Schwing TP 100 Original Operating Instructions

Schwing TP 100 Original Operating Instructions

Trailer pump truck-mounted concrete pump
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Original operating instructions
Trailer pump
Truck-mounted concrete pump
TP 100
- EN-

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Summary of Contents for Schwing TP 100

  • Page 1 Original operating instructions Trailer pump Truck-mounted concrete pump TP 100 - EN-...
  • Page 2 Specify the machine type and the machine number stamped on the type plate of your machine when placing an order. Pass on these operating instructions when leaving the machine to someone else. Imprint: Editor: Schwing GmbH Department: TDS 1 Address: Heerstr. 9-27...
  • Page 3 2.6 Technical specifications for TP 100 ........
  • Page 4 Pictographs............. 54 2.10 Control, warning and steering elements TP 100 ......57 2.10.1 On the right in the direction of travel .
  • Page 5 3.4 EMERGENCY-STOP system for TP 100 ........
  • Page 6 3.6 Readying the machine for operation TP 100 ....... .
  • Page 7 3.12 Working operation - concrete pump TP 100 ....... .
  • Page 8 3.19 Readying the machine for transport TP 100 ....... .
  • Page 9 4.4 Explanation of the maintenance schedule - Stationary concrete pump / trailer pump . 4.5 Maintenance schedule for stationary concrete pump TP 100 ....263 4.5.1...
  • Page 10 4.11.11 Preventive maintenance of the unarmoured swivel head (rock) ....309 4.12 Pumping and differential cylinders, pumping piston change TP 100 ... . 311 4.12.1 Pumping piston change .
  • Page 11 4.14.3 Changing the fuses in SCHWING components ....... . 341...
  • Page 12 1 Content 4.14.20 Disposal ............. . . 350 4.15 Safety inspections .
  • Page 13 1 Content 5.2.19 Storage, maintenance, upkeep, disposal ........383 5.2.20 Maintenance .
  • Page 14 1 Content Appendix ............425 7.1 Information service .
  • Page 15 2 Introduction This chapter contains the most important informa- tion about your machine/system, in addition to: Layout Conventions Handling of these operating instructions. Trennblatt-Einleitung-EN.fm...
  • Page 16 2 Introduction Trennblatt-Einleitung-EN.fm - 01.00.01...
  • Page 17 In addition to the operating instructions, the general relevant legal and other rules on accident prevention of the country of operation should be observed. SCHWING GmbH is not liable for damages caused by a failure to observe these provisions and/or these operating instructions or by improper use of the machine!
  • Page 18 The same also applies for the manufacturer of integrated motors used in our sta- tionary concrete pumps and trailer pumps. Other special pieces of equipment on your SCHWING machine may also have their own operating instructions. Please observe these documents, in addition to the SCHWING operating instruc- tions, in order to service and maintain these components properly.
  • Page 19 If you still have any questions or doubts after reading the operating instructions, please do not hesitate to contact the customer service department at Schwing GmbH. If necessary, you can also organise individual training seminars. These operating instructions are also intended as reference work. The clear table of contents and the headers in the document were designed with that purpose in mind.
  • Page 20 2.2 Structure of the operating instructions 2.2.2 Contents of the individual chapters in these operating instructions Introduction This chapter is intended to familiarise you with your machine. It contains, for example, the technical specifications, a short description and an overview of the machine. Operation In this chapter, you will find descriptions of all machine operating procedures, from commissioning to working operation and cleaning to decommissioning.
  • Page 21 2.2 Structure of the operating instructions 2.2.3 Page layout of the operating instructions Header A dynamic column title is contained in the header on the outer edge of the page. The column title shows the corresponding sub-chapter currently being read, along with the chapter number and title.
  • Page 22 2.2 Structure of the operating instructions 2.2.4 Structure of the warnings In these operating instructions, warnings are placed in front of certain sections to warn readers of dangers that could cause potential personal injury or material dam- age. The measures described to avert these dangers must be adhered to. Warnings are structured as follows: Signal word Type of danger and its source...
  • Page 23 2.2 Structure of the operating instructions 2.2.6 Warning of material damage The following warning describes the meaning of the signal word for material dam- age. ACHTUNG! Attention! Material damage! Damage to your own machine or other objects. Describes how the material damage can be avoided. 2.2.7 Additional information The following symbol indicates useful tips and recommendations, as well as infor-...
  • Page 24 2.2 Structure of the operating instructions Aufbau-BA-EN.fm - 01.05.02...
  • Page 25 2.3.1 Declaration of conformity SCHWING declares that the machine placed on the market in the European Eco- nomic Area complies with the relevant EC directives. We confirm this by issuing a declaration of conformity and affixing a CE mark to the machine.
  • Page 26 2.3 CE labelling 2.3.2 Declaration of incorporation for separate placing boom (SPB) Separate SCHWING placing booms are generally delivered along with a declara- tion of incorporation. After consultation, in exceptional cases a declaration of con- formity can also be issued.
  • Page 27 Complete list of the applied national standards and technical specifications, see »Ref- erences in DIN EN 12001 conveying, spraying and placing machines for concrete and mortar — Safety requirements«, as well as the SCHWING factory standard. Noise emission Installed effective output...
  • Page 28 Complete list of the applied national standards and technical specifications, see »Ref- erences in DIN EN 12001 conveying, spraying and placing machines for concrete and mortar — Safety requirements«, as well as the SCHWING factory standard. Noise emission P hydraulic = kW (hydraulic drive)
  • Page 29 Person authorised, at the request of the market surveillance authorities, for the compilation of the relevant technical documents (declaration of conformity): CE-person authorised by SCHWING GmbH. This declaration loses its validity in the event of any unauthorised changes to the machine.
  • Page 30 Safety requirements« Complete list of the applied national standards and technical specifications, see »Ref- erences in DIN EN 12001 conveying, spraying and placing machines for concrete and mortar — Safety requirements«, as well as the SCHWING factory standard CE-Konformität-EN.fm - 01.14.02...
  • Page 31 CE marking and declaration of conformity only apply to design and scope of deliv- ery of the machine delivered ex works. Making changes to the machine without the approval of SCHWING, in addition to using accessories without the approval of SCHWING, shall cause both to lose their validity.
  • Page 32 2.3 CE labelling CE-Konformität-EN.fm - 01.14.02...
  • Page 33 • Improper operation by machine operators without adequate training or instruction • Using concrete pipelines that are not approved by SCHWING • Not performing the boom inspections and corresponding repairs on time See “Maintenance” chapter for restrictions One construction job is generally defined as one extension and retraction cycle.
  • Page 34 In the event of damages of any kind, the entire machine must be inspected. Contact SCHWING in the event of operations outside of the indicated reference values The following applies to all SCHWING machines: Fresh concrete +15 °C...
  • Page 35 2.5 Labelling SCHWING machines Labelling SCHWING machines The most common abbreviations and their meanings are listed and explained here. 2.5.1 Stationary concrete pumps SP 1800 BR02 Stationary concrete Pump 1800 technical parameters (minimum value) Series SP 3800 BR02 Stationary concrete Pump...
  • Page 36 The type plate for the concrete pump is located on the machine frame (Fig. 2). Fig. 2 The factory plate is located on the inside of the machine frame on the right in the direction of travel. Fig. 3 Factory plate (only for TP 100) Maschinenkennzeichnung-SP-EN.fm - 01.05.00...
  • Page 37 2.6 Technical specifications for TP 100 Technical specifications for TP 100 Information Power ratings are theoretical max. values! WARNUNG! Warning! The specified concrete pressures require suitable pumping line material! (see “Operating the pumping line” on page 141) Techn-Daten-TP-100-EN.fm - 01.01.00...
  • Page 38 2.6 Technical specifications for TP 100 Technische Daten/Technical Data TBS, Juli 2019 TP100 Stage3a / Tier 3 Pumpenbatterie 650x150 - 80/45 Pump kit Motorhersteller und Typ Deutz D2011 L03 Engine Abgasstufe EU Stage3a Emission standard Motorleistung (kW) 34,5 Engine power (hp) 46,3 max.
  • Page 39 2.6 Technical specifications for TP 100 Technische Daten/Technical Data TBS, Januar 2020 TP100 Stage V(EU) / Tier 4 f(US) Pumpenbatterie 650x150 - 80/45 Pump kit Motorhersteller und Typ CAT C1.7 Engine Abgasstufe EU Stage V / US Tier 4f Emission standard...
  • Page 40 2.6 Technical specifications for TP 100 Technische Daten/Technical Data TBS, Januar 2020 TP100 Stage V(EU) / Tier 4 f(US) Pumpenbatterie 650x150 - 80/45 Pump kit Motorhersteller und Typ CAT C2.2 Engine Abgasstufe EU Stage V / US Tier 4f Emission standard...
  • Page 41 2.6 Technical specifications for TP 100 Technische Daten/Technical Data TBS, Januar 2020 TP100E 50Hz IE3 Pumpenbatterie 650x150 - 80/45 Pump kit Motorhersteller und Typ HMC3 200L B5 Engine Abgasstufe Emission standard Motorleistung (kW) Engine power (hp) 40,2 max. Motordrehzahl (min-1) 1485 max.
  • Page 42 2.6 Technical specifications for TP 100 Techn-Daten-TP-100-EN.fm - 01.01.00...
  • Page 43 2.7 Assembly groups and designations for your machine TP 100 Assembly groups and designations for your machine TP 100 This chapter contains an overview of the main assembly groups for your machine and their respective positions. 2.7.1 Machine description The trailer pump (TP = trailer pump) is suitable for pumping concrete (up to 25 mm maximum grain size), fine concrete and flowing screed as well as for grouting work and for the use in shotcrete work (additional equipment is required).
  • Page 44 2.7 Assembly groups and designations for your machine TP 100 2.7.5 Concrete pump The concrete pump is a two-cylinder piston pump with a rock valve. The most important assembly groups (Fig. 5 Example: Concrete pump) include: 1 Rock valve 2 Pumping cylinder and piston...
  • Page 45 2.7 Assembly groups and designations for your machine TP 100 By switching to “Suction” (reverse running), the concrete can be drawn from the pumping line and back into the filling hopper. At the end positions, the hydraulic cylinders of the concrete pump and of the rock valve control hydraulic control valves, which coordinate the cylinder movements.
  • Page 46 2.7 Assembly groups and designations for your machine TP 100 2.7.7 On the left in the direction of travel Fig. 6: Side view on left in the direction of travel without hood Caption (Fig. 6: Side view on left in the direction of travel without hood) Pos.
  • Page 47 2.7 Assembly groups and designations for your machine TP 100 2.7.8 On the right in the direction of travel Fig. 7 Side view on the right in the direction of travel Caption (Fig. 7 Side view on the right in the direction of travel) Pos.
  • Page 48 2.7 Assembly groups and designations for your machine TP 100 2.7.9 Aerial view Fig. 8: Aerial view without hood Caption (Fig. 8: Aerial view without hood) Pos. Description Pos. Description Control block CP Grid assembly Water box EMERGENCY-STOP button Diesel tank Starter battery Baugruppen-TP-100-EN.fm - 01.01.00...
  • Page 49 Fig. 9 Example: Noise level The indicated value represents an average value for the respective series, plus a safety margin. SCHWING guarantees that this value will not be exceeded by newly delivered, ex works machines. Information Regarding noise emissions, please observe the regionally applicable reductions in operating time! Geraeuschemission-SP-EN.fm - 01.11.01...
  • Page 50 2.8 Noise information 2.8.2 The highest sound pressure level (L The sound pressure level is a measure of the sound emissions in the workplace. Machines equipped with a remote control unit as standard have no fixed workplace. In this case, the Machine Directive prescribes that the highest sound pressure level be measured at a distance of 1 m from the machine surface and 1.6 m across the ground, which must be indicated in the operating instructions.
  • Page 51 (L pAmax level (L (control station) pAmax 4 m from the front, TP 100 106dB(A) on the right in the 123dB(A) driving direction 4 m from the front, SP 305, 500, 750 95dB(A) on the right in the...
  • Page 52 2.8 Noise information Fig. 11 Measuring point (L ) measured from the front pAmax Ground clearance: 1.6 m Operate the machine at maximum hydraulic Taking the measurement: power Information The measured sound pressure level (L ) is also influenced by the installed drive power and the drive motor used.
  • Page 53 Pictographs without text Different warning and information signs in the national language are located on your SCHWING concrete pump, in addition to textless pictographs. An overview of all signs without text can be found below. Furthermore, all signs are kept in our spare parts lists.
  • Page 54 2.9 Pictographs without text 2.9.1 Pictographs Concrete pump Start-up damping Delivery rate Start-up damping on / off adjustment Pumping - 0 - Sucking 10144573 10187511 10144566 98362082 Agitator Concrete pump Isolation valve Isolation valve Pump operation (P) - 0 - Suck - 0 - Pump open close...
  • Page 55 2.9 Pictographs without text Speed adjuster Water pump Compressor CE signs 10086507 10158389 10144568 10148919 Main switch battery Delivery note box - No tread surface on - off 98394724 98393988 Stowing box EASy display Underride protection device Up - 0 - Down 10191719 10200927 98361549...
  • Page 56 2.9 Pictographs without text Lifting eye; 98363577* 10163380 Attention! Example values for: • Horizontal trailer load • Vertical trailer load 98381870* 98381419* Warning of hot surfaces 98380738* * = For stationary concrete pumps only Textlose-Bildzeichen-EN.fm - 01.04.01...
  • Page 57 2.10 Control, warning and steering elements TP 100 2.10 Control, warning and steering elements TP 100 This chapter clearly describes the positions of the control, warning and steering el- ements on your machine. Functions / indicators for special equipment that is not present will be hidden automatically.
  • Page 58 2.10 Control, warning and steering elements TP 100 2.10.2 Forced motor switch-off (for CAT engines only) If the operating temperature of the drive motor is too high, the drive motor may continue running for another few minutes, despite being shut down using the “motor stop key-operated switch”.
  • Page 59 2.10 Control, warning and steering elements TP 100 2.10.3 EMERGENCY-STOP button Pressing the EMERGENCY-STOP button deactivates the hydraulic circuit. To reset the system and activate the hydraulic circuit, turn the EMERGENCY- STOP button clockwise and press the horn button on the control panel or on the remote control.
  • Page 60 2.10 Control, warning and steering elements TP 100 Kontroll-Warn-Steuerelemente-TP-100-EN.fm - 01.06.00...
  • Page 61 3 Operation This chapter describes: All of your machine’s operating modes Safe and proper handing Safe and economical operation Trennblatt_Kapitel-Betrieb-EN.fm...
  • Page 62 3 Operation Trennblatt_Kapitel-Betrieb-EN.fm - 01.00.00...
  • Page 63 3.1 Driving operation TPs Driving operation TPs The driver of the towing vehicle must be familiar with the operation of the trailer pump, as is required for safe driving operation. Among other things, the trailer is equipped with a braking system, appropriate tires and the required lighting system.
  • Page 64 3.1 Driving operation TPs 3.1.3 General safety instructions • Trailer pumps may only be driven on public roads with the relevant approval. The operating licence becomes void if unauthorised modifications are made on the chassis frame, or if unauthorized spare parts and accessories are used. •...
  • Page 65 3.1 Driving operation TPs 3.1.4 Trailer lighting Optionally, the lighting can be delivered as an LED version. Fig. 15 TP100 lighting Caption (Fig. 15) Pos. Description Multi-point lights: a) Licence plate light 10W b) Rear fog light 21W c) Backup lamp 21W d) Rear brake light 21/5W e) Indicator light 21W Rear reflector, red triangle...
  • Page 66 3.1 Driving operation TPs 3.1.5 Coupling the trailer pump WARNUNG! Warning! Risk of being crushed between the vehicles! Remaining between the vehicles while driving up with the truck is prohibited.  With the help of a guide, drive the towing vehicle in reverse until it touches the trailer pump.
  • Page 67 3.1 Driving operation TPs Fig. 16 Caption (Fig. 16) Pos. Description Pos. Description Crank for crank support Parking brake Power outlet for lighting Fig. 17 Caption (Fig. 17) Pos. Description Pos. Description Release cord Trailer coupling for towing vehicle Fahrbetrieb-TP-EN.fm - 01.06.01...
  • Page 68 3.1 Driving operation TPs 3.1.6 Check before driving Clean the machine and make sure that it is sound operating condition before driv- ing. Rectify any defects before driving. Make sure the machine is roadworthy before driving. This includes: • Maintenance flaps sealed and secure •...
  • Page 69 3.1 Driving operation TPs Information On public roads, the parking brake must always be engaged when the trailer is parked. Should the trailer be parked for an extended period of time, at the depot for exam- ple, we recommend parking the machine on the supports of the concrete pump. This method is recommended in particular for extended downtimes in order to pro- tect the tyres.
  • Page 70 3.1 Driving operation TPs 3.1.10 Transporting people and goods Trailer pumps are work machines. They may not be used for the transport of people and goods. This also applies for the transport of concrete in the filling-in hopper of the concrete pump.
  • Page 71 3.2 Installation site of the stationary concrete pump / trailer pump Installation site of the stationary concrete pump / trailer pump SCHWING recommends not driving onto the jobsite until you have been briefed by an “instructor” authorised by the site management.
  • Page 72 Prior to loading, determine the actual weight of the machine by weighing it. Using the machine number, ask SCHWING for the machine-specific loading plans and loading box. The machine-specific loading plan and the loading box allow precise information regarding, for e.g.
  • Page 73 As the threads are located on both spars (1), the earthing connection can be relo- cated as needed. On the TP 100, the stainless steel screw (1) (Fig. 21) can be found on the right of the vehicle frame in the direction of travel.
  • Page 74 3.2 Installation site of the stationary concrete pump / trailer pump Fig. 20 Rock valve support Fig. 21 Aufstellungsort-SP-waehlen-EN.fm - 01.06.02...
  • Page 75 3.3 Electrical connection (optional) Electrical connection (optional) GEFAHR! Danger! Only authorised personnel may connect, commission and disconnect electri- cally driven machines. Only authorised personnel may open the switch cabinet. The operator must initiate the correct connection of the machine. In Germany, a special feed point is required in accordance with VDE 0100 § 55 (e.g.
  • Page 76 3.3 Electrical connection (optional) 3.3.2 Checking the rotational direction of the electric motors (control without phase sequence monitoring) The electric motors rotate towards the left when observed from the front (anti-clock- wise). Make sure that when observing the fan wheel from the front at the same time, the fan wheel rotates towards the right (clockwise).
  • Page 77 Repeat the start-up procedure. 3.3.4 Electrical connection TP 100 TP 100 E machines can be electrically connected via a 5-pin 63 ampere CEE plug. The connection (1) (Fig. 23) is located in the frame on the right in the direction of travel.
  • Page 78 3.3 Electrical connection (optional) Elektrischer-Anschluss-EN.fm - 01.11.01...
  • Page 79 3.4 EMERGENCY-STOP system for TP 100 EMERGENCY-STOP system for TP 100 Your machine’s EMERGENCY-STOP system is intended to allow you to shut off dangerous machine functions as quickly as possible when other protective meas- ures that have already been taken do not suffice.
  • Page 80 3.4 EMERGENCY-STOP system for TP 100 3.4.1 How to test the EMERGENCY-STOP buttons • Switch on the control system. • Press an EMERGENCY-STOP button. You can read the results of the test on the display of control unit. • Unlock the EMERGENCY-STOP button that was tested.
  • Page 81 3.4 EMERGENCY-STOP system for TP 100 3.4.3 Restarting the machine after an EMERGENCY STOP • Remedy the fault. • Set all engaged selector switches on the active control unit to the "0 or centre position" and unlock all EMERGENCY-STOP buttons.
  • Page 82 3.4 EMERGENCY-STOP system for TP 100 Not-Halt-System-TP-100-EN.fm - 01.02.00...
  • Page 83 3.5 Electric control TP/SP Electric control TP/SP This chapter describes the electric control for your machine. 3.5.1 Concrete pump control The concrete pump control lets the operator control all machine functions electron- ically. The system includes the operator keyboard (2) (Fig. 26) and cable remote control, as well as the optional radio control.
  • Page 84 3.5 Electric control TP/SP Caption (Fig. 26 Concrete pump control) Pos. Description HMI (human machine interface) Operator keypad Key-operated switch (control) 0 = Control OFF / I = Control ON Key-operated switch (motor) 0 = Motor OFF / ignition ON / I = Motor OFF Power outlet for remote control 3.5.2 HMI (human machine interface)
  • Page 85 3.5 Electric control TP/SP 3.5.3 Navigation window The navigation window displays the available functions and menu actions for each screen. When the OK symbol is displayed on the navigation window, the operator can carry out a menu action by pressing OK. If a symbol appears above a function button, the respective function is activated by pressing that button.
  • Page 86 3.5 Electric control TP/SP 3.5.4 Start screen When the key-operated switch of the control is set to position ON (I), the control panel is supplied with power. The start-up screen appears briefly on the LCD screen of the HMI. Fig. 29 Start screen 3.5.5 The motor status screen (diesel engine) The motor status screen appears after the start-up screen and displays the...
  • Page 87 3.5 Electric control TP/SP Press OK to open the menu screen. Press the left/right navigation button to switch between the pump and motor status screen. For motors with manual regeneration, the runtime remaining until the next “forced regeneration” can be viewed on the screen (8) (Fig. 30 Motor status screen for diesel engine).
  • Page 88 Consult your motor operating manual for the definition of the error codes. Concrete pump faults are listed on the pump code screen. Make a note of the error code and contact SCHWING customer service. Fig. 32 Alerts, symbols on the SP display...
  • Page 89 3.5 Electric control TP/SP Descriptions of (Fig. 32 Alerts, symbols on the SP display) Smart Switch position • Undefined status Regeneration deactivated – lights up when the regeneration has been disabled • Piston-side pressure • Rod-side pressure Motor fault – lights up when the motor or the Only actuate the main battery switch in the after-treatment system returns a fault.
  • Page 90 3.5 Electric control TP/SP 3.5.8 Alerts All existing EMERGENCY-STOP notifications and alerts flash consecutively in the message window. When an alert is displayed, the horn sounds continuously until the mute control button for the horn is pressed on the HMI. The horn is switched off, the message appears, however, until the fault is rectified.
  • Page 91 3.5 Electric control TP/SP 3.5.10 General warnings Alerts Description LOW FUEL If activated - filling level of tank below 10% LOW GREASE If activated - lubricating grease in the reservoir below sensor PUMP FAULT Check pump code screen. LOW HYD OIL If activated - oil level below oil level sensor LOW BATTERY Battery voltage under 10 Volt...
  • Page 92 3.5 Electric control TP/SP 3.5.11 Pump status screen The pump status screen shows information about the battery voltage and installed options. Press the left/right navigation button to switch between the pump and motor status screen. Press ESC to open the menu screen. Fig.
  • Page 93 • Options A small SCHWING logo indicates which menu item is currently selected. Use the up/down navigation buttons to scroll through the menu items. When you get to the screen you want to access, press OK. Press ESC to return to the motor status screen.
  • Page 94 3.5 Electric control TP/SP 3.5.13 Motor code screen Displays error codes for the motor by means of both diagnostic screens DM1 and DM2. Use the up/down navigation buttons to scroll through the motor codes. Press ESC to return to the menu screen. Press the F4 function button under DM2 to open the diagnostic screen 2.
  • Page 95 3.5 Electric control TP/SP Fig. 38 Caption (Fig. 38 ) Pos. Description Cause Cause of the error 1. byte Source Source of the error 2. byte User Application-specific error code 3. byte Class Error class 4. byte E-Steuerung-TP-SP-EN.fm - 01.07.02...
  • Page 96 3.5 Electric control TP/SP 3.5.15 Error code descriptions (assignment of inputs and outputs) 1 byte Class User Source Cause Value (dec.) Description Suggested solution No cause of error or application-specific error No error present Fracture Check line for interruptions Closure Electrical check Overload Electrical check...
  • Page 97 3.5 Electric control TP/SP Error code descriptions (assignment of inputs and outputs) 1 byte Class User Source Cause Value (dec.) Description Suggested solution CANsafety receive error Electrical check of CAN bus CANsafety send error Electrical check of CAN bus CANsafety configuration corrupt Electrical check of CAN bus Board link warning (ExtendedController) Report TSR error...
  • Page 98 3.5 Electric control TP/SP Error code descriptions (assignment of inputs and outputs) 2 byte Class User Source Cause Source Output (Q) Equipment Function Concrete pump EMERGENCY STOP Pressure accumulator EMERGENCY STOP Concrete pump forward (pumping) Concrete pump reverse running (sucking) Agitator backward Agitator forward Water pump...
  • Page 99 3.5 Electric control TP/SP 3.5.17 Error description 4th byte Class User Source Cause Code Description No error General error - not safety related • Error flags, error code • Resetting errors possible Severe error - component error • Error flags, error code •...
  • Page 100 3.5 Electric control TP/SP 3.5.18 SPS E/A (PLC-IO) screen Displays the electronic input and output signals. This screen is designed to support the search for and resolution of electrical problems. Press ESC to return to the menu screen. Fig. 39 SPS screen 3.5.19 Local control screen (operator keypad) Displays active functions on the control panel.
  • Page 101 (Fig. 43 Customer service menu). The menu is password-protected. Displays additional information and enables the setting of parameters of any options installed. Use the up/down navigation buttons to move the SCHWING symbol through the screen list. Press OK to reach the selected screen.
  • Page 102 This screen used to change the parameters for the concrete pump’s hydraulic oil sensors (Fig. 44 Oil temperature sensor). Use the up/down navigation buttons to move the SCHWING symbol through the list of sensors. If the symbol appears next to the sensor parameter you want to change, increase or decrease the parameter setting using the left/right navigation buttons.
  • Page 103 (ALWAYS ON) or only when the concrete pump is in forward pumping mode (PUMP FWD). Use the up/down navigation buttons to move the SCHWING symbol through the list of greaser parameters. If the symbol appears next to the ON time or OFF time parameter you wish to change, increase or decrease the parameter setting using the left/right navigation buttons.
  • Page 104 This screen (Fig. 46 ) allows you to change the minimum and maximum cur- rent values. The setting takes place in milliamperes. Use the up/down navigation buttons to move the SCHWING symbol between the settings for “Min. current” and “Max. current”. If the symbol appears next to the parameter you want to change, increase or decrease the parameter setting using the left/right navigation buttons.
  • Page 105 3.5 Electric control TP/SP 3.5.26 Machine options screen This screen can be used to activate the features of any options installed (Tabelle 3: Machine options). When options were added, then you need to select the option “Hinzugefügt” (added) from the menu to activate it. Use the up/down navigation buttons to move the ESC symbol between the option settings.
  • Page 106 3.5 Electric control TP/SP Fig. 50 Operator keypad Caption (Fig. 50 Operator keypad) Pos. Description Pos. Description Local control unit or Optional accessories 3 Remote control Concrete pump forward Floodlight - ON / OFF Delivery rate (+) Motor speed adjuster (-) Concrete vibrator: Concrete pump backward Auto / ON / OFF...
  • Page 107 3.5 Electric control TP/SP 3.5.28 Description of individual keys 3.5.28.1 Local control / remote control (Pos. 1) (Fig. 50 Operator keypad) Used to switch between local mode (operator keypad) and radio or cable remote control mode. When starting up, the button switches to local mode by default. Press the button once to switch to remote control mode.
  • Page 108 3.5 Electric control TP/SP CP status LED display (ON) Function CP forward (pumping) Green CP reverse (sucking) Green CP OFF Green CP switched off All OFF 3.5.28.3 Output regulation Increase delivery rate (+) (pos. 3) (Fig. 50 Operator keypad) The delivery rate buttons control the pump’s “stroke rate per minute”. Press the but- ton once to increase the “stroke rate per minute”...
  • Page 109 3.5 Electric control TP/SP Delivery rate indicators LED display (ON) Delivery rate ( ˗ ) red ( ˗ ) yellow ( ˗ ) green ( ˗ ) blue ( ˗ ) all ( ˗ ) all + ( + ) red ( ˗...
  • Page 110 3.5 Electric control TP/SP 3.5.30 Horn (Pos. 5) (Fig. 50 Operator keypad) Press the button once or press and hold it to actuate the horn. 3.5.31 Speed adjuster ( + ) increase (pos. 6) (Fig. 50 Operator keypad) Press the button once to increase the motor speed. Press and hold the button or press it several times to increase the motor speed continuously.
  • Page 111 3.5 Electric control TP/SP 3.5.33 Spotlight (Pos. 10) (Fig. 50 Operator keypad) Press the button to switch on the spotlights. Press the button again to switch off the spotlights. 3.5.34 Oil cooler (Pos. 9) (Fig. 50 Operator keypad) Available for optional accessories. 3.5.35 Optional accessories (Pos.
  • Page 112 3.5 Electric control TP/SP Agitator indicator LED display (ON) Agitator function Yellow Auto Green All OFF Fig. 51 Agitator button for reverse operation 3.5.37 EMERGENCY-STOP button Pressing the EMERGENCY-STOP button deactivates the hydraulic circuit. To reset the system and activate the hydraulic circuit, turn the EMERGENCY-STOP button clockwise and press the horn button on the control panel or on the remote control.
  • Page 113 3.5 Electric control TP/SP 3.5.38 Description of cable remote control The descriptions of the indicators are identical to the descriptions for the local con- trol (operator keypad). Fig. 53 Cable remote control Caption for (Fig. 53) Pos. Description Pos. Description EMERGENCY-STOP button Decrease delivery rate (-) Horn...
  • Page 114 3.5 Electric control TP/SP 3.5.39 Description of radio remote control Fig. 54 Radio remote control Caption for (Fig. 54) Pos. Description Pos. Description EMERGENCY-STOP button Agitator: ON / OFF Concrete pump delivery rate indication Optional accessories 1 (water pump) Light for active connection Remote control ON Indicator light for concrete pump flow/return flow 14 Concrete pump –...
  • Page 115 3.5 Electric control TP/SP 3.5.39.1 LED delivery rate indicators The delivery rate indicator on the remote control contains 2 LEDs (1, 2) (Fig. 55). Items 3 and 4 are not LEDs but rather printed symbols for flashing LEDs. The de- livery rate is determined as a percentage based on the combinations of lights.
  • Page 116 3.5 Electric control TP/SP Delivery rate (%) Flashing rate (ms) LED 1 LED 2 LED 1 1000 LED 2 LED 1 0700 LED 2 LED 1 0400 LED 2 LED 1 0100 LED 2 LED 1 Lit continuously LED 2 LED 1 Lit continuously LED 2...
  • Page 117 3.6 Readying the machine for operation TP 100 Readying the machine for operation TP 100 Check the hydraulic oil level in the reservoir. The hydraulic oil box is located in front. The machine must be positioned horizontally. A temperature scale is located next to the level indicator (1) (Fig.
  • Page 118 3.6 Readying the machine for operation TP 100 • Ensure that all oil-filled aggregates are tight. Check oil levels and top up with oil, if necessary. • Ensure that the screw joints of the hydraulic system are tight and tighten them, if necessary.
  • Page 119 3.6 Readying the machine for operation TP 100 Fig. 58 The ball valve is used to block the concrete pump during repair work. • Check the hopper grate in the concrete filling hopper. A locking bar (3) (Fig. 59) is used to secure the hopper grate.
  • Page 120 3.6 Readying the machine for operation TP 100 Fig. 59 3.6.1 Diesel engine • Carry out the necessary work in accordance with the motor operating instruc- tions prior to commissioning the drive motor (check oil level, etc.). • Check the fuel supply on the concrete pump control unit.
  • Page 121 3.6 Readying the machine for operation TP 100 • Top up diesel fuel, if necessary. Refer to the motor operating instructions for the fuel quality. ACHTUNG! Attention! Risk of confusion with the hydraulic oil filling neck! Fig. 60 GEFAHR! Danger! Risk of explosion! •...
  • Page 122 3.6 Readying the machine for operation TP 100 Fig. 61 • Any water present must be drained daily from the settling vessel on the fuel pre- filter according to manufacturer's instructions. Collect fuel mixture and dispose of properly! 3.6.2 Theoretical operating time Plan the operating times of the machine carefully before commencing work.
  • Page 123 3.7 Drive circuit TP 100 Drive circuit TP 100 3.7.1 Starting the diesel engine VORSICHT! Caution! Hydraulic oil pressure is built up automatically! After starting the drive motor, the hydraulic pumps immediately deliver oil. • Turn the key-operated switch (3) to the centre position to switch on the current supply for the control (Fig.
  • Page 124 ACHTUNG! Attention! If the nominal speed (see “Technical specifications for TP 100” on page 37) is exceeded, lower the rotational speed immediately with the button (11). Have engine timing checked.
  • Page 125 3.7 Drive circuit TP 100 3.7.2 Switching off the diesel engine • Reduce the delivery volume (stroke rate) of the concrete pump to 0 using the button (8) (Fig. 63). • Switch off the concrete pump (6) and possibly the agitator (9).
  • Page 126 3.7 Drive circuit TP 100 Fig. 64 Indicator for run-on function SP control Fig. 65 Antriebsschaltung-TP-100-EN.fm - 01.06.00...
  • Page 127 3.7 Drive circuit TP 100 Fig. 66 Antriebsschaltung-TP-100-EN.fm - 01.06.00...
  • Page 128 3.7 Drive circuit TP 100 Antriebsschaltung-TP-100-EN.fm - 01.06.00...
  • Page 129 3.8 Starting the electric motor (optional) Starting the electric motor (optional) 3.8.1 Starting the electric motor (TP 100 / SP 1800 / 2800 / 3800 / 7000 / 7500 / 9000 / 9500) VORSICHT! Caution! Hydraulic oil pressure is built up automatically! After starting the drive motor, the hydraulic pumps immediately deliver oil.
  • Page 130 3.8 Starting the electric motor (optional) Fig. 68 SP 1800/2800 Fig. 69 SP 3800/7000/7500/9000/9500 Elektromotor-starten-EN.fm - 01.01.01...
  • Page 131 3.8 Starting the electric motor (optional) Fig. 70 Concrete pump control Elektromotor-starten-EN.fm - 01.01.01...
  • Page 132 3.8 Starting the electric motor (optional) 3.8.2 The motor status screen (electric motor) When the key-operated switch on the control unit is set to the (I) position, the control panel is supplied with power and the electric motor status screen appears. The following information is displayed.
  • Page 133 3.8 Starting the electric motor (optional) 3.8.3 Shutting down the electric motor (TP 100 / SP 1800 / 2800 / 3800 / 7000 / 7500 / 9000 / 9500) • Reduce the delivery volume (stroke rate) of the concrete pump to “0” with the button (8) (Fig.
  • Page 134 3.8 Starting the electric motor (optional) 3.8.4 Starting the electric motor (SP 1800 / 2800 BR02) VORSICHT! Caution! Hydraulic oil pressure is built up automatically! After starting the drive motor, the hydraulic pumps immediately deliver oil. In order to prevent a function from starting unintentionally, switch all engaged steer- ing elements to the "0 position"...
  • Page 135 3.8 Starting the electric motor (optional) Fig. 74 Concrete pump control (electric motor)  Switch on the electric motor by pressing the illuminated button (15) (Fig. 74). The button lights up. The motor starts in star connection and switches automatically to delta connection. ...
  • Page 136 3.8 Starting the electric motor (optional) 3.8.5 Shutting down the electric motor (SP 1800 / 2800 BR02) Fig. 75 Pressure reducing valve  Reduce the stroke rate of the concrete pump as far as possible using the pres- sure reducing valve (1) (Fig. 75). ...
  • Page 137 3.9 Setting up the machine TP 100 Setting up the machine TP 100 The installation site must be set up so that the transport vehicles can reach the concrete filling hopper without any problems and the machine is accessible for maintenance and cleaning purposes.
  • Page 138 3.9 Setting up the machine TP 100 3.9.2 Machine with chassis frame (TP 100) • Drive the machine to the prepared installation site. • Disconnect the lighting cable and release cord from the towing vehicle. • Insert the lighting cable in the vacant power outlet.
  • Page 139 3.9 Setting up the machine TP 100 3.9.3 Servicing the crank support • Lubricate the grease nipple (1) (Fig. 77) in accordance with the maintenance plan. WARNUNG! Warning! The operator has to carry out an expert inspection prior to each first commis- sion, after any kind of changes to the support equipment and at least once a year according to manufacturer's instructions.
  • Page 140 3.9 Setting up the machine TP 100 Maschine-aufstellen-TP-100-EN.fm - 01.00.00...
  • Page 141 3.10 Operating the pumping line This chapter describes how to operate the pumping line on various SCHWING products. The principle remains the same in each case. Before each pumping operation, make sure that the pumping line system is in good working order.
  • Page 142 We strongly recommend setting up the pumping line exclusively with appropriate SCHWING material. This is an important contribution to high operational safety and efficiency. SCHWING is not liable for any damages caused as a result of using inappropriate material! 3.10.2 Marking pumping pipes and elbows All SCHWING pumping pipes and elbows are marked as follows, example (Fig.
  • Page 143 Fig. 82 Elbow marking as of approx. 2017 Caption for (Fig. 80) - (Fig. 82) Designation Meaning Charge Order no., customer no. Date Production week (MM/YY) Material SCHWING item no. Dimensions mm/degree Nominal size in mm (inner diameter) Foerderleitung_Betrieb-EN.fm - 01.15.04...
  • Page 144 3.10 Operating the pumping line Caption for (Fig. 80) - (Fig. 82) Designation Meaning SUPER 1000 SCHWING quality label WTmm Total thickness (inside wall + outside wall) permissible operating pressure in bar WeightNET/pc. Net unit weight Outer diameter mm Tube, elbow and tapered tube weight per Weight-FWC/pc.
  • Page 145 3.10 Operating the pumping line Fig. 83 Example: Type plate on 5-part boom Caption for (Fig. 83) Designation Meaning max. DN max. nominal size for inlet side Length of the pipe on the corresponding boom max. DN max. nominal size for outlet side Fig.
  • Page 146 This also applies to the use of individual parts, such as: Tubes, couplings, elbows, etc. We would like to draw attention once again to the fact that SCHWING is not liable for damages caused by improper or negligent operation, maintenance and repair or improper use.
  • Page 147 Severe to fatal injuries as a result of liquid being discharged explosively from de- fective pipelines. The machine must only be modified by SCHWING’s customer service. With piston-side pressure, only use suitable pumping line material. These concrete pumps must not pump through the end hose and boom pumping line with piston-side pressure.
  • Page 148 3.10 Operating the pumping line GEFAHR! Danger! Danger to life due to moving parts! Severe injuries or even death due to severed limbs. Do not reach into the gate valve. Before opening the pumping line / outlets, switch the drive motor off and secure it against unauthorised activation.
  • Page 149 3.10 Operating the pumping line 3.10.7 Short outlet (foldable) The foldable pipeline outlet can make the connection flange of the rock valve ac- cessible and cleaned trough the foldable pipeline outlet. In order to make the connection flange freely accessible: ...
  • Page 150 3.10 Operating the pumping line Fig. 88 Wedge lock 3.10.8 Short outlet (foldable and rotatable) In order to connect a separate pumping line more easily, certain SCHWING truck- mounted concrete pumps can be optionally equipped with a foldable and rotatable outlet (6; (Fig. 89)).
  • Page 151 3.10 Operating the pumping line Fig. 89 Outlet, foldable and rotatable Foerderleitung_Betrieb-EN.fm - 01.15.04...
  • Page 152 3.10 Operating the pumping line 3.10.9 Large outlet DN 180/180/150 (foldable) The folding function is the same as for the short outlet. The larger outlet 180/180/ 150 has the advantage of having less concrete resistance. Use the “large outlet” when pumping concrete that is difficult to pump. The larger outlet 180/180/150 also has a 14-degree elbow mounted on the rock valve, see (1) (Fig.
  • Page 153 In addition to the selection of the right pump, the selection and installation of the pumping line is of great significance. Both must be done with great care and expertise. SCHWING offers an extensive range of pumping lines and accessories. Should you have any questions regarding the pumping line, please contact SCHWING Customer Service.
  • Page 154 3.10 Operating the pumping line Separate pumping lines are available in different versions: 1 Pumping pipes for split couplings (Fig. 91) These correspond to the system used for placing booms. They can be used with a pressure of up to 85 bar depending on the nominal sizes (DN). Separately installed pumping lines are suitable up to 110 bar.
  • Page 155 3.10 Operating the pumping line Fig. 91 1 - Flange 3 - Seal 4 - Split coupling Fig. 92 Fig. 93 1 - Flange with male face 2 - Flange with female face 3 - Seal 4 - Cup expansion coupling Foerderleitung_Betrieb-EN.fm - 01.15.04...
  • Page 156 3.10 Operating the pumping line 3.10.12 Concrete pumping hoses 3.10.12.1 End hoses An end hose is connected at the end of the pumping line for the distribution of the concrete. GEFAHR! Danger! Direct danger to life in the danger zone of the end hose! Danger of death due to flapping end hose, spraying concrete and stones shooting out! Always adhere to the required safety regulations!
  • Page 157 3.10 Operating the pumping line Observe the warnings on the machine, see (Fig. 94) - (Fig. 96). Fig. 94 Fig. 95 Fig. 96 3.10.13 Connecting hoses Connecting hoses with double-sided fixing can be used as flexible intermediate pieces in rigid pumping lines based on their permissible pumping pressure. Foerderleitung_Betrieb-EN.fm - 01.15.04...
  • Page 158 3.10 Operating the pumping line 3.10.14 Hose pipes Multiple connecting hoses are often connected to hose pipes in mobile restoration operations. The hoses are usually carried on a specially equipped truck-mounted concrete pump, installed before use and removed again after use. 3.10.14.1 Installing and operating a hose pipe The installation of the hose line, as well as its operation, requires special care and expertise.
  • Page 159 3.10 Operating the pumping line 3.10.14.2 Cleaning the hose pipe GEFAHR! Danger! Direct danger to life due to flapping hoses! Blowing out pumping hoses with compressed air is prohibited, see safety manual. Hoses must be carefully cleaned after each use. A thorough internal cleaning is especially important for this.
  • Page 160 3.10 Operating the pumping line Foerderleitung_Betrieb-EN.fm - 01.15.04...
  • Page 161 3.11 Working operation - General information for TP 100 3.11 Working operation - General information for TP 100 3.11.1 Special equipment The high-pressure cleaner (special equipment) is supplied by the agitator pump (see switching diagram). VORSICHT! Caution! Unintentional start-up! After starting the drive motor, the hydraulic pumps immediately deliver oil.
  • Page 162 3.11 Working operation - General information for TP 100 Fig. 98 Concrete pump control 3.11.3 CP - remote controls (special equipment) The concrete pump can be controlled using a radio or cable remote control during working operation. • Press the button (1) (Fig. 99) once to switch to remote control mode. Press the button again to switch back to the local mode.
  • Page 163 3.11 Working operation - General information for TP 100 Fig. 99 3.11.4 Close maintenance flaps VORSICHT! Caution! Hearing can be damaged! Personal hearing protection must always be worn when a sound pressure level of 80 dB(A) is exceeded. Failure to observe this may be harmful to your health.
  • Page 164 3.11 Working operation - General information for TP 100 Arbeitsbetrieb-Allgemeine-Hinweise-TP-100-EN.fm - 01.05.00...
  • Page 165 3.12 Working operation - concrete pump TP 100 3.12 Working operation - concrete pump TP 100 3.12.1 General • Lightly spray the concrete filling hopper with mould oil from the outside before pumping for the first time. This facilitates subsequent cleaning.
  • Page 166 Adjust the operating speed of the diesel engine (pos. 6, 11) (Fig. 100). • Observe the different modes when switching on the agitator and concrete vibra- tor, see (“Control, warning and steering elements TP 100” on page 57).. Fig. 100 3.12.3 Concrete pump •...
  • Page 167 3.12 Working operation - concrete pump TP 100 VORSICHT! Caution! Hearing can be damaged! Close the maintenance flaps and move away from the machine, taking the remote control with you. Personal hearing protection must always be worn when a sound pressure level of 80 dB(A) is exceeded.
  • Page 168 3.12 Working operation - concrete pump TP 100 Arbeitsbetrieb-Betonpumpe-TP-100-EN.fm - 01.05.00...
  • Page 169 3.13 Working operation - high-pressure cleaner TP 100 3.13 Working operation - high-pressure cleaner TP 100 The machine can be equipped with a high-pressure cleaning system (1) (Fig. 101) (special equipment). Make sure to read the chapter (chap. 6.1). Fig. 101 High-pressure cleaner 3.13.1 Preparation...
  • Page 170 3.13 Working operation - high-pressure cleaner TP 100 The hydraulically powered high-pressure cleaner is self-priming. We recommend setting up a water case with clean water next to the pump. The water must be free of solids, as they cause rapid wear on the high-pressure cleaner.
  • Page 171 3.13 Working operation - high-pressure cleaner TP 100 3.13.2 Operation • Start the drive motor and adjust the speed of the diesel engine to idle. Regula- tion is not possible with the electric version. • Switch on the high-pressure cleaner using the button (14) (Fig. 103).
  • Page 172 3.13 Working operation - high-pressure cleaner TP 100 3.13.4 Winter operation If there is danger of frost, the high-pressure cleaner must be drained after each op- eration. • Remove the suction and pressure hose and drain them. • Switch on the high-pressure cleaner briefly to remove any residual water.
  • Page 173 3.14 Clearing blockages 3.14 Clearing blockages If interventions are required in the machine technology to release blockages, which go beyond the measures described below, these may only be carried out by qual- ified personnel. GEFAHR! Danger! Danger to life! If interventions are required in the machine technology to release blockages, which go beyond the measures described below, these may only be carried out by qual- ified personnel.
  • Page 174 3.14 Clearing blockages The following blockages are likely to occur: 3.14.1 Blockage in the pumping line In the event of a clog (blockage) in the pumping line, the pressure in the concrete pump’s hydraulic system will rise until the pressure relief valve (hereinafter: PRV) opens.
  • Page 175 3.14 Clearing blockages GEFAHR! Danger! Danger to life due to pressurised pumping lines and blockages! Concrete exiting at high pressure may seriously injure persons due to violent move- ments of the pumping line and also at a distance due to stones or fragments of the pumping line flying about.
  • Page 176 3.14 Clearing blockages 3.14.2.2 Blockages in the control system Blockages in the hydraulic pilot control system are often caused by dirt in the hy- draulic oil. This dirt causes the control piston to jam and in turn to not execute control com- mands or to execute them incorrectly.
  • Page 177 3.15 Control of operations TP 100 Pressing an EMERGENCY-STOP button interrupts the main hydraulic functions, see (“EMERGENCY-STOP system for TP 100” on page 79). • Pay attention to unusual noises, vibrations, etc. caused by the machine. There may be a damage that could be localised through timely repair.
  • Page 178 3.15 Control of operations TP 100 Fig. 104 Fig. 105 • Monitor the water level and contamination in the water box (1) (Fig. 106). Drain any contaminated water and fill with clean water up to the top edge of the pump- ing pistons.
  • Page 179 3.15 Control of operations TP 100 WARNUNG! Warning! Danger of crushing! Before opening the water box, always switch off the drive motor and discharge the pressure accumulator (if available) in order to prevent the concrete pump from per- forming any unwanted working movements! After filling up, mount the cover for the water box (1) properly and secure it using a wedge (2) and clip pin (3) (Fig.
  • Page 180 The pumpability of the concrete needs to be improved. Refer to the switching diagram or data sheet for Pmax. The pressure relief valves set in the factory may not be altered. Have SCHWING’s customer service reconnect the concrete pump to piston-side pressure when great- er power is required.
  • Page 181 3.15 Control of operations TP 100 WARNUNG! Warning! Observe the safety regulations for handling fuel! Information Acquaint yourself early on with the operating instructions of the motor manufacturer so that you can respond appropriately in the event of an engine failure.
  • Page 182 3.15 Control of operations TP 100 Betriebsueberwachung-TP-100-EN.fm - 01.00.00...
  • Page 183 3.16 Troubleshooting - Emergency operation TP 100 3.16 Troubleshooting - Emergency operation TP 100 3.16.1 Control failure If a functional failure occurs, first check whether: • An EMERGENCY-STOP button has been actuated. • The grid assembly in the agitator hopper is raised.
  • Page 184 3.16 Troubleshooting - Emergency operation TP 100 Fig. 110 Verhalten-bei-Stoerungen-TP-100-EN.fm - 01.04.00...
  • Page 185 3.16 Troubleshooting - Emergency operation TP 100 Fig. 112 Vehicle fuse door Fig. 111 Vehicle fuse cabinet 3.16.3 Main fuses The main battery switch (3) is located on the right in the direction of travel near the starter battery (5) (Fig. 113).
  • Page 186 3.16 Troubleshooting - Emergency operation TP 100 Fig. 113 Fig. 114 Main fuse Verhalten-bei-Stoerungen-TP-100-EN.fm - 01.04.00...
  • Page 187 3.16 Troubleshooting - Emergency operation TP 100 3.16.4 Dummy plug The dummy plug (5) (Fig. 110) must inserted during operation. Without this plug, no electrical power is available for the machine control unit and the EMERGENCY STOP valve remains open. The concrete pump cannot be oper- ated.
  • Page 188 3.16 Troubleshooting - Emergency operation TP 100 Fig. 115 EMERGENCY-STOP valves for equipment with VarioPressure 3.16.6 Emergency actuation of CP directional valve A small control lever is available in the tool set for testing the concrete pump pilot control. When installing and operating the control lever, wear personal protective clothing and hearing protection and stay away from moving and hot machine parts.
  • Page 189 3.16 Troubleshooting - Emergency operation TP 100 The control lever can switch the concrete pump into the "pump" or "suction" direc- tion. For this purpose, insert the dummy plug into the power outlet (5) (Fig. 110). Switch on the concrete pump with the control lever (5) (Fig. 116).
  • Page 190 3.16 Troubleshooting - Emergency operation TP 100 Verhalten-bei-Stoerungen-TP-100-EN.fm - 01.04.00...
  • Page 191 Cleaning After concreting, the pumping line and concrete pump must be cleaned thoroughly in order to prevent material damage. This chapter describes how to clean various SCHWING products. But the principle remains the same in each case. • Finish the concrete feeding in good time so that the content of the hopper and pumping line can still be situated at the construction site.
  • Page 192 3.17 Cleaning Fig. 118 (Schematic diagram) Fig. 119 Cleaning head and trap basket Information For information on the special equipment “High-pressure cleaning system”, please read the separate chapter. 3.17.2 Cleaning the pumping line After work, clean the pumping line first since this is where the concrete sets quicker.
  • Page 193 3.17 Cleaning GEFAHR! Danger! Danger caused by concrete under pressure! When opening pumping lines, sudden releases of pressure can cause severe inju- ries or even death. Before opening the pumping line, the concrete column must be released by pump- ing backwards. Various methods can be applied to clean a pumping line.
  • Page 194 3.17 Cleaning Fig. 120 Cover for PLC filling hopper Fig. 121 Cover for TP100 filling hopper  Slowly pump hopper as empty as possible.  Position the placing boom as shown in (Fig. 122). A pumping pipe with a cleaning cover (2) (Fig. 123) is available as special equip- ment.
  • Page 195 3.17 Cleaning Fig. 122 Cleaning position for placing boom (schematic diagram) Fig. 123 Cleaning cover Fig. 124 Sponge rubber ball  Briefly tap on the pumping pipe with the handle of a hammer just in front of the cleaning aperture. If there is still concrete in the line at this point, the tapping will produce a deep, dull sound (Fig.
  • Page 196 3.17 Cleaning If the concrete and sponge rubber ball have passed the tapping point, the tapping will produce a high-pitched sound (Fig. 126). ACHTUNG! Attention! Damage to the pumping line! Only use the handle of the hammer to tap the pumping line. Do not use metal ob- jects: •...
  • Page 197 3.17 Cleaning It depends on several factors whether the concrete filling hopper can completely re- ceive the flowing back concrete or how quick the hopper is full: 1. Volume of the filling hopper 2. Volume of the pumping line 3. Volume of the pumping cylinder 4.
  • Page 198 3.17 Cleaning 3.17.4 Clearing the pumping line with water This method is ideal for separately laid, long pipelines, vertical lines and lines with a downstream placing boom. For stiff, rough, fine-grained or sand-poor concretes, this method can also be rec- ommended for the boom pipeline of truck-mounted concrete pumps.
  • Page 199 3.17 Cleaning Fig. 129 Blowing out the pumping line Fig. 130 Rinsing the pumping line Reinigung-EN.fm - 01.19.03...
  • Page 200 3.17 Cleaning 3.17.6 Blowing out the pumping line with compressed air WARNUNG! Warning! Severe injuries due to compressed air Severe injuries due to flying material. Air can become compressed in pumping pipes and be discharged explosively, which can result in severe injuries. Avoid excessive concentrations of compressed air in pumping pipes.
  • Page 201 3.17 Cleaning Fig. 131 Trap basket Fig. 132 Cleaning head Reinigung-EN.fm - 01.19.03...
  • Page 202 3.17 Cleaning 3.17.7 Cleaning the concrete pump GEFAHR! Danger! Danger to life due to electric shock! • Do not direct water jets or the jet of a pressure cleaner towards the electrical components of the machine. WARNUNG! Warning! Risk of being crushed by machine components starting automatically! Do not remove or step on the hopper grate in the concrete filling hopper.
  • Page 203 3.17 Cleaning 3.17.7.1 Behaviour of truck-mounted concrete pumps after closing the hopper grate After closing the hopper grate: • The agitator turns back on. • The concrete pump must be switched back on (restart protection for end hose). 3.17.7.2 Behaviour of stationary concrete pumps / trailer pumps after closing the hop- per grate After closing the hopper grate: •...
  • Page 204 3.17 Cleaning Fig. 134 Cleaning the filling hopper Fig. 135 Rotatable outlet  Open the cleaning flap (Fig. 136) under the rock valve housing.  Flush out the rock valve housing.  Clean the agitator, gate valve housing, outlet, etc. using a strong water jet. Only hold the water jet and not the hose nozzle inside the opening of the gate valve housing (Fig.
  • Page 205 3.17 Cleaning ACHTUNG! Attention! Material wear! Switch off concrete pump immediately if water no longer comes out  Hose out the water box with pressure water (Fig. 138). Do not remove the grid from the water box!  Fill water box with fresh water. ...
  • Page 206 3.17 Cleaning Fig. 137 Clean concrete filling hopper Fig. 138 Hose out water box  Close and secure the cleaning flap on the rock valve (Fig. 139).  Close the slewing lever on the cleaning flap by hitting it with a hammer in the axial direction.
  • Page 207 3.17 Cleaning ACHTUNG! Attention! Material damage! Never let rock valve machines run "dry". The kidney seal faster can be damaged. Fig. 139 A = close B = open C = secure 3.17.10 Exterior cleaning • We recommend the occasional hosing down with a water hose during breaks to prevent the concrete setting.
  • Page 208 3.17 Cleaning 3.17.11 Using high-pressure cleaners (HP cleaners) WARNUNG! Warning! Poor preparation can cause accidents! Observe the operating instructions of the high-pressure cleaner system, and wear the appropriate personal protective covering. Information New paints are only properly dry after approx. 3 months. Do not clean the machine with an HP cleaner during this time.
  • Page 209 Information Ask the manufacturer of the cleaning agent to confirm its suitability. Observe his directives on the application and health protection. SCHWING’s customer service can help you choose a cleaning agent that is suita- ble for your needs.  Always rinse off the cleaning agents thoroughly with clean water. Do not leave puddles.
  • Page 210 3.17 Cleaning 3.17.14 Water box flushing (special equipment) Our concrete pumps can be equipped with a pressure flush function for the water box as a special accessory. With this device, the usual manual cleaning of the water box is omitted to a large extent.
  • Page 211 3.17 Cleaning Fig. 141 Flushing the water box Reinigung-EN.fm - 01.19.03...
  • Page 212 3.17 Cleaning Reinigung-EN.fm - 01.19.03...
  • Page 213 3.18 Hazard prevention on the concrete filling hopper 3.18 Hazard prevention on the concrete filling hopper GEFAHR! Danger! Danger of death due to exposed agitator! Danger of death as a result of being crushed by or pulled into the agitator! Disassembled or open hopper grates, as well as defective or manipulated end limit switches, can cause serious injuries and even death.
  • Page 214 3.18 Hazard prevention on the concrete filling hopper 3.18.2 Cleaning flap and pipeline outlet Fig. 142 Do not reach into the hopper Fig. 143 Additional label for stationary concrete pumps Secure the machine from being switched off before opening the cleaning flap under the rock valve housing or the elbow of the pipeline outlet of concrete pumps.
  • Page 215 3.19 Readying the machine for transport TP 100 3.19 Readying the machine for transport TP 100 WARNUNG! Warning! Checking safety components! The operator has to carry out an expert inspection prior to each first commission, after any kind of changes to the support equipment and at least once a year accord- ing to manufacturer's instructions.
  • Page 216 3.19 Readying the machine for transport TP 100 3.19.1 Crane loading  Use suitable slings and only attach them to the lifting eyes on the machine! GEFAHR! Danger! Falling loads! Do NOT exceed the load capacity of the lifting eyes with additional weight from ac- cessories and remnants of pumping medium! Determine weight of loads prior to raising.
  • Page 217 3.20 Difficult operating conditions Heat, cold, dust, dirt, high humidity, sea water, continuous operation, etc. compli- cate the working conditions of your SCHWING machine. Under certain circumstances, these working conditions exceed the "limits of the machine". Refer to chapter (2.4).
  • Page 218 3.20 Difficult operating conditions 3.20.1 Low ambient temperatures (up to - 15 °C) 3.20.1.1 General information • Move the machine into an enclosed building overnight, if possible. 3.20.1.2 Vehicle motor and integrated motor Observe the manufacturer's operating instructions. Experience has shown that at least the following measures are required: •...
  • Page 219 3.20.1.4 Hydraulic system SCHWING recommends appropriate hydraulic fluids for different climates and ap- plications, see “Recommended lubricants and fuels” on page 245. The multi-purpose hydraulic oil filled in at the Herne factory can remain in the sys- tem, as long as the starting temperature does not drop below -10 °C.
  • Page 220 3.20 Difficult operating conditions Viscosity-temperature diagram: Fig. 145 Viscosity-temperature diagram Erschwerter-Betrieb-EN.fm - 01.08.03...
  • Page 221 3.20 Difficult operating conditions Concessions must also be made for various winter oils regarding the pressure load and wear protection. Please ask your supplier about the measures required when using its oil. We recommend using a hydraulic oil from the same supplier and same series, as was the case for "summer operation".
  • Page 222 3.20 Difficult operating conditions 3.20.1.5 Air system Rotation compressors can be used at up to -15 °C, with appropriate maintenance. Since the vehicle air system supplies the electro-pneumatic pilot control for some truck-mounted concrete pumps, it is also important to set the vehicle air system to winter operation.
  • Page 223 3.20 Difficult operating conditions 3.20.1.7 Comparison of viscosity classes Industry standard Vehicle standard e.g. hydraulic oil Motor oil Gear oil ISO-VG "thin" 10 W 15 W 20 W / 20 1000 "thick" Table 4 Comparison of viscosity classes 3.20.1.8 Grease lubrication points The KP2K lubricating greases listed in (chap.
  • Page 224 3.20 Difficult operating conditions 3.20.1.10 Radio remote control The radio control can be used at up to -20 °C. Please heat the driver's cab or use a separate charger, if possible, at a room tem- perature of +20 °C. Information Charging the battery becomes problematic at temperatures below +10 °C.
  • Page 225 3.20 Difficult operating conditions 3.20.1.14 Decommissioning • Clean the machine after the work assignment. • Clean steps, platforms, etc. from ice and dirt. • Position the machine on firm, dry ground. • Secure the machine properly from rolling away. • Only release the parking brake (can freeze) if the machine can be otherwise se- cured effectively from rolling away.
  • Page 226 3.20 Difficult operating conditions • Do not open the maintenance flaps in order to augment the cooling effect. This could interfere with the air circulation and have the opposite effect. • Ensure that the hydraulic system is configured correctly. For example, a pres- sure relief valve that is set too low will cause the oil temperature to increase be- cause oil is continuously discharged under high pressure through a small cross section.
  • Page 227 3.20 Difficult operating conditions 3.20.2.4 Hydraulic system The multi-purpose hydraulic oil filled in at the Herne plant covers the viscosity class VG 46 and the viscosity class VG 68, intended for tropical applications, see “Rec- ommended lubricants and fuels” on page 245. If a single-purpose oil VG 46 is used, the oil must be changed to VG 68.
  • Page 228 3.20 Difficult operating conditions 3.20.2.8 Electrical system Check the acid level of the battery cells more frequently at high ambient tempera- tures. Only refill with distilled water! 3.20.2.9 Radio remote control The radio control can be used at up to +60 °C. 3.20.2.10 Setting up the machine The load-bearing capacity of heat-sensitive subsoils, such as asphalt, decreases as the ambient temperature rises.
  • Page 229 3.20 Difficult operating conditions 3.20.2.13 Decommissioning Let the machine idle for some minutes with the pump drive active. This way, the turbo charger transports the heat away from the diesel engine and cools the hydraulic oil by continuing to pump it through the radiator. Erschwerter-Betrieb-EN.fm - 01.08.03...
  • Page 230 3.20 Difficult operating conditions Erschwerter-Betrieb-EN.fm - 01.08.03...
  • Page 231 3.21 Decommissioning 3.21 Decommissioning If the machine is to be decommissioned for an extended period of time, please ob- serve the following list. 3.21.1 Tasks prior to decommissioning Clean and lubricate the machine thoroughly. Check the concentration of antifreeze for liquid-cooled motors and top up if necessary.
  • Page 232 Carry out functional testing. Information For storage of the machine under difficult conditions, special regulations apply. Difficult conditions include, for example: • Storage periods of over 6 months. • High air humidity. • Sea air, etc. Contact SCHWING customer service. Stilllegung-EN.fm - 01.05.02...
  • Page 233 3.22 Technical preconditions for concreting 3.22 Technical preconditions for concreting Information Pumped concrete is not a special concrete, but a standardised quality concrete. 3.22.1 Properties of pumped concrete • Minimum fine grain content (grain size < 0.125 mm) of approx. 400 kg/m³ with a maximum grain size of 32 mm (+ 10% when using maximum grain size of 16 mm), •...
  • Page 234 3.22 Technical preconditions for concreting Betontechnologische-Vorauss-EN.fm - 01.04.03...
  • Page 235 4 Maintenance This chapter contains maintenance instructions for a SCHWING product. Further measures should be implemented by SCHWING’s customer service department or by trained and qualified personnel. Otherwise, the warranty and liability shall become void for this product. Trennblatt_Kapitel-Wartung-EN.fm...
  • Page 236 4 Maintenance Trennblatt_Kapitel-Wartung-EN.fm - 01.00.02...
  • Page 237 We recommend copying the maintenance report (chap. 4.6). The maintenance personnel can then acknowledge the work carried out on the copies. Schwing expressly prohibits any maintenance work carried out by personnel who are not specially trained and authorised. GEFAHR! Danger!
  • Page 238 4.1 General maintenance instructions 4.1.3 Corrosion protection Heavy rust weakens the material and may cause fractures and cracks. • Repair damaged painted surfaces within due time and grease bare machine parts. 4.1.4 Checking the oil level In general, take the following points into account when checking the oil: •...
  • Page 239 By opening the drain screw on the hydraulic oil box, you can then drain the water from the bottom of the box. Information Best downtime! The hydraulic oil used at SCHWING requires a downtime period of at least 2 days in order to achieve good results. Allgemeine_Wartungshinweise-EN.fm - 01.14.02...
  • Page 240 4.1 General maintenance instructions 4.1.7 Seals and fuse elements • Make sure that no seals, spring washers, etc. are lost when removing top cov- ers, closing screw plugs, and the like. • Before closing them again, clean the sealing surfaces of the screws and covers, etc.
  • Page 241 These instructions must be included in the operating instructions. SCHWING GmbH is not liable for damage resulting from the use of worn or defec- tive components. WARNUNG!
  • Page 242 Contact SCHWING’s customer service for an individual consultation.  Only use original SCHWING spare parts for repairs or replacements. SCHWING will not be held liable for damage caused by use of third-party products or improper equipment.  Only use mineral oil-based greases for installation work on the hydraulic system.
  • Page 243 4.1 General maintenance instructions 4.1.13 Mechanical processes Cover devices, cables etc. when drilling or grinding work etc. is to be carried out on the machine. 4.1.14 Painting and working with aggressive substances Cover devices, cables etc. to protect them against paint mist and aggressive sub- stances.
  • Page 244 4.1 General maintenance instructions Allgemeine_Wartungshinweise-EN.fm - 01.14.02...
  • Page 245 4.2 Recommended lubricants and fuels Recommended lubricants and fuels Oil under pressure is very dangerous! The following points must be observed: • Only qualified personnel may work on hydraulic systems. • Personal protective equipment must be worn during work (safety glasses, suit- able gloves and clothing).
  • Page 246 4.2 Recommended lubricants and fuels 4.2.1 Behaviour in case of injuries Immediately seek a doctor familiar with such injuries. Seek a doctor even if the wound seems harmless. Hydraulic fluid sprayed under the skin must be removed immediately. This could result in serious circulatory disorders and tissue damage (gangrene).
  • Page 247 = Special lubricant for material pairing: Plastic / metal for prolonged lubrication of the slider in the telescopic arms. Art. no.: = SCHWING drive line grease. 10197297 Only use this grease to lubricate the SCHWING drive lines. Schmier-Betriebstoffempfehlung-EN.fm - 01.22.06...
  • Page 248 Using hydraulic oil from another manufacturer, or using an oil of a different quality, requires a complete oil and filter change. Mixing the same oils with different viscosities is only permitted after consultation with SCHWING GmbH. Only use oils that contain zinc. Schmier-Betriebstoffempfehlung-EN.fm - 01.22.06...
  • Page 249 4.2 Recommended lubricants and fuels 4.2.4 Recommended gear oil (see gear type plate) 4.2.4.1 Industrial gear oil Viscosity according to ISO: VG 220 Quality according to DIN: ARAL Degol BG 220/Degol BMB 220 Energol GR-XP 220 KLÜBER Klüberoil GEM 1-220 MOBIL Mobilgear 600 XP 220 SHELL...
  • Page 250 4.2 Recommended lubricants and fuels 4.2.4.3 Industrial gear oil (polyglycol base) Viscosity according to ISO: VG 220 Quality according to DIN: ARAL Degol GS 220 AVIA Avilub VSG 220 Energol SG - XP 220 Syntherma P 270 FUCHS Renodiol PGP 220 MOBIL Glygoyle 30 SHELL...
  • Page 251 4.2 Recommended lubricants and fuels 4.2.5 Recommended compressor oil 4.2.5.1 Rotary compressor ACHTUNG! Attention! Material damage caused by the wrong oil! Only synthetic ROTOR OIL 8000 F2 may be used for our rotary compressors. Schmier-Betriebstoffempfehlung-EN.fm - 01.22.06...
  • Page 252 - strong impact load and vibrations - multi-week abandonment. It is imperative to use OPTIMOL-OPTIPIT in the mounting of the above components. It is available in 400g cartridges under art. no.: 10087948 from SCHWING’s spare parts service. Schmier-Betriebstoffempfehlung-EN.fm - 01.22.06...
  • Page 253 Mobilgear OGL 007 LUB-A 4.2.6.5 Special lubricants for the plastic sliders in the telescopic arm Designation according to DIN: MLE2N-40 SCHWING item no.: 10194658 10 kg tin 4.2.6.6 Special lubricants for couplings and seals in pumping lines OPTIMOL OLIT CLS 10 kg tin SCHWING item no.: 10149905...
  • Page 254 4.2 Recommended lubricants and fuels 4.2.7 Excerpt from the safety data sheet for hydraulic oil This is an excerpt from the manufacturer’s safety data sheet according to regulation 1907/2006/EU. Please request the complete safety data sheet from your oil supplier in your country of operation.
  • Page 255 4.2 Recommended lubricants and fuels ACCIDENTAL RELEASE MEASURES: GENERAL PROTECTIVE- AND HYGIENIC MEASURES: Person-related measures: Do not carry oil-soaked cleaning rags within the Ventilate affected rooms thoroughly. Avoid skin clothing. Do not eat, drink, smoke, sniff during contact. work. Environmental protection: SAFETY-RELEVANT DATA: Prevent further leakage and flow into drains.
  • Page 256 4.2 Recommended lubricants and fuels Schmier-Betriebstoffempfehlung-EN.fm - 01.22.06...
  • Page 257 SCHWING machine. Please note that SCHWING must rule out all warranties in the event that you or a third party commissioned by you carry out improper work.
  • Page 258 Careful maintenance and upkeep, as well as proper use of the machine can delay, but not entirely prevent, this so-called wear. Since the wear and tear on various components of your SCHWING machine can vary greatly depending on their operating conditions, there are no universal rules to be applied for inspecting and replacing these parts.
  • Page 259 4.3 Spare parts and accessories Information Our machines are constantly optimised in the course of improving the specification. In doing so, a critical focus is on the improvement of the wear and tear. Special components are also available for special applications. If necessary, please ask our customer service for the optimal solution to your wear problem.
  • Page 260 4.3 Spare parts and accessories Ersatzteile-Zubehoer-EN.fm - 01.05.03...
  • Page 261 4.4 Explanation of the maintenance schedule - Stationary concrete pump / trailer pump Explanation of the maintenance schedule - Stationary concrete pump / trailer pump Fig. 148: Example figure Symbols used in the following maintenance schedule:  = CHECK = LUBRICATE  = CLEAN = REPLACE ...
  • Page 262 4.4 Explanation of the maintenance schedule - Stationary con- crete pump / trailer pump Deckblatt-Wartungsplan-SP-EN.fm - 01.01.01...
  • Page 263 4.5 Maintenance schedule for stationary concrete pump TP 100 Maintenance schedule for stationary concrete pump TP 100 4.5.1 General information Description Chap. (chap. 7.4) A1 Technical safety inspection by experts. Intervals according to time or operating hours, whichever occurs first.
  • Page 264 4.5 Maintenance schedule for stationary concrete pump TP 100 4.5.2 Concrete pump (pump kit) Description CHAP: (chap. B1 Flush water box  3.15) (chap. B2 Check water box for deposits, clean as required  3.15) Replace main hydraulic oil filter after maintenance in- (chap.
  • Page 265 4.5 Maintenance schedule for stationary concrete pump TP 100 4.5.3 Special equipment Description G CHAP. Check grease supply and function of the central greas- (chap. 6.2)  (chap. 6.1) Clean suction filter on high-pressure cleaner  Description G CHAP. Diesel engine: D1 Check fuel supply and AdBlue (if present) every 4 hours ...
  • Page 266 4.5 Maintenance schedule for stationary concrete pump TP 100 4.5.4 Test intervals according to concrete delivery rate The amount of wear on your machine’s parts depends on the operating conditions (e.g.: concrete type, concrete pump stroke rate, etc.). We therefore recommend testing new components after having pumped a speci- fied amount of concrete.
  • Page 267 4.6 Maintenance report Maintenance report (Copy template) Type of Date Signature Comments maintenance A, V, B, S, P (please enter) G: General information P: Placing boom (only S/SPB) C: Concrete pump (pump kit) S: Special equipment T: Test intervals Wartungsbericht-EN.fm - 01.00.01...
  • Page 268 4.6 Maintenance report Type of Date Signature Comments maintenance A, V, B, S, P (please enter) G: General information P: Placing boom (only S/SPB) C: Concrete pump (pump kit) S: Special equipment T: Test intervals Wartungsbericht-EN.fm - 01.00.01...
  • Page 269 Hydraulic fluid and filters for stationary concrete pump / trailer pump 4.7.1 Checking the fill level of the reservoir The reservoir for the hydraulic oil is equipped with an oil level indicator (1) (Fig. 149) - (Fig. 151). Fig. 149 TP 100 Fig. 150 SP 1800 Hydraulikflüssigkeit-Filter-SP-EN.fm - 01.02.01...
  • Page 270 4.7 Hydraulic fluid and filters for stationary concrete pump / trailer pump Fig. 151 SP 3800 / 7000 / 7500 Fig. 152 SP 9000 / 9500 Caption (Fig. 149) / (Fig. 151) Oil level indicator Filler cap Cleaning cover Hydraulikflüssigkeit-Filter-SP-EN.fm - 01.02.01...
  • Page 271 Do not mix different types of oil. ACHTUNG! Attention! Ensure absolute cleanliness! To do this, we recommend using SCHWING’s flushing and filtration unit. For more information on this, contact SCHWING. 4.7.1.1 Checking without temperature scale When the oil is cold, the oil level must be shown in the middle of the oil level indi- cator (Fig.
  • Page 272 4.7 Hydraulic fluid and filters for stationary concrete pump / trailer pump Fig. 153 4.7.2 Filling the empty oil box  Top up the hydraulic oil box as described above.  Wait approx. 10 minutes until the oil is free of air bubbles and top up with more oil if necessary.
  • Page 273 4.7 Hydraulic fluid and filters for stationary concrete pump / trailer pump For components used in SCHWING GmbH hydraulic systems, a purity classifica- tion as set out in the manufacturer's specifications is required, which should at least be compliant with or better than classification 20/18/15 according to ISO 4406.
  • Page 274 4.7 Hydraulic fluid and filters for stationary concrete pump / trailer pump 4.7.5 What advantages are there in observing the purity classification? Adherence to the purity classification contributes significantly to the reduction of costs due to the extension of the oil change interval and to the prevention of dam- age due to contamination.
  • Page 275 4.7 Hydraulic fluid and filters for stationary concrete pump / trailer pump You can obtain suitable measuring and flushing devices via SCHWING. Please contact our Customer Services: Telephone: + 49 (0) 2325 / 987 - 231/232 Email: service@schwing.de 4.7.8 Draining condensation water...
  • Page 276  Clean the box and replace the filter inserts whenever you change the oil.  Document the oil and filter changes using the appropriate SCHWING tags, see (Fig. 160) and (Fig. 161). 4.7.10 Cleaning the reservoir In particular during long periods at standstill, the hydraulic oil excretes dirt particles which are deposited onto the bottom of the container.
  • Page 277 Clean and check all individual parts. Look out for rubbed-off metallic particles in the filter, as this would be an indication of damage. Document the oil and filter changes using the appropriate SCHWING tags, see (Fig. 160) and (Fig. 161).
  • Page 278 4.7 Hydraulic fluid and filters for stationary concrete pump / trailer pump Fig. 156 TP 100 Fig. 157 SP 1800 Hydraulikflüssigkeit-Filter-SP-EN.fm - 01.02.01...
  • Page 279 4.7 Hydraulic fluid and filters for stationary concrete pump / trailer pump Fig. 158 SP 3800 / 7000 / 7500 / 9000 / 9500 4.7.11.1 Dismantling  Unscrew the filter bowl (3) (Fig. 159) at the bottom hexagon (4) using a ring spanner.
  • Page 280 4.7 Hydraulic fluid and filters for stationary concrete pump / trailer pump Fig. 159 Fig. 160 Fig. 161 Hydraulikflüssigkeit-Filter-SP-EN.fm - 01.02.01...
  • Page 281 Appropriate settings are carried out on the hydraulic pump and pressure relief valve. If, during the check, the prescribed values are clearly exceeded or fallen short of, leave the required setting adjustment work to SCHWING’s customer service. Take the machine out of service and transmit the measured values to customer ser- vice.
  • Page 282 After the pressure check, first switch off the concrete pump, then switch the ball valves back to their operating position. In this way, you prevent uncontrolled running of the concrete pump after turning the ball valve. Fig. 162 TP 100 Druckkontrolle-SP-EN.fm - 01.02.02...
  • Page 283 4.8 Pressure checks - stationary concrete pumps / trailer pump Fig. 163 SP 1800 Fig. 164 SP 3800, 7000, 7500 Druckkontrolle-SP-EN.fm - 01.02.02...
  • Page 284 4.8 Pressure checks - stationary concrete pumps / trailer pump Fig. 165 SP 9000, SP 9500 Fig. 166 Pressure gauge pressure control TP 100 Druckkontrolle-SP-EN.fm - 01.02.02...
  • Page 285 4.8 Pressure checks - stationary concrete pumps / trailer pump Fig. 167 Pressure gauge (2) for pressure control SP 1800/2800 Fig. 168 Pressure gauge (2) for pressure control SP 3800/7000/7500/9000/9500 Druckkontrolle-SP-EN.fm - 01.02.02...
  • Page 286 4.8 Pressure checks - stationary concrete pumps / trailer pump Druckkontrolle-SP-EN.fm - 01.02.02...
  • Page 287 The hydraulic oil system can be equipped with an oil cooler. Dusty precipitation on the fins of the oil cooler (1) (Fig. 169) - (Fig. 171) reduces the cooling efficacy. Fig. 169 Hydraulic oil cooler TP 100 Hydraulikölkühler-SP-EN.fm - 01.01.00...
  • Page 288 4.9 Radiator Fig. 170 Hydraulic oil cooler SP 1800/2800 Fig. 171 Hydraulic oil cooler SP 3800/7000/7500 Hydraulikölkühler-SP-EN.fm - 01.01.00...
  • Page 289 4.9 Radiator 4.9.1.1 Cleaning the exterior of the hydraulic oil cooler Carefully clean the radiator with compressed air. To do this, bring the air flow par- allel to the cooler fins and against the normal flow direction. Cleaning with water or steam jet is possible for heavy soiling. ACHTUNG! Attention! Steam jet cleaning can potentially cause damage!
  • Page 290 4.9 Radiator Hydraulikölkühler-SP-EN.fm - 01.01.00...
  • Page 291 4.10 Air-filter system 4.10 Air-filter system Only service air filter when motor is not running. Do not start the motor while the filter element is removed. Assess the condition and tightness of the suction line each time the filter is ser- viced.
  • Page 292 4.10 Air-filter system Fig. 173 Fig. 174 4.10.3 Cleaning the filter element Replace the filter element after 3 cleanings or after one year at the latest. ACHTUNG! Attention! Improper cleaning! Never wash or brush filter element or clean by slamming. Clean and dry compressed air is used for the cleaning (max.
  • Page 293 4.10 Air-filter system VORSICHT! Caution! Health hazard! Do not inhale dust! Wear respiratory protection (dust mask)!  Inspect the cleaned element for damages (paper bellows, seals) before re-in- stalling it. Cracks and holes in the paper bellows can be detected with a torch. ACHTUNG! Attention! Potential motor damage!
  • Page 294 4.10 Air-filter system 4.10.4 Installing the filter element  Insert filter element carefully into the housing.  Mount cover of housing. Ensure that the dust discharge valve faces down- wards. When closing the top cover, the filter element is automatically pressed into the correct position.
  • Page 295 4.11 Rock valve maintenance 4.11 Rock valve maintenance GEFAHR! Danger! Risk of being crushed and sheared! To prevent unwanted working movements prior to working on the rock valve, al- ways follow the points below! • Switch off the drive motor and prevent it from starting up. •...
  • Page 296 4.11 Rock valve maintenance TP 100 SP 9000 / 9500 Fig. 177 Greasing strip on stationary concrete pumps / trailer pumps (X) Rockschieber-EN.fm - 01.18.03...
  • Page 297 4.11 Rock valve maintenance Fig. 178 Greasing strip on truck-mounted concrete pumps Information In various pumping units, the swivel head of the rock valve is powered by the mounted ball bearing of the hydraulic cylinder. Cylinders with unilateral and bilateral ball bearings are allowed. The appropriate lubrication points are connected to the lubrication point (or the cen- tral greasing) through the greasing lines.
  • Page 298 4.11 Rock valve maintenance Fig. 179 4.11.2 Checking the screw-type connections Regularly make sure that the cover screws (14) and clamping screws on the swivel head (15) are tight, in accordance with the maintenance schedule (Fig. 180). If necessary, tighten screws using a torque wrench in accordance with the torque table in the preface of the spare parts catalogue.
  • Page 299 4.11 Rock valve maintenance Fig. 180 Example Caption (Fig. 180) Pos. Designation See detailed view (Fig. 181) See detailed view (Fig. 182) Cover screws Clamping screws 4.11.3 Checking the axial play of the slewing shaft No air gap may be visible between the bearing bushing (4), the locking wheel (2) and the adjusting nut (1) (Fig.
  • Page 300 4.11 Rock valve maintenance Fig. 182 Fig. 181 Caption for (Fig. 181) and (Fig. 182) Pos. Designation Adjusting nut Locking disc Safety screw Bearing bushing Swivel head (rock) Housing lining Kidney seal 4.11.4 Configuring the axial play of the slewing shaft ...
  • Page 301 4.11 Rock valve maintenance 4.11.5 Checking the cutting ring The cutting ring and wearing insert on the housing lining are worn unevenly due to external influences (e.g. varying types of concrete) and different stresses in sub- areas (area "B", (Fig. 180)). Grooves are caused primarily by friction and breaking of stones.
  • Page 302 4.11 Rock valve maintenance Fig. 184 4.11.6 Rotating the cutting ring In order to be able to rotate the cutting ring, proceed as follows:  Disconnect the pumping line from the outlet of the rock valve. To do this: a) Remove the tapered tube for stationary concrete pumps. b) Remove the wedges (1+2) and the coupling (3) for truck-mounted concrete pumps.
  • Page 303 4.11 Rock valve maintenance Fig. 185  Loosen the adjusting nut (1) (Fig. 186) by two to three turns.  Loosen the cover screws (14) evenly by approx. two to three turns to release the pressure spring in the cutting ring. VORSICHT! Caution! Danger of crushing and breakage!
  • Page 304 4.11 Rock valve maintenance  Make sure that the cutting ring is guided securely by the rock and cannot fall out or tilt.  Also make sure that no stones etc. are trapped between the individual compo- nents when tightening the cover screws. ...
  • Page 305 4.11 Rock valve maintenance  Check the distance between the cutting ring (10) and the swivel head (rock) (5) (Fig. 187) and (Fig. 188) after each rotation. If it is more than 8 mm, the cutting ring is no longer guided securely in the rock and must be replaced.
  • Page 306 4.11 Rock valve maintenance Fig. 189 4.11.7 Checking the seal of the slewing shaft The bearings of the slewing shaft are sealed against the medium being pumped with 0-rings (Fig. 189). In the event of leaks, replace the 0-rings (super-fine concrete components pene- trate outwards through the bearing) immediately before the bearing is destroyed.
  • Page 307 4.11 Rock valve maintenance 4.11.9 Checking the wear of the swivel head (rock) There are two types of swivel head, • armoured swivel head, see (Fig. 190), • unarmoured swivel head, see (Fig. 191). Depending on the type of swivel head, the wear test varies. The armoured swivel head is serviced by a visual inspection, the unarmoured swiv- el head is serviced by measuring the wall thickness.
  • Page 308 4.11 Rock valve maintenance Fig. 191 Unarmoured swivel head (rock) Caption (Fig. 191) Pos. Designation inner wall outer wall 4.11.10 Preventive maintenance of the armoured swivel head (rock) Since the wear largely depends on the operating conditions, we recommend check- ing a new armoured swivel head (rock) from the inside for the first time after about 5000 m³...
  • Page 309 We strongly advise against unqualified welding and the use of replicas. SCHWING is not liable for damages caused by improper repair attempts or replicas. 4.11.11 Preventive maintenance of the unarmoured swivel head (rock) Since the wear largely depends on the operating conditions, we recommend check- ing a new unarmoured swivel head for the first time after about 5000 m³...
  • Page 310 4.11 Rock valve maintenance Rockschieber-EN.fm - 01.18.03...
  • Page 311 4.12 Pumping and differential cylinders, pumping piston change TP 100 4.12 Pumping and differential cylinders, pumping piston change TP 100  Make sure the six draw rods (1) on the differential (2) and pumping cylinders (3) are tight.  Tighten any loose nuts (4) (Fig. 192) on the draw rods crosswise in three steps using a torque wrench.
  • Page 312 4.12 Pumping and differential cylinders, pumping piston change TP 100 WARNUNG! Warning! Different water boxes can be available depending on the installed concrete pump kit! The covers are designed correspondingly. The basic principles are: • If the top cover of the water box can be opened without tools, bolted protective grids are located under the top cover.
  • Page 313 4.12 Pumping and differential cylinders, pumping piston change TP 100 Fig. 193 Example of water box Fig. 194 Example of TP 100 concrete pump driving in repair mode Foerder-Diff-Zyl-TP-100-EN.fm - 01.08.01...
  • Page 314 4.12 Pumping and differential cylinders, pumping piston change TP 100 4.12.2.1 “Pumping piston change” operating mode (TP 100) The machine is equipped with a special control for the pumping piston change. Activate "Pumping piston change" operating mode by actu- ating the momentary key-operated switch (2) (Fig. 194).
  • Page 315 4.12 Pumping and differential cylinders, pumping piston change TP 100 4.12.4 Changing the pumping piston ACHTUNG! Attention! Material damage caused by leaking pumping pistons. If sand is in the water box, the pumping pistons are worn and need to be replaced.
  • Page 316 4.12 Pumping and differential cylinders, pumping piston change TP 100  Remove the coupling flange (2) (Fig. 199).  Remove the pumping piston from the water box.  Clean and check all parts. Fig. 196 “Piston connection” in water box Fig.
  • Page 317 4.12 Pumping and differential cylinders, pumping piston change TP 100 Fig. 198 Piston rod on pumping piston Fig. 199 Pumping piston for replacement in water box Foerder-Diff-Zyl-TP-100-EN.fm - 01.08.01...
  • Page 318 4.12 Pumping and differential cylinders, pumping piston change TP 100 4.12.4.2 Installing the pumping piston  Apply a thick layer of grease to the new piston and cylinder wall.  Mount the new pumping piston with a coupling flange on the piston rod and tighten by hand (Fig.
  • Page 319 4.13 Servicing the pumping line 4.13 Servicing the pumping line This chapter describes how to service the pumping line on various SCHWING products. The principle remains the same in each case. GEFAHR! Danger! Risk of explosion due to ruptured tubes! Pumping lines are wear parts.
  • Page 320 4.13 Servicing the pumping line Information Depending on the installation situation, the wear and tear on the pumping lines can vary greatly. Check the elbows and reductions under highest strain especially carefully. Experience has shown that the concrete pump outlet as well as the “impact elbows” on the last section of the boom (see “Impact bend”...
  • Page 321 4.13 Servicing the pumping line 4.13.1 Diagrams For determining the required minimum wall strengths of concrete pumping lines from P 355 (with prescribed, twofold safety): (Y) = Pumping pressure PN in bar (X) = Minimum wall strength in mm 1) Tube 70x2.9 2) Tube 88.9x3.2 3) Tube 108x4 4) Tube 114.3x7.1...
  • Page 322 4.13 Servicing the pumping line 7) Tube 139.7x8.8 8) Tube 159x4.5 9) Tube 165.1x7.1 10) Tube 168.3x10 11) Tube 191x5.5 Wartung-Foerderleitung-EN.fm - 01.15.02...
  • Page 323 4.13 Servicing the pumping line 4.13.2 Main wear zones (pay particular attention during inspections) Pumping pipes The main wear zone is located in the direction of the flowing concrete approx. 100 mm behind the flange (Fig. 200). Fig. 200 Elbows The main wear zone is located in the direction of the flowing concrete in the "inlet bend"...
  • Page 324 4.13 Servicing the pumping line Fig. 202 4.13.3 Impact bend The impact bend (1) (Fig. 203) is the penultimate bend in the boom pumping line. The concrete frequently falls into this elbow and the impacting material causes so- called impact wear. Impact wear can be mostly avoided if the last boom section is positioned horizon- tally during the pumping process (Fig.
  • Page 325 4.13 Servicing the pumping line Fig. 203 Fig. 204 Wartung-Foerderleitung-EN.fm - 01.15.02...
  • Page 326 Determine which type is available in which quality. The measurement sheet is selected based on the type. Should you have questions or be missing measurement sheets, please contact SCHWING’s customer service. 2. Specification of the installation situation The respective installation situation is specified on the measurement sheet, ac- cording to the installation present.
  • Page 327 4.13 Servicing the pumping line 5. Decision on further use If one of the measured values has been reached, then at this critical point the pumping pipe has a remaining wall thickness of 0.5 mm and should be replaced as soon as possible.
  • Page 328 4.13 Servicing the pumping line 4.13.5 Measurement points for different installation situations 4.13.5.1 Tube after tube Measurement points: (P1) approx. 20-30mm behind the welding seam of the inlet flange (P2) measurement on the shoulder of the inlet flange around the entire circumfer- ence.
  • Page 329 4.13 Servicing the pumping line 4.13.6 Measurement sheet - tubes (As of 31/10/2012, excerpt from Esser Sales Booklet EM120029 _ EM130023 DE 141208): Removal of the pipe component must be done on reaching a measurement point (P1 or P2) at the latest! Type: SUPER 2000 TUBES (ESSER TWIN PIPE 700 TUBES) Nominal size DN Quality type...
  • Page 330 4.13 Servicing the pumping line Wartung-Foerderleitung-EN.fm - 01.15.02...
  • Page 331 4.13 Servicing the pumping line 4.13.7 Measurement sheet - elbows (As of 31.10.2012, excerpt from the Esser Sales Booklet ES4045): Removal of the pipe component must be done on reaching a measurement point (P1 or P2) at the latest! Type: SUPER 2000 ELBOWS (ESSER TWIN PIPE 700 ELBOWS) Nominal size DN Quality type Wall thickness...
  • Page 332 4.13 Servicing the pumping line 4.13.8 Tube type - tapered tubes Measurement points: (P1) measurement in the 50 mm area in front of the outlet flange welding seam. (P2) measurement on the shoulder of the outlet flange around the entire circumfer- ence.
  • Page 333 4.13 Servicing the pumping line 4.13.8.1 Measurement sheet - tapered tubes (As of 31.10.2012, excerpt from the Esser Sales Booklet ES4045): Removal of the pipe component must be done on reaching a measurement point (P1 or P2) at the latest! Type: SUPER 2000 TAPERED TUBES (ESSER TWIN PIPE 700 TAPERED TUBES) DN inlet DN outlet...
  • Page 334 For this purpose, directional arrows are located on the material. • Pay attention to the quality and correct size of spare parts. Only original SCHWING spare parts correspond exactly to the factory-installed parts. • During the initial assembly at the factory, the boom pumping line is assembled without tension on a folded placing boom.
  • Page 335 4.13 Servicing the pumping line Information While being assembled at the factory, the pumping lines are fitted with special web seals. As such, the required precision is achieved when first assembling the pump- ing line. The centres of rotation for the pumping lines, however, are fitted with sim- ple seals without web.
  • Page 336 4.13 Servicing the pumping line 4.13.12 Visual inspection (exterior) • Check the safety catch on one of the placing boom end hoses to make sure it is in proper working order. • The outlet end of an end hose must not be "frayed". •...
  • Page 337 4.13 Servicing the pumping line Fig. 209 Wartung-Foerderleitung-EN.fm - 01.15.02...
  • Page 338 4.13 Servicing the pumping line Wartung-Foerderleitung-EN.fm - 01.15.02...
  • Page 339 The following should be observed in terms of jump-starting and welding due to the spatial separation of both batteries (one on the right-hand and one on the left-hand side). The electrical system of the TP 100 with Deutz and Caterpillar motors is powered by 12V batteries. 4.14.1.1...
  • Page 340 4.14 Electrical / Electronic system, software Fig. 210 Example: Operator station on a stationary concrete pump SP 1800. Elektrische-Elektronische-Anlage-SP-EN.fm - 01.05.02...
  • Page 341 4.14 Electrical / Electronic system, software Fig. 211 Example: Operator station on a stationary concrete pump TP 100, SP 3800 4.14.3 Changing the fuses in SCHWING components  Switch off the machine’s control unit and the drive motor.  Switch the main battery switch (1) to the “0” position (Fig. 213), (Fig. 214) or (Fig.
  • Page 342 Stop the machine and have an electrician inspect the electrical system. If a fuse is tripped once again, there is a short circuit. Stop the machine and have an electrician inspect the system. Fig. 212 Example: TP 100 CAT motor Elektrische-Elektronische-Anlage-SP-EN.fm - 01.05.02...
  • Page 343 4.14 Electrical / Electronic system, software Fig. 213 Example SP 1800 Fig. 214 Example: SP 3800 BR02 Fig. 215 Example: SP 9500 BR02 Elektrische-Elektronische-Anlage-SP-EN.fm - 01.05.02...
  • Page 344 Never disconnect a cable from the starter batteries, alternator or regulator while the motor is running. • Earth the machine to establish equipotential bonding between the machine and the ground. 4.14.5 Software Only representatives of SCHWING are permitted to alter the machine’s software. This also applies to updates. Elektrische-Elektronische-Anlage-SP-EN.fm - 01.05.02...
  • Page 345 Danger! Unauthorised modifications to the software can result in serious damage and accidents. SCHWING is not liable for the consequences of unauthorised software modifica- tions. 4.14.6 Electrically powered machines Have an electrician disconnect the power supply to such machines prior to carrying out repair work on the respective machine.
  • Page 346 4.14 Electrical / Electronic system, software Make sure to observe the correct order! Under no circumstances may the terminals of the batteries be connected the other way round. If the engine starts, then the cables can be removed again in the reverse order. A diesel engine uses considerably more power to start than a gasoline engine, which must be taken into account when selecting the donor unit.
  • Page 347 4.14 Electrical / Electronic system, software ACHTUNG! Attention! The following instructions do not apply to maintenance-free starter batteries. Strictly observe the manufacturer instructions! 4.14.14 Checking the acid level • Clean battery surface, open locking caps. • The fluid should typically be 10 to 15 mm above the plates or at the level of the control device.
  • Page 348 4.14 Electrical / Electronic system, software Fig. 216 Hydrometer Acid density (kg/l) Charging status Action 1.28 1.23 good 1.20 1.12 half charged 1.12 1.08 empty charge immediately! Table 5 4.14.17 Charging the battery Charge battery by running the motor for several hours or with a charger. When charging with a charger, the battery must be at a temperature of at least 10 °C.
  • Page 349 4.14 Electrical / Electronic system, software  Stop charging after reaching an acid density of 1.28 kg/l or 1.23 kg/l (in the trop- ics) if the charger does not have an automatic regulator.  Check acid level and refill with distilled water, if necessary. ...
  • Page 350 4.14 Electrical / Electronic system, software 4.14.20 Disposal Turn in old batteries at a collection point. Observe regional regulations for disposal of batteries and sulphuric acid. Information Please refer to the operating instructions from the vehicle or engine manufacturer for further information on the starter batteries Elektrische-Elektronische-Anlage-SP-EN.fm - 01.05.02...
  • Page 351 The definition of a competent person is given in the SAFETY MANUAL. We recommend only contracting SCHWING employees to carry out this inspection. 4.15.3 Expert An expert must be consulted in case of significant changes and extensive repairs (for example, if welding is carried out on load-bearing parts).
  • Page 352 As a rule, special skills are required to carry out repairs, which is why we strongly recommend contracting SCHWING’s customer service to perform this inspection. If you carry out repairs on safety components yourself or hire a third party to do this, we encourage you to notify us of the damage and the work carried out.
  • Page 353 4.15 Safety inspections 4.15.6.1 What are safety components? The SCHWING factory standard distinguishes between safety components of the first (S1) and second order (S2). The failure of S1 parts can pose a danger to life and limb. All persons inside the danger zone are in extreme danger of being killed.
  • Page 354 4.15 Safety inspections 4.15.7 Notification of damage for safety components Please complete the copy of this questionnaire and send the completed copy to: SCHWING GmbH Service Heerstraße 9-27 44653 Herne GERMANY Of course you can also fax us this page or reply by email: Email: service@schwing.de...
  • Page 355 4.15 Safety inspections Short description of the damage: The following parts were replaced (item number, if known): Sicherheitspruefung-EN.fm - 01.07.02...
  • Page 356 4.15 Safety inspections Was welded?   If so, where? Were mechanical procedures carried out?  Drilling  Sanding  Other If so, where? Was the work documented by photos or drawings?   If so, is this document attached to this message? ...
  • Page 357 4.16 Repair welding 4.16 Repair welding On the placing boom, on the outrigger or on other components important to work safety, welding may only be carried out by authorised representatives of the man- ufacturer. In general, welding should only be carried out by personnel specially trained and qualified for this activity.
  • Page 358 4.16 Repair welding Reparaturschweissen-EN.fm - 01.05.02...
  • Page 359 5 Remote control Trennblatt_Kapitel-Fernsteuerung-EN.fm...
  • Page 360 5 Remote control Trennblatt_Kapitel-Fernsteuerung-EN.fm - 01.00.00...
  • Page 361 Scope of the operating instructions These operating instructions apply to the G5* radio remote control system, as in- tended for SCHWING stationary concrete pumps with an "SP control". (* = hereinafter referred to as radio system or remote control) It does not contain any information on a specific machine, but rather complements the existing machine operating instructions.
  • Page 362 Report all faults to your supervisor. • The remote control must only be used for its intended purpose of controlling a SCHWING machine set up for this purpose. Any other use is not permitted! • Misuse, incorrect operation, poor maintenance and unauthorised interventions in the system can lead to serious material damage and personal injury! •...
  • Page 363 5.2 Technical data 5.2 Technical data 5.2.1 G5 CAN receiver Attributes Information Current supply 9-36 V DC Weight 1.2 kg IP 67, protected against the ingress of dust and water in case of Protection class temporary immersion in standardised conditions Stop function ISO 13849, Cat.
  • Page 364 5.2 Technical data 5.2.3 Battery operation Attributes Information Current supply 9-36 V DC Weight 70 g Protection class IP 21 Power consumption < 15 mA Charge time 2.2 hours Cable length 1.8 m Ambient temperature - 20 °C to + 70 °C Charging temperature + 5 °C to + 45 °C Dimensions...
  • Page 365 Identification of the remote control, type plates Transmitters, receivers, and batter chargers are provided with an individual type plate. When contacting SCHWING, please always provide the information on these type plates. When you assign this operating manual to a particular remote control, you can en-...
  • Page 366 The current supply is supplied to the transmitter by a replaceable AA battery. The receiver is mounted on a suitable point on the SCHWING machine. For com- missioning, you must use a supplied Y cable to connect the receiver to the connec- tion socket of the machine control system.
  • Page 367 5.2 Technical data 5.2.7 Overview of the components 5.2.7.1 The transmitter The following inspection and control elements are found on the transmitter: EMERGENCY-STOP button Concrete pump delivery rate indication Light for active connection Indicator light for concrete pump flow/ return flow Battery charge light Warning light for low battery status Horn...
  • Page 368 5.2 Technical data 5.2.8 Inserting / Replacing the batteries in the radio transmitter The radio transmitter requires three rechargeable AA batteries. Proceed as follows to change the batteries.  Remove the belt clip by loosening the two fastening screws (A) (Fig. 221). ...
  • Page 369 5.2 Technical data 5.2.9 The components 5.2.9.1 The charger for the transmitter on the machine The charger for the transmitter (Fig. 222) is mounted on the machine for some models. The transmitter charges continuously via the starter battery of the motor, as long as the main battery switch is in position “1”.
  • Page 370 GEFAHR! Danger! Risk of falling! Entering the SCHWING machine during operation is prohibited! If it is necessary to enter the machine for repair work on the remote control, this must only occur when the machine is switched off. Safe climbing aids and fall arresters are required for working on the machine.
  • Page 371 5.2 Technical data Fig. 224 Dummy plug fastener TP 100 5.2.10.1 Pairing connector The pairing connector (Fig. 225) is required to safely pair transmitters and receivers. * Pairing = unique assignment between an individual transmitter and an individual G5 receiver.
  • Page 372 5.2 Technical data Receiver off Standby mode: Transmitter search (shown through circulating bar) Radio transmission O.K. (frequency hopping) Table 6 5.2.10.3 Y cable The Y cable (Fig. 226) is used to connect the receiver to the machine’s control sys- tem. ...
  • Page 373 5.2 Technical data Fig. 227 Fig. 228 Caption for (Fig. 228) Pos. Designation Y cable for connection 1 Y cable for connection 2 Fernsteuerung_EN.fm - 01.05.00...
  • Page 374 5.2 Technical data Receiver cable for connection A Receiver cable for connection C Connection for pairing B 5.2.11 Commissioning the remote control Once the receiver has been installed and the batteries inserted, the transmitter should be fully operational with the standard settings. 5.2.11.1 Switching on the receiver ...
  • Page 375 5.2 Technical data  Wait until the receiver's display shows “Radio transmission OK” (Fig. 229). The correct radio transmission is confirmed by this display. Radio transmission O.K. (frequency hopping) Fig. 229 Indicators for the button (4) (Fig. 230) Local control system LED = yellow / green Remote control LED = red / blue...
  • Page 376 5.2 Technical data 5.2.11.2 Switching on the radio transmitter  Release the EMERGENCY STOP button (1) (Fig. 231) by turning it clockwise.  Release all EMERGENCY STOP buttons on the machine as well; otherwise, it will not be possible to start the machine. ...
  • Page 377 5.2 Technical data 5.2.11.3 Starting up the cable remote control  Connect the cable remote control to the machine control system. The connection socket (1) for the cable remote control (Fig. 232) is located under the housing. The connection socket for the cable remote control on the machine is located on the operating panel for the machine control system (5) (Fig.
  • Page 378 5.2 Technical data The transmitter sends the EMERGENCY STOP signal, which immediately inter- rupts all primary machine functions. Then the transmitter switches off automatically. The transmitter must be restarted for recommissioning. 5.2.13 EMERGENCY STOP By pressing an EMERGENCY-SOP button, the main machine functions are inter- rupted immediately.
  • Page 379 5.2 Technical data 5.2.15 Automatic speed adjuster with remote control When operating with the remote control, the machine features an automatic speed adjuster. If the concrete pump is stopped during operation, the control unit adjusts the motor speed automatically to idling speed. If the concrete pump is then restart- ed, the motor speed is automatically switched back to the previously configured working speed.
  • Page 380 5.2 Technical data Fig. 233 ACHTUNG! Attention! Securely store the cable or radio transmitter to prevent it from becoming damaged during the ride! Always make sure you know where your transmitter is before setting off! Transmit- ters have been forgotten at the jobsite! 5.2.18 Programming 5.2.18.1 Pairing the transmitter with the receiver...
  • Page 381 5.2 Technical data  Insert the G5 CAN pairing plug (Fig. 235) into the receiver's plug connector (B) (Fig. 234).  Press the transmitter buttons (7) and (8) (Fig. 236) while the transmitter is switched off. The upper LED (1) flashes and signals that the transmitter is ready for a secure pairing.
  • Page 382 5.2 Technical data Fig. 235 Fig. 236 5.2.18.2 Transmitter test mode The transmitter is equipped with a test mode to test the operational readiness of the buttons.  Browse through the menu items in the machine control system using the cursor buttons.
  • Page 383 5.2 Technical data Fig. 237 Fig. 238 5.2.19 Storage, maintenance, upkeep, disposal 5.2.19.1 Storage  Store the remote control in a dry environment. Avoid humidity and extreme tem- peratures.  Remove the batteries when the transmitter is not in use for an extended period of time.
  • Page 384 5.2 Technical data 5.2.20 Maintenance • Check the remote control regularly or if abnormal behaviour is noticed. • Check the transmitter for damages. Pay particular attention to such damages enabling water to ingress. • Check the cables on the receiver for damages. •...
  • Page 385 5.2 Technical data 5.2.23 Troubleshooting This section includes actions that the operator can or should take before contacting a service technician. This applies for the unlikely case that problems occur with the transmitter, receiver, or radio link. Read through the "Troubleshooting" section for the most frequently occurring sce- narios/symptoms.
  • Page 386 5.2 Technical data Fernsteuerung_EN.fm - 01.05.00...
  • Page 387 6 Special equipment Please note that the possibility to use special equipment depends on the machine model. Trennblatt_Kapitel-Sonderausstattung-EN.fm...
  • Page 388 6 Special equipment Trennblatt_Kapitel-Sonderausstattung-EN.fm - 01.00.00...
  • Page 389 6.1 High-pressure cleaner SP / TP High-pressure cleaner SP / TP SCHWING machines can be equipped with a high-pressure cleaning system (here- inafter referred to as an HPC) (1) (Fig. 239) as a special accessory. The present operating instructions are based on the manufacturer's documentation and take into account the installation in SCHWING machines.
  • Page 390 6.1 High-pressure cleaner SP / TP 6.1.1 General safety instructions for HPC system Also observe the manufacturer’s instructions on high-pressure cleaning systems, which have been enclosed separately with your machine. The operator of the machine is responsible for instructing the operating personnel in how to use the machine.
  • Page 391 6.1 High-pressure cleaner SP / TP WARNUNG! Warning! Risk of severe injury due to high-pressure water jet! The high-pressure water jet can cause severe injuries. Never leave the HPC’s spray lance unattended while under operating pressure! At the end of work, separate the connections on the oil and water side. Never work with the high-pressure cleaning system from a ladder or the like.
  • Page 392 6.1 High-pressure cleaner SP / TP GEFAHR! Danger! Danger to life due to voltage transfer! Electrically live components may not come into contact with water. This may result in danger to life due to voltage transfer Never hold the water jet of the HPC directly on or in the vicinity of electrical or elec- tronic components.
  • Page 393 6.1 High-pressure cleaner SP / TP Fig. 241 Components in the HPC system Caption (Fig. 241) Pos. Description Pos. Description High-pressure pump Suction line ball valve Turn-lock fastener for suction pipe Closing screw plug for gear oil drainage Pressure settings Thermal safety valve (Never change factory configuration!) Pressure gauge...
  • Page 394 6.1 High-pressure cleaner SP / TP Fig. 242 Fig. 243 HPC suction and delivery connection HDR-Anlage-SP-TP-EN.fm - 01.05.02...
  • Page 395 Any accessories available on the market will be neither tested nor approved by SCHWING. Neither SCHWING nor the pump manufacturer can be charged with damages or accidents caused by unsuitable accessories. Information Any damages caused as a result of incorrect or negligent operation, maintenance and repair, or due to improper use, shall void all warranty and liability claims against the company SCHWING GmbH.
  • Page 396 6.1 High-pressure cleaner SP / TP ACHTUNG! Attention! Material damage caused by air in the system! Vent the system on the water side before each commissioning. Otherwise, damage to the high-pressure pump can occur, which is not covered by the manufacturer warranty. 6.1.6.2 Connecting the high-pressure hose The system is delivered with a high-pressure hose and a spray lance.
  • Page 397 6.1 High-pressure cleaner SP / TP  Carry out trouble shooting (siehe “Troubleshooting” auf Seite 405). Only start cleaning up if you are convinced that the HPC is functioning properly. Fig. 244 Spray lance 6.1.7 Cleaning operation • Begin the cleaning work by actuating the spray lance trigger. •...
  • Page 398 6.1 High-pressure cleaner SP / TP 6.1.9 Operating faults WARNUNG! Warning! Severe injury may be caused by systems under pressure! If a malfunction occurs, hydraulic oil and water steam under high pressure can es- cape from the corresponding overpressure valves on the pump. This can result in severe injuries.
  • Page 399 6.1 High-pressure cleaner SP / TP 6.1.10 Winter operation (below 5 °C) Only switch on a system that is free of ice! This can be achieved by carefully draining the system after the last use (siehe “Draining the system” auf Seite 399). •...
  • Page 400 6.1 High-pressure cleaner SP / TP  Switch on the pump and actuate the spray lance until the system is completely drained, which will take 5 seconds at most.  Switch off the pump after the 5 seconds.  After draining the pump, close the ball valve (7) (Fig. 246) and the turn-lock fas- tener (8) (Fig.
  • Page 401 6.1 High-pressure cleaner SP / TP Fig. 247 Suction filter Caption for suction filter (Fig. 247) Pos. Description Pos. Description O-ring Ring Screen Housing O-rings Turn-lock fastener for draining 6.1.12.2 Functional testing Under normal operating conditions, the water pressure is at approx. 170 bar. The highest value is reached when the spray lance is closed.
  • Page 402 6.1 High-pressure cleaner SP / TP 6.1.12.3 Changing the oil in the pump Before changing the oil, you must have read and understood the instructions of the manufacturer “INTERPUMP GROUP s.P.a.” In particular, the required torque for the oil drain screw (3). Fig.
  • Page 403 6.1 High-pressure cleaner SP / TP 6.1.12.4 Recommended oil type for the pump The manufacturer recommends the following oil for a temperature range between -10 °C and 40 °C: SAE 15 W-40 Mineral -– ISO VG100DIN 51524 – Interpump X 9.9 The manufacturer recommends the following oil for a temperature range between 0 °C and 50 °C: SAE 80 W-910 - ISO VG220 DIN 51524...
  • Page 404 Do not dismantle the high-pressure pump! Improperly assembled high-pressure pumps can cause severe injuries on failure. If you cannot remedy a fault, please contact SCHWING customer service or send the high-pressure pump to the manufacturer for repairs. For proper repairs, special tools are required.
  • Page 405 6.1 High-pressure cleaner SP / TP 6.1.16 Troubleshooting (not exhaustive) HIGH-PRESSURE PUMP DOES NOT RUN: water case empty • Top up • Switch hydraulic directional valve Switching error • Acknowledge electrical control SPRAY PRESSURE FLUCTUATES: • Ball valve in the water suction line not switched properly insufficient water supply •...
  • Page 406 Caution! Do not dismantle the high-pressure pump. If you cannot remedy the fault with the help of the table above, please contact SCHWING customer service or send the high-pressure pump to the manufacturer for repairs Interpump Group VIA E. FERMI, 25 - 42049 S. ILARIO - REGGIO EMILfA (ITALY) TEL.
  • Page 407 6.2 Central lubrication system SP / TP (special equipment) Central lubrication system SP / TP (special equipment) SCHWING machines can be equipped with a central lubrication system as special equipment. The electrically powered piston pump and the reservoir are combined into a single unit (Fig.
  • Page 408 6.2 Central lubrication system SP / TP (special equipment) Fig. 250 Example of a progressive system 6.2.1 Safety Information Supply documentation. In addition to these operating instructions, the supplier documentation and any oth- er legal provisions and related regulations on accident prevention and environmen- tal protection must be observed and applied.
  • Page 409 6.2 Central lubrication system SP / TP (special equipment) 6.2.2.1 Filling with lubricant The machine is filled with lubricant via the cone-type lubricating nipple (1) (Fig. 251) using a conventional grease gun. In the event of a defect in the piston pump, the cone-type lubricating nipple (2) (Fig.
  • Page 410 6.2 Central lubrication system SP / TP (special equipment) 6.2.2.3 Vent system  Fill reservoir with lubricant  Remove main line at position (4) (Fig. 252)  Let the pump run until lubricant emerges from position (4) (Fig. 252) without any air bubbles ...
  • Page 411 Check the supplied bearing points (visual inspection) daily There must be clearly visible traces of lubricant.  If any faults are detected during the check, have SCHWING’s customer service repair the system immediately in order to prevent any consequential damages caused by a lack of lubrication.
  • Page 412 6.2 Central lubrication system SP / TP (special equipment) Zentralschmieranlage-SP-TP-EN.fm - 01.00.00...
  • Page 413 The “VarioPressure” accessory can be used to adjust the pumping pressure of the SCHWING pump at any time to the situation at hand, thus ensuring that no critical pumping pressure builds up in the pumping pipes connected to the SCHWING pump that could exceed the bursting pressure of your tubes and lines.
  • Page 414 6.3 VarioPressure 6.3.3 Manual setting For manual setting, the maximum delivery pressure is set directly on the machine via the hydraulic block (Fig. 253). This solution is mainly used for stationary con- crete pumps. Fig. 253 6.3.3.1 Delivery condition When delivered, the ball valve (1) (Fig. 253) is situated in an upright position (=max.
  • Page 415 10. Move the ball valves on the pump kit of your SCHWING pump back to the “op- erating position”. To do this, carefully follow the descriptions in the “Pressure control”...
  • Page 416 6.3 VarioPressure Fig. 254 Ball valve pressure control SP 1800/2800 Fig. 255 Ball valve pressure control truck-mounted concrete pumps VarioPressure-EN.fm - 01.07.00...
  • Page 417 6.3 VarioPressure Fig. 256 Pressure control signs and labels Fig. 257 Fig. 258 VarioPressure TP100 VarioPressure-EN.fm - 01.07.00...
  • Page 418 6.3 VarioPressure Fig. 259 VarioPressure SP 1800/2800 Caption for (Fig. 257) / (Fig. 258) / (Fig. 259) Pos. Designation Pos. Designation Ball valve CP pressure gauge Hand-wheel Sign; ball valve position Sign; hydraulic pressure to Hand-wheel key delivery pressure conversion factor VarioPressure-EN.fm - 01.07.00...
  • Page 419 6.3 VarioPressure Fig. 261 SP 1800/2800 (98449899) Fig. 260 TP 100 (98449338+98449340) Fig. 263 SP 7500/9500 (98449901) Fig. 262 SP 3800/7000/9000 (98449900) Table 7 Scales for pumping pressure with VarioPressure VarioPressure-EN.fm - 01.07.00...
  • Page 420 6.3 VarioPressure 6.3.5 Electronic configuration in control system For the electronic configuration of VarioPressure, the required value for maximum delivery pressure is set in the control system of your machine. The VarioPressure function is switched on by default To interrupt the VarioPressure function, you can switch it on and off on the remote control using a switch combination.
  • Page 421 6.3 VarioPressure Fig. 267 Use the down arrow key to Fig. 268 Press ENTER to access the access the "Parameters" "Silent Diagnosis" menu menu Fig. 269 Use the down arrow key to Fig. 270 Press ENTER to access the navigate to the setting mask VarioPressure menu Save the set value by pressing the...
  • Page 422 6.3 VarioPressure 6.3.5.2 How to interrupt VarioPressure Fig. 272 Interrupt VarioPressure on the SC 30 Once you have set the required value for VarioPressure, you can activate and de- activate VarioPressure on your remote control. To do so, proceed as follows, observing the sequence: ...
  • Page 423 6.3 VarioPressure 6.3.6 Electronic setting on the SC50 remote control (optional) For electronic setting of VarioPressure on the SC50 remote control, the value for maximum delivery pressure is set using the remote control of the machine. The set- ting of the delivery pressure with the remote control is only possible in the REMOTE operating mode.
  • Page 424 6.3 VarioPressure Fig. 274 VarioPressure screen  Use the pumping pressure -/+ keys to set the required pumping pressure be- tween 10 bar and 70 bar.  Activate and deactivate the VarioPressure using the VarioPressure button. The red and white area in the indicator shows that the VarioPressure is activated and the value to which the pumping pressure is limited.
  • Page 425 7 Appendix Trennblatt_Kapitel-Anhang-EN.fm...
  • Page 426 7 Appendix Trennblatt_Kapitel-Anhang-EN.fm - 01.00.00...
  • Page 427 Are you already using our information service? - 5 minutes that are worth it! Dear Customer, With the purchase of your SCHWING machine, you have acquired a high quality product. Of course, we are constantly working to improve our products and would like to in- form you when new findings become available.
  • Page 428 7.1 Information service Please complete in block letters: Customer no.: Address: Country: Contact person: Telephone: Fax: Email: Machine type: Machine no.: Infodienst-EN.fm - 01.00.02...
  • Page 429 7.2 Always nearby Always nearby HERNE SCHWING GmbH Service Centre Heerstraße 9-27 44653 Herne Telephone: 02325/9870 ET Sales: 02325/987-352 Customer Service: 02325/987-231/232 Fax: 02325/987-470 Email: parts@schwing.de Contact: Mr Beiersdorf HAMBURG BERLIN SCHWING Stetter SCHWING Stetter Service Branch Service Support Centre...
  • Page 430 7.2 Always nearby DRESDEN LORSCH SCHWING Stetter Eberhard Becker & Partner GmbH Service Branch Hamburger Ring 13a In der Wolfshecke 5 01665 Klipphausen 64653 Lorsch Telephone: 035204/47888 Telephone: 06251/9648-0 Fax: 035204/47887 Fax: 06251/9648-20 Email: Dresden@schwing.de Email: Lorsch@schwing.de Contact: Mr Rahming...
  • Page 431 7.3 Always Ready Always Ready Schwing / Stetter GmbH 0049 - 2325 - 987 0 info@schwing.de Heerstr. 9 - 27 D - 44653 Herne 0049 - 2325 - 72922 Deutschland Schwing Hydraulik-Elektronik 0049 - 2325 - 987 0 info@schwing.de GmbH Dorstener Str.
  • Page 432 0032 - 3766 7666 reginald.judy@skyne Værkstedsvej 23 t.be 9100 Sint Niklaas 0032 - 3766 2958 Royaume de Belgique Schwing Equipamentos Ind. 0055 - 11 - 4486 8500 info@schwing- Ltda. stetter.com.br Rod. Fernão Dias, Km 56 0055 - 11 - 4486 1344 Bairro terra Preta Rep.
  • Page 433 12, Rue des Tuileries stetter.fr B.P.44 0033 - 3 - 8833 9955 République française 67460 Souffelweyersheim Schwing / Stetter Hellas S. A. 0030 - 210 - 5155 505 m.karvouni@schwing- G. Margaritis - G. Karvounis stetter.gr Leoforos Athinon 169 0030 - 210 - 5150 034 Ellinikí...
  • Page 434 PVT. LTD., rindia.com F71, F72 SIPCOT Industrial Estate, Republic of India Irungattukottai Sriperumpudur, Kanchipuram District 602117, Tamil Nadu, India Schwing / Stetter (India) PVT. 0091 - 22 - 256 24862 $SSIPL- Ltd. - /863 Mumbai$@Schwing.d 620 / 621, Nirmal Lifestyle Corporate...
  • Page 435 7.3 Always Ready Thor Ltd. 00354 - 681 500 P.O. Box 1194 Reykjavik Republik Island M. Bar Maintenance Ltd. 00972 - 4 - 6378595 info@mbar.co.il P.O. Box 3055 20 Harduf Hanechalim Street 00972 - 4 - 6378667 Medinat Jisra'el 38900 Caesarea Farradj &...
  • Page 436 7.3 Always Ready Comat S.A. 00352 - 496 121 Zone Industrielle 10, Rue de bruyeres 00352 - 402 274 1274 Howald Grand-Duché de Luxembourg UMW Equipment Sdn Bhd 0060 - 3 - 5519 1911 ong.keng.toh@umw.co Jalan Utas 15/7 m.my P.O. Box 7052 0060 - 3 - 5510 5517 Malaysia 40915 Shah Alam, Sengalor Darul...
  • Page 437 7.3 Always Ready Schwing / Stetter Baumachinen 0043 - 16 16 73 13 n.stengl@schwing- Ges.m.b.H stetter.at Heizwerkstraße 6 0043 - 16 16 70 66 1230 Wien Republik Österreich Schwing GmbH 0043 - 43 52 28 12 Friedrich-Wilh. Schwing Str. 1 9431 St.
  • Page 438 108 International Road 0065 - 6265 8494 Singapore 629 173 Republic of Singapore Schwing / Stetter Iberica S. L. 0034 - 91 - 6162 700 info@schwing.es C.I.F.: B-84832997 C/Nardos, n° 15, Polígono Industrial 0034 - 91 - 6162 753 El Molino Reino de España...
  • Page 439 495 Krungthep Kreetha Road Huamark. Bangapi Bangkok 10240 0066 - 2 - 7316824 Ratcha Anachak Thai servis@schwing.cz Schwing / Stetter Ostrava s.r.o. 00420 - 596 - 746 780 Moravska 1215/6 CZ-70030 Ostrava-Hrabuvka Česká republika 00420 - 596 - 746 783 info@gurisendustri.com...
  • Page 440 No. 14 lot 10B, Trung yen New Vietnam 0084 - 4 - 3783 4256 Residential Area Trung Hoa, Cau giay Hanoi Schwing Shanghai Machinery 0086 - 21 - 5764 5855 Co.Ltd. 5 Xin Xiao Road 0086 - 21 - 5764 5577 Xin Qiao Industrial Zone...
  • Page 441 This chapter serves as the safety manual and contains basic safety instructions re- garding the operation of pumping, spraying and spreading machinery for concrete. SCHWING also provides the safety manual for download. To do so, scan the QR code. The safety manual is prepared jointly by leading manufacturers of concrete pump- ing and spreading machines under the auspices of the VDMA (Verband Deutscher Maschinen- und Anlagenbau/Mechanical Engineering Industry Association).
  • Page 442 7.4 VDMA safety manual Vorwort-Sicherheitshandbuch-VDMA-EN.fm - 01.00.02...
  • Page 443 Safety Manual Concrete delivery and placing machines 09/2020 Rev18 en...
  • Page 444 Verband Deutscher Maschinen- und Putzmeister Concrete Pumps GmbH Anlagenbau e. V. (VDMA) Max–Eyth–Straße 10 Baumaschinen und Baustoffanlagen 72631 Aichtal Lyoner Straße 18 60528 Frankfurt SCHWING GmbH Heerstraße 9–27 Telefon +49 69 6603-1262 44653 Herne +49 69 6603-2262 E-Mail bub@vdma.org Liebherr–Mischtechnik GmbH Internet bub.vdma.org...
  • Page 445 Table of contents Concrete delivery and placing machines . . . Table of contents Changes in this revision ............Foreword ................. Terms, definitions, requirements ..........Definition of terms ......................1.1.1 Machine ........................... 1.1.2 Concrete pump ........................ 1.1.3 Arm assembly ......................... 1.1.4 Placing boom ........................
  • Page 446: Table Of Contents

    Table of contents Concrete delivery and placing machines . . . 1.3.11 Changes to the machine ....................Exclusion of liability ......................Personnel ........................1.5.1 Requirements ........................1.5.2 Qualifications ........................1.5.3 Responsibility of the machine operator ................Operating Instructions, operating procedures and other regulations ......1.6.1 Operating Instructions .....................
  • Page 447 Table of contents Concrete delivery and placing machines . . . 2.5.3 Guiding the end hose ergonomically ................2.5.4 Connecting drills ......................2.5.5 Procedure in storms ......................2.5.6 Concreting in cold weather ....................Delivery line systems ...................... 2.6.1 Suitable delivery lines ..................... 2.6.2 Securing delivery lines ....................
  • Page 448 Table of contents Concrete delivery and placing machines . . . 3.8.1 General ........................... 3.8.2 Replacing hydraulic hoses ....................Noise emissions ......................3.10 Exhaust fumes ........................ 3.11 Functional fluids ......................3.12 Disposal of the machine ....................Index ..................09/2020 Rev18 en...
  • Page 449 Safety Manual Concrete delivery and placing machines Changes in this revision ● Earthing: Wording amended (Danger due to high voltage P. 35) ● Stationary machines: Marking of lifting points (Loading and transporting P. 39) ● Corner bearing loads: Note added (Corner bearing loads P.
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  • Page 451 Safety Manual Concrete delivery and placing machines Foreword This Safety Manual contains important information on how to operate concrete delivery and placing machines safely, properly and economi‐ cally. Observing these instructions helps to avoid danger, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.
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  • Page 453 Safety Manual Concrete delivery and placing machines Terms, definitions, requirements 09/2020 Rev18 en...
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  • Page 455 Safety Manual Concrete delivery and placing machines Definition of terms The terms used in this Safety Manual are explained below, along with descriptions of the requirements placed on specific groups of people. 1.1.1 Machine For the purposes of this Safety Manual, concrete delivery and placing machines are defined as: ●...
  • Page 456 Safety Manual Concrete delivery and placing machines 1.1.6 Truck mixer For the purposes of this Safety Manual, truck mixers are defined as vehicles with mixing equipment for transporting concrete. 1.1.7 Delivery line systems For the purposes of this Safety Manual, delivery line systems are de‐ fined as self-contained pipes or hoses in which concrete is pumped from the concrete pump to the placement site.
  • Page 457 Safety Manual Concrete delivery and placing machines 1.1.13 Signaller and other auxiliary personnel Persons instructed by the site management to help the machine oper‐ ator in his work if the latter is unable to observe all areas of operation and danger zones. Signallers must be able to independently evaluate all dangerous situations which may occur when working with a con‐...
  • Page 458 Safety Manual Concrete delivery and placing machines 1.1.19 Place of work, working area, danger zone 1.1.19.1 Mobile machines Figure 1: Example 1.1.19.2 Stationary machines Figure 2: Example 09/2020 Rev18 en...
  • Page 459 Safety Manual Concrete delivery and placing machines Pos. Designation Explanation Place of work (during Machine operator In normal operation, with the remote con‐ pumping operations) trol Hoseman At the end hose in the danger zone Signaller In the machine operator's range of vision Auxiliary personnel As machine operators of the manual placing system...
  • Page 460 Safety Manual Concrete delivery and placing machines 1.1.19.3 Place of work The place of work is the area in which people must remain in order to carry out the work. Place of work – machine operator The machine operator's place of work is with the remote control when the pump is in operation.
  • Page 461 Safety Manual Concrete delivery and placing machines Impermissible working area Because of their high manoeuvrability, some placing booms can also be shifted into positions for which they are not designed. This may overload or damage the placing boom. Placing booms must therefore (Impermissible only be moved within the permitted working area.
  • Page 462 Safety Manual Concrete delivery and placing machines Machine All the time the vehicle is in operation, there is a risk of injury on and below the machine from moving parts and bursting delivery lines or hydraulic hoses, as well as a risk of falling on slippery surfaces or steps.
  • Page 463 Safety Manual Concrete delivery and placing machines You must also observe the Operating Instructions and comply with the intervals and conditions for inspections (particularly retesting) and maintenance work in order to operate the machine within the limits of its proper use. 1.2.1 Retesting (safety inspection) After initial commissioning of the machine, the operational safety of...
  • Page 464 Safety Manual Concrete delivery and placing machines Inspect after every 500 operating hours or 1 year, whichever is soonest. The interval is repeated after every retest. ● Machines more than 10 years old: Inspect after every 250 operating hours or 1 year, whichever is soonest.
  • Page 465 Safety Manual Concrete delivery and placing machines 1.3.2 Lifting loads The placing boom must never be used for lifting loads. 1.3.3 Removing obstacles The placing boom must not be used under any circumstances to re‐ move obstacles. This would overload the placing boom, causing dam‐ age and endangering people.
  • Page 466 Safety Manual Concrete delivery and placing machines 1.3.6 Impermissible end hose There must be no couplings, spouts, discharge stops or other items fixed to the outlet end of the end hose unless they are approved by the manufacturer. 1.3.7 Impermissible working area During pumping operations, the end hose must not be moved back‐...
  • Page 467: Changes To The Machine

    Safety Manual Concrete delivery and placing machines In addition to this, additional impermissible working areas exist, de‐ pending on the machine model and manufacturer, which are descri‐ bed in the Operating Instructions. 1.3.8 Climbing the placing boom It is prohibited to climb the placing boom, to stand on top of it or to misuse it as a working platform or climbing aid.
  • Page 468: Exclusion Of Liability

    Safety Manual Concrete delivery and placing machines Exclusion of liability Where the manufacturer's delivery conditions are agreed, liability will be as described in the provisions there. The manufacturer is not liable for damage in cases specified there. Unless the responsibility of the manufacturer, the warranty will be in‐ validated in the following situations in particular: ●...
  • Page 469: Qualifications

    Safety Manual Concrete delivery and placing machines ● They must have demonstrated their competence to the operator. ● They can be expected to reliably execute the tasks with which they are charged. The operating personnel must not wear loose garments or jewellery, including rings.
  • Page 470: Operating Procedures

    Safety Manual Concrete delivery and placing machines As the operator, you must always make sure that the Operating In‐ structions are available. The Operating Instructions and check book must always be kept to hand at the site of use of the machine (in the tool compartment or container provided for this purpose).
  • Page 471: Other Regulations

    Safety Manual Concrete delivery and placing machines 1.6.3 Other regulations The current regulations for concrete delivery and placing machines as issued by: ● The legal authorities in your country ● The national supervisory bodies ● The responsible commercial liability insurance company. Personal protective equipment To reduce the risk to life and limb, personal protective equipment must be used by the operating personnel whenever necessary or re‐...
  • Page 472 Safety Manual Concrete delivery and placing machines Symbol Meaning Hearing protectors Hearing protectors protect you against the noise generated in the vicinity of the machine when you are standing close to it. (DIN EN 352-1:2003; Hearing protectors - General requirements - Part 1: Earmuffs or DIN EN 352-3:2003;...
  • Page 473 Safety Manual Concrete delivery and placing machines Symbol Meaning Safety harness When working at heights, use climbing aids and platforms that are intended for this pur‐ pose and comply with the safety regulations or wear a safety harness. Relevant national regulations must be observed.
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  • Page 475: Setting Up And Working With The Machine

    Safety Manual Concrete delivery and placing machines Setting up and working with the machine 09/2020 Rev18 en...
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  • Page 477: Before Working With The Machine

    Safety Manual Concrete delivery and placing machines Before working with the machine 2.1.1 Checking that the machine is ready for operation As machine operator, it is your responsibility to check the machine for external damage and defects before any use of the machine. You must immediately report any changes (including changes in the work‐...
  • Page 478: Discharge Voltage Pattern

    Safety Manual Concrete delivery and placing machines 2.2.2 Discharge voltage pattern In the event of a flash over, what is known as a “discharge voltage pattern” is formed in the vicinity of the machine. The voltage decrea‐ ses from the inside to the outside in this discharge voltage pattern. If you step inside this discharge voltage pattern, you will bridge different potentials.
  • Page 479: Highvoltage Warning Devices

    Safety Manual Concrete delivery and placing machines You must stand as close as possible to the unfolded placing boom if you wish to correctly estimate the movements of the boom and, above all, the clearance between the placing boom and obstacles or high-voltage lines.
  • Page 480: Earthing In The Event Of Electrostatic Charging

    Safety Manual Concrete delivery and placing machines If your machine comes into contact with high-voltage lines: ● Warn people standing outside the area not to approach or touch the machine. ● Have the power switched off. ● Only leave the machine once you are sure that the line you have touched or damaged has been deenergised.
  • Page 481: Stationary Machines

    Safety Manual Concrete delivery and placing machines Stationary machines 2.3.1 Setup site Stationary machines are generally used on a construction site for a lengthy period. For this reason, site management should prepare the setup site carefully. Site management must deliver the necessary documents in good time in order to be able to prepare the founda‐...
  • Page 482: Mobile Machines

    Safety Manual Concrete delivery and placing machines The machine/components must be properly secured during transport. Many lifting points fitted to the machine are provided for assembly purposes only. They are not suitable for lifting the complete machine. The lifting points for lifting the entire machine are specially marked. The transport vehicle and machine must be marked to conform with the road traffic regulations in the country concerned if they are to use the public highway.
  • Page 483: Supporting Ground

    Safety Manual Concrete delivery and placing machines You must also check the approach route to the site where the ma‐ chine will be set up. If you are unsure whether the approach route is suitable, prepare the route before work is started. It is especially nec‐ essary to walk the approach route once in darkness and at dusk or dawn.
  • Page 484: Corner Bearing Loads

    Safety Manual Concrete delivery and placing machines Factors which reduce stability include, for instance: ● Modifications to the ground conditions, particularly caused by rain water or the thawing of frozen ground ● The support sinking on one side ● Fluid losses through leaks in the support hydraulics 2.4.3 Corner bearing loads The corner bearing load is stated on each support leg.
  • Page 485: Supports

    Safety Manual Concrete delivery and placing machines 2.4.4 Supports The placing boom must not be raised until the machine has been sup‐ ported in accordance with the Operating Instructions. There is other‐ wise a risk of the machine toppling over. Swing out and telescope the support legs to their end positions in se‐...
  • Page 486: Driving

    Safety Manual Concrete delivery and placing machines Check stability regularly during operation. The elastic distortions to the machine frame occasionally occurring under extreme positions of the placing boom (one support foot lifts from the ground) must be compensated for by resetting the support cylinders until all support feet are firmly placed on the ground.
  • Page 487: Towing

    Safety Manual Concrete delivery and placing machines boom. Be aware of the height of the truck. Only drive over arches, bridges or other supporting structures if their load-bearing capacity is sufficient. Do not drive across uphill or downhill gradients. Be aware of the ele‐ vated position of the truck's centre of gravity when travelling on a slope and on ascending or descending routes.
  • Page 488: Placing Booms

    Safety Manual Concrete delivery and placing machines The lifting points for lifting the entire machine are specially marked. Use only appropriate means of transport and lifting equipment of ade‐ quate load-bearing capacity. Lifting equipment, lifting tackle, support trestles and other auxiliary equipment must be reliable and safe in op‐ eration.
  • Page 489 Safety Manual Concrete delivery and placing machines The range of a radio remote control is long enough for the machine to receive control commands (e.g. from a great distance, from inside en‐ closed spaces) even without visual contact. If there is no visual con‐ tact, for example, because you are changing workplace, you must switch off the remote control.
  • Page 490: End Hose

    Safety Manual Concrete delivery and placing machines the placing boom. Uncontrolled movements may result from the sud‐ den, violent release of the placing boom after collisions. This may al‐ so result in (possibly fatal) personal injury. The manufacturer has indicated such impermissible working areas by the use of warning signs and information plates on the machine and appropriate notes in the Operating Instructions.
  • Page 491: Guiding The End Hose Ergonomically

    Safety Manual Concrete delivery and placing machines The concrete may also spray from the end hose due to the presence of air in the delivery line. To prevent this from occurring, the hopper must be filled with concrete at least as far as the agitator shaft so that no air can be sucked in.
  • Page 492: Concreting In Cold Weather

    Safety Manual Concrete delivery and placing machines Lightning strikes pose a risk of death. The machine and the surround‐ ing area will be charged with electricity. Earthing the machine does not reduce this risk. For this reason, you should fold in the placing boom if there is a risk of lightning strike.
  • Page 493: Securing Delivery Lines

    Safety Manual Concrete delivery and placing machines 2.6.2 Securing delivery lines Delivery lines, delivery hoses, end hoses and couplings must be se‐ curely fastened and secured to prevent spontaneous opening. 2.6.3 Leak tightness and blockages Regularly force water through the delivery line under operating pres‐ sure to check that the system is watertight.
  • Page 494: Opening Delivery Lines

    Safety Manual Concrete delivery and placing machines 2.6.4 Opening delivery lines Delivery lines must not be opened or tapped off while they are pres‐ surised. Concrete exiting under pressure can cause injury. The con‐ crete column must be depressurised by reverse pumping before the delivery line is opened.
  • Page 495: Devices For Shutting Off, Diverting And Cleaning

    Safety Manual Concrete delivery and placing machines 2.6.8 Devices for shutting off, diverting and cleaning During operation, there is a risk of being crushed and of injury by shearing. Hydraulically driven devices are generally supplied with power by the hydraulic system of a machine. For this reason, there must always be a line of sight between the devices and the machine fitted with the control unit.
  • Page 496: Remote Control

    Safety Manual Concrete delivery and placing machines 2.7.3 Remote control You must always carry the remote control on your person when the machine is ready for operation. Only in this way can it be guaranteed that you can press the EMERGENCY STOP in the event of an BUTTON emergency situation.
  • Page 497: Constant Observation Of The Machine

    Safety Manual Concrete delivery and placing machines Do not insert any objects (shovel handle, trowel, etc.) into moving ma‐ chine components. Such objects could become trapped and dragged into the machine. They might then hit you or be torn from your hands and cause you injury.
  • Page 498: Cleaning Agents

    Safety Manual Concrete delivery and placing machines The preferred methods for cleaning the delivery line are reverse pumping or forced cleaning with water. The agitator must be switched on during reverse pumping. Otherwise, the concrete flowing back into the hopper can bend the agitator shaft. Use a catch basket, pipe cleaning head and wash-out ball for forced cleaning to prevent any water from flowing into the formwork.
  • Page 499: Cleaning With Compressed Air

    Safety Manual Concrete delivery and placing machines manufacturer's instructions regarding use and safe handling. Wear protective clothing. Always rinse off cleaning agent thoroughly with clean water; do not allow puddles to form. Do not use sea water or other water containing salt for cleaning pur‐ poses.
  • Page 500 Safety Manual Concrete delivery and placing machines ● A catch basket must be fastened at the end of the delivery line and a wash-out adaptor must be fitted on the head of the delivery line. The catch basket and washout adaptor must fit the delivery line system.
  • Page 501: Protection Against Water

    Safety Manual Concrete delivery and placing machines 2.8.4 Protection against water Water spraying on the machine from random directions has no dam‐ aging effect. The electrical system is protected against spray water, but is not waterproof. You must close/seal all openings into which water/steam/cleaning agent must not penetrate for safety or functional reasons before cleaning the machine with water or a steam jet (high-pressure clean‐...
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  • Page 503: Maintenance And Special Work

    Safety Manual Concrete delivery and placing machines Maintenance and special work 09/2020 Rev18 en...
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  • Page 505: Requirements For Special Work

    Safety Manual Concrete delivery and placing machines Requirements for special work As the operator, it is your responsibility to provide all the necessary information to the personnel involved before special work or mainte‐ nance work is carried out. Someone should be nominated as the per‐ son responsible for this.
  • Page 506: Welding

    Safety Manual Concrete delivery and placing machines Work on chassis, braking and steering systems must only be carried out by qualified personnel trained for such work. Clean any traces of oil, fuel or preservatives from the machine, espe‐ cially connections and threaded unions, before carrying out mainte‐ nance or repair work.
  • Page 507: Working On The Placing Boom

    Safety Manual Concrete delivery and placing machines Electronic components can be destroyed by stray voltage during arc welding processes. For this reason: ● Disconnect the remote control cable from the control console. ● Disconnect all cables leading to the receiver of the radio remote control system.
  • Page 508: Safetyrelevant Components

    Safety Manual Concrete delivery and placing machines Safetyrelevant components Work on safety-relevant components requires particular specialist knowledge. The following activities in particular must only be carried out by quali‐ fied personnel that have been authorised by the manufacturer: ● Repairing, replacing or adjusting safety-relevant components and adjustable devices (pressure limiting valves, potentiometers, fluid flow limiters, hydraulic cylinders, sensors, etc.) ●...
  • Page 509: Electrical Power

    Safety Manual Concrete delivery and placing machines Electrical power 3.7.1 General Work on electrical systems or operating equipment must only be car‐ ried out by qualified personnel. For further information on machines (Power at that are operated using the site power supply, see also the the construction site P.
  • Page 510: Power At The Construction Site

    Safety Manual Concrete delivery and placing machines IP 54 means: ● Complete protection against contact with live components or inter‐ nal moving parts. Protection against damaging dust deposits. ● Water spraying on the equipment from random directions must not have a damaging effect. Use only original fuses with the specified voltage rating.
  • Page 511 Safety Manual Concrete delivery and placing machines Injection through the skin is a major medical emergency. In the event of injuries caused by pressurised fluid, inform the company medical officer and call a medical specialist immediately. This also applies for injuries which may seem only slight.
  • Page 512: Replacing Hydraulic Hoses

    Safety Manual Concrete delivery and placing machines Open vent valves very carefully until hydraulic fluid starts to escape. You should on no account open vent valves further than necessary or go so far as to remove them. Damaged hydraulic lines must be replaced rather than repaired. You must replace damaged or saturated hydraulic hoses immediately.
  • Page 513: Functional Fluids

    Safety Manual Concrete delivery and placing machines Wear personal protective clothing and equipment for all work in which exhaust gases or particles of building material can enter the body through the respiratory passages. Comply with the information issued by the manufacturer of the building material. 3.11 Functional fluids When handling oils, greases and other functional fluids, observe the...
  • Page 514: Disposal Of The Machine

    Safety Manual Concrete delivery and placing machines Have used operating equipment and functional fluids such as filters, batteries, oil, brake fluid, etc. disposed of properly. Used cleaning rags should also be disposed of properly. 3.12 Disposal of the machine To dispose of the machine, you must proceed in accordance with all points in the disposal regulations which apply in your country.
  • Page 515: Index

    Safety Manual Concrete delivery and placing machines Index In this chapter, you will find the most important keywords and the number(s) of the page(s) on which they appear. This index of key words is in alphabetical order.  P. 19 Danger zone  P.
  • Page 516 Safety Manual Concrete delivery and placing machines  P. 25  P. 52 Highpressure delivery Opening delivery lines  P. 35  P. 27 High-voltage lines Operating Instructions  P. 37 Highvoltage warning devices Operating Instructions, operating procedures and other  P. 27 regulations  P. 20 Hopper  P.
  • Page 517 Safety Manual Concrete delivery and placing machines  P. 23 Removing obstacles  P. 35  P. 46 Rendering the machine ready for operation Unfold placing boom  P. 70 Replacing hydraulic hoses  P. 26 Requirements  P. 64 Welding  P. 63 Requirements for special work  P.
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