Service Manual

HOME

PRINT

HOME

PRINT

SCHWING SERVICE DEPARTMENT jlkjlkjlkjlkjlkjkj (651) 429-0999

OR

1-888-292-0262 OR

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

SCHWING PARTS DEPARTMENT 1-800-328-9635 OR

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

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

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

HOME

PRINT

SERVICE TRAINING

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

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

PRINT

SERVICE TRAINING

Maintenance, Lubrication Schedules, etc.

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

√

Service Manual

1

HOME

PRINT

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

√

2

Service Manual

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_________________________

HOME PRINT

SERVICE TRAINING

Maintenance, Lubrication Schedules, etc.

Operators Check list for Weekly Maintenance (Ex.)

S0167.eps

3

HOME

PRINT

SERVICE TRAINING

Maintenance, Lubrication Schedules, etc.

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

4

Service Manual

HOME

PRINT

SERVICE TRAINING

Maintenance, Lubrication Schedules, etc.

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

Service Manual

S0024.eps

5

HOME

PRINT

Maintenance, Lubrication Schedules, etc.

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

6

Service Manual

HOME

PRINT

SERVICE TRAINING

Maintenance, Lubrication Schedules, etc.

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

Service Manual

7

HOME

PRINT

Maintenance, Lubrication Schedules, etc.

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.

Service Manual

HOME

PRINT

SERVICE TRAINING

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.

Service Manual

9

HOME

PRINT

Maintenance, Lubrication Schedules, etc.

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).

SERVICE TRAINING

•

•

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

10

Service Manual

S0027.eps

HOME

PRINT

SERVICE TRAINING

Maintenance, Lubrication Schedules, etc.

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.

Service Manual

11

HOME

PRINT

Maintenance, Lubrication Schedules, etc.

SERVICE TRAINING

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.

Service Manual

HOME

PRINT

SERVICE TRAINING

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.

Service Manual

13

HOME

PRINT

Maintenance, Lubrication Schedules, etc.

SERVICE TRAINING

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

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

15

HOME

PRINT

Maintenance, Lubrication Schedules, etc.

SERVICE TRAINING

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

Service Manual

HOME

PRINT

SERVICE TRAINING

Maintenance, Lubrication Schedules, etc.

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

Service Manual

17

HOME

PRINT

Maintenance, Lubrication Schedules, etc.

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

Service Manual

S0029.eps

HOME

PRINT

SERVICE TRAINING

Maintenance, Lubrication Schedules, etc.

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

Service Manual

19

HOME

PRINT

Maintenance, Lubrication Schedules, etc.

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.

20

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

Service Manual

HOME

PRINT

SERVICE TRAINING

Maintenance, Lubrication Schedules, etc.

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

Service Manual

21

HOME

PRINT

Maintenance, Lubrication Schedules, etc.

SERVICE TRAINING

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.

HOME

PRINT

SERVICE TRAINING

Maintenance, Lubrication Schedules, etc.

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.

Service Manual

23

HOME

PRINT

Maintenance, Lubrication Schedules, etc.

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

24

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

25

HOME

PRINT

Maintenance, Lubrication Schedules, etc.

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

26

Service Manual

HOME

PRINT

SERVICE TRAINING

Maintenance, Lubrication Schedules, etc.

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

Service Manual

27

HOME

PRINT

Maintenance, Lubrication Schedules, etc.

SERVICE TRAINING

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

28

Service Manual

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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)

HOME

PRINT

SERVICE TRAINING

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

Service Manual

31

HOME

PRINT

SERVICE TRAINING

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.)

32

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

Service Manual

HOME

PRINT

SERVICE TRAINING

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.

Service Manual

33

HOME

PRINT

SERVICE TRAINING

Pumpkits

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.

34

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.

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

35

HOME

PRINT

SERVICE TRAINING

Pumpkits

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

36

Service Manual

HOME

PRINT

SERVICE TRAINING

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.

Service Manual

37

HOME

PRINT

SERVICE TRAINING

Pumpkits

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.

38

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

39

HOME

PRINT

SERVICE TRAINING

Pumpkits

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

40

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

HOME PRINT

SERVICE TRAINING

Pumpkits

Sealing Gland Replacement No.: SAIE - 5221

Date: 12-19-95

By: T.A. Rev.: D

1

of 1

41

HOME

PRINT

SERVICE TRAINING

Pumpkits

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.

42

Service Manual

HOME

PRINT

SERVICE TRAINING

Pumpkits

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.

Service Manual

43

HOME

PRINT

Pumpkits

44

SERVICE TRAINING

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

45

HOME

PRINT

SERVICE TRAINING

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

46

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

47

HOME

PRINT

SERVICE TRAINING

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.

48

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.

Service Manual

PRINT

SERVICE TRAINING

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

Service Manual

49

HOME

PRINT

SERVICE TRAINING

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

50

Service Manual

PRINT

SERVICE TRAINING

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 -

HOME

Service Manual

51

HOME

PRINT

SERVICE TRAINING

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

52

Service Manual

PRINT

SERVICE TRAINING

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

HOME

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.

Service Manual

53

HOME

PRINT

SERVICE TRAINING

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

54

Service Manual

HOME

PRINT

SERVICE TRAINING

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

55

HOME

PRINT

SERVICE TRAINING

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

56

Service Manual

HOME

PRINT

SERVICE TRAINING

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.

Service Manual

57

HOME

PRINT

SERVICE TRAINING

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

58

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

59

HOME

PRINT

SERVICE TRAINING

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.

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

61

HOME

PRINT

SERVICE TRAINING

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

62

Service Manual

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

63

HOME

PRINT

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

64

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

65

HOME

PRINT

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

66

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Service Manual

67

HOME

PRINT

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.

68

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

69

HOME

PRINT

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

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm



 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.

Service Manual

71

HOME

PRINT

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).

Service Manual

revDate

PRINT

SERVICE TRAINING

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

openclsd.eps

HOME

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

Service Manual

73

HOME

PRINT

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

74

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

Service Manual

75

HOME

PRINT

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.

76

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Service Manual

77

HOME

PRINT

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).

78

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

Service Manual

79

HOME

PRINT

Pressure Settings

80

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

Service Manual

81

HOME

PRINT

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

•E

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.

82

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

83

HOME

PRINT

Pressure Settings

84

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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)

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

85

HOME

PRINT

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.

86

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.

Service Manual

revDate

HOME

PRINT

agit.shutoff.eps

SERVICE TRAINING

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.

Service Manual

87

HOME

PRINT

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.

88

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

89

HOME

PRINT

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.

90

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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).

Service Manual

91

HOME

PRINT

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

92

Service Manual

revDate

HOME

PRINT

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).

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

93

HOME

PRINT

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.

94

Service Manual

revDate

HOME

PRINT

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

vlv

mp

/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).

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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.

Service Manual

95

HOME

PRINT

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.

Service Manual

revDate

HOME

PRINT

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

97

HOME

PRINT

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).

98

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

closed

Blckgrvs.eps

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.

Service Manual

99

HOME

PRINT

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.

100

Service Manual

revDate

HOME

PRINT

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).

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

@@@@@@@@@@@@@@@@@@@@@@@@  ;;;;;;;;;;;;;;;;;;;;;;;;  ;@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
;@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
;@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
;@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
;@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
;@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
;@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
;@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
;@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
;@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
;@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
;@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
;@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.)

Service Manual

101

HOME

PRINT

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

The with hydr aulic CLE a "ON ANIN E-W oil filte REP AY G r LAC AND PAP is equi ER flash E CAR RE-U CAR pped TRID SE IS es TRID and GE NOT temp hydr whe POS GE." erat aulic n indi SIBL light ure. oil cato E! flash Do is at r light es not repl oper whe atin g n oil ace is cold if .

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.

102

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

PS X.E -28 lve va om o ig/b

Figure 101 Boom/outrigger hand valve

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

103

HOME

PRINT

Pressure Settings

;;;;;;;;;;;;; @@@@@@@@@@@@@   @@@@@@@@@@@@@   ;;;;;;;;;;;;; @@@@@@@@@@@@@   ;;;;;;;;;;;;; @@@@@@@@@@@@@   ;;;;;;;;;;;;; @@@@@@@@@@@@@   ;;;;;;;;;;;;; @@@@@@@@@@@@@   ;;;;;;;;;;;;; @@@@@@@@@@@@@   ;;;;;;;;;;;;; @@@@@@@@@@@@@   ;;;;;;;;;;;;; @@@@@@@@@@@@@   ;;;;;;;;;;;;; @@@@@@@@@@@@@   ;;;;;;;;;;;;; @@@@@@@@@@@@@   ;;;;;;;;;;;;; WARNING

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

@@@@@@@@@@@@@@@@   ;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@   ;;;;;;;;;;;;;;;; @@@@@@@@@@@@@@@@   ;;;;;;;;;;;;;;;;

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

17bmcntl.epsL

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.

104

;;;;;;;;;;;   @@@@@@@@@@@ ;;;;;;;;;;;   @@@@@@@@@@@ ;;;;;;;;;;;   @@@@@@@@@@@ ;;;;;;;;;;;   @@@@@@@@@@@ ;;;;;;;;;;;   @@@@@@@@@@@ ;;;;;;;;;;;   @@@@@@@@@@@ ;;;;;;;;;;;   @@@@@@@@@@@ Figure 103 DA

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 .

NG

ER

W

AR

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.

NIN

G

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

Turn body of valve to adjust.

Higher

280 bar Relief Valve

Pressure Settings

Lower

s

.ep

17

lblk

ntr

mc

o bo

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

Service Manual

105

HOME

PRINT

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

NG

ER

W

AR

Do m no a tra chint op th inin e w erate m e wa g. U ith an o this ua rnin nde ut rs g ls an s in tan d on safe d de ty ca ls.

NIN

G

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Pressure Settings Turn body of valve to adjust. Higher Lower

200 bar Relief Valve

PS

7.E

lv1

pv

/cm

p rpm

wt

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.

Service Manual

107

HOME

PRINT

Pressure Settings

agit.shutoff.eps

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

108

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

52qrttrn.epsL

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:

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

109

HOME

PRINT

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

110

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

quarter turn.eps

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.

Service Manual

111

HOME

PRINT

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

W008.eps

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.

112

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

Pressure Settings

w

Gauge port

Hif

lrv

vw .ep

s

Main relief valve Soft switch relief valve

Soft switch shutoff valve

Mount bolt and washer removed for illustration

grooves2.eps

Concrete pump shutoff valve

Grooves in handle should line up with grooves in valve shaft

hif

low

brn

.ep

s

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)

Service Manual

113

HOME

PRINT

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).

.

Accumreg.eps

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

s

.ep

rt ca

no

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).

estopleft.epsL

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.

114

Service Manual

revDate

PRINT

SERVICE TRAINING

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.

W010.eps

HOME

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

On some pump units the relief valve may be in a slightly different location (opposite side) than shown in Figure 11.

Service Manual

115

HOME

PRINT

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.

WARNING

W026.eps

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.

116

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

Service Manual

revDate

PRINT

SERVICE TRAINING

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

W009.eps

HOME

E-Stop Manifold

∆P Regulator

Q-min Adjust Screw

Figure 12 Location of components used to check or set boom pressures

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

117

HOME

PRINT

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 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.

W009.eps

WARNING

3. To ensure that the pump is putting out only enough oil needed to maintain ∆P, we need to change the setting of the Q-min adjustment screw. Q-min is

118

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

Check or set Q-min

Qminscrew.eps

Q-max

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.

W009.eps

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.

deltaPvlv.eps

HOME

T

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.

Set boom pressures (load sensing proportional booms) Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

119

HOME

PRINT

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

ap

ipo

.ep nly

deltaPvlv.eps

0-60 bar gauge port

s

boom control block relief valve

estop/right.eps

T

E-Stop Manifold Redundant Relief Valve

ps

rt.e

ca

no

Original Production Current Production

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

120

two:

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Service Manual

121

HOME

PRINT

Pressure Settings

140 bar gauge port

140 bar relief valve

Figure 17 140 bar relief valve and gauge port

ap

it14

0.e

ps

Pretension gauge port

Figure 18 Pretension adjustment screw and gauge port

s

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.

122

.ep

rtn

itp

ap

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

ps

2.e

itrlf

ag

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.

52qrttrn.epsL

10.

Closed

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

Service Manual

123

HOME

PRINT

Pressure Settings

124

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

000174.eps

Grooves in shaft

000273.eps

Open Mounting screw and washer removed for illustration

Motor

Figure 108 Agitator shutoff valve (left) and Open/closed orientation of shutoff valve (right)

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

125

HOME

PRINT

Pressure Settings Check the concrete pump pressure -4 pumpkits

Wear safety glasses any time you check or set pressures. Oil expulsion hazard!

000438.eps

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.

126

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

00

02

97

.ep

s

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.

Service Manual

revDate

PRINT

SERVICE TRAINING

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

00

02

74

.e

ps

Figure 110 Showing the concrete pump and soft switch shutoff valves

Grooves in handle

Grooves in shaft

Closed

Closed

Open

Main relief cartridge

000273.eps

000276.eps

HOME

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

127

HOME

PRINT

Pressure Settings Setting the soft switch circuit relief pressure Gauge port

00 04 32 .ep s

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.

128

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.

Service Manual

revDate

PRINT

SERVICE TRAINING

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

000433.eps

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!

000442.eps

HOME

Boom control block relief valve (non-adjustable)

15 bar pretension adjusment screw

30 bar pilot pressure relief cartridge

000

448

.ep

s

140 bar downside relief cartridge (non-adjustable) Figure 114 Location of the boom circuit pressure devices (Hoses removed for clarity.) Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

129

HOME

PRINT

Pressure Settings

Q-min adjustment screw

000434.eps

Q-max

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.

000435.eps

Delta-p

T

P adjustment screw 000281.eps

Figure 116 Location of the delta P adjustment screw for a unit with A7VO pump (left) and A11VO pump (right)

130

Service Manual

revDate

PRINT

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 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

T

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

000436.eps

HOME

High pressure adjustment screw

0-60 bar gauge port

15 bar pretension adjusment screw

30 bar pilot pressure relief cartridge

000

448

.ep

s

140 bar downside relief cartridge (non-adjustable) Figure 117 The boom pressure devices

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

131

HOME

PRINT

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!

000438.eps

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.

132

Service Manual

revDate

PRINT

SERVICE TRAINING

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

10189517

DANGER

000

451

.ep

s

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.

000453.eps

AGITATOR

280 bar Relief valve

CONCRETE PUMP

Boom 1

Boom 2

Boom 3

Boom 4

Boom 1 Telescope

Slewing Boom / Outrigger

Water / Compressor

10189517

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

4 1

3

Outrigger control block

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

2

HOME

WARNING Clear area before activating outriggers

REAR EXTEND

REAR JACKING

FRONT JACKING

FRONT EXTEND

00

04

40

.ep

s

Figure 119 Location of the 280 bar outrigger pressure relief valve (Hoses removed for clarity)

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

133

HOME

PRINT

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

s

.ep

450

000

Figure 120 Pretension adjustment screw and gauge port

134

Service Manual

revDate

PRINT

SERVICE TRAINING

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

10189517

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

1

3

4

Agitator Fwd/Reverse

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

2

HOME

WARNING Clear area before activating outriggers

Concrete pump Fwd/Reverse

REAR EXTEND

FRONT JACKING

FRONT EXTEND

88

02

00

REAR JACKING

s .ep

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Agitator quarter turn shutoff valve (open position)

000174.eps

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.

Service Manual

135

HOME

PRINT

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).

@@@@@@@@ 







 ;;;;;;;; QQQQQQQQ @@@@@@@@   ;;;;;;;; QQQQQQQQ







@@@@@@@@   ;;;;;;;; QQQQQQQQ







@@@@@@@@   ;;;;;;;; QQQQQQQQ







;;;;;;;; @@@@@@@@   QQQQQQQQ







@@@@@@@@   ;;;;;;;; QQQQQQQQ







;;;;;;;; @@@@@@@@   QQQQQQQQ







;;;;;;;; @@@@@@@@   QQQQQQQQ









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.

000292.eps

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

136

000446.eps hgacugc.psd

Figure 125 Accumulator manifold pressure relief cartridge and manual bleed valve

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

WARNING Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.

000075.eps

HOME

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

137

HOME

PRINT

Pressure Settings

138

Service Manual

revDate

PRINT

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).

in2

.ep

s

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

HOME

Pressure gauge Main relief valve

Jam nut Lower pressure

Raise pressure

Adjustment handle

scmnrlf2.eps

Figure 126 The main relief valve, concrete pump

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

139

HOME

PRINT

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.

Service Manual

revDate

PRINT

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

loc .ep

s

REV

32

HOME

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.

Service Manual

141

HOME

PRINT

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

Qminscrew.eps

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.

142

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

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

CAUTION Do not operate any functions while setting ∆P.

000435.eps

HOME

T

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.

Service Manual

143

HOME

PRINT

Pressure Settings

000436.eps

Redundant relief valve T

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

s

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

144

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).

Service Manual

revDate

HOME

PRINT

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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).

Service Manual

145

HOME

PRINT

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).

146

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

Pressure Settings

Gauge port

Figure 135 Position of the outrigger selector valve

s

.ep

hd

itor

ap

Outrigger handle

32Porct5.eps

REAR EXTEND

FRONT EXTEND

REAR FOOT

FRONT FOOT

Figure 136 Location of the passenger side outrigger control block

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

147

HOME

PRINT

Pressure Settings

280 bar Relief Valve

Lower

PS

oc

Higher

bb

ck.

ep

s

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:

148

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.

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

CAUTION Truck engine must be at an idle while setting pretension.

Pretension gauge port

s

.ep

rtn

itp

ap

Pretension adjustment screw Figure 138 Pretension adjustment screw and gauge agitator pressure check.eps L

HOME

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.

Service Manual

149

HOME

PRINT

Pressure Settings

ag its o. ep s

closed

Figure 140 The agitator shutoff valve

150

open

Service Manual

revDate

HOME

PRINT

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:

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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

Service Manual

151

HOME

PRINT

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.

152

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Service Manual

153

HOME

PRINT

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

s

ep

m.

oo

lcb

7p

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.

154

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.

Service Manual

revDate

HOME

PRINT

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

s

.ep

res

pp sto

S

P3

e

P2

P4

Boom override button

P1

Boom/outrigger inlet port

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

Service Manual

155

HOME

PRINT

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

32

XL lo

c.e p

s

REV

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.

156

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

itprd ap

ps v.e

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

Service Manual

157

HOME

PRINT

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.

T

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.).

158

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

1

TT

10

16

78

92

-7.

ep

s

P2

P3

P4

P1

M

T

0-400 bar gauge port 0-60 bar gauge port

a

•

o pip

.ep nly

s

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

Service Manual

159

HOME

PRINT

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.

160

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

ps

0.e

it14

ap

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.

Service Manual

161

HOME

PRINT

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

s

.ep

hd

itor

ap

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

162

Service Manual

revDate

PRINT

SERVICE TRAINING

32Porct5.eps

PS

oc

Higher

Pressure Settings

280 bar Relief Valve

Lower

bb

ck.

ep

s

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

HOME

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.)

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

163

HOME

PRINT

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.

164

Service Manual

revDate

HOME

PRINT

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

165

HOME

PRINT

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

166

Service Manual

revDate

HOME

PRINT

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.

Service Manual

167

HOME

PRINT

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

168

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Service Manual

169

HOME

PRINT

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.

170

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.

Service Manual

revDate

HOME

PRINT

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

171

HOME

PRINT

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.

172

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.

Service Manual

revDate

HOME

PRINT

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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.

Service Manual

173

HOME

PRINT

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

174

Service Manual

revDate

HOME

PRINT

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.

Service Manual

175

HOME

PRINT

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

176

Service Manual

revDate

HOME

PRINT

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:

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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

Service Manual

177

HOME

PRINT

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.

178

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:

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

179

HOME

PRINT

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.

Service Manual

revDate

PRINT

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

HOME

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

Service Manual

181

HOME

PRINT

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

Service Manual

revDate

HOME

PRINT

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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.

Service Manual

183

HOME

PRINT

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

s

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

184

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

Service Manual

revDate

HOME

PRINT

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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.

Service Manual

185

HOME

PRINT

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

186

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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

Service Manual

187

HOME

PRINT

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.

188

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.

Service Manual

revDate

PRINT

SERVICE TRAINING

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.)

closed ag its o. ep s

HOME

Figure 188 The agitator shutoff valve

open

9. Replace the aluminum diamond plate over the agitator handvalve.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

189

HOME

PRINT

Pressure Settings

190

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

32 XL Hi-Flow Prop, A11VO Units above 450 l/m (-5 and -6 units) •

Check the fluid level of the distribution gearcase. (See Figure 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

Service Manual

191

HOME

PRINT

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,

192

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

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

Pressure Settings Soft switch shutoff valve Main pressure gauge port

Concrete pump shutoff valve

hif

low

br

n.

ep

s

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

n-c

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

Service Manual

193

HOME

PRINT

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.

194

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.

Service Manual

revDate

HOME

PRINT

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,

Service Manual

195

HOME

PRINT

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.)

196

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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:

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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.

Service Manual

197

HOME

PRINT

Pressure Settings Redundant relief valve

MP

1

TT

10

16

78

92

-7.

ep

0-60 bar gauge port

s

P2

P3

P4

P1

M

0-400 bar gauge port

ap

ipo

.ep nly

s

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

198

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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.

Service Manual

199

HOME

PRINT

Pressure Settings

140 bar gauge port

140 bar relief valve

ap

it14

0.e

ps

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

Pressure Settings 7plcORhndl.eps

Outrigger handle

Gauge port

1 Gauge port

SECTION 1

SECTION 2

SECTION 3

SECTION 4

SLEWING

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

1

s

h

itor

ap

Outrigger handle

p d.e

AIR / WATER

BOOM / OUTRIG.

WARNING SAFETY

MANUAL

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

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 201 Location of the 280 bar outrigger pressure relief valve. (Hoses removed for clarity).

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

201

HOME

PRINT

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

202

s

.ep

rtn

itp

ap

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

Service Manual

revDate

PRINT

SERVICE TRAINING

agitator pressure check.eps L

Pressure Settings

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.

its

o.

ep

s

closed ag

HOME

Figure 204 The agitator shutoff valve

open

5. Activate the agitator in forward. Read the pressure on the gauge. 6. If adjustment is needed, put your wrench on the body of the relief valve, which is located on the back of the agitator handvalve. While reading the gauge, turn the body in to raise pressure, or out to lower pressure until 200 bar is achieved. 7. Put the agitator handle in neutral. 8. Remove the whip hose and pressure gauge. Replace the gauge port cover. 9. Replace the aluminum diamond plate over the agitator handvalve.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

203

HOME

PRINT

Pressure Settings

204

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

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

Agitator quarter turn shutoff valve (open position)

Motor

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!

000438.eps

HOME

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.

Service Manual

205

HOME

PRINT

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!

Gauge port

Hif

lo_

4.e

ps

Main relief valve Soft switch relief valve

Figure 22 Location of the concrete pump circuit main relief valve and soft switch relief valve

206

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

Soft switch shutoff valve Main Pressure Gauge port

Concrete pump shutoff valve

hif

low

br

n.

ep

s

Figure 23 Showing the concrete pump and soft switch shutoff valves

Grooves in handle

Grooves in shaft

Closed

Closed

Open

Main relief cartridge

grooves2.eps

openclsd.eps

HOME

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

207

HOME

PRINT

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

Hif lo_ 4.e ps

Main relief valve Soft switch relief valve

Figure 25 Location of the main relief valve

208

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

Pressure Settings

0-400 bar gauge port Boom control block relief valve Redundant relief valve

0-60 bar gauge port

15 bar pretension adjusment screw

oo 34b

p e.e alv mv

s newestop.eps

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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

Service Manual

209

HOME

PRINT

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!

000438.eps

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.

210

ps

dl.e

ghn

otr new

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.)

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

34manco3.eps

WARNING Clear area before activating outriggers

REAR EXTEND

REAR JACKING

FRONT JACKING

FRONT EXTEND

otr 200 100

300 bar

gb lk.e

ps

400

WIKA

280 bar Relief valve

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

000439.eps

HOME

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:

Service Manual

211

HOME

PRINT

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

new

pre

tns

n.e

ps

Agitator hand valve

Relief valve

Gauge Port 34agithandvalve.eps

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.

212

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

agitoff.eps

Figure 31 The agitator shutoff valve

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Agitator quarter turn shutoff valve (open position)

Service Manual

Motor

213

HOME

PRINT

Pressure Settings Setting accumulator circuit pressure

45Accreg.eps

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

newredun.eps

accumpmp.eps hgacugc.psd

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.

214

Figure 34 Accumulator circuit pressure gauge

Service Manual

revDate

PRINT

SERVICE TRAINING

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.

accuman1.eps

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

000075.eps

HOME

Service Manual

215

HOME

PRINT

Pressure Settings

216

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

S 34 X

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!

000438.eps

HOME

agitoff.eps

Agitator quarter turn shutoff valve (open position)

Motor

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.

Service Manual

217

HOME

PRINT

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.

Gauge port

Hif

lo_

4.e

ps

Main relief valve Soft switch relief valve

Figure 37 Location of the concrete pump circuit main relief valve and soft switch relief valve

218

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

Soft switch shutoff valve Main Pressure Gauge port

Concrete pump shutoff valve

hif

low

br

n.

ep

s

Figure 38 Showing the concrete pump and soft switch shutoff valves

Grooves in handle

Grooves in shaft

Closed

Closed

Open

Main relief cartridge

grooves2.eps

openclsd.eps

HOME

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

219

HOME

PRINT

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.

Gauge port

Hif lo_ 4.e ps

Main relief valve Soft switch relief valve

Figure 40 Location of the main relief valve

220

Service Manual

revDate

HOME

PRINT

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

34cmploc.eps

Q-min adjustment screw

Service Manual

221

HOME

PRINT

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

34blck.eps

Q-min adjustment screw 000442.eps

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.

Q-minscrew.eps

Q-max

Figure 43 Location of the Q-min adjustment screw

∆P adjustment screw

deltaPvlv.eps

Do not operate any function during this procedure. Gauge damage possible!

140 bar downside relief cartridge

T

Figure 44 The ∆P regulator valve

222

Service Manual

revDate

PRINT

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

deltaPvlv.eps

HOME

T

15 bar pretension adjustment screw

140 bar gauge port (use 0-400 bar gauge when checking)

0-60 bar gauge port

newestop.eps

0-400 bar gauge port

boom control block relief valve

140 bar downside relief cartridge

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

Figure 45 The three boom pressure devices 34blck.eps

two:

Service Manual

223

HOME

PRINT

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

224

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.

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

Setting the outrigger pressures

Outrigger handle

0-400 bar gauge port

otrghndl.eps

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!

000438.eps

HOME

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.

Service Manual

225

HOME

PRINT

Pressure Settings

34manco3.eps

1

10

280 bar Relief valve

9 4

2 3 AGITATOR

6 5

SECTION 1

SECTION 2

SECTION 3

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

1

3

4

SECTION 4

SLEWING

8 7

CONCRETE PUMP

AIR / WATER

BOOM / OUTRIG.

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

2

WARNING Clear area before activating outriggers

REAR EXTEND

REAR JACKING

FRONT JACKING

FRONT EXTEND

otr

gb

lk.e

ps

200 100

300 bar

400

WIKA

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.

226

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).

Service Manual

revDate

PRINT

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.

000439.eps

HOME

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).

NOTE! If your unit does not have a shutoff valve, you can order one using part number 10004680 (valve) and part number Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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.

Service Manual

227

HOME

PRINT

Pressure Settings 34manco3.eps

1 agitator handvalve

10

9

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).

1

3

4

SECTION 4

SLEWING

8 7

CONCRETE PUMP

AIR / WATER

BOOM / OUTRIG.

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

2

AGITATOR forward/reverse

s

ep dv.

WARNING

han

Clear area before activating outriggers

agit

REAR EXTEND

REAR JACKING

FRONT JACKING

FRONT EXTEND

CONCRETE PUMP forward/reverse

200 100

Figure 49 Agitator handvalve

300 bar

400

WIKA

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.

agitoff.eps

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.

228

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

Pressure Settings

45Accreg.eps

Accumulator pump pressure regulator

Redundant Relief cartridge

newredun.eps

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

229

HOME

PRINT

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.

accuman1.eps

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.

230

000075.eps

WARNING

Service Manual

revDate

HOME

PRINT

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).

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

231

HOME

PRINT

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

232

Service Manual

revDate

HOME

PRINT

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

233

HOME

PRINT

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

234

Service Manual

revDate

HOME

PRINT

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

235

236

Service Manual 10

11

8

G2 - HIGH PRESS. GAUGE PORT

G1 - PRETENTION GAUGE PORT

11 - SECTION COMPENSATORS

10 - HIGH PRESS. RELIEF (340 Bar)

9 - PRETENTION RELIEF

8 - PRETENTION VALVE

7 - OUTRIGGER SPEED

6 - COMPRESSOR RPM

5 - WATERPUMP RPM

4 - SWING LEFT SPEED

3 - SWING RIGHT SPEED

2 - BOOM RETRACT SPEED

1 - BOOM EXTEND SPEED

(Waterpump/Compressor & Outrigger)

BOOM HANDVALVE KVM 36LW & 36X

9

7

24V 24V

OUTRIG

6

5

WTR CMP

4

3

10

SLEW R&L

8

9

O-ring

Filter

O-ring

Orifice

G2

G1

2

1

BOOM 4

2

1

BOOM 3

2

1

BOOM 2

2

1

BOOM 1

HOME PRINT

Pressure Settings KVM 36 LW & 36 X W/Rexroth Boom Handvalve

revDate

HOME

PRINT

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

237

HOME

PRINT

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

238

Service Manual

revDate

HOME

PRINT

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

239

HOME

PRINT

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

240

Service Manual

revDate

HOME

PRINT

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

Service Manual

241

Service Manual

10

7

11

1 2 3 4 5 6 7 8 9 10 11

8 Orifice

O-ring

Filter

O-ring

8

9

- BOOM EXTEND SPEED - BOOM RETRACT SPEED - SWING RIGHT SPEED - SWING LEFT SPEED - WATERPUMP RPM - COMPRESSOR RPM - OUTRIGGER SPEED - PRETENTION VALVE - HIGH PRESS. RELIEF (330 Bar) - SECTION COMPENSATORS - DOWN-SIDE RELIEF VALVE

(Waterpump/Compressor,Throttle, & Outrigger)

KVM 42LW BOOM HANDVALVE

24V

242 24V

BOOM 2

24V

2

2

24V

1

24V

2

2

24V

24V

24V

1

4

24V

24V

3

BOOM SWING 4 R/L

1

BOOM 3

24V

24V

1

BOOM 1

RPM

24V

24V

6

24V

24V

5

WTR/ OUTCOMP. RIGGER

HOME PRINT

Pressure Settings KVM 42 LW, W/Rexroth BoomHandvalve

revDate

HOME

PRINT

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.

52qrttrn.epsL

OFF

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

Service Manual

243

HOME

PRINT

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

244

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:

Service Manual

revDate

HOME

PRINT

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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

Service Manual

245

HOME

PRINT

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.

246

Service Manual

revDate

HOME

PRINT

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.

Service Manual

247

HOME

PRINT

Pressure Settings 4. Be sure to open the concrete pump shutoff valve when you are finished. The unit cannot stroke with this valve closed.

e-stop/right.epsL

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).

248

Service Manual

revDate

PRINT

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.

W010.eps

HOME

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.

NOTE! Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

249

HOME

PRINT

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

250

Service Manual

revDate

W009.eps

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

HOME

PRINT

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

ep

dv.

s

15 bar pretension adjustment screw

Figure 20 Boom hand valves

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

251

HOME

PRINT

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

Q-minscrew.eps

Q-max

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.

252

Remove the gauge, and adjust ∆P until the boom is responsive and smooth. When done, the gauge (reinstalled) must read between 14 and 25 bar. The electronics in the control system can also affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 20 bar and check the electrical settings. Once electrical settings are verified, you could again refine the boom action with the ∆P adjustment. CAUTION! Do not operate any functions while setting ∆P.

deltaPvlv.eps

Check or set ∆P

T

∆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.

Service Manual

revDate

PRINT

SERVICE TRAINING

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

.e Va

om

Bo

36

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)

deltaPvlv.eps

HOME

T

e-stop/right.epsL

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

Service Manual

253

HOME

PRINT

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

254

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

Pressure Settings

0-400 bar gauge port 0-60 bar gauge port boom control block relief valve s

ep dv.

itpr

ap

36

15 bar pretension adjustment screw

Figure 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.

With a seven place hand valve, the #1 down brake Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

255

HOME

PRINT

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.

10.

11. 52qrttrn.epsL

Closed

Shown in the open position

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.

256

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

Pressure Settings

KVM 39X Closed

Check all hydraulic pressures

52qrttrn.epsL

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

Service Manual

257

HOME

PRINT

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

39Xtop.eps

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

258

Service Manual

revDate

PRINT

SERVICE TRAINING

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.

W008.eps

HOME

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

Service Manual

259

HOME

PRINT

Pressure Settings w

Gauge port

39 hif lw1 .ep s

Main relief valve Soft switch relief valve

Soft switch shutoff valve

Mount bolt and washer removed for illustration

grooves2.eps

Concrete pump shutoff valve

39

Grooves in handle should line up with grooves in valve shaft

hif

low

.ep

s

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.

Service Manual

revDate

HOME

PRINT

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).

Accumreg.eps

NOTE!

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

ps

rt.e

ca

no

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).

e-stop/right.epsL

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

Service Manual

261

HOME

PRINT

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.

W010.eps

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.

262

Service Manual

revDate

HOME

PRINT

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.

W009.eps

W026.eps

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)

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

263

HOME

PRINT

Pressure Settings

Boom Hand Valves

∆P Regulator

E-Stop Manifold

Q-min Adjust Screw

39Xtop.eps

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

pitp

.ep rdv

s

15 bar pretension adjustment screw Figure 36 Boom hand valves

264

Service Manual

revDate

PRINT

SERVICE TRAINING

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

Q-minscrew.eps

Q-max

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.

NOTE! If the boom does not operate smoothly at 20 Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Remove the gauge, and adjust ∆P until the boom is responsive and smooth. When done, the gauge (reinstalled) must read between 14 and 25 bar. The electronics in the control system can also affect how the boom operates, so if ∆P adjustment does not seem to help, reset to 20 bar and check the electrical settings. Once electrical settings are verified, you could again refine the boom action with the ∆P adjustment. CAUTION! Do not operate any functions while setting ∆P.

deltaPvlv.eps

HOME

T

∆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

Service Manual

265

HOME

PRINT

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.

e-stop/right.epsL

E-Stop manifold redundant relief valve

ps

rt.e

ca

no

E-Stop manifold redundant relief valve

Figure 39 E-Stop manifold (current production left - original production right

266

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

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

.e Va

om

Bo

36

15 bar pretension adjustment screw

∆P Regulator Valve (high pressure adjustment screw)

deltaPvlv.eps

HOME

T

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.

Service Manual

267

HOME

PRINT

Pressure Settings

0-400 bar gauge port 0-60 bar gauge port boom control block relief valve 36

ap

itpr

ep

dv.

s

15 bar pretension adjustment screw Figure 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 -

268

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.

Service Manual

revDate

HOME

PRINT

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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).

Service Manual

269

HOME

PRINT

Pressure Settings

Agitator Relief Valve Turn body of valve Gauge port

Higher

to adjust.

Lower

ps

2.e

itrlf

ag

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.

270

Service Manual

revDate

HOME

PRINT

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

Service Manual

271

HOME

PRINT

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

hif

lob

rn

.e

ps

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.

272

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

Service Manual

revDate

HOME

PRINT

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

Service Manual

273

HOME

PRINT

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.

274

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

0-600 bar gauge port ps

0.e

60

top

es

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

HOME

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)

Service Manual

275

HOME

PRINT

Pressure Settings

Q-min adjustment screw

Delta-P

Pressure cut-off

A7VX section min.top.eps

hifloreg.eps

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.

276

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

0.e

60

top

es

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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.

Service Manual

277

HOME

PRINT

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.

278

testport.eps

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

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

279

HOME

PRINT

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

000289a.eps

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

000446a.eps

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

280

4. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring the engine RPM to maximum.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

@@@@@@@@  







;;;;;;;; QQQQQQQQ @@@@@@@@   ;;;;;;;; QQQQQQQQ







@@@@@@@@   ;;;;;;;; QQQQQQQQ







@@@@@@@@   ;;;;;;;; QQQQQQQQ







;;;;;;;; @@@@@@@@   QQQQQQQQ







@@@@@@@@   ;;;;;;;; QQQQQQQQ







;;;;;;;; @@@@@@@@   QQQQQQQQ







;;;;;;;; @@@@@@@@   QQQQQQQQ









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

acumrlf.epsL

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

Service Manual

281

HOME

PRINT

Pressure Settings

282

Service Manual

revDate

PRINT

SERVICE TRAINING

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)

4194 gearcase scan.eps

HOME

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).

Service Manual

283

HOME

PRINT

Pressure Settings

Jam nut

Lower pressure

Raise pressure

Adjustment handle

gray valve.eps L

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

quarter turn.eps

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

284

will retract. Oil will be forced over the main relief valve. This procedure is called high-pressuring the concrete pump.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

quarter turn.eps

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.

Service Manual

285

HOME

PRINT

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).

286

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

Pressure Settings

42 apitech back.epsL

Adjustment screw (15 bar pretension)

Pretension check port (0–40)

Pressure check port (except pretension) 0-40 and 0-600

Figure 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

Q-minscrew.eps

Q-max

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,

Service Manual

287

HOME

PRINT

Pressure Settings

pressreg.eps deltaPvlv.eps

simply reset the Q-min screw as described in paragraph . If adjustment is needed, continue to step (5).

5. Delta P is adjusted by the ∆P adjustment screw on the boom pump (Figure 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

288

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:

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

pressreg.eps deltaPvlv.eps

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

P3

P2 P4 P1

M

TT MP

1

HOME

Figure 20 Emergency stop manifold, and boom redundant relief

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

289

HOME

PRINT

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).

290

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

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

291

HOME

PRINT

Pressure Settings

292

Service Manual

revDate

PRINT

SERVICE TRAINING

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

4194 gearcase scan.eps

HOME

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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.

Service Manual

293

HOME

PRINT

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

294

hif

lob

rn

.e

ps

Service Manual

Open





2. Be sure that the waterbox covers and guards are installed on the waterbox. Schwing does not recommend using the remote control box when setting the main relief pressure. 3. Start the truck engine, and put the PTO and transmission into gear, just as you would to pump a job. 4. Locate and close the concrete pump shutoff valve (quarter-turn valve), and the soft switch shutoff valve (quarter-turn valve) (Figures 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

revDate

PRINT

SERVICE TRAINING

Pressure Settings

Soft switch shutoff valve Main Pressure Gauge port

Concrete pump shutoff valve

hif

lob

rn

.e

ps

Figure 25 Locations of the concrete pump and soft switch shutoff valves

Groove lined up with ports - open

Closed

Open

grooves.eps

openclsd.eps

HOME

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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.

Service Manual

295

HOME

PRINT

Pressure Settings

Soft switch shutoff valve

Open

sftopen.eps

Main Pressure Gauge port

Soft switch relief valve

Concrete pump shutoff valve

hif

lob

rn

.e

ps

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).

296

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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).

42 apitech back.epsL

Adjustment screw (15 bar pretension)

Pretension check port (0–40)

Pressure check port (except pretension) 0-40 and 0-600

Figure 29 Boom control handvalve (Apitech)

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

297

HOME

PRINT

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

298

continue.

Service Manual

revDate

PRINT

SERVICE TRAINING

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

P3

P2 P4 P1

M

TT MP

1

HOME

Figure 32 Emergency stop manifold, and boom redundant relief valve Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

299

HOME

PRINT

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

350 bar relief

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).

300

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

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

the pressurized function and lock the jam nut. The boom pressures are now set. If you did not get the readings specified after following the instructions, contact Schwing’s Service Department for advice on how to continue.

Setting 15 bar pretension

Pressure Settings

1. Stop the truck engine. Plug the 0–40 bar gauge into the pretension check port of the Apitech handvalve (Figure 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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

301

HOME

PRINT

Pressure Settings

302

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

Service Manual

303

HOME

PRINT

Pressure Settings

Jam nut

Raise pressure

Lower pressure

Adjustment handle

gray valve.eps L

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

quarter turn.eps

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

304

Service Manual

revDate

HOME

PRINT

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).

Shutoff valve

quarter turn.eps

Figure 39 Concrete pump shutoff valve Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

305

HOME

PRINT

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:

306

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).

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

307

HOME

PRINT

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

Q-minscrew.eps

Q-max

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

308

Service Manual

revDate

PRINT

SERVICE TRAINING

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

nP age

3

Adjustment screw

Loc

atio

Protective cover

42

HOME

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).

Service Manual

309

HOME

PRINT

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.

rxboomblk.eps

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

310

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

Pressure Settings

Down side relief valve is located behind this section.

rxdnside.eps

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).

Service Manual

311

HOME

PRINT

Pressure Settings

280 Bar relief valve

280 Bar relief valve

Lower

Lower

Higher

PS

Higher

ou

trig

cn

trb

lk-

6p

lc

ou

tri

g

42

.ep

cn

trb

s

lk

-4

2.

ep

s

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

42 p.s. outrigger.epsL

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

312

into the valve. While holding the handle, have your helper read the pressure gauge installed on the boom control block.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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.)

Service Manual

313

HOME

PRINT

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

s

.ep lvlv

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).

314

Service Manual

revDate

PRINT

ac cm an rl. ep s

SERVICE TRAINING

Pressure Settings

Accumulator relief valve P2

P1

P4

P3 MP

S

T

MP

S

HOME

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

acc

ma

nrlf

.ep

s

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

Service Manual

315

HOME

PRINT

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.

316

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

Pressure Settings

S 45/47SX

Spline flange breather

Figure 54 Oil check plug for spline flange cavity (4400 gearcase)

Oil check plug flange.eps

Setting Pressures


   

 
  
 



The following pages provide the proper techniques for checking and setting hydraulic pressures of each system included on your unit.

agitoff2.eps

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm



 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:

Service Manual

317

HOME

PRINT

Pressure Settings Soft switch shutoff valve Main Pressure Gauge port

Concrete pump shutoff valve

hif

lob

rn

.e

ps

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

318

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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).

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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

Service Manual

319

HOME

PRINT

Pressure Settings

Closed

Soft switch shutoff valve

Open   

  





Main Pressure Gauge port

Concrete pump shutoff valve

   

hif

lob

rn

.e

ps

   

   

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.

320

WARNING Entanglement hazard. Stop drive shafts before adjusting Delta P on A11VO pump.

Service Manual

revDate

W020.eps

Setting boom circuit pressures

PRINT

SERVICE TRAINING

Pressure Settings

0-600 bar gauge port ps

0.e

60

top

es

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 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).

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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 .

pressreg.eps

HOME

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)

Service Manual

321

HOME

PRINT

Pressure Settings

Q-min adjustment screw

Delta-p

Pressure Cut-off

A7VX section min.top.eps

hifloreg.eps

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 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.

pressreg.eps

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.

322

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

0-600 bar gauge port ps

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

0.e

60

top

es

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

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.

Service Manual

323

HOME

PRINT

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.

testport.eps

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 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

324

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm


   

 
  
 



agitoff2.eps



 Figure 67 Agitator shutoff valve

Plugs Straight Fitting Figure 68 Approved hydraulic dead plugs

Service Manual

capplug.eps

Cap Nuts

325

HOME

PRINT

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.

45Accreg.eps

accurlf2.eps

Accumulator pump pressure regulator

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

accumpmp.eps hgacugc.psd

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,

326

4. Clear all personnel away from the drive lines, start the truck engine, engage the pumps, and bring the engine RPM to maximum.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

@@@@@@@@  







;;;;;;;; QQQQQQQQ @@@@@@@@   ;;;;;;;; QQQQQQQQ







@@@@@@@@   ;;;;;;;; QQQQQQQQ







@@@@@@@@   ;;;;;;;; QQQQQQQQ







;;;;;;;; @@@@@@@@   QQQQQQQQ







@@@@@@@@   ;;;;;;;; QQQQQQQQ







;;;;;;;; @@@@@@@@   QQQQQQQQ







;;;;;;;; @@@@@@@@   QQQQQQQQ







45acumpr.epsL

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

acumrlf.epsL

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

Service Manual

327

HOME

PRINT

Pressure Settings

328

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

S 45SX Hi-Flow - 6 Breather

Breather filter filler spout

grbx-5-6.eps

Oil check plug

Oil Check Plug Oil Drain Plug

Drain plug

4194 gearcase scan.eps

HOME

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

Oil check plug flange.eps

Pressure settings must be made with the oil at normal operating temperatures (40°− 60° C). In the past we could pressure out a function in the boom or outrigger system to create heat, but load sensing systems no longer allow maximum oil flow to be forced over relief. Because of this the agitator circuit must be used to heat the hydraulic oil. To preheat the hydraulic oil: 1. Locate the agitator shutoff valve (Figure 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.

Service Manual

329

HOME

PRINT

Pressure Settings 2. Activate the agitator. With the valve closed the agitator will not be able to turn and the oil will be forced over the relief valve. At an idle (about 600 RPM), 4.5 horsepower is being converted to heat.


   

 
  
 



agitoff2.eps



 Figure 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

hif

lob

rn.

ep

s

Figure 76 Concrete pump, Soft switch shutoff valves

330

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

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

-6adjust.eps

Figure 77 A11VO adjustment screws for Hi-flo – 6 units 190/130

Service Manual

331

HOME

PRINT

Pressure Settings

Concrete pump gauge port

Closed

NOTE: The main control block (brain) of a 2525 pumpkit will be rotated 180 degrees from the illustration shown

Open

Main relief cartridge opencls.eps

Main and soft switch relief cartridges

soft switch relief cartridge 9/16" jam nut

5/32" Allen head ga

ug

pr

9/16" jam nut

t.e

ps

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.

332

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

Service Manual

333

HOME

PRINT

Pressure Settings Component Location Guide- KVM 52 FIGURE 2

FIGURE 1

FIGURE 4

FIGURE 3

FIGURE 5

KVM 52M

Illustration 3

item 5

item 4 item 3

a6

b6

A6 T

FIGURE 1

a5

item 2

b5

A4

B4

b4

FIGURE 3

FIGURE 2

STOP for Q min

B5

a4 24V

item 1

A5

item 8

L

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

334

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

Service Manual

revDate

HOME

PRINT

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

335

HOME

PRINT

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

336

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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).

Service Manual

337

HOME

PRINT

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

338

Service Manual

b1-b3

revDate

HOME

PRINT

SERVICE TRAINING

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

b4-b6

339

HOME

PRINT

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.

340

Service Manual

revDate

HOME

PRINT

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

341

342

PV (PST)

Service Manual

P

34 BAR

50 BAR

L

b1

b1

a1

a1

b2

b2

a2

a2

PART # 995 120 002 651 (Complete)

b3

52 PRE-CONTROL BLOCK 1-C

b3

a3

a3

HOME PRINT

Pressure Settings Pre-Control Block 1-C for KVM 52

revDate

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

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

343

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

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

A SAI ITEM# (Cartridge Only) 10055188

Service Manual

345

HOME

PRINT

Pressure Settings

346

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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)

000174.eps

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

Service Manual

347

HOME

PRINT

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

348

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

Service Manual

revDate

HOME

PRINT

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.

000277.eps

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

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

1 4

M1 GAUGE PORT (BOTTOM OF EACH PUMP)

Service Manual

349

HOME

PRINT

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.

350

Entanglement hazard. Stop drive shafts before adjusting Delta P on A11VO pump.

Service Manual

revDate

000004.eps

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.

HOME

PRINT

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

000281.eps

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

Service Manual

351

HOME

PRINT

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

lf.e

ssr

pre

0-600 bar gauge port

Wear safety glasses any time you check or set pressures. Oil expulsion hazard!

000438.eps

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.

352

Delta-p

Pressure Cut-off

000282.eps

Q-min

Service Manual

Q-max (Bottom Of Pump)

Figure 86 Location of Q-min screw

revDate

HOME

PRINT

SERVICE TRAINING

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

lf.e

ssr

000257.eps

Cap Nuts

pre

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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.

Service Manual

353

HOME

PRINT

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

000282.eps

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).

dwnsdrlf.eps

Figure 93 Piston side relief Figure 91 Boom slewing relief valves

354

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.

Service Manual

revDate

PRINT

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.

000359.eps

HOME

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

Higher

to adjust.

Lower

ag

itrlf

2.e

ps

otrigrlf.eps

Figure 94 Outrigger valve bank relief cartridge Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Figure 95 Agitator relief cartridge located on back side hand valve

Service Manual

355

HOME

PRINT

Pressure Settings Agitator quarter turn shutoff valve (open position)

000174.eps

Motor

Figure 96 Agitator shutoff valve 000289.eps

Plugs Straight Fitting

Figure 97 Approved hydraulic dead plugs

Accumulator pump pressure regulator

000257.eps

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 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

356

Service Manual

000446.eps hgacugc.psd

revDate

HOME

PRINT

SERVICE TRAINING

Pressure Settings

000449.eps

Manual bleed valve

Boom pressure relief cartridge

ps

lf.e

ssr

pre

Pressure relief cartridge

0-600 bar gauge port

Figure 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.

000292.eps

Figure 100 Accumulator circuit pressure gauge

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

357

HOME

PRINT

Pressure Settings

Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.

000075.eps

WARNING

6. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 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.

358

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

agitoff.eps

Agitator quarter turn shutoff valve (open position)

Motor

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

Service Manual

359

HOME

PRINT

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.

360

hif

low

br

n.

ep

s

8. Now, turn the screw back in (clockwise) two or three full turns to give you a proper starting point and tighten the jam nut. 9. Stop the truck engine, put the key in your pocket and adjust the pressure cutoff screw (Figure 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

Service Manual

revDate

PRINT

SERVICE TRAINING

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.

Closed

Open

Concrete pump gauge port

Main relief cartridge openclsd.eps

HOME

soft switch relief cartridge 9/16" jam nut

5/32" Allen head ga

ug

pr

9/16" jam nut

t.e

ps

Figure 104 Location of soft switch shutoff and relief cartridges

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

361

HOME

PRINT

Pressure Settings

130-6.eps

1 Stroke Regulation

2 Pressure Cut Off

3

4

Horse Power 2

Q-Min 2 3

1

3

4

1 4

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.

362

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

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

“cue min”). To set the boom or outrigger hydraulic pressures on a load sensing system, begin by checking ∆ P and Q-min.t

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.

adjustable relief cartridge L

P

52pilot.eps

preset pressure reducing valve gauge port

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.

Service Manual

363

HOME

PRINT

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.

pressreg.eps

Delta-p

Regulator pressure adjustment T

Adjustment for P pressure smdeltap.eps

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.

364

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

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

time before making the adjustment. When pressure is correct, tighten the jam nut on the adjustment screw before continuing with the other procedures. Delta-p

Pressure Settings

Note! If you don’t have a 0-100 bar gauge you can order one from Schwing Spare Parts Department at (800) 328-9635, part #10004659.

Q-min adjustment screw

Pressure Cut-off

A7VX section min.top.eps

hifloreg.eps

Q-min

Q-max (Bottom Of Pump)

Q max

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

lftblock.eps

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

365

HOME

PRINT

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

lftblock.eps

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.

pressreg.eps

Delta-p

Pressure Cut-off

Regulator pressure adjustment T

Adjustment for P pressure hifloreg.eps

Q-min

Q-max (Bottom Of Pump)

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.

366

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

5.

(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.

adjustable relief cartridge L

P

lrgpilot.eps

preset pressure reducing valve

gauge port Figure 114 Showing the precontrol valve gauge port and adjustment points

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

367

HOME

PRINT

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

1

2

EXTEND

Relief cartridge

FOLD - REAR

PULL

PULL

3 FOLD - FRONT

PULL

4 FOOT

PULL

Relief cartridge

Gauge port Gauge port 1

2

3

4

5

Outrigger controls after mid 1999 1. 2. 3. 4. 5.

Front extend Rear fold Front fold Rear foot Front foot

otrgrlf2.eps

Outrigger controls prior to mid 1999 1. 2. 3. 4.

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)

368

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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).

Relief cartridge

Figure 116 Location of the agitator relief cartridge

agitrlf.eps

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!

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

369

HOME

PRINT

Pressure Settings agitoff.eps

Plugs Straight Fitting

capplug.eps

Agitator quarter turn shutoff valve (open position)

Cap Nuts Motor

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).

370

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

KVM 55M Check all hydraulic pressures Changes in pressure can indicate trouble in one or more components and will serve as early warning indicators if you check them on a regular basis. The specifications for each circuit are shown on the hydraulic schematics found in the Appendix section of this manual. The hydraulic schematics are the only documents in this manual that have been updated specifically for your unit, by the serial number, so in each of the following procedures you will be told to refer to the schematic for the pressure required. 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

agitoff2.eps

Grooves in shaft

grooves2.eps

Open Mounting screw and washer removed for illustration

Motor

Figure 46 Agitator shutoff valve (left) and Open/closed orientation of shutoff valve (right)

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

371

HOME

PRINT

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.

372

hif

low

br

n.

ep

s

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.

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

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.

Service Manual

373

HOME

PRINT

Pressure Settings Main and soft switch relief cartridges

Closed

Open

Concrete pump gauge port

soft switch relief cartridge

openclsd.eps

Main relief cartridge

9/16" jam nut

5/32" Allen head ga

ug

pr

9/16" jam nut

t.e

ps

Figure 48 Location of soft switch shutoff and relief cartridges

130-6.eps

1 Stroke Regulation

2 Pressure Cut Off

3

4

Horse Power 2

Q-Min 2 3

1

3

4

1 4

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.

374

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Service Manual

375

HOME

PRINT

Pressure Settings

Entanglement hazard. Stop drive shafts before adjusting Delta P on A11VO pump.

W020.eps

WARNING

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.

adjustable relief cartridge L

P

52pilot.eps

preset pressure reducing valve gauge port

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

pressreg.eps

Delta-p

Regulator pressure adjustment T

Adjustment for P pressure smdeltap.eps

Figure 52 Location of the delta P adjustment screw for a unit with A7VO pump (left) and A11VO pump (right)

376

Service Manual

revDate

PRINT

SERVICE TRAINING

Pressure Settings

Setting Q-min Delta-p

Q-min adjustment screw

Pressure Cut-off

A7VX section min.top.eps

hifloreg.eps

Q-min

Q-max (Bottom Of Pump)

Q max

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.

W009.eps

HOME

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.

Service Manual

377

HOME

PRINT

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

lftblock.eps

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.

pressreg.eps

Delta-p

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)

378

Service Manual

revDate

W021.eps

Setting main boom circuit pressures

HOME

PRINT

SERVICE TRAINING

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.

adjustable relief cartridge L

P

lrgpilot.eps

preset pressure reducing valve

Figure 57 The precontrol valve gauge port and adjustment points

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

gauge port

Service Manual

379

HOME

PRINT

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.

PScntrl#.eps

Outrigger controls on units built in U.S. prior to 2000

EXTEND

PULL

FOLD - REAR

PULL

FOLD - FRONT

PULL

FOOT

PULL

1. Front extend 2. Rear fold

Relief cartridge

3. Front fold 4. Foot (jacking)

1

2

3

4

Gauge port

Figure 58 Passenger side outrigger valve bank

380

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

itrlf

ag

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.

agitoff2.eps

Plugs Straight Fitting

capplug.eps

Cap Nuts

Motor

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

Service Manual

381

HOME

PRINT

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.

45Accreg.eps

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

accumpmp.eps hgacugc.psd

accurlf2.eps

Accumulator redunant relief cartridge

Figure 62 Accumulator redundant relief cartridge

382

Service Manual

revDate

PRINT

SERVICE TRAINING

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.

acumrlf.epsL









@@@@@@@@   ;;;;;;;; QQQQQQQQ @@@@@@@@   ;;;;;;;; QQQQQQQQ







@@@@@@@@   ;;;;;;;; QQQQQQQQ







@@@@@@@@   ;;;;;;;; QQQQQQQQ







@@@@@@@@   ;;;;;;;; QQQQQQQQ







@@@@@@@@   ;;;;;;;; QQQQQQQQ







;;;;;;;; @@@@@@@@   QQQQQQQQ







;;;;;;;; @@@@@@@@   QQQQQQQQ







45acumpr.epsL

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

W010.eps

HOME

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.

Service Manual

383

HOME

PRINT

Pressure Settings

384

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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

000174.eps

Motor

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

Concrete pump shutoff valve

00

02

74

.e

ps

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.

Service Manual

385

HOME

PRINT

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

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

000277.eps

1 Stroke Regulation

2 Pressure Cut Off

3

4

Horse Power 2

Q-Min 2 3

1

3

4

Figure 120 A11VO adjustment screws for Hi-flo – 6 units 190/130

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

1 4

M1 GAUGE PORT (BOTTOM OF EACH PUMP)

Service Manual

387

HOME

PRINT

Pressure Settings

Soft switch shutoff valve

Open

Main relief cartridge 000276.eps

Main Pressure Gauge port

Closed

Concrete pump shutoff valve

soft switch relief cartridge 9/16" jam nut

5/32" Allen head 00

02

74

9/16" jam nut

.e

ps

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.

388

Entanglement hazard. Stop drive shafts before adjusting Delta P on A11VO pump.

Service Manual

revDate

000004.eps

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.

HOME

PRINT

SERVICE TRAINING

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.

Delta-p

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

000281.eps

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

Service Manual

389

HOME

PRINT

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

lf.e

ssr

pre

WARNING

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.

390

Delta-p

Pressure Cut-off

000282.eps

Q-min

Service Manual

Q-max (Bottom Of Pump)

Figure 125 Location of Q-min screw

revDate

HOME

PRINT

SERVICE TRAINING

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 127 Hose for boom section number two

Plugs Straight Fitting Boom pressure relief cartridge

Figure 128 Approved dead plugs

ps

lf.e

ssr

pre

0-600 bar gauge port

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.

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

000257.eps

Cap Nuts

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.

Service Manual

391

HOME

PRINT

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

000282.eps

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

mainrlf.eps

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).

dwnsdrlf.eps

Figure 132 Piston side relief

NOTE! Figure 130 Boom slewing relief valves

392

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.

Service Manual

revDate

PRINT

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.

000359.eps

HOME

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








otrigrlf.eps

Figure 134 Agitator relief cartridge located on back side hand valve

Service Manual

393

HOME

PRINT

Pressure Settings Agitator quarter turn shutoff valve (open position)

000174.eps

Motor

Figure 135 Agitator shutoff valve 000289.eps

Plugs Straight Fitting Figure 136 Approved hydraulic dead plugs



 

    000257.eps

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

394

Service Manual

000446.eps hgacugc.psd

revDate

HOME

PRINT

SERVICE TRAINING

Pressure Settings

000449.eps

Manual bleed valve

Boom pressure relief cartridge

ps

lf.e

ssr

pre

Pressure relief cartridge

0-600 bar gauge port

Figure 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.

000292.eps

Figure 139 Accumulator circuit pressure gauge

Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm

Service Manual

395

HOME

PRINT

Pressure Settings

Entanglement hazard. Stop drive shafts before adjusting the accumulator pump pressure regulator.

000075.eps

WARNING

6. After the truck engine is stopped, go back to the accumulator circuit hydraulic pump pressure regulator (Figure 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.

396

Service Manual

revDate

HOME

PRINT

SERVICE TRAINING

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.

Service Manual

397

HOME

PRINT

SERVICE TRAINING

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.

398

Service Manual

PRINT

SERVICE TRAINING

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

Service Manual

TO BOOM

399

HOME

PRINT

SERVICE TRAINING

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

Service Manual

PRINT

SERVICE TRAINING

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

Service Manual

401

HOME

PRINT

SERVICE TRAINING

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

Service Manual

21

22

24

HOME

PRINT

SERVICE TRAINING

Electrical

Motherboard for Proportional Units POWER SUPPLY CARD (PART# BEFORE 1992 10074135 AFTER 1992 10023316)

PROPORTIONAL AMPLIFIER CARD (PART# BEFORE 1992 10074136 AFTER 1992 10023317)

PROPORTIONAL AMPLIFIER CARD (PART# BEFORE 1992 10074136 AFTER 1992 10023317)

PROPORTIONAL AMPLIFIER CARD (PART# BEFORE 1992 10074136 AFTER 1992 10023317)

ADAPTER CARD FOR TEST METER (PART# BEFORE 1992 10074136 AFTER 1992 10023317)

EMPTY SLOT

9

1

2

3

Service Manual

5

403

HOME

PRINT

SERVICE TRAINING

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

404

Service Manual

Function

Fuse for voltage regulation. It should be off. When it is on, check the fuse.

HOME

PRINT

SERVICE TRAINING

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

Service Manual

405

HOME

PRINT

SERVICE TRAINING

Electrical

Calibration of Proportional Amplifier Cards Note: The average Proportional solenoid valve operates between 300 and 800 mA. 1. Push the emergency stop button (Only if not using the Schwing proportional card test meter). 2. Connect Amp meter in the circuit of the proportional function that is to be calibrated. The most convenient way to measure the current is using the Schwing proportional card test meter (ID 77706). 3. Release the Emergency Stop button. 4. Tilt the Joystick to the point that the micro-switch is in the closed position (trigger point is at I min). The circuit is now in a closed position, the LED on the proportional amplifier card is illuminated, and the current can be read on the test meter. 5. Adjust the minimum current (at the min potentiometer) to the point where the boom section just starts to move (approximately 300 - 450 mA). 6. Tilt the Joystick all the way (I max.). Adjust your maximum current (at the max potentiometer) on the proportional amplifier card (approximately 700 - 800 mA).

After adjusting the maximum current, repeat steps 4 though 6 until the correct result has been achieved. The reason for this is because as the min or max is adjusted, the other is effected. CARD 1, 2, 3 BOOM FUNCTION UP

DOWN MICROSWITCH OPEN

CLOSED

CLOSED

I MIN I

I MIN I MAX

MAX

MIN MAX LED 1 MIN MAX

Channel 1

LED 2 MIN MAX LED 3 MIN MAX LED 4 LED 5 LED 6 1

406

2

3

Service Manual

Channel 2

PRINT

SERVICE TRAINING

Electrical

Linear Signal Diagram

1000 MAXIMUM CURRENT OUTPUT (mA)

HOME

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

Service Manual

2

3

PROPERLY ADJUSTED

407

HOME

PRINT

SERVICE TRAINING

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

Service Manual

6

4

2

HOME

PRINT

SERVICE TRAINING

Electrical

Wiring Diagram - DUVAC II 12V / 24V Transformer

Truck batteries GND

IGN. 12v

24v 30A

30A

+ 12V -

+ 12V -

+ 12V -

+ 12V -

Ignition switch (on) PTO switch

(on)

12V ACTUATED

12V ACTUATED

24v solenoid

12v solenoid 24v output to Schwing unit

12v output to Schwing unit

DUVAC II . . . . . . . . . . . . . . Part #319438 SOLENOID . . . . . . . . . . . . .Part #302563 (continuous duty) PTO SWITCH . . . . . . . . . . .Part #302178 (cam type)

Service Manual

01/26/95 GRP

409

HOME

PRINT

SERVICE TRAINING

Electrical

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.

410

Service Manual

PRINT

SERVICE TRAINING

Electrical

Digital Proportional - Overview (1 of 5) Overview The term DigiProp is used to describe Schwing Americas digital proportional control system. Proportional refers to the fact that the boom adjusts it's speed in response to the movement of the joysticks. The farther the joystick is moved, the faster the boom moves. Digital means that the movement of the joystick is translated (by an analog to digital converter) to numbers (zeros and ones). Once translated to numbers the signal moves into a processor not unlike a computer. The processor responds to the joystick movements and compares them to a set of values that are preprogrammed into memory. It then translates the numbers into a signal that is fed to the coils of the hydraulic valves. See Figure 1.

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

HOME

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.”

Service Manual

411

HOME

PRINT

SERVICE TRAINING

Electrical

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

412

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

Processor Unit The digital control system is housed in the device called the Processor unit. The processor unit replaces the relay enclosure found on analog systems. This processor unit contains various types of electronic function cards and the optional radio receiver. The SCV9 card is the master card in the system. Its function is to coordinate the entire system by decoding instructions from the operator control panels, then sending commands to the appropriate slave cards. The SCV9 card holds all the programmed settings. It has been programmed at the factory for your specific machine. Replacement cards contain generic settings. In an emergency, they can be used as is, but they should be programmed to match the hydraulic system on your machine. The HC2 and DG8 cards are known as slave cards because they receive commands from the master card, SCV9. See Figure 4

+ .A12 REC 2

+ A11 SCV

+ .A10 HC2L-1

+ .A9 + .A8 HC2L-1 HC2L-1

+ .A7 HC2L-1

+ .A6 HC2L-1

+ .A5 HC2L-1

+ .A4 DG8-1

+ .A3 DG8-1

M.A.T. CONNECTOR

SCV 9

HC 2

(master card)

(slave card

DG 8 (slave card

Figure 4

Service Manual

413

HOME

PRINT

SERVICE TRAINING

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

414

Service Manual

4 5 6 7 8

HOME

PRINT

SERVICE TRAINING

Electrical

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

Service Manual

415

HOME

PRINT

SERVICE TRAINING

Electrical

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

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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.)

417

HOME

PRINT

SERVICE TRAINING

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

418

Service Manual

1H1 200 1H2 300 1H3 900 1S1 200 1S2 300 1S3 900 2H1 200 2H2 300

M M M M M M

HOME

PRINT

SERVICE TRAINING

Electrical

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

Service Manual

419

HOME

PRINT

SERVICE TRAINING

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”=

420

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

“?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.

Service Manual

421

HOME

PRINT

Electrical “FM3

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.

422

“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.

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

“?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.

Service Manual

423

HOME

PRINT

SERVICE TRAINING

Electrical The following submenus can be found: “?BDI_A”=

“Input Date from BDI_A (Rear Panel) Display” submenu display or selection.

“?BDI_F”=

“Input Date from BDI_F (Cable or Radio Remote Control) Display” submenu display or selection.

“?RACK”=

“Input Date from Rack Display” submenu display or selection.

“?RACK” Submenu Functions and Parameters “?RACK”= Submenu for the display of input date from the rack. The individual displays are: “LDK O/F” = Entry indicating how the system recognized the “alternator (D+)” input nstruction.

424

“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.

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

“?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 %.

Service Manual

425

HOME

PRINT

SERVICE TRAINING

Electrical

“?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.

426

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

“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:

Service Manual

427

HOME

PRINT

Electrical

SERVICE TRAINING

“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

428

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.

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

“?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.

Service Manual

429

HOME

PRINT

Electrical

SERVICE TRAINING In such case, the system will request you to acknowledge by the same keys if you really want to change the parameters.

“?GERAET” Main Menu (In Service Menu Only!) After selecting the “?GERAET” main menu, you can scroll the individual submenus and entries with the “⇑” and “⇓” keys. In the “?GERAET” main menu, all unit-specific settings are concentrated. The following individual entries can be found: “TYP

XXX” = The type of equipment can be selected here: NORM Boom 2 / 3 changeover R_A2 Boom 2 ramp control Default: NORM

“REP

OFF”

= This serves to select the concrete pump on-site control mode. If on-site control is to be activated by a release switch, this parameter must be programmed “ON”. Default: OFG

“RWK 0”

= This switches off the optional agitator (0), and activates it for simple functioning forward only / 1), or for extended functioning (forward and reverse / 2). Default: 0

“FHYS 2.0”

= This serves to set the hysteresis compensation factory within the range from 1.0 to 10.0. Default 2.0

“IVOR 50”

= This serves to set the driver current within the range from 0 to 200mA. Default: 50 mA

V2.4 Menus The V2.4x software version has two different levels of access, the customer menu and the service menu. The customer menu has the parameter settings for the current that is used for driving the hydraulic valves. These settings are changeable from the customer menu in the “?PAR” portion of the main menu. The customer menu also allows you to view non-changeable entries such as inputs to and outputs from the “SCV” card. The customer menu only allows you access to the “SCV” card. The service menu allows you to access some extra troubleshooting entries in the “SCV” card along with all HCL and DG cards. Along with this, you can also view the BDI_A (rear operators panel card and the BDI_F (cable remote) card. On the following pages containing the 2.4 menu structure, the service menu entries are all the entries in the shaded boxes. All the entries in the unshaded boxes can be accessed from the customer or the service menu. To access the service menu, do the following: 1. From the “SCV” entry in the controller column, you press the “P” button. This will bring up the “?PAR” entry in the main menu column. 2. Press the arrow key down “⇓” until the “?SYSTEM” entry is displayed on the mat. 3. Press “P” to display “SCV_S”. 4. Press the “P” key one, then the “C” key once, and finally the arrow up “⇑” key once. The display should now read NR500. 5. Press the “P” key and a dotted line will appear under the NR500. 6. Press the arrow up “⇑” key until the display reads NR530. 7. Press the “P” key and a dashed line will appear under the NR530. You now have access to all entries in the customer and service entries. Every time the unit is reset, either by shutting off the power and turning it back on, or my using the reset function in the mat, you will automatically be in the customer menu and must re-enter the code to access the service menu.

430

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

Software Versions There are a few different software versions used on the digital proportional units. The SCV cards have versions 2.2x, 2.3x and 2.4x. The x denotes that there could be another digit in that location, for example 2.46 or 2.48. The earlier versions (2.2x and 2.3x) have a ? in front of the SCV display on the MAT. The 2.4x version will have a * in front of the SCV displayed on the MAT. You can also see what version software you have by scrolling to the “system” entry in the main menu column. Version 2.3x and 2.4x can be used in place of a version 2.2x. The 2.2x and 2.3x version cannot be used in a unit that has ramp functions for boom controls or remote agitator control, as used in the 52m’s. The 2.2x and 2.3x also cannot be used in units that have on site activation switches. On the following pages there is one menu structure for the 2.2x and 2.3x version and one menu structure for the 2.4x version. The BDI cards or the cards used for the rear panel and remote control box can also have various versions. The versions are either 1.xx or 2.xx. In the 1.xx version the cards were specific to their location, ie., the BDIA card was used for the rear panel and the BDIF card was used for the remote box. The 2.xx version is called BDI S and it can be programmed to be used in the rear panel or remote box. The versions are interchangeable, however the 1.xx version cannot be used in systems with remote agitator controls as used in the 52m. The HCL and DG cards have different versions and they are interchangeable and compatible with all SCV card version

Service Manual

431

HOME

PRINT

SERVICE TRAINING

Electrical

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

432

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.) Max. current (mA.)

Stroke limiter

HOME

PRINT

SERVICE TRAINING

Controller

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

433

HOME

PRINT

SERVICE TRAINING

Electrical

Controller

Main Menu

Submenus

Display

Sxa 0000

?DIN

Translation Rear panel all functions Hexidecimal code

?BDI-A ?DIGa

ASWa O/F HUPa O/F RTHa O/F RTAa KPRa WPEa BPVa BPRa

O/F O/F O/F O/F O/F

MONa O/F MOFa O/F MUPa MDNa FSTa RE1a RE2a

O/F O/F O/F O/F O/F

RE3a O/F FMpa Sxf

O

Spotlight Horn Vibrator Manual Vibrator Automatic Compressor Water Pump Concrete Pump Forward Concrete Pump Reverse Engine Start Engine Stop RPM Up RPM Down Local (on)/Remote (off) Spare Spare Spare Stroke Limiter Remote control all functions hexidecimal code

0000

?BDI_F ?DIGf

?MSTS

Version 2.4X

434

Service Manual

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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 ...

Service Manual

439

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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)

HOME

PRINT

SERVICE TRAINING

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

449

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

SERVICE TRAINING

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

Service Manual

PRINT

SERVICE TRAINING

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

Service Manual

value can now be changed.

455

HOME

PRINT

SERVICE TRAINING

Electrical 8. 9.

Press the arrow keys to adjust the value up or down to the desired setting. If you make a mistake, press the “C” key to start over. When the parameter is set to the desired value, press the program key again. The dotted line changes to a dashed line indicating the change has been saved.

After setting the driver currents, check the operation of the hydraulic valve by watching the boom and the handle on the hydraulic valve as you move the joy stick. The boom should just start to move as you move the joy stick off neutral and you hear the micro switch activate. Then move the joy stick to the 100% position, the handle on the hydraulic valve should just contact the maximum stop. Correctly balancing the valve currents precisely tailors the digital controller to the hydraulic system on your unit. This provides smooth proportional control of boom functions and concrete output. The initial settings that were programmed into your machine are located on a decal near the digital processor. See Figure 16.

CURRENT MEASUREMENT DATA PROPORTIONAL BOOM - DIGITAL MODEL: SERIAL NO. FUNCTION

MIN STOPPING CURRENT (mA)

MIN STARTING CURRENT (mA)

1H1

1H2

1H3

1S1

1S2

1S3

2H1

2H2

2H3

2H1

2H2

2H3

3H1

3H2

3H3

3S1

3S2

3S3

4H1

4H2

4H3

4S1

4S2

4S3

ML1

ML2

ML3

MR1

MR2

MR3

FM1

FM2

FM3

HYSTERESIS COMPENSATION: DRIVER CURRENT:

Figure 16

456

MAXIMUM CURRENT (mA)

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

Digital Proportional - Troubleshooting The digital proportional control is designed with self-diagnostic capabilities built-in to help you quickly and efficiently locate faults in the system. When the unit is activated, it continuously monitors the systems and communicates their status using LED’s located on the digital processor. See Figure 17.

Troubleshooting LED’s

+ .A12 REC 2

+ A11 SCV

+ .A10 HC2L-1

+ .A9 + .A8 HC2L-1 HC2L-1

+ .A7 HC2L-1

+ .A6 HC2L-1

+ .A5 HC2L-1

+ .A4 DG8-1

+ .A3 DG8-1

M.A.T. CONNECTOR

Figure 17 If a problem exists, the first step is to check the status of the LED’s on the digital controller. Use the charts to interpret the messages communicated by the LED’s, then follow the appropriate troubleshooting (T.S.) procedure on the following page.

Service Manual

457

HOME

PRINT

SERVICE TRAINING

Electrical

Message

Meaning

Troubleshooting procedure

All LED’s steady green

No faults, system ready

None (If a boom function is inoperative see T. S. procedure 1)

All LED’s off

No power to unit

“E” Stop pressed, Main power switch off

SCV 9 steady green all others off

Communication error

T. S. procedure 2

SCV 9 & HC 2 flashing

Hardware fault

T. S. procedure 3

SCV 9 flashing

Intermit hardware fault

T. S. procedure 4

SCV Red

M.A.T. plugged in

None

Rear panel card off (inside rear panel)

No faults

None

Rear panel blinking (inside rear panel)

Matching blinking error from SCV card

T. S. procedure 4

Red LED on cable remote box or LED on card inside cable remote box blinking.

Matching blinking error from SCV card

T. S. procedure 4

Problem in card

Replace card

Rear card or cable card steady red

NOTE: The rear panel board will light for approximately 1 second on system activation or restart. Note: The troubleshooting procedures listed below pertain to the electrical system. Make sure that there are no problems with the hydraulic system before performing any of these procedures.

458

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

Troubleshooting procedure 1 If one boom function is not working and the LED’s are steady green, you’ll need to use the M.A.T. and menu survey to pinpoint the problem. To do this, first connect the M.A.T. and scroll to the P-A-R main menu, then to the affected boom display. Check the minimum start, stop and max current parameters. They should approximate the values written on the decal. If not, reprogram the function to the correct values. If the parameters are set correctly, scroll to the P-OUT main menu, then to the affected boom display. Move the joystick and watch the value. When the joystick is at the neutral position, the reading should be 50, indicating the 50 milliamp diagnostic current. As the joystick is moved towards the 100% position, the reading should rise to the max current setting. If these functions are not correct, try using the other remote control panel. If that doesn’t help or the readings are correct but the boom function still is not working, check the output current of the affected HC 2 card.

Troubleshooting procedure 2 If none of the control functions are working and the SCV9 card is steady green, but the other cards are off, it indicates a communication error between SCV9 and one or more of the slave cards. To locate the problem, connect the M.A.T. and scroll to the INS main menu. Then scroll to the C-E-R-R display which is the entry for communication errors. The number in the display indicates the position to the right of the SCV 9 card where the first error occurred. To determine if the problem is on the card, swap it into another position of the same card type and reset the system. If the error follows to the new position, the board is defective. If the error is still in the same position, call Schwing Service for assistance.

Troubleshooting procedure 3 If the card that controls the problem function is flashing, along with the SCV9 card, there is a hardware fault somewhere between the output of the digital processor and the hydraulic valve. To determine if the problem is the solenoid or the wiring, swap the solenoid caps. If the problem is unchanged, replace the solenoid. If the problem follows the solenoid caps, the problem is in the wiring. If this is the case, you should consult the electrical schematics to track the faulty wire.

Troubleshooting procedure 4 If the SCV9 is the only card flashing, it means the problem is intermittent, possibly a bad connection. It continues to flash because it stores fault information in its memory until the system is reset. Because of the sensitivity of the system the SCV light may blink for various reasons, if resetting the system does not clear the problem refer to troubleshooting procedure 3. Resetting the system can be accomplished either by turning the power off and on, or by using the M.A.T.

Service Manual

459

HOME

PRINT

SERVICE TRAINING

Electrical Troubleshooting The Radio

The radio remote consists of a transmitter built into the battery powered remote control and a receiver built into the digital processing unit. All commands transmitted are safety coded, that is they contain an identifier, so that the unit will only respond to commands from the correct remote control. The receiver checks the command and passes it on only if it is complete and correct. If there is interference, the unit will automatically shut down, however, there are two frequencies available that can be switched at the remote control. See Figure 18. When using the radio remote, it is important to stay within a safe operating range, always knowing where the boom is.

Low Battery LED

Communications LED

Frequency Selector

Emergency Stop

Figure 18

E- stop LED

There are 3 LED’s on the radio remote. The one on the left warns you when the radio battery voltage is getting low. The center LED indicates when a digital message is being sent. The E-stop LED lights when the emergency stop on the transmitter has been pressed. The rechargeable transmitter battery will operate the system for about 8 hours, depending on the age of the batteries and the operating conditions. When the battery warning light starts to flash, you have about thirty minutes operating time left before the unit shuts down due to low battery voltage. The battery charger is located in the cab of the truck. See Figure 19.

POWER

Figure 19

460

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

The other half of the radio remote control is the receiver, which is located in the truck mounted digital processor. It receives the digital code from the transmitter, checks to make sure the instructions are correct and complete, then passes them on to the digital processor. See Figure 20.

SCHWING NG

NF

UF UE1 UCC1 UE2 UCC2 NOT1 K1

K1 K2

20

MC2 TEL

T 2

K28

MC1 ST 1 ST 2 REL PROP TEL TST 3 TST 2 TST 1

T 1

RADIO CONTROL FCC ID. DA87G6 FW SCHWING AMERICA . GERMANY SERIAL NR 003 143 FREQ. 456.962S (mHZ) 457.762S

Radio Receiver

Figure 20

Operation With the Local/Remote switch located on the rear operators panel in the local mode: 1.

Connect the Funk plug or cable remote to the remote receptacle (one or the other must be connected to operate a digital machine). See Figure 21.

2.

Properly set the machine, as described in the operators manual, then turn the mode switch back to the remote position.

FUNK

Figure 3.

Make sure all the function switches on the remote control transmitter are in the neutral position.

4.

Turn the remote control power supply on. (the LED on the right should start flashing)

5.

Turn the power switch located on the transmitter to the “on” position. (the E-stop LED should flash faster) See Figure 22.

Service Manual

461

HOME

PRINT

SERVICE TRAINING

Electrical 6.

Pull the emergency stop button. (the communication LED should now be on)

7.

Activate one of the control functions. (the communication LED should start flashing, indicating messages are being sent)

Low Battery LED

Communications LED

Emergency Stop

E- stop LED

Frequency Selector

Figure 22

Emergency Stop Pushing the emergency stop button stops the main functions of the machine.

Automatic Shut down The unit will automatically shut down in case of: • • • •

Low battery voltage Message errors. Electronic module failure. No command messages sent for 30 minutes.

462

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

Trouble-shooting Many problems with the radio remote control can be identified by interpreting the LED’s on the radio receiver. The following is a brief explanation of the LED’s: NG= power supply UF= vehicle system voltage UE 1= controller 1 supply UCC 1= controller 1 supply (+5V) UE 2= controller 2 supply UCC 2= controller 2 supply (+5V) NOT 1= EMERGENCY STOP circuit of controller 1 for controller MC 1 NOT 2 = EMERGENCY STOP circuit of controller 1 for controller MC 2 HF= receiver K1= RF-channel 1 selected K2= RF-channel 2 selected MC 2= controller 2

data message reception TEL= data message recepton MC 1= controller 1 ST 1= controller 1 failure ST 2= controller 2 failure REL= relay output defective PROP= proportional control output defective TEL= data message recepton TST3= data message error 3 TST2= data message error 2 TST1= data message error1

SCHWING NG UF UE1 UCC1 UE2 UCC2 NOT1 NOT2

HF K1 K2

F W 20 MC2 TEL

T2

K28

V24

MC1 ST 1 ST 2 REL PROP TEL TST 3 TST 2 TST 1

T1

RADIO CONTROL FW20 FCC ID. DA87G6 FW20RL SCHWING AMERICA INC. GERMANY SERIAL NR 003 143 FREQ. 456.962S (mHZ) 457.762S

Service Manual

463

HOME

PRINT

SERVICE TRAINING

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

464

Service Manual

HOME

PRINT

SERVICE TRAINING

LED

DISPLAY

MESSAGE

REMEDIAL ACTION

PROP

On

Vehicle power supply voltage 28V

Check vehicle power supply

No radio reception Transmitter off or defective Antenna not installed or defective

Check transmitter and antenna Call Schwing Service

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

Service Manual

465

HOME

PRINT

Electrical

466

SERVICE TRAINING

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

Comfort Control Manual Chp.

Contents

1.0

Working with the info & diagnosis system

2.0

3.0

4.0

5.0

Page

1.1

Introduction into the info & diagnosis system

2

1.2

Menu structure of the info & diagnosis system / Operation data display

4

Parameter setting concrete pump efficiency / Central lubricating system / Prop characteristics 2.1

Password entry and parameter selection menu

9

2.2 2.3 2.4

Setting the concrete pump efficiency for pumped volume determination Setting the central lubricating system Setting proportional parameters for boom functions

10 11 12

I/O status display signals & references 3.1

Machine control

15

3.2 3.3 3.4 3.5

Concrete pump control Boom control Rear panel Extension module (central lubricating system)

17 18 20 22

Fault messages and fault causes 4.1

Introduction / Structure of error codes

4.2 4.3 4.4 4.5 4.6 4.7 4.8

Control diagnosis electronic modules Remote control system diagnosis Machine diagnosis - General Diesel engine diagnosis / P.T.O. Concrete pumpe diagnosis Boom control diagnosis Central lubricating system diagnosis / Extension

23 (fault code S) (fault code F) (fault code A) (fault code D) (fault code B) (fault code M)

24 25 26 28 30 31

(fault code Z / E)

34

Interdependence list of most important output signals

35

Annex :Overview info center menu Vers.: 1.2

Status:02.10.97

Service Manual

U.Weber (TEW)

467

HOME

PRINT

SERVICE TRAINING

Electrical

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.

468

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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 !

Service Manual

469

HOME

PRINT

SERVICE TRAINING

Electrical

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.

470

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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

Service Manual

471

HOME

PRINT

SERVICE TRAINING

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 ]

→

472

[ 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

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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

Service Manual

473

HOME

PRINT

SERVICE TRAINING

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 ]

474

→

Back to main menu

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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

Service Manual

475

HOME

PRINT

SERVICE TRAINING

Electrical

[ 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

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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

Service Manual

477

HOME

PRINT

SERVICE TRAINING

Electrical

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.

478

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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

Service Manual

479

HOME

PRINT

SERVICE TRAINING

Electrical

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

480

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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

Service Manual

481

HOME

PRINT

SERVICE TRAINING

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

482

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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

483

HOME

PRINT

SERVICE TRAINING

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!

[↓]

484

Service Manual

slewing!

HOME

PRINT

SERVICE TRAINING

Electrical

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

Service Manual

485

HOME

PRINT

SERVICE TRAINING

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

486

Service Manual

HOME

PRINT

SERVICE TRAINING

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

Service Manual

487

HOME

PRINT

SERVICE TRAINING

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 !!!

488

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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!)

Service Manual

489

HOME

PRINT

SERVICE TRAINING

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.

490

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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 !

Service Manual

491

HOME

PRINT

Electrical

SERVICE TRAINING

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) !

492

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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) !

Service Manual

493

HOME

PRINT

SERVICE TRAINING

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) !

494

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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.

Service Manual

495

HOME

PRINT

SERVICE TRAINING

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) !

496

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

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) !

Service Manual

497

HOME

PRINT

SERVICE TRAINING

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 !

498

Service Manual

HOME

PRINT

SERVICE TRAINING

Electrical

- Correct mode of operation LOCAL / REMOTE selected ! - Vibrator activated on remote-control box or at rear panel in MANUAL mode or vibrator in AUTO mode and CP FORWARDS activated at the same time !

Cleaning systems Water pump ON (switched output !) depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation ! - Correct mode of operation LOCAL / REMOTE selected ! - Water tank level switch indicates sufficient amounts of water in tank ! (dry running protection for water pump !) - Water pump activated on remote-control box or at rear panel ! Compressor ON (switched output !) depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation! - Correct mode of operation LOCAL / REMOTE selected ! - Compressor activated on remote-control box or at rear panel!

Truck engine control Engine Start (switched output !) depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation ! - Correct mode of operation LOCAL / REMOTE selected and RAM CHANGE mode not activated ! - Gearbox in neutral position ! - Engine not yet running (D+ signal) ! - Safety delay of "Engine Stop" command (ca. 5 seconds) already elapsed ! - Engine Start activated on remote-control box or at rear panel ! Engine Stop (switched output !) depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation ! - Correct mode of operation LOCAL / REMOTE selected and RAM CHANGE mode not activated ! - Gearbox in neutral position ! - Engine Stop activated on remote-control box or at rear panel! Engine RPM +/- adjust (switched output !) depends on: - Emergency-stop not actuated ! - Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation! - Correct mode of operation LOCAL / REMOTE selected and RAM CHANGE mode not activated! - Engine RPM +/- adjust activated on remote-control box or at rear panel!

Service Manual

499

HOME

PRINT

SERVICE TRAINING

Electrical

Info-Center Menu Overview

Status: 03.02.97

INFO-SYSTEM Enter=On

[ ... ] = key !

[ENTER]

PUMPED VOLUME ↓/ /Enter/Clear [↓] [↑]

OPERATION DATA ↓/↑/Enter/Clear

→ [ENTER] → ← [CLEAR] ←

PUMPED ON JOB ~ 1752.3 cbm

(S !)

→ [START] →

Restart delivery-rate measurement!

------------------------------------------------------------------------------------------------------------------------

→ [ENTER] → ← [CLEAR] ←

HYD OIL TEMP 62 ß C

Display temperature of oil in hydraulic reservoir !

[↓] [↑]

PTO SHAFT RPM 1270 rpm

Display RPM of PTO shaft !

[↓] [↑]

HYD PRESSURE CP 159 bars

Display concrete pump hydraulic oil pressure !

[↓] [↑]

CONCR-PUMP HOURS 328.3 h

Concrete pump operating hours !

[↓] [↑]

BOOM HOURS 406.1 h [↓] [↑]

Placing boom operating hours !

[↓] [↑]

PTO HOURS 469.8 h

PTO operating hours !

[↓] [↑]

TOTAL STROKES CP 1398743 strokes

Total number of concrete pump strokes !

[↓] [↑]

TOTAL VOL. PUMPED 109125 cbm

Total pumped volume of concrete pump !

[↓] [↑]

STROKES PER MIN 21 strokes/min

Actual number of strokes of concrete pump unit !

------------------------------------------------------------------------------------------------------------------------

500

Service Manual

HOME

PRINT

SERVICE TRAINING

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!

------------------------------------------------------------------------------------------------------------------------

I/O-STATUS DISPL ↓/↑/Enter/Clear

→ [ENTER] → ← [CLEAR] ←

MACHINE-CONTROL ↓/ /Enter/Clear

Display of I/O status of individual control modules

[↓] [↑]

CP-CONTROL ↓/↑/ENTER/CLEAR

Cf. page 3 I/O display sub-menu

[↓] [↑]

BOOM-CONTROL ↓/↑/ENTER/CLEAR [↓] [↑]

[↓] [↑]

REAR PANEL ↓/↑/ENTER/CLEAR [↓] [↑]

EXTENSION I/O /↑/ENTER/CLEAR -----------------------------------------------------------------------------------------------------------------------INTERNAL TIMER ↓/↑/Enter/Clear [↓] [↑] SCROLLING ↓/↑/Enter/Clear [↓] [↑]

→ [ENTER] → ← [CLEAR] ←

DATE 23.08.95 TIME 16:32

Display of date & time

-----------------------------------------------------------------------------------------------------------------------→ [ENTER] → ← [CLEAR] ←

Scroll rate 400 ms

→ [ENTER] → ← [ENTER] ←

Setting of scroll rate with ↓ & ↑ keys

------------------------------------------------------------------------------------------------------------------------

Service Manual

501

HOME

PRINT

SERVICE TRAINING

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

502

Service Manual

Cf. page 5 Parameter adjustment menu

HOME

PRINT

SERVICE TRAINING

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

------------------------------------------------------------------------------------------------------------------------

CP-CONTROL ↓/↑/ENTER/CLEAR

→ [ENTER] → ← [CLEAR] ←

INP CP-CONTROL

1■2❏3■4❏5❏6■7■8❏

Concrete pump control Digital-inputs

[↓] [↑]

OUTP CP-CONTROL

1■2❏

Concrete pump control Digital-outputs

[↓] [↑]

STROKE LIMITER

■■■■■■■ [↓] [↑]

Concrete pump control Prop-output stroke limiter CP

[↓] [↑]

PRESS LIMITER CP

■■

Concrete pump control Prop-output pressure limiting

[↓] [↑]

HYD PRESSURE CP

■■■■■■

Concrete pump control Analogue-input oil pressure CP

[↓] [↑]

HYD OIL TEMP

■■■

Concrete pump control Analogue-input hydraulic oil temperature

------------------------------------------------------------------------------------------------------------------------

Service Manual

503

HOME

PRINT

SERVICE TRAINING

Electrical BOOM-CONTROL ↓/↑/ENTER/CLEAR

→ [ENTER] → ← [CLEAR] ←

INP BOOM-C1

1■2❏3■4❏5❏6■

Boom-control 1 Digital-inputs

[↓] [↑] INP BOOM-C2

1■2❏3❏4■5❏6❏

Boom-control 2 Digital-inputs

[↓] [↑] BOOM-SLEW RIGHT

■■

Boom-control 1 Prop-output boom-slew right

[↓] [↑]

BOOM-SLEW LEFT

■■■■■■■

Boom-control 1 Prop-output boom-slew left

[↓] [↑]

BOOM 1 EXTEND

■■■■■■■

Boom-control 1 Prop-output boom 1 extend

[↓] [↑]

BOOM 1 RETRACT

■■■■■■■

Boom-control 1 Prop-output boom 1 retract

[↓] [↑]

BOOM 2 EXTEND

■■■■■ [↓] [↑]

Boom-control 1 Prop-output boom 2 extend

[↓] [↑]

BOOM 2 RETRACT

■■■■■

Boom-control 1 Prop-output boom 2 retract

[↓] [↑]

BOOM 3 EXTEND

■■■■■■

Boom-control 2 Prop-output boom 3 extend

[↓] [↑]

BOOM 3 RETRACT

■■■

Boom-control 2 Prop-output boom 3 retract

[↓] [↑]

BOOM 4 EXTEND

■■■■■■

Boom-control 2 Prop-output boom 4 extend

[↓] [↑]

BOOM 4 RETRACT

■■■■■■

[↓] [↑]

504

Service Manual

Boom-control 2 Prop-output boom 4 retract

HOME

PRINT

SERVICE TRAINING

BOOM 5 EXTEND

■■■■■■■

Electrical Boom-control 2 Prop-output boom 5 extend

[↓] [↑]

BOOM 5 RETRACT

■■■■

Boom-control 2 Prop-output boom 5 retract

------------------------------------------------------------------------------------------------------------------------

REAR PANEL ↓/↑/ENTER/CLEAR

→ [ENTER] → ← [CLEAR] ←

INP REAR PANEL 1

1■2❏3■4❏5❏6■7■8❏

Rear panel Digital-inputs 1

[↓] [↑]

INP REAR PANEL 2

1■2❏3■4❏5❏6■7■8❏

Rear panel Digital-inputs 2

[↓] [↑]

INP REAR PANEL 3

1■2❏3■4❏ [↓] [↑]

Rear panel Digital-inputs 3

[↓] [↑]

OUTP REAR PANEL

1■2❏3❏4❏

Rear panel Digital-outputs

[↓] [↑]

POT REAR PAN SL

■■■■■■■

Rear panel Analogue-input stroke limiter CP

------------------------------------------------------------------------------------------------------------------------

EXTENSION I/O /↑/ENTER/CLEAR

→ [ENTER] → ← [CLEAR] ←

INP EXTENSION

1■2❏3■4❏5❏6■7■8❏

Machine-control 3 Digital-inputs

[↓] [↑]

OUTP EXTENSION

1■2❏3■4❏5❏6■7■8❏

Service Manual

Machine-control 3 Digital-outputs

505

HOME

PRINT

SERVICE TRAINING

Electrical

Parameter adjustment menu overview

Status : 03.02.97

Entry of PASSWORD and access to parameter adjustment menu PARAMETER /↑/ENTER/CLEAR

→ [ENTER] → ← [CLEAR] ←

PASSWORD **** ↓/↑/ENTER/CLEAR

Enter password with [↓] [↑] keys

[↓] [↑]

PASSWORD 1234 ↓/↑/ENTER/CLEAR [↓] [↑]

End password entry with [ENTER] key

[ENTER]

PASSWORD 1234 Password OK

Correct password entry confirmed

[↓] [↑]

EFFICIENCY CP ↓/↑/ENTER/CLEAR

Display of PARAMETER ADJUSTMENT MENU

Parameter adjustment menu for EFFICIENCY concrete pump / Central lubrication / Prop current values

EFFICIENCY CP ↓/↑/ENTER/CLEAR

[↓] [↑]

LUBRIC. PARAM ↓/↑/ENTER/CLEAR

→ [ENTER] → ← [CLEAR] ←

EFFICIENCY CP 94 %

→ [ENTER] → ← [ENTER] ←

Parameter adjustment ON [↓] [↑] change EFFICIENCY CP

------------------------------------------------------------------------------------------------------------------------

→ [ENTER] → ← [CLEAR] ←

LUBRIC. CYCLES BOOM 07

→ [ENTER] → ← [ENTER] ←

Parameter adjustment ON [↓] [↑] change number of cycles

→ [ENTER] → ← [ENTER] ←

Parameter adjustment ON [↓] [↑] change number of cycles

→ [ENTER] → ← [ENTER] ←

Parameter adjustment ON [↓] [↑] change number of cycles

[↓] [↑]

LUBRIC. CYCLES CP / AGITATOR 09 [↓] [↑]

[↓] [↑]

LUBRIC. CYCLES OUTRIGGERS 12

------------------------------------------------------------------------------------------------------------------------

The parameter adjustment menu for prop current values of the current control (Rexroth valves) please turn over

506

Service Manual

HOME

PRINT

SERVICE TRAINING

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

HOME

PRINT

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

HOME

PRINT

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

HOME

PRINT

Electrical

510

SERVICE TRAINING

Service Manual

HOME

PRINT

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

HOME

PRINT

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

HOME

PRINT

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

513

HOME

PRINT

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

HOME

PRINT

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

HOME

PRINT

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

HOME

PRINT

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

517

HOME

PRINT

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

PRINT

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

HOME

PRINT

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

HOME

PRINT

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

HOME

PRINT

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

PRINT

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

HOME

PRINT

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

PRINT

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

HOME

PRINT

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

PRINT

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