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Schwing SP 500 Operation Manual

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Operation Manual
SP 500 / 750-15 / 750-18 / 1000 / 1250
Part# 98418850
Revision: 1.1
Date: 02/13/17
5900 Centerville Road
St. Paul, MN 55127
1-888-SCHWING (724-9464)
www.schwing.com

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  • Page 1 Operation Manual SP 500 / 750-15 / 750-18 / 1000 / 1250 Part# 98418850 Revision: 1.1 Date: 02/13/17 5900 Centerville Road St. Paul, MN 55127 1-888-SCHWING (724-9464) www.schwing.com...
  • Page 2 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.
  • Page 3 Operation Manual SP 500 / 750-15 / 750-18 / 1000 / 1250 Part# 98418850 Revision: 1.1 Date: 02/13/17 Copyright © 2017, Schwing America, Inc. All rights reserved...

  • Page 5: Table Of Contents

    Machine Overview ..........38 Pump Codes Screen ........59 Pumpkit Overview ..........39 Input Error Codes ..........59 S1/S2/S3 Control Valve .........40 Output Error Codes ........59 Accumulator / Accumulator Manifold .....40 Error Cause ...........59 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 6 Maintenance Chart ........97 Cleanout ............80 Daily maintenance ..........98 Clean the waterbox ........83 Weekly maintenance ........101 Preparing for travel ........83 Monthly maintenance ........103 External Cleaning ..........84 Semi-annual maintenance ......104 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 7 Minimum Pipe Wall Thickness ......127 Twin Wall .............127 Output Charts ..........128 Using a Nomograph........134 The quadrants ..........136 Glossary of Terms ...........141 Additional Reading Material......145 Alphabetical Index ......... 147 Short Instructions ........151 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 9: Introduction

    Introduction Introduction Manufacturer’s Statement ......11 Concrete Pump Nomenclature ......12 Identification Tag (ID Tag) ......12 How to order missing tags ......13 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 11: Manufacturer's Statement

    Keep this manual and all included literature in a safe and convenient location. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 12: Concrete Pump Nomenclature

    HYDRUALIC PRESSURES/PRESIONES HIDRAULICAS MATERIAL PRESSURE/PRESIONES Concrete P.S.I. Agitator P.S.I. Accumulator P.S.I. Auxiliary P.S.I. P.S.I. Material Pump / Bomba El Agitador El Acumulador Auxiliar De Concreto Figure 1 ID Tag SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 13: How To Order Missing Tags

    HYDRUALIC PRESSURES/PRESIONES HIDRAULICAS MATERIAL PRESSURE/PRESIONES Concrete P.S.I. Agitator P.S.I. Accumulator P.S.I. Auxiliary P.S.I. P.S.I. Pump / Bomba Material El Agitador El Acumulador Auxiliar De Concreto Figure 2 ID Tag Location SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 14 Introduction SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 15: Specifications

    Specifications Specifications Concrete Pump Specifications......17 SP 500 ............17 SP 750-15 ............18 SP 750-18 ............19 SP 1000 ............20 SP 1000HP ............21 SP 1250 ............22 Optional Equipment ........23 SP 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 17: Concrete Pump Specifications

    Specifications Concrete Pump Specifications SP 500 Concrete Pumpkit 80/50 x 1000:150 Concrete Valve Long Rock Maximum Strokes/minute 32.5 Maximum Concrete Volume 45 cu. yd 35 cu. m C4.4 Tier 3 - Diesel Motor 80 hp 60 Kw C3.4 Tier 4 - Diesel Motor 74.5 hp...
  • Page 18 Specifications SP 750-15 Concrete Pumpkit 80/50 x 1000:150 Concrete Valve Long Rock Maximum Strokes/minute Maximum Concrete Volume 50 cu. yd 38 cu. m C4.4 Tier 3 - Diesel Motor 100 hp 75 Kw C3.4 Tier 4 - Diesel Motor 100 hp 75 Kw Electric Motor 100 hp...
  • Page 19 Specifications SP 750-18 Concrete Pumpkit 90/50 x 1000:180 Concrete Valve Long Rock Maximum Strokes/minute Maximum Concrete Volume 70 cu. yd 53.5 cu. m C4.4 Tier 3 - Diesel Motor 100 hp 75 Kw C3.4 Tier 4 - Diesel Motor 100 hp 75 Kw Electric Motor 100 hp...
  • Page 20 Specifications SP 1000 Concrete Pumpkit 90/50 x 1000:180 Concrete Valve Long Rock Maximum Strokes/minute Maximum Concrete Volume 70 cu. yd 53.5 cu. m Diesel Motor (C4.4 Tier 3) 139 hp 104 Kw Diesel Motor (C4.4 Tier 4) 137 hp 102 Kw Electric Motor 125 hp 93 Kw...
  • Page 21 Specifications SP 1000HP Concrete Pumpkit 90/50 x 1000:150 Concrete Valve HP Short Rock Valve Maximum Strokes/minute Maximum Concrete Volume 35 cu. yd 26.7 cu. m Diesel Motor (C4.4 Tier 3) 139 hp 104 Kw Diesel Motor (C4.4 Tier 4) 137 hp 102 Kw Electric Motor 125 hp...
  • Page 22 Specifications SP 1250 Concrete Pumpkit 80/55 x 1400:180 Concrete Valve Long Rock Maximum Strokes/minute Maximum Concrete Volume 95 cu. yd 73 cu. m Diesel Motor (C4.4 Tier 3) 173 hp 129 Kw Diesel Motor (C4.4 Tier 4) 173 hp 129 Kw Electric Motor 150 hp 112 Kw...

  • Page 23: Optional Equipment

    Specifications Optional Equipment For more information on optional equipment, see “Optional Equipment” on page 88 • Autogreaser - Rock Valve • Auxiliary Hydraulic Circuit • Water Pump - Hydraulic • Air Compressor • Aux Hydraulic Connection • Carbide Wear Parts •...
  • Page 24 Specifications SP 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 25: Safety

    Safety Safety Safety Alert Symbols ........27 Safety Manual ..........28 How to Order Additional Safety Manuals ..28 Schwing phone numbers .......28 Warning Labels (Decals) ........28 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 27: Safety Alert Symbols

    All persons working near the concrete pump must be able to recognize hazardous situations. They must know how to avoid these situations and how to re-act quickly and appropriately whenever hazardous situa- tions arise. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 28: Safety Manual

    30381024 Co-worker Safety, laminated, English 30381022 Co-worker Safety, Spanish 30381027 Small line Safety Manual, English 30381680 Small line Safety Manual, Spanish 30381841 Figure 2 Sample Decal Location Guide SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 29 Start up Screen ..........44 Warning Horn..........37 Engine Status Screen ........44 Machine Overview ..........38 Warning Messages and Symbols ....44 Pumpkit Overview ..........39 Warning Messages ........45 S1/S2/S3 Control Valve .........40 E-stop Warnings ..........45 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 30 Overview General Warnings ..........45 Pump Status Screen ........46 Menu Screen ..........46 Pump Codes Screen ........46 Engine Codes Screen ........47 PLC I/O Screen ..........47 Operator Keypad Screen .......47 Radio Remote Screen ........47 Cable Remote Screen ........47 Options Screen ..........48 Oil temperature Sensor Settings Screen ..48 Greaser Settings Screen .......48 Stroke Limit Settings Screen ......49 Language Screen ..........49...

  • Page 31: Product Overview

    This shared oil, called rocking oil, keeps the two cylinders moving. A third hydraulic cylin- der (the Rock Valve slewing cylinder) cycles the Rock Valve back and forth. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 32: Twin-Circuit Switching Vs Single-Circuit

    This is not the case with twin-circuit ma- chines. Even with the engine shut-off, pressure could SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 33 1/4” Turn - Shutoff Valve Soft Switch shutoff handle Hydraulic oil filter with bypass valve Main relief poppet valve Accumulator unloading valve Soft Switch valve Accumulator Concrete Pump Pressure Gauge SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 34: Safety Devices

    To bypass the dump valve, press and hold the override button. Press to engage Turn clockwise to release Figure 1 Emergency stop button SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 35: Emergency Stop (E-Stop) Manifold

    Figure 4 either from above (through the hop- Concrete pump forward/reverse handle per) or from below (through the outlet pipe or clean out door). Serious inju- ry can result. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 36: Manual Bleed-Off Valve

    Find the cause of the problem, and repair it Soft Switch Relief Valve before activating the circuit again. Figure 7 Example of a pressure relief valves SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 37: Warning Horn

    HMI panel. Reset Procedure The horn must be sounded to reset the machine after an emergency stop button is reset. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 38: Machine Overview

    I. Rear Outrigger B. Power Pack J. Ram Change Station C. Rear Control Station (SCT) K. Agitator Handvalve D. Hydraulic Tank E. Fuel Tanks L. Horn Button F. Hopper SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 39: Pumpkit Overview

    Overview Pumpkit Overview A. Material Cylinders B. Differential Cylinders C. Rams D. Water Box E. Control Valve (S1/S2/S3) F. Accumulator G. Rock Valve SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 40: S1/S2/S3 Control Valve

    D. Breather E. E-Stop Manifold F. Main System Filter G. Agitator Relief Valve Accumulator / Accumulator Manifold A. Pressure Relief Valve B. Manual Bleed Off Valve C. Accumulator SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 41: Hopper

    D. Stroke Limiter E. Tension Nut E. Gear Pumps F. Locking Pin F. Accumulator Manifold Fuel Tanks A. Breather B. Fuel Cap / Gauge C. Cross Over Hose SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 42: Sct (Schwing Control Technology)

    The Operator Panel contains the following item: A. HMI (Human Machine Interface) B. Ignition Switch C. Operator Panel Keypad Operator Panel Cable Remote Radio Remote 100% ACC1 ACC2 ACC3 ACC1 ACC2 98413629-00 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 43: Hmi (Human Machine Interface)

    To assist the reader, we will represent the symbols as follows: = OK = Escape = Navigation Arrows Left/Right = Navigation Arrows Up/Down = Navigation Arrows Left/Right /Up/Down SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 44: Lcd Screens

    Concrete pump faults are listed on the Pump Codes °C Screen. Reference the “Concrete Pump Error Codes” LOW FUEL on page 59 to cross reference the error codes. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 45: Warning Messages

    If enabled - Temperature is above alarm set point ENGINE FAULT Check Engine Codes screen RAM CHANGE MODE Disables the Operator Panel and Remote controls. Idle goes to minimum, strokes go to minimum. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 46: Pump Status Screen

    Cable Remote SP_PLC_ver-01.24.00F Options SP_MMI_ver-01.21.00F LEFT E-STOP Pump Codes Screen Displays pump code faults. - Press to return to the Menu screen. Pump Codes CLASS USER SOURCE CAUSE SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 47: Engine Codes Screen

    INPUTS / OUTPUTS Displays active functions on the Cable Remote VBBs: - Press to return to the Menu screen. 22362 VBBo: Cable Remote 22362 VBBr: 22387 Vref: Test SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 48: Options Screen

    Oil Temp Sensor Settings Hydraulic Oil Temp -30 C Cooler On Temp 55 C Cooler Off Temp 50 C High Oil Temp Alarm 85 C Oil Temp Offset SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 49: Stroke Limit Settings Screen

    Used to change the current language of the HMI screens - Use the to move the through the list of languages. - Press to return to the Menu Screen Language Language Select ENGLISH SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 50: Operator Panel Keypad

    Press once to put the concrete pump in reverse. If the concrete pump is in forward, press and hold to change from pump forward to pump reverse. = Pump/Reverse = Inactive ACC1 ACC2 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 51 Output =10% Output =20% Output =30% Output =40% Output =50% Press=10 Output =0% Press=6 Press=7 Press=8 Press=9 Press=10 Output =60% Output =70% Output =80% Output =90% Output =100% SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 52 OFF position and then back Lights to the START position. Press to turn on the lights. Press again to shut the lights off. = Lights / On = Lights / Off SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 53: Cable Remote

    Press once to put the concrete pump in reverse. Press and hold to change from pump forward to pump reverse. ACC1 ACC2 ACC1 ACC2 = Pump/Reverse = Inactive SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 54 Output =10% Output =20% Output =30% Output =40% Output =50% Press=10 Output =0% Press=6 Press=7 Press=8 Press=9 Press=10 Output =60% Output =70% Output =80% Output =90% Output =100% SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 55 = Throttle (-) = Inactive (Push/Hold) Horn Press once or press and hold to sound the horn. = Horn / On = Horn / Off (Push/Hold) SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 56: Radio Remote (Optional)

    N. Concrete Pump Forward O. Concrete Pump - Off P. Concrete Pump - Reverse Q. Stroke Limiter (+) R. Stroke Limiter (-) S. Optional Accessories 2 T. Remote - Off SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 57: Radio Remote Buttons And Lights

    Pressing the button again or moving Forward Reverse Neutral the handle to the neutral position will stop the agitator. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 58 Stroke Limiter (-) button to continually ramp down the strokes per minute setting. The Stroke Limit- er Indicator Lights will flash or become solid depending upon the current output. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 59: Concrete Pump Error Codes

    Water pump Pump Codes Compressor Stroke Limiter CLASS USER SOURCE CAUSE Oil Cooler Agitator on Grease lubrication Concrete vibrator Horn Work Light Error Cause Cause Description Break Short SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 60 Overview SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 61: Operation

    Operation Preparing for the Job ........63 Selecting the setup location ......67 Personal Protection ........63 Laying out the pipeline ........68 Pipeline and Clamps ........63 Machine Preparation ........68 Tools and Accessories ........63 Starting the Machine ........70 Tow Vehicle ............64 Checking the machine ........70 Tow Vehicle Pre-Check ........64 Shutting the Machine Down ......71 Lubricating Slurry ...........71...
  • Page 62 Quick cleanout ..........85 Cold-weather pumping ........85 Emergency Procedures .........87 Emergency Override Button ......87 Loss of Radio/Cable remote ......87 Optional Equipment ........88 Hydraulic Outriggers ........88 Hopper Vibrator ..........88 Auto Greaser ..........88 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 63: Preparing For The Job

    • Water hose and nozzle Steel Toed Shoes • Clean-out rake • Working lamps for night work • An approved air blow-out cap • Hand tools • Hammer Figure 1 Protective clothing SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 64: Tow Vehicle

    40 40 packages to accomplish anti-foaming, DIESEL D IE DIES Minimum silt settling, anti-wear, etc. The mixing Fill Level of these different chemical additive packages may render them useless. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 65: Attaching The Tow Hitch

    8. Plug in the electrical connections for the trailer brake lights and hook up the breakaway switch cable (Figure 5). SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 66: Towing The Stationary Pump

    SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 67: Machine Loading/Unloading

    Shifting cargo can result in loss of Figure 7 control of the trailer, and can lead to Setting rear outriggers death or serious injury. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 68: Laying Out The Pipeline

    • When using the Cable Remote, position the re- Figure 8 mote box and cable where they will be out of the Laying pipeline way. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 69 This is one of the few times when it is better to under-grease than to over-grease. Re-grease agitator bearings every 2 or 3 hours, as the pour allows. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 70: Starting The Machine

    “Pumping the Job” on page 77 to continue. • Use the Throttle Up button (Figure 16) to increase engine RPM’s. Press and hold this button until the engine is at maximum RPM. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 71: Shutting The Machine Down

    These products usually come in sandwich sized plastic bags, and lubricate about 100 feet of 5 inch pipe per bag. Instructions for mixing vary by the different man- ufacturers. These products are less expensive than SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 72 Mix more slurry as needed for the length of the pipeline, as described Figure 14 above. Mixing Slurry In Barrel SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 73 If the first chute full is all rock, have the driver dump it off to the side and show you the next chute full. The second chute full will almost always SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 74: Controlling The Concrete Pump

    (clockwise) to decrease strokes or out (counter clockwise) to increase strokes. Always return the manual stroke limiter to maximum strokes (full counter clockwise out position) when electrical power is restored. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 75: Wireless Remote (Optional)

    Power ON Power OFF 5. The Transmitter will confirm the download is Button Button complete by flashing LED#3 eight times. Figure 19 Connecting the wireless remote LED #3 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 76 Transmitter it may look like the paring works but it does not. This is related to a safety precaution. Replace battery and repeat the par- ing procedure. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 77: Pumping The Job

    Even with Figure 21 the hopper full of concrete, some compressed air will be Wash system as it’s removed introduced into the delivery pipeline. When it reaches SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 78: Time Constraints

    Always keep the hopper at least half full. If the concrete is getting stiff, add water to the hop- per while you are waiting. A word of warning regarding SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 79: Blockages

    If you encounter another blockage, relieve the pressure again by pumping in reverse for several strokes before finding the remaining blockages. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 80: Cleanout

    The result could be a violent whip of the hose as the air is released. If water must be conserved, dump the hoses manually and rinse them with the water nozzle. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 81 Rock Valve and material cylinders. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 82 • Close the hopper cleanout door, and reattach the pull any material from the exposed material cylinder, the bungy cord, if used. Rock Valve, and the outlet pipe (Figure 25). SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 83: Clean The Waterbox

    • Replace the waterbox cover. • Put the pump into forward or reverse for one or two strokes to force the clean water out the drain. • Close the drain. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 84: External Cleaning

    • Maximum water pressure 100 bar / 1450 psi. • Minimum permissible spraying distance 12”. If the high pressure washer used generates a high- er water pressure, the spraying distance must be in- creased accordingly. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 85: Special Pumping Situations

    ISO VG 32. Be aware, however, that this oil cannot protect the components to as high a temperature as the standard oil shipped with your unit (ISO VG 46). SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 86 Do not waste time when cleaning a machine in these conditions. Be very careful of ice when pumping in cold conditions. Never stand on ice-coated pipes or other round objects. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 87: Emergency Procedures

    Do not dispose of nickel cadmium or nickel metal hydride batteries in Figure 28 household or business trash. Connecting the Emergency Power Harness SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 88: Optional Equipment

    7. Move the outrigger valve handle towards the front of machine to raise the outrigger cylinder. Outrigger Handvalve Needle Valve Outrigger Cylinder Figure 30 Hydraulic outrigger components SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 89: Maintenance

    Maintenance Hoses and Fittings .........91 Filtration ............95 Torque specifications ........91 General information ........95 Welding precautions ........91 Specific information ........95 Adjusting relief valves ........91 Bypass Check valve ........96 Removing safety devices .......92 Scheduled Maintenance.........97 Lock Out - Tag Out procedure .......92 Maintenance Chart ........97 Daily maintenance ..........98 Replacing the hydraulic pump .......92...
  • Page 90 Setting main relief / Pressure cut off .... 113 Setting the soft switch relief pressure ..114 Set accumulator pressure cut-off ....115 Set the agitator pressure......115 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 91: Hoses And Fittings

    To be safe, you should be- gin the adjustment procedure by turning the adjustment device to the lowest possible setting, and then bring the device back up to the proper setting. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 92: Removing Safety Devices

    • Perform the needed service on the unit. • Remove the labels, and reinstall the key Store the label in the document holder for future use. Typical Hydraulic Pump Spline Figure 2 Hydraulic pump spline SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 93: Hydraulic Oils

    On the other hand, the thinner the oil, the lower the temperature will have to be before it breaks down the lubricating film that protects your components. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 94: Hydraulic Oil Recommendations

    Premium ECO HT-E 32 HT-E 46 SHELL Naturelle Naturelle Naturelle HF-X 32 HF-E 46 HF-E 68 Naturelle HF-X 46 VALVOLINE Ultrasyn Unisyn Unisyn PG 46 HLP 22/46 HLP 32/68 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 95: Filtration

    1 will make it through. Although we are not happy about the one particle that is allowed through, we do not use finer filtration because the SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 96: Bypass Check Valve

    The filter could also split open and leak to the ground, draining the reservoir, and contaminating the environ- ment. Dirty Filter Indicator Inlet Outlet Filter Figure 3 Hydraulic Oil Filter SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 97: Scheduled Maintenance

    Check The Pre-charge Of The Accumulator √ Change Hydraulic Oil For Seasonal Reasons √ Change Hydraulic Oil Return Filter √* Change Hydraulic Oil For Age Reasons √ * or as needed SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 98: Daily Maintenance

    If the oil has turned milky quickly, such as from one day to the next, then simply replacing the oil will not solve your problem. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 99 Figure 6 Agitator Grease Points Inspect for Damage or Leaks Visually inspect the unit for damage or leaks each day. Repairs should be made before the unit is operated. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 100 “Setting the soft switch relief pressure” on page 114. Soft Switch Shutoff Valve Quarter Turn Shutoff Valve Figure 9 Open Soft switch quarter turn valve SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 101: Weekly Maintenance

    Keeper Bolt Tension Nut Tension Nut Cover Bolts Figure 12 Loosen bolts on Rock valve cover and shaft Keeper Bolt Figure 11 Adjusting the Rock Valve tension nut SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 102 Tighten the keeper bolt. Lubricate mechanical moving parts Lubricate mechanical moving parts with oil or a lubri- cant such as WD-40. This applies to pins, hinges, valve handles and other components. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 103: Monthly Maintenance

    Never point or aim the gun/wand at yourself or anyone else. Never put your hand, fingers or body directly in front of the spray nozzle. Do not spray directly at electronics or electrical components. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 104: Semi-Annual Maintenance

    6. Apply light grease around the gasket of the new filter, such as Lubriplate 105. 7. Tighten by hand, with the oil filter wrench, tighten another half turn. 8. Start the engine, and check for leaks. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 105: Annual Maintenance

    Ram Change Mode Button 7. Change the main return filter before restarting the unit. See “Change hydraulic oil return filter” on page 104. Figure 15 Ram Change Mode button SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 106: Remove The Old Rams

    7. Remove the spacer coupling from the waterbox about 1.5 inches of travel, which will allow you to (Figure 20). remove the spacer coupling (dogbone). When in position, shut-off the engine. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 107 9. There is a groove in the ram flange that will line up with a groove in the cylinder flange. The M12 x 45 bolt with nut will drop into this groove and allow SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 108: Install The New Rams

    Again, you should tighten the nut only finger-tight. Figure 25 Figure 27 Install new ram Retract cylinder away from ram SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 109 Be careful not to go too far (Figure 29). Figure 29 Move cylinder to spacer coupling SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 110: Changing The Material Cylinders

    2500 1000 3000 hose 3500 Material cylinder assembly 30355456 ACCUMULATOR CHARGING KIT (Includes hose and charge valve assy) SCHWING PART NUMBER: Accumulator 30355436 Figure 32 Accumulator charging kit SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 111 9. Do not open the nitrogen bottle supply valve yet. Turn the regulator adjustment handle on the high-pressure regulator (Figure 35) counter clockwise to its minimum setting (closed). SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 112 Never let nitrogen out of the accumulator by Accumulator pressing the gas valve pin with a foreign object. accum closeup The high pressure may rupture the valve seal! Figure 36 Accumulator protection cap SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 113: Setting Main Relief / Pressure Cut Off

    4mm allen wrench then tighten the jam nut. This should raise pressure cut-off above the main relief valve pressure set- ting. Restart the engine and place the concrete SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 114: Setting The Soft Switch Relief Pressure

    RPM to idle, open the soft switch quarter turn valve, and either proceed to other pressure set- 5/32” Allen Head tings or shutoff the engine. 9/16” Jam Nut Figure 41 Soft switch relief valve SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 115: Set Accumulator Pressure Cut-Off

    Accumulator pressure cut-off screw 3. Read the pressure on the accumulator gauge. It should read the proper accumulator system pres- sure. Figure 44 Install pressure gauge in agitator circuit SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 116 7. Return the agitator handle to the neutral position. 1. Stop the engine and follow “Lock Out - Tag Out procedure” on page 92. 2. Remove the pressure gauge and cap fitting from the agitator circuit. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 117: Appendix

    Appendix Hydraulic Oil Viscosity Chart ...... 119 Single Wall ...........126 Torque Specifications for Metric Bolts ..120 Minimum Pipe Wall Thickness ....127 Twin Wall .............127 Torque Chart ..........121 Dacromet/Geomet 500 Coating ....121 Output Charts ..........128 Torque Chart ..........122 Using a Nomograph ........134 Black and Silver Chromated ......122 The quadrants ..........136 Recommended Emergency Hose Kit ..123...

  • Page 119: Hydraulic Oil Viscosity Chart

    (very thick oil) Optimum Operating Viscosity Minimum permissible viscosity 100 110 120 104 122 140 158 176 194 212 230 248 C = degrees Celsius F = degrees Fahrenheit SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 120: Torque Specifications For Metric Bolts

    The torque specifications on the following pages refer to wrench size, bolt size and thread pitch. Above is an example showing what those numbers refer to. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 121: Torque Chart

    90 % by tension and torsion. a. DACROMET/GEOMET 500 means coated with Te on and silver colored. ** Octagonal Mast b. Conversion: 1 Nm = .738 ft-lb. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 122: Torque Chart

    90 % by tension and torsion. a. DACROMET/GEOMET 500 means coated with Te on and silver colored. ** Octagonal Mast b. Conversion: 1 Nm = .738 ft-lb. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 123: Recommended Emergency Hose Kit

    Straight fittings Fitting or Metric Wrench Sizes Nearest American Wrench Sizes Tube Size Cap Nut (mm) Coupling Body (mm) Cap Nut (in.) Coupling Body (in.) (mm) SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 124: Banjo Fittings

    2 in. 16 mm 20 mm 25 mm 30 mm 38 mm End Cap Part of Stem 12 / R 8 in. 16 mm 25 mm 38 mm SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 125: Weld-On Ends / Coupling Comparison

    All pressure ratings listed refer to 5-inch (125mm) diameters in like-new condition. Other pressures would apply to other sizes. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 126: 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. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 127: Minimum Pipe Wall Thickness

    DN125/4.8 .180 / 4.572 .110 / 2.794 .230 / 5.842 S3000 Size Overall Wall Thinkness (New) in./mm in./mm DN125/4.8 .188 / 4.775 .090 / 2.286 .230 / 5.842 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 128: Output Charts

    125 mm / 80 mm x 2000 mm 230mm x 2000 mm 2 x A7VO-107 pumpkit and hydraulic 2 x 66KW output chart explain.eps pumps is shown here. Slewing cylinder 80 / 45 x 185 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 129 21). NUMBER OF STROKES (stroke / min.) SIDE OIL VOLUME (liter / min.) 15.5 NUMBER OF STROKES PISTON (stroke / min.) SIDE OIL VOLUME (liter / min.) SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 130 • Make two copies of the output chart so you don’t ruin your original. You need one chart for each pump tested. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 131 CONCRETE OUTPUT (cu yd / h) NUMBER OF STROKES (stroke / min.) SIDE OIL VOLUME (liter / min.) 15.5 NUMBER OF STROKES PISTON (stroke / min.) SIDE OIL VOLUME (liter / min.) SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 132 Total (read on meter) (for plotting) (read on meter) (for plotting) 0 bar 100 bar breakpoint breakpoint 150 or 200 bar 250 bar 300 bar Check output form-fill2 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 133 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 134: Using A Nomograph

    6" 3000 2500 2000 1800 1500 1200 1000 Pumpkit Model: 120/80 x 1600:200 Proportional value of pipeline in feet Slump of fresh concrete in inches Power: 132 KW SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 135 • 40 ft of 5-in. rubber hose All of these criteria will be explained in detail as we go • 150 ft of 5-in. horizontal steel pipe through the individual quadrants. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 136: The Quadrants

    The power factor number (PF) replaces the TK number should have a PF of 61,750 or greater. on a truck-mounted unit. It is the Kw multiplied by a SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 137 Pipeline diameter in inches 6" 5" 4.5" 4" uppr rght quad-eps SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 138 Round down to 500 feet to make it easy to use the chart. NOTE: Proportional value of the 41 meter boom and deck pipe system is 260 feet. This value includes elbows, reducer, and tip hose. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 139 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 P in PSI The engine is a little too small. The intersection of 100 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 140 Example Job 132 kW 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 P (in PSI) up lft 132Kw Qwad 2000R-eps SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 141: Glossary Of Terms

    An operator who has been issued a certification card by the American Concrete Pumping Association. There are several classes of certification, each relat- ing to a different category of pump. For an operator to SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 142 In some locations, electricians are not required to be SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 143 The area around a working piece of equipment or point of discharge where dangers can be encountered because of the nature of the machinery or process in use. For safety reasons, do not allow unauthorized SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 144 (larger aggregates of the mix) form a wedge inside the pipe. Resistance to movement then becomes overpowering and the concrete stops. Increasing pressure to try to remove the wedge only results SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 145: Additional Reading Material

    Rock Valve is moved by the oil stored in an accumulator. Unauthorized Without authority, without permission. Examples: Un- SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 146 Appendix SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 147: Alphabetical Index

    Blockages ..............79 Concrete Pump Specifications ........17 Bypass Check valve ............. 96 SP 750-18 ..............17 SP 1000 ............... 20 SP 1000HP ..............21 Cable Remote ............... 74 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 148 Quarterly maintenance ..........103 Quick cleanout ............. 85 Identification Tag ............12 ID tag 12 ID tags are missing ............13 Radio Remote Screen ..........47 Ram Change Mode ............ 105 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 149 Tools and Accessories ..........63 Torque Chart .............. 121 Torque specifications........... 91 Torque Specifications ..........120 Towing ................66 Tow Vehicle ..............64 Tow Vehicle Pre-Check ..........64 Twin-circuit ..............32 SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...
  • Page 150 Index SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 151: Short Instructions

    Short Instructions Preparation............153 Starting the Machine ........153 Checking the machine .........154 Shutting the Machine Down ......154 Controlling the Concrete Pump ....155 Stroke Limiter ..........155 Cable Remote..........155 Cable Remote Functions ......156 Radio Remote (Optional) ......156 Radio Remote Functions ......157 Emergency Procedures .......158 Emergency Override Button ......158 Loss of Radio/Cable remote ......158...
  • Page 152 Short Instructions SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 153: Preparation

    Horn button, to clear the E-Stops. • Use the Throttle Up button to increase engine RPM’s. Press and hold this button until the engine is at maximum RPM. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 154: Checking The Machine

    Wait to Disconnect symbol / Battery switch • If the machine is stroking properly, you can either shutdown the machine or begin pumping the job, see “Pumping the Job” on page 77 to continue. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 155: Controlling The Concrete Pump

    (clockwise) to decrease strokes or out (counter clockwise) to increase strokes. Always return the manual stroke limiter to maximum strokes (full counter clockwise out position) when electrical power is restored. SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 156: Cable Remote Functions

    Dummy Plug Wireless Remote Plug Dummy Plug (removed) E-stop Button 100% Horn Button ACC1 ACC2 ACC1 ACC2 Power ON Power OFF Button Button Figure 6 Connecting the wireless remote SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 157: Radio Remote Functions

    N. Concrete Pump Forward O. Concrete Pump - Off P. Concrete Pump - Reverse Q. Stroke Limiter (+) R. Stroke Limiter (-) S. Optional Accessories 2 T. Remote - Off SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

  • Page 158: Emergency Procedures

    Do not dispose of nickel cadmium or nickel metal hydride batteries in Figure 7 household or business trash. Connecting the Emergency Power Harness SP 500 / 750-15 / 750-18 / 1000 / 1250 Operation Manual...

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