Page 1 Home Print Print OPERATION MANUAL ORIGINAL INSTRUCTIONS FOR CONCRETE LINE PUMPS All SP “Rock Valve” Models Part Number 30100750 Line Pump Division 5900 Centerville Rd White Bear, MN. 55127 1-888-SCHWING (724-9464) www.schwing.com...
Page 2 Home Print Print CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Version 3.0.8 Revision date 05/14...
Page 4: Table Of Contents
Phase E....................44 Phase F ....................46 Phase G ....................48 Phase H ....................50 Phase I....................52 Phase J....................54 Phase K ....................56 Component Locations ................58 Hopper Area..................63 Operation Manual - All SP Rock Valve models revDate...
Page 5 Blockages................... 87 Clean-out.................... 87 Disposing of excess concrete ............. 88 Clean the hopper ................88 Clean the rock valve and material cylinders ........92 Be careful with acid ................93 Clean the waterbox ................94 Preparation for travel ................. 95 Special Pumping Situations ..............
Page 6 Using a Nomograph ................137 Weld On Ends / Coupling Comparison ..........145 MInimum Pipe Wall Thickness .............. 146 Glossary of Terms................... 147 Additional Reading Material..............152 List of Lubricants and Nitrogen.............. 153 Operation Manual - All SP Rock Valve models revDate...
Page 7 Home Print Print Table of Contents End of Life Protocol................156 Operation Manual - All SP Rock Valve models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:AllSPRockvalveTOC.fm...
Page 8 Home Print Print Table of Contents Operation Manual - All SP Rock Valve models viii revDate...
Page 9 Print Print Introduction swg99a001.eps INTRODUCTION Manufacturer’s Statement................. 8 Model Number: ..................9 Serial Number:.................... 9 ID Tag Location ..................10 ID Tag......................11 Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Intro.fm...
Page 10: Manufacturer's Statement
The illustrations contained in this manual are intended to clarify text passages. They may look slightly different from your unit, but this has only been allowed if it does not fundamentally change the factual information. Operation Manual - All SP Rock Valve Models revDate...
Page 11: How To Reach Us
CAUTION When replacing parts always use original Schwing replacement parts Hazard and consequence will be shown in this space. Model Number: Serial Number: Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Intro.fm...
Page 12: Id Tag Location
The ID tag for this machine is located on the right hand side of the tongue on the passenger side as shown in Figure 1. SWG99a002.eps Figure 1 Location of ID tag and serial number Operation Manual - All SP Rock Valve Models revDate...
Page 13: Id Tag
The unit serial number is located on the tongue directly below the ID tag as shown in Figure 2. When you locate the number, call the Schwing Service Department for the information. The unit ﬁles are arranged by this serial number and the service personnel can ﬁnd out anything about the unit from the...
Page 14 Home Print Print Introduction NOTES Operation Manual - All SP Rock Valve Models revDate...
Page 15 Home Print Print Specifications swg99a001.eps SPECIFICATIONS Unit Speciﬁcations ................... 14 Hydraulic Pressure Speciﬁcations ............16 Operation Manual - All SP Rock Valve Models...
Page 16: Specifications
1651 mm (65 in.) Height 2209.8 mm (87 in.) 1879.6 mm (74 in.) 1879.6 mm (74 in.) Remote Control Cable Length 30.5 m (100 ft.) 30.5 m (100 ft.) 30.5 m (100 ft.) Operation Manual - All SP Rock Valve Models...
Page 17 * Max RPM of the hydraulic pumps is calculated while the pump is under a full load. Depending on the unit, it is acceptable for the max RPM to vary slightly from the published estimate. Operation Manual - All SP Rock Valve Models...
Page 18: Hydraulic Pressure Specifications
Stroke limiter circuit 0-25 (0-363) Nitrogen pressure 100 (1450) Noise emission levels Decibels SP 500 107 dB SP 750 110 dB SP 1000 113 dB SP 1250 113 dB SP 2000 113 dB Operation Manual - All SP Rock Valve Models...
Page 19 Home Print Print Safety swg99a001.eps SAFETY How to Order Additional Safety Manuals ..........18 Safety Manual (Separate Document) ...Immediately following page 20 Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Safety.fm...
Page 20: Safety
Schwing phone numbers • Spare Parts ....(888) SCHWING • Spare Parts (fax) ....(651) 429 - 2112...
Page 21 Thank you in advance for your consideration in this matter. Best Regards, Danny L. Mace Manager, Product Safety Department Schwing America, Inc. safemanbulletinletter.fm Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Safety.fm...
Page 22 Line Pump, Bound, English v 6.0.1 ..................Part #30381680 Line Pump, Bound, Spanish v 6.1.1 ..................Part #30381841 Feel free to copy or otherwise reproduce this form if more copies are needed. internal250:servicebulletins:601order form.ai Operation Manual - All SP Rock Valve Models revDate...
Page 23 First Commissioning ................. 22 Machine Description ................. 23 SP Circuit Diagram ................... 28 SP 2000 Circuit Diagram ................36 Component Locations................58 Safety Devices ..................66 Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 24: Product Overview
32. Tail light and clearance lights 33. Safety decals (see decal sheet) 34. Tools/Spare Parts (see tool check list) 35. Visual inspection of paint job * Please note any other comments on back of white copy Operation Manual - All SP Rock Valve Models revDate...
Page 25: Machine Description
Emergency Stop switches Pressing one of the RED EMERGENCY PUSH STOP switches (Figure 3) will stop the engine. SWG98n135.eps Figure 3 Emergency Stop Switches (4) Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 26: Concrete Pump Hydraulic Pumps
The pumps also accept external signals for devices and by adjustment of external valves (the control of the output. At Schwing, we route signals to stroke limiter). the pump from the hydraulic stroke limiter. The net...
Page 27 12. Hydraulic return ﬁlter with bypass valve 25. Main ﬂow poppet valve 13. Accumulator Figure 5 The fully hydraulic pump control system (for hi-ﬂo pumpkit) Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 28 Print Print Overview Figure 6 The rock valve slewing cylinders (shown as item 5 in Figure 3) Figure 7 “S” valve diagram explanation for S2 and S3 valves (shown as items 6 and 7 in Figure 3) The term “differential cylinder” refers to the fact that each of the hydraulic cylinders that push the concrete have an area difference (referred to as an “area...
Page 29 2:1. Figure 9 Switching valve diagram explanation Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 30: Sp Circuit Diagram
• A pilot signal (high pressure oil) is routed from the accumulator circuit to the end cap of the S2 directional control valve (7), which moves into the parallel position. Operation Manual - All SP Rock Valve Models revDate...
Page 31 Soft Switch Pressure Zero Pressure (Tank, or oil at rest) Nitrogen pressure set at 100 bar (1450 PSI) 14 15 310 bar 20 bar WPhifloA.eps Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 32: Phase B
A pilot signal (high pressure oil) is routed from the accumulator circuit to the left side end cap of the S2 directional control valve (7). The S2 valve slides into the cross-over position. Operation Manual - All SP Rock Valve Models revDate...
Page 33 Soft Switch Pressure Zero Pressure (Tank, or oil at rest) Nitrogen pressure set at 100 bar (1450 PSI) 14 15 310 bar 20 bar WPhifloB.eps Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 34: Phase C
Please note that right and left refer to the orientation you would have if you were looking from the trailer hitch towards the front of the unit. • The rock valve slewing cylinder (5) has fully extended • High pressure oil (red) continues to ﬂow into...
Page 35 Soft Switch Pressure Zero Pressure (Tank, or oil at rest) Nitrogen pressure set at 100 bar (1450 PSI) 14 15 310 bar 20 bar WPhifloC.eps Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 36: Phase D
Overview Phase D • At the same time that the rock valve cylinder is extending, a high pressure pilot signal is sent Please note that right and left refer to the orientation to the right end port of the S2 spool. It slides you would have if you were looking from the trailer into the parallel position.
Page 37 Soft Switch Pressure Zero Pressure (Tank, or oil at rest) Nitrogen pressure set at 100 bar (1450 PSI) 14 15 310 bar 20 bar WPhifloD.eps Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 38: Sp 2000 Circuit Diagram
S2 and S1 and through the ﬁlter (7). Oil directed through the S3 has the rock valve shift cylinder held in the retracted (right) position so that concrete from the left hand material cylinder is being pushed into the delivery pipe line.
Page 39 High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest) 1.5 mm hole drilled through spool To Agitator To Fwd/Rev Handvalve Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 40: Phase B
ﬂow through check valve (17) on the right hand differential until the left hand differential is fully extended. Operation Manual - All SP Rock Valve Models revDate...
Page 41 High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest) 1.5 mm hole drilled through spool To Agitator To Fwd/Rev Handvalve Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 42: Phase C
High pressure oil from switching valve (5) has now shifted the S3 valve (3) fully to the right hand position. At this point the pressure oil to the rock valve shift cylinder (4) is changed and the right hand side of the cylinder is getting oil so that the cylinder will extend.
Page 43 High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest) 1.5 mm hole drilled through spool To Agitator To Fwd/Rev Handvalve Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 44: Phase D
At this point a signal is sent to the left hand end cap of the S2 valve (2) from a signal port on the rock valve shift cylinder (4). As the S2 valve (2) shifts to the right oil from the right hand end cap of the S2 valve (2) is routed to the hydraulic tank via check valve (13), valves (3, 1) and the ﬁlter (7).
Page 45 High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest) 1.5 mm hole drilled through spool To Agitator To Fwd/Rev Handvalve Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 46: Phase E
(1) and the S2 valve (2) to the rod side of the left hand differential cylinder. Please note that while the left hand differential cylinder is starting to retract, check valve (17) must close otherwise the right hand differential cylinder will not extend. Operation Manual - All SP Rock Valve Models revDate...
Page 47 Low Pressure Zero Pressure (Tank, or oil at rest) 1.5 mm hole drilled through spool To Agitator To Fwd/Rev Handvalve Note: Check Valve Must Close Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 48: Phase F
(2 and 1), ﬁlter (7) and back to the tank. Oil directed through the S3 valve has the rock valve shift cylinder held in the extended position so that concrete from the right hand...
Page 49 High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest) 1.5 mm hole drilled through spool To Agitator To Fwd/Rev Handvalve Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 50: Phase G
ﬂow through check valve (16) and back to the hydraulic tank until the left hand differential cylinder is fully retracted. Operation Manual - All SP Rock Valve Models revDate...
Page 51 High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest) 1.5 mm hole drilled through spool To Agitator To Fwd/Rev Handvalve Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 52: Phase H
High pressure oil from the switching valve (6) has not shifted the S3 valve (3) fully to the left hand position. At this point the pressure oil to the rock valve shift cylinder (4) is changed and the left hand side of the cylinder is getting oil so that the cylinder will retract.
Page 53 High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest) 1.5 mm hole drilled through spool To Agitator To Fwd/Rev Handvalve Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 54: Phase I
At this point a signal is sent to the right hand end cap of the S2 valve (2) from a signal port on the on the rock valve shift cylinder (4). As the S2 valve (2) shifts to the left oil from the right hand end cap of the S2 valve (2) is routed to the hydraulic tank via check valve (12), valves (3, 1) and ﬁlter (7).
Page 55 High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest) 1.5 mm hole drilled through spool To Agitator To Fwd/Rev Handvalve Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 56: Phase J
S2 valve (2) to the rod side of the right hand differential cylinder. Please note that check valve (16) must close otherwise the right hand differential cylinder will not retract. Operation Manual - All SP Rock Valve Models revDate...
Page 57 High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest) 1.5 mm hole drilled through spool To Agitator To Fwd/Rev Handvalve Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 58: Phase K
Home Print Print Overview Phase K Refer to diagram 1 for explanation of ﬁrst working stroke. Operation Manual - All SP Rock Valve Models revDate...
Page 59 High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest) 1.5 mm hole drilled through spool To Agitator To Fwd/Rev Handvalve Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 60: Component Locations
Electronic throttle control switch (optional)- This switch is only utilized when it has been included as an option on the unit. • Pump Off switch - Controls the concrete pump on and off function. Operation Manual - All SP Rock Valve Models revDate...
Page 61 On-Off_ throttle control switch Pump Oil cooler switch switch Dummy Pump Plug -Forward- -Reverse- Pump switch -Local- -Off- Key switch -Remote- 98351115 murphypanel.eps switch Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 62 NOTE! system that reduces main system pressure The stroke limiter must be turned down to during the shifting of the Rock Valve. In the 60% or less before disabling the soft switch function to prevent damaging the hydraulic event of a failure in the soft switch system, it is system.
Page 63 Figure 12 Supplied Accessories The supplies accessories include the following: 1. Remote control with 30 meters of cable 2. Rock valve cover alignment bolts 3. Clean-out rake 4. Tool box complete with tools 5. Box containing parts books, operator manuals,...
Page 64 • Emergency Stop Switch (Figure 14). Pushing this switch shuts off the engine and dumps all hydraulic oil circuits to the reservoir, thereby preventing machine movement. Figure 14 Emergency Stop Switch Operation Manual - All SP Rock Valve Models revDate...
Page 65: Hopper Area
Components of the Hopper Area • Agitator motor (Figure 16) is a hydraulically driven motor that is directly coupled to the agitator shaft. Figure 16 Agitator Motor Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 66 Overview • Rock valve grease manifold (Figure 17). From other points on the rock valve assembly that this manifold, you can grease all points on the must be greased, but they are in accessible rock valve assembly that would normally not locations.
Page 67 SP hopper grate interlock switch Figure 20 Hopper grate interlock switch SP units Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame...
Page 68: Safety Devices
ﬁgures. They are the pressures that the machine was designed to work with, and that the components were designed to accommodate. There are a very few instances where Operation Manual - All SP Rock Valve Models revDate...
Page 69: Warning Labels
To address the problem of fading labels, Schwing has made the decision to supply warning labels at cost for as long as the machine is in service.
Page 70 Home Print Print Overview NOTES Operation Manual - All SP Rock Valve Models revDate...
Page 71 Operation swg99a001.eps OPERATION Preparation ....................70 Towing the unit..................74 Unit Set-Up ....................75 Operating the Pump.................. 76 Special Pumping Situations ..............95 Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:operation.fm...
Page 72: Preparation
• Grease gun and grease tubes are present and in good working order until it’s too late to do anything about it. Operation Manual - All SP Rock Valve Models revDate...
Page 73 First aid kit • Flares • Reﬂector signs • Fire extinguisher • Job ticket • Map(s) • Job site phone number and contact person Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:operation.fm...
Page 74: Have The Right Personal Protective Equipment For The Job
HARD HAT HEARING SAFETY PROTECTION GOGGLES BREATHING MASK SNUG SAFETY FITTING VEST CLOTHES GLOVES STEEL TOED SHOES SafegearWvest.eps Figure 21 Wear personal protective equipment Operation Manual - All SP Rock Valve Models revDate...
Page 75: Check The Equipment Before Leaving The Yard
Department before using the unit. If the engineers determine that repair is necessary for safe operation, DO NOT OPERATE THE UNIT UNTIL REPAIRS ARE COMPLETED. Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:operation.fm...
Page 76: Towing The Unit
These parts were deﬁnitely NOT designed to support the entire unit load. Operation Manual - All SP Rock Valve Models revDate...
Page 77: Unit Setup
If you suspect that you and if you are pumping in an area where exhaust fumes may have a job like this booked, call the Schwing may linger or be conﬁned, proper ventilation must be Service Department for advice before you set up the assured.
Page 78: Setting The Stabilizers
ﬂash. c. After 6 to 10 seconds, turn the engine start switch to the START position and crank the 4. Disengage E-stop on radio remote, light engine. will be solid. Operation Manual - All SP Rock Valve Models revDate...
Page 79: Basic Troubleshooting
(found on control panel) will illuminate and Engine quit running: will not go out until the engine starts. • Check diesel fuel level. Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:operation.fm...
Page 80: Before The First Truck Backs Up To Your Hopper
Schwing radio remote control system. Check it out before the pour begins. Figure 24 Be sure the waterbox is full of water Operation Manual - All SP Rock Valve Models revDate...
Page 81 Put a couple of shovelfuls of sand or dirt in the • If you will be using portland cement and water bottom of the rock valve housing, above the to make your lubricating slurry, prepare for it clean-out door. This will prevent concrete from now (Figure 27).
Page 82 There are 4 zerks to grease for the cones to bulge out slightly because they the rock valve, plus the two for the agitator. are full of grease, but you don’t want to have the grease come out around the shaft,...
Page 83: Lubricate Your Pipeline
When the cement has all been washed to the bottom, job situation. Before you begin to mix the slurry, put on you can cycle the rock valve back and forth a few times your breathing mask and the rest of your personal to agitate the mix a little more.
Page 84 Home Print Print Operation Figure 29 Mixing the slurry in a barrel Operation Manual - All SP Rock Valve Models revDate...
Page 85: To Control The Speed Of The Unit
ﬁnd the source of the blockage and remove it manually. Beware...because it can go to zero strokes per minute, Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:operation.fm...
Page 86: Pump The Job
(Figure 30). output until the rock valve cylinder has completed its...
Page 87: Time Constraints
Under certain hot weather and old on page 96. concrete circumstances, the concrete may go from being pumpable to setting very, very quickly. This is Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:operation.fm...
Page 88: To Disable The Entire Unit In An Emergency
Your grate will catch it anyway. If you have to wait so long that the concrete is before it goes into the hopper (providing it is in place). Operation Manual - All SP Rock Valve Models revDate...
Page 89: Blockages
Check Your Water Supply! You Will Need Water For Reassemble the pieces, and pin the clamp(s) if Clean-out. Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:operation.fm...
Page 90: Disposing Of Excess Concrete
Never bottom of the rock valve housing before you begin climb the ladder holding the hose on your shoulder or pumping, as documented on page 79.
Page 91 SWG98n186.eps Figure 33 Clean the agitator and hopper through the grate with water Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:operation.fm...
Page 92 Agitator On-Off switch Agitator X 1000 On-Off_ switch 98347087 98351115 agitoff.eps Figure 34 Stop the agitator by placing the switch on the control panel in the “OFF” position. Operation Manual - All SP Rock Valve Models revDate...
Page 93 Don’t spend too much time on this procedure, or the before removing any concrete that has completely set. concrete will have time to set up in the rock valve and Once the concrete has set, there is no advantage to material cylinders.
Page 94: Clean The Rock Valve And Material Cylinders
Operation Clean the rock valve and material cylinders Figure 36 Use the rake to remove material from the rock valve and material cylinders Figure 37 Never put your hands in the concrete valve Once the hopper is clean, you should clean out the rock thereby eliminating the need to pull material from deep valve and material cylinders.
Page 95: Be Careful With Acid
Be careful with acid Spray water into the opening, washing the end of the rubber ram, the material cylinder, the rock valve and the outlet pipe. Continue washing until the water that CAUTION leaves the valve is clear and clean. Visually inspect that no rocks, sand or clumps of concrete remain.
Page 96: Clean The Waterbox
See the section on cold weather operation for further details. Figure 39 Stop the pump, be sure of your footing, then spray out the waterbox. Operation Manual - All SP Rock Valve Models revDate...
Page 97: Preparation For Travel
(the end from which the rod protrudes). The rocking oil loop hose is connected from one cylinder to the other on the piston end. Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:operation.fm...
Page 98: Quick Clean-Out
-10° Fahrenheit, and even colder under certain circumstances. This can present a variety of problems compared with pumping in moderate temperatures, such as: Operation Manual - All SP Rock Valve Models revDate...
Page 99: Preheating The Hydraulic Oil
This could Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:operation.fm...
Page 100 Home Print Print Operation NOTES! Operation Manual - All SP Rock Valve Models revDate...
Page 101 Hydraulic Oils..................102 Pressure, Hoses and Fittings............... 102 General Maintenance Tips..............104 Preventative Maintenance ..............105 Scheduled maintenance checklist ............115 Unscheduled maintenance ..............116 Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Maintenance.fm...
Page 102: Filtration
8 PSI P when the element is in a Schwing needs to be ﬁltered to a MINIMUM of clean. The pressure drop varies with the viscosity of 25μ, and preferably ﬁner than that. Filters are rated by: the oil, which is why you can ignore the delta P pop out •...
Page 103 DO NOT change the housing or element to some other type. You may learn that, in the long run, sometimes cheaper is more expensive. Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Maintenance.fm...
Page 104: Hydraulic Oils
Appendix section of this manual for help in selecting Hydraulic oils are rated for viscosity, heat dissipation, the proper oil for your requirements. foaming characteristics, pour point, antiwear additives, The quality of the oil needed for use in a Schwing anticorrosive additives, lubricating qualities, machine is rated in the DIN system.
Page 105: Specific Information
All of the horsepower that it took to send the Schwing uses high pressure ﬁttings and hoses on all oil out of the pumps at 2500 PSI is turned to heat, circuits, even if the relief valve for that circuit is set to which will boil the oil.
Page 106: General Maintenance Tips
In this example, bolt “B” would last MUCH longer than bolt “A”. The torque speciﬁcations DANGER DANGER for bolts used on Schwing equipment are found in the Appendix section of this manual. LOCKED This unit has been LOCK OUT Adjusting relief valves.
Page 107: Preventative Maintenance
The drain cock used to drain water hydraulic oil reservoir, by opening the drain from the reservoir. cock or faucet located at the bottom of the Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Maintenance.fm...
Page 108: Weekly Maintenance
The tension nut adjusts the free play of your pocket and remove the hopper grate or the rock valve on the kidney seal end. Wear on waterbox covers and inspect with a wrench. If the cutting ring end is compensated for you ﬁnd that they are loose, tighten with a...
Page 109: Monthly Maintenance
The rock valve will slide far enough out for and on the hydraulic schematic that applies to you to rotate the cutting ring 90°. that circuit. The schematics are all contained in g.
Page 110 Figure 49 The main relief valve, concrete pump circuit. The Schwing concrete pump circuit on the WP Series 750-15 and the BPA 450 and 500. Return the pumps are designed to be operated at a maximum pump to “neutral” whether in needs adjustment pressure of 330 bar (4785 PSI).
Page 111: Quarterly Maintenance
ﬁlters every 500 hours or once a year, which ever loosen the jam nut and a 4mm allen wrench to comes ﬁrst. Schwing uses Mobile 10W-30 in all turn the relief valve. Turn it clockwise to engines. For speciﬁc grades of motor oil and general maintenance of your engine, refer to your Duetz operation manual.
Page 112: Semiannual Maintenance
1500 2000 2500 1000 3000 hose 3500 30355456 ACCUMULATOR CHARGING KIT HYDAC bladder (Includes hose and charge valve assy) Accumulator SCHWING PART NUMBER: 30355436 chargkit.eps Operation Manual - All SP Rock Valve Models revDate...
Page 113 Replace the valve guard. The job adjustment handle, and ﬁll the SLOWLY is complete. accumulator. Shut off the supply when the Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Maintenance.fm...
Page 114 Home Print Print Maintenance BLADDER ACCUMULATOR Cross Section of the Accumulator 1. Steel Shell 2. Bladder 3. Bladder Stem 4. Port Assemblies 5. Fluid Ports 6. Gas Valve Operation Manual - All SP Rock Valve Models revDate...
Page 115 3. Inﬂux of hydraulic oil for storage 4. Fluid charged to maximum working pressure P3 5. Discharge of hydraulic oil 6. Fluid discharged down to minimum working pressure p2 Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Maintenance.fm...
Page 116: Annual Maintenance
See the information at the beginning of this chapter for speciﬁc information about hydraulic oils that are approved for use in Schwing machines. f. Change the main return ﬁlter before restarting the unit. Operation Manual - All SP Rock Valve Models revDate...
Page 117: Scheduled Maintenance Checklist
Bleed Moisture From Hydraulic Tank √ Check Differential Cylinder Rod Packings √ Inspect Bolts On Rams √ Grease Rock Valve and Agitator Bearings √ Inspect For Damage and Leaks √ Check If Maintenance Is Due √ Check Rock Valve Tension Nut √...
Page 118: Unscheduled Maintenance
Start engine and run at low RPM until unit are greatly increased if more than one person is reaches operating temperature and cycle pump. around. There are also less distractions when Operation Manual - All SP Rock Valve Models revDate...
Page 119 (dogbone). Figure 55 Retract the left side rod into the waterbox all but about an inch and a half Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Maintenance.fm...
Page 120 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 Operation Manual - All SP Rock Valve Models revDate...
Page 121 Clean and inspect the bolts and cone washers, the dog bone, and the cylinder ﬂange. Replace any damaged or worn parts with new ones. Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Maintenance.fm...
Page 122 Be careful not to go too far Cone Washer Sets. At this time ﬁnger tighten only. (Figure 61)! NOTE! Figure 61 Slowly move the cylinder to meet the dog bone Operation Manual - All SP Rock Valve Models revDate...
Page 123: Tier Iv Engine Regeneration Control Logic
Service Bulletin G-102/88. When optimum soot loading is reached, between 90%- Contact the Schwing Service Department at (651) 130% and all of the preconditions are met, an active 429-0999 or 678-560-9801 if you need a copy of the regeneration will start.
Page 124: Regeneration Monitoring And Warning Levels
Active regeneration can be triggered from the ﬂow resistance model if the DPF is becoming blocked at a higher rate than expected (according to the soot load estimation model) (Figure 64 Point F). Operation Manual - All SP Rock Valve Models revDate...
Page 125 AUTOMATIC ACTIVE REGENERATION J1939 SPN 3701 - 000 PASSIVE REGENERATION STATE 3 STATE 4 STATE 5 TIME Figure 64 Monitoring and warning levels Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Maintenance.fm...
Page 126 Home Print Print Maintenance NOTES! Operation Manual - All SP Rock Valve Models revDate...
Page 127 Weld On Ends / Coupling Comparison ........... 145 MInimum Pipe Wall Thickness ..............146 Glossary of Terms................... 147 Additional Reading Material..............152 List of Lubricants and Nitrogen............... 153 Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 128: Appendix
90° C (194° F). The optimum gets thicker when the temperature is low, and thinner as range is at about 50° C to 76° C. the temperature rises. Operation Manual - All SP Rock Valve Models revDate...
Page 129: Torque Specifications For Metric Bolts
Torque Speciﬁcations for Metric Bolts The following charts show the tightening torques speciﬁed for the bolts used on Schwing equipment. The charts are to be followed unless there is different torque spec. indicated for a particular procedure. Torque speciﬁcations are very important for proper machine function.
Page 130: Recommended Emergency Hose Kit
Each size listed represents the longest WPhose lengths.eps Diameter Length Part Number 1000mm 10050174 1200mm 10049906 800mm 10049943 1250mm 10049962 1100mm 30347674 Operation Manual - All SP Rock Valve Models revDate...
Page 131: Fitting Wrench Sizes
Appendix Fitting Wrench Sizes This chart is provided as an aid to selecting the proper wrench to hold or tighten the hydraulic ﬁttings found on Schwing equipment. Sizes may change, use only as a guide. Straight Fittings Banjo Fittings Operation Manual -...
Page 132: Maintenance Checklist
Clean Hydraulic Oil Cooler Fins √ Change Hydraulic Oil For Temperature Reasons √ Check the Pre-Charge Of The Accumulator √ Change Hydraulic Oil For Age Reasons √ Change Hydraulic Oil Return Filter Operation Manual - All SP Rock Valve Models revDate...
Page 133: Output Charts
Appendix. • the maximum output (in cubic yards per hour) of the pump kit model. Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 134: Using The Chart
At 220 bar you should be that the hydraulic oil pressure is at 220 bar. getting a little more than 21 strokes per minute. Your unit is ﬁne. Operation Manual - All SP Rock Valve Models revDate...
Page 135 The breakpoint speciﬁcation is shown on each output chart. As an example, we’ll pretend that we have just taken these readings: Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 136 Do the same thing with each pressure reading. use the piston side scale and curve instead). You should end up with 6 dots. The ruler is shown ready to draw a line at 250 bar hydraulic pressure. Operation Manual - All SP Rock Valve Models revDate...
Page 137 ﬂow meter just as when we checked the ﬁrst pump. Again, be sure that you have the correct speed, gear, chart, etc. This time our example will have worse results. Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 138 If you accidentally destroy your original output chart, please have your serial number handy when you call to get a replacement. Also, please advise us if you have changed differential cylinders, Operation Manual - All SP Rock Valve Models revDate...
Page 139: Nomograph
The nomograph is divided into 4 quadrants. available to the concrete pump and should not be used for power calculations). Figure 65 Quadrants Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 140 Kw rating, and the maximum ﬂow and maximum pressure of a particular All of these criteria will be explained in detail as we go concrete pump. through the individual quadrants. Operation Manual - All SP Rock Valve Models revDate...
Page 141 ﬂow in cubic meters per hour), the pressure hydraulic pumps, the number of strokes per multiplied by the ﬂow will always directly minute and the size of the differential and Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 142 ﬁnes coats the inside of the will use 5" pipeline (Figure 68). pipeline and forms a slippery layer on which Figure 68 Upper right quadrant - Pipeline diameter Operation Manual - All SP Rock Valve Models revDate...
Page 143 Our example pipeline is shown below (Figure • each 90° bend with a radius of 250 mm (boom 69). elbow) = 3.5 feet Figure 69 Calculating Proportional Values Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 144 In our example, we use 3" through the pressure scale (Figure 71). Figure 71 Lower left quadrant - Pumpability of the Concrete Operation Manual - All SP Rock Valve Models revDate...
Page 145 (2775). The curved black line represents the TK of the unit. If the unit is going to be able to handle the job, the Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 146 Remove some of the rubber hose at the end of the horizontal run. With job circumstances that did not require a substantial vertical run, you could also use 6" instead of 5" diameter pipeline. Operation Manual - All SP Rock Valve Models revDate...
Page 147: Weld On Ends / Coupling Comparison
NOTE: All pressure ratings listed refer to 5 inch (125mm) diameters in like-new condition. Other pressures would apply to other sizes. Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 148: Minimum Pipe Wall Thickness
This chart does not apply to double-wall pipe. Double wall pipe can be checked by inspecting the inside of the pipe. If the insert is intact, the pipe is okay. If the insert is worn through, the pipe must be replaced. Contact your pipe supplier for the pressure capacity of your double-wall pipe. Operation Manual - All SP Rock Valve Models revDate...
Page 149: Glossary Of Terms
Maximum Pressure For example, 1 cubic foot of air weighs much less than 1 cubic foot of water. 1 cubic foot of lightweight concrete Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 150 See Also: Sponge Ball See also: Conductors Guide An assistant brought in to help in back- ing up a truck or trailer, or other cir- cumstances where the driver cannot Operation Manual - All SP Rock Valve Models revDate...
Page 151 An old saying that goes like this: “Any- thing that can go wrong, will go wrong, and at the worst possible moment”. Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 152 • can be expected to perform these Operation Manual - All SP Rock Valve Models revDate...
Page 153 It is the vehicle that you will use to tow the trailer on the road, Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 154: Additional Reading Material
Water Jet The actual stream of water that comes out of the end of a water hose or pres- sure washer. This is the only part of Operation Manual - All SP Rock Valve Models revDate...
Page 155: List Of Lubricants And Nitrogen
Optimoly Paste White T - 250 grams spline and couplers Grease for autogreaser EP2/NLGI No. 2 Any brand of dry nitrogen is suitable for Dry nitrogen recharging accumulators 000566.eps Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 156 • New hydraulic oil is not clean enough for use in a Schwing concrete pump or placing boom and should be installed in the machine through a filter. The filtering should be done at β 25 = 200 or finer.
Page 157 Motanol - HE 100 Motanol - HE 150 Energol - RC 100 Energol - RC 150 Wintershall Wiolan - CD 100 Wiolan - CD 150 Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:Appendix.fm...
Page 158 The most practical method of doing so would be to ship it back to Schwing. If you choose to dispose of it yourself, you must be sure to...
Page 159 Home Print Print Alphabetical Index swg99a001.eps ALPHABETICAL INDEX Operation Manual - Line pumps...
Page 160 ..97 emergency hose kit ... 128 time constraints ...85 Operation Manual - All SP Rock Valve Models revDate...
Page 161 ..147 hydraulic oil grease points specific information ..102 rock valve ... . . 64 preventive maintenance greasing scheduled maintenance checklist . . 130 agitator bearings .
Page 162 ... .73 service department ... . 9 rock valve ... .79 slickline selecting a set-up location .
Page 163 ..78 keeping it full ... 86 Operation Manual - All SP Rock Valve Models Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame ﬁles:AllSPRockvalveIOM.fm...
Page 164 Home Print Print Alphabetical Index Operation Manual - All SP Rock Valve Models revDate...

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