Page 1 Operation Manual SPB (Separate Placing Boom) Part# 98370060 Revision: 1.2 Date: 10/28/20 5900 Centerville Road St. Paul, MN 55127 1-888-SCHWING (724-9464) www.schwing.com...
Page 5 Tools and Accessories ........47 Final Decommissioning .........15 General Information ........48 SPB 28 - Specifications........19 Safety instructions .........48 SPB 28 - Working Range Diagram ....20 Proper Hardware ...........49 SPB 35 - Specifications........21 Maxiumum Allowable Incline ......49 SPB 35 - Working Range Diagram ....22 Zero Elevation on Cross Frame ....50...
Page 6 Table of Contents From the Electrical Panel ......66 Climbing ............82 From Radio or Cable Remote ......66 Climbing ............85 Operating the Boom ........68 After Climbing ..........88 Controlling the Boom ........68 Maintenance and Troubleshooting ....89 Pumping the Job ..........70 Emergency operation control ......89 Maintenance ............93 Blockages ............72 Pumping Constraints ........73...
Page 7 Table of Contents Monthly Maintenance ........101 Twin Wall ............. 117 Check slewing gear oil .........101 Glossary of Terms ........118 Visually inspect the turret bolts ....101 Pictograms ............123 Semiannual Maintenance......102 Change the oil for temperature reasons ..102 Changing oil - boom slewing gearcase ..102 Hydraulic Boom Filter ........103 Yearly Maintenance ........103 Change the hydraulic oil ......103...
Page 8 Table of Contents SPB Operation Manual...
Page 9: Table Of Contents
Introduction Introduction Manufacturer’s Statement ......11 Safety Alert Symbols ........12 How to reach us ..........13 ID Tags .............13 Boom ID and Pipeline tag ......13 Power Pack Lifting Weight tag .......13 Power pack ID tag .........13 How to order missing tags ......14 Expected Service Life ........15 Final Decommissioning .........15 SPB Operation Manual...
Page 11: Manufacturer's Statement
Introduction Manufacturer’s Statement Schwing America is a member of the Schwing Group, Read and understand this manual before operating, a worldwide designer, manufacturer and distributor of repairing, or adjusting your Schwing seperate placing premium concrete production and handling equipment, boom. The individuals who operate and maintain it headquartered in Herne, Germany.
Page 12: Safety Alert Symbols
Introduction Safety Alert Symbols DANGER The triangle with the exclamation point inside is used to alert you to an important safety point and is called a safety alert symbol. One Electrocution hazard! Keep boom at least 17 feet away from electrical wires. of the following signal words will appear after the safety alert symbol: •...
Page 13: How To Reach Us
Consulte los manuales. When configured for ROD side pumping, this unit will produce by this manual, Schwing America’s Call Center will be a maximum material pressure of: Maximum pressure in boom hyd. system: 350 bar Cuando está...
Page 14: How To Order Missing Tags
How to order missing tags If ID tags are missing or have been removed, you can order new tags through Schwing America’s Call Center. Simply provide the serial number of your seperate plac- ing boom and new ID tags can be created. The serial number is punched into the steel subframe just ahead of the front driver side outrigger (Figure 5).
Page 15: Expected Service Life
Introduction Expected Service Life When used properly, the separate placing boom will have a serivce life of up to 15 years. Below are the recommended operating conditions for seperate placing booms: • Maximum 8 hours of operation per job. • Maximum ambient temperature of 86˚ F •...
Page 16 Introduction SPB Operation Manual...
Page 17 Specifications Specifications SPB 28 - Specifications........19 SPB 28 - Working Range Diagram ....20 SPB 35 - Specifications........21 SPB 35 - Working Range Diagram ....22 SPB 37 - Specifications........23 Working Range Diagram - SPB 37 ....24 SPB Operation Manual...
Page 19 Specifications SPB 28 - Specifications Vertical Reach Center of slewing axis 93 ft. Horizontal Reach Center of slewing axis 93 ft. Slewing Range 730 degrees Design Full Articulation, Roll & Fold Number of Sections Four Section Lengths Main Section 25 ft. 11 in Second Section 23 ft.
Page 20 Specifications SPB 28 - Working Range Diagram SPB 28 End Hose 12' 20' 10“ 23' 1“ 23' 1“ 25' 11“ SPB Operation Manual...
Page 21 235 degrees Boom Pipeline Diameter 5 in. Wall thickness Twin Wall Super 2000 Ends Schwing Raised Boom Pipeline Elbows Quantity 10 @ 90˚ & 4 @ 45˚, 2 @ 32.5˚ Radius 10.8 in. centerline Wall thickness Twin Wall Super 2000...
Page 22 Specifications SPB 35 - Working Range Diagram SPB 35 SPB Operation Manual...
Page 23 235 degrees Boom Pipeline Diameter 4.5 in. Wall thickness Twin Wall Super 3000 Ends Schwing Raised Boom Pipeline Elbows Quantity 10 @ 90˚ & 4 @ 45˚, 2 @ 32.5˚ Radius 9.8 in. centerline Wall thickness Twin Wall Super 3000...
Page 24 Specifications Working Range Diagram - SPB 37 SPB 37 SPB Operation Manual...
Page 25 Safety Safety Safety Manual ..........27 How to Order Additional Safety Manuals ..27 Schwing phone numbers .......27 Warning Labels (Decals) ........27 S 39/41 SX Operation Manual...
Page 27 How to Order Additional Safety Manuals For replacement labels, call the Schwing America Call Center with your seperate placing boom serial number. To order additional Safety Manuals, you can call our toll...
Page 28 Safety S 39/41 SX Operation Manual...
Page 29 SAFETY MANUAL SAFETY MANUAL A GUIDE FOR THE PREVENTION OF ACCIDENTS WHEN DRIVING, OPERATING, CLEANING, AND MAINTAINING CONCRETE PUMPS, PLACING BOOMS, AND RELATED EQUIPMENT Introduction coworkers out of harm’s way. No attempt has been made in this Safety Manual to provide the highly spe- Safety is one of the major concerns of every person cialized knowledge of the workings of the individual involved in the concrete pumping industry.
Page 30 SAFETY MANUAL Table of Contents Introduction ......iii General Rules ......1 Table of Contents .
Page 31 SAFETY MANUAL GENERAL RULES General Rules Table of Contents Before You Leave The Yard ..... . 2 Safety Alert Symbol And Signal Word Explanation .
Page 32: General Rules
SAFETY MANUAL GENERAL RULES I. Before You Leave The Yard Safety Alert Symbol And Signal Word Explanation The triangle with the exclamation point inside is used to alert you to an important safety point, and is called a Safety Alert Symbol . One of the following color-coded signal words will appear after the safety alert symbol: DANGER WARNING...
Page 33 SAFETY MANUAL GENERAL RULES Dress in appropriate apparel and Personal Protective Equipment (P.P.E., or just PPE) (see Figure 1). You should always wear these items when pumping concrete: • hard hat • safety glasses or goggles • snug-ﬁtting clothes • gloves •...
Page 34 SAFETY MANUAL GENERAL RULES WARNING Be sure that any clothing you wear does not have strings, fringes, or other external tightening means that could be caught in moving parts (Figure 2). This is a Knot and cut off hazard! excess string Figure 2 No strings attached Safewntr.eps...
Page 35: What To Check Before You Leave The Yard
SAFETY MANUAL GENERAL RULES 3. What To Check Before You Leave The Yard WARNING Do not operate the machine until you read and understand the unit’s operation manual. Lack of understanding of proper operating procedures could result in unsafe operation. Operation manuals are issued with each new unit. If you haven’t seen it, ask your supervisor.
Page 36 SAFETY MANUAL GENERAL RULES WARNING Be sure that the unit is equipped with all the pipes, clamps, gas- kets and hoses, blowout adapters, ball catchers, and other accessories that you will need for the day’s work. “Making do” with inappropriate equipment could cause accidents.
Page 37 SAFETY MANUAL GENERAL RULES WARNING The operator is responsible for checking that all safety decals 3.12 are in place and are in readable condition. If found to be missing or unreadable for any reason, steps should be taken to obtain replacements. WARNING (See Figure 6.) Mount or dismount the pump or truck using the 3.13...
Page 38: Safety Rules For Driving Truck-Mounted Concrete Pumps
SAFETY MANUAL GENERAL RULES • Ask the machine’s normal operator, the dispatcher, or your supervisor ques- tions regarding any unusual or unique operational characteristics of the machine. • Familiarize yourself with the machine by setting it up in the yard and running the functions, and by familiarizing yourself with the operation manual.
Page 39 SAFETY MANUAL GENERAL RULES Carefully select your route of travel. Avoid steep hills, residential areas, construc- tion, low overpass clearances and narrow bridges whenever possible. The driver is responsible for knowing the weight and height of the machine. WARNING Collision/falling hazard! Before driving on bridge or elevated roadways, be sure that they can support the weight of the vehicle (Figure 9).
Page 40: Safety Rules For Towing Trailer-Mounted Concrete Pumps
SAFETY MANUAL GENERAL RULES WARNING Possible boom movement. Before driving the unit, be sure that the distribution gearcase (PTO) has disconnected the hydraulic pumps. Driving with the hydraulic pumps engaged creates a hazard and is destructive to the pumps. WARNING Never drive the unit with concrete in the hopper.
Page 41 SAFETY MANUAL GENERAL RULES trlrbg.eps Figure 12 Do not under size the towing vehicle WARNING Never tow a pump that has concrete in the hopper. The extra weight in the back of the machine will remove weight from the tongue and cause the trailer to ﬁshtail.
Page 42: On The Job Site
SAFETY MANUAL GENERAL RULES II. On The Job Site 6. Safety Rules For Job Setup SETTING UP A TRUCK-MOUNTED BOOM PUMP The job setup phase can set the stage for accidents. Taking a few extra moments to correctly set up the job will improve your chances of having a safe, trouble-free day.
Page 43 SAFETY MANUAL GENERAL RULES If you are in doubt about your proximity to power lines, or if it DANGER is not possible to maintain a 20 or 50 foot clearance, you must lay a separate pipe- line or use a different placement method; otherwise do not do the pour. Never take chances with high voltage! (See Figure 14.) slbptbad2.eps High-Voltage...
Page 44 SAFETY MANUAL GENERAL RULES It is crucial to take power lines into consideration during DANGER setup, even if they are away from the area to be pumped! Accidents occur dur- ing clean-out and moving that can be avoided by proper initial setup. In the illus- trations below, the pour is outside of the minimum safety distance, but the danger still exists.
Page 45 SAFETY MANUAL GENERAL RULES Depth perception varies from person to person and is affected DANGER by the distance from the objects being observed. Minimum distances from power lines and other obstructions during setup should always be judged from a viewing position that does not require depth perception judgements.
Page 46 SAFETY MANUAL GENERAL RULES Always assume that a power line is live. Never take the word 6.10 DANGER of someone on the job site that it has been de-energized. Only a qualiﬁed repre- sentative of the responsible power company can verify that a power line has been de-energized (see Figure 18).
Page 47 SAFETY MANUAL GENERAL RULES WARNING Possible boom damage and tipping hazard! Never exceed the 6.14 manufacturer’s rated weight limit for the placing boom! If continuation pipes are connected to the end hose, they must NOT impose any additional load on the boom (Figure 20).
Page 48 SAFETY MANUAL GENERAL RULES 125mm (or 5 inch) diameter end hose, when ﬁlled with normal, hard rock con- crete weighs 376 pounds. Certain units may have a lower allowable weight and, thus, a different tip hose. The operation manual included with the unit, and/or a decal on the end of the boom will inform you of the speciﬁcation.
Page 49 SAFETY MANUAL GENERAL RULES WARNING All hanging system components must be fastened with safety 6.18 cables or straps, and each component must be capable of handling the maxi- mum concrete pressure of the machine (see Figure 23). Use a safety cable or strap on each Hanging system hanging piece.
Page 50 SAFETY MANUAL GENERAL RULES WARNING Consider the safe approach and departure of the ready mix 6.21 trucks and adjust your setup accordingly. Adjusting your setup position by a few degrees one way or another could mean the difference between a safe approach and an unsafe approach.
Page 51 SAFETY MANUAL GENERAL RULES • Don’t get lazy! If it is possible to extend all of the outriggers, do it! • Don’t forget that you didn’t fully extend all the outriggers. Explain to other workers on the job what will happen if you forget and slew the boom over unextended outriggers.
Page 52 SAFETY MANUAL GENERAL RULES WARNING Tipping hazard! Do not unfold the boom until the outriggers 6.23 have been correctly positioned and secured! The outriggers must be completely extended and opened as described in the operation manual. Do not partially extend the outriggers because intermediate positions are not safe! See the infor- mation regarding shortrigging (paragraph 6.22).
Page 53 SAFETY MANUAL GENERAL RULES THE ONE-TO-ONE RULE: For every 1 foot of vertical drop, stay back from the base edge 1 foot. (Distance "B" must be equal to or greater than distance "A") DISTANCE Figure 28 DISTANCE The one-to-one rule Base edge WARNING! Even though the base edge is at a 1-to-1 ratio...
Page 54 SAFETY MANUAL GENERAL RULES WARNING Look for recently backﬁlled areas, septic tanks and other indi- 6.28 cations of soft soil or underground voids (see Figure 31). hidden voids2.eps Figure 31 Look for clues of hidden voids WARNING Tipping hazard! Take care when setting the outriggers (Figure 6.29 32).
Page 55 SAFETY MANUAL GENERAL RULES • If the outrigger sinks, make the cribbing base larger until the outrigger is sta- ble using two layers of cribbing perpendicular to each other; • After all outriggers are stable and the pump is within 3˚ of level, unfold the boom and slowly extend it over each fully extended outrigger.
Page 56 SAFETY MANUAL GENERAL RULES nalperson. If a signalperson is used, agree on hand signals before beginning the pour! (ACPA recommended hand signals are shown on page 74 of this Safety Manual.) If the boom will be moved extensively, arrange for a workman to stay with the pump and to put yourself in a position to see the end of the boom (Figure 34).
Page 57 SAFETY MANUAL GENERAL RULES WARNING It is extremely important to verify that the material deliv- 6.36 ery system of the boom is capable of handling the pressure of the concrete pump. In some cases, you may not be able to use the boom if you are pumping on piston side.
Page 58: Setting Up A Trailer-Mounted Pump And/Or A Separate Pipeline
SAFETY MANUAL GENERAL RULES 7. Setting Up A Trailer-Mounted Pump and/or A Separate Pipeline The job setup phase sets the stage for most accidents. Taking a few extra moments to correctly set up the job will improve your chances of having a safe, trouble free day.
Page 59 SAFETY MANUAL GENERAL RULES line material, and other factors. Read and understand the minimum wall thickness chart in the Appendix of this Safety Manual. Bursting pipes and concrete escap- ing under pressure is a serious safety hazard! (See Figure 37.) Figure 37 Delivery system components must be able to withstand maximum pump pressure...
Page 60 SAFETY MANUAL GENERAL RULES WARNING In vertical runs, the weight of the vertical sections of pipe must 7.17 be supported by a thrust block (often called a deadman, Figure 38) or other load- bearing device. Each section of pipeline in a vertical run must be secured from lateral and horizontal movement.
Page 61 SAFETY MANUAL GENERAL RULES WARNING Watch for children! It is possible for children to access the 7.20 machine, but it is not safe for them to do so. WARNING If spectators will be near the job, cordon off an area where they 7.21 will be safe.
Page 62 SAFETY MANUAL GENERAL RULES WARNING There are two types of ball catchers. Know which type of 7.23 catcher you are using. You may need to adjust your clean-out procedure according to which type you have. The two types are as follows. 1.
Page 63: Concrete Pump Operation
SAFETY MANUAL GENERAL RULES III. Concrete Pump Operation 8. Safety Rules For Pump Operators WARNING Only qualiﬁed operators are allowed to operate the pump. A “Qualiﬁed Operator” is deﬁned as someone who: • has reached the age of 18 years (21 for interstate travel); •...
Page 64 SAFETY MANUAL GENERAL RULES WARNING Electrocution hazard! If you are operating and lightning moves into the area, put the boom into the transport position, or another low posi- tion, and seek shelter until the lightning is gone. WARNING Crushing hazard! Never, ever position yourself between a ready mix truck and the pump! Stand off to the side, so the ready mix driver can see you at all times (Figure 43).
Page 65 SAFETY MANUAL GENERAL RULES When power lines are in the area where the boom will be DANGER moving to complete a pour, a spotter must be employed whose only job is to warn the operator if the boom comes within 20 feet (50 feet above 350 Kv) of power lines.
Page 66 SAFETY MANUAL GENERAL RULES Watch for power lines that are not directly in the area of the 8.12 DANGER pour. Accidents can happen when moving between points of placement, or when moving the boom after the pour is completed (Figure 47). Never let down your guard when the boom is in the air! Minimum of 20-foot shckbhnd.eps...
Page 67 SAFETY MANUAL GENERAL RULES CAUTION Loss of hearing! While standing near a working concrete 8.14 pump, sound pressure levels may exceed O.S.H.A. standards for constant expo- sure (Figure 49). PERMISSIBLE NOISE EXPOSURES* *Under part 1910.95 “Occupational Noise Exposure,” (Dept. of Labor) of the Code of Federal Regulations, Chap.
Page 68 SAFETY MANUAL GENERAL RULES WARNING Do not let the concrete level in the hopper become low! If air 8.18 is sucked into the material cylinders, the pump will compress the air. Compressed air always poses a hazard as it is expelled from the hopper or the delivery pipeline (Figure 51).
Page 69 SAFETY MANUAL GENERAL RULES WARNING Air can be introduced into the delivery system in several ways 8.19 besides being sucked in through the hopper: • when initially priming the delivery system; • when restarting after moving; • when restarting after adding or removing delivery system; •...
Page 70 SAFETY MANUAL GENERAL RULES • Foreign matter in the concrete. Pieces of old concrete that break away from mixer ﬁns, unmixed clumps of cement, mixer ﬁns, hammers, and furry mam- mals are examples of foreign matter that have caused blockages. •...
Page 71 SAFETY MANUAL GENERAL RULES WARNING The following points must be observed when locating a block- 8.23 age. • Pump in reverse for at least two strokes, then stop the pump. In the case of a mechanical pump (which cannot be reversed), it is important to carefully fol- low the manufacturer’s instructions for relieving line pressure before any clamp is opened.
Page 72 SAFETY MANUAL GENERAL RULES WARNING It would be better to let the pipe be ruined by setting concrete 8.27 than to risk injury by ignoring safe procedures. Always use safe practices when cleaning pipe. Remember, pipeline is replaceable, you are not. WARNING Never stand on, sit on, or straddle a pipeline while it’s in use, or 8.28...
Page 73 SAFETY MANUAL GENERAL RULES Figure 56 Keep your body out of the water box • the safety rules for a person stationed at the pump (the rules are listed in this Safety Manual, beginning on page 59); • how to stop the pump; •...
Page 74 SAFETY MANUAL GENERAL RULES engines, the key must be removed. If there is more than one key, you should tag the ignition. On units driven by electric motors, the main disconnect must be locked out according to applicable standards. WARNING 8.36 Never operate the boom “blind.”...
Page 75: Cleaning The Pump And System
SAFETY MANUAL GENERAL RULES IV. Cleaning The Pump And System 9. Safety Rules For Cleaning The Boom WARNING Do not let down your guard when the pour is completed. Acci- dents also happen during clean-out and the drive back to the yard. It is important not to become relaxed about job safety until you are no longer on the job.
Page 76 SAFETY MANUAL GENERAL RULES WARNING Crushing and amputation hazard! Never put your hands or 10.3 any other body part into the concrete valve. Instead, use water jets and the sup- plied rake (Figure 60). WARNING Never put any body part or tool into the pumping area 10.4 when the hydraulic system is operational.
Page 77: Safety Rules For Cleaning The Water Box
SAFETY MANUAL GENERAL RULES 11. Safety Rules For Cleaning The Water Box WARNING Crushing and amputation hazard! Stop the concrete pump 11.1 before removing the water box covers. If your unit has bolt down guards, do not remove them for cleaning. If there is not a bolt-down guard over the water box, then stop the pump, take the transmission out of gear, and lock the cab so the pump cannot be restarted until you are ﬁnished cleaning and the covers are back in place.
Page 78 SAFETY MANUAL GENERAL RULES WARNING The point of discharge must be controlled. Use a ball catcher or 12.3 some other containment device at the point of discharge, even when cleaning with water. Figure 63 Cleaning with confacegy2.eps compressed air can be extremely hazardous if you don’t follow the safety rules...
Page 79 SAFETY MANUAL GENERAL RULES Water/air inlet Air inlet regulator valve Air discharge regulator valve Figure 64 Ball catcher and blowout head blowout head ball catcher • Be sure to open both valves on the blowout cap and verify all air has been removed from the system before opening any clamps.
Page 80 SAFETY MANUAL GENERAL RULES hosepop9.eps Figure 66 Never use air to blow out hoses or short pipelines WARNING When blowing out a vertical line, a shutoff valve is required to 12.6 prevent the following scenario. 1. (See diagram A in Figure 67.) Without a shutoff valve installed, the pipeline is disconnected from the pump.
Page 81 SAFETY MANUAL GENERAL RULES Figure 67 Blowout of a vertical line 4. When pumping is complete, close the shutoff valve before disconnecting the pipeline from the pump (item 1, Figure 67). Failure to do this will cause the concrete to fall out of the vertical sections of pipe, leaving concrete in the horizontal sections of pipe and an air pocket in the vertical sections.
Page 82 SAFETY MANUAL GENERAL RULES 9. Divert the vertical pipe line to the clean-out area, or open the shutoff valve in the delivery pipe line now. (Figure 68.) Allow gravity to start the concrete moving through the discharge line. As the concrete falls from the vertical sections, it will take the ball with it, making it impossible to trap air in the line.
Page 83: Maintenance Of The Machinery
SAFETY MANUAL GENERAL RULES V. Maintenance Of The Machinery 13. Safety Rules Regarding Inspection WARNING It is imperative that your boom, outriggers, and other structural 13.1 members be inspected by a certiﬁed boom inspector on a regular basis. The results should be documented carefully and a record kept.
Page 84: Safety Rules Regarding Scheduled Maintenance
SAFETY MANUAL GENERAL RULES WARNING Do not neglect the delivery pipeline, clamps, or hoses. Check 13.11 them often for wear, dents, and frays. Never send a unit to a job with a worn or damaged delivery system. For single-wall pipes, ultrasonic thickness testers are more accurate than the tap method (see Figure 69).
Page 85: Safety Rules When Servicing The Machinery
SAFETY MANUAL GENERAL RULES WARNING When installing new pipe and/or hose on the machine be sure 14.5 that it is capable of handling the maximum concrete pressure of the pump. WARNING Remember that boom pipe cannot weigh more than the manu- 14.6 facturer’s speciﬁcation for weight per foot.
Page 86 SAFETY MANUAL GENERAL RULES WARNING If it is necessary to unfold the placing boom to do mainte- 15.4 nance work, the outriggers must be extended and jacked; just as if the machine were on a job site. If you are not an operator, have the operator set up the machine for you.
Page 87 SAFETY MANUAL GENERAL RULES WARNING Crushing hazard! Secure the placing boom and relieve all 15.8 pressure before working on the boom hydraulic system. WARNING Only operators should operate the unit. If work on the 15.9 machine requires that it be operated and you are not qualiﬁed as an operator, you must get someone who is qualiﬁed to assist you.
Page 88 SAFETY MANUAL GENERAL RULES WARNING Remember to mount and dismount the unit using the “3-Point 15.18 Rule.” One hand and two feet or two hands and one foot are to be in contact with a secure surface at all times (Figure 73). safestep.eps Figure 73 The 3-Point Rule...
Page 89: Coworker Safety
SAFETY MANUAL GENERAL RULES VI. Coworker Safety Safety Rules For Workers Assigned To The Pump WARNING You must know how to stop the pump and boom. Have the 16.1 operator show you the locations of the emergency stop switches (Figure 74). E-Stop Switch WARNING Stop agitator before...
Page 90 SAFETY MANUAL GENERAL RULES Electrocution hazard! If the pump or boom becomes energized 16.3 DANGER with high voltage and you are in contact with any part of it, you are at risk of elec- trocution! You should monitor the movement of the boom and alert the operator if the boom comes within 20 feet of power lines (50 feet above 350 Kv).
Page 91 SAFETY MANUAL GENERAL RULES WARNING Crushing hazard. Never, ever position yourself between the 16.6 ready mix truck and the pump! Stand to the side, where the driver can see you (Figure 78). Figure 78 Never stand between the ready mix truck and the pump bkupguy.eps WARNING...
Page 92 SAFETY MANUAL GENERAL RULES WARNING Do not let the concrete level in the hopper become low! If air is 16.13 sucked into the material cylinders, the pump will compress the air. Compressed air always poses a hazard as it is expelled from the hopper or the delivery pipeline (Figure 80).
Page 93 SAFETY MANUAL GENERAL RULES WARNING When initially priming the delivery system, when restarting 16.14 after moving, when restarting after adding or removing hoses, or whenever air has been introduced into the line, warn everyone to stay away from the discharge until concrete runs steadily and there is no movement of the delivery system.
Page 94 SAFETY MANUAL GENERAL RULES not open it. The operator is responsible for knowing how to safely release the air pressure. Even after the pump is reversed, use a shovel or other tool that will assure a safe distance from clamps to avoid concrete blowing in your eyes. explode2col.eps Figure 82 Never open a pressurized pipeline...
Page 95 SAFETY MANUAL GENERAL RULES WARNING Never lift or remove the hopper grate for any reason (Figure 16.20 84). agitguy.eps Figure 84 Lifting hopper grate exposes the agitator and the concrete valve WARNING Do not remove the water box covers or grates when the 16.21 machine is stroking (Figure 85).
Page 96: Safety Rules For The Placing Crew
SAFETY MANUAL GENERAL RULES WARNING Mount or dismount the pump or truck using the 3-Point Rule. 16.23 One hand and two feet or two hands and one foot are to be in contact with a secure surface at all times (Figure 86). safestep.eps Figure 86 The 3-Point Rule...
Page 97 SAFETY MANUAL GENERAL RULES When power lines are in the area where the boom will be 17.2 DANGER moving to complete a pour, a spotter must be employed whose only job is to warn the operator if the boom comes within 20 feet (50 feet above 350 Kv) of power lines.
Page 98 SAFETY MANUAL GENERAL RULES WARNING Wear Personal Protective Equipment (P.P.E. or just PPE) when 17.6 working around a concrete pump (Figure 89). The gloves should resist concrete lime burns. If you will be working in the concrete, protect your feet and hands with rubber boots and gloves.
Page 99 SAFETY MANUAL GENERAL RULES hosepop7.eps Figure 90 Stay away from the point of discharge when starting or restarting, and when there’s air in the pipeline WARNING Never open a pressurized pipeline (Figure 91). The pump oper- 17.10 ator must release the pressure before you open the line. If the line is pressurized with compressed air, let the operator release the pressure and verify that the air has escaped before you proceed.
Page 100 SAFETY MANUAL GENERAL RULES WARNING The hose-person should not hug the hose, but hold it with both 17.13 hands, to allow the hose to move freely (Figure 92). donthug.eps Figure 92 Do not hug the boom hose WARNING The hose-person should not walk backwards (Figure 93). 17.14 Walking forward allows obstacles and tripping hazards to be seen.
Page 101 SAFETY MANUAL GENERAL RULES hosekinkcolor.eps This man could be injured if the pump unkinks the hose by force! Do not allow the hose to kink! Figure 94 Never kink the hose; Never hold the hose with your shoulder WARNING When using tools or hooks to drag the hose, be sure they are 17.18 not sharp enough to damage the hose.
Page 102 SAFETY MANUAL GENERAL RULES WARNING Do not allow the boom hose to get lower than two feet above 17.21 the deck to prevent the boom hose from hitting the feet of the hose-person, and to prevent the hose opening from being blocked by the deck, which could cause the hose to whip.
Page 103: Appendix
SAFETY MANUAL APPENDIX Appendix Table of Contents VII. Weld-On Ends/Coupling Comparison ....74 VIII. Minimum Pipe Wall Thickness Chart ....75 Glossary Of Terms .
Page 104: Weld-On Ends/Coupling Comparison
APPENDIX SAFETY MANUAL VII. Weld-On Ends/Coupling Comparison Shown is a comparison among commonly used ends/couplings. No two ends shown can be joined without the use of an adapter pipe or a special adapter clamp. Clamps and pipe strength must also be considered when determining proper system requirements.
Page 105: Minimum Pipe Wall Thickness Chart
APPENDIX SAFETY MANUAL VIII. Minimum Pipe Wall Thickness Chart SCHEDULE 40 11 gauge 9 gauge 7 gauge 3/16” (1/4 wall) 4200 4000 3800 3600 3400 3200 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 .050" .100" .150" .200"...
Page 106: Glossary Of Terms
APPENDIX SAFETY MANUAL IX. Glossary Of Terms Accumulator A hydraulic device that stores ﬂuid power energy in much the same way that a battery stores electrical energy. Because an accumulator will store energy, it MUST be drained and depressur- ized before work begins on an accumulator-equipped actuator or hydraulic system. Agitator A device that sits in the concrete hopper to keep concrete moving;...
Page 107 APPENDIX SAFETY MANUAL Concrete Pressure The force per square area that is exerted on the concrete. The concrete pressure will always be a ratio in direct proportion to the hydraulic oil pressure on the concrete pump circuit. See Also: Maximum Pressure Conductors Materials that will conduct electricity.
Page 108 APPENDIX SAFETY MANUAL residential areas, the voltage will be approx. 8000 volts to ground, or 13,800 volts from phase to phase (distribution voltage). When dealing with power lines mounted on concrete or tall wooden poles with multiple bells on the insulators, the voltage will be higher—in the 50,000 to 150,000 volt range, but may still be considered distribution to industrial feeds.
Page 109 APPENDIX SAFETY MANUAL O.S.H.A. Occupational Safety and Health Administration. A branch of the United States federal govern- ment that deals with job safety. It establishes and enforces safety regulations for industry and business. Among the areas over which it has authority are construction job sites and work shops. Personal Protective Equipment (P.P.E., or just PPE) Things you can wear to protect yourself from potential dangers in a concrete placing environ- ment.
Page 110 APPENDIX SAFETY MANUAL Qualiﬁed Workshop Personnel An individual who: • has reached the age of 18 years, • is physically and mentally capable, • has been trained in proper repair, maintenance, and inspection procedures plus the perti- nent safety rules for concrete pumps and related equipment, •...
Page 111 APPENDIX SAFETY MANUAL weight of the vertical run and for lateral stabilization of the pipeline. It stabilizes and supports the vertical run by virtue of its enormous mass (normally one cubic yard or larger). Towing Vehicle In this Safety Manual, Towing Vehicle applies only to vehicles that tow trailer-mounted concrete pumps.
Page 112: Recommended Hand Signals
Further information regarding concrete pumping is available from the sources listed below. Information for this book was gathered from several different sources, including the following books: PUMPING CONCRETE AND CONCRETE PUMPS © F. W. Schwing, GmbH CONCRETE PUMP OPERATOR’S GUIDE TO SAFETY © British Concrete Pumping Association The MANUAL and ADVISORY SAFETY CODE of PRACTICE for CONCRETE PUMPING ©...
Page 113: Alphabetical Index
SAFETY MANUAL ALPHABETICAL INDEX 402indexcov.eps Alphabetical Index PAGE 83 700indxcov.fm...
Page 114 ALPHABETICAL INDEX SAFETY MANUAL Numerics boom, watching ..... . . 67 brakes, worn ......6 1-to-1 rule .
Page 115 SAFETY MANUAL ALPHABETICAL INDEX compressed air caution ......2 attachments ... . 5, 31, 45, 48 certified operator .
Page 116 ALPHABETICAL INDEX SAFETY MANUAL vertical run ......81 stopping distance ....10 warning .
Page 117 SAFETY MANUAL ALPHABETICAL INDEX height notifying operator ....61 knowledge of ..... . . 9 personal protective equipment .
Page 118 ALPHABETICAL INDEX SAFETY MANUAL weld on ends ..... . 74 removal ......16 pipeline, weight per foot .
Page 119 SAFETY MANUAL ALPHABETICAL INDEX PPE See Personal Protective Equipment soil pressure, defined ....80 sponge ball catcher ......32 qualified operator, defined .
Page 120 ALPHABETICAL INDEX SAFETY MANUAL vertical run, defined ....81 Victaulic, See delivery system, pipe ends, grooved walking with end hose backwards ......70 correctly .
Page 121 Overview Overview First Commissioning ........31 Joystick Configuration ........39 Installation of your new unit ......31 Radio/Cable Remote Buttons/Switches ..40 Safety Devices ..........32 Status Lights ..........41 Emergency Stop Switches (E-Stop Button) ...32 Pairing Transmitter to Receiver ....42 Pressure Relief Valves ........32 Setting Joystick Min/Max Speeds ....43 Safety guards ..........33 Supplied accessories ........44 Warning Horn ..........33...
Page 122 Overview S 39/41 SX Operation Manual...
Page 123 White Bear, Minnesota 55127 IMPORTANT, PLEASE READ This DELIVERY INSPECTION REPORT must be completed and the white copy returned to SCHWING America's SERVICE DEPARTMENT (at the above address) within 15 days of the above mentioned delivery date. All FUTURE WARRANTY CLAIMS WILL BE BASED UPON THE RETURN OF THIS REPORT!
Page 124 • Radio Remote cause dangerous operation. Check with the Schwing America Call Center before changing • Boom Handvalve on Power Pack any hydraulic relief pressure settings. Pushing the Emergency Stop Switch (E-Stop button) stops the electric motor and disables the hydraulic cir- cuit.
Page 125 Overview Safety guards Holding Valves Safety guards were placed for your protection. Do not The holding valves seal the hydraulic cylinder to pre- operate the machine unless all the safety guards are vent it from creeping or moving until pressure is applied. in place.
Page 126 Overview Fuses and circuit breakers Fuses and circuit breakers are devices that are intend- ed to protect against circuit overload. They do so by melting or opening when the current in an electrical cir- cuit becomes higher than it was designed for. Here are a couple of examples of causes for over current: •...
Page 127 Overview Power Pack H. Hydraulic Pump A. Operator Control Panel I. Hydraulic Level / Temperature Gauge B. Boom Handvalve J. Support Legs C. Slew Drive K. Turret Adapter D. Electric Motor L. Electrical Sockets E. Hydraulic Filter M. Hydraulic Tank Fill Cap F.
Page 128 Overview Boom Handvalve A. Boom #1 - Extend / Retract Handle B. Boom #2 - Extend / Retract Handle C. Boom #3 - Extend / Retract Handle D. Boom #4 - Extend / Retract Handle E. Boom Slewing Handle F. Boom Enable Handle G.
Page 129 Overview Operator Control Panel A. E-Stop Button B. Start Button C. Stop Button D. Remote Manual / Off / Remote E. Power Disconnect Handle F. Power Plug G. Self Climber Remote Cable Plug / Dummy Plug START STOP LOCAL REMOTE WARNING 30355887 Do not touch hydraulic...
Page 130 Overview Cable/Radio Remote Box A. LCD Display J. Emergency Stop Button (E-Stop) B. Joysticks K. LED Power/Battery Indicator Light C. Motor Start / Stop Switch L. N/A D. Air Cuff Closed - Optional M. Power On Switch E. Browse LCD Button N.
Page 131 Overview Status LCD Display The Status LCD Display gives the operator feedback on various functions through the display window. ITEM FUNCTION Charging Status of the Battery Machine Status Symbol Operating Mode Status Signal Strength Statues Machine Status - RPMs / Strokes per minute Start Machine Status - Hydraulic Oil Temperature / Concrete Pump Pressure...
Page 132 Overview Radio/Cable Remote Buttons/Switches Turns the LCD backlight on or off. Motor Start / Stop Switch = off (stop) = on (start) Boom Speed Selector Switch The boom Speed Selector switch will Air Cuff Auto / Chamber Valve Enable raise or lower the speed of each boom section.
Page 133 Overview Status Lights = ON = OFF = FLASHING DESCRIPTION "Antenna" (1) "Voltage" (2) Transmitter off Transmitter is operationally ready. No function actuated (basic position). green, on green, on One or more functions actuated. Transmitter transfers control data. green, on green, flashing Transmitter on, but no connection to the receiver.
Page 134 Overview Pairing Transmitter to Receiver Pairing is necessary to get a unique assignment be- Receiver Power Switch Receiver ID Window tween a single Transmitter and a single Receiver. When replacing either the Receiver or Transmitter in a system follow the procedure below: 1.
Page 135 Overview Setting Joystick Min/Max Speeds Transmitter switches and buttons PWM outputs are adjustable and should be tuned to 5. Press and release the power button to increment control the valves through their entire range of motion. to the next PO number in the table. Receiver LED To obtain optimal function movement in relation to the display will increment with each press.
Page 136 Overview Supplied accessories 85, 90, 100 Item Description Part# 0001 Filter element 98333016 0005 Seal - 5-1/2" Coupling - All KVM 10002526 0010 SPONGE - BALL, CLEAN-OUT, DN 125, SOFT, 10002832 0015 Coupling - Screw-Type Lock 5-1/2" Primed 10006587 0020 Coupling - Lever Style 5-1/2"...
Page 137 Operation Operation Preparing for the Job ........47 Assembling Mast Sections ......52 Personal Protection ........47 Self-Climbing Mast .........55 Pipeline and Clamps ........47 Installation of Boom and Column ....55 Tools and Accessories ........47 Assembly of ladder and back rest ....56 General Information ........48 Flying the Boom and Power Pack ....57 Safety instructions .........48 Requirements for flying the boom: ....57...
Page 138: Operation
Operation From the Electrical Panel ......66 Climbing ............82 From Radio or Cable Remote ......66 Climbing ............85 Operating the Boom ........68 After Climbing ..........88 Controlling the Boom ........68 Maintenance and Troubleshooting ....89 Pumping the Job ..........70 Emergency operation control ......89 Blockages ............72 Pumping Constraints ........73 Wind restrictions ..........73 Time constraints ..........73...
Page 139: Preparing For The Job
Operation Preparing for the Job Pipeline and Clamps Use the following checklist to determine your equip- Personal Protection ment needs: Concrete is made from lime, which is very alkaline. If it stays on your skin long enough, it will cause severe •...
Page 140: General Information
Minimum Fill Level ble and sockets at the boom control panel and generator every day. 5. Schwing recommends a generator size of 60kW. Figure 2 6. On a SPB35 placing boom, the 30 HP electric mo- Hydraulic oil level/temperature gauge tor requires 36 full load amps / 480V and 29 full load amps / 575V.
Page 141: Proper Hardware
“R” clips must be in place (such as the working platform mounting points). Maxiumum Allowable Incline When installing Schwing placing booms on octagonal masts, lattice towers or similar supports, the base frame must be completely level in all directions.
Page 142: Zero Elevation On Cross Frame
DETAILS Figure 7 Anchor bolt spacing 4000 (13’ - 1 1/2”) Schwing provides an optional cross frame alignment template to hold the threaded rods in position while the concrete is cured (Figure 8). • 98436224 - Upper Assembly (Re-usable) 110 (4 5/16”) 2900 (9’...
Page 143: Cross Frame Installation
(1 of 3)” on page 62. 4. Place the cross frame into position on the slab. For speciﬁc information regarding bolt speciﬁca- tions refer to Schwing drawing number 30502676 5. Check with levelling instrument to ensure that the and 30502677.
Page 144: Freestanding Mast On Cross Frame
For more speciﬁc information regarding max- imum ground pressure and concrete founda- • 36mm socket/ spanner. tion density, refer to Schwing drawing number • 27mm socket/ spanner. 30502678 found in the Octagonal mast technical data book which came with this manual and other Assembling Mast Sections documents accompanying your SPB.
Page 145 Operation 8. Insert the bolts, washers and nuts. working platform. A support is then placed under the mast. Figure 14 Assemble head section to mast Figure 12 The working platform is then fitted into Mast sections being fastened together place, secured using the bolts supplied. 9.
Page 146 Operation The mast is now ready to stand vertically. A With the mast standing vertical it is raised flat piece of material should be placed under the maneuvered into position onto the cross flanged joint end of the mast; this will prevent the frame.
Page 147: Self-Climbing Mast
14’- 9” (4.5 meters), with an SPB 35/37 boom. 2. If the floor spacing is less than 11’- 6” SPB 28 or 14’- 9” SPB 35/37 , the floor frames should be lo- cated at alternate floors, i.e. between 1st and 3rd Floor Frame or 2nd and 4th etc.
Page 148: Assembly Of Ladder And Back Rest
Support Pins A suitable back propping scheme must be employed to support the floor slabs. Schwing would provide the load calculations for each ap- plication. Position A All ladders over 15’...
Page 149: Flying The Boom And Power Pack
Operation Flying the Boom and Power Pack Do not perform this procedure with- out complete understanding of the warnings in these instructions and on decals. Raise boom, insert wood block on boom Requirements for flying the boom: rest • At least two men, one of whom will act as a spotter •...
Page 150 Operation Use This Configuration When Lifting Power Pack And Boom Assembly. MASS = 8532 kg. [18810 lbs] - SPB 35 MASS = 8600 kg. [18960 lbs] - SPB 37 56° 56° AS SHOWN AS SHOWN 45° 45° MINIMUM MINIMUM Use This Configuration When Lifting Turret And Boom Assembly MASS = 5829 kg.
Page 151 Operation 5. Have the crane operator apply very light tension. 8. Use extreme caution while separating the boom. Keep light tension on the cables, and pry the boom 6. Attach a tag rope, at least twenty feet long, to the apart from the tower if necessary.
Page 152 Operation SPB Remote Socket Self-Climber Remote Socket Dummy plug Main Power Inlet Figure 28 Boom tower and ﬂoor frames Attach the power and remote cables (Figure 28). Position pipeline gasket, and connect the concrete pipeline. SPB Operation Manual...
Page 153: Quick Disconnect Color Code Markings
Operation Quick Disconnect Color Code Markings BOOM CYLINDER PORT COLOR LABEL Gray CYLINDER #1 Black Brown Blue CYLINDER #2 Black Piston Side Gray A1ZC3 CYLINDER #3 Black Rod Side Blue B1ZC3 Yellow CYLINDER #4 Black Green Piston Side Orange Yellow A1ZE5 CYLINDER #5 Black...
Page 154: Lifting Instructions (1 Of 3)
Operation Lifting Instructions (1 of 3) SPB Operation Manual...
Page 155: Lifting Instructions (2 Of 3)
Operation Lifting Instructions (2 of 3) SPB Operation Manual...
Page 156: Lifting Instructions (3 Of 3)
Operation Lifting Instructions (3 of 3) SPB Operation Manual...
Page 157: Set-Up Of Delivery Pipeline
Operation Set-up of Delivery Pipeline Two Bolt Clamp Pipeline identification Delivery pipeline can be identified in three separate categories: baseline, vertical run, and horizontal run. A fourth, and very important component of the pipeline, is the thrust block. Lateral movement restraint Figure 31 Standard two bolt clamp Thrust Block (Deadman)
Page 158: Starting The Machine
Operation Starting the Machine From Radio or Cable Remote • Be sure all safety guards are in place. From the Electrical Panel • Be sure all safety guards are in place. • At the Electrical Panel, ensure the power cable is inserted and the Power Disconnect Handle is •...
Page 159 Operation Shutting the Machine Down To shut the motor off, do one of the following: • Press any E-stop button. • Press the Motor On/Off toggle switch on the ca- ble/radio remote (Figure 35). • Press the Stop button on the Electrical Panel (Local Mode only).
Page 160: Operating The Boom
The tip hose that is supplied by Schwing is rated to handle the pressure of the pump when it is new, but the pressure rating must be lowered as wear dictates.
Page 161 It is not possible to safely connect hoses or pipes that more than 550 pounds from the end have dissimilar ends. The hose supplied by Schwing of the boom. has 125 millimeter metric ends. If you are trying to at-...
Page 162: Pumping The Job
Operation Pumping the Job Remind the pump operator to not let the concrete level in the hopper become low! If air is sucked into the ma- If you are not able to see the point of discharge from terial cylinders, the pump will compress the air. Com- where you must operate the unit, be sure your spotter pressed air always poses a hazard as it is expelled from is in position before starting the pump.
Page 163 Operation If workers are positioned in high or precarious places, taken during setup: warn them to expect a loud sound as the air escapes •The boom must be placed in a favorable position as the pipeline. (Warn them even if they are well away from shown in (Figure 39).
Page 164: Blockages
Operation Do not drag system with boom is past. All of the strength of the boom is in the vertical direc- 4. Remove the blockage from the affected piece of tion. For this reason, never drag anything with the boom system by elevating it and tapping on the pipe or from side to side.
Page 165: Pumping Constraints
Operation Pumping Constraints Stop the dripping concrete while moving When you need to swing a full boom over personnel, a Wind restrictions finished slab, or equipment, it is your responsibility to Boom damage. High winds can dam- protect the area below. Air activated concrete shut-off age the boom.
Page 166: Keeping The Concrete Alive
Operation remember is that concrete begins to set as soon as it most contractors will finish the job with a tower crane to becomes motionless. Every five minutes or so, give the avoid having to wait with concrete in the delivery pipe- pump a stroke, which will make the concrete in the el- line.
Page 167: Preheating The Hydraulic Oil
Operation are some general tips for cold weather pumping: will require that you arrive at the job early enough to do the procedure. Allow about 10 or 15 extra 1. Store the machine indoors in locations that have minutes. cold winters, like the northern U.S. and Canada. If Preheating the hydraulic oil you don’t have a heated shop for the winter, con- sider renting one.
Page 168: Cleanout
Extra sponge balls first thing in the morning, but the ball won’t last as long may be ordered from Schwing at (800) 328-9635. if it is always in water. If you have to use compressed air for cleaning...
Page 169: Cleaning The Vertical Pipeline
Many qualified people have their own ideas about how to control the flow and speed of the concrete at this point, but we at Schwing rec- ommend that the air supply be turned off as soon as the concrete begins to move and feathered lightly as needed to keep it moving.
Page 170: Folding Up The Clean Boom
Operation Emergency Procedures should tap lightly on the pipeline, as far from the pump as possible, and listen for the ringing sound of an empty Loss of remote control pipe. This will tell him that the cleanout ball has passed The remote control box is considered the primary control his location.
Page 171: External Cleaning
Operation External Cleaning Use of Cleaning Agents Do not use aggressive cleaning agents. They can affect We recommend washing the exterior of the SPB during different materials (e.g. rubber) and painted surfaces. breaks to prevent concrete from setting. High Pressure Washer Commercially available paint-cleaning and - care prod- ucts can be used, provided they do not exceed a pH Observe the operating instructions of the high-pressure...
Page 172: Description
Operation Self-Climbing Mast Description When building floors are finished with poured concrete, the placing boom must rise to the next level. This can be done by means of a crane. If no crane is available, hydraulic climbing equipment must be used. This allows the placing boom and the boom tower to be lifted gradually or, in other words, “to climb”...
Page 173: Components
Operation Components The components of the climbing equipment must be The hydraulic climbing equipment is composed of the moved from floor to floor when the maximum lifting following components: height of the lower climbing floor frame is reached. 1. cable remote control, Warning and instruction decals on tower 2.
Page 174: Controllers
Operation Controllers Emergency Operation Control *Control lever: Climbing equipment UP -0-DOWN Cable Remote Control 1. Emergency shut-off button: stops the drive motor of the hydraulic unit 2. Not used (Figure 34) 3. Momentary contact switch: climbing UP - 0 - DOWN Emergency Control Valve Figure 47 Figure 45...
Page 175 If you detect damage or excessive wear, have the con- 3. Check the oil level in the hydraulic reservoir of the cerned parts inspected by the Schwing after-sales ser- hydraulic unit. vice who will then decide whether the parts can still be used or whether they have to be replaced.
Page 176 Operation 4. Connect the hydraulic hoses for the climbing cylin- Unscrew the base cross from the boom tow- ders to the screwed couplings (Figure 39) per the er (16 screws). table below: Attach the lifting arms (Item 2 Figure 41) to both climbing cylinders (Item 4 Figure 41) and se- Connection for: cure the pins (Item 3 Figure 41).
Page 177: Climbing
Operation “B” and secure. Stop Switch Local/Remote Switch Start Switch Main Power Switch Support Pins START STOP LOCAL REMOTE Position A WARNING Position B 30355887 Do not touch hydraulic oil leaks. Get immediate oil lea medical attention if oil penetrates skin. ADVERTENCIA No toque las fugas de aceite hidráulico.
Page 178 Operation 2. When the climbing cylinders are fully extended, insert a supporting pin (Item 1 Figure 45) on both sides above the floor frame. The safety latches (Item 2 Figure 45) of the supporting pins must be inserted into the next higher bore of the boom tow- Holder Bolt Figure 58...
Page 179 Operation and eight wedges into the guides of the lower frame (arrows, Figure 49). Wedges should never be driven in more than two ﬂoor frames. Remember that A minimum distance between ﬂoor frames is required. Due to the variety of models available, please contact the factory for corresponding technical data (have the serial number of the unit ready).
Page 180: After Climbing
Operation SPB Remote Socket (x8) Self-Climber Remote Socket Dummy plug Main power switch Figure 61 Figure 63 Secure wedge pins into the guides of the upper and Remote control receptacle lower frames. (For the purpose of representing the 4. Reconnect the remote control of the placing boom wedge guides in the figure, the boom column is not to the receptacle (Item 1 Figure 52) of the control shown)
Page 181: Maintenance And Troubleshooting
Emergency stop button on left side of remote control protect it against unauthorized use. Faults in the electrical or hydraulic system should be rectiﬁed by calling the Schwing Ser- 4. Stow all parts properly. Check and replace dam- vice Department.
Page 182 Close and lock the cover of the control block (Figure 56). START STOP LOCAL REMOTE Have the equipment checked and repaired as soon as WARNING possible by the Schwing Service Department. 30355887 Do not touch hydraulic oil leaks. Get immediate oil lea medical attention if oil penetrates skin. ADVERTENCIA No toque las fugas de aceite hidráulico.
Page 183 Maintenance Maintenance ............93 Maintenance Checklist ........97 Pressure, Hoses, and Fittings .......93 Scheduled Maintenance ........97 General information ........93 Pressure settings ...........97 Specific information ........93 Daily Maintenance ..........98 Torque specifications ........93 Visually Inspect the Machine ......98 Removing safety devices .......94 Check Hydraulic Fluid Levels ......98 Replacing the hydraulic pump .......94 Check End Hose ..........98 Hydraulic Oils ..........95...
Page 184 Maintenance Grease boom zerks, hollow pin and bearings ... Monthly Maintenance ........101 Check slewing gear oil .........101 Visually inspect the turret bolts ....101 Semiannual Maintenance......102 Change the oil for temperature reasons ..102 Changing oil - boom slewing gearcase ..102 Hydraulic Boom Filter ........103 Yearly Maintenance ........103 Change the hydraulic oil ......103 Unscheduled maintenance ......104...
Page 185: Pressure, Hoses, And Fittings
A. The torque specifications for low or medium pressure. The fittings and hoses are rat- bolts used on Schwing equipment are found in the Ap- ed at a minimum of 5000 PSI working pressure and up pendix section of this manual.
Page 186: Removing Safety Devices
For these situations, you (Figure 3). Schwing recommends Optimoly Paste White must take extra care to be sure of your own safety, and T to add extended life to the spline and related parts.
Page 187: Hydraulic Oils
Maintenance Hydraulic Oils The quality of the oil needed for use in a Schwing con- crete pump is in the DIN system. The ratings have to do General information with the chemical additive package that is introduced Hydraulic oils are rated for viscosity, heat dissipation, into the oil.
Page 188: Hydraulic Oil Recommendations
Maintenance Hydraulic Oil Recommendations Viscosity (ISO): VG32 VG 46 VG68 Quality (DIN): HVLP HVLP HVLP GF 32 HF 32 GF 46 HF 46 GF 68 ARAL-Vitam BP-Energol HLP HM 32 HV 32 HM 46 HV 46 HM 68 HV 68 BP-Bartran KLÜBER-Lamora HLP 32...
Page 189: Maintenance Checklist
Maintenance Maintenance Checklist The following are the normal recommended mainte- nance schedules (after the break-in period). Scheduled Maintenance Component Daily Weekly Monthly Semi Annually Annually √ Visually inspect machine √ Check hydraulic oil level √ Check End Hose Check slewing brake function √...
Page 190: Daily Maintenance
• Check the connection between the hose and the problem. If you need ideas about where to look for the clamp, ensure a tight fit. source of water contamination, call Schwing America’s • Check the pipe clamp for wear Service Department at (651) 429-0999 or (800) 328- •...
Page 191: Check Slewing Brake Function
This is done with a throttle check valve. The throttle is preset at the factory and should not be readjusted unless you first consult the Service Department at Schwing America. Multiple disk brake system Alternative filling port...
Page 192: Weekly Maintenance
Maintenance Weekly Maintenance Manually Lubricate the Boom Place the grease gun coupler at the end of the grease Bleed Mositure from Hydraulic Reservoir zerk. Squirt grease unit it squirts out of the bearing area. Drain water from the hydraulic reservoir ever week. The boom should be rotated while grease is applied to Open the ball valve under the hydraulic reservoir (Fig- achieve adequate lubrication.
Page 193: Monthly Maintenance
Maintenance Monthly Maintenance Visually inspect the turret bolts If you find any loose nuts or bolts, do not re-tighten Check slewing gear oil them! Instead, replace any bolt that is loose, as well as 1. Be sure the machine is set up in a reasonably flat the two bolts on each side of it.
Page 194: Semiannual Maintenance
Change the oil for temperature reasons 7. Fill the case to the proper line on the dipstick. You Your Schwing unit was delivered with Mobil will have to fill very slowly because of the thickness Univis N46 hydraulic oil. This multi viscosity oil of 90W gear lube.
Page 195: Hydraulic Boom Filter
See the information at the beginning of this chapter for specific infor- mation about hydraulic oils that are approved for Filter use in Schwing machines. 6. Change the main system filter and the boom filters before restarting the unit. Clean Out Covers...
Page 196: Unscheduled Maintenance
Maintenance Unscheduled maintenance Elbows tend to wear on the upstream side, or where concrete enters the elbow (Figure 18). The amount and quality of service you get from your unit varies according to the conditions to which the ma- chine is subjected. Differences in concrete types and pressure play a major role in the wear of machine com- ponents.
Page 197: Frequent Inspections
Maintenance Frequent inspections while traveling; Frequent inspections should be performed by a desig- • Proper lubrication of moving parts. nated person at daily to monthly intervals, and should Inspection of delivery system include observations prior to and during operation. Pipeline The designated person should determine whether con- •...
Page 198: Changing Boom Pipe
You may obtain a copy of inspection intervals and pro- • Always install new or like new pipeline on the cedures by calling the Schwing America Service De- boom. partment at (651) 429-0999.
Page 199 Appendix Hydraulic Oil Viscosity Chart ......109 Single Wall ........... 116 Torque Specifications for Metric Bolts ..110 Minimum Pipe Wall Thickness ....117 Torque Chart ..........111 Twin Wall ............. 117 Dacromet/Geomet 500 Coating ....111 Glossary of Terms ........118 Torque Chart ..........
Page 201: Appendix
(thermal break- as the temperature rises. down). Your Schwing concrete pump was delivered with Mobil • The optimum operating viscosity is the range Univis N46 hydraulic oil. This multi viscosity works for of oil thickness at which the oil works best (thin any temperature between -20˚...
Page 202: Torque Specifications For Metric Bolts
The following charts show the tightening torques speci- Wrench Size = 13 mm fied for the bolts used on Schwing equipment. A torque wrench must be calibrated to within 1% of its indicated value throughout its range. Bolts must be torqued to within 4% of the requirement if the wrench has a dial scale.
Page 203: Torque Chart
Appendix Torque Chart Dacromet/Geomet 500 Coating 1. Nuts and Bolts as per DIN 912 – 931 – 933 – 934 – 6914 - 6915 1. Dacromet/Geomet 500 coating. Applicable to: 2. Black and silver-chromated nuts and bolts fitted with mounting paste such as Cu or MOS These are the torque values as of January 09.
Page 204: Torque Chart
Appendix Torque Chart Black and Silver Chromated 2. Nuts and Bolts as per DIN 912 – 931 – 933 – 934 – 6914 - 6915 Black and silver chromated nuts and bolts. Applicable to: These are the torque values as of January 09. Coarse-Pitch Thread Fine-Pitch Thread * Fitting Tightening Torque...
Page 205: Recommended Emergency Hose Kit
Appendix Recommended Emergency Hose Kit Schwing recommends that you carry one of each of the following hoses on the unit in case you blow a hose on the job. Each size listed represents the longest hose of each diameter that is installed on the unit at the facto- ry.
Page 206: Banjo Fittings
Appendix Banjo fittings End Cap Separate from Stem Metric Wrench Sizes Nearest American Wrench Sizes Fitting or Tube Cap Nut Coupling End Cap Cap Nut (mm) Coupling End Cap (in.) Size (mm) Body (mm) (mm) Body (in.) 8 mm 12 / R 4 in.
Page 207: Weld-On Ends / Coupling Comparison
Appendix Weld-on Ends / Coupling Comparison Shown is a comparison among commonly used ends/couplings. No two ends shown can be joined with- out the use of an adapter pipe or a special adapter clamp. Clamps and pipe strength must also be consid- ered when determining proper system requirements.
Page 208: Minimum Pipe Wall Thickness
Appendix Minimum Pipe Wall Thickness Single Wall SCHEDULE 40 11 gauge 9 gauge 7 gauge 3/16” (1/4 wall) 4200 4000 3800 3600 3400 3200 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 .050" .100" .150" .200" .250" .300"...
Page 209: Minimum Pipe Wall Thickness
Appendix Minimum Pipe Wall Thickness Twin Wall Measuring points on pipe wall: Measure multiple points circumferential, approx. 20- 30 mm behind the weld zone as illustrated in (D1)and (D1A). Measurements should be done on both ends of the pipe. 20-30mm Measuring points on Weld end: Measure multiple points circumferential in the weld end groove as illustrated in (D2) and (D2A).
Page 210: Glossary Of Terms
Appendix Glossary of Terms Certified Operator An operator who has been issued a certification card Accumulator by the American Concrete Pumping Association. A hydraulic device that stores fluid power energy in There are several classes of certification, each relat- much the same way that a capacitor stores electri- ing to a different category of pump.
Page 211 Appendix Decibels crete that breaks away from ready- mix truck fins, A measurement of volume equal to one tenth of a bel, and soft drink cans. Many of these items can create abbreviated dB. As it applies to concrete pumps, it is a blockage if they are pumped through the system.
Page 212 Appendix licensed, but the work should still be completed by presence in the operational area. a competent professional. Under no circumstances OSHA should high-voltage connections be made by a con- Occupational Safety and Health Administration. A crete pump operator or related personnel. branch of the U.
Page 213 Appendix Qualified Operator pressure to try to remove the wedge only results An individual who meets all the following qualifica- in forcing more of the finest particles past the rocks, tions: compounding the problem. In some cases, the wedge can be broken up by alternately pumping in forward •...
Page 214 Appendix Spotter Twin Circuit A spotter is a person who stands at a vantage point The plumbing method used for the pumpkit in which where he or she can see both the point of discharge the differential cylinders are moved by the main hy- and the pump operator.
Page 215: Pictograms
Appendix Pictograms Shown below are the pictograms used on Schwing con- crete pumps and accessories. REMOTE CONTROL BOX Boom #1 (main) Boom #2 Boom #2 speed control Boom #3 Boom #4 (tip) Boom slewing slow medium clockwise counter- fast extend...
Page 216 Appendix SPB Operation Manual...

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Schwing SPB 28 Operation Manual

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