Vector Manual

05. 2004

SCHWING ñ Control system " VECTOR "

SERVICE MANUAL valid from software version V 1.10 onwards

OK

2

1

OFF

x1000 3 0 PTO 1500 rpm 62˚C

Menu: [ENTER]=ON

HOME

+

HELP

START

CLEAR

-

ENTER

QUIT

PART 1: OPERATION

PART 2: TEACH MODE

Published by: SCHWING GmbH Dept.: VVW Postfach : 20 03 62 D - 44647 Herne Id. no.: 10207417 15.04.04 13:06 All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH.

004.103.01-en

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 E-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

All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH.

004.103.00-en

PART 1

-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

1.

COMMISSIONING

3.1

CONTROL CABINET

1.1

LOCAL CONTROL

3.1.1 DISPLAY

1.2

REMOTE CONTROL

3.1.2 MENU CONTROL

1.3

RAM CHANGE MODE

3.2

LOCAL CONTROL

2.1

ENGINE START / STOP

3.3

REMOTE CONTROL

2.2

EMERGENCY STOP

4.

MENU OVERVIEW - MAIN MENU / SUBMENUS

2.3

BYPASS MODE

5.

MENU OPERATION - EXAMPLE

3.

CONTROL AND MONITORING ELEMENTS

6.

DIAGNOSTIC SYSTEM FAULT HANDLING

6.1

SUMMARY OF MESSAGES

All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH. 004.104.01-en

PART 1

-2-

1. COMMISSIONING

Now, the following functions can be activated:

The electrical machine control system can only be activated if the drive configuration has been properly selected:

- signal horn on

- Switch on the ignition of the vehicle.

- speed reduction

- engine off

- Shift the travel gearbox to neutral position (idling)*. - Apply the parking brake.

1

- Switch on the P.T.O*.

3

Menu: [ENTER]=ON

7

The starting screen is displayed after the initialization (Fig. 1).

6

Fig. 1

8

- Select the desired mode of operation with switch 3 (Fig. 2):

1

6

local control 1

OK

2

7

OFF

5

x1000 3 0 PTO 1500 rpm 62˚C

Menu: [ENTER]=ON

pumping piston replacement

5

x1000 3 0 PTO 1500 rpm 62˚C

The system is being initialized as indicated by the bar graph on the display.

remote control

4

OK

2

1

* For vehicles without P.T.O. see machine operating instructions. - Switch on the machine control in the driver's cab.

2

2 HOME

+

HELP

START

CLEAR

-

ENTER

QUIT

4 3 Fig. 2

The mode selected is indicated in display section 5 (Fig. 1).

All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH. 004.104.01-en

PART 1

-3-

1.1 LOCAL CONTROL

1

This symbol is displayed in section 5 (Fig. 1) of the screen.

2

4

OK

2

1

This symbol flashes in section 4 when a E-stop has been pressed:

3

5

x1000 3 0 PTO 1500 rpm 62˚C

Menu: [ENTER]=ON

Unlock all emergency stop stations

7

6

Fig. 1

This symbol flashes in section 4 when one a of the switches on the local control panel is on (Fig. 2): Set all switches to neutral.

This symbol flashes in section 4 when the system is ready for startup.

HP

R

P

Fig. 2

Start the control with pushbutton 4 (Fig. 3).

8 1 Starting is confirmed by a brief acoustic signal and the symbol on the left is displayed in section 4 (Fig. 1).

6 1

OK

2

7

OFF

5

x1000 3 0 PTO 1500 rpm 62˚C

Menu: [ENTER]=ON

2 HOME

+

HELP

START

CLEAR

-

ENTER

QUIT

4 3 Fig. 3

All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH. 004.104.01-en

PART 1

-4-

1.2 REMOTE CONTROL

1

This symbol is displayed in section 5 of the screen (Fig. 1).

2

4

OK

2

1

This symbol flashes in section 4 when an emergency stop button on the machine or on the remotecontrol box (Figs. 2) has been pressed:

3

5

x1000 3 0 PTO 1500 rpm 62˚C

Menu: [ENTER]=ON

7

6

Fig. 1

The symbol flashes also when the remote-control box is off: Unlock all emergency stop buttons or switch on the remote-control box. 1

30356534 C

2 3

48 4

5

6

3

2

8

1

9 10

0

303623

7

This symbol flashes in section 4 when a switch on the remote-control box is on.

Fig. 2 Set all switches toneutral.

This symbol flashes in section 4 when the system is ready for startup:

Start up the control with this pushbutton on the remote-control box.

Starting is confirmed by a brief acoustic signal and the symbol on the left is displayed in section 4 (Fig. 1).

All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH. 004.104.01-en

PART 1

-5-

1.3 RAM CHANGE MODE

1

This symbol is displayed in section 5 of the screen (Fig. 1).

2

4

OK

2

1

This symbol flashes in section 4 when a E-stop station on the machine has been pressed:

3

5

x1000 3 0 PTO 1500 rpm 62˚C

Menu: [ENTER]=ON

Unlock all emergency shut-off buttons.

7

6

This symbol flashes in section 4 when the system is ready for startup.

Fig. 1

8 1 Start up the control with pushbutton 4 (Fig. 2).

6 1

OK

2

Menu: [ENTER]=ON

The activation of the 'RAM CHANGE MODE automatically reduces thespeed of the engine.

OFF

5

x1000 3 0 PTO 1500 rpm 62˚C

Starting is confirmed by a brief acoustic signal and the symbol on the left is displayed in section 4 (Fig. 1).

7

2 HOME

+

HELP

START

CLEAR

-

ENTER

QUIT

4 3 Fig. 2

The concrete pump and the diesel engine can now be controlled with the switches on the special control box (Fig. 3). See machine operating instructions, chapter 4.43: 'RAM CHANGE MODE' .

Fig. 3

All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH. 004.104.01-en

PART 1

-6-

2.1 ENGINE START / STOP To prevent unintended starting of a machine function, the engine can only be started when all switches (controlling hydraulic functions) are in their neutral (0) position. Shutting off the engine when a function is active is possible, but should be avoided. If there is no emergency, always proceed as follows. - deactivate the function(s), then - reduce the engine rpm to idle - shut off the engine. 2.2 EMERGENCY STOP Do not use the emergency stop switches as an on/off switch, it is for emergencies only. In normal operating conditions always stop the machine functions and the engine with the controls provided for this purpose.

All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH. 004.104.01-en

PART 1

-7-

2.3 BYPASS MODE

ATTENTION: RISK OF ACCIDENT AND DAMAGE Perform all machine movements with the lowest possible speed and under permanent supervision. Commands from electrical controls will not be executed. The emergency shut-off system and all safety limit switches are not operational. During the work, the key must not be left in the key-switch. It must be withdrawn and kept in a safe place.

The dump valves of the machine are open without current. This means: These valves will open when the power supply has been interrupted (E-stop is active).

ATTENTION: RISK OF ACCIDENT The machine may only be used when the emergency stop system is fully operational.

8 1

If - in certain emergency situations (machine loaded with concrete) - the machine cannot be repaired immediately, the power supply to the dump valves can be reactivated manually:

6 1

OK

2

Menu: [ENTER]=ON

In this position, the key cannot be withdrawn.

OFF

5

x1000 3 0 PTO 1500 rpm 62˚C

- To do so, insert the key into key-switch 7 (Fig. 1) and turn it to the locked position.

7

2 HOME

+

HELP

START

CLEAR

-

ENTER

QUIT

4 3

- Control the machine movements with the manual levers of the control valves. - Clean the machine and bring to it transport position. - Stop working on the job and have the emergency shut-off system be repaired immediately.

All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH. 004.104.01-en

PART 1 3.

-8-

CONTROL AND MONITORING ELEMENTS

3.1 CONTROL CABINET (Fig. 1)

8 1 - Display

1

2 - Key: menu control 3 - Operating mode selector: - local control - remote control - ram shange mode

7

6 1

OK

2

OFF

5

x1000 3 0 PTO 1500 rpm 62˚C

Menu: [ENTER]=ON

2

4 - Momentary-contact switch: control on

HOME

+

HELP

START

CLEAR

-

ENTER

QUIT

4 3

5 - Switch: Select EASy working range *

Fig. 1

6 - Switch: EASy* off 7 - Key-switch: Emergency stop bypass 8 - Connector: radio or cable remote control * Optional equipment: One-Side Outrigger System (EASy), see separate operating instructions

1

2

3 2

1

OK 5

x1000 3 0 PTO 1500 rpm 62˚C

3.1.1 DISPLAY

Menu: [ENTER]=ON

On start-up, the following data are displayed on screen (Fig. 2):

7

1 - P.T.O. speed

4

6 Fig. 2

2 - Hydraulic oil temperature 3 - Oil cooler "on" 4 - Control status 5 - Selected mode of operation 6 - Concrete pump delivery rate 7 - Menu options

All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH. 004.104.01-en

PART 1

Important note: After pressing the key on the menu control panel, further operational data can be displayed:

-9-

Operating mode display: Section 5 (Fig. 1) of the screen displays the following modes of operation: Remote-control (radio or cable)

- concrete pump hydraulic oil pressure - hydraulic oil reservoir level indication (optional equipment)

Local control

- engine load factor (optional equipment independent of vehicle)

Pumping piston replacement

Control status indications: Section 4 (Fig. 1) of the screen displays the following conditions: Control system is running.

1

2 2

1

Control off, start up.

3

4

OK 5

x1000 3 0 PTO 1500 rpm 62˚C

Menu: [ENTER]=ON

Starting not possible: switches not in neutral position.

7

6 Fig. 1

Starting not possible: emergency stop activated

All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH. 004.104.01-en

PART 1

- 10 -

3.1.2 MENU CONTROL Basic functions of the keys (2) in Fig. 1: 8

One step back in menu.

1

6 1

OK

2

7

OFF

Select indicated menu item or activate changes

5

x1000 3 0 PTO 1500 rpm 62˚C

Menu: [ENTER]=ON

2 HOME

+

HELP

START

CLEAR

-

ENTER

QUIT

Confirmation and reset of diagnostic messages.

4 3 Fig. 1

When a key pressed, the corresponding function is identified by a symbol in the upper left corner of the display.

Fast selection / abbreviated function keys (shortcuts): Press the following keys at the same :

Full return to start screen and

or

to set the contrast of the LCD display manually. Up one item in the menu selection list.

During setting, the contrast is indicated on display between 0 and 99 %.

Down one item in the menu selection list. and Supplementary information for certain screens of the diagnostic function. Presently not implemented.

to go to the manual language selection for all displays.

Execution of certain actions, e.g. resetting of the concrete pump's delivery rate counter.

All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH. 004.104.01-en

PART 1

- 11 -

3.2 LOCAL CONTROL Compressor

Concrete pump delivery rate HP

(+)

= increase

(-)

= reduce

R

Agitator

P

P RPM engine (+) (-)

Agitator

= up = down

(P) = forwards (pumping)

R

(R) = reverse (suction)

Vehicle engine

Concrete pump

(I)

= start

forwards (pumping)

(0)

= stop Concrete pump

Work light

reverse (suction)

Water pump (I) = locked (continuous) (T)= momentary (special control)

Vibrator

Ball injection system

High-pressure water pump

All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH. 004.104.01-en

PART 1

- 12 -

3.3 REMOTE CONTROL Water pump

Agitator in: 1

( ) = forward ( ) = reverse

30356534 C

2 3

303623

48 4

5

6

3

7

2

8

1

9 10

Compressor

0

RPM engine (+)

= up

Concrete pump

(-)

= down

forwards (pumping)

Vehicle engine

Concrete pump

(I)

= on (starting

reverse (suction)

(0)

= off (stopping) boom speed slow (placing operations)

Control on Diagnostic horn signal confirm (shut-off)

(0)

boom functions off boom speed fast (set-up and take-down)

Vehicle signal horn on Radio remote control only: End hose shutoff valve.

LED: charge condition of transmitter battery

Ball injection system.

LED: tansmitter state of operation: continuously on = transmitter ready

Concrete pump delivery rate (+)

= increase

(-)

= reduce

flashing

= transmitting control signals

Vibrator in automatic mode on

All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH. 004.104.01-en

PART 1

- 13a -

4.1 MENU OVERVIEW - MAIN MENU

OK

2

1

x1000 3 0 PTO 1500 rpm

Menu: [ENTER]=Ein

3 0

50

2

x1000 3 0 PTO 1500 rpm

CP Hydraulic Engine 2 100 100 1

1

75

OK

E-Stop Chain Dump Valve BOOM Dump Valve CP Dump Valve MPS

A: 0 C: 0 DW: 0

1

0 h C

Pumped Volume Counter Start

Pumped on the job: 2.4 cbm Reset ? - > [START] Pumped Volume

2

OK

C

Malfunction List !

x1000 3 0 PTO 1500 rpm

OK

B: 0 D: 0 E: 0

Malfunct.List?

n/a

Start

!!

Malfunct.List!

C

0 h C

Function: Boom Switch/Command Hopper Grate Stroke Limiter Valve Output

OK

OK 0%

Function: Radio Remote Command Valve Valve Valve

2

Pumped Volume?

C

0˚C 50 ---%

1

x1000 3 0 PTO 1500 rpm

Active :Radio Error :No CAN Data! SigPTOl : =OK

p

4 0 0 bar ---%

OK

Function: E-Stop

Status-Screen?

OK

OK On On On

OFF CLOSE 0% OFF

0 OK

Valve Output

0 0 h C

Switch/Command Water Tank

0 OK

Valve Output

0

2

Oper.Data?

OK

Function: Water Pump

1

x1000 3 0 PTO 1500 rpm

33 h C

Function: Concrete Pump Switch/Command Water Tank

OK

OK

Oil Pressure CP Oil Temperature Oil Tank Level PTO Hours CP Hours Boom Hours Oper. Data! Water Pump Hp-Water Pump Compressor Agitator Oilcooler Vibrator

Hrs Hrs Hrs Hrs Hrs Hrs

Pumped Vol. Pumped Vol. Strokes CP Stroke Rate

Job Ttl Ttl CP

Central Lubr. Hrs 0 h C

bar ˚C % h h h

C 0.00 0.00 0.00 0.05 33.51 0.00

Oper. Data!

OK

Function: HP-Water Pump

69.8 64 ---.33.84 0.09 0.10

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 ! Switch/Command Overheating

0 No

Valve Output

0

OK O h C

Function: Compressor Switch/Command Output Switch/Command Output

0 0 0 0 33 h C

Oil Temp. Hydr. Diesel Engine

84˚C Off

Output

0

OK 33 h C

Function: Oilcooler Outrigger Station Brakes Lim-Sw right Brakes Lim-Sw left Valve Output

0 0 0 0

OK 0 h C

Function: Outrigger Switch Command Hopper Grate Rever. Station Valve Output

Oper. Data!

OK

Function: Diesel Engine

OFF close No OFF

OK 0 h C

Function: Agitator Switch Command Hopper Grate

0 close

Output

0

Function: Vibrator

OK 0 h C

Manufacturer/Type KFZ.-TYP

OK

Truck Serial Number KFZ.-NR Truck Data Main MMI Remote Manufact.

ID SW ID SW ID

: : : : : :

System Data Mach.-Nr. Mach.Type CP-Type Hyd.-Type Hotline

C

03.09.002 V01.10 03.09.002 V01.10 PROTOTYP OX

OK

1-888-292-0262

Machine Data

C

interPTOl clock!!! cond. batt. :OK date time

OK

C

:TEST SHE :03.09.001 :LS :.-.-.-.-.-.-

OK

d.m.y : h.m.s : System Clock

C

Boom Slewing Outrigger

0.00 h 0.00 h 0.00 h C

PART 1 1

2

- 13b -

OK

1

x1000 3

0

NA 1350 U/min

I/O-Readout?

1

0

2

x1000 3

OK

x1000 3

0

NA 1350 U/min

2

Dig. Input?

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 -----------------------Change? [ENTER] Select Language [ ] [ ] Store? [ENTER]

OK

Language MMI!

OK

x1000 3

0

OK

NA 1350 U/min

Pumped Volume shown in: Current: cbm -----------------------Change? [ENTER] Select Language [ ] [ ] Store? [ENTER]

OK

Display cbm/cby? Displ cbm/cby! 1

0

2

x1000 3

NA 1350 U/min Password?

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