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Schwing SPTO 1000 Operation Manual

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Operation Manual
SPTO 1000/1250
Part# 98470331
Revision: 2.1
Date: 01/20/25
5900 Centerville Road
St. Paul, MN 55127
1-888-SCHWING (724-9464)
www.schwing.com

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  • Page 1 Operation Manual SPTO 1000/1250 Part# 98470331 Revision: 2.1 Date: 01/20/25 5900 Centerville Road St. Paul, MN 55127 1-888-SCHWING (724-9464) www.schwing.com...
  • Page 2 CALIFORNIA PROPOSITION 65 WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer, birth defects, and other reproductive harm. Always start and operate the engine in a well-ventilated area. If in an enclosed area, vent the exhaust to the outside.
  • Page 3 Operation Manual SPTO 1000/1250 Part# 98470331 Revision: 2.1 Date: 01/20/25 Copyright © 2025, Schwing America, Inc. All rights reserved.
  • Page 5 Introduction ..........9 Operator Panel (Inside) .........39 Manufacturer’s Statement ........ 11 Hopper ............39 Concrete Pump Nomenclature ......12 SCT II (SCHWING Control Technology) ...40 ID Tags .............12 HMI (Human Machine Interface) ......41 Unit Built-To Tag ..........13 Pendant Remote..........41 How to Order Missing Tags ......13 Pendant Remote Buttons ......42...
  • Page 6 Adjusting the Stroke Limiter - Manually ..86 Check Gearbox Oil Level ......103 Quarterly Maintenance ........103 Maintenance ..........89 Check the Accumulator Pre-Charge ....103 Hoses and Fittings ..........91 Semi-Annual Maintenance ......104 Torque Specifications ........91 Change Hydraulic Oil (Seasonal Change) ...104 SPTO 1000/1250 Operation Manual...
  • Page 7 Output Charts ..........129 Using a Nomograph........135 The Quadrants ..........137 Glossary of Terms ...........142 Additional Reading Material......146 Alphabetical Index ......... 147 Short Instructions ........151 Preparing for the Job ........153 Pumping the Job..........153 Stroke Limiter ..........154 Soft Switch ...........155 SPTO 1000/1250 Operation Manual...

  • Page 9: Table Of Contents

    Introduction Manufacturer’s Statement ......11 Concrete Pump Nomenclature ......12 ID Tags .............12 Unit Built-To Tag ..........13 How to Order Missing Tags ......13 SPTO 1000/1250 Operation Manual...

  • Page 11: Manufacturer's Statement

    Manufacturer’s Statement Read and understand this manual before operating, repairing, or adjusting your SCHWING concrete pump. SCHWING America is a member of the SCHWING Individuals who operate and maintain it must be trained Group, a worldwide designer, manufacturer, and and know the equipment. Death or severe injury can distributor of premium concrete production and handling occur if this equipment is misused or poorly maintained.

  • Page 12: How To Reach Us

    The complete model number of a SCHWING If you encounter a circumstance that is not covered by concrete pump is designated by the following this manual, the SCHWING Service Center is more than code: happy to assist you with all of your parts and service SPTO 1000 needs.

  • Page 13: Unit Built-To Tag

    If an ID tag is missing or has been removed, a new tag to the hydraulic and electrical schematics used can be ordered through the SCHWING Service Center. manufacture this machine (Figure 2). The tag provides Simply provide the concrete pump serial number, and a quick reference numbers that can be used when new ID tag will be created.

  • Page 15: Specifications

    Specifications Concrete Pump Specifications......17 SPTO 1000 ............17 SPTO 1250 ............18 Assembled Unit Specifications .....19 Hydraulic Pressure Specifications ....19 Optional Equipment ........19 SPTO 1000/1250 Operation Manual...

  • Page 17: Concrete Pump Specifications

    30.5 m Max RPM of the hydraulic pumps is calculated while the pump is under a full load. Depending on the unit, it is acceptable for the max RPM to vary slightly from the published estimate. SPTO 1000/1250 Operation Manual...

  • Page 18: Spto 1250

    30.5 m Max RPM of the hydraulic pumps is calculated while the pump is under a full load. Depending on the unit, it is acceptable for the max RPM to vary slightly from the published estimate. SPTO 1000/1250 Operation Manual...

  • Page 19: Assembled Unit Specifications

    11 ft Water Tank Capacity 150 gal 150 gal Hydraulic Pressure Specifications Concrete Pump Pressure SPTO 1000 - Long Rock 300 bar (4350 psi) SPTO 1250 - Long Rock 330 bar (4785 psi) Agitator 125 bar (1812 psi) Accumulator Dump Valve...
  • Page 21 Safety Safety Alert Symbols ........23 Safety Manual ..........24 How to Order Additional Safety Manuals ..24 Warning Labels (Decals) ........24 SPTO 1000/1250 Operation Manual...

  • Page 23: Safety Alert Symbols

    All persons working near the concrete pump must be able to recognize hazardous situations. They must know how to avoid these situations and how to react quickly and appropriately whenever hazardous situations arise. SPTO 1000/1250 Operation Manual...
  • Page 24 Part Number Safety Manual, English 30327535 Safety Manual, Spanish 30381024 Co-worker Safety, laminated, English 30381022 Co-worker Safety, Spanish 30381027 Small line Safety Manual, English 30381680 Small line Safety Manual, Spanish 30381841 Figure 2 Sample Decal Location Guide SPTO 1000/1250 Operation Manual...

  • Page 25: Safety Manual

    SAFETY MANUAL A GUIDE FOR THE PREVENTION OF ACCIDENTS WHEN DRIVING, OPERATING, CLEANING, AND MAINTAINING CONCRETE LINE PUMPS AND RELATED EQUIPMENT Introduction must keep your mind on the job if knowledge of the rules is going to keep you and your coworkers alive Safety is one of the major concerns of every person and well.
  • Page 26 SAFETY MANUAL Table of Contents Introduction ........iii General Rules .
  • Page 27 SAFETY MANUAL GENERAL RULES General Rules Table of Contents Before You Leave The Yard ........2 Safety Alert Symbol And Signal Word Explanation .

  • Page 28: General Rules

    SAFETY MANUAL GENERAL RULES I. Before You Leave The Yard Safety Alert Symbol And Signal Word Explanation The triangle with the exclamation point inside is used to alert you to an important safety point, and is called a Safety Alert Symbol . One of the following color-coded signal words will appear after the safety alert symbol: DANGER WARNING...
  • Page 29 SAFETY MANUAL GENERAL RULES • breathing mask whenever there is cement dust in the air; • rubber gloves during cleanout or if you’ll be touching wet concrete; • rubber boots anytime you have to stand in concrete; • full face-shield when shotcreting, or any time material is rebounding. HARD HAT HEARING PROTECTION...

  • Page 30: What To Check Before You Leave The Yard

    SAFETY MANUAL GENERAL RULES Arrive to work on time. Accidents can be caused by hurrying through procedures. WARNING Never go to work on a construction site or work on, around or near a piece of machinery when under the influence of drugs or alcohol. Beware of prescription medications or over the counter drugs, many of which have spe- cific warnings about operating machinery after taking the medication (Figure 3).
  • Page 31 SAFETY MANUAL GENERAL RULES • A blowout head with properly sized air discharge regulator valve and separate water/air inlet. The two openings should be spaced apart far enough that a blowout ball could not cover both openings at once. • A go-devil , or a hard sponge ball. Regardless of which is used, it must fit into the pipeline tight enough that air cannot escape ahead of it.
  • Page 32 SAFETY MANUAL GENERAL RULES WARNING The operator is responsible for checking that all safety equip- ment and guards are in place and in good condition. If found to be missing, incomplete, or damaged, work must not begin until the situation has been made safe.
  • Page 33 SAFETY MANUAL GENERAL RULES WARNING If applicable, be sure that outriggers are pinned and locked 3.14 before traveling. If the locking device is damaged or worn, it should be repaired immediately and the unit must not be driven until the outriggers can be posi- tively locked against accidental opening.

  • Page 34: Safety Rules For Towing Trailer-Mounted Concrete Pumps

    SAFETY MANUAL GENERAL RULES 4. Safety Rules For Towing Trailer-Mounted Concrete Pumps WARNING Be sure the towing vehicle is sized appropriately for the trailer. It must be heavy enough and have enough braking ability to maintain control at highway speeds and to stop—even on hills. If the trailer is heavier than the towing vehicle, braking distances will be greatly increased (Figure 7).

  • Page 35: On The Job Site - Safety Rules For Job Setup

    SAFETY MANUAL GENERAL RULES II. On The Job Site - Safety Rules For Job Setup Setting Up A Trailer-Mounted Pump and/or A Separate Pipeline The job setup phase sets the stage for most accidents. Taking a few extra moments to correctly set up the job will improve your chances of having a safe, trouble free day.
  • Page 36 SAFETY MANUAL GENERAL RULES WARNING Do not use a piece of pipeline, end hose, coupling, or any other 5.10 material delivery component that is not in good condition. Replace, do not repair damaged pipes and hoses. Concrete pipeline system is subject to wear, and the rate of wear is affected by pumping pressure, concrete composition, pipeline material, and other factors.
  • Page 37 SAFETY MANUAL GENERAL RULES dents, cracks, wear, and continuous connection each day before the pour begins. WARNING 5.18 In vertical runs, the weight of the vertical sections of pipe must be supported by a thrust block (often called a deadman, Figure 10) or other load- bearing device.
  • Page 38 SAFETY MANUAL GENERAL RULES WARNING Watch for children! It is possible for children to access the 5.21 machine, but it is not safe for them to do so. WARNING If spectators will be near the job, cordon off an area where they 5.22 will be safe.

  • Page 39: Air Pressure

    SAFETY MANUAL GENERAL RULES WARNING There are two types of ball catchers. Know which type of 5.24 catcher you are using. You may need to adjust your cleanout procedure according to which type you have. The two types are as follows: 1.

  • Page 40: Concrete Pump Operation

    SAFETY MANUAL GENERAL RULES III. Concrete Pump Operation 6. Safety Rules For Pump Operators WARNING Only qualified operators are allowed to operate the pump. A Qualified Operator is defined as someone who: • has reached the age of 18 years (21 for interstate travel); •...
  • Page 41 SAFETY MANUAL GENERAL RULES WARNING All guards, covers, and service flaps must be secured in place during operation. WARNING Electrocution hazard! If you are operating and lightning moves into the area, seek shelter until the lightning is gone. WARNING Crushing hazard! Never, ever position yourself between a ready mix truck and the pump! Stand off to the side, so the ready mix driver can see you at all times (Figure 15).
  • Page 42 SAFETY MANUAL GENERAL RULES WARNING Do not let the concrete level in the hopper become low! If air 6.10 is sucked into the material cylinders, the pump will compress the air. Compressed air always poses a hazard as it is expelled from the hopper or the delivery pipeline (Figure 17).
  • Page 43 SAFETY MANUAL GENERAL RULES • when restarting after adding or removing delivery system; • when attempting to remove a blockage by rocking the concrete; • when opening the system to remove a blockage; • when pumping is stopped and the pipeline is at a downward angle. WARNING When initially priming the delivery system, when restarting 6.12...
  • Page 44 SAFETY MANUAL GENERAL RULES creating a blockage due to the dry conditions inside the pipe or hose. It is for this reason that the job should be set up so pipe or hose need only be removed (never added) as the day progresses. If dry pipe or hose must be added, it must be lubricated just like the rest of the pipe was lubricated when you first started.
  • Page 45 SAFETY MANUAL GENERAL RULES jammed material will keep the pipeline from vibrating. (This method won’t find a plug in a hose.) • To find a plug in a hose: with the pressure relieved, tap or step on the hose to locate the hard spot where the hose is plugged.
  • Page 46 SAFETY MANUAL GENERAL RULES WARNING Never stand on, sit on, or straddle a pipeline while it’s in use, or 6.21 whenever it is pressurized. Pipeline wears out with each stroke of the pump. If the pipe bursts, you want to be to the side of it, not on top of it (Figure 20). Figure 20 Never straddle or sit on a pressurized pipeline...
  • Page 47 SAFETY MANUAL GENERAL RULES • how to stop the pump, • the location of the emergency stop switches (E-stops), • how to signal you. WARNING To prevent any unintentional movements of the machine, all 6.24 control devices on the operator’s panel and the remote control box must be switched off before changing from remote control to local control, or vice-versa.

  • Page 48: Safety Rules For Shotcreting

    SAFETY MANUAL GENERAL RULES 7. Safety Rules For Shotcreting Keep the pump clean. A clean machine runs more efficiently. To enhance the cleaning of your pump, it will help to spray some type of bond breaker on the entire unit before each use (form oil or equivalent). Do not put oil on surfaces that will become hot, such as exhaust manifolds.
  • Page 49 SAFETY MANUAL GENERAL RULES Figure 25 Cover reducers and use containment boxes for cleanout reducercover.eps WARNING Crushing/amputation hazard! Always keep the hopper grate in place (Figure 26). Never put your hands, feet, or any other body part into the con- crete valve, hopper, or water box when the hydraulic system is operational or ready to operate! Never stand on the hopper grate! In addition, the grate can keep many items from entering the hopper that would become blockages in the line.

  • Page 50: Cleaning The Pump And System

    SAFETY MANUAL GENERAL RULES IV. Cleaning The Pump And System 8. Safety Rules For Cleaning The Concrete Valve And Hopper WARNING Wear protective clothing and equipment when cleaning the concrete pump because the lime in concrete can burn your skin. Protect against concrete burns and concrete poisoning by wearing rubber boots and gloves during cleanout or any other time that you will be in contact with the concrete.

  • Page 51: Safety Rules For Cleaning A Separately Laid Pipeline

    SAFETY MANUAL GENERAL RULES WARNING WARNING toolwarn2.eps Stop agitator before putting Do not put solid objects in any solid object in hopper. water box cleanout holes. Figure 28 Don’t put solid objects into working systems be restarted until you are finished cleaning and the covers are back in place. If a bolt-down grate is installed, you may simply stop the pump from stroking before removing the water box covers.
  • Page 52 SAFETY MANUAL GENERAL RULES WARNING Using compressed air to clean the delivery system should only 10.2 be done when no other method is practical, or as recommended by the manufac- turer. The point of discharge must be controlled. Use a ball catcher or 10.3 WARNING some other containment device at the point of discharge, even when cleaning with...
  • Page 53 SAFETY MANUAL GENERAL RULES cleanout station erected to route the discharge into the ready mix truck. • The point of discharge must be controlled. Clear the discharge area of personnel and equipment before beginning the blowing out process. Do not allow anyone to enter the area during the blowout process.
  • Page 54 SAFETY MANUAL GENERAL RULES move unpredictably; short pipelines don’t have enough concrete to resist the force of the air, causing it to discharge too quickly, like a cannon (Figure 33). hosepop9.eps Figure 33 Never use air to blow out hoses or short pipelines •...
  • Page 55 SAFETY MANUAL GENERAL RULES Figure 34 Blowout of a vertical line Blowing out vertical sections of pipe (for example on a high- 10.10 WARNING rise building) requires additional safety precautions 1. Know where the discharge area for blowing out will be before the pour begins.
  • Page 56 SAFETY MANUAL GENERAL RULES 6. If you will be diverting the discharge to a cleanout area, lubricate the dis- charge line with slurry, or a plug could occur. 7. Position the ready mix truck at the cleanout standpipe, or install the ball catcher or other containment device at the end of the discharge line.

  • Page 57: Maintenance Of The Machinery

    SAFETY MANUAL GENERAL RULES V. Maintenance Of The Machinery 11. Safety Rules Regarding Inspection WARNING Visually inspect your unit each day before it is put into opera- 11.1 tion. If any problem is found that will affect the safe operation of the pump, don’t use the pump until it is repaired! WARNING If safety decals are faded, missing, damaged, or otherwise...

  • Page 58: Safety Rules Regarding Scheduled Maintenance

    SAFETY MANUAL GENERAL RULES 12. Safety Rules Regarding Scheduled Maintenance WARNING Proper and timely maintenance is important to the safe opera- 12.1 tion of a concrete pump. The proper procedures are outlined in the operation man- ual supplied with the pump. Do not put it off. Do not treat it lightly. Do not fudge results.

  • Page 59: Safety Rules When Servicing The Machinery

    SAFETY MANUAL GENERAL RULES NOTICE Electronic components can be destroyed by welding current. 12.12 Before welding on the unit, you must disconnect the battery cables, and unplug all radio remote control power wires. If in doubt, contact the Service Department of the manufacturer for instructions before proceeding.
  • Page 60 SAFETY MANUAL GENERAL RULES WARNING Never activate the system hydraulics without checking if 13.10 another workman is in a hidden position. Always yell “clear” before starting the engine or electric motor, and allow time for response. WARNING Never work on a pressurized hydraulic system. Stop the 13.11 engine or electric motor, relieve the accumulator circuit and verify zero pressure on the gauge (if so equipped), and be sure that no hydraulic components are...

  • Page 61: Coworker Safety

    SAFETY MANUAL GENERAL RULES VI. Coworker Safety 14. Safety Rules For Workers Assigned To The Pump. WARNING You must know how to stop the pump. Have the operator 14.1 show you the locations of the emergency stop switches (E-stops) (Figure 39). E-Stop Switch WARNING Stop agitator before...
  • Page 62 SAFETY MANUAL GENERAL RULES WARNING Crushing hazard. Never, ever position yourself between the 14.3 ready mix truck and the pump! Stand to the side, where the driver can see you (Figure 41). bkupguy.eps Figure 41 Never stand between the ready mix truck and the pump WARNING 14.4 When backing in ready mix trucks, use clear and concise hand...
  • Page 63 SAFETY MANUAL GENERAL RULES WARNING Do not operate the pump unless you are also a trained operator 14.9 and the regular operator has released the controls to you. There must not be more than one operator at a time. This does not apply to stopping the pump or boom if there is a need to do so.
  • Page 64 SAFETY MANUAL GENERAL RULES WARNING When initially priming the delivery system, when restarting 14.11 after moving, when restarting after adding or removing hoses, or whenever air has been introduced into the line, warn everyone to stay away from the discharge until concrete runs steadily and there is no movement of the delivery system.
  • Page 65 SAFETY MANUAL GENERAL RULES WARNING Crushing/amputation hazard! Never put your hands, feet, or 14.16 any other body part into the water box, concrete valve, or hopper when the hydraulic system is operational or ready to operate! Never stand on the hopper grate! (See Figure 46.) Figure 46 Never put your body in the machine!
  • Page 66 SAFETY MANUAL GENERAL RULES WARNING Do not remove the water box covers or grates when the 14.18 machine is stroking (Figure 48). Do not remove the water box cover (to add water, for example), until the operator has disabled the machine. Replace the covers before the operator restarts the pump.

  • Page 67: Safety Rules For The Placing Crew

    SAFETY MANUAL GENERAL RULES 15. Safety Rules For The Placing Crew WARNING Wear Personal Protective Equipment (P.P.E., or just PPE) when 15.1 working around a concrete pump (Figure 50). The gloves should resist concrete lime burns. If you will be working in the concrete, protect your feet and hands with rubber boots and gloves (including *full face shield and/or ** breathing mask, when necessary, as shown below).
  • Page 68 SAFETY MANUAL GENERAL RULES hosepop9.eps Figure 51 Stay away from the point of discharge when starting or restarting, and when there’s air in the pipeline WARNING Never use compressed air to clear a blockage! It is unsafe 15.3 and unnecessary. If the pump pressure cannot move it, air pressure won’t either. Stand away from the discharge and the line if anyone attempts to use compressed air in this manner.
  • Page 69 SAFETY MANUAL GENERAL RULES WARNING Concrete is being moved through the delivery system by pres- 15.8 sure. Failure of a pipe, clamp, hose, or elbow is possible. For this reason, spend as little time as possible standing near the pipeline, and wear protective clothing. WARNING Do not kink the end hose.
  • Page 70 SAFETY MANUAL GENERAL RULES WARNING To avoid confusion and conflicting signals, only one person 15.13 should act as a signalperson (give operational signals to the pump operator). However, the operator is trained to obey a stop signal from anyone and everyone. Before the pour begins, the hose person, the signalperson, and 15.14 WARNING...

  • Page 71: Appendix

    SAFETY MANUAL APPENDIX Appendix VII. Weld-On Ends/Coupling Comparison ......46 VIII. Minimum Pipe Wall Thickness Chart ......47 Glossary Of Terms .

  • Page 72: Weld-On Ends/Coupling Comparison

    SAFETY MANUAL APPENDIX VII. Weld-On Ends/Coupling Comparison Shown is a comparison among commonly used ends/couplings. No two ends shown can be joined without the use of an adapter pipe or a special adapter clamp. Clamps and pipe strength must also be considered when determining proper system requirements.

  • Page 73: Minimum Pipe Wall Thickness Chart

    SAFETY MANUAL APPENDIX VIII. Minimum Pipe Wall Thickness Chart SCHEDULE 40 11 gauge 9 gauge 7 gauge 3/16” (1/4 wall) 4200 4000 3800 3600 3400 3200 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 .050" .100" .150" .200"...

  • Page 74: Glossary Of Terms

    SAFETY MANUAL APPENDIX IX. Glossary Of Terms Accumulator A hydraulic device that stores fluid power energy in much the same way that a battery stores electrical energy. Because an accumulator will store energy, it MUST be drained and depressur- ized before work begins on an accumulator-equipped actuator or hydraulic system. Agitator A device that sits in the concrete hopper to keep concrete moving, preventing it from setting.
  • Page 75 SAFETY MANUAL APPENDIX Decibels One tenth of a bel. Abbreviated dB. It is a measurement of sound volume. As it applies to con- crete pumps, it is a measurement of the sound pressure level one meter away from a noise source. O.S.H.A.

  • Page 76: Concrete Pump Nomenclature

    SAFETY MANUAL APPENDIX reaches the relief valve setting. Concrete pressure is the force at which the differential cylinders are moving, divided by the cross sectional area of the concrete cylinder. Maximum concrete pressure, then, is developed when the differential cylinders are moving with maximum force, which is determined by the hydraulic system relief valve setting.
  • Page 77 SAFETY MANUAL APPENDIX Qualified Operator Operators shall be considered qualified when they have completed a program of training and supervised operation of concrete pumps and have passed a practical operating examination of their ability to operate a specific model and type of equipment as well as their understanding of the controls and operating procedures.
  • Page 78 SAFETY MANUAL APPENDIX Spotter A person positioned at a vantage point where the distance between a hazard and the pump can be clearly seen and evaluated and the pump operator can be alerted if a predetermined safety dis- tance is compromised. See Also: Guide Sucking Back The act of putting the concrete pump into the reverse mode for any of several reasons.

  • Page 79: Recommended Acpa Hand Signals

    Further information regarding concrete pumping is available from the sources listed below. Information for this book was gathered from several different sources, including the following books: PUMPING CONCRETE AND CONCRETE PUMPS © F. W. Schwing, GmbH CONCRETE PUMP OPERATOR’S GUIDE TO SAFETY © British Concrete Pumping Association The MANUAL and ADVISORY SAFETY CODE of PRACTICE for CONCRETE PUMPING ©...
  • Page 80 SAFETY MANUAL APPENDIX PAGE 54 smlineappndx.fm...

  • Page 81: Alphabetical Index

    SAFETY MANUAL ALPHABETICAL INDEX indexcov.eps Alphabetical Index PAGE 55 700indxcov.fm...
  • Page 82 SAFETY MANUAL ALPHABETICAL INDEX bulk density, defined ....48 accidents causes of ......5, 9 catcher, types of .
  • Page 83 SAFETY MANUAL ALPHABETICAL INDEX hose ......5, 12 expert ......50 go-devil foreign material .
  • Page 84 SAFETY MANUAL ALPHABETICAL INDEX handling ......38, 43 emergency stop (E-stop) ... 7, 21, 35 hose end hose .
  • Page 85 SAFETY MANUAL ALPHABETICAL INDEX daily ......31 maximum pressure, defined ....49 safety devices .
  • Page 86 SAFETY MANUAL ALPHABETICAL INDEX pressurized ......42 shutoff valve placing boom pressure requirements ....28 as hoist .
  • Page 87 SAFETY MANUAL ALPHABETICAL INDEX explained warning, defined ..... . . 2 water box checking while pumping ... . . 20 danger .
  • Page 88 SAFETY MANUAL ALPHABETICAL INDEX PAGE 62 smalllineIOM.fm...
  • Page 89 Gearbox ............39 Emergency Stop (E-stop) Manifold ....32 Operator Panel (Inside) .........39 Hopper Grate Interlock Switch .......33 Hopper ............39 SCT II (SCHWING Control Technology) ..40 Pressure Relief Valves ........33 HMI (Human Machine Interface) ....41 Safety Guards ..........34 Fuses and Circuit Breakers ......34 Pendant Remote ..........41...
  • Page 90 Radio/Pendant Screen ........51 Settings Screen ..........52 Event Log Screen ..........52 Event History Screen ........53 Maintenance Screen ........54 Fuses ...............58 Fuse/Relay Locations........58 Relays ..............58 Checking Solenoids ........59 Troubleshooting Screens ......59 PLC IO Screen ..........59 Radio/Pendant Screen ........59 SPTO 1000/1250 Operation Manual...
  • Page 91 Operation section of this manual. Concrete Pump Circuit Overview SCHWING concrete pumps have a fully hydraulic, twin- cylinder, reciprocating design. The pumpkit consists of: • Two differential hydraulic cylinders Differential Cylinders •...

  • Page 92: Overview

    Replacement bladders can be ordered the kidney seal and kidney plate, and the rock valve through SCHWING’s Spare Parts Department, or slewing cylinder. the accumulator can be sent in for repair. Call the...

  • Page 93: First Commissioning

    Overview First Commissioning Installation of Your New Unit When your new SCHWING pump was delivered, it was accompanied by several documents in addition to this operation manual. One of those important documents is the “Delivery Inspection Report.” Each of the thirty-five items listed should be checked before your new pump is sent to the first job.
  • Page 94 Overview ACCUMULATOR 1450PSI 6.75 6.75 100 BAR 2 bar 2 bar SEE CHART 100 bar 20 bar NG 06 10306430 SPTO 1000/1250 Operation Manual...
  • Page 95 200 BAR To Pumpkit 1.7 BAR Water Pump 10µ 11cc 31cc g min g max 11cc Main Pump Accumulator Pump Oil Cooler Gear Pump Optional Water Pump Oil Cooler Filter E-stop Manifold Accumulator Unloading Valve Stroke Limiter SPTO 1000/1250 Operation Manual...

  • Page 96: Safety Devices

    S1/S2 control block (Figure 3). Manual Forward/Reverse Handle Press to Engage Pull Out to Release (on the Concrete Pump) Turn Clockwise to Release (on Remotes) Figure 3 Concrete Pump Forward/Reverse Handle Figure 1 Emergency Stop (E-stop) Button SPTO 1000/1250 Operation Manual...

  • Page 97: Hopper Grate Interlock Switch

    In some extreme cases, will continue moving. raising or lowering hydraulic relief pressures may cause dangerous operation. Check with the SCHWING Service Center before changing any hydraulic relief pressure settings. Pressure Roller Hopper Grate...

  • Page 98: Safety Guards

    A very good rule of thumb for fuses is this: if it blows once, replace it, but if it blows again, something is wrong. Find the cause of the problem, and repair it before activating the circuit again. SPTO 1000/1250 Operation Manual...

  • Page 99: Machine Overview

    Overview Machine Overview A. Pumpkit B. Operator Control Station C. Hydraulic Tank D. Water Tank E. Gearbox F. Hopper G. E-stop Buttons H. In-Cab Controller H (inside cab) SPTO 1000/1250 Operation Manual...

  • Page 100: Pumpkit Overview

    Overview Pumpkit Overview A. Material Cylinders B. Differential Cylinders C. Rams D. Water Box E. S1/S2/S3 Control Valve F. Accumulator G. Rock Valve H. Agitator SPTO 1000/1250 Operation Manual...

  • Page 101: S1/S2/S3 Control Valve

    A. Hydraulic Oil Level / Temperature Gauge B. Drain C. Cleanout Cover D. Breather E. Agitator Dump Valve F. E-stop Manifold G. Oil Cooler Accumulator H. Filter A. S3 Spool (Internal) B. Stroke Limiter C. Accumulator Bottle SPTO 1000/1250 Operation Manual...

  • Page 102: Water System

    H. Water Pump A. Access Flap I. Waterbox Drain (pneumatic) B. Pressure Relief C. Water Level Gauge D. Water Tank Drain E. Waterbox Fill Valve F. Passenger Side Water Supply Outlet G. Rear Water Supply Outlet SPTO 1000/1250 Operation Manual...

  • Page 103: Gearbox

    E. Main Hydraulic Pump E. Tension Nut F. Water Pump Gear Pump F. Clean Out Door Operator Panel (Inside) A. PLC Controller B. PLC IO module C. Fuse Box D. SCC Solenoid Valve E. Air Regulator SPTO 1000/1250 Operation Manual...

  • Page 104: Sct Ii (Schwing Control Technology)

    Overview SCT II (SCHWING Control Technology) The SCT II system allows the operator to electronically run all functions of the concrete pump. The system includes the operator control panel, pendant remote, and radio remote. The SCT II system contains the following components: A.

  • Page 105: Hmi (Human Machine Interface)

    H. Work Light Button E. Enter Button I. Agitator (On/Off) Button F. (F2) Function Button J. Stroke Limiter Increase Button G. (F4) Function Button K. Stroke Limiter Decrease Button L. Accessory 1 Button M. Accessory 2 Button ACC1 ACC2 SPTO 1000/1250 Operation Manual...

  • Page 106: Pendant Remote Buttons

    = Pump/Reverse = Inactive = Throttle (-) = Inactive (Push/Hold) Work Light Button Press once to turn on the work lights, press again to turn work lights off. = Work Light (On) = Work Light (Off) SPTO 1000/1250 Operation Manual...
  • Page 107 Press and hold to ramp down strokes rate. Press=0 Output =0% Press=0 Output =100% Press=1-4 Press=5 Press=6-9 Press=10 Press=11-14 Press=1-4 Press=5 Press=6-9 Press=10 Press=11-14 Press=25 Press=15 Press=16-19 Press=20 Press=21-24 Press=25 Press=15 Press=16-19 Press=20 Press=21-24 Press=26-29 Press=30 Output =100% Press=26-29 Press=30 Output =0% SPTO 1000/1250 Operation Manual...
  • Page 108 ACC button will flash blue and the compressor can’t be activated. = Optional = Optional ACC1 ACC1 Accessories / On Accessories / Off = Interlock ACC2 Function not available SPTO 1000/1250 Operation Manual...

  • Page 109: Radio Remote

    P. Work Light Button Q. Concrete Pump Forward Button R. Concrete Pump Reverse Button S. Stroke Limiter Increase Button ACC1 ACC2 T. Stroke Limiter Decrease Button U. Accessory 2 Button V. Power Off Button ca6019 A-3 SPTO 1000/1250 Operation Manual...

  • Page 110: Radio Remote Buttons And Lights

    When the vibrator button is pressed twice (manual mode), the vibrator will run until the vibrator is shut off. Pressing the button a third time will turn the vibrator off. SPTO 1000/1250 Operation Manual...
  • Page 111 (3%). Hold down the stroke limiter (-) button to continually ramp down the strokes rate. Accessory 1 and Accessory 2 Buttons These buttons are used with optional accessories installed on the concrete pump. Press once to activate the installed function. SPTO 1000/1250 Operation Manual...

  • Page 112: Safe Pairing Of Transmitter To Receiver

    4. Within 10 seconds, reapply power to the receiver by putting the ignition key switch in the RUN position. 5. The transmitter will confirm the download is complete by flashing LED #3 eight times. LED #3 SPTO 1000/1250 Operation Manual...

  • Page 113: Hmi Lcd Screens

    Event Log Screen. - Press and hold to reset stroke counter 1. - Press to go to the Menu Screen. - Press and hold to reset stroke counter 2. - Press to go to the Maintenance Screen. SPTO 1000/1250 Operation Manual...

  • Page 114: Warning And Info Messages

    Info messages flash through the Message Center and are also displayed on the Event Log Screen. A Fault Isolation Manual is available with detailed troubleshooting steps. Contact the SCHWING Service Center for assistance addressing warning messages. Warning Messages Agitator Dump Valve-Short Circuit...

  • Page 115: Menu Screen

    This screen can be used to assist in troubleshooting electrical issues. - Press to return to the Home Screen. - Press to return to the previous screen. - Press to scroll through the PLC IO Screen. SPTO 1000/1250 Operation Manual...

  • Page 116: Settings Screen

    Home Screen. - Press to change or reset the password. - Press to return to the Menu Screen. - Press to return to the Home Screen. - Press to return to the Menu Screen. SPTO 1000/1250 Operation Manual...

  • Page 117: Event History Screen

    - Press “Start Date,” and a calendar will appear. Chose the start date. - Press to return to the Home Screen. - Press to return to the previous screen. - Press to return to the Event Log Screen. SPTO 1000/1250 Operation Manual...

  • Page 118: Maintenance Screen

    - Use the arrows to change the language function. - Press to change the internal clock settings. It’s important to have the correct time set to validate the Event Log Screen. SPTO 1000/1250 Operation Manual...
  • Page 119 ETH0 light on the PLC. If the ETH0 light isn’t flashing green, communications between the PLC and HMI has been lost. - Press to activate the manual grease cycle. - Press to return to the Home Screen. - Press to return to the Menu Screen. SPTO 1000/1250 Operation Manual...
  • Page 120 HMI panel while turning the key switch to the ON position. BACK With the software updated on the HMI, we now have to Press and hold three of update the PLC (see page 57). these buttons simultaneously while starting the machine SPTO 1000/1250 Operation Manual...
  • Page 121 PLC. After a number pad appears, use the keypad to enter the access code and then press OK. Once logged in, the “Download to Controller” button will appear; press this button to update the PLC. SPTO 1000/1250 Operation Manual...

  • Page 122: Fuses

    Spare Ignition Ignition Spare Ignition Spare PLC Vbb30 Vibrator Pendant, PLC Vbb15, Display Vbb15 Grease Pot Horn E-stop Circuits, Radio Power SCT2 Sensors Fuse/Relay Locations F14 F13 F15 F21 F16 F17 F22 Spare Fuses Spare Fuses SPTO 1000/1250 Operation Manual...

  • Page 123: Checking Solenoids

    Radio or Pendant icons (Communication). - Press to return to the Home Screen. - Press to return to the previous screen. Figure 8 Testing the Resistance Ohms Solenoid Concrete Pump Forward/Reverse E-stop Manifold Stroke Limiter Agitator SPTO 1000/1250 Operation Manual...
  • Page 125 Unit Setup ............67 Keep the Waterbox Full .........77 Selecting the Setup Location ......67 Blockages ............77 Laying Out the Pipeline .........67 Clean Out ............78 Preparing for Ready-Mix Trucks ....67 Cleaning the Waterbox ........81 SPTO 1000/1250 Operation Manual SPTO 1000/1250 Operation Manual...

  • Page 126: Operation

    High Pressure Washer........84 Use of Cleaning Agents .........84 Protecting New Paint ........84 Emergency Procedures .........85 Electrical Power Loss ........85 Emergency Override Button ......86 Adjusting the Stroke Limiter - Electrically ..86 Adjusting the Stroke Limiter - Manually ..86 SPTO 1000/1250 Operation Manual...

  • Page 127: Preparing For The Job

    • Clean out balls Steel Toed Shoes • Water hose and nozzle • Clean out rake • Working lamps for night work • Approved air blow-out cap • Hand tools Figure 1 • Hammer Personal Protective Equipment (PPE) SPTO 1000/1250 Operation Manual...

  • Page 128: Additional Items

    Oil that holds air bubbles overnight should be replaced. Air bubbles in the oil during operation do not indicate an oil issue but instead indicate a problem with the integrity of the hydraulic seals somewhere in the system. SPTO 1000/1250 Operation Manual...
  • Page 129 If your use of the concrete pump includes pumping of low slump concrete, you will find this option invaluable. SPTO 1000/1250 Operation Manual...

  • Page 130: Driving The Unit

    Before changing lanes, check the convex mirrors for other drivers who may be “hiding” in your blind spots. Signaling well in advance will warn other drivers of your intention to change lanes. SPTO 1000/1250 Operation Manual...

  • Page 131: Unit Setup

    • Review the safety rules with any oilers or laborers who have been assigned to work with you at the pump. Show them the concrete pump stop switch and emergency stop buttons. SPTO 1000/1250 Operation Manual...
  • Page 132 • Put a couple of shovelfuls of sand or dirt in the bottom of the rock valve housing, above the cleanout door (Figure 6). This will prevent concrete from filling the door area and setting Figure 4 during the course of the day. Fill Waterbox SPTO 1000/1250 Operation Manual...
  • Page 133 This is one of the few times when it is better to under-grease than to over-grease. SPTO 1000/1250 Operation Manual...

  • Page 134: Lubricating The Pipeline

    Lubricating the Pipeline When the ready-mix trucks arrive on the job, the pipeline can be lubricated. SCHWING highly recommends that you pre lubricate the pipeline each time you pump into dry pipe. In some parts of the United States and...
  • Page 135 The machine can now be operated from this pendant any other body part into the hopper. Mix more slurry as needed for the length of the pipeline, as described above. SPTO 1000/1250 Operation Manual...
  • Page 136 (Figure 13) to cycle the rock Reverse valve back and forth a few times. This will agitate the mix a little more. Do not try to pump this mix until you can add concrete. Figure 13 Cable/Radio Remote Buttons SPTO 1000/1250 Operation Manual...
  • Page 137 If the line plugs, immediately switch the pump to reverse mode, and notify the ready-mix driver to stop dumping. To remove the plug, rock the concrete by alternately pumping a few strokes in forward and a few in reverse, or SPTO 1000/1250 Operation Manual...

  • Page 138: Pumping The Job

    Even with Figure 15 the hopper full of concrete, some compressed air will be Washing the Pipe System introduced into the delivery pipeline. When it reaches the discharge point, the air will cause the concrete to SPTO 1000/1250 Operation Manual...

  • Page 139: Controlling The Concrete Pump

    If you didn’t buy a Lock nut vibrator with your unit, you can purchase one for field Pressure reducing retrofit by calling the SCHWING Service Center at valve (not manual stroke limiter) 1-888-292-0262.

  • Page 140: Cold Conditions

    Broken Hose or Fitting For additional assistance with electrical power loss If an emergency requires you to disable the hydraulic issues, contact the SCHWING Service Center at system completely (such as if a hose or fitting breaks), 1-888-292-0262. you must stop the truck engine or at least take the transmission out of gear.

  • Page 141: Keep The Waterbox Full

    “Tapped” is a key word here. You can damage the pipe by striking it hard. You should be able to SPTO 1000/1250 Operation Manual...

  • Page 142: Clean Out

    5-gallon bucket when 1/2 hour of Figure 19 pumping remains, or you can start soaking the Opening the Hopper Cleanout Door ball in the morning; if you let the ball soak all day, however, it will not last as long. SPTO 1000/1250 Operation Manual...
  • Page 143 For safety reasons, return to your shop before you remove any concrete that has completely set. Once the concrete has set, there is no advantage to chipping it away at the job site. SPTO 1000/1250 Operation Manual...
  • Page 144 Using your cleanout rake, • Close the hopper cleanout door, and reattach the pull any material from the exposed material cylinder, the bungee cord, if used. rock valve, and the outlet pipe (Figure 22). SPTO 1000/1250 Operation Manual...

  • Page 145: Cleaning The Waterbox

    After opening all drain cocks and activating the pump, you may want to run the Figure 24 pump again to be sure all water has Spraying out Waterbox been removed. SPTO 1000/1250 Operation Manual...

  • Page 146: Preparing For Travel

    Once you have used water to remove the bulk of the concrete from a component, it will be thinned enough to not completely set until you can return to it. SPTO 1000/1250 Operation Manual...

  • Page 147: Cold-Weather Pumping

    Arrange for the last truck to be filled with hot water and to be prepared to let you clean out using this water. SPTO 1000/1250 Operation Manual...

  • Page 148: External Cleaning

    • Do not use additives. • Maximum water pressure: 100 bar / 1450 psi. • Minimum permissible spraying distance: 12 in. If the high pressure washer used generates a higher water pressure, the spraying distance must be increased accordingly. SPTO 1000/1250 Operation Manual...

  • Page 149: Emergency Procedures

    . This will disable the override. Figure 26 Connecting the Emergency Power Harness Figure 27 Maintenance Screen - Override Enable With Override Enable activated on the Maintenance Screen, the throttle up/down buttons on the pendant and radio remotes will be disabled. SPTO 1000/1250 Operation Manual...

  • Page 150: Emergency Override Button

    Figure 28 E-stop Override Buttons / Concrete Pump Forward/ Reverse Override Handle For information on where to look and what to do if you lose electricity on the unit, contact the SCHWING Figure 29 Service Center at 1-888-292-0262. Removing Power Connector...
  • Page 151 Valve (not Manual Stroke Limiter) Figure 30 Stroke Limiter Control Block Return the lock nut and cap to the solenoid assembly and reconnect the power connector to the solenoid once power is restored to the unit. SPTO 1000/1250 Operation Manual...
  • Page 153 Hydraulic Oil Recommendations ....94 Inspect Bolts on Rams ........99 Biodegradable Hydraulic Oils .......94 Grease Rock Valve and Agitator Bearings ..99 Filtration ............95 Inspect for Damage or Leaks ......99 General Information ........95 Check if Maintenance is Due ......99 SPTO 1000/1250 Operation Manual...
  • Page 154 Unscheduled Maintenance ......105 Changing Rams ...........105 Changing the Material Cylinders ....110 Accumulator Charging Procedure ....110 Setting Main Relief/Pressure Cut-Off ..113 Setting the Soft Switch Relief Pressure ..115 Set Accumulator Pressure Cut-Off ....116 SPTO 1000/1250 Operation Manual...

  • Page 155: Hoses And Fittings

    In the examples below, bolt B would SCHWING uses metric fittings and hoses with metric last much longer than bolt A. The torque specifications threads on the couplings. There are six sizes of tubes...

  • Page 156: Removing Safety Devices

    Figure 1 Safety Guard Example (Waterbox Safety Guard) Lockout/Tagout Procedure SCHWING includes approved warning devices with all new concrete pumps and recommends the following procedure prior to performing any maintenance in an area of the unit that would normally be guarded: •...

  • Page 157: Hydraulic Oils

    Maintenance Hydraulic Oils The quality of the oil needed for use in a SCHWING concrete pump is in the DIN system. The ratings have to General Information do with the chemical additive package that is introduced Hydraulic oils are rated for viscosity, heat dissipation, into the oil.

  • Page 158: Hydraulic Oil Recommendations

    Envirosyn 46 H Envirosyn 68 H PETRO-Canada Premium ECO Premium ECO HT-E 32 HT-E 46 SHELL Naturelle Naturelle Naturelle HF-X 32 HF-E 46 HF-E 68 Naturelle HF-X 46 VALVOLINE Ultrasyn Unisyn Unisyn PG 46 HLP 22/46 HLP 32/68 SPTO 1000/1250 Operation Manual...

  • Page 159: Filtration

    10 μm or larger in size, 1 will make it through. Although we are not happy about the one particle that is allowed through, we do not use finer filtration because the SPTO 1000/1250 Operation Manual...

  • Page 160: Bypass Check Valve

    Worse yet, the filter could split open and leak to the ground, draining the reservoir, and contaminating the environment. Both potential problems are avoided by the bypass check valve. Dirty Filter Indicator Inlet Outlet Filter Figure 3 Hydraulic Oil Filter SPTO 1000/1250 Operation Manual...

  • Page 161: Scheduled Maintenance

    Check Gearbox Oil Level √ Check the Accumulator Pre-Charge √ Change Hydraulic Oil (Seasonal Change) √ Change Hydraulic Oil Return Filter √* Change Gearbox Oil √ Change Hydraulic Oil (Age Reasons) √ * or as needed SPTO 1000/1250 Operation Manual...

  • Page 162: Daily Maintenance

    Add only filtered oil. Use a filter cart to pump oil into the tank. New oil contains more contaminants than SCHWING approves for their machines. Replace milky looking oil, Hydraulic Tank Drain which is a sign of water contamination.

  • Page 163: Inspect Bolts On Rams

    (Figure 6). One zerk a daily basis. (the outside end of the rock valve slewing cylinder) is accessible from the drivers side of the unit. Pressure Cut-Off - SPTO 1000 300 bar Right-Hand Inside Shift Cylinder Pressure Cut-Off - SPTO 1250...
  • Page 164 Concrete Pump and Accumulator Pressure Gauges pressure (Figure 10). If the reading is different from your schematic, refer to “Setting the Soft Switch Relief Pressure” on page 115. SPTO 1000/1250 Operation Manual...

  • Page 165: Weekly Maintenance

    12x30 Bolt (end of rock shaft) Spacer Keeper Bolt Tension Nut Tension Nut Cover Bolts Figure 12 Loosen Bolts on Rock Valve Cover and Shaft Keeper Bolt Figure 11 Adjusting the Rock Valve Tension Nut SPTO 1000/1250 Operation Manual...

  • Page 166: Lubricate Mechanical Moving Parts

    “Check the Rock Valve Tension Nut” procedure. Tighten the keeper bolt. Lubricate Mechanical Moving Parts Lubricate mechanical moving parts with oil or a lubricant such as WD-40. This applies to pins, hinges, valve handles and other components. SPTO 1000/1250 Operation Manual...

  • Page 167: Monthly Maintenance

    2 5 0 needed, add it by removing the breather and pouring in the oil through the top. Figure 16 Accumulator Charging Kit Filler Spout Oil Check Plug Drain Plug Figure 15 Gearbox Oil Plugs and Fill Spout SPTO 1000/1250 Operation Manual...

  • Page 168: Semi-Annual Maintenance

    7. Refill through the filler spout to the full level plug to the installation instructions that come with the or oil check plug with 90W gear lube. Replace the filter. full level plug and the breather filter. 6. Start the engine, and check for leaks. SPTO 1000/1250 Operation Manual...

  • Page 169: Annual Maintenance

    2. The oil should be cool. This is for safety reasons. Do not change oil that is above 120°F (50°C). To assist in ram replacement, SCHWING offers a ram change mode feature. This feature drops engine 3. Drain the old oil into barrels or another waste RPMs and stroke limiter outputs to minimal levels.
  • Page 170 (Figure 21). Leave about 1.5 inches of travel, which will allow you to the engine. remove the spacer coupling (dogbone). When in 7. Remove the spacer coupling from the waterbox position, shut-off the engine. (Figure 23). SPTO 1000/1250 Operation Manual...
  • Page 171 Call the SCHWING Service Center for additional assistance. Figure 26 Retract Ram into Waterbox 11.
  • Page 172 Again, you should tighten the nut only finger-tight. Figure 28 Figure 30 Install New Ram Retract Cylinder Away from Ram SPTO 1000/1250 Operation Manual...
  • Page 173 Slowly move the cylinder down to where its flange butts up to the spacer coupling. Be careful not to go too far (Figure 32). Figure 32 Move Cylinder to Spacer Coupling SPTO 1000/1250 Operation Manual...

  • Page 174: Changing The Material Cylinders

    The procedure for changing and aligning the material cylinders is the subject of Service Bulletin G-102/88. For a copy of this bulletin, contact the SCHWING Service High pressure gas regulator is not included with the kit. These are Center at 1-888-292-0262.
  • Page 175 1500 2000 accumulators without one. Order the charge valve 1000 2500 3000 kit assembly from the SCHWING Service Center 3500 using part number 30355436. 2. You must use a high-pressure regulator with the Swivel Nut nitrogen bottle. If it was not supplied with the bottle, order one before proceeding with this job.
  • Page 176 Never let nitrogen out of the accumulator by pressing the gas valve pin with a foreign object. Valve Stem The high pressure may rupture the valve seal! O-ring Figure 39 Accumulator Protection Cap HYDAC bladder Accumulator SPTO 1000/1250 Operation Manual accum closeup...

  • Page 177: Setting Main Relief/Pressure Cut-Off

    Figure 40 Relief Cartridges and Pressure Cut-Off Screw 4. Stop the truck, put the key in your pocket, and place a “Do Not Operate” sign on the windshield. SPTO 1000/1250 Operation Manual...
  • Page 178 Repeat this process until the proper main relief pressure is achieved. 10. When the proper main relief pressure is achieved, the pressure cut-off can be set. Turn off the engine, and apply the proper lock-out/tag-out procedures. SPTO 1000/1250 Operation Manual...

  • Page 179: Setting The Soft Switch Relief Pressure

    5/32 allen key to adjust the pressure. Turn the adjustment screw in (clockwise) to raise the pressure or out (counter clockwise) to lower the pressure. 5/32-inch Allen Head 9/16-inch Jam Nut Figure 44 Soft Switch Relief Valve SPTO 1000/1250 Operation Manual...

  • Page 180: Set Accumulator Pressure Cut-Off

    Repeat this process until the proper main concrete pressure is achieved 5. Lock the jam nut when the pressure is correct. SPTO 1000/1250 Operation Manual...
  • Page 181 Black and Yellow Chromated .......122 The Quadrants ..........137 Glossary of Terms ........142 VZD .............123 Recommended Emergency Hose Kit ..124 Additional Reading Material ......146 Fitting Wrench Sizes ........124 Straight Fittings ..........124 Banjo Fittings ..........125 Weld-On Ends/Couplings Comparison ..126 SPTO 1000/1250 Operation Manual...

  • Page 183: Appendix

    (thermal breakdown). as the temperature rises. • The optimum operating viscosity is the range Your SCHWING concrete pump was delivered with of oil thickness at which the oil works best (thin Mobil Univis N46 hydraulic oil. This multi viscosity enough to flow easily, yet thick enough to protect works for any temperature between -20˚F and 100˚F.

  • Page 184: Torque Specifications For Metric Bolts

    The following charts show the tightening torques Wrench Size = 13 mm specified for the bolts used on SCHWING equipment. A torque wrench must be calibrated to within 1% of its indicated value throughout its range. Bolts must be torqued to within 4% of the requirement if the wrench has a dial scale.

  • Page 185: Torque Chart

    Appendix Torque Chart ZFSHL/Geomet 500 Coated Electro-Galvanized SPTO 1000/1250 Operation Manual...

  • Page 186: Black And Yellow Chromated

    Appendix Torque Chart Black and Yellow Chromated SPTO 1000/1250 Operation Manual...

  • Page 187: Vzd

    Appendix Torque Chart SPTO 1000/1250 Operation Manual...

  • Page 188: Recommended Emergency Hose Kit

    Recommended Emergency Hose Kit SCHWING recommends that you carry one of each of the following hoses on the unit in case a hose is blown on the job. Each size listed represents the longest hose of each diameter that is installed on the unit at the factory. Keep the insides of the hoses clean until they are needed by capping the ends and using tape to hold the cap in place.

  • Page 189: Banjo Fittings

    Body (in) 8 mm 12 / R 12 / R 12 / R 16 mm 20 mm 25 mm 30 mm 38 mm End Cap Part of Stem 12 / R 16 mm 25 mm 38 mm SPTO 1000/1250 Operation Manual...

  • Page 190: Weld-On Ends/Couplings Comparison

    Grooved couplings are not recommended for concrete pumping applications. All pressure ratings listed refer to 5 inch (125 mm) diameters in like-new condition. Other pressures would apply to other sizes. SPTO 1000/1250 Operation Manual...

  • Page 191: Minimum Pipe Wall Thickness

    This chart does not apply to double-wall pipe. Double wall pipe can be checked by inspecting the inside of the pipe. If the insert is intact, the pipe is okay. If the insert is worn through, the pipe must be replaced. Contact your pipe supplier for the pressure capacity of your double-wall pipe. SPTO 1000/1250 Operation Manual...

  • Page 192: Twin Wall

    S2000 Size Overall Wall Thickness (New) in/mm in/mm DN125/4.8 .180 / 4.572 .110 / 2.794 .230 / 5.842 S3000 Size Overall Wall Thickness (New) in/mm in/mm DN125/4.8 .188 / 4.775 .090 / 2.286 .230 / 5.842 SPTO 1000/1250 Operation Manual...

  • Page 193: Output Charts

    125 mm / 80 mm x 2000 mm 230 mm x 2000 mm 2 x A7VO-107 pumpkit and hydraulic 2 x 66KW pumps is shown here. output chart explain.eps Slewing cylinder 80 / 45 x 185 SPTO 1000/1250 Operation Manual...
  • Page 194 CONCRETE OUTPUT (cu yd / h) this case, a little over 21). NUMBER OF STROKES (stroke / min.) SIDE OIL VOLUME (liter / min.) 15.5 NUMBER OF STROKES PISTON (stroke / min.) SIDE OIL VOLUME (liter / min.) SPTO 1000/1250 Operation Manual...
  • Page 195 • Make two copies of the output chart so you don’t ruin your original. You need one chart for each pump tested. SPTO 1000/1250 Operation Manual...
  • Page 196 157 170 183 178 bar 170.5 CONCRETE OUTPUT (cu yd / h) NUMBER OF STROKES (stroke / min.) SIDE OIL VOLUME (liter / min.) 15.5 NUMBER OF STROKES PISTON (stroke / min.) SIDE OIL VOLUME (liter / min.) SPTO 1000/1250 Operation Manual...
  • Page 197 1st Pump 2nd Pump Breakpoint specification Liters/min Total Liters/min Total (read on meter) (for plotting) (read on meter) (for plotting) 0 bar 100 bar breakpoint breakpoint 150 or 200 bar 250 bar 300 bar Check output form-fill2 SPTO 1000/1250 Operation Manual...
  • Page 198 You may notice possible to make an adjustment. Contact the SCHWING high heat with this unit if you are pumping at high oil Service Center for the procedure.

  • Page 199: Using A Nomograph

    Lower Left Quadrant Lower Right Quadrant 2.5" 3" 4" 5" 6" 3000 2500 2000 1800 1500 1200 1000 Pumpkit Model: 120/80 x 1600:200 Proportional value of pipeline in feet Slump of fresh concrete in inches Power: 132 KW SPTO 1000/1250 Operation Manual...
  • Page 200 77 psi. Separately laid pipeline: All of these criteria will be explained in detail as we go • 40 ft of 5-inch rubber hose through the individual quadrants. • 150 ft of 5-inch horizontal steel pipe SPTO 1000/1250 Operation Manual...

  • Page 201: The Quadrants

    Again, any pump you select for the job in this example should have a PF of 61,750 or greater. The power factor number (PF) replaces the TK number on a truck-mounted unit. It is the Kw multiplied by a SPTO 1000/1250 Operation Manual...
  • Page 202 4-inch pipeline. When pressure is exerted on concrete in a pipeline, a paste of water and cement fines coats the inside of the pipeline Pipeline diameter in inches 6" 5" 4.5" 4" uppr rght quad-eps SPTO 1000/1250 Operation Manual...
  • Page 203 Total = 530.0 ft Round down to 500 ft to make it easy to use the chart. NOTE: Proportional value of the 41-meter boom and deck pipe system is 260 ft. This value includes elbows, reducer, and tip hose. SPTO 1000/1250 Operation Manual...
  • Page 204 3" 4" 5" 6" lwr left quad-eps Slump of fresh concrete in inches 103 KW 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 P in PSI SPTO 1000/1250 Operation Manual...
  • Page 205 For vertical placing, add 1.105 psi per foot of level di erence. Example Job 132 kW 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 P (in PSI) up lft 132Kw Qwad 2000R-eps SPTO 1000/1250 Operation Manual...

  • Page 206: Glossary Of Terms

    American Concrete Pumping Association. is in section 6.9 of the Safety Manual. There are several classes of certification, each relating to a different category of pump. For an operator to become certified, he or she must pass tests regarding SPTO 1000/1250 Operation Manual...
  • Page 207 Go devils are intended to be inserted in a steel delivery pipeline and pushed with water or compressed air for the purpose of cleaning the pipe. Not to be used with rubber hose or short sections of pipe. SPTO 1000/1250 Operation Manual...
  • Page 208 Things worn to protect yourself from potential dangers in a concrete placing environment. Examples are: snug-fitting work clothes, steel-toed work boots, lime- resistant glove, safety glasses, ear muffs or ear plugs, rubber boots, and hard hats. SPTO 1000/1250 Operation Manual...
  • Page 209 It stabilizes and supports the vertical run by virtue which the pump is capable. of its enormous mass (normally one cubic yard or larger). SPTO 1000/1250 Operation Manual...

  • Page 210: Additional Reading Material

    • Pumping Concrete and Concrete Pumps. Karl straps need not be secured if no travel is imminent. Ernst v. Eckardstein. F. W. Schwing GmbH, 1983. Twin Circuit • Pumping Concrete—Techniques and Applications. The plumbing method used for the pumpkit in which Robert Allen Crepas.
  • Page 211 Changing the Material Cylinders ......110 Emergency Stop (E-stop) Buttons ....32, 42, 46 Cleaning Agents ............. 84 Event Log Screen ............52 Clean Out ............... 78 Event History Screen ............. 53 Cleaning the Hopper ............. 78 Cleaning the Waterbox ..........81 SPTO 1000/1250 Operation Manual...
  • Page 212 Manufacturer’s Statement ..........11 Stroke Limiter ..............75 Menu Screen..............51 Stroke Limiter Decrease Button ......43, 47 Minimum Pipe Wall Thickness .........127 Stroke Limiter Increase Button ......43, 47 Monthly Maintenance ..........103 New Paint ............... 84 Nomograph ..............135 SPTO 1000/1250 Operation Manual...
  • Page 213 Unit Setup ............... 67 Vibrator ................75 Vibrator On/Off Button ..........42, 46 Warning Labels .............. 24 Warning Messages ............50 Waterbox ................. 37 Water System ..............38 Water Tank ..............65 Work Light Button ..........42, 47 SPTO 1000/1250 Operation Manual...
  • Page 215 Stroke Limiter ..........154 Soft Switch ...........155 Vibrator (Optional) ........155 Time Constraints..........155 Emergency Procedures .......155 Electrical Power Loss ........155 Emergency Override Button ......156 Adjusting the Stroke Limiter - Electrically ..156 Adjusting the Stroke Limiter - Manually ..157 SPTO 1000/1250 Operation Manual...

  • Page 217: Short Instructions

    Even with the hopper full of concrete, some compressed air will be introduced into the delivery pipeline. When it reaches the discharge point, the air will cause the concrete to SPTO 1000/1250 Operation Manual...

  • Page 218: Stroke Limiter

    (clockwise) to decrease strokes or out (counter clockwise) to increase strokes. Always return the manual stroke limiter to maximum strokes (full Figure 3 counter clockwise out position) when electrical Washing the Pipe System power is restored. SPTO 1000/1250 Operation Manual...

  • Page 219: Soft Switch

    If you didn’t buy a vibrator with your unit, you can purchase one for field retrofit by calling the SCHWING Service Center at 1-888-292-0262. Time Constraints...

  • Page 220: Emergency Override Button

    E-stop Override Buttons / Concrete Pump Forward/ Reverse Override Handle For information on where to look and what to do if you lose electricity on the unit, contact the SCHWING Service Center at 1-888-292-0262. Adjusting the Stroke Limiter - Electrically...

  • Page 221: Adjusting The Stroke Limiter - Manually

    1/2-inch wrench. Use a 5/32-inch allen wrench and turn the screw in (clockwise), this will decrease the strokes per minute. When the proper speed is reached, lock the jam nut with the 1/2-inch wrench (Figure 10). SPTO 1000/1250 Operation Manual...

This manual is also suitable for:

Spto 1250

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