stops, the MAX is too high.
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1760 rpm A
B
52 ˚C C
D
E
OK Teach mode!
18. The procedure is the same for all functions, so activate the “I” switch and move to the next function until you have completed all parameter settings. Any time you have entered information and then change the position of the local/remote switch, the controller will first ask if you want to store the new parameters Figure 32.
Teach Mode maxextendstored.eps
Store new parameters ?
Extend MAX stored Figure 30 Boom #1 MAX extend stored 17. Now activate the “I” switch again and move the right hand joystick to the retract position. Follow the same procedure adjusting the manual control handle to the mechanical stop on the opposite side. When the adjustment is complete and you have stored the information by sounding the horn, release the joystick and the display window should look like the one in Figure 31.
1760 rpm A
B
52 ˚C C
D
E
OK Teach mode!
Teach Mode maxretractstored.eps
Retract MAX stored
no [CLEAR]
?
yes [ENTER]
Teach Mode
E C Storenew.eps
Figure 32 Window for storing new parameters 19. IF you answer yes, the system will restart and store the new parameters Figure 33. If you answer no, the window will ask If you want to restore to the original factory settings. If you answer no to that question the system will remain unchanged.
SYSTEM MESSAGE !!! Attention !!! Parameter changed by Terminal ! MAIN Board will restart automatically !
Figure 31 Boom #1 MAX retract stored
rebootscreen.eps
Figure 33 System restart screen will appear when the local/remote switch is moved
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Service Manual NOTE! When the system restart screen appears after setting the parameters, allow the controller time to complete the process before performing any other system functions to prevent losing your stored information. The restart takes only seconds and when completed the display will again show the screen below (Figure 34).
1
2 Start
x1000 3 0 PTO 1760 rpm 52˚C
Menu: [ENTER]=ON vectornormal.eps
Figure 34 Vector normal operation screen
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Service Manual
UN-ASSIGNED
UN-ASSIGNED
CONCRETE PUMP POWER
MAIN POWER 12 VOLTS
MOTOR "ON" (S.P.B.)
MOTOR "OFF" (S.P.B.)
POT. VOLTAGE + 15V
POT. VOLTAGE + 0V
ELEC. STROKE LIMITER
MAIN POWER 24 VOLTS
UN-ASSIGNED
UN-ASSIGNED
REVISED 1/25/94 GRP
3 4 5 6 7 8 9 10 16 17 15 11 12 21 22
2 9 3 10 4 11 6 13 15 22 32 31 42 7 36
18 13 14 19 20 23
2
8
30 16 23 17 24 39
1
1
U N P V W Y
Z
J K L M R S T X
C D E F G H
B
A
C-6 B-7 B-6 B-8 C-1 C-9
B-5
B-3 B-4
A-9 B-2
A-1 A-2 A-3 A-4 A-5 A-6
A-8
A-7
V R P S T U
N
L M
J K
A B C D E F
H
G
10 9 13 12 15
11
3 4
7 8 5 6
2
1
12 13
11 9 10
14
3 4
7 8 5 6
2
1
C-2 C-3
C-1 B-4 B-5
C-4
A-3 A-4
B-2 B-3 A-5 B-1
A-2
A-1
B-5 B-4 C-3 C-4 C-5
C-1
C-2
A-3 A-4
B-2 B-3 A-5 B-1
A-2
A-1
10 9
11
12
3 4
7 8 5 6
2
1
up & down
11
9
3 4
7 8 5 6
2
1
throttle
HARTING WEILAND BURNDY HARTING AMPHENOL INTERCON 16 POLE HARTING 15 POLE INTERCON 12 POLE w/throttle without BPL’s S.P.B.’s S.P.B.’s BPL’s 42 POLE 24 POLE 23 POLE 25 POLE 19 POLE
* PIN ASSIGNMENTS FOR CONNECTORS USED ON S.A.I. REMOTE BOXES, PRIMARY CABLES AND EXTENSION REELS
* Per this chart, designations of the boom slewing speed functions for KVM 32XL and KVM 32XL with Flyaway Boom are NOT applicable. Refer to the repective electrical print for wiring information.
VOLTAGE OUTPUT TO EMERGENCY DUMP VALVE RELAY
CONCRETE PUMP FORWARD STROKE
CONCRETE PUMP REVERSE STROKE
ENGINE THROTTLE INCREASE
ENGINE THROTTLE DECREASE
INDICATOR LAMP (NOT USED)
BOOM SLEW SPEED III
HOPPER VIBRATOR
MICRO-SWITCH
BOOM SLEW SPEED I
POTENTIOMETER
BOOM SLEW SPEED II
BOOM SLEWING (CCW)
BOOM SLEWING (CW)
MICRO-SWITCH
ENGINE STOP (KVM 52M)
# 4 BOOM EXTEND
# 4 BOOM RETRACT
POTENTIOMETER
# 3 BOOM RETRACT
# 3 BOOM EXTEND
MICRO-SWITCH
POTENTIOMETER
ENGINE START (KVM 52M)
BOOM SLEW
#4 BOOM
#2 & 3 BOOM
# 2 BOOM EXTEND
# 2 BOOM RETRACT
REMOTE HORN SWITCH
# 1 BOOM RETRACT
MICRO-SWITCH
BOOM # 2 AND # 3 RELAY
#1 BOOM
# 1 BOOM EXTEND
BLACK & WHITE UNITS
POTENTIOMETER
PROPORTIONAL UNITS
REMOTE CONTROL FUNCTIONS
CROSS REFERENCE CHART FOR S.A.I. CABLE REMOTE CONTROL SYSTEMS
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Remote Control Cable/Radio
Radio Remotes
Cross Reference Wiring Chart
S0063.eps
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Radio Control FW 18 Table of Contents Black-and-white control / proportional control (as from series 1987) 1. SAFETY AND ACCIDENT PREVENTION REGULATIONS 2. SHORT INSTRUCTIONS 3. PREFACE 4. EXTRACT FROM THE TERMS OF WARRANTY 5. MODEL PLATES 6. TECHNICAL DATA 7. SHORT DESCRIPTION 8. CONTROL AND MONITORING EQUIPMENT 9. COMMISSIONING 10. OPERATING THE RADIO CONTROL 11. PUTTING OUT OF OPERATION CHANGEOVER 12. SAFETY DEVICES AND TROUBLESHOOTING 13. MAINTENANCE WORKS AND CHECKS, 14. CHANGING AND CHARGING OF BATTERY
• Only specialists are allowed to repair the radio controls. • In case of any failure, notify the SCHWING after-sales service. • Only persons authorized by Messrs. SCHWING are allowed to open leaded housings. • Unauthorized manipulations may result in great damages and render all warranty claims void. See also section 4.1.
ATTENTION! Before welding the machine, make absolutely sure that the plugs of the connection cables are detached from sockets 7, 8, and 9 of the receiver. Protect the socket by means of a sealing cap. Non-observance would result in damage to the electronic control system (see also customer information K 29).
4 5
7
9
8
1. Safety and Accident Prevention Regulations The safety and accident prevention regulations stipulated in the operating instructions for the truck-mounted concrete pump are applicable and binding for the operation with the remote control too. • To avoid any unintended working movement of the machine and before changing from one control system to another:
!SET ALL CONTROL ELEMENTS IN THE DRIVER’S CAB AND ON THE REMOTE CONTROL PANEL TO ZERO POSITION. STOP DRIVING ENGINE.
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Remote Control Cable/Radio Safety Regulations - Concrete Pumps with placing booms READ OPERATION MANUAL FOR THE MACHINE. It describes the safe, proper, and most efficient way to operate. KNOW YOUR MACHINE! When operating the concrete pumps and placing booms, the safety regulations of the responsible employers’ liability insurance company have to be observed. The observation of these regulations shall be the responsibility of the contractor and operator.
KVM 32 - 309779 KVM 36 - 309780 KVM 42 - 309855 KVM 52 - 309930
• Check the operational reliability of the machine each time before it is put into operation. Any defects found must be repaired immediately. • Allow the machine to be operated and maintained by qualified personnel only. • Make use of handles and steps when ascending or descending. • Keep steps, platforms, control and monitoring devices, etc. free of dirt, oil, snow, and ice. • Before leaving the machine, protect it from unauthorized use and unintentional movements. • Unauthorized presence in the immediate area of the concrete pump and placing boom is not allowed. Warn persons who are in the immediate area. Stop work if persons do not leave the area after having been warned. • Wear personal protective equipment when operating the machine.
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• Drive on bridges, decks, etc. only if the bearing & height capacity is adequate. • The vehicle must not travel with an unfolded boom. • When traveling, the shut-off valves of the outrigger cylinders must be shut, and the outrigger must be locked by means of the transport safety devices.
Jacking
The following are some supplementary recommendations: • All safety devices and provisions against accidents, such as warning labels and information signs, coverings, etc., must be in place. Do not remove or tamper with them. If they are missing, replace them. See the following drawings for location of labels: KVM 23 - 309903 KVM 25 - 309918 KVM 28 - 309778 KVM 31 - 309878
Traveling
• Prior to jacking, check soil conditions. If necessary, increase the support foot area by placing square timbers underneath. • Keep sufficient distance from excavations; slopes could break away because of support pressures. • On inclines, place chocks behind the wheels, release the break, let the vehicle run against the chocks, and apply the brake again; then jack. • After jacking, close the shut-off valves of the outrigger cylinders, otherwise the cylinders will lose oil, and the machine could sink to one side.
Concrete Pump • In order to avoid concrete splashes due to suction of air, the agitator hopper must always be filled with concrete up to the mixing shaft. • DO NOT OPERATE THE CONCRETE PUMPS WITHOUT THE HOPPER GRILL FIRMLY BOLTED DOWN. • NEVER ALLOW HANDS NEAR THE GATE, VALVE, OR AGITATOR HOPPER WHILE THE MACHINE IS RUNNING. • Before the gate or valve housing is opened, stop the driving motor. If this is not possible (e.g. in the case of cleaning work), the remote control cable has to be disconnected to avoid unintentional movement of the valve. The concrete pump operator must make sure that no unauthorized person is present in the area of the open gate or valve housing or starts the concrete pump accidently.
Placing Boom • The placing boom may be operated only up to a maximum wind speed of 48 m.p.h. (77 km/h = wind force 8).
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Remote Control Cable/Radio • Under all circumstances, keep the boom sufficiently away from obstacles such as boom cranes, scaffolds, buildings, etc. • The placing boom must never be used as a crane for lifting materials. • The length of the end hose must not exceed 4 meters (13 feet) in length. The end hose should not be kinked during pumping operations. The safety cable between the boom pipeline and the end hose must be in place and attached. • If end hose is replaced with a combination of reducers and hoses (for example, a 5-4 reducer and 4” hose), then all hoses, reducers, etc. must be fastened with safety cables and may not exceed the weight of the recommended end hose. Any of the above mentioned items should be capable of handling the pumping pressures of the specific equipment. • Perform regular maintenance and lubrication of boom at 1 year prescribed intervals and do a complete check of the boom and tower annually using Schwing America’s “Regular Check-Up Concrete Placing Booms” form, SAE-510. This form is supplied with all units and is available from Schwing America.
Pipelines • PIPELINE AND CLAMPS MUST BE SUFFICIENT FOR PUMP CAPABILITY. • The pipeline connections must not be opened under working pressure. Before the pipeline is opened, pressure must be relieved by sucking back the concrete. Secure couplings after assembly of the pipeline. • Because of the increased danger of accidents, the following important points must be adhered to when blowing out the pipeline with compressed air: a. Blowing-out should be performed under the supervision of an expert. b. No pipe bends or hoses should be connected to the end of the pipeline during the blow-out process. c. No person is allowed to be next to the concrete discharge end. d. A catch basket must be fitted to the concrete outlet. e. The concrete outlet should be positioned high
enough to permit easy discharge of the concrete. f. The pipe cleaning head must be equipped with a working gauge and a properly sized air regulator hand valve. g. The plug must be long enough to ensure air tight sealing of the pipeline at the catch basket after the pipeline has been blown out. h. The plug must be tight-fitting to prevent compressed air from flowing around the plug and into the concrete. i. Work at the pipeline is allowed only after the pipeline has been relieved of compressed air. Ensure that the air pressure has been completely relieved. j. Single pipe sections and short pipes up to a length of 40 feet must not be blown out. Great danger of accidents exists because of rapid expulsion due to too little mass! • When laying pipeline, use as few bends as possible. Horizontal pipelines must be adequately supported. When installing a vertical pipeline, the best method is to use upright struts supporting the lowest vertical pipe. Each succeeding pipe should then be anchored to the building. • It is preferable to install pipelines within buildings whenever possible. See operator’s manual and “Pumping Concrete” booklets for more information on pipeline installation.
Remote Controls • To avoid unintended operating movements of the machine, set all control levers or switches in the operator’s cabin and on the remote control panel to the neutral position prior to any switch-over to local or remote control and prior to disconnection of the remote control line.
Electrical Connections on the siteHydraulic Power Packs, etc. • The power supply connection for electrically driven stationary concrete pumps or the electric power packs for pumps or booms has to be arranged by the contractor. • The power supply on construction sites, according to VDE 0100 paragraph 55, may be taken only from a special feed point, e. g. an electrical distribution box with current-operated
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Remote Control Cable/Radio ground protection. The connection of the power supply cable to the feed point may be carried out only by a qualified electrician. • Fuse protection and conductor size are the responsibility of the electrician and must comply with the National Electrical Code and any local codes.
IMPORTANT:
2. Short Instructions NOTE: These short instructions are to be regarded as a memory aid only and do not dispense from the full knowledge of the complete operating instructions. Preparing the Commissioning • Switch all controls on the machine and on the transmitter to “0” and “off.” • Switch truck engine off when warm. • Check whether the cables are connected to the antenna, power supply, receiver control, and machine control panel.
Making Ready for Operation • Switch ignition “on.” • Place charged rechargeable battery into the transmitter and the spare battery into the charger.
NOTE! Place battery into charger with poles in the correct position. • Set selector switch on machine control panel to “Remote Control.” • Unlock all EMERGENCY OFF buttons on the machine. • Switch on receiver. LED indicates: RED. • Unlock EMERGENCY OFF button of transmitter. • Switch on transmitter power supply (selector switch to “ON”). LED on receiver lights up GREEN. • If there is no reason for a fault, every further control command will be passed on by receiver to the machine pilot control.
Operating Mode • •
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trol command is indicated on the transmitter and receiver by the green LEDs flashing. • If no command is sent within a period of 20 seconds, the transmitter reverts to “idle state.” The LED of the receiver indicates permanently GREEN = READY. The “idle state” is cancelled by operating any switch.
Start truck engine. The transmission and reception of a valid con-
• Comply with safety and accident prevention regulations. • Consider maximum range of transmitter. • Avoid radio shadows. • Switch the transmitter off by turning the selector switch to “OFF.” All machine functions are immediately interrupted when the EMERGENCY OFF button is pressed.
Reasons for Automatic Switch-off • Interference by external transmitters • Insufficient range due to radio shadows • Empty battery • Transmitter controls are not switched to “0” or “OFF” when switching on the receiver.
3. Preface The operating instructions contain important information concerning the operation and maintenance of your SCHWING MACHINE. A copy thereof should always be within easy reach of the machine operator and the members of the maintenance crew. Any handling of the machine implies knowledge and close observation of the operating instructions. It is advisable, therefore, especially prior to commissioning, to read the instructions carefully several times and to become familiar with the machine. NOTE: Perfect operation and maintenance ensure lasting operational reliability. Downtimes as the result of avoidable maintenance work can largely be avoided if particular attention is given to the following points:
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Remote Control Cable/Radio • Always operate the machine gently and without force! • Never change of your own values set or specified by the manufacturer, such as hydraulic oil pressures, tightening torques, etc.! • Carry out all the prescribed maintenance and inspection work completely and punctually! • Use only lubricants and operating supplies according to our recommendations! • During operation, regularly read all the built-in monitoring instruments and note any unusual reactions (noises, lack of power, etc.)! • Install only ORIGINAL SCHWING SPARES!
During operation and maintenance work, the relevant safety regulations must be strictly observed. (Note the extract from the terms of warranty.) In the event of failure, possible queries, and for ordering spare parts, please contact: Schwing America, Inc. 5900 Centerville Road White Bear, MN 55110 (651) 429-0999 TWX: 910-563-3539 Subsidiary of: Friedrich Wilh. Schwing GmbH or the authorized representative for your area. Always quote the machine model, the serial number, and the information on the model plates. Carry out operation and maintenance of the chassis and the engine installed according to the maker’s instructions.
4. Extract from the Terms of Warranty The following extract from the terms of warranty deals with those damages which may result from incorrect operation and maintenance: The warranty does not extend a. to defects arising in consequences of natural wear and tear, inadequate installation and erection work by third parties, inadequate commissioning, inadequate or negligent handling, subjection to unsuitable stresses and loadings; b. to defects caused by modifications or repair work carried out by the purchaser or by third parties without our prior approval. c. to defects arising due to the installation of spare parts which are not genuine SCHWING parts.
If a defective machine continues to be used in spite of the defect, the warranty shall be confined only to the original defect. **Complete terms of warranty, see section 7 of the General Trading Terms. When exporting our machines, special regulations possibly in force in the destination country must be complied with. *Any export of SCHWING machines without authorization from SCHWING is not allowed. Appropriate Applications The machine is assigned exclusively to the application purposes mentioned in these operating instructions. The company of Schwing will not be liable for damages, if • the machine is used for operations which are not the normal practice. • the operation instructions, the safety regulations, and the accident prevention regulations are not observed.
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Remote Control Cable/Radio
5. Model Plates A model plate is attached to both the transmitter and the receiver. Radio remote control can only be performed with equipment which have identical characteristics on their model plates.
Transmission of the control functions Charging unit for transmitter battery
: digital
: installed in the receiver
Receiver:
Operation of the radio remote control is without charge in the FRG according to PTT approval AGB-242.
Operating frequency (27.55 inches)
: in the 70 cm band
Please note here:
Telegram evaluation
: by microcomputer
Model: ______________________
Operating voltage 23 to 28 V, 200 mA
: 11.5 to 14.5 V or
Relay outputs
: 18
Analogous outputs 12, 18, V for 24 V or 6, 9 V for 12 V
: 8 in sequence + 6,
Equipment Number: ______________________ Frequency: _____________________ of your remote control equipment, and always quote them in case of queries, etc.
6. Technical Data
: 8 in sequence = 3,
Proportional control
7. Brief Description
Transmitter: Operating Frequency (27.55 inches)
: in the 70 cm band
RF output power
: 4 mW
Control channels and 8 proportional
: 18 black-and-white
Operating voltage and power requirements
: 9,6 V DC 70 mA
Type of operation transmitter
: portable hand
Transmission range
: approximately 50 m (164.5 feet)
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The new generation of SCHWING RADIO REMOTE CONTROLS are an advanced development of the systems first introduced in 1983. Radio remote controls can be retrofitted or fitted at the factory. Dependent on the machine model, black-andwhite or proportional controls are available. Transmitter The transmitter is powered by a rechargeable nickel-cadmium battery. An inbuilt “idle state circuit” ensures optimized utilization of the battery charge. The “idle state circuit” switches the power supply off when no switch is operated within a period greater than 20 seconds. The power supply switches on again when a switch is operated. The operating voltage is permanently monitored.
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Remote Control Cable/Radio An LED indicates to the machine operator that the battery needs to be changed. If the battery is not changed in approximately 30 minutes, the monitoring circuit blocks the transmitter. The “coding electronics” converts every switch operation into an unmistakable transmit signal which is combined with a special identification code before being sent by the transmitter. As is known from the cable remote control system, the boom speed with PROPORTIONAL CONTROL is dependent on the excursion of the control lever: Short excursion = low speed Long excursion = high speed By a precise graduation of the ranges of adjustment, the speed is almost continuously variable. With the respective actuation of the control levers, several movements can be made simultaneously.
The “radio telegram” emitted by the transmitter is detected and monitored by the receiver. If the receiver electronics recognizes the “radio telegram” as correct and complete, the signal is sent to the connected machine pilot control. The transmitter and receiver are precisely tuned to each other. An external transmitter cannot affect operation because different information (e.g. equipment no.) belongs to the contents of each radio telegram, and this is checked by the receiver. In the event of an electronic fault or loss of telegram, the previous functions initiated are stopped. The two-colour LED indicates the state of the receiver electronics: “FAULT”, “READY”, “OPERATING.” A storage rack incorporating the recharge electronics for one transmitter battery is mounted in the receiver housing.
Receiver The receiver is mounted in the driver’s cabin and is powered by the truck voltage. The hydraulic component (pilot control) is connected by cable to the machine control panel via the socket provided. NOTE: ONLY connect the receiver of the PROPORTIONAL CONTROL to 24 V on-board voltages with negative pole connected to the chassis (negative to ground). The BLACK-AND-WHITE CONTROL receiver can be connected to 24 V onboard voltages with negative to ground or, AFTER SPECIFIC READJUSTMENTS, to 12 V systems, or AT ZERO POTENTIAL to systems with positive to ground. NOTE! INCORRECT VOLTAGE, SHORT-CIRCUIT, AND OVERLOAD destroy the electronics. For warranty reasons, we advise against installing the system by yourself.
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8. Control and Monitoring Equipment Radio Remote Figure 1 = Black-and-white transmitter Figure 2 = Proportional transmitter 1 - Control lever with spring-centered 0-position for placing boom functions 2 - see 1 3 - EMERGENCY OFF button 4 - Potentiometer: output adjustment of concrete pump 5 - Antenna socket with removable antenna
6*- Selector switch: vibrator on/off 7*- Button: horn on truck 8 - LED: EMERGENCY OFF button operated 9 - Selector switch: truck engine speed adjustment 10*- Selector switch: engine on/off 11- Selector switch: concrete pump (pumping - off - reverse) 12- LED: battery charge monitor 13- LED: radio signal output monitor 14- Selector switch: transmitter power supply ON/ OFF * = Optional extra
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Remote Control Cable/Radio Receiver 1 - Toggle Switch: receiver ON/OFF 2*- 0.4 A fuse (receiver power supply) 3*- 1.6 A fuse (charger power supply) 4 - Two -colour LED: receiver state GREEN = receiver READY GREEN, flashing = receiver OPERATING RED = receiver FAULT 5 - Two-colour LED: Battery charge control GREEN = battery CORRECTLY inserted (pole), charging
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RED = battery INCORRECTLY inserted (pole), replace correctly (turn) immediately OFF = no battery inserted 6 - Plug-in module: transmitter battery charger 7 - Socket for connecting cable to machine control panel 8 - Antenna socket 9 - Socket: power supply for receiver and charger * = Not included in the new radio remote control series
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Remote Control Cable/Radio
9. Commissioning Preparations
3
1. Switch all controls on the machine and on the transmitter to “0” or “OFF.” 2. Switch truck engine off when warm and with PTO switched on.
NOTE: After a “remote start”, the engine should run smoothly immediately. The remote control can give no cold start assistance. 3. Disconnect remote control cable from control panel and replace with cable: receiver - control panel. 4. Check whether power supply cable, antenna cable, and connecting cable are connected to the receiver. 5. Check whether antennas for transmitter and receiver are mounted. If not, install.
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4 5 6. Unlock EMERGENCY OFF button of transmitter by turning to the right.
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Ready for operation
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1. Switch on “ignition”. 2. Insert charged battery into the transmitter and spare battery into charger.
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NOTE! Make sure that the charger is inserted with the correct polarity
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3. Set selector switch on machine control panel to “remote control”. WARNING Do not operate at pressures exceeding the rating of the entire material delivery system.
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ERGENC M
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T OPERATE NO ZONE RED !
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7. Set selection switch to “ON”. This causes the following:
STOP
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4. Unlock all EMERGENCY OFF buttons on the machine by turning them to the right. 5. Switch on the receiver using the toggle switch. LED lights up: RED. The receiver is waiting for a control signal.
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a) The power supply of the transmitter is switched on. The red LED lights up for a short time and extinguishes if the battery voltage is correct. The rhythmical flashing of the LED indicates that a radio telegram is being transmitted. b) The receiver is switched to “READY”. The display of the two-colour LED changes to GREEN. If the two-colour LED continues to indicate “RED”, the receiver is at FAULT. NOTE: The fault may be caused by an external transmitter in the immediate vicinity. The equipment is ready for operation.
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Remote Control Cable/Radio
10. Operating the Radio Remote Control NOTE! In order to avoid undesired movements of the machine, ALWAYS switch off the power supply of the transmitter (selector switch to “OFF”) when the machine is not in use.
Transmitter mode 1. When the receiver is ON, unlock the EMERGENCY OFF button of the transmitter by turning to the right, and set the selector which to “ON”.
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If the engine is not fitted with an engine ON/OFF switch, start the engine with the “ignition key”.
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Putting on the transmitter
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1. Insert the spring hooks of the upper belts into the carrying frame. 2. Place the belts over the shoulders. 3. Insert the spring hooks of the lower belts into the carrying frame. 4. Adjust the length of the upper belts as required by means of the buckles.
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*If desired, the carrying belt can be completely removed from the transmitter.
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2. If an engine ON/OFF switch is fitted, start the truck engine using the selector switch. 3. If no control switch is operated when the transmitter power supply is switched on, the transmitter first sends “address telegrams” without a control command. The LEDs flash “GREEN”. After 20 seconds the “idle state circuit” switches the transmitter power supply off. The LED extinguishes. The receiver remains in the “READY” state and the LED remains permanently
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Remote Control Cable/Radio “GREEN”. After operating any switch, the power supply of the transmitter returns. Work may then proceed.
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Transmitter range For safety reasons, the transmitter range is limited but is sufficient for all conceivable construction site situations. If the transmitter is taken out of this broadcast range, all of the machine’s functions will be stopped automatically. Radio shadows The machine operator must select his location in such a way that he has unrestricted visibility into the machine’s working area and that there is no hindrance to the radio traffic.
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4 5 Operation of the machine by wireless remote control is identical to that for cable remote control. Please observe the following instructions for safe, uninterrupted operation: Capacity of the transmitter battery The capacity of each battery is dependent upon: • the age of the battery, • the charge level, and • the ambient temperature.
The following may be taken as a rule of thumb: The location has been chosen correctly if, at a maximum distance of 50 meters (164.5 feet), the machine and the receiver’s antenna can be seen without restrictions. Breaks in the work In order to prevent unauthorized operation of the machine, the operator should not set down the transmitter once it has been switched on.
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Under extreme conditions, the capacity of the transmitter battery may be exhausted after about 8 hours of service. (System will be shut down by the undervoltage.)
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In order to ensure uninterrupted operation, we recommend always having a charged battery on hand while charging another battery.
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The integrated charge electronics prevents an overload. NOTE: In order to prevent unnecessary reduction of NiCd battery lifetime, we recommend that the batteries be regularly changed after every 3-4 operating hours BEFORE the voltage monitor indicates a battery change by flashing.
3
IMPORTANT! Before removing the transmitter, switch off the truck engine and press the EMERGENCY OFF button. Set the selector switch to “OFF” and lock the transmitter into the driver’s cabin. Secure the machine against unauthorized
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Remote Control Cable/Radio use (see operating instructions of truck-mounted concrete pump).
4. Switch off the receiver by means of the toggle switch.
Turn the receiver off by means of the toggle switch.
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5. **The LED extinguishes. 6. Switch the truck engine off and remove the “ignition key”. 7. Lock the transmitter in the driver’s cabin and secure the machine against unauthorized use.
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Putting out of Operation 1. Set all controls on the transmitter to “0” or “OFF” position. 2. Set the selector switch to “OFF”.
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Changeover to Cable Remote Control 1. Put out of operation as described above. 2. Remove the connecting cable: between receiver and control panel from machine control panel. 3. Connect standard remote control cable to the machine control panel. 4. Perform commissioning as normal for cable remote control.
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3. Press the EMERGENCY OFF button.
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Remote Control Cable/Radio
12. Safety Facilities In addition to manual switch-off (EMERGENCY OFF button), the radio remote control is provided with automatic facilities to immediately interrupt or inhibit work operations in the event of a radio fault. 1. SAFETY TEST DURING COMMISSIONING
After switch-on, the receiver first tests whether its radio channels are free and undisturbed. If a signal is received, the receiver immediately returns to the state: FAULT. NOTE: After reception of a VALID signal, the receiver reverts to the state: READY. 2. SAFETY CHECK DURING OPERATION
The operational status will be suspended by: • switching the system off manually. • actuating one of the EMERGENCY OFF buttons. • undervoltage of the transmitter battery.
switch off the transmitter power supply. • Set all controls of the transmitter to “0” or “OFF” position. • Change location (the transmitter may be in a radio shadow). • Unlock the EMERGENCY OFF buttons by turning them to the right, and switch on the • ransmitter power supply.
The equipment is ready for operation again. Fuses (not included in new series) Sockets to receive two fuses are built into the upper part of the receiver. 0.4 A = receiver 1.6 A = charger
The undervoltage monitor will shut down the transmitter if battery voltage falls below the safety threshold. Work may proceed after exchanging the battery. •
receipt of an invalid “telegram”
Transmission of the control commands from the transmitter to the receiver is effected using “telegrams”. These telegrams consist of a so-called basic code (“address telegram”) in addition to the actual control command. It is on the basis of this basic code that the receiver recognizes the “voice of its transmitter”. Invalid telegrams may be caused, for example, by: • • •
interference due to external transmitters radio shadows contradictory control commands
IMPORTANT! Should you note during operation that the machine does not execute any control commands: •
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press the EMERGENCY OFF button and
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Remote Control Cable/Radio
13. Maintenance Works and Checks The radio control is virtually maintenance-free. To insure uninterrupted operation, observe the following instructions: IMPORTANT! 1. The entire system is resistant to splashed water, but it is not waterproof. 2. Keep all components clean and dry and use the cover caps to close off immediately any connection plugs which are not being used.
Changing the transmitter battery 1. Switch off the transmitter and press the EMERGENCY OFF button. 2. Undo the locking screws by rotating through 90 degrees.
NOTE: Check that the cover is correctly mounted. If mounted upside down, there is a visible gap through which humidity can penetrate into the battery compartment. Charging the transmitter battery The battery in the charger is exchanged in the same way as described above, but: CAUTION! The charger is not equipped with an automatic polarity switch-over circuit. If the LED lights up RED, IMMEDIATELY remove the battery and change over the contact position (turn the battery around). The LED will indicate GREEN if the polarity is correct. NOTE! The time it takes to charge a battery completely is approximately 14 hours or less, if the battery is exchanged in good time.
3. Remove battery. 4. Insert charged battery with its contacts first into the battery compartment. The position of the positive and negative poles is not important due to the automatic polarity switch-over circuit. 5. Replace cover. Turn the locking screws 90 degrees and clip in by applying a slight pressure. DO NOT screw in.
NOTE! DO NOT USE any other chargers: RISK OF EXPLOSION. NOTE! Only use ORIGINAL SCHWING NiCd rechargeable batteries: There is a RISK OF DAMAGE to the equipment if incorrect rechargeable batteries are used. NOTE! Do not open the batteries (fumes hazardous to health). NOTE! Do not throw away batteries that are dead or defective. Instead, dispose of them at an approved collection point, which is equipped to deal with special wastes.
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Radio Control FW 20 Table of Contents 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
TABLE OF CONENTS SHORT OPERATING INSTRUCTIONS FOREWORD DESIGNATED USE, WARRANTY SAFETY REGULATIONS AND ACCIDENT PREVENTION REGULATIONS CERTIFICATE OF APPROVAL SHORT DESCRIPTION TECHINCAL DATA, RATING PLATES MONITORING-, WARNING-, AND CONTROL ELEMENTS PRE-OPERATING INSTRUCTIONS OPERATION EMERGENCY SHUT-OFF INTERRUPTIONS OF WORK, END OF OPERATION REPLACING OF BATTERY MALFUNCTIONS MAINTENANCE, REPLACING OF FUSES REPAIR
Copyrighted. These operating instructions must not be duplicated, used improperly, or communicated to third parties without our consent - not even by way of excerpts.
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Remote Control Cable/Radio
2. Short Operating Instructions The short operating instructions are to be used as a short reference only. They are by no means a replacement for the detailed operating instructions. Please observe also the operating instructions of the machine!
•
•
Pull EMERGENCY SHUT-OFF 1; LEDs 2 and 4 are extinguished; LED 3 is permanently lit: empty messages are being transmitted. Actuate control element; LED 3 is flashing: instruction messages are being transmitted.
Emergency Shut-Off Pushing in the EMERGENCY SHUT-OFF BUTTON interrupts the main functions of the machine.
Preparations • Set up the machine. • Set all control elements on the machine and the transmitter to their “0” position. • Shut off the vehicle engine as long as it is still warm, and leave the ignition on. • Plug in the receiver cable. • Set the operating mode selector switch on the machine to “REMOTE”. • Set the power supply switch of the electric control to “ON”. • Unlock all EMERGENCY SHUT-OFF buttons of the machine.
Ready-for-Operation State • Switch on power supply of transmitter; LED 4 is flashing. • Push EMERGENCY SHUT-OFF 1; LED 4 is flashing faster.
Automatic Shut-Off for example, in case of: • low battery voltage • message errors • electronic module failure • no command instruction messages received (for more than 30 minutes).
Interruptions of Work • Bring placing boom into transport position. • Set control elements to “0”-position. • Shut-off power supply of transmitter • Set power supply switch of the electric control to “OFF”. • Lock away transmitter.
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3. Foreward The present operating instructions are addressed to all persons in charge of operating and servicing the SCHWING RADIO REMOTE-CONTROL UNIT described overleaf and to owners or users of the equipment.
or the authorized representative for your area, quoting always the machine model, the serial number, and the information on the model plates. Carrying out operation and maintenance of the chassis and the engine installed according to the maker’s instructions.
4. Designated Use The operating instructions are to help you familiarize yourself with the equipment in order to • use it for the purposes for which it has been designed, • operate the equipment safely in order to avoid dangers, and • use it properly and efficiently in order to save costs. The equipment has been built in accordance with stateof-the-art standards and the recognized safety rules. Nevertheless, the equipment may constitute a risk to persons and property if it is incorrectly used, operated, serviced, or repaired. Using the equipment presupposes the perfect knowledge and strict observance of the operating instructions. Therefore, you should read the operating instructions carefully and repeatedly in order to familiarize yourself with the equipment before putting it into operation for the first time. Reading the instructions after the work has begun is too late! In addition to the operating instructions, the generally applicable legal and other mandatory accident prevention rules in the country of use are to be observed.
The equipment is exclusively designed for the control of certain types of SCHWING machines. Any other use is considered as contrary to its designated use. The equipment must be used in accordance with the operating instructions. In addition to these, the operating instructions of the machine must also be observed. The equipment may only be installed by persons entrusted with such work by SCHWING. The designated use also includes the observance of the operating, servicing, and repair instructions prescribed by the manufacturer: • SCHWING radio remote control units must be installed, removed, operated, and repaired only by specially trained and qualified personnel. Unauthorized additions and modifications are not permitted. • For servicing purposes only, ORIGINAL SCHWING SPARE PARTS are to be used. • Before export, the equipment must be adapted by the manufacturer to the regulations in force in the country of use.
Non Designated Use In the event of failures, possible queries, and for ordering spare parts, please contact: Schwing America, Inc. 5900 Centerville Road
The manufacturer cannot be held liable for damage of the equipment resulting from use outside its designated use and from incorrect and inappropriate operation and maintenance.
White Bear, MN 55127 (651) 429-0999 TWX: 910-563-3539
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Extract from Terms of Warranty The conditions mentioned below are an extract from the terms of warranty relating particularly to damage which may be caused by incorrect operation and maintenance. The warranty does not include: a) defects due to natural wear, inappropriate installation and fitting by third parties, incorrect commissioning, incorrect or negligent treatment and inappropriate use; b) defects caused by modifications or repair work performed by the customer or by third parties without our previous approval; c) defects caused by the installation of non-original SCHWING spare parts. If defective machinery/equipment is kept in use in spite of defects, the warranty only includes the original defect. For the complete terms of warranty, please refer to our “General Conditions of Sale”.
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5. Safety Rules and Accident Prevention Regulations The safety rules and accident prevention regulations contained in the machine’s operating instructions are also applicable to the operation of the machine with the radio remote control unit. Some additional information is given below: • During the operation, the operator must have a clear view of the machine and the concrete placing site. • Do not place aside the transmitter as long as it is ready for operation. • Always carry the transmitter in such a way that any intentional contact with the control elements is avoided. • Cut off the transmitter’s power supply during interruptions of the work. • Always protect the transmitter against unauthorized use (by locking it away). • Before changing the control mode, set all control elements of the direct-, cable-, and radioremote units to the “0” position. • The transmitter is splash-proof (only when the cover is closed), but not watertight.
after-sales service. • Electric welding procedures always bear the risk of damaging electronic components. These components must be properly protected by an expert in electronics before such work is carried out. If the vehicle is to be retrofitted with a mobile car telephone, the safe distance between the two antennas must be at least 2 meters. If this distance is not respected, telephone calls may cause control signal transmission interference.
The equipment may only be put into operation when the cover of the receiver is properly closed. Keep all parts clean and dry. Close all unused connectors immediately with the corresponding caps. Keep the receiver cover closed when the machine is being cleaned. Avoid any contact of the equipment with steam jets and aggressive detergents. • In case of trouble, never carry out repairs on the equipment beyond those indicated in the troubleshooting measures of the present operating instructions, but rather inform the SCHWING
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7. Short Description The equipment consists of a portable transmitter, a receiver built into the machine, and a charger device for the rechargeable transmitter battery. Depending on the type of machine, the equipment can be supplied either in the proportional control version or in the pulse control version (black-and-white control).
A power-saving feature automatically switches the transmitter off during work interruptions in order to save battery power. The equipment bears the type-approval mark of the Deutsche Bundespost (German Telecommunications Authority), is approved for use by the general public, and is not subject to registration or to licence fees.
All the control commands transmitted are safety-coated in the transmitter so that only the pertaining receiver responds to the signals. The safety code is an individual code which does not repeat itself. Other transmitters, and also those of a different design, will not cause the receiver to accept command signals. The receiver checks the input signal, passing it on to the machine control unit only if it is correct and complete. The channel switching of the radio equipment supplied permits the simultaneous and interference-free operation of several FW-20 units. The transmitting and receiving frequencies of the unit are selected in such a way that interference from other radio services is virtually excluded. Moreover, the transmitter is designed for operation with two different transmitting frequencies. Frequency switching in the receiver is fully automatic. In case of interference in spite of these features, the equipment automatically switches over to the safe EMERGENCY SHUT-OFF state. The transmitting range is limited to an area from which the machine can be clearly seen.
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8. Technical Data: Transmitter General Operating temperature range: . . . . . . . . . . . . . . . . . . . . . . . . . . : -10 to +50 C Type of protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : IP 65 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 280 x 140 x 135 Transmitter-rechargeable battery set . . . . . . . . . . . . . . . . . . . . . : 9.6 V / 1000 mAh Battery replacement at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : < 9.0 V Automatic transmitter shut-off at . . . . . . . . . . . . . . . . . . . . . . . . : < 8.7 V Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 3 kg
Transmitter Frequency range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 430 to 470 MHz, 2 RF channels, switch-selected Transmitter output power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 5 mW Transmitting range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : > 100 m
Digital System CMOS microcontroller PCM data transmission Transmission time of radio commands -pulse control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 110 msec -proportional control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 155 msec Operating time with fully charged battery. . . . . . . . . . . . . . . . . . : approximately 12 hours
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Remote Control Cable/Radio Receiver General
Operating temperature range: . . . . . . . . . . . . . . . . . . . . . . . . . . : -10 to +50 C Type of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : IP 00 (casing = IP 55) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 19 cassette 3HE/28FE resp. 42 TE Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 2 kg (without casing) Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 20 to 28 V Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : max. 0.5 A
Receiver Frequency range
: 430 to 470 MHz, automatic transmitting frequency scan Sensitivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 1 uV
Digital System CMOS microcontroller PCM data telegramme decoding Active EMERGENCY SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . . : by EMERGENCY SHUT-OFF message from transmitter or in case of component failure in EMERGENCY SHUT-OFF circuit Passive EMERGENCY SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . : by data message interference of > 1 sec. or failure of one EMERGENCY SHUT-OFF channel Control channel output depending on type of unit FW 20 - K28 - V 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 32 switching - 6 proportional channels FW 20 - K42 - IMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 20 switching - 1 proportional channel FW 20 - K42 - PROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 20 switching - 8 proportional channels FW 20 - K42 - SANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 32 switching - 1 proportional channel
The transmitter and the receiver are equipped with a rating plate. The unit serial number and the frequency must be the same for both units.
Please note here:
Transmission and reception of radio signals is only possible with units having the same rating data.
Serial number:____________________________
Type of equipment: ________________________
Frequency: ______________________________ of your equipment and indicate these whenever you have any questions.
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9. Monitoring-, Warning-, and Control Elements TRANSMITTER (fig. 1)
2 3 4 5
1- EMERGENCY SHUT-OFF button
6
2- LED: battery voltage monitoring 3-LED: Transmitter signal output monitoring 4-LED: EMERGENCY SHUT-OFF 5- Selector switch: transmitter power supply ON/OFF 6-Selector switch: transmitter channel selection HF1/HF2
1 fig. 1
The other monitoring-, warning- and control elements correspond to those of the cable control units of the coresponding machine.
BATTERY CHARGER (fig. 2) 1-LED: battery charger power supply ON 2- Bi-coloured LED green LED
= battery is being charged
red LED
= battery not correctly inserted - change polarity
3-Socket outlet: power supply 4-Battery compartment
fig. 2
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RECEIVER POWER SUPPLY (fig. 1) 1- Key switch in driver’s cab: power supply ON 2- Pilot lamp: power supply ON
fig. 1
INSTALLATION OF RECEIVER (fig. 2) 1-Cover lock 2-Pilot lamp: power supply ON
fig. 2
RECEIVER (fig. 3) T1-Connector for diagnostic unit T2-Connector for diagnostic unit
fig. 3
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Fig. 1
= proportional control receiver
Fig 2.
= black and white control receiver
LEDs 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
= failure in EMERGENCY SHUT-OFF circuit of controller 1 fig. 1
HF
= receiver
K1
= RF-channel 1 selected
K2
= RF-channel 1 selected
MC 2
= controller 2 data message reception
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 reception
TST3
= data message error 3
TST2
= data message error 2
TST1
= data message error 1
fig. 2
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Remote Control Cable/Radio
10. Pre-Operational Instructions • Position the vehicle as described in the machine operating instructions. • Set all control elements of the cable control unit (if connected) and the control elements of the machine to “0” position. • Shut off drive engine when it is warm. Remote control cannot be used to activate any existing cold-starting aid. Leave the ignition on. • If required, remove the cable control unit connector and insert the radio receiver connector into the socket outlet.
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• During “cable-controlled” operation, the radio receiver connector is in the unwired socket. • Lock the cable-connector. • Set selector switch on the machine to “REMOTE”. • Release all EMERGENCY SHUT-OFF buttons of the machine (cf. machine operating instructions). • Switch on receiver power supply with key switch in the driver’s cab. • The ON state is indicated by lamps on the receiver.
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Remote Control Cable/Radio After the switching on of the power supply, the LEDs of the receiver must indicate the following state of operation:
MODULE
LED
DISPLAY
NG
all LEDs
on
HF
K1 + K2
alternating in 1-second-intervals (transmitter-scanning)
MC 2
MC 2
flickering irregularly
MC1
TEL TST 2
flickering irregularly on all others off
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Remote Control Cable/Radio •
Put the transmitter into operation:
2 3 4 5
6
1
ACTION
590
LED
EFFECT
Set all control elements of transmitter to “0” position
all LEDs off
putting into operation otherwise not possible
Switch on power supply with selector-switch 5
LED 4 flashing
request to test the EMERGENCY SHUT-OFF button
Push EMERGENCY SHUT-OFF button
LED 4 flashing faster
EMERGENCY SHUTOFF O.K.
Unlock EMERGENCY SHUT-OFF button
LEDs 2+4 off; 3 permanently lit
transmitter ready for operation, empty messages are being transmitted
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Remote Control Cable/Radio The following operating state must now be displayed at the receiver:
MODULE
LED
DISPLAY
NG
NOT1 + NOT2
off (EMERGENCY SHUT-OFF circuit closed)
HF
K1 or K2
permanently lit (depending on transmitter channel selection)
MC 2
MC 2
flashing regularly (data message transmission rate)
MC 1
TEL
flashing regularly, all others off
REL
REL
flashing regularly (only for black-andwhite control)
The unit is now ready for operation. In case of trouble, cf. section 15.
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Remote Control Cable/Radio
11. Operation IMPORTANT! Depressing the EMERGENCY SHUTOFF button in case of danger immediately interrupts the main functions of the machine. Cf. section 12.
2 3 4 5
The LEDs of the REL module on the black-and-white control unit receiver indicate that the relay is activated.
6
1
Choose your location in such a way that the concrete placing site and the receiver antenna can be clearly seen from a distance of not more than 50 meters.
An energy-saving feature prevents the transmitter battery from deep discharge. The energy-saving feature is reset after activation of any switch. If all control elements of the transmitter are in their “0”-position, the transmitter power supply is cut off after 30 minutes. In case of radio signal interruption, the receiver switches the machine into the EMERGENCY OFF state. Cf. section 12. To reactivate the radio control system (and to close the EMERGENCY OFF valve), short activation of one of the control elements of the transmitter is sufficient. In order to readjust the support outriggers, it is also sufficient to switch the mode-selector on the machine to the “DIRECT CONTROL” position.
Battery Capacity The operations required to control the machine with the radio transmitter are the same as with the cable control unit.
The capacity of the battery depends on • the age of the battery • the charge condition • the ambient temperature
Flashing of LED 3 indicates that “active messages” are being transmitted.
Under normal conditions, the operating time of a new and fully charged battery is approximately 12 hours.
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Remote Control Cable/Radio It is recommended always to have a charged battery available, to charge another battery in the charger, and to change the batteries about every eight hours or before each new working shift.
Disturbances If, during the operation, the machine does not respond to control commands: • change the transmit frequency. If this is unsuccessful: • push the EMERGENCY SHUT-OFF button • change your location • put the control unit into operation • check LEDs on transmitter: 2 + 4 = off
12. Emergency Shut-Off The control unit is equipped with 2 separate EMERGENCY SHUT-OFF modules. If a fault is detected by at least one of the modules, the machine control system passes over to the EMERGENCY SHUT-OFF state. The EMERGENCY SHUT-OFF valve in the hydraulic system opens. The hydraulic system is now working in the pressureless circulation mode and the main functions are stopped.
3 = permanently lit or flashing If the control unit cannot be put into operation, see section 15
2 3 4 5
The EMERGENCY SHUT-OFF condition is triggered, for instance, by pressing an EMERGENCY SHUTOFF button or by low battery voltage. In addition, the receiver carries out constant checks: • of the transmitted data messages • whether the control commands are executed (double reading) • the electric components of the receiver and output circuits.
6
If faults are detected, the unit passes over to EMERGENCY SHUT-OFF.
1
Cf. section 15.
Frequency Change Changing the transmit frequency with selector switch 6 makes sense only if another transmitter with the same frequency is being operated in the vicinity, or if irregularities in the transmission are suspected.
The unit can be restarted only after the fault has been rectified. Cf. section 10.
During a change of the frequency, the operation will be interrupted for about 3 seconds, as the EMERGENCY SHUT-OFF circuit of the receiver will be interrupted.
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13. Interruptions of Work/End of Operation • Fold placing boom back to its transport position. • Set all control elements of the transmitter to “0”-position. • Switch off the transmitter power supply with selector switch 5.
2 3 4 5
6
Never use an EMERGENCY SHUT-OFF button for ordinary shut-off. If the power supply remains on, the unit continues to transmit the EMERGENCY SHUT-OFF signal. This leads to unnecessary discharging of the battery. • Switch off the power supply of the receiver with the key switch in the driver’s cab. • Protect the transmitter against unauthorized use (lock it away!). • If required, remove the receiver cable from socket 1 and plug connector into unwired socket 2.
1
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14. Replacing the Battery A flashing LED 2 indicates that the rechargeable battery must be replaced.
2 3 4 5
6
• Put the machine out of operation. • Set all control elements of the transmitter to “0”-position. • Switch off transmitter with selector switch 5. • Turn the locking screws of the battery compartment counter-clockwise by 90 degrees and take off the lid. • Withdraw the battery. • Insert a charged battery with the contacts ahead into the battery compartments. Observe battery polarity.
1
In case of wrong polarity, the transmitter cannot be put into operation. • Put on compartment lid.
It is recommended to interrupt the power-supply of the battery charger if longer operating breaks are to be expected (e.g. weekends).
Turn locking screws clockwise by 90 degrees, and engage under slight pressure without further turning.
To do so, withdraw cable from socket 3. • Replace the battery as described on the front side.
Take care that the lid fits correctly. Turning the lid 180 degrees during fitting leaves a visible air gap. In this position, moisture can penetrate into the battery compartment.
The polarity is correct if LED 2 displays green, and it is wrong if it displays red.
Recharging of Battery The battery charger is permanently connected to the power-supply. The ready-for-operation state is indicated by LED 1.
• If the LED shows a red light, remove the battery immediately and change polarity by turning the battery. Charging of the battery is completed after 14 hours max. The battery cannot be overcharged. If the battery is full,
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Remote Control Cable/Radio the charger automatically switches over to “trickle charge”.
15. Malfunctions Malfunctions are mainly caused by radio signal interference, leading to an EMERGENCY SHUT-OFF. Radio signal interference may have different causes: TRANSMITTER OUT OF RANGE The transmitter range is limited for safety reasons but is, nevertheless, sufficient for normal use on construction sites. RADIO SHADOW
ATTENTION - DANGER! RISK OF EXPLOSION OF THE BATTERY: • Never use chargers from other manufacturers. RISK OF DAMAGE if the unit is used with the wrong batteries: • Use only ORIGINAL SCHWING BATTERIES.
Use the following rule of thumb: The location has been correctly chosen if the concrete placing site and the receiver antenna can be clearly seen from a distance of not more than 50 meters max. LOW VOLTAGE OF TRANSMITTER BATTERY
NOXIOUS FUMES: •
Choose your location in such a way that the working range of the machine can be clearly seen and that undisturbed radio communications are ensured.
LED 2 gives a warning signal if the low voltage limit of the battery is exceeded.
Never open rechargeable batteries.
ATTENTION PROTECTION OF THE ENVIRONMENT! • Always bring unusable batteries to special collection points for disposal.
If the battery is not replaced within 30 minutes, the transmitter shuts off automatically.
2 3 4 5
1
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Remote Control Cable/Radio Message Interference Messages may be disturbed, for instance, by interference from other transmitters. An interference of up to 1 second does not affect the functions of the machine. The interference is, nevertheless, indicated by LEDs TST 1, 2, 3, of the MC 1 module on the receiver.
• Switch over to another transmit frequency with selector switch 6 if you suppose message interference.
2 3 4 5
6
1
• If the vehicle is retrofitted with a mobile car telephone, take care that the distance between the antennas is not less than two meters.
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Trouble Shooting For function checking and fault detection, the transmitter and the receiver are both equipped with LEDs. In case of proper function, only the green LEDs may be lit. Red LEDs indicate fault.
Never attempt repairs beyond those recommended in the troubleshooting section. SCHWING assumes no responsibility for inappropriate repairs. [TROUBLESHOOTING TABLE (needs to be made)]
For troubleshooting, use the fault detection tables on the following pages and state the last fault message recorded if you contact us for help.
= LED on /
Troubleshooting: Receiver LEDs Troubleshooting Table: Transmitter LED s
= LED flashing / X = LED flashing faster /
= LED off
+
STOP LED
LED
LED
DESCRIPTION Battery empty, battery wrongly inserted, power OFF Valid empty messages, energysaving timer ON
ACTION Charge Battery; Turn Power On Begin machine control
Valid control commands
Control O.K.
Low battery voltage, approx. 30 minutes operating time left Transmittter shut-off due to low battery voltage
Replace battery
EMERGENCY SHUT-OFF
See receiver
Replace battery
EMERGENCY SHUT-OFF test request
X
Push EMERGENCY SHUT-OFF button Unlock EMERGENCY SHUTEMERGENCY SHUT-OFF O.K. OFF Not all control elements in 0 Control elements in 0 position before the transmitter was position, restart. switched on. Only if check is carried out by Fault detection mode quailified personnel Module failure
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Remote Control Cable/Radio Table 1: Power Supply (NG) LED
DISPLAY
MESSAGE/ POSSIBLE CAUSE OF TROUBLE
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, short circuit in receiver
Call after-sales service
NOT1, NOT2
ON
EMERGENCY SHUTOFF activated Fault detected by electronic system
Rectify fault, unlock EMERGENCY SHUT-OFF see MC1
NOT1, NOT2
off, but no function
Fuse defective
Replace fuse, cf. section 16
LED
DISPLAY
K1, K2
alternately flashing
MESSAGE/POSSIBLE CAUSE OF TROUBLE Transmitter scan, no radio contact Message format error
LED
DISPLAY
TEL
not flashing at message transmission rate
MESSAGE/POSSIBLE CAUSE OF TROUBLE Transmitter off, no radio contact Transmitter defective, RF section defective
Service Manual
REMEDIAL ACTION Switch on transmitter, choose better transmitter location, check antenna see MC1
REMEDIAL ACTION Switch on transmitter, choose better transmitter location, check antenna Call after-sales service
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Remote Control Cable/Radio Troubleshooting Controller (MC1) LED
DISPLAY
MESSAGE/ POSSIBLE CAUSE OF TROUBLE
REMEDIAL ACTION
ST1
on
Failure in MC 1 or in periphery module, e.g. REL, NG, PROP
Call after-sales service
ST2
on
Failure in MC2, no exchange of data
Call after-sales service
REL
on
Failure in REL
See relay output
PROP
on
Failure in PROP, analogue outputs out of tolerance, adjuster deregulated Vehicle power supply voltage <20V resp. >28V
Call after-sales service Check vehicle power supply voltage
TEL
not flashing at the rhythm of transmitted msg. on
No radio reception Transmitter off or defective
Check transmitter and antenna
Antenna not installed or defective
Call after-sales service
TST2
600
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Remote Control Cable/Radio Troubleshooting Table: Transmitter LED’s = LED on /
TST3
TST2
TST1
= LED flashing / X = LED flashing faster /
= LED off
MESSAGE/POSSIBLE CAUSE OF TROUBLE REMEDIAL ACTION No empty message after switch-on Set control element to 0 -pos. EMERGENCY SHUT-OFF act. Unlock EMERGENCY SHUT-OFF Call Service Department Contact jamming Format error in pulse-coded Call Service Department message Format error in proportional Call Service Department message Another transmitter with same frequency nearby, message affected Call Service Department by address error Message affected by mode error; Call Service Department encoder switch in wrong position Message affected by cyclic Call Service Department redundancy check error EMERGENCY SHUT-OFF Rectify fault, unlock EMERGENCY message SHUT-OFF
LED
DISPLAY
MESSAGE/POSSIBLE CAUSE OF TROUBLE
REMEDIAL ACTION
REL
not flashing
Relay outputs defective or not connected
Call after-sales service
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Remote Control Cable/Radio
16. Maintenance
Replacing of Fuses
The control unit is largely maintenance-free. Nevertheless, a check should be carried out every 4 years by SCHWING.
The circuit board of the black-and-white control receiver and the circuit board of the proportional control receiver are equipped with one fuse each.
Use only miniature fuses 5 x 20 mm, 3.15 A. Fuses can be replaced as follows: • Switch off the unit. • Open lock 1 and swing back cover.
602
• Open lid of mounting rack with special key. • Swing back lid of mounting rack and replace fuse. • Close mounting rack and put on cover.
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17. Repair For repairs or for regular checks, the receiver must be removed from the vehicle and sent to the factory for repair complete with the transmitter. For repairs outside Germany, please address to your local agent.
REMOVAL OF RECEIVER • Push EMERGENCY SHUT-OFF button. • Open cover, as described in section 16 • Withdraw the (blue) multipole connector from the circuit board. • Pull off the antenna cable. • Loosen the four fastening screws at the front side.
Take care that the equipment is packed shock-proof.
Depress the screws slightly and turn counter-clockwise by 90 degrees without further turning. Withdraw the receiver unit carefully an d smoothly from its compartment in the vehicle. INSTALLATION OF THE RECEIVER • Push EMERGENCY SHUT-OFF button. • Insert receiver carefully and smoothly into its compartment. • Turn the fastening screws clockwise by 90 degrees, and engage under slight pressure without further turning. • Plug in antenna and multipole connector. • Close the cover.
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SERVICE TRAINING
Operating Instructions - Radio Remote Control FW 20 Dual Fr equency - Reference Chart FREQUENCY
COORDINATOR
456.7525 456.8125 456.8625 456.9625 457.0125 457.5125 457.525 457.5625 456.575 457.6125 457.6625 457.6875 457.7125 457.7625
1P-(PFCC) 1S-(ITA) 1S-(ITA) 1S-(ITA) 1S-(ITA) 1S-(ITA) 1B-(NABER) 1B-(NABER) 1B-(NABER) 1B-(NABER) LM (ATA) LM (ATA) LM (ATA) LM (ATA)
(IS)
ITA
SPECIAL INDUSTRIAL RADIO SERVICE INDUSTRIAL TELECOMMUNICATIONS ASSOCIATION ATTN. FREQUENCY COORDINATION DEPARTMENT 1110 NORTH GLEBE ROAD, SUITE 500 ARLINGTON, VA 22201 703-528-5115 (IB) NABER NATIONAL ASSOCIATION OF BUSINESS AND EDUCATIONAL RADIO, INC. ATTN. FREQUENCY COORDINATION DEPARTMENT 1501 DUKE STREET, SUITE 200 ALEXANDRIA, VA 22314 800-759-0300 703-739-0300 (LM) ATA AMERICAN TRUCKING ASSOCIATION, INC. ATTN. GUS GYLLENHOFF 2200 MILL ROAD ALEXANDRIA, VA 22314 703-838-1730 (IP) PFCC PETROLEUM FREQUENCY COORDINATING COMMITTEE ATTN. MARIE HAWKINS 1110 NORTH GLEBE ROAD, SUITE 500 ARLINGTON, VA 22201 703-528-5115
604
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Radio Control FW 24 Table of Contents 1. 2. 3. 4. 5. 6. 7. 8.
Safety Instructions Scope of Application Start-up Operation Charging the Battery Maintenance Operation Fault Indicators
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Safety Instructions SAFETY INSTRUCTIONS Please read these operating instructions completely before putting your TELETEC remote-control into operation. Observe also the corresponding working safety and accident prevention regulations. The instructions relating to the operation of the machine itself are contained in the machine manual. Remote-control units may be used by duly authorized persons after they have been instructed by a specialist.
If your remote-control is a "COMFORTControl" unit, the radio receiver must not be disconnected. Cable operation may otherwise be impossible. Repair work on the remote-control unit may only be performed by TELETEC or by qualified personnel duly authorized by TELETEC. Non-observance of the safety instructions will discharge TELETEC from any and all of their warranty and liability obligations.
Do not put the operational transmitter aside, but always protect it against unauthorized use by locking it away. The remote-control may only be used for purposes complying with its designated use i.e. only for controlling the machine or plant for which it is designated. Any other use is forbidden. Using the device for purposes other than its designated use, faulty operation, insufficient maintenance and unauthorized repairs of the remote-control unit may cause severe material damage and injury to persons. In the event of malfunction or defects of the remote-control unit depress immediately the red EMERGENCY SHUT-OFF button, switch the transmitter off and keep it in a safe place. Disconnect all cables from the receiver if your remote-control is a "MULTI-Control" unit.
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Scope of Application SCOPE OF APPLICATION The present operating instructions are applicable to FW 24 radio remote-control units in proportional and digital design suitable for SCHWING truck-mounted concrete pumps equipped with control systems of the "MULTI-Control" and "COMFORT-Control" type.
1 FW24-ID.eps
2
3 Stop
POWER HF1
4
HF2
FW24rmbx.eps
HOME
6
5
The operator panels of the radio transmitters are the same (with the exception of switch 6, Fig.1) for both control systems. For detailed description please refer to chapter 3. The present manual does not contain instructions relating to a particular type of machine.
Fig.1
Switch 6:
For machine-specific instructions please refer to the corresponding machine manual.
0 MULTI-Control
MANUFACTURER FW 24 remote-control units manufactured for SCHWING by:
are
TELETEC GmbH Paul-Lincke-Ufer 39/40 10999 Berlin Tel. 030-612 40 45 FAX 030 - 611 50 39
COMFORT-Control
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Start-Up START-UP 1
Remote-control system FW24-ID.eps
Transmitter and receiver are each equipped with an identification plate.
2
3 Stop
POWER HF1
4
HF2
Proceed as follows to put the system into operation: 1. Switch on the receiver:
FW24rmbx.eps
To permit communication between transmitter and receiver it is necessary that both devices have the same serial number and frequency.
6
5
Fig.1 3. Switch on the transmitter with "Power" switch 4 by setting the switch to "HF 1" or "HF 2" (frequency selection).
- Switch on the ignition and the power takeoff of the truck.
POWER HF1
- Apply the parking brake. - Switch on the machine control unit with the key-switch in the driver’s cab. - Set the selector switch on the local control panel to "Remote".
HF2
- Insert charged battery pack into the transmitter housing and lock the battery case.
The red light-emitting diode (LED 3) now starts flashing at a slow rate.
Stop 2. Make sure all switches are in their basic (or neural) position before switching on the transmitter (Fig. 1) Fig. 1 shows only those control and monitoring elements as a are typical of radio remote-control unit.
4. Perform the emergency shut-off test:
All other elements correspond to those of the standard cable remote-control.
-The red LED 3 now flashes at a fast rate.
Refer to the machine operating instructions.
- Release the emergency shut-off button (unlock).
-Depress the emergency shut-off test,
Unlock the EMERGENCY SHUT-OFF button. Without unlocking, starting of the system is inhibited for reasons of safety.
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Remote Control Cable/Radio
To switch off the transmitter, e.g. after the work has ended, set the "Power" switch 5 to neutral position ("0").
Stop 1
2
3
POWER HF1
"MULTI-Control" system" The green LED 2 (antenna) is lit up continuously and the red LED 3 is flashing.
0
Enable the control system by setting switch 6 briefly to
HF2
Do not depress the EMERGENCY SHUTOFF button for normal shut-off to prevent the emergency shut-off signal from being transmitted permanently and the rechargeable battery from being emptied.
0
Special transmitter operation features Only then will the red diode (LED 3) go out and the green one will flash. The transmitter is now ready for operation and the commands given with the control elements are executed by the concrete pump.
1. Selecting the boom speed The boom control functions must be activated with switch 6.
"COMFORT-Control" system: The red diode (LED 3) goes out and the green one (LED 2) is lit up.
In the center position ("0") of this switch all functions of the boom are deactivated.
The transmitter is now ready for operation and the commands given with the control elements are executed by the concrete pump.
Moving the joysticks causes the red diode (LED 3) to light up to indicate that boom operation is disabled.
Note:
The switch must be set to the "Snail" or "Hare" symbol.
The "COMFORT-Control" system does not provide an enabling function for switch 6.
"Snail" = slow is the preferred speed for normal working operation and
Switch 6 is needed for a faultacknowledging function labeled "quitt" [acknowledge].
"Hare" = fast is the speed used for setting up of the placing boom.
See also the abbreviated "COMFORTControl" operating instructions, i.d. no. 10167123.
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Depending on the type of control, the selection of either "Snail" or "Hare" has a different effect: Control
proportional digital reduced slewing- 0-50% speed for gear speed all boom functions full slewing-gear speed
0-100% speed for all boom functions
After switching over to another channel, the transmitter must be re-activated as described on page 3.1 (EMERGENCY SHUT-OFF test etc.). The receiver will be switched over automatically to the new transmission channel. In the event of persisting radio transmission disturbances or other defects, the system shuts itself off automatically and passes into the protected EMERGENCY SHUT-OFF state.
Note: In the neutral position of switch (6) all functions are available except the placing boom functions. This is important when the placing boom is connected to a stationary delivery line (by a hose bridge) and must therefore be prevented from being moved by accident. 2. Changing the transmit channel If the radio channel in use is disturbed (transmission of control commands interrupted or no transmission at all) you can use the "Power" switch (5) to select between "HF 1" and "HF 2". POWER HF1
0 HF2
This switch channel.
610
selects
the
transmission
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Remote Control Cable/Radio
Operation
. og Pr M
N
4
5
6
7
11 de tla
n de
En
Figs. 1 and 2 show the layout of the receiver front panels:
La
Indicator lamps on receiver
Ve r
po
tt
n
N
O
C
T
2
T O
2
1
C M
C
1
M
Fr e
3
When the remote-control is ready for operation and after all EMERGENCY SHUT-OFF buttons on the machine have been unlocked, all functions of the concrete pump can be operated with the remotecontrol unit (see the machine operating instructions.)
ig .
OPERATION
8
9
10
+
Fig. 1 = "MULTI-Control"
-
Fig. 2 = "COMFORT-Control"
2 N
4
5
6
7
11 de En
tla
n de La
They are lit up if no valid radio data telegrams are being received or when the emergency shut-off button on the transmitter has been depressed.
Ve r
po
tt
n
M
O
T
2 C
T O N
C
1
1
Fig.1
The red light-emitting diodes 5 and 7 ("NOT/EMERGENCY" 1 + 2) monitoring the emergency shut-off circuits go out if the signals from the correctly activated transmitter are being received.
M
HOME
8
9
10
+
-
In this case, the receiver in in the EMERGENCY SHUT-OFF state, i.e. deactivated. Fig.2 The green light-emitting diodes 4 and 6 ("MC 1 + 2") indicate by fast flashing that valid radio data telegrams are being recieved.
"Multi-Control" only In this system, the green LED 1 ("MC 3") and the green LED 2 ("Freigabe/Enable") are lit up in addition. These two LEDs indicate that the built-in control module is activated, too. LED 3 ("Prog.") remains off and is not relevant for working operations. The diode is used for servicing only.
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Charging the Battery CHARGE THE BATTERY When the red LED 1 (battery) of the transmitter starts to blink during normal operation, the battery is almost empty. Stop
To maintain the full charging capacity of the battery over a long time, it should be completely discharged once a week before recharging. For this purpose, your charger is equipped with an automatic discharge function:
. og Pr 2 N O T
2 M C
1
When the battery is charged (after 3 hours maximum), this LED begins to flash.
1
M C
3
The green LED 9 ("Laden/Charge") on the receiver panel (fig. 1 or 2) lights up.
g.
When the battery is completely discharged the charger switches automatically to normal charge and later on to trickle charge (green LED 9 flashing). ei
Insert the empty battery for recharging into the charging case of the receiver and lock. Make sure the battery is inserted into the case with the correct polarity.
The yellow LED 10 ("Entladen/Discharge") will now light up.
Fr
After replacing, restart the transmitter as described in chapter 3.
N O T
During this time, the empty battery must be replaced with a new one.
For discharging keep the yellow button 11 depressed, insert the battery into the charger and lock.
M C
Ca. 10 to 20 minutes later the transmitter will be shut off automatically.
4
5
6
7 de En
tla
n de
10
-
N O T
2
M C
2
1 N O T
1
Fig.1 4
5
6
7
+
Service Manual
En
tla de
n de La
po
tt
n
11
Ve r
In this case, withdraw the battery and reinsert correctly.
612
9
+
if you insert the battery by mistake (+ and _ terminals marked on the housing) with wrong polarity into the charging case (the battery can be wrongly inserted into the case only with force), the red LED 8 ("Verpolt/Wrong polarity") lights up
Note: On compact units, LED 8 is not available. In these units, the green LED 9 ("Laden/Charge") does not light up when the battery is inserted with wrong polarity.
8
M C
In both ways, the battery will retain its full charge.
La
The battery can now either be removed from the or left in the charger case.
Ve r
po
tt
n
11
8
9
10
Fig.2
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Maintenance MAINTENANCE The FW 24 radio remote-control unit is largely maintenance-free. You should nevertheless make sure that - damaged rubber bellows at the switches are immediately replaced. - the transmitter is never exposed to the jet of a high-pressure cleaner or to caustic liquids. - proper functioning of all control elements is checked at regular intervals. - all cables are disconnected from the receiver when electric welding is performed at the machine (concrete pump). There is otherwise a risk of damage to electronic components.
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Operation Fault Indicators OPERATION AND FAULT INDICATORS The light-emitting diodes indicate different operational states and malfunctions.
= ON
= OFF
= FLASHING
1. TRANSMITTER START-UP/OPERATION LED
MESSAGE
ACTION
Stop
transmitter activated, EMERGENCY SHUT-OFF test required.
depress EMERGENCY SHUT-OFF button (LED flashing faster) and release
Stop
"Multi-Control" only: enable required
depress enable button
Stop
enable accepted, transmitter ready for operation, no function activated (basic position)
Stop
enable not accepted, restart protection set all switches to "0" position active
Stop
one or more functions activated, transmitter sending data
start working
machine executes control commands
MALFUNCTIONS Stop
boom functions de-actived, "STOP" lamp lights up when joystick is moved. select
614
or
Stop
EMERGENCY SHUT-OFF button actuated
set all switches to "0" position, unlock EMERGENCY SHUT-OFF
Stop
battery empty, remaining time for operation = 10 to 20 min.
replace battery
Stop
transmitter defective
repair by authorized personnel only
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OPERATION AND FAULT INDICATORS (Cont.) 2. RECEIVER MC 1 MC 2
EM 1 wrong charge disEM 2 pol. charge
MESSAGE
ACTION
valid radio data signals are being received
machine executes control commands
no reception
change frequency, choose other location
EMERGENCY SHUTOFF actuated
set all switches on transmitter to "0", unlock EMERGENCY SHUT-OFF button.
battery being charged
battery being finished
remove battery from or leave in charger (trickle charge)
battery inserted with wrong polarity
insert battery correctly
battery being discharged charger switches automatically to normal charge when the battery is discharged
"MULTI-Control" receiver only MC 1 MC 2
EM 1 wrong EM 2 pol.
MESSAGE
ACTION
built-in control module active
required for servicing purpose only
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Remote Control Cable/Radio
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SERVICE TRAINING
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Remote Control Cable/Radio
C32/CPC Radio Remote
The license-free spread spectrum band goes from 902 to 928 MHz, a 26 MHz wide spectrum using the full band width. Compare that to a conventional radio that uses a band only 0.03 MHz wide.
Spread Spectrum Technology
Where traditional radios tune to one frequency, a Spread Spectrum radio uses 63 different frequencies. It stays 20 milliseconds on any one frequency and then moves on to the next (i.e. it uses 50 different frequencies every second).
The Schwing T45 Remote Control systems employ frequency hopping spread spectrum technology to provide the optimum performance allowable under present FCC and ISC regulations. This technology provides a unique performance advantage compared to conventional fixed frequency systems. The major benefits are listed below: Interference Free: It cannot be jammed by other RF transmitters or extraneous noise sources. 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 is a unique frequency for each unit in existence. Any number of these units can be operated in the same location at the same time. 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.
On each frequency the Spread Spectrum transmitter sends all the information it reads from the switches and joysticks (both on/off and proportional). It adds a unique transmitter address (ID) plus an error checking code (CRC-16) to make the link safe and secure. The Spread Spectrum receiver thus gets 50 switch readings from the transmitter each second, all sent on a different frequencies. If you work in a radio spectrum that is 'clean', the SSP radio will function just like a traditional narrow band radio. But if someone else is operating in the same area on the same frequency, you could get blocked or jammed by the other radio signal making the radio useless at that site. This will not happen with a Spread Spectrum radio. If interference causes trouble for the Spread Spectrum at one frequency, the Spread Spectrum radio quickly moves onto another frequency where the information is likely to get through. It would take hundreds of ordinary radios at a site to block the 26MHz wide spectrum used by the SSP.
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. SPREAD SPECTRUM OPERATION (How does a frequency hopper work?)
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Mounting the Receiver Antenna: The receiver antenna assembly (Figure 1) consists of a mounting bracket with attached coaxial cable and a removable whip antenna. For most close range applications (< 300') the location of the antenna is not too critical since the receiver is sensitive enough to pick up the signal almost any-
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where. The mounting bracket may be bolted to the vehicle frame, but do not allow the antenna whip to contact metal parts! After mounting, insert the connector end of the cable into the mating receiver connector and secure the cable with tie-wraps if required to prevent damage. Figure 1. Receiver Antenna Assembly
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Remote Control Cable/Radio
Transmitter Operation The transmitter has been designed for the utmost in durability and light weight. For ease of maintenance, it uses a readily available rechargeable MAKITA battery unit (Figure 2). In addition, a number of diagnostic features have been built into it.
To ensure the utmost safety, the Emergency Stop switch is monitored each time during power up. In addition, the power off switch provides an additional level of safety. These switches activate different mechanisms and different relays on the receiver to ensure that a system can be shut down.
Service Manual
Figure 2. MAKITA battery
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Remote Control Cable/Radio 1. RADIO TRANSMITTER ON/OFF SWITCH
If you have depressed and released the EStop button and both the stop light and power light are flashing, you have a function turned on.
To ensure safe operation, the E-Stop switch on the transmitter is checked each time the unit is powered up (Figure 3). In addition, all functions must be off or the unit will not power up. (ON)
You must honk the horn to clear the EStops and power the E-Stop solenoids.
The ON or start up sequence is as follows: Ensure all functions are turned OFF. Turn Power switch ON, the Stop light will flash slowly until the E-Stop is depressed and released. If the E-Stop is depressed on power up, the light will flash rapidly until it is released. #2 Boom Speed Control Left Joystick
Motor Stop/Start
Power LED
(OFF) Turning off the Transmitter will cause the receiver to go into an E-Stop mode and all functions will stop. Figure 3. T45 Radio Remote
Radio Transmitter On/Off Communication (Not on cable remotes) Boom Control LED E-Stop LED On/Off Right Joystick
Throttle Up/Down
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Vibrator Agitator Horn/Reset Off/Automatic Forward/Off/Reverse Emergency Stop
Service Manual
Concrete Pump Forward/Off/Reverse
Stroke Limiter
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Remote Control Cable/Radio 2. POWER LED
The power LED indicates the status of the battery. (OFF) Battery OK (with communication LED on or flashing or battery dead with all LED s off. (FLAHSING) Battery low. 3. COMMUNICATION LED
The Power light indicates the status of the transmitter. (ON)
Transmitter on and ready to function
(OFF) Transmitter turned off or no battery installed (FLASHING) Function turned on. 4. E-STOP LED
Depressing the E-Stop will remove power to all outputs from controller and open the dump valves located on the E-Stop manifold (ON)
If this light is on, it indicates the E-Stop button is depressed.
(OFF) Unit is operational, E-Stop clear. (FLASHING) E-Stop still active due to power up sequence or function On. 5. EMERGENCY STOP PUSH BUTTON
All outputs are disabled, E-Stop manifold solenoids are de-energized.
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Remote Control Cable/Radio
Remote Radio Controller
Each T45 transmitter is supplied with a unique ID code (Figure 4). This code is marked on the label located on the handle mounting plate, along with the radio serial number. The receiver must be set to match this code. To match the settings, the power to the receiver must be off.
have the numbers 1 & 8 printed above it. The second row SW2 will have 9 & 16 printed above it. In order for the radio to operate, the switches must be set the same as the decal. EXAMPLE: if the punched hole in the decal for SW1-1 is a 1 (Figure 7), then the corresponding dip switch must be set to ON. If the punched hole in the decal for SW1-1 is a 0, then the corresponding dip switch must be set to OFF. After all switches are set, repower the receiver.
On the cover of the HOPLINK (located in the receiver) (Figure 5), you will see the dip switches (Figure 6). In the box marked ID, there are two rows of switches. The first row is SW1, it will
Figure 4. ID Code
DIP SWITCH SETTINGS
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Remote Control Cable/Radio Please note that the HOPLINK units recalculate its spread spectrum sequence every time the ID is changed -- be patient, it may take up to 5 seconds on the first power up after an ID change before the receiver goes operational.
*** Make sure that switch #5 of the MODE dip switch (SW3) is on, all others must be off. SW3 will also have 1 & 8 printed below it, SW3 is located closest to the ribbon cable connection. Figure 5. Hoplink
Figure 6. Dip Switches, Radio Transmitter, and Receiver
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WARNING Do not operatre this machine without training. Understand the warnings in safety manuals and on decals. SERIAL NUMBER ID CODE L1393-01
SW 1:
ASSY-326-08 ISSUE 2
70136
1 0
SW 2:
1 0
Figure 7. Dip Switch
0 = Off 1 = On
SW1
SW2
SW3
1
ID
8
1 2 3 4 5 6 7 8
9
16
1 2 3 4 5 6 7 8
Set all switches to 00001000
1 2 3 4 5 6 7 8
1 624
8
MODE
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Remote Control Cable/Radio Troubleshooting Table: Transmitter LED s = LED flashing / X = LED flashing faster / = LED off
l = LED on / +
STOP LED
LED
LED
X
/
l
/ /
/
l
/ X X
DESCRIPTION Battery Dead; Power Off E-Stop Test
ACTION Charge Battery; Turn Power On Press E-STOP button
E-Stop Test Part Two
Release E-STOP Button
Not all functions off on E-Stop release Valid Data, all functions
Set all functions off
Valid Data, 1 + functions on
OK, continue as required
Emergency Stop
E-STOP Button Pressed
Low Battery
Replace/Recharge Battery
Module failure: Joystick
Cycle Power - if not remedied, call service Cycle Power - if not remedied, call service
Module failure: Radio
Service Manual
OK, continue as required
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Remote Control Cable/Radio
Omnex Radio Control System 1. Introduction The Comfort Concrete Pump Remote Control System consists of a T47 cable, a T45 radio transmitter, and a custom receiver (grey box). The cable control has a North American standard 10 pin Sine connector, and the receiver has a European standard 12 pin Burndy connector. Both the cable unit and the receiver communicate to the Comfort Control system via its standard CAN-Bus interface for remote control. This manual describes considerations that should be taken during installation and documents the information displayed by the lights and the settings available. This issue of the manual describes the operation for the cable unit with Issue 2 of the AFRM-152502 software, the radio transmitter with Issue 3 of the AFRM-1236-06 software, and the receiver interface board with Issue 3 of the AFRM-1530-01 software.
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Remote Control Cable/Radio
2. Physical Mounting The receiver should be mounted with the connectors down and in a location that allows the enclosure door to be opened conveniently for access to the inside. Shock mounts must be used to mount the enclosure! Under no circumstance should the enclosure be directly bolted to the machine. The picture below illustrates how the shock mounts should be installed:
3. Considerations for Electrowelding The high currents and voltages employed by electrowelding can damage the electronics in the Comfort Concrete Pump Remote Control System. If electrowelding must be performed after the Control System has been installed, observe the following precautions to reduce the risk of damage: The enclosure is sealed and has a NEMA-4 rating. When installing, ensure that nothing is done to compromise the watertightness of the enclosure. When performing maintenance, it may be necessary to gain access to the inside of the enclosure; take care to close the door securely when you are done.
• Unplug the connectors to the receiver and cable units. • Do not strike an arc close to the enclosure.
The antenna should be mounted pointing upward and should be as high as possible, preferably with a large metal surface below it but without metal above or to the side. The antenna must be mounted on the outside of the machine; do not mount it inside the cab or in a tool box. Assemble the antenna as shown below, and turn (finger-tight only) the connector onto the matching receptacle on the receiver until it locks.
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Remote Control Cable/Radio
4. Receiver Connector Assignments The receiver has a 12-pin Burndy connector for power and all output functions. The following
table specifies the assignment of each pin, with corresponding connectors on the TPCB-1527-01 circuit board for reference.
Function
Burndy Conn. Pin
TPCB-1527-01 Conn.
Receiver Power (24V Bat.)
C
J7-6
Receiver Ground
D
J7-5
E-Stop Contact 1A
E
J7-4
E-Stop Contact 1B
F
J7-2
E-Stop Contact 2A
G
J7-3
E-Stop Contact 2B
H
J7-1
Hydraulic Enable Valve Output (drives power out when boom function on)
J
J6-3
CAN-Bus High
K
J6-1
CAN-Bus Low
L
J6-2
The Receiver Power Input (C) supplies the electronics, the E-Stop Relays, and the Hydraulic Enable Output. The total power required is 0.1A + 0.1A + 1.0A = 1.2A. The Ground pin (D) should go to a low-impedance ground point either on the vehicle chassis or at the battery or fuse box.
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Remote Control Cable/Radio
5. Cable Unit Connector Assignments The Cable Unit has a 10-pin Sine connector for power and all output functions. The following table specifies the assignment of each pin, with corresponding internal connectors for reference. Function
Sine Conn. Pin
Internal Connection
Cable Unit Ground
A
TPCB-1605-01 J1-4
Cable Unit Power (24V Bat.)
B
TPCB-1605-01 J1-2
E-Stop Contact 1A
C
Contact Block 1
E-Stop Contact 2A
D
Contact Block 2
Hydraulic Enable Valve Output (drives power out when boom function on)
E
PCB-I24-MC DB15-4
CAN-Bus High
G
PCB-I24-MC DB15-6
CAN-Bus Low
H
PCB-I24-MC DB15-7
E-Stop Contact 1B
J
Contact Block 1
E-Stop Contact 2B
K
Contact Block 2
The Cable Unit Power Input (B) supplies the electronics and the Hydraulic Enable Output. The total power required is 0.1A + 1.0A = 1.1A. The Ground pin (A) should go to a low-impedance ground point either on the vehicle chassis or at the battery or fuse box.
6. Fuses There is one replaceable fuse on the receiver TPCB-1527-01 circuit board. It is an American automotive cartridge (ATO) style fuse; F2 should be 5A (brown color code). It provides power to the E-Stop relays. The other fuses used are selfresetting. They need the input power removed in order to reset after a fault is corrected. The Hydraulic Enable Output Supply has no internal protection in either the receiver or the cable unit.
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7. Operations
section).
This section describes how the Comfort Concrete Pump Remote Control System operates. It details the operation of the lights and special considerations. 7.1 Receiver The receiver is operational when power is applied. The receiver is designed to be a plug in replacement of the German unit. The Hydraulic Enable Output is capable of supplying 1 Amp. and is short-circuit protected. It has a one-second hold over after all boom functions are released. 7.1.1 Receiver Lights - General Function
The receiver lights are defined according to the list below. 1. POWER-on=normal -off=no power, input power fuse blown or power supply fault on TPCB-1527-01. 2. RECEIVER MICRO STATUS -on=normal -off=micro. on TPCB-1527-01 failed -other =error condition - see next section 3. COM LINK -on=radio communications link with transmitter -off=no link with transmitter 4. SIGNAL STRENGTH -on or mostly on =good link with transmitter -mostly off =poor link with transmitter -off= no data from transmitter 5. CAN-BUS MICRO STATUS -blinking continuously=normal when receiving data -blink every 2 seconds=no CANBUS link to Comfort but receiver interface OK -off=normal when E-Stop is on. When E-Stop is off or blinking: CANBUS micro. failed or interface failed (check error conditions in next
6. BOOM ENABLE -on =boom function on - hydraulic enable output active -off=boom functions off - hydraulic enable output off 7. E-STOP -on=Receiver in E-Stop mode, E-Stop contacts open. -off=Receiver in operating mode, E-Stop contacts closed. -flashing (with RECEIVER MICRO STATUS on) = restart blocking -other=error condition - see next section 7.1.2 Receiver Lights - Error Conditions
The receiver lights also indicate error conditions as defined according to the list below. 1. RECEIVER MICRO STATUS flashing continuously on first time power up of micro. (only will occur if new micro. installed). Cause: CONFIG register programmed. Resolution: Cycle power to continue. 2. RECEIVER MICRO STATUS flashing once per second on power up Cause: Software initialization failed. Resolution: Cycle power. If not cleared, CPU or EPROM circuitry is faulty. 3. RECEIVER MICRO STATUS and E-STOP flashing continuously together. Cause: E-Stop Drive circuitry fault detected. Resolution: If COM LINK is on, HopLink module is faulty. Otherwise, cycle power. It if recurs, TPCB-1527-01 board is faulty. 4. RECEIVER MICRO STATUS blinks off three times with a 2-second interval. Cause: HopLink failure detected. Resolution: Check ribbon cable to HopLink. Check that HopLink ON light is on. Check power to HopLink. If ON light off and power is good, then HopLink is faulty. In all other
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Remote Control Cable/Radio cases, the problem could be the HopLink, ribbon cable, or interface board. 5. RECEIVER MICRO STATUS blinks off two times with a 2-second interval. Cause: Interface to CANBUS board has no response. Resolution: Check wiring between boards. Otherwise fault could be on either board. 6. RECEIVER MICRO STATUS blinks off one time with a 2-second interval. Cause: CANBUS error detected by CANBUS board. Resolution: Check CANBUS interface wiring (external and internal). Internal connections are from the CANBUS board through the 4 pin headers on the TPCB-1527-01 board to the output connector on the box.
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7. RECEIVER MICRO STATUS blinks off four times with a 2-second interval. Cause: Communications fault detected to CANBUS board. Resolution: Check wiring between boards. Otherwise fault could be on either board. 7.1.3 Operator Adjustments:
The ramping for the Boom (2) functions on the transmitter can be dynamically adjusted using the DIP switches in the receiver from 0.1 second to 2.3 seconds in several steps. The ramp up time is the time for the signal to go from OFF to the full ON setting (100%). The ramp down time is the time for the signal to from the full ON setting (100%) to OFF. If the Boom (2) switches have been set to a lower ON value, the ramp times to that value will be proportionately less. The following charts outline the settings available.
Time (sec.)
DIP Switch #1
DIP Switch #2
DIP Switch #3
0.1
off
off
off
0.25
off
off
on
0.5
off
on
off
0.65
off
on
on
0.9
on
off
off
1.1
on
off
on
1.5
on
on
off
2.3
on
on
on
Time (sec.)
DIP Switch #4
DIP Switch #5
DIP Switch #6
0.1
off
off
off
0.25
off
off
on
0.5
off
on
off
0.65
off
on
on
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Remote Control Cable/Radio Time (sec.)
DIP Switch #4
DIP Switch #5
DIP Switch #6
0.9
on
off
off
1.1
on
off
on
1.5
on
on
off
2.3
on
on
on
7.2 Transmitter 7.2.1 Transmitter Lights
The transmitter lights are similar to all the other transmitter products supplied to SAI. The following chart details their operation.
= LED on /
Troubleshooting Table: Transmitter LED s
= LED flashing / X = LED flashing faster /
= LED off
+
STOP LED
LED
Battery Dead; Power Off
ACTION Charge Battery; Turn Power On
E-Stop Test
Press E-STOP button
X
E-Stop Test Part Two
Release E-STOP Button
X
E-Stop Failed
Set all functions off
N/A
Not all functions off on E-Stop release
OK, continue as required
N/A
Valid Data, all functions
OK, continue as required
N/A
Valid Data, 1 + functions on
E-STOP Button Pressed
N/A
Emergency Stop
Replace/Recharge Battery
N/A
Boom Function on when Boom disabled
Cycle Power - if not remedied, call service Cycle Power - if not remedied, call service Cycle Power - if not remedied, call service Cycle Power - if not remedied, call service Cycle Power - if not remedied, call service
N/A
NORMAL
LED
DESCRIPTION
NORMAL
Low Battery
X
Module failure: Joystick
X
Module failure: Radio Module failure: Micro
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Remote Control Cable/Radio 7.2.2 Operator Controls:
The position of the operator controls is as per Schwing America and is the same as the units supplied out of Germany. The Boom Enabled Slow (snail) setting cuts all boom control outputs in half (max.=50%) compared to the Boom Enabled Fast
(rabbit) setting. The Boom (2) speed switch selects three Boom (2) speeds in each of the Boom Enable settings. The speed switch settings are as per the table below.
Boom 2 Speed Switch
Boom Enable Fast
Boom Enable Slow
I
25%
13%
II II
50% 100%
25% 50%
7.3 Cable Unit 7.3.1 Cable Unit Lights
The cable unit lights are unique. That is, they do not act the same as other cable units supplied to SAI. The STOP light is used only for error condi= LED on /
tions since the Comfort System does not supply EStop status information to the cable unit. The following chart details the operation of the lights. Troubleshooting Table: Transmitter LED s
= LED flashing / X = LED flashing faster /
= LED off
+
STOP LED
LED
LED
DESCRIPTION
ACTION
No Power
Connect Cable, check fuse
Valid Data, all function off
OK, continue as required
Valid Data, 1 + functions on
OK, continue as required
Boom Function on with Boom Disabled
Enable Boom to activate Boom Function.
Function on after E-Stop release
Reset all function to neutral
Internal Interface Failure
CAN-Bus Interface Failure
Joystick Failure
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Cycle Power - if not remedied internal wiring or board faulty Check cable/truck wiring otherwise - internal I24-MC board or wiring faulty* Cycle Power-if not remedied joystick faulty (LED on faulty joystick ON when powered)
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Remote Control Cable/Radio 7.3.2 Operator Controls:
The position of the operator controls is as per Schwing America and is the same as the units supplied out of Germany. The Boom Enabled Slow (snail) setting cuts all boom control outputs in half (max.=50%) compared to the Boom Enabled Fast
(rabbit) setting. The Boom (2) speed switch selects three Boom (2) speeds in each of the Boom Enable settings. The speed switch settings are as per the table below.
Boom 2 Speed Switch
Boom Enable Fast
Boom Enable Slow
I
25%
13%
II
50%
25%
II
100%
50%
The Boom (2) Ramp speed is fixed at 1.0-second ramp up to 100% and 0.25-second ramp down from 100%.
8. Troubleshooting Information This section includes information on the circuit boards in the receiver and cable units, including a description of on-board LED’s. 8.1 I24-MC Board The I24-MC board is used in both the receiver and the cable units to provide the CAN-Bus interface and the Hydraulic Enable Output to the Comfort Control System. The on-board LED’s are defined as follows: LED 1 = CAN-BUS MICRO STATUS LED 2 = BOOM ENABLE LED 3 = CAN-Bus Link Failure LED 4 = Internal Error (Hydraulic Enable Output shorted to supply) LED 5 = Internal Diagnostic Mode
8.2 Receiver TPCB-1527-01 Board The TPCB-1527-01 board is used in the receiver to provide the interface between the I24-MC board and the HopLink module. The MAIN BYPASS jumper (JPI) must have a shorting block on pins 2 to 3 (position nearest the edge of the board) in order for the E-stop Relays to work. The on-board LED’s are defined as follows: CR3 (MICRO PWR) = 5V Power to microprocessor. CR4 = Relay Drive Power through 5A fuse F2. D6 (Top Red LED) = HopLink E-Stop Relay Drive OFF. D4 (Bottom Red LED) = TPCB-1527-01 EStop Relay Drive OFF.
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Formulas, Conversions & Specifications
Conversion Charts METRIC TO AMERICAN AND VICE-VERSA Abbreviation A A A b b b b btu btu/min btu/min cm cm cm cm cc or cm3 cc or cm3 cc or cm3 cc or cm3 ft3 ft3 ft3 ft3 in3 in3 in3 in3 in3 m3 m3 m3 m3 m3 m3/hr yd3 yd3 yd3 yd3 yd3 3 yd /hr daN daN ft ft ft ft ft-lb ft-lb ft-lb
TO CONVERT atmospheres atmospheres atmospheres bars bars bars bars british thermal units british thermal units/min. british thermal units/min. centimeters centimeters centimeters centimeters cubic centimeters cubic centimeters cubic centimeters cubic centimeters cubic feet cubic feet cubic feet cubic feet cubic inches cubic inches cubic inches cubic inches cubic inches cubic meters cubic meters cubic meters cubic meters cubic meters cubic meters/hour cubic yards cubic yards cubic yards cubic yards cubic yards cubic yards/hour dekanewtons dekanewtons feet feet feet feet foot-pounds foot-pounds foot-pounds
MULTIPLY BY 1.0132739 1.0333 14.7 0.9869 1 0.98069 14.5 778.16 .000393 0.01757 .03281 0.3937 10. 0.01 0.001 0.000001 0.00003531 0.061 28,320. 1,728. 0.03704 7.48052 16.39 0.0005787 0.00002143 0.004329 0.01639 1,000,000. 35.31 1.308 1,000. 264.2 1.308 764,600 27. 46,656. 764.526 202. 0.764526 1. 14.50377 30.48 0.0003048 0.3048 304.8 0.001286 0.1383 1.356
TO OBTAIN bars kilograms/sq. centimeter pounds/sq. inch atmospheres deka newtons kilograms/sq. centimeter pounds/sq. inch foot-pounds horsepower kilowatts feet inches millimeters meters liters cubic meters cubic feet cubic inches cubic centimeters cubic inches cubic yards gallons (U.S. liquid) cubic centimeters cubic feet cubic yards gallons (U.S. liquid) liters cubic centimeters cubic feet cubic yards liters gallons (U.S. liquid) cubic yards/hour cubic centimeters cubic feet cubic inches liters gallons (U.S. liquid) cubic meters/hour bars pounds/sq. inch centimeters kilometers meters millimeters british thermal units kilogram.-meters newton-meters
Abbreviation b kgs./cm2 PSI A daN kgs/cm2 PSI ft-lbs hp kw ft in mm m l m3 ft3 in3 cc or cm3 in3 yd3 G cc or cm3 ft3 yd3 G l cc or cm3 ft3 yd3 l G yd3/hr cc or cm3 ft3 in3 l G m3/hr b PSI cm km m mm btu kg-m Nm
Metric Conversion01.eps
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Formulas, Conversions & Specifications Abbreviation ft-lb/sec ft-lb/sec G G G G G G N/A G N/A g g hp hp ps hp hp in in kg kg kg/cm2 kg/cm2 kg/cm2 kg/m2 kw kw l l l l l m m m µm mm mm mm N Nm Nm oz oz lb lb lb lb lb-ft PSI PSI
TO CONVERT foot-pounds/second foot-pounds/second gallons gallons gallons gallons gallons gallons gallons (imp.) gallons (U.S.) gallons of water grams grams horsepower horsepower horsepower (metric) horsepower horsepower inches inches kilograms kilograms kilograms/square centimeter kilograms/square centimeter kilograms/square centimeter kilograms/square meter kilowatts kilowatts liters liters liters liters liters meters meters meters microns millimeters millimeters millimeters newtons newton meters newton meters ounces ounces pounds pounds pounds pounds pound-feet pounds/square inch pounds/square inch
SERVICE TRAINING
MULTIPLY BY 0.001818 0.001356 3,785. 0.1337 231. 0.003785 0.004951 3.785 1.20095 0.83267 8.337 0.001 0.03527 42.44 33,000. 0.9863 1.014 0.7457 2.540 25.4 2.2046 0.001 0.9678 0.9807 14.22 0.00009807 56.92 1.341 1000 61.02 0.001 0.001308 0.2642 3.281 39.37 1.094 0.000001 0.003281 0.03937 0.001 0.2248 8.850252 0.7375621 28.3 0.0625 453.597 4.4484552 .4536 16 0.1383 0.06804 0.06895
TO OBTAIN horsepower kilowatts cubic centimeters cubic feet cubic inches cubic meters cubic yards liters U.S. gallons imperial gallons pounds of water kilograms ounces (avdp.) british thermal units/min. foot-pounds/min. horsepower horsepower (metric) kilowatts centimeters millimeters pounds metric tons atmospheres bars pounds/square inch bars brit. thermal units/min. horsepower cubic centimeters cubic inches cubic meters cubic yards gallons (U.S. liquid) feet inches yards meters feet inches meters pounds inch-pounds foot-pounds grams pounds grams newtons kilograms ounces meter-kilograms atmospheres bars
Abbreviation hp kw cc or cm3 ft3 in3 m3 yd3 l G N/A N/A kg oz btu/min ft-lbs/min hp ps kw cm mm lb N/A A b PSI b btu/min hp cc or cm3 in3 m3 yd3 G ft in yd m ft in m lb in-lbs ft-lbs g lb g N kg oz m-kg A b
Metric_Conversion02.eps
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Formulas, Conversions & Specifications Abbreviation PSI cm2 in2 in2 in2 m2 mm2 N/A N/A N/A T w w w w yd
TO CONVERT
MULTIPLY BY
pounds/square inch square centimeters square inches square inches square inches square meters square millimeters tons (metric) tons (metric) tons (metric) tons (short) (U.S.) watts watts watts watts yards
0.0703 0.155 6.4516 645.163 0.0007716 10.7639 0.00155 1000 2204.6 1.1023 0.907194 0.05688 44.27 0.0013405 0.001 0.9144
TO OBTAIN kilograms/sq. centimeter square inches square centimeters square millimeters square yards square feet square inches kilograms pounds tons (short) (U.S.) tons (metric) british thermal units/min. foot-pounds/min. horsepower kilowatts meters
Abbreviation kg/cm2 in2 cm2 mm2 yd2 ft2 in2 kg lb T N/A btu/min ft-lb/min hp kw m
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CONVERSION FORMULAS - TO MILLIMETERS FROM INCHES: MULTIPLY INCHES BY 25.4 - TO INCHES FROM MILLIMETERS: MULTIPLY mm BY 0.03937 MILLIMETERS 0
INCHES 0
INCHES FRACTIONS
1/64
1/32
3/64
1/16
5/64
3/32
7/64 1/8
10
1/2"
20
30
1"
DECIMALS
mm
0.00004 0.00039 0.00079 0.00100 0.00118 0.00157 0.00197 0.00200 0.00236 0.00276 0.00300 0.00315 0.00354 0.00394 0.00400 0.00500 0.00600 0.00700 0.00787 0.00800 0.00900 0.00984 0.01000 0.01181 0.01563 0.01575 0.01969 0.02000 0.02362 0.02500 0.02756 0.02950 0.03000 0.03125 0.03150 0.03543 0.03937 0.04000 0.04687 0.04724 0.05000 0.05512 0.05906 0.06000 0.06250 0.06299 0.06693 0.07000 0.07087 0.07500 0.07813 0.07874 0.08000 0.08661 0.09000 0.09055 0.09375 0.09843 0.10000 0.10236 0.10937 0.11811 0.12500
0.0010 0.0100 0.0200 0.0250 0.0300 0.0400 0.0500 0.0510 0.0600 0.0700 0.0762 0.0800 0.0900 0.1000 0.1016 0.1270 0.1524 0.1778 0.2000 0.2032 0.2286 0.2500 0.2540 0.3000 0.3969 0.4000 0.5000 0.5080 0.6000 0.6350 0.7000 0.7500 0.7620 0.7938 0.8000 0.9000 1.0000 1.0160 1.1910 1.2000 1.2700 1.4000 1.5000 1.5240 1.5875 1.6000 1.7000 1.7780 1.8000 1.9050 1.9844 2.0000 2.0320 2.2000 2.2860 2.3000 2.3812 2.5000 2.5400 2.6000 2.7781 3.0000 3.1750
40
50
60
70
2"
80
90
3"
4"
INCHES FRACTIONS
9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 33/64 17/32 35/64 9/16 37/64
100 mm
DECIMALS
mm
0.13780 0.14063 0.15000 0.15625 0.15748 0.17188 0.17500 0.17717 0.18750 0.19685 0.20000 0.20313 0.21654 0.21875 0.22500 0.23438 0.23622 0.25000 0.25591 0.26563 0.27500 0.27559 0.28125 0.29528 0.29688 0.30000 0.31250 0.31496 0.32813 0.33465 0.34375 0.35000 0.35433 0.35938 0.37402 0.37500 0.39063 0.39370 0.40000 0.40625 0.41339 0.42188 0.43307 0.43750 0.45000 0.45276 0.45313 0.46875 0.47244 0.48438 0.49213 0.50000 0.51181 0.51563 0.53125 0.53150 0.54688 0.55000 0.55118 0.56250 0.57087 0.57813 0.59055
03.5000 03.5719 03.8100 03.9688 04.0000 04.3656 04.4450 04.5000 04.7625 05.0000 05.0800 05.1594 05.5000 05.5562 05.7150 05.9531 06.0000 06.3500 06.5000 06.7469 06.9850 07.0000 07.1438 07.5000 07.5406 07.6200 07.9375 08.0000 08.3344 08.5000 08.7312 08.8900 09.0000 09.1281 09.5000 09.5250 09.9219 10.0000 10.1600 10.3188 10.5000 10.7156 11.0000 11.1125 11.4300 11.5000 11.5094 11.9062 12.0000 12.3031 12.5000 12.7000 13.0000 13.0969 13.4938 13.5000 13.8906 13.9700 14.0000 14.2875 14.5000 14.6844 15.0000
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Formulas, Conversions & Specifications CONVERSION FORMULAS - TO MILLIMETERS FROM INCHES: MULTIPLY INCHES BY 25.4 - TO INCHES FROM MILLIMETERS: MULTIPLY mm BY 0.03937 MILLIMETERS 0
INCHES 0
INCHES
10
1/2"
20
30
1"
FRACTIONS
DECIMALS
mm
19/32
0.59375 0.60000 0.60938 0.61024 0.62500 0.62992 0.64063 0.64961 0.65000 0.65625 0.66929 0.67188 0.68750 0.68898 0.70000 0.70313 0.70866 0.71875 0.72835 0.73438 0.74803 0.75000 0.76563 0.76772 0.78125 0.78740 0.79688 0.80000 0.80709 0.81250 0.82677 0.82813 0.84375 0.84646 0.85000 0.85938 0.86614 0.87500 0.88583 0.89063 0.90000 0.90551 0.90625 0.92188 0.92520 0.93750 0.94488 0.95000 0.95313 0.96457 0.96875 0.98425 0.98438 1.00000 1.06299 1.10240 1.18110 1.25000 1.29921 1.37800 1.41732 1.50000 1.53543
15.0812 15.2400 15.4781 15.5000 15.8750 16.0000 16.2719 16.5000 16.5100 16.6688 17.0000 17.0656 17.4625 17.5000 17.7800 17.8594 18.0000 18.2562 18.5000 18.6531 19.0000 19.0500 19.4469 19.5000 19.8438 20.0000 20.2406 20.3200 20.5000 20.6375 21.0000 21.0344 21.4312 21.5000 21.5900 21.8281 22.0000 22.2250 22.6219 22.8600 23.0000 23.0188 23.0188 23.4156 23.5000 23.8125 24.0000 24.1300 24.2094 24.5000 24.6062 25.0000 25.0031 25.4000 27.0000 28.0000 30.0000 31.7500 33.0000 35.0000 36.0000 38.1000 39.0000
39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1
1 1/4
1 1/2
40
50
60
70
2"
80
90
3"
4"
INCHES FRACTIONS
1 3/4
2
2 1/4 2 1/2 2 3/4 3 3 1/2 4 4 1/2 5 6
8
10
12
16 20 24 36 48 60 72 96
100 mm
DECIMALS
mm
1.57480 1.65354 1.75000 1.77170 1.88976 1.96850 2.00000 2.04724 2.16540 2.20472 2.25000 2.36220 2.50000 2.51968 2.75000 2.83464 2.95280 3.00000 3.14960 3.50000 3.54330 3.93700 4.00000 4.33070 4.50000 4.72440 5.00000 5.51180 5.90550 6.00000 6.29920 7.08660 7.87400 8.00000 8.66140 9.44880 9.84250 10.00000 10.23620 11.02360 11.81100 12.00000 12.59840 13.38580 13.77950 14.17320 14.96060 15.74800 16.00000 17.71650 19.68500 20.00000 23.62200 24.00000 36.00000 39.37000 48.00000 60.00000 72.00000 78.74000 96.00000 118.11000 196.85000
040.00 042.00 044.45 045.00 048.00 050.00 050.80 052.00 055.00 056.00 057.15 060.00 063.50 064.00 069.85 072.00 075.00 076.20 080.00 088.90 090.00 100.00 101.60 110.00 114.30 120.00 127.00 140.00 150.00 152.40 160.00 180.00 200.00 203.20 220.00 240.00 250.00 254.00 260.00 280.00 300.00 304.80 320.00 340.00 350.00 360.00 380.00 400.00 406.40 450.00 500.00 508.00 600.00 609.60 914.40 1000.00 1219.20 1524.00 1828.80 2000.00 2438.40 3000.00 5000.00
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Formulas, Conversions & Specifications
Fluid Power Formulas The following represent some of the formulas commonly used when working with concrete pumps and related equipment. No attempt has been made to list all possible applications for these formulas. *The diagram below relates 3 formulas regarding force, pressure, and area:
U.S. F = FORCE (in pounds) (lb)
P
P = PRESSURE (in pounds per square inch) (P.S.I.) A = AREA (in square inches) (in2)
F=PxA P = F/A
F A
METRIC
A = F/P
F = FORCE (in kilograms) (Kg) P = PRESSURE (in kilograms per square centimeter) (Kg/cm2) A = AREA (in square centimeters) (cm2) *The following relates to power required by a hydraulic system
GENERAL POWER =
QxP CONSTANT
Q = FLOW RATE (unit of volume per time period) P = PRESSURE (unit of force per unit of area)
U.S. HP = HORSEPOWER HP =
GPM x PSI
GPM = GALLONS PER MINUTE
1714
PSI = POUNDS PER SQUARE INCH 1714 = KNOWN CONSTANT
METRIC KW = KILOWATTS KW =
LPM x BAR 600
LPM = LITERS PER MINUTE BAR = METRIC UNIT OF PRESSURE 600 = KNOWN CONSTANT
The above state only the power drawn by the system, and make no allowance for the efficiency of the components. To determine the power needed to drive a specific system, the answer to the formula must be divided by the efficiency factor. QxP REQUIRED POWER =
E = EFFICIENCY FACTOR
CONSTANT
E The rule of thumb for figuring efficiencies is: E = 0.7 for internal combustion engines, or E = 0.85 for electric motors. It would be the same in Metric as in U.S. calculations. *The following relates to theoretical flow rates by a hydraulic pump Q=
Q (in GPM) =
Q (in liters/min.) =
RPM x PUMP DISPLACEMENT CONVERSION FACTOR RPM x CUBIC INCHES/REV.
GENERAL
U.S.
231 = number of cubic inches in 1 gallon
231 RPM x CUBIC CENTIMETERS/REV. 1000
METRIC 1000 = number of cubic centimeterss in 1 liter
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Formulas, Conversions & Specifications Torque and Horsepower relations: T=
P x CONSTANT RPM
P=
T x RPM CONSTANT
RPM =
T=
HP =
HP x 5252 RPM
RPM = REVOLUTIONS PER MINUTE
U.S. T = TORQUE (in foot-pounds) (ft-lb) HP = HORSEPOWER
T x RPM 5252 HP x 5252 T
T=
KW x 9543 RPM
RPM =
P = POWER
P x CONSTANT T
RPM =
KW =
GENERAL T = TORQUE
5252 = K
NOWN CONSTANT
METRIC T = TORQUE (in newton-meters) (Nm) KW = KILOWATTS
T x RPM 9543
9543 = K
NOWN CONSTANT
KW x 9543 T
Torque and Displacement relations:
U.S. T = TORQUE (in foot-pounds) (ft-lb) D = DISPLACEMENT (in cubic inches per revolution) (in3/rev.)
DxP T= 24 π
P = PRESSURE (in pounds per square inch) (PSI) π = Pi (3.1415927)
Finding pressure on concrete
Piston
U.S.
Rubber Ram
PC = PRESSURE ON THE CONCRETE (In PSI) PA = PISTON AREA (In square inches) (in2)
Rod
(PA)
(RRA) (RSA)
(RA)
RA = ROD AREA (In square inches) (in2) RSA = ROD SIDE AREA (In square inches) (in2) RRA = RUBBER RAM AREA (In square inches) (in2)
(on piston side) PC =
(on rod side) PC =
RSA =
PA x MAX. P RRA RSA x MAX. P RRA
MAX. P = MAXIMUM HYDRAULIC OIL PRESSURE (In PSI) (relief valve setting) EXAMPLE: Piston diameter 4.72 inches (120mm), Rod diameter 3.15 inches (80mm), Rubber ram diameter 9.05 inches (230mm), relief valve set at 4,350 PSI (300 bar). Area of the piston = 17.5 in2. Area of the rod = 7.79 in2. Area of the rubber ram = 64.33 in2.
PA - RA (on rod side) PC =
(17.5 - 7.79) x 4350 64.33
(on rod side) PC = 656.6 PSI
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Torque Specifications The following charts show the tightening torques specified for the bolts used on Schwing equipment. The charts are to be followed unless a different torque specification is indicated for a particular procedure. A torque wrench must be calibrated to within 1% of its indicated value throughout its range. Bolts must be torqued to within 4% of the requirement if the wrench
644
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has a dial scale. If no dial scale is present, the bolts must be torqued to within 6% of the requirement. For example, a bolt to be torqued to a 200-lb requirement must be within the range of 208–192 ft-lb for a dial scale torque wrench. Schwing equipment uses two different types of bolts, one black/yellow chromated finish and one Dacromet finish.
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Formulas, Conversions & Specifications I. APPLICABLE TO: A. 500 Geomet fasteners, nuts, and washers B. Black or yellow-chromate fasteners, nuts, and washers (using Cu or MOS2 mounting paste)
Coarse-Pitch Thread
Fine-Pitch Thread
*Tightening Torque
*Tightening Torque
Property Class
Property Class
8.8
10.9
12.9
Nm
ft lb
Nm
ft lb
Nm
ft lb
M 4 X 0.7
2.2
1.6
3.2
2.4
3.8
2.8
M 5 X 0.8
4.3
3.2
6.4
4.7
7.5
M 6X1
7.5
5.5
10.8
8.0
M 8 X 1.25
18
13
27
M 10 X 1.5
36
27
M 12 X 1.75
62
M 14 X 2
Thread Designation
Thread Designation
HOME
8.8
10.9
12.9
Nm
ft lb
Nm
ft lb
Nm
ft lb
M 8X1
20
15
28
21
33
24
5.5
M 10 X 1
40
29
57
42
68
50
12.6
9.3
M 10 X 1.25
37
27
55
41
64
47
20
31
23
M 12 X 1.25
67
49
100
74
115
85
53
39
62
46
M 12 X 1.5
65
48
95
70
110
81
46
90
66
108
80
M 14 X 1.5
105
77
155
114
180
133
100
74
140
103
170
125
M 16 X 1.5
160
118
235
173
280
206
M 16 X 2
150
111
225
166
260
192
M 18 X 1.5
240
177
345
254
400
295
M 18 X 2.5
220
162
310
228
365
269
M 20 X 1.5
335
247
475
350
560
413
M 20 X 2.5
300
221
440
324
510
376
M 22 X 1.5
460
339
650
479
750
553
M 22 X 2.5
420
310
590
435
700
516
M 24 X 2
560
413
810
597
940
693
M 24 X 3
530
391
750
553
880
649
M 27 X 2
820
604
1170
862
1390 1025
M 27 X 3
780
575
1120
826
1300
958
M 30 X 2
1170
862
1660 1224 1930 1423
M 30 X 3.5
1080
796
1530 1128 1750 1290
S0180.eps
* The tightening torque corresponds to the axial force in the fastener where the limit of elasticity of the latter is utilized 90% by tension and torsion assuming a friction coefficient of m = 0.1. REFERENCES: 1. DIN 912, 931, 933, 934, 6914, and 6915 2. VDI 2230
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II. APPLICABLE TO: A. Black and yellow chromate fasteners, nuts, and washers
Fine-Pitch Thread
*Tightening Torque
*Tightening Torque
Property Class
Property Class
8.8
10.9
12.9
Nm
ft lb
Nm
ft lb
Nm
ft lb
M 4 X 0.7
2.7
2.0
4
2.9
4.6
3.4
M 5 X 0.8
5.3
3.9
7.8
5.7
9.0
M 6X1
8
5.9
13.5
10.0
M 8 X 1.25
22
16
32
M 10 X 1.5
44
32
M 12 X 1.75
76
M 14 X 2
Thread Designation
Thread Designation
Coarse-Pitch Thread
8.8
10.9
12.9
Nm
ft lb
Nm
ft lb
Nm
ft lb
M 8X1
24
18
35
26
41
30
6.6
M 10 X 1
50
37
70
52
85
63
16.2
11.9
M 10 X 1.25
46
34
65
48
80
59
24
38
28
M 12 X 1.25
83
61
120
88
145
107
64
47
75
55
M 12 X 1.5
80
59
115
85
140
103
56
112
83
130
96
M 14 X 1.5
130
96
190
140
230
170
120
88
180
133
210
155
M 16 X 1.5
200
147
295
217
350
258
M 16 X 2
185
136
275
203
325
240
M 18 X 1.5
300
221
435
321
510
376
M 18 X 2.5
270
199
385
284
450
332
M 20 X 1.5
425
313
610
450
710
523
M 20 X 2.5
380
280
550
405
640
472
M 22 X 1.5
580
428
825
608
940
693
M 22 X 2.5
520
383
740
545
870
641
M 24 X 2
720
531
1030
759
1210
892
M 24 X 3
650
479
940
693
1095
807
M 27 X 2
1030
759
1480 1091 1750 1290
M 27 X 3
990
730
1390 1025 1620 1194
M 30 X 2
1480 1091 2110 1555 2470 1821
M 30 X 3.5
1300
958
1890 1393 2200 1622
* The tightening torque corresponds to the axial force in the fastener where the limit of elasticity of the latter is utilized 90% by tension and torsion assuming a friction coefficient of m = 0.14. REFERENCES: 1. DIN 912, 931, 933, 934, 6914, and 6915 3. VDI 2230
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Formulas, Conversions & Specifications
Torque Specification: Slewing Roller Bearing Bolts
Part Number
Size (Course Threads)
Grade
Bolt
10207022
M20 x 140
10.9
Washer
10141124
M20
Bolt
10030718
M24 x 130
Washer
10141125
M24
Bolt
10072024
M20 X 2.5 X 110
Washer
10001509
M21
Bolt
10030718
M24 x 130
Washer
10141125
M24
Bolt
10120666
M20 X 2.5 X 140
Washer
10001509
M21
Bolt
10009258
M20 X 2 X 150
Washer
10001509
M21
Nut
10007993
M20
Bolt
10120666
M20 X 2.5 X 140
Washer
10001509
M21
Bolt
10117168
M24 X 150
Washer
10141124
M24
Bolt
10012926
M22 X 2.5 X 180
Washer
10012937
M23
Nut
10029928
M23
Bolt
10117168
M24 X 150
Washer
10141125
M24
Bolt
10044746
M24 X 3 X 140
Washer
10001504
M25
Unit
S 17
S 31 XT KVM 32XL and KVM 36L KVM 34X
KVM 36X
KVM 36
KVM 39
S 42 SX
KVM 42
S 45 SX S 47 SX KVM 52 KVM 55
DIN
Torque - Ft-Lbs (Newton-meters) Black or Yellow Cromate
Dacrometer Geomet
931
405 (550 Nm)
326 (440 Nm)
10.9
931
694 (940 Nm)
553 (750 Nm)
10.9
6914
405 (550 Nm)
326 (440 Nm)
10.9
931
694 (940 Nm)
553 (750 Nm)
12.9
6914
472 (640 Nm)
376 (510 Nm)
12.9
960
472 (640 Nm)
376 (510 Nm)
12.9
960
472 (640 Nm)
376 (510 Nm)
10.9
931
694 (940 Nm)
553 (750 Nm)
10.9
931
546 (740 Nm)
440 (592 Nm)
10.9
931
694 (940 Nm)
553 (750 Nm)
10.9
6914
694 (940 Nm)
553 (750 Nm)
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Formulas, Conversions & Specifications S 52 SX S 58 SX S 61 SX
648
Bolt
10188613
M24 X 3 X160
Washer
10188948
M25
Bolt
10188613
M24 X 3 X160
Washer
10188948
M25
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10.9
6914
694 (940 Nm)
553 (750 Nm)
10.9
6914
694 (940 Nm)
553 (750 Nm)
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Torque for Boom Cylinder Bolts Torque Unit
KVM 23
KVM 24x-4
KVM 25
KVM 26X-4
KVM 28M
KVM 28X
KVM 31
Cyl. No.
Part Number
Piston
Cylinder End
Nm
Ft-Lb
Nm
Ft-Lb
#1
10004728
128
94
313
231
#2
10000661
128
94
313
231
#3
10004747
36
27
128
94
#1
10025228
627
463
190
140
#2
10032825
627
463
269
199
#3
10025223
627
463
190
140
#4
10079930
626
462
322
238
#1
10004738
128
94
313
231
#2
10004738
128
94
313
231
#3
10004721
73
54
313
231
#1
10082091
1075
793
627
463
#2
10111663
627
463
269
199
#3
10111514
626
462
322
238
#4
10110660
441
325
132
97
#1
10004740
128
94
428
316
#2
10004738
128
94
313
231
#3
10004722
128
94
313
231
#1
10082091
1075
793
627
463
#2
10110776
626
462
322
238
#3
10110660
441
325
132
97
#1
10004724
128
94
313
231
#2
10004734
128
94
313
231
#3
10004722
128
94
313
231
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Torque Unit
KVM 32M
KVM 32XL
KVM 34X
KVM 36 STD
KVM 36X
KVM 39X
650
Cyl. No.
Part Number
Piston
Cylinder End
Nm
Ft-Lb
Nm
Ft-Lb
#1
10024056
1075
793
440
325
#2
10023914
1075
793
269
199
#3
10023699
627
463
269
199
#4
10023615
441
325
269
199
#1
10110190
1075
793
627
463
#2
10023914
1075
793
269
199
#3
10062795
627
463
269
199
#4
10023615
441
325
269
199
#1
10158046
960
710
-
-
#2
10158047
960
710
-
-
#3
10158049
-
-
-
-
#4
10158050
-
-
-
-
#1
10000655
128
94
428
316
#2
10000651
128
94
428
316
#3
10004738
128
94
313
231
#4
10004721
73
54
313
231
#1
10111029
1075
793
627
463
#2
10110461
1075
793
627
463
#3
10110776
626
462
322
238
#4
10110660
441
325
132
97
#1
10111029
1075
793
627
463
#2
10110461
1075
793
627
463
#3
10110776
626
462
322
238
#4
10110660
441
325
132
97
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Formulas, Conversions & Specifications Torque Unit
KVM 42M
S 42 SX
S 45SX and S 47SX
Cyl. No.
S 58SX and S 61SX
Piston
Cylinder End
Nm
Ft-Lb
Nm
Ft-Lb
#1
10023914
1075
793
269
199
#2
10080103
1075
793
627
463
#3
10025228
627
463
190
140
#4
10037135
441
325
269
199
#1
10201085
950
700
--
--
#2
10110461
1075
793
627
463
#3
10110776
626
462
322
238
#4
10110660
441
325
132
97
#1
10167681
-
-
1950
1450
#2
10146611
1220
900
960
700
#3
10146612
1350
1000
-
-
#4
10146613
441
325
132
100
10049567
--
--
2350
1734
10142494
--
--
2100
1550
#2
10049568
--
--
820
605
#3
10049569
--
--
--
--
#4
10049570
--
--
--
--
#1
10185967
--
--
--
--
#2
10185968
1150
850
#3
10185969
--
--
--
--
#4
10185970
--
--
--
--
#1 KVM 52 and KVM 55
Part Number
Service Manual
651
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Formulas, Conversions & Specifications
SERVICE TRAINING
WP Number Codes
EXPLANATION OF NOMENCLATURE WP 1000 XE World Pump Frame (Concrete Pump) Pump Model Twin Circuit (X) or Single Circuit (blank) Switching Electric (E) or Diesel (blank)
WP 750 - 15XE World Pump Frame (Concrete Pump) Pump Model 15 cm Diameter Material Cylinder Bore Twin Circuit (X) or Single Circuit (blank) Switching Electric (E) or Diesel (blank)
WP 750 - 18XE World Pump Frame (Concrete Pump) Pump Model 18 cm Diameter Material Cylinder Bore Twin Circuit (X) or Single Circuit (blank) Switching Electric (E) or Diesel (blank)
In practical usage, it would be common to refer to these units as a 1000, 750-15, and a 750-18. The pumpkit has its own complete model number. You will nd this used on the output char ts and nomographs for speci c machines . An example:
Pumpkit:
80 / 50 X 1000 :
180
Differential Cylinder Bore Diameter (in mm) Differential Cylinder Rod Diameter (in mm) Stroke Length (in mm) Material Cylinder Bore Diameter (in mm) S0014.eps
652
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Formulas, Conversions & Specifications
BP Model Number Codes EXPLANATION OF NOMENCLATURE The model numbers of other Schwing concrete pumps are explained by these code examples:
EXAMPLE
BPL 1200 HDR - 23 KVM 32/28 XL - 125
The code for the truck pump is broken down as follows:
BP L 1200 HD R 23
Beton Pumpe (Concrete Pump) Lastkraftwagen (Truck mounted) Pumpkit Model# Heavy - Duty Rock Valve ("omit" if gate valve) Diameter of Material Cylinders (in centimeters)
The code for the placing boom is broken down as follows:
K VM 32/28 **** - 125
Knickbarrer Verteiler Mast (Integrated placing boom) or Derrick Verteiler Mast (Counter-jib placing boom) Boom’s Vertical Reach (in meters) Boom’s Horizontal reach (in meters) * Special Dseignations: ("LW" - LightWeight) ("X"-outrigger configuration) ("L"-longer boom reach) Diameter of Boom Pipeline (in millimeters) EXAMPLE
BPA 3001 HDD - 18R
The code for the trailer pump is broken down as follows:
BP A 3001 HD D 18 HP R
Beton Pumpe (Concrete Pump) Highway Axle ("omit" if jobsite axle) Pumpkit Model# Heavy - Duty Diesel Engine ("E" if Electric Motor) Diameter of Material Cylinders (in centimeters) High Pressure Rock Valve ("omit" if gate valve) The pumpkit has its own complete model number. You will find this used on the output charts and nomographs for specific units. An example:
125 / 80 x 2000 - 230
Differential Cylinder Bore Diameter (in millimeters) Differential Piston Rod Diameter (in millimeters) Differential Stroke Length (in millimeters) Material Cylinder Bore Diameter (in millimeters) S0015.eps
Service Manual
653
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SERVICE TRAINING
Outrigger Spreads and Loads
OUTRIGGER SPREADS AND LOADS 1 Schwing America, Inc.
REAR OUTRIGGER SPREAD (in) (mm)
FRONT to REAR OUTRIGGER SPREAD (in) (mm)
MAXIMUM FRONT OUTRIGGER (lbs) (kN)
MAXIMUM REAR OUTRIGGER LOAD (lbs) (kN)
PRODUCT
FRONT OUTRIGGER SPREAD (in) (mm)
KVM 17
141
3581
86
2184
173
4394
16,860
75
11,240
50
S 17 2
152
3861
87
2210
184
4674
22,026
98
8,810
39
KVM 23
236
5994
86
2184
222
5639
20,947
93
14,332
64
KVM 23-4 H
225
5715
134
3404
236
5994
22,050
98
15,250
68
KVM 24-4 H
235
5969
142
3607
268
6807
27,000
120
20,500
91
KVM 25
225
5715
134
3404
244
6198
23,200
103
14,300
64
KVM 26-4
235
5969
142
3607
268
6807
29,000
129
23,500
105
KVM 28
245
6223
180
4572
271
6883
27,560
123
17,420
78
KVM 28 X
235
5969
142
3607
268
6807
28,500
127
22,800
101
S 28 X
235
5969
142
3607
259
6579
40,464
180
38,216
170
KVM 31
244
6198
244
6198
248
6299
24,255
108
28,665
128
S 31 EZ (HT)
245
6223
202
5131
293
7442
39,700
177
30,900
137
KVM 32
278
7061
192
4877
271
6883
30,430
135
22,930
102
KVM 32 XL
234
5944
204
5182
294
7468
32,600
145
27,000
120
KVM 34 X
245
6223
225
5715
283
7188
39,500
176
31,500
140
KVM 36
274
6960
294
7468
282
7163
32,630
145
36,380
162
KVM 36 X
292
7417
232
5893
353
8966
37,800
168
33,300
148
KVM 39 X
307
7798
252
6401
359
9119
42,000
187
35,200
157
S 41 SX
312
7925
252
6401
352
8941
42,000
187
35,200
157
KVM 42 HW
354
8992
354
8992
363
9220
49,600
221
52,900
235
KVM 42 LW
335
8509
331
8407
333
8458
43,400
193
45,400
202
S 42 SX
327
8306
327
8306
348
8839
50,700
226
52,900
235
S 45/47 SX
327
8306
327
8306
348
8839
58,500
260
56,200
250
KVM 52/55
374
9500
374
9500
410
10414
60,000
267
60,000
267
S 52 SX
350
8890
411
10439
424
10770
75,308
335
78,680
350
S 58/61 SX
350
8890
493
12522
453
11506
78,680
350
83,176
370
Notes: 1. All dimensions and weights are approximate; 2. Two axle Mack truck listed.
654
S0016.eps
Service Manual
Prepared by: Mark Berggren Issue: 01/31/05 04/13/05
LWR .099 .108 .108 .108 .108 Rollix Rollix
Service Manual
UPR .150 .138 .138 .158 .158 Rollix Rollix
HP A0 .098 .098 .098 .114 .114 .045 .114
5115-1.eps
NA A1 -----------------------------
A A2 .041 .047 .047 .041 .054 .044 .047
A (A2)
NA A2.1 -----------------------------
B (A3)
B A3 .041 .047 .047 .041 .054 .044 .047
NA A4 -----------------------------
1 B0 .047 .044 .044 .044 .044 .044 .054
2 B1 .041 .047 .047 .047 .041 .041 .049
3 (B2)
(B1) 2
3 B2 .041 .047 .047 .047 .044 .044 .054
3.1 B2.1 -----------------------------
C B3 .041 .047 .047 .047 .044 .044 .054
D (C3)
4 B4 .041 .047 .047 .047 .044 .044 .049
5 C0 .035 .035 .035 .067 .067 .045 .067
6 C1 .030 .030 .030 .035 .035 .035 .041
7 (C2)
7 C2 .030 .030 .035 .035 .041 .041 .047
(C0) 5 (C1) 6
7.1 C2.1 -----------------------------
D C3 .030 .030 .035 .035 .041 .041 .047
8 C4 .030 .030 .030 .035 .041 .041 .041
E (D3)
9 D0 ----------------.035 .035 .035
10 D1 ----------------.030 .030 .030
11 D2 ----------------.035 .035 .030
11.1 D2.1 -----------------------------
(D4) 12 (D0) 9 (D1) 10 11 (D2)
E D3 ----------------.035 .035 .030
12 D4 ----------------.035 .035 .030
SAIE STANDARD
Approved by: Jason
NOTES: 1. REFERENCE SAIE 5114 FOR SLEWING BEARING INSPECTION. 2. ALL MEASUREMENTS ARE IN INCHES AND REPRESENT MAXIMUM ALLOWABLE CLEARANCES. 3. FOR SPLIT BOOM AND DETACH TOWER CONNECTIONS, ALLOWED BOOM PIN CLEARANCE IS 0.050 MAXIMUM 4. CONTACT THE SAI SERVICE DEPARTMENT AT (651) 429-0999 IF YOU HAVE QUESTIONS 5. ALL DIMENSIONS ARE IN INCHES.
KVM 23M 25M 28M 31M 32M 32XL 36M
Lower
Upper
(A0) HP
C (B3)
(B4) 4
(B0) 1
(C4) 8
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Boom Pin Clearances Standard: 5115 Page: 1 of 10
Subject: Maximum Pin-Bushing-Bore Clearances
Mehl
655
Prepared by: Mark Berggren Issue: 01/31/05 04/13/05
656
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LWR .108 .108 Rollix Rollix Rollix Rollix
UPR .138 .138 Rollix Rollix Rollix Rollix
HP A0 .060 .060 .045 .045 .045 .114
NA A1 -------------------------
A A2 .044 .044 .049 .044 .044 .044
NA A2.1 -------------------------
B A3 .044 .044 .049 .044 .044 .044
NA A4 -------------------------
7.1 7 (C2.1) (C2)
1 B0 .041 .041 .049 .044 .044 .044
2 B1 .041 .041 .047 .044 .047 .044
3 B2 .041 .032 .047 .047 .047 .047
3.1 B2.1 .047 .047 .049 .049 .049 .049
C B3 .041 .032 .047 .047 .047 .047
4 B4 .047 .047 .049 .049 .049 .049
5 C0 .045 .027 .045 .045 .038 .041
6 C1 .035 .027 .038 .041 .038 .041
7 C2 .035 .024 .038 .032 .032 .032
BEARING CLEARANCES
D (C3)
7.1 C2.1 .041 .032 .047 .047 .047 .047
D C3 .035 .024 .038 .032 .032 .032
E (D3)
8 C4 .041 .032 .047 .047 .047 .047
9 D0 .027 ----.032 .027 .024 .030
10 D1 .027 ----.032 .027 .024 .027
11 D2 .024 ----.032 .024 .024 .027
(D4) 12 (D0) 9 (D1) 10 11 11.1 (D2) (D2.1)
11.1 D2.1 .032 ----.032 .032 .032 .035
E D3 .024 ----.032 .024 .024 .027
12 D4 .032 ----.032 .032 .032 .035
SAIE STANDARD
Mehl
NOTES: 1. REFERENCE SAIE 5114 FOR SLEWING BEARING INSPECTION. 2. ALL MEASUREMENTS ARE IN INCHES AND REPRESENT MAXIMUM ALLOWABLE CLEARANCES. 3. FOR SPLIT BOOM AND DETACH TOWER CONNECTIONS, ALLOWED BOOM PIN CLEARANCE IS 0.050ʼ MAXIMUM 4. CONTACT THE SAI SERVICE DEPARTMENT AT (651) 429-0999 IF YOU HAVE QUESTIONS. 5. ALL DIMENSIONS ARE IN INCHES.
KVM 26-4 28X 34X 36LW 36X 39X
5115-2.eps
A (A2)
B (A3)
3 (B2)
3.1 (B2.1)
(B1) 2
(C0) 5 (C1) 6
Formulas, Conversions & Specifications
Lower
Upper
(A0) HP
C (B3)
(B4) 4
(B0) 1
(C4) 8
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Standard: 5115 Page: 2 of 10
Subject: Maximum Pin-Bushing-Bore Clearances
Prepared by: Mark Berggren Issue: 01/31/05 04/13/05
Approved by: Jason
Service Manual B (A3)
A A2 .044 .044 .044
NA A2.1 -------------
B A3 .044 .044 .044
NA A4 -------------
1 B0 .054 .054 .054
2 B1 ----.044 .054
3 B2 ----.049 .054
3.1 (B2.1) 3 (B2)
(B1) 2
11.1 11 (D2) (D2.1)
(D1) 10
(D4) 12 (D0) 9
7 (C2)
(C1) 6
3.1 B2.1 ----.047 .059
C B3 ----.049 .054
4 B4 ----.049 .059
5 C0 .073 .073 .073
6 C1 .047 .047 .047
7 C2 .047 .047 .047
7.1 C2.1 -------------
11 (D2)
(D1) 10
(D4) 12 (D0) 9
D C3 .047 .047 .047
8 C4 .047 .047 .047
9 D0 .035 .035 .035
10 D1 .035 .035 .035
11 D2 .035 .035 .035
11.1 D2.1 .035 ---------
KVM 42M L.W. & H.W.
E (D3)
KVM 42M CURRENT PRODUCTION
E (D3)
D (C3)
(C0) 5
E D3 .035 .035 .035
12 D4 .035 .035 .035
SAIE STANDARD
NOTES: 1. REFERENCE SAIE 5114 FOR SLEWING BEARING INSPECTION. 2. ALL MEASUREMENTS ARE IN INCHES AND REPRESENT MAXIMUM ALLOWABLE CLEARANCES. 3. CONTACT THE SAI SERVICE DEPARTMENT AT (651) 429-0999 IF YOU HAVE QUESTIONS. 4. ALL DIMENSIONS ARE IN INCHES.
NA A1 -------------
A (A2)
HP KVM A0 42M .114 42LW .114 42HW .114
5115-3.eps
(A0) HP
C (B3)
(B4) 4
(B0) 1
(C4) 8
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Formulas, Conversions & Specifications Standard: 5115 Page: 3 of 10
Subject: Maximum Pin-Bushing-Bore Clearances
Mehl
657
658
Prepared by: Mark Berggren Issue: 01/31/05 04/13/05
HP A0 .045 .045 .045 .045 .045 .045 .045
NA A1 .051 .051 .079 .079 .079 .055 .055
A A2 .051 .051 .071 .071 .071 .055 .055
NA A2.1 .075 .075 .075 .075 .075 .075 .075
B A3 .051 .051 .071 .071 .071 .055 .055
(A3) B
Approved by: Jason
Service Manual NA A4 .075 .075 .079 .079 .079 .079 .079
1 B0 .054 .054 .059 .059 .059 .051 .051
2 B1 .054 .054 .059 .059 .059 .051 .051
3.1 B2.1 .051 .051 .059 .059 .059 .071 .071
5115-4.eps
(A4) 13
3 B2 .049 .049 .059 .059 .059 .059 .059
14 (A1)
(B3) C
15 (A2.1)
A (A2)
(B2.1) 3.1 (B2) 3
D (C3)
C B3 .049 .049 .059 .059 .059 .059 .059
(A0) HP
7.1 (C2.1)
4 B4 .051 .051 .071 .071 .071 .071 .071
(C1) 6
5 C0 .044 .044 .054 .054 .054 .054 .054
6 C1 .044 .044 .054 .054 .054 .044 .044
E (D3)
7 C2 .047 .047 .054 .054 .054 .044 .044
D C3 .047 .047 .054 .054 .054 .044 .044
11.1 (D2.1)
7.1 C2.1 .054 .054 .055 .055 .055 .049 .049
11 (D2)
8 C4 .054 .054 .055 .055 .055 .049 .049
(D4) 12
9 D0 .045 .045 .045 .045 .045 .045 .045
(D1) 10
(D0) 9
10 D1 .032 .032 .035 .035 .035 .035 .035
11 D2 .027 .027 .035 .035 .035 .032 .032
11.1 D2.1 .035 .035 .035 .035 .035 .044 .044
E D3 .027 .027 .035 .035 .035 .032 .032
12 D4 .035 .035 .035 .035 .035 .044 .044
Formulas, Conversions & Specifications
SAIE STANDARD
Mehl
NOTES: 1. REFERENCE SAIE 5114 FOR SLEWING BEARING INSPECTION. 2. ALL MEASUREMENTS ARE IN INCHES AND REPRESENT MAXIMUM ALLOWABLE CLEARANCES. 3. CONTACT THE SAI SERVICE DEPARTMENT AT (651) 429-0999 IF YOU HAVE QUESTIONS. 4. ALL DIMENSIONS ARE IN INCHES.
KVM 45SX 47SX 52M 52EX 55M 58SX 61SX
(B0) 1 (B4) 4
(B1) 2
7 (C2)
(C4) 8
(C0) 5
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Standard: 5115 Page: 4 of 10
Subject: Maximum Pin-Bushing-Bore Clearances
Prepared by: Mark Berggren Issue: 01/31/05 04/13/05
Approved by: Jason
Service Manual
UPR .138 .138
HP A0 .060 .060
5115-5.eps
NA A A1 A2 ----- .047 ----- .044
A (A2)
D (C3) 7 7.1 (C2) (C2.1) E (D3)
11.1 E 12 D2.1 D3 D4 .030 .035 .035 .030 .035 .035
(D1) 10
(D0) 9
11.1 (D2.1)
11 (D2)
(D4) 12
NA B NA 1 2 3 3.1 C 4 5 6 7 7.1 D 8 9 10 11 A2.1 A3 A4 B0 B1 B2 B2.1 B3 B4 C0 C1 C2 C2.1 C3 C4 D0 D1 D2 ----- .047 ----- .044 .041 .041 ----- .041 .041 .035 .030 .047 .030 .047 .041 .065 .030 .035 ----- .044 ----- .044 .041 .041 ----- .041 .041 .035 .030 .047 .030 .047 .041 .065 .030 .035
3 (B2)
(B1) 2
(C0) 5 (C1) 6
SAIE STANDARD
NOTES: 1. REFERENCE SAIE 5114 FOR SLEWING BEARING INSPECTION. 2. ALL MEASUREMENTS ARE IN INCHES AND REPRESENT MAXIMUM ALLOWABLE CLEARANCES. 3. CONTACT THE SAI SERVICE DEPARTMENT AT (651) 429-0999 IF YOU HAVE QUESTIONS. 4. ALL DIMENSIONS ARE IN INCHES.
KVM LWR 23-4H .108 24-4H .108
Upper Lower
(A0) HP
C B (B3) (A3)
(B4) 4
(B0) 1
(C4) 8
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Formulas, Conversions & Specifications
Standard: 5115 Page: 5 of 10
Subject: Maximum Pin-Bushing-Bore Clearances
Mehl
659
Prepared by: Mark Berggren Issue: 01/31/05 04/13/05
660
Approved by: Jason
Service Manual
UPR .138
7 (C2)
HP NA A NA B NA 1 2 3 3.1 C 4 5 6 7 7.1 D 8 9 10 11 11.1 E 12 A0 A1 A2 A2.1 A3 A4 B0 B1 B2 B2.1 B3 B4 C0 C1 C2 C2.1 C3 C4 D0 D1 D2 D2.1 D3 D4 .060 ----- .035 ----- .035 ----- .030 .030 .035 .035 .035 .035 .030 .024 .030 ----- .030 .024 ----- ----- ----- ----- ----- -----
D (C3)
SAIE STANDARD
Mehl
NOTES: 1. REFERENCE SAIE 5114 FOR SLEWING BEARING INSPECTION. 2. ALL MEASUREMENTS ARE IN INCHES AND REPRESENT MAXIMUM ALLOWABLE CLEARANCES. 3. CONTACT THE SAI SERVICE DEPARTMENT AT (651) 429-0999 IF YOU HAVE QUESTIONS. 4. ALL DIMENSIONS ARE IN INCHES.
KVM LWR 17-270 .108
5115-6.eps
A (A2)
3 (B2)
3.1 (B2.1)
(B1) 2
(C0) 5 (C1) 6
Formulas, Conversions & Specifications
Upper Lower
(A0) HP
B (A3)
C (B3)
(B4) 4
(B0) 1
(C4) 8
HOME PRINT
SERVICE TRAINING
Standard: 5115 Page: 6 of 10
Subject: Maximum Pin-Bushing-Bore Clearances
Prepared by: Mark Berggren Issue: 01/31/05 04/13/05
Service Manual
Approved by: Jason NA A1 -----
A NA B NA 1 2 3 3.1 C 4 5 6 7 7.1 D 8 9 10 11 11.1 E 12 A2 A2.1 A3 A4 B0 B1 B2 B2.1 B3 B4 C0 C1 C2 C2.1 C3 C4 D0 D1 D2 D2.1 D3 D4 .049 ----- .049 ----- .041 .035 .032 .047 .032 .047 .035 .035 .035 .041 .035 .041 .027 .027 .027 .030 .027 .030
A (A2)
B (A3)
C (B3)
8 (C4)
6 5 (C1) (C0)
9 12 (D0) (D4)
10 (D1)
SAIE STANDARD
NOTES: 1. REFERENCE SAIE 5114 FOR SLEWING BEARING INSPECTION. 2. ALL MEASUREMENTS ARE IN INCHES AND REPRESENT MAXIMUM ALLOWABLE CLEARANCES. 3. CONTACT THE SAI SERVICE DEPARTMENT AT (651) 429-0999 IF YOU HAVE QUESTIONS. 4. ALL DIMENSIONS ARE IN INCHES.
HP KVM A0 31-5HT .045
5115-7.eps
(A0) HP
3.1 3 (B2.1) (B2)
(B1) 2
(B4) (B0) 4 1
(C3) D
(D3) (C2) E 7 (C2.1) 7.1
(D2) (D2.1) 11 11.1
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SERVICE TRAINING
Formulas, Conversions & Specifications
Standard: 5115 Page: 7 of 10
Subject: Maximum Pin-Bushing-Bore Clearances
Mehl
661
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Formulas, Conversions & Specifications
SERVICE TRAINING
Standard: 5115 Page: 8 of 10
SAIE STANDARD Subject: Maximum Pin-Bushing-Bore Clearances
NOTE: 1. CLEARANCE OF SOLID PINS AND HOLLOW PINS TO BORE WITH KEEPER CAN NOT EXCEED THE FOLLOWING. 2. CLEARANCE BETWEEN INDIVIDUAL PINS AND BUSHINGS ARE PER CHARTS FROM PREVIOUS PAGES. PER CHART 0.005 MAX. CLEARANCE BOOM BOOM
HYDRAULIC CYLINDER or GUIDE LEVER BOOM
PER CHART 0.015 MAX. CLEARANCE TYP.
GUIDE LEVER OR BOOM
BOOM
PER CHART 0.015 MAX. CLEARANCE TYP. Prepared by: Mark Berggren Issue: 01/31/05 04/13/05
662
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Formulas, Conversions & Specifications
Standard: 5115 Page: 9 of 10
SAIE STANDARD Subject: Maximum Pin-Bushing-Bore Clearances
HOLLOW PINS MAIN COLUMN OR TURRET
BOOM #1
PER CHART
0.030 MAX. CLEARANCE TYP. HOLLOW PIN
TURRET
BOOM #1
PER CHART
HOLLOW PIN
0.030 MAX. CLEARANCE TYP.
BOOM #3
PER CHART BOOM #2
0.030 MAX. CLEARANCE TYP. HOLLOW PIN Prepared by: Mark Berggren Issue: 01/31/05 04/13/05
Approved by: Jason
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Mehl
663
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SERVICE TRAINING
Standard: 5115 Page: 10 of 10
SAIE STANDARD Subject: Maximum Pin-Bushing-Bore Clearances
GUIDE LEVER PER CHART
0.015 MAX. CLEARANCE TYP. GUIDE LINK
HYDR. CYLINDER
0.015 MAX. CLEARANCE TYP.
Prepared by: Mark Berggren Issue: 01/31/05 04/13/05
664
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Formulas, Conversions & Specifications
Nozzle Chart
MALE to MALE AR TYPE
MALE to FEMALE REDS TYPE
FEMALE to FEMALE
NOZZLE SCREW
ID NUMBER
ORIFICE SIZE (MM)
10067689
1.2
10010117
0.7
10078594
0.8
10010119
LETTER CODE
EY NUMBER
THREADS & FITTING SIZES
F
N.O.F.
R1/4" x 12 mm
A
EV 302 003
R1/2" x 12 mm
G
EV 302 003
R1/2" x 12 mm
1.0
B
EV 302 003
R1/2" x 12 mm
10139911
1.1
H
EV 302 003
R1/2" x 12 mm
10077812
1.2
F
EV 302 003
R1/2" x 12 mm
10010120
1.3
C
EV 302 003
R1/2" x 12 mm
10139112
1.4
P
EV 302 003
R1/2" x 12 mm
10014925
1.5
I
EV 302 003
R1/2" x 12 mm
10010122
1.7
D
EV 302 003
R1/2" x 12 mm
10010276
2.0
E
EV 302 003
R1/2" x 12 mm
10012077
1.2
F
EV 302 001
R1/2" x 16 mm
10012080
1.3
C
EV 302 001
R1/2" x 16 mm
10033578
1.5
I
EV 302 001
R1/2" x 16 mm
10012079
1.7
D
EV 302 001
R1/2" x 16 mm
10012078
2.0
E
EV 302 001
R1/2" x 16 mm
ID NUMBER
ORIFICE SIZE (MM)
LETTER CODE
EY NUMBER
THREADS & FITTING SIZES
10077553
0.4
M
EV 302 000
R3/8" x R3/8"
10077555
0.55
N
EV 302 000
R3/8" x R3/8"
10012075
0.7
A
EV 302 000
R3/8" x R3/8"
10012083
0.8
G
EV 302 000
R3/8" x R3/8"
10012086
1.0
B
EV 302 000
R3/8" x R3/8"
10012259
1.1
H
EV 302 000
R3/8" x R3/8"
10012084
1.2
F
EV 302 000
R3/8" x R3/8"
10012087
1.3
C
EV 302 000
R3/8" x R3/8"
10041326
1.4
P
EV 302 000
R3/8" x R3/8"
10041325
1.5
I
EV 302 000
R3/8" x R3/8"
10012088
1.7
D
EV 302 000
R3/8" x R3/8"
10100230
2.5
S
EV 302 000
R3/8" x R3/8"
ID NUMBER
ORIFICE SIZE (MM)
LETTER CODE
EY NUMBER
THREADS & FITTING SIZES
10013886
0.7
A
EV 302 004
R3/8" x R3/8"
10033540
0.8
G
EV 302 004
R3/8" x R3/8"
10037858
0.9
K
EV 302 004
R3/8" x R3/8"
10034181
1.0
B
EV 302 004
R3/8" x R3/8"
10033541
1.1
H
EV 302 004
R3/8" x R3/8"
10033543
1.3
C
EV 302 004
R3/8" x R3/8"
10037859
1.8
L
EV 302 004
R3/8" x R3/8"
ID NUMBER
ORIFICE SIZE (MM)
LETTER CODE
EY NUMBER
THREADS & FITTING SIZES
10077811
1.2
F
N.O.F.
HD 44 X 12
10077806
1.5
I
N.O.F.
HD 44 X 12 S0017.eps
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Formulas, Conversions & Specifications
Boom Times/Without Weights Type Boom
Boom #1 Up/Down 90 Degrees
Boom #2 Up/Down ( ) Degrees
Boom #3 Boom #4 Up/Down *180 Up/Down Degrees *180 Degrees
Boom #5 Slewing Right & Up/Down *90 Left 90 Degrees Degrees
Front Outrigger Extension In/Out
Rear Outrigger Extension In/Out
Outrigger Slewing In/Out N/A
KVM 17
58/52
30/22 (90¡)
37/25 *(180¡)
N/A
N/A
35
N/A
N/A
KVM 23
52/72
60/74 (180¡)
43/46
N/A
N/A
23
N/A
N/A
N/A
KVM 23-4H
54/65
43/40 (90¡)
27/30 *(90¡)
26/34 *(90¡)
N/A
27
9/14
N/A
N/A
KVM 24-4
50/59
36/35 (90¡)
26/36 *(90¡)
24/33 *(90¡)
N/A
29
9/14
N/A
N/A
24-4 Prop. (Apitech)
53/60
48/43 (90¡)
27/33 *(90¡)
22/31 *(90¡)
N/A
35
14/27
N/A
N/A
KVM 26-4
54/65
43/40 (90¡)
27/36 *(90¡)
26/34 *(90¡)
N/A
27
9/14
N/A
N/A
26-4 Prop. (Apitech)
50/64
45/43 (90¡)
53/68
45/61
N/A
33
12/20
N/A
N/A
KVM 26 Meter
55/70
69/77 (180¡)
45/60
N/A
N/A
27
9/14
N/A
N/A
KVM 28
65/62
62/67 (180¡)
40/48
N/A
N/A
28
N/A
N/A
N/A
KVM 28X
65/58
43/42 (90¡)
41/51
N/A
N/A
28
13/22
N/A
N/A
KVM 28X (Apitech)
53/60
74/78 (180¡)
44/46
N/A
N/A
34
13/22
N/A
N/A
S 28-4 H
50/50
35/35 (90¡)
50/50
25/25
N/A
40
13/26
N/A
N/A
KVM 31
81/79
75/85 (180¡)
47/51
N/A
N/A
28
N/A
N/A
S 31 HT
70/70
33/33 (90¡)
43/43
23/23
N/A
43
12/23
8/12
KVM 32
94/90
63/54 (90¡)
75/70
40/46
N/A
30
7/12
7/12
8/14
KVM 32XL
Black & White or Proportional KVM 34X Standard Outrigger System KVM 34X Regenerative Outrigger System
76/73
63/54 (90¡)
75/70
40/46
N/A
43
13/21
8/10
N/A
63/63
46/46 (90¡)
62/62
31/31
N/A
35
12/23
8/12
N/A
63/63
46/46 (90¡)
62/62
31/31
N/A
35
12/13
6/6
N/A
KVM 36 with 3 SPD.
65/92
50/61 (90¡)
70/105
31/75
N/A
6/6
6/6
22/15
KVM 36 Prop.
73/75
48/47 (90¡)
55/63
39/44
N/A
45
8/10
8/10
17/25
36X Prop.(Rexroth)
80/78
49/47 (90¡)
59/63
47/52
N/A
49
8/10
8/10
N/A
36X Prop.(Apitech)
80/95
49/47 (90¡)
59/65
47/52
N/A
60
8/10
8/10
N/A
S 36 RZ
70/70
50/50 (90¡)
70/70
20/20
N/A
50
10/10
10/10
N/A
KVM 39 X
80/80
60/60 (90¡)
75/75
50/50
N/A
60
15/12
7/6
N/A
S 41 SX
80/80
60/60 (90¡)
80/80
50/50
N/A
60
10/10
7/8
N/A
KVM 42
75/80
68/70 (90¡)
76/79
51/53
N/A
70
11/19
11/19
17/30
KVM 42 with 2 SPD.
75/80
68/70 (90¡)
76/79
51/53
N/A
10/18
10/18
16/28
42 Prop. (Rexroth)
76/80
52/61 (90¡)
71/76
60/61
N/A
60
10/18
10/18
16/28
42 Prop. (Apitech)
80/90
60/60 (90¡)
80/83
55/64
N/A
65
10/18
10/18
16/28
S 45/47 SX
90/95
70/70 (90¡)
90/90
60/60
N/A
70
12/12
N/A
8/7
KVM 52
76/90
60/67 (90¡)
66/76
81/75
N/A
82
17/26
Front Slewing
Rear Slewing
S 52 SX
105/105
90/90 (90¡)
65/65
40/40
20/20
85
25/25
23/37 N/A Front Slewing
KVM 55
110/110
90/90 (90¡)
120/120
70/70
N/A
95
17/26
S 58 SX
120/120
95/95 (90¡)
120/120
65/65
N/A
90
25/25
N/A
S 61 SX
130/130
105/105 (90¡)
135/135
70/70
N/A
100
25/25
N/A
Oil must be at 40¡ - 50¡ Celsius before testing. Times are without weights. Times are considered within specifications at +/- 5 seconds.
666
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N/A #1 Boom Telescopic In / Out 40/50
6/10 Rear Slewing
17/17 Rear Slewing
6/10 Rear Slewing
17/17 Rear Slewing
17/17
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Formulas, Conversions & Specifications
Boom Pressures & Nozzle Chart Size Hydraulic Valve Pressure Settings (BAR) BOOM SIZE
32XL 32XL (B&W)
(proportional)
32M
31M
(proportional)
28X
28X (B&W)
320 290 350 140 280 15 30
320 290 350 140 280 15 30
28M 26M (proportional) 26-4 26-4 24-4 23-4H 23M 17M (B&W) (proportional)
FUNCTION DumpValve/E-Stop Boom Regulator Handvalve Relief Downside Relief OUTRIGGER PRETENSION Pretension Relief Piston Side Relief
300 140 280 6 (air)
310 140 320 5.5
280 140 200 5.5
280 140 300 5.5
290 140 290 5.5
250 290 330 140 280 15 30
250 290 140 280 5-7 30
320 290 350 140 280 15 30
350 280 140 280 5-7
260 140 260 5.5
280 170 280 5-7
Boom Holding Valve Relief Settings (BAR) FUNCTION Sec. 1 Piston Side Sec. 1 Rod Side
320 320
400 320
400 300
400 300
320 320
320 320
Sec. 2 Piston Side Sec. 2 Rod Side
320 320
320 320
300 300
300 300
320 320
320 320
Sec. 3 Piston Side Sec. 3 Rod Side
320 320
320 320
300 300
300 300
320 320
320 320
Sec. 4 Piston Side Sec. 4 Rod Side
320 320
320 320
300 300
320 320
320 320
320 300
320 320
270 270
300 300
300 300
270 270
320 300
320 320
270 270
300 300
300 300
270 270
320 320
270 270
300 300
320 320
270 270
300 300
300 300
270 270
320 320
320 320
270 270
300 300
300 300
320 320
320 320
Boom Circuit Nozzle Sizes are in mm / "T" after size denotes a Throttle Check FUNCTION 1.9T 1.5T 1.5 1.3
Sec. 1 Piston Side Sec. 1 Rod Side
1.9T 1.5
1.9T 1.5
2.0T 1.7
1.9T 1.5
Sec. 2 Piston Side Sec. 2 Rod Side
1.7 1.3
1.7 1.3
1.7 1.3
1.1 1.5
1.7 1.3
1.4 1.1
1.0 1.2
1.0 1.3
1.3 1.0
1.1 0.9
Sec. 3 Piston Side Sec. 3 Rod Side
1.4 1.1
1.4 1.1
1.3 1.0
0.8 1.1
1.3 1.0
1.1 0.9
1.1 1.5
1.2 1.7
1.0 0.7
0.9 0.5
Sec. 4 Piston Side Sec. 4 Rod Side
1.1 0.8
1.1 0.8
1.0
0.7
Tower Slewing
1.3
1.9T 1.8T 1.7 1.4
1.1 0.8
1.1 0.9
1.2 1.0 1.2
1.3
1.3
1.2
1.3
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Boom Pressures & Nozzle Chart Size Hydraulic Valve Pressure Settings (BAR) BOOM SIZE
58SX 52M 55M
45SX 42M 42M 47SX (proportional) (B&W)
39X
36X 36LW
36M
34X
31HT
320 310 330 80 280 25 34
330 300 350 140 280 15 30
330 310 340
300
330 300 350 140 280 15 30
350 310 350 140 280 15 30
FUNCTION DumpValve/E-Stop Boom Regulator Handvalve Relief Downside Relief OUTRIGGER PRETENSION Pretension Relief Piston Side Relief
350 310 360
360 320 350
330 310 350
350 20
150 35 50
300 35 40 230
320 290 330 80 280 25 34
280 25 40
330 310 330 80 160 25 40
280 80 200 5.5
Boom Holding Valve Relief Settings (BAR) FUNCTION Extend Piston Side Extend Rod Side Sec. 1 Piston Side 250 Sec. 1 Rod Side 310
320 350
330 330
400 300
400 320
330 320
350 320
350 320
400 300
320 180
150 240 320 180
Sec. 2 Piston Side Sec. 2 Rod Side
330 320
320 320
310 310
300 300
320 320
320 330
320 320
320 320
300 300
320 310
270 290
Sec. 3 Piston Side Sec. 3 Rod Side
260 320
320 350
320 320
300 300
320 320
310 330
320 320
320 320
300 300
280 320
230 320
Sec. 4 Piston Side Sec. 4 Rod Side
240 320
260 350
260 300
300 300
320 320
320 330
320 320
320 320
300 300
290 320
220 300
Boom Circuit Nozzle Sizes are in mm / "T" after size denotes a Throttle Check FUNCTION Sec. 1 Piston Side Sec. 1 Rod Side
1.4T 1.4T
Sec. 2 Piston Side Sec. 2 Rod Side
1.8T 1.3
Sec. 3 Piston Side Sec. 3 Rod Side
1.3T 1.2
Sec. 4 Piston Side Sec. 4 Rod Side
0.9T 0.8
Tower Slewing
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Rotek Bearing Clearance Instructions - SAIE - 5114 Standard: 5114 Page: 1 of 9
SAIE STANDARD Subject: Slewing Bearing & Drive Gear Inspection
When doing the boom inspections on slew bearing units, the drive spur gear and the turret slewing bearing gear must be inspected for wear and/or galling, tipping, and gear lash as outlined. The drive gear must all be inspected by axial and radial movement. Slewing Bearing Tipping Clearance 1. Before inspecting the drive spur. Gear and turret slewing bearing, you must first secure the vehicle on which you will be working, make sure that you are on solid ground and there is plenty of clearance around the vehicle.
Outrigger Support
Warning! Allow yourself enough room to move the boom without causing danger to yourself or others. Set up the outriggers for support, the same as you would for any job, use carpenters level or the units bubble level to set the base both longitudinally and laterally level. 2. Remove the slewing bearing and drive gear shroud. To do this, you must remove four bolts from the underside of the shroud and two bolts holding the two havles together.
Shroud
Bolts connecting the two shroud halves
Warning! While the shroud is removed from the gears, there is the potential danger of injury or dismemberment to yourself or others. Use caution at all times and beware of the potential hazards. Visually inspect both the drive spur gear and the turret slewing gear teeth for wear and/or galling, any metal shavings or slivers are an indication of excessive teeth wear caused by too swall a gear lash or excessive bearing wear.
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Standard: 5114 Page: 2 of 9
SAIE STANDARD Subject: Slewing Bearing & Drive Gear Inspection
3. Raise the boom in a straight, vertical position. Note: Steady the boom, there should be no movement in the boom while tacking the measuremens, or it will result in a false reading. Extends booms as shown.
4. Once the boom is steady, locate point “A” on the underside of the slewing bearing gear. This will be the starting point from which you will determine the amount of tipping clearance on the slewing bearing. Mount dial indicator as necessary.
Boom Direction
Point "A" (Leave no gap)
The location of point “A” must be on the opposite side from the direction the boom will be lowered. 5. Rock the boom back and forth to determine its balancing point. Then tilt the boom slightly opposite the measurement side so that the boom will not rock. Make sure that before you lower the boom, opposite measurement side, that there is no gap between the underside of the slewing bearing and the dial indicator which is in ful contact
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Standard: 5114 Page: 3 of 9
SAIE STANDARD Subject: Slewing Bearing & Drive Gear Inspection
Neutral Position 5-10˚ Set dial indicator at zero
Dial indicator will move fast when indicator slows down to slow movement. Take reading approximately 5-10˚ then divide dial indicator reading by 2 and compare to maximum tipping clearances listed below.
Pressure #1 out
2˚ to 3˚ Maximum
• • • •
Unfold the boom as shown above KVM 36 STD and 42 LW and HV must be positioned as shown with 3˚ maximum tilt by raising the rear outriggers. KVM 32XL, 31 EZ, 34X, 36X, 39X, 41SX, 45SX, 47SX, 52, 52 EXT & 55, do not require the 3˚ tilt (can be level becuase boom assembly can move over neutral position). It is only required to measure in the one position shown.
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Standard: 5114 Page: 4 of 9
SAIE STANDARD Subject: Slewing Bearing & Drive Gear Inspection
For Overhead Roll n Fold - Tipping Clearances 1. Rock the boom back and forth to determine it’s balancing point. 2. Then using a protractor, position the #1 boom over top dead center toward the cab at 10˚ 3. Zero out dial indicator at point “A” 4. The position the #1 boom over top dead center toward the hopper at 10˚ at this position the reading on dial indicator is divided by 2 and compare to maximum tipping clearance chart below. Neutral Position 10˚
10˚
Table 1: Maximum Tipping Clearances Above Initial Clearance KVM 32XL
.059
+.010 = .069
S 41 SX
.025
+.010 = .035
KVM 34X
.059
+.010 = .069
KVM 42LW
.025
+.010 = .035
KVM 36X
.074
+.010 = .084
KVM 42HW
.025
+.010 = .035
KVM 36
.019
+.010 = .029
S 45/47 SX
.074
+.010 = .084
KVM 39X
.074
+.010 = .084
KVM 52, 52 EXT
.078
+.010 = .088
KVM 31EZ
.059
+.010 = .069
KVM 55
.078
+.010 = .088
S 58/61SX
.078
+.010 = .088
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Standard: 5114 Page: 5 of 9
SAIE STANDARD Subject: Slewing Bearing & Drive Gear Inspection
Gear Lash / Axial Movement Inspection 1. Determine the maximum and minimum clearance between the drive spur gear teeth and the turret slewing bearing teeth. the minimum clearance, should be found in the tooth grooves marked in color or stamped “H”. Note: If the markings are not visible, rotate the boom 360˚ in small increments and measure the clearance (gap) until the minimum and maximum clearances have been located. Mark the minimum clearance gear points on the slewing bearing teeth with an “H” stamp. 2. Raise the boom in the verticle position (neutral) as shown.
3. Once the boom is steady, use a pry bar and rotate the drive gear just enough so that the side of the drive gear tooth is in solid contact with the side of the accompanying gear tooth. this will leave the total clearance (gap) on the opposite side of the drive gear tooth.
Total Gap
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Standard: 5114 Page: 6 of 9
SAIE STANDARD Subject: Slewing Bearing & Drive Gear Inspection
4. Check at thigh point using feeler gauge, measure the gap between the gear teeth. This is the gear lash clearance.
GEAR LASH CLEARANCE
MINIMUM GEAR LASH IS 0.008" MINIMUM GEAR LASH IS 0.040"
5. Using a pry bar and dial indicator, the axial movement shall be measured by prying up the spur gear. Maximum axial movement is 0.040”.
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Formulas, Conversions & Specifications Standard: 5114 Page: 7 of 9
SAIE STANDARD Subject: Slewing Bearing & Drive Gear Inspection
6. Once inspection is complete, and the gear lash is satisfactory, replace the slewing bearing and drive gear shroud.
Shroud
Bolts connecting the two shroud halves
Warning! To prevent any danger to yourself or others and to protect the gears from damage from any foreigh objects or debris, replace the protective shrouding for both the slewing gear and drive gear.
Drive Gear Shroud
Shroud Bolts
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Standard: 5114 Page: 8 of 9
SAIE STANDARD Subject: Slewing Bearing & Drive Gear Inspection
Gear Lash Adjustment 1. To adjust the gear lash, you must first support the drive gear from above. Screw two 10mm eye bolts Schwing part #10014781 (997-126-001-013) into the top of the drive gear, and support it with chain and hoist. remove all the outer bolts from the underside, holding the gear housing to the tower weldment. Note: Check hydraulic supply tubes or hoses for adequate movement. Remove bolts after chain and hoist are in place
2. The drive gear housing was designed eccentrically, so depending on the direction of rotation, and the eccentric position when installed, the gear lash will either increase or decrease. determine the proper rotation direction before continuing. Decrease
Increase
Increase
Right of Center
Decrease
Left of Center
3. Lower the drive gear enough to rotate it at least one bolt hole position, which will amount to approximately .017” gear lash depending on the location of eccentricity and amount of tolerance desired. Lower hoist
Note: Once the drive gear has been rotated, the supply tubes on the 42M will not fit becuase of their alignment features. Replace the three tubes with three hydraulic hoses, Schwing part#10050169 (944-070-308-100). The 36M may not need any replacement hoses, unless the tower weldment interfers with the tubing while rotating the gear housing. In this case, use one hydraulic hose, Schwing part #10050168 (994-070308-080).
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Standard: 5114 Page: 9 of 9
SAIE STANDARD Subject: Slewing Bearing & Drive Gear Inspection
4. Once the drive gear has been rotated, reinstall 4 of the gear housing bolts in 90˚ increments and re-connect the hydraulic supply tubes and hoses. return to “Gear Lash inspection.” If the clearance is within the .012 to eye bolt and chain hoist, and continue with step 5. However, if the gear lash still requires further adjustment, repeat adjustment until it is within the allowed clarance. 5. Once the inspection is complete, and the gear lash is satisfactory, replace the slew bearing and drive gear shroud.
Maximum Gear Lash is 0.040” Minimum is 0.008”
90˚ 90˚
90˚ 90˚
Warning!
Shroud
To prevent any danger to yourself or others and to protect the gears from damage from any foreign objects or debris, replace the protective shrouding for both the slewing gear and drive gear.
Bolts connecting the two shroud halves
Drive Gear Shroud
Shroud Bolts
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Special Tools
Special Tools
Hydraulic Oil Filter Cart
Hydraulic Trouble Shooting Kits
Prevent premature failure with this filter cart from Schwing America. This filter cart moves easily around your shop on pneumatic tires and operates on 120-volt power. Dule elements (included) filter synthetic and oil based fluids at up to 8 GPM
These kits contain a 0-600 Bar pressure gauge, a 0-40 Bar pressure gauge, plus all the necessary fittings, locking plugs, manitrol valves, and hoses to plumb the gauges into any hydraulic circuit on the unit. These kits include the heavy duty foam lied carrying case
S0038.eps
Trouble Shooting Kit for All BPA and BPL Models except BPA 750 • Part # .......................................................30308553
S0179.eps
H.P. Portable Filtration Cart • Part #........................................................30380898 Replacement Filter Element • Part #........................................................30380857
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Special Tools
Flow Meters and Accesories
Accessories:
AC/DC Power Supply • Part # .......................................................30314788
Flow Meter Y223 Model HT200
Blow-Out Disc • Schwing Part#..........................................30314789 Adapter Flange (SAE to BSP) • Schwing Part#..........................................30303384 Calibrator • Schwing Part#..........................................30328467 Schwing America offers the flow meter with or without the calibrator. Please contact our Spare Parts Department for current pricing.
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Flow Meter (only) • Part #........................................................30314787 Specifications:
Maximum Flow (G.P.M.).........................................200 Flow Ranges-High Scale: U.S.G.P.M .......................................................... 25-200 t/min. ................................................................ 100-750 Flow Ranges-Low Scale: U.S.G.P.M .............................................................. 5-40 t/min ................................................................... 20-150 Maximum Operating Pressure ........345 Bar (5000 psi) Temperature Scale Range ... 100°-250° F (40°-120° C) Port Sizes ................................. 11/2" SAE (split flange) Weight ................................................. 30 lbs. (13.6kg) Dimensions: Length ............................................ 15 7/8" (403.47mm) Width.............................................. 13 1/4" (336.55mm) Height............................................... 6 3/4" (171.45mm)
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Material Cylinder Alignment Tool Schwing America offers a tool which aligns the material cylinders after rotation or replacement has been completed. To determine whick tool your
Special Tools
machine requires, measure the O.D. of your differential rod and the I.D. of the material cylinders installed. To order one of those tools, find the proper tool from the following chart, and contact our Spare Parts Department.
Rod Diameter
Material Cylinder Diameter
Ordering Chart Rod Cylinder Item Diameter Diameter Number
Pumpkit Model Number
50 mm
150 mm
30379547
450, 500, BP 750-15
50 mm
180 mm
30339165
WP 750-18, WP 1000-18, BP 1000-18
55 mm
150 mm
30379532
250-15
55 mm
180 mm
30379533
350-18, 500-18, 650-18
63 mm
150 mm
30379534
650-15
63 mm
180 mm
30379535
580-18, 600-18, 650-18, 601-18, 900-18, 901D-18
63 mm
200 mm
30379536
800-20, 801-20, 901-20
80 mm
150 mm
30379541
3000-15, 3001-15, 5000-15
80 mm
150 mm
30379544
5000-15
80 mm
180 mm
30379548
900-18, 2000-18, 3000-18, 3001-18, 4000-18, 5000-18,
80 mm
200 mm
30379542
900-20, 1200-20, 1201-20, 2000-20, 3000-20, 3001-20, 4000-20, 5000-20, 8000-20, 2020
80 mm
230 mm
30379543
1200-23, 1201-23,2000-23, 4000-23, 5000-23, 8000-23, 2023
85 mm
180 mm
30379538
4000-18
90 mm
180 mm
30379549
8000-18HPR, 4000-18
85 mm
200 mm
30379540
1001-20
90 mm
200 mm
30379550
4000-20
85 mm
230 mm
30379539
1001-23, 4000-23
85 mm
250 mm
30364756
2525
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Special Tools
Piston Installation Tools for Differential Cylinders
completely installed. Attempting to install the piston without this tool can cause damage to the piston rings.
Because the differential cylinders are designed with a counter bore, it is extremely difficult to install the differential piston while compressing the piston rings at the same time. These piston intalling tools have a taper at the mouth of tool to help compress the piston rings and keep them compressed untill the piston is
To obtain any of these tools, find the proper sized tool for your application from the chart below, and contact our Spare Parts Department to place your order.
Ordering Chart Piston Diameter
Item Number
Description
70 mm 80 mm 90 mm 120 mm 125 mm 130 mm 150 mm
10061734 10061732 10061733 10061737 10061736 10061735 10103894
PISTON INSTALLING TOOL 70MM PISTON INSTALLING TOOL 80MM PISTON INSTALLING TOOL 90MM PISTON INSTALLING TOOL 120MM PISTON INSTALLING TOOL 125MM PISTON INSTALLING TOOL 130MM PISTON INSTALLING TOOL 150MM S0045.eps
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Special Tools
Gland Packing Installation Tools for Differential Cylinders
pushed into the mouth of the guide bushing and then pushed completely into position by using the packing tool as a slide-hammer.
Important! Reference SAIE 5221 regarding proper shimming, in "Rock Valve" section in this Service Manual.
To do this, first * lightly lubricate the inside radius of the packing tool to avoid scratching the rod surface. Then gently slide the packing tool along the rod surface, drawing away from the seal and then back to the seal; again and again tapping it a little further in with each slide until the packing section is completely home.
The gland packing tools are designed to aid in installing the gland packing seal kit (chevrons) into the guide bushing of the diff cylinder. The packing tool has a "V" groove machined into one end to fit the shape of the individual seals of the packing set. The guide tool is beveled on one end forcing the hard edge of the seal section to compress thus providing easy installation into the bushing. To properly use these tools together, first * lightly lubricate the inside radius of the guide tool and also the rod surface. Then insert the guide tool onto the rod with beveled edge facing outward. Now take one section of the packing set and slide it onto the piston rod all the way to the beveled edge of the guide tool. Slide the packing tool onto the rod, with "V" groove inward mating the "V" groove with the curvature of the seal section. Using a rubber mallet, softly strike the flat end of the packing tool to start the seal section into the guide tool. With this seal section inside the guide tool, check to be sure the guide tool is resting flush with the guide bushing of the diff cylinder. Now the section can be
NOTE: do not attempt to insert all seal sections at the same time. Rather, remove both tools from the rod and check the seal section you just installed to be sure it did not catch on the mouth of the guide bushing and roll inside-out. If seal appears correctly installed, repeat this exact procedure with the remaining seal sections, * but do not reapply any more lubricant. * To avoid trapping air or lubricant between the packing sections, we recommend using a silicone spray lubricant, if oil is used, be careful not to over-lubricate any surfaces or seal sections. To obtain any of these tools, find the proper sized tool for your application from the following chart, and contact our Spare Parts Department to place your order.
PACKING TOOL
GUIDE TOOL
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Ordering Chart Bushing Diameter of Differential Cylinder
Rod Diameter of Differential Cylinder
Item Number Guide Tool
90 mm 125 mm 120 mm 150 mm 120 mm
50 mm 80 mm 80 mm 90 mm 85 mm
30378922 30378923 30378924 30378925 30356740
Service Manual
Item Number Packing Tool 30378926 30378927 30378927 30378929 30356741
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Special Tools
Seal Replacement Tools
Bushing Installation Tool
Piston Seal Guide Tool
Rock Shaft Bushing Installation Tool
This tool is designed to aid in installing the piston seal onto the piston rod of the Rock Valve Shifting Cylinder. The tool allows the piston seal to stretch uniformly to the diameter size of the piston and then be easily slid into the groove of the piston rod.
This 4 piece tool aids in removal and installation of the brass bushings that are pressed into the rock valve housing and housing cover. This tool works for both the short rock and long rock models. This tool prevents damage to the bushings by eliminating any need to pound the bushings into place. With the rock housing cover bolted into place, a bushing is placed between one of the tool’s plates and the rock housing. The tool’s other plate is placed onto the tool’s threaded rod between the opposite end of the rock housing and the tool’s threaded nut. The threaded nut is then slowly wrenched onto the rod, drawing the brass bushing into its place in the rock housing.
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Piston Seal Guide Tool • Schwing Part#..........................................30313746 • Schwing Part# (150mm)..........................30356740
Piston Seal Form Tool This tool, much like the piston installation tool for differential cylinders, has a taper at the mouth to compress (form) the piston seal and keep it formed until the piston is completely installed into the rock shifting cylinder barrel. The tool prevents the piston seal from damage due to rolling.
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Piston Seal Form Tool • Schwing Part#..........................................30313745 • Schwing Part# (150mm)..........................30356741
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Tool, Installation, 95 mm Rock Shaft Bushing • Schwing Part#..........................................10013417
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Accumulator Charging Kit
Special Tools
Technition Support Kit
100 1
50 150 100 0 20 00 0 25 00 0
50
50
30
0
35
00
20 0
00
25 0
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Accumulator Charging Kit • Schwing Part# .........................................30355436
Adjustment Meters for Analog Proportional Cards Analog Adjustment Meter
O-Ring 13 X 2 10061730
O-Ring 25.12 X 1.78 10000442
O-Ring 37.69 X 3.53 10166320
O-Ring 21 X 26 10004056
O-Ring 12 X 5 10000205
O-Ring 22 X 2.5 10061728
O-Ring 34 X 2.5 10077601
O-Ring - 48 X 55 10004053 O-Ring - 56.74 X 3.53 10118767
O-Ring 10.77 X 2.62 10000175
Flat Ring 19.5 X 24 X 1 10002827
O-Ring 32.93 X 3.53 10000497
O-Ring 52 X 4 10000721
O-Ring 9.19 X 2.62 10000155
O-Ring 18.72 X 2.62 10000361
O-Ring 32.92 X 3.53 10068689
O-Ring 47.2 X 3.53 10015089
O-Ring 9X2 10016731
O-Ring 17 X 2.5 10061729
O-Ring 32 X 2.5 10000489
O-Ring 44 X 3 10000677
O-Ring 8.73 X 1.78 10000151
O-Ring 15.54 X 2.62 10067850
O-Ring 27 X 2.5 10077249
O-Ring 38 X 4 10000652
Drawer 1 Toggle Switch ON/OFF/ON 1TL 1-8 30315771
Toggle Switch ON/ON 1TL 1-3 30315770
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Adjusting Device • Schwing Part# .........................................30321192
Toggle Switch ON/ON 2TL 1-3 30341455
Corrosion Inhibitor 30346014
Press Out Tool - Harting 10083751
Crimp Pin - 0.5 MM 10022656 Toggle Switch ON/OFF/ON 2TL 1-7 Crimp Pin - 1.5 MM 30333041 10013423
Toggle Switch ON/OFF/ON 1TL 1-1 30314009
Toggle Switch ON/OFF/ON Crimp Pin - 0.5 MM 1TL 1-7 10013422 30324217
Toggle Switch OFF/ON 1TL 1-2 30333040
Toggle Switch ON/ON 4TL 1-3 30324215
Crimp Bushing - 0.5 MM 10013421
Fuse, 80 AMP 30348131
E-stop Contact 303038211
Crimp Bushing - 1.5 MM 10013420
Press Out Tool - Burndy 10028823
Drawer 2 Technition Support Cabinet • Schwing Part#..........................................30366963
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Special Tools
Electrical Tools and Accessories Schwing America Inc. is offering an Electrical Service Kit for the repair of electrical connections in cables and connectors. This kit enables a wide range of repairs to Schwing electrical equipment. The kit includes crimp style pin and bushing contacts for the BURNDY brand electrical connectors as well as the HARTING brand
connectors. The kit includes an ejection tool for removing and inserting the contacts into the connectors. The kit also includes a crimping pliers with interchangeable jaw inserts that adapt to both styles of connector contacts. All the following pieces of this kit are contained in a painted metal box with a plastic divider tray and may be ordered separately or as a complete kit.
Part Description Service-Kit (complete)
Item #
686
Qty
Item Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10083745
Part Description
Item Number
1
1
Crimping tool w/exchangeable inserts . . . . . . . . . . . . . . . . . . . . 10083746
2
1
Insert for "Burndy" contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10083747
3
1
Insert for "Harting" contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10083748
4
1
Insert for insulated pin and socket connections . . . . . . . . . . . . . 10083749
5
1
Insert for un-insulated pin and socket connections. . . . . . . . . . . 10083750
6
1
Ejection tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10083751
7
25
Contact (crimp style pin), 0.32-0.52 qmm. . . . . . . . . . . . . . . . . . 10030557
8
25
Contact (crimp style bushing), 0.32-0.52 qmm . . . . . . . . . . . . . . 10030558
9
5
Contact (crimp style pin), 0.52-1.5 qmm. . . . . . . . . . . . . . . . . . . 10027381
10
5
Contact (crimp style bushing), 0.5-1.52 qmm . . . . . . . . . . . . . . . 10027382
11
25
Contact (crimp style pin), 0.5 qmm . . . . . . . . . . . . . . . . . . . . . . . 10013422
12
25
Contact (crimp style bushing), 0.5 qmm . . . . . . . . . . . . . . . . . . . 10013421
13
5
Contact (crimp style pin), 1.5 qmm . . . . . . . . . . . . . . . . . . . . . . . 10013423
14
5
Contact (crimp style bushing), 1.5 qmm . . . . . . . . . . . . . . . . . . . 10013420
15
2
Connector guide pin, M3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10013424
16
2
Connector guide bushing), M3 . . . . . . . . . . . . . . . . . . . . . . . . . . 10013425
17
10
Blade terminal, female (RED), 6.3 x 1.0 qmm . . . . . . . . . . . . . . 10007591
18
10
Blade terminal, female (BLUE), 6.3 x 2.5 qmm . . . . . . . . . . . . . 10007297
19
10
Blade terminal, female (RED), 2.8 x 0.5 qmm . . . . . . . . . . . . . . 1000772
20
10
Butt connector (RED), 0.5-1.0 qmm . . . . . . . . . . . . . . . . . . . . . . 10013447
21
10
Butt connector (BLUE), 1.0-2.5 qmm. . . . . . . . . . . . . . . . . . . . . 10012176
22
10
Ring terminal (RED) M4, 0.5-1.0 qmm . . . . . . . . . . . . . . . . . . . . 10007299
23
10
Ring terminal (RED) M6, 0.5-1.0 qmm . . . . . . . . . . . . . . . . . . . . 10022491
24
10
Ring terminal (BLUE) M4, 1.0-2.5 qmm . . . . . . . . . . . . . . . . . . . 10007301
25
10
Ring terminal (BLUE) M6, 1.0-2.5 qmm . . . . . . . . . . . . . . . . . . . 10007295
26
100
Conductor end sleeve (WHITE), 0.75 qmm . . . . . . . . . . . . . . . . 10012648
27
100
Conductor end sleeve (YELLOW), 1.0 qmm . . . . . . . . . . . . . . . 10012917
28
100
Conductor end sleeve (RED), 1.5 qmm . . . . . . . . . . . . . . . . . . . 10012649
29
100
Conductor end sleeve (BLUE), 2.5 qmm . . . . . . . . . . . . . . . . . . 10012650
30
10
Blade terminal, female, 6.3 x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 10014953
31
10
Blade terminal, male, 6.3 x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10009698
32
10
Blade terminal, male, 6.3 x 2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . 10009701
33
10
Blade terminal, male, 2.8 x 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . Not on File
34
1
Steel box with higged cover and divider tray. . . . . . . . . . . . . . . . 10083752
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Spanner Socket Tools for Boom Pins The spanner socket tools are designed to remove and install the round, notched nuts which thread onto certain boom pins. These handy sockets prolong the
Special Tools
life of the boom pin nuts by preventing the need to hammer the nuts on and off with a drift. To order these tools, find the sizes for your machine from the chart below, and contact the Schwing America Spare Parts Department with the corresponding part number:
Ordering Chart Boom Pin Nut
Item Number
Tool Description
66 mm/2.596" 99 mm/3.879" 69 mm/2.702" 95 mm/3.745" 110 mm/4.350" 135 mm/5.334"
30331885 30331886 30331887 30334225 30331884 30331883
FOUR LUG NUT SOCKET (3/4" Drive) FOUR LUG NUT SOCKET (3/4" Drive) SIX LUG NUT SOCKET (3/4" Drive) SIX LUG NUT SOCKET (3/4" Drive) SIX LUG NUT SOCKET (3/4" Drive) SIX LUG NUT SOCKET (3/4" Drive)
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Special Tools
Truck Engine Tools
Micellaneous Tools
Pro-Link 9000
Whip Hose and Fittings
The Pro-Link 9000 is a microprocessor-based test instrument designed to tap into the vehicle’s on-board computer. It’s programmed to communicate with the engine and/or transmission and ABS(Anti-lock Brake System) and provide readouts you can use for diagnostics. You have instant access to any of the vehicle’s operating data as long as the Pro-Link 9000 is connected to the vehicle.
1 or 2
3 5 4
The Pro-Link 9000 can be used on V-MacII/E-tech, Detroit Diesel, Navistar and Cummins engines, as well as CEEMAT and Allison transmissions.
POS.
1 2 3 4 5
DESCRIPTION
GAUGE (0-40 Bar) GAUGE (0-400 Bar) GAUGE CONNECTOR WHIP HOSE GAUGE PORT
PART #
10012414 10004662 10018990 10018991 10020459 S0053.eps
+
Rock Valve Cover Alignment 9 8 7
6 5
4
_ +
3 2
1 O
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• •
Schwing Part# (Small Rock valve)..........30309007 Schwing Part# (Standard Rock Valve).....30304515
For ordering information contact:
Kent-Moore Heavy Duty Division 29784 Little Mack Roseville, MI 48066-2298 1-800-328-6657 MPSI Micro Processor System, Inc. 6405 Nineteen Mile Road Sterling Heights, MI 48314 1-810-731-6410 688
Service Manual
