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SCHWING TrainingManual PDF
SCHWING TrainingManual PDF
TRAINING MANUAL
5900 Centerville Road White Bear, MN 55127 TEL 651-429-0999 FAX 651-429-2112 www.schwing.com
SCHWING SERVICE DEPARTMENT
(651) 429-0999
OR
1-888-292-0262
OR
Branches
Florida............................................................. 1-813-985-8311
Northern California........................................ 1-925-371-8595
Southern California ....................................... 1-562-493-1012
Georgia ........................................................... 1-678-560-9801
Texas .............................................................. 1-972-245-5166
SERVICE TRAINING
Table of Contents
Typical Twin Circuit ........................ 1 Typical Boom Circuit .................... 16
PTO Switch/Air Valve ..................................................1 Boom Pump ................................................................16
PTO ...............................................................................2 E-Stop Manifold .........................................................17
Continuous Duty Solenoid ............................................2 Poppet Valve Theory ..................................................17
CPC/CPCII Controller ..................................................3 E-Stop - Override .......................................................18
Hydraulic Pumps ...........................................................3 Boom Handvalve - No functions activated ................18
Fixed Displacement ......................................................4 Boom Handvalve - Outrigger enabled ........................19
Variable Displacement ..................................................4 Outrigger Handvalve ..................................................19
Main Control Block “Brain” .........................................4 Boom Handvalve - Boom Function Activated ...........20
Concrete Pump Forward/Reverse Valve .......................5 Pulsar Coil Theory ......................................................20
Main Control Block - S1/S2 Spool ...............................5 Boom Holding Valves ................................................21
Main Relief Valve .........................................................6 Manual Controls and Overrides ..................................21
Differential Cylinders ...................................................6
Material Cylinders ........................................................7
Differential Cylinder - Bottomed Out ...........................7
MPS Valve ....................................................................8
S3/Accumulator Control Block .....................................8
Accumulator Theory .....................................................9
Rock Valve Slewing Cylinder ......................................9
Soft Switch Relief Valve ............................................10
Main Control Block - S2 Spool ..................................10
Differential Cylinder - Beginning of stroke ................11
MPS ............................................................................11
Differential Cylinder - Bottomed Out .........................12
MPS ............................................................................12
S3/Accumulator Control Block ...................................13
Rock Valve Slewing Cylinder ....................................13
Soft Switch Relief Valve ............................................14
Main Control Block - S2 Spool ..................................14
Differential Cylinders .................................................15
Training Manual
SERVICE TRAINING
Table of Contents
Service Manual
SERVICE TRAINING
MPS Valve
Differential Cylinders
S3/Accumulator Valve
Rock Valve
Slewing Cylinder Accumulator Pump
Boom Pump
Rock Valve
PTO
Material Cylinders Hydraulic Pumps
PULL
TO APPLY
PARKING
QUARTZ
BRAKE
00000.1
PUSH TO
RELEASE 1 HOURS
PTO switch
Power to fuse
Must be pulled
Training Manual 1
SERVICE TRAINING
PTO
• Air is routed to the small cylinder mounted
in the distribution gear case (PTO).
• When the cylinder is pushed “in” the PTO is
in the pumping position.
• When the cylinder is pushed “out” the PTO
is in the travel position.
Air Supply Block All hydraulic pumps for the concrete pump, plac-
ing boom, agitator, etc. are mounted on a distri-
bution gearcase. When you are driving the truck,
the power of the truck engine is transmitted
through the truck transmission, through a propel-
ler shaft, through the bottom of the distribution
To:12v Controller
gearcase, through another propeller shaft, and
into the rear end(s) of the truck. When you are
operating the unit, the distribution
gearcase interrupts the power to the rear ends,
and transmits it to internal gears that turn the
hydraulic pumps. Changing between travel and
PTO.eps Fork pumping modes is accomplished by means of an
air switch in the truck cab.
Cont_Solenoid.eps
2 Training Manual
SERVICE TRAINING
CPC/CPCII Controller
The CPC/CPC II provides a proportional signal
CPC/CPC II
to
POWER
REAR CTR
UMB CTR
each of the boom functions and the concrete
RADIO CTR
ID
LINK
pump
ALARM
E-STOP
output. It also controls all on/off functions on the
unit. The CPC/CPC II receives power via the
WHEN WELDING ANYWHERE ON UNIT
POWER CABLE MUST BE DISCONNECTED
PTO switch through the Continuos duty solenoid
and into the “Power” connector.
L1357-01
“Power” Connector
Vector Controller
The Vector control system is a completely digi-
tal control system, which means that the function
movements are converted to numbers (0’s and
Vector 1’s). The numbers are sent to the controller
where they are analyzed, converted back to ana-
log (voltage or current), and sent to the valves
and indication devices.
1 2
OK OFF
0 x1000 3
PTO 1500 rpm 62˚C
Menu: [ENTER]=ON
X12 Connector
HOME + HELP START (Behind)
CLEAR - ENTER QUIT
Hydraulic Pumps
The hydraulic pumps for the concrete pump cir-
Typical Gearbox
cuit are bent axis, variable displacement piston
To: Boom Control Block To: Main Control Block pumps. They are horsepower controlled, which
means that as pressure rises towards maximum,
Pumpkit Pumps
the flow can decrease, so the power consumption
remains constant. We use this type of pump so
the truck engine will not bog down under hard
pumping conditions. The pumps also accept
external signals for control of the output. At
Schwing, we route signals to the pump from the
hydraulic stroke limiter. The net effect of these
devices is to tell the pump to put out less oil per
revolution, as required by the pump operator.
s
ps
.ep To: S3 Accumulator
um
ulicP
dra To: Agitator
Hy
Training Manual 3
SERVICE TRAINING
Fixed Displacement
Puts out a set amount of oil, that can only be
changed by increasing/decreasing the RPMs.
Fixed Dispalcement Variable Displacement
Bent Axis
Variable or Positive displacement pumps deliver
to the system, a variable amount of oil according
to the angle for the rotary group or swash plate.
min
min max
Variable Displacement
Swash Plate
PumpCutaways.eps
S1 Spool
From: Pump
From: Pump
S2 Spool
HiFlowBrain.eps
4 Training Manual
SERVICE TRAINING
From: Pump
HiFlowBrain_S1.eps
Training Manual 5
SERVICE TRAINING
Differential Cylinders
The term differential cylinder means that each
hydraulic cylinder that pushes the concrete has
an area difference (referred to as an “area differ-
ential”) between the two sides of the piston. This
Loop Oil area differential exists because the rod extends
only from one side of the piston. This is in con-
trast to the rock
valve slewing cylinder, for example, which has a
rod
extending from both ends of the piston and there-
fore has the same area on both sides of the piston
To:MPS ZK2 (it is a nondifferential cylinder).
To:MPS ZK1 • Hydraulic oil from the Main Control Block
flows to the rod side of the left hand differen-
High pressure oil
tial cylinder.
• The pressure from the hydraulic oil extends
the rod of the left hand differential cylinder.
From: Pumps • Loop oil on the piston side of the left hand
To:MPS ZS1 differential cylinder crosses over to piston
To:MPS ZS2 side of the right hand differential cylinder,
From: Pumps DiffCylinders.eps
causing that rod to retract.
6 Training Manual
SERVICE TRAINING
Material Cylinders
The material cylinders contain rubber rams that
are connected to the differential cylinder rods.
One side will push the concrete through the Rock
valve while the opposite side will suck concrete
from the hopper.
MatCylinders.e
To:MPS ZK2
To:MPS ZK1
From: Pumps
To:MPS ZS1
To:MPS ZS2
DiffCylinders_Bottom.ep
From: Pumps
Training Manual 7
SERVICE TRAINING
MPS Valve
The MPS system consists of three small direc-
tional control valves. The main pressure that is
X3 supplied to these directional control valve is sup-
To: Soft Switch
Reversing Valve
plied by the accumulator.
A B • A high pressure signal line from the Differ-
To:
S3 Spool ential Cylinder enters the MPS valve through
the “ZK2” port.
XB XA • This moves the NG 6 directional valve over
creating a passage way for the Accumulator
oil to flow through MPS valve and out the
ZS1 ZS2
“A” and “X3” port.
SP T
Passage way created
To:S3 Spool
To: S2 spool
Manual Bleed
S3_Block02.eps
8 Training Manual
SERVICE TRAINING
Accumulator Theory
The accumulator can be considered an energy
storage device for hydraulics, similar to the func-
tion of a battery in an electrical circuit. The accu-
mulator stores the oil flow of a small hydraulic
pump until it is time to shift the Rock Valve.
When needed all of the oil that as been stored in
the accumulator is quickly released. This has the
Without Nitrogen With nitrogen charged Influx of hydraulic oil following benefits:
Charge to pressure P1 for storage
• Lower power requirements for switching the
RockValve (less horsepower taken from the
engine).
• Simpler switching to begin the next stroke
(the differential cylinders get the signal to
change direction as soon as the S3 spool
moves, regardless if the Rock Valve has
moved or not).
Fluid charged to Discharge of Fluid discharged
maximum working hydraulic oil down to minimum
pressure P3 working pressure P2
AccumulatorTheory.eps
RockSlewingCylinder.eps
Training Manual 9
SERVICE TRAINING
From: Pump
S2 Spool
“XB” “XA”
10 Training Manual
SERVICE TRAINING
From Pumps
To:MPS ZS1
To:MPS ZS2
DiffCylinders_NewStroke.eps
From Pumps
MPS
Signal lost • A high pressure signal line from the Differ-
ential Cylinder is sent to the “ZK1” port of
X3 the MPS valve.
• Pressure is greater on the “ZK1” side of the
A B
NG 6 spool than the “ZK2” side.
• The NG 6 spool will move to the “right”
closing the passage way for high pressure
XB XA accumulator oil.
ZS1 ZS2
From: Differential Cyl.
ZK1 ZK2
SP T
Passage way closed
From: Differential Cyl.
Training Manual 11
SERVICE TRAINING
To:MPS ZK2
To:MPS ZK1
From Pumps
To:MPS ZS1
To:MPS ZS2
DiffCylinders_03.eps
From Pumps
MPS
• A high pressure signal line from the Differ-
ential Cylinder enters the MPS valve through
X3
To: Soft Switch
the “ZS2” port.
Reversing Valve • This moves the NG 6 directional valve over
A B
creating a passage way for the Accumulator
To: S3 Spool
oil to flow through MPS valve and out the
“B” port and unto the S3 spool.
XB XA
• Accumulator oil also travels out the “X3”
port and unto the Soft Switch Reversing
ZS1 ZS2 Valve.
From:
Differential Cylinder
To:Soft Switch Reversing Valve
ZK1 ZK2 To:S3 Spool
From:Differential Cylinder
SP T
12 Training Manual
SERVICE TRAINING
S3_Block.eps
To: Rock valve slewing cylinder
To: S2 spool Manual Bleed
Training Manual 13
SERVICE TRAINING
From: Pump
S2 Spool
14 Training Manual
SERVICE TRAINING
Differential Cylinders
• Hydraulic oil from the Main Control Block
flows to the rod side of the left hand differen-
tial cylinder.
• The pressure from the hydraulic oil extends
the rod of the left hand differential cylinder.
• Loop oil on the piston side of the left hand
differential cylinder crosses over to piston
side of the right hand differential cylinder,
causing that rod to retract.
From Pumps
Training Manual 15
SERVICE TRAINING
Boom Cylinder
To:Outrigger Function
Outrigger Handvalve
Boom Pump
P1
1 PM
M P4
T
T
P3
P2
Boom Handvalve
Estop Manifold
Boom Pump
To: Boom Control Block To: Main Control Block The hydraulic pump for the placing boom is a
variable displacement, bent axis, axial piston
pump. It feeds all of the following components:
• the hydraulic cylinders on the boom sections
• the hydraulic cylinders on the outriggers
• the hydraulic motor for the boom slewing
Boom Pump
gear
• the hydraulic motor for the water pump
• the hydraulic motor of the compressor
(optional equipment)
s
.ep To: S3 Accumulator
02
s_
ump
P
ulic To: Agitator
dra
Hy
Training Manual 16
SERVICE TRAINING
E-Stop Manifold
• Hydraulic oil from the boom pump enters the
P2 E-stop Manifold from the “P1” port.
T T • With the solenoid energized, a signal line
P3
P4
Equal Pressure
from the “P1” port enters the spring side of
P1 the poppet valve. This will equalize the pres-
Poppet Closed
sure on both sides of the poppet. The pres-
sure plus spring tension will hold the poppet
Energized Solenoid closed.
• If the solenoid is not energized, a passage
Signal Line from P1 port way will be created for the signal line to go
to tank.
P2 • This will create a pressure drop on the spring
T T side of the poppet valve.
P4 Greater Pressure
P3 Poppet Opened • Pressure from the P1 port will overtake the
P1 spring tension, allowing the poppet to open.
• A passage way is created for the oil from the
De-energized Solenoid “P1” port to escape to tank.
Training Manual 17
SERVICE TRAINING
E-Stop - Override
• Turn the bypass key switch to “Bypass”
Override
Concrete pump, position. If control is not restored, there
agitator, accumulator probably a hydraulic problem; Proceed to the
buttons dump valve
MP
S next step.
Boom/outrigger
T circuit dump • To manually bypass each system, the inlet
valve plumbing to the nonworking system must be
S
MP
by-pass2.eps
Apitech_Side_03.eps
From: Pump
18 Training Manual
SERVICE TRAINING
Apitech_Side_02.eps
Solenoid Energized
Passage open
From: Boom Pump
Outrigger Handvalve
The Outrigger hand valve is a simple control
device, containing four - 3 position, 6 way spools
attached to handles. The valve receives hydraulic
oil from the Boom Handvalve.
A B • In the neutral position, the passage way for
the hydraulic oil is blocked
• In the “extend” position, a passage way is
created between the pressure port and the
“A” port of the Outrigger hand valve.
• This will send oil to whatever outrigger func-
tion has been activated. Example “Outrigger
To: Outrigger Function Extend”.
A B
Training Manual 19
SERVICE TRAINING
Passage open
Apitech_Side_01.eps
From: Boom Pump
Control Disk
0.040 Orifice
Pilot Pressure
20 Training Manual
SERVICE TRAINING
LINE B
LINE A
From:Boom Handvalve
LINE B
LINE A
Boom 1
Boom 2
Boom 3
Boom 4
Boom 1 Telescope
Slewing
Boom / Outrigger
Water / Compressor
DANGER WARNING
10189517
WARNING
11. Agitator Handle
12. Two Position Boom/Outrigger Handle.
Clear area
before activating
outriggers
9
REAR EXTEND REAR JACKING FRONT JACKING FRONT EXTEND
Training Manual 21
SERVICE TRAINING
22 Training Manual
SERVICE TRAINING
Table of Contents
The Schwing Group ............................................................ 1 494 Block ....................................................................34
Schwing America, Inc. ................................................. 1 Hydraulically Unlockable CheckValve ......................35
Gate Valve ..................................................................35
Hydraulic Training 900-1200 Single Circuit .....................................................37
900-1200 Single Circuit Schematic ............................38
General Principles ............................................................... 3 Concrete Pump Control Block ....................................39
Mechanical Versus Hydraulic ............................................. 7 Stroke Limiter .............................................................40
Transfer of Energy .............................................................. 7 494 Block ....................................................................40
Switching Valve .........................................................41
Hydraulic Jack ..................................................................... 8
A7VO .........................................................................41
Linear & Rotary Actuators .................................................. 8 Rock Valve .................................................................42
Basic Hydraulic Components .............................................. 9 Phase A .......................................................................44
Check Valve Comparison ................................................. 10 Phase B .......................................................................45
Phase C .......................................................................46
Shuttle Valve ..................................................................... 11
Phase D .......................................................................47
Throttle Check Valve ........................................................ 12 Phase E .......................................................................48
Switching Valves .............................................................. 13 Phase F ........................................................................49
Hydraulic Pumps ............................................................... 14 Phase G .......................................................................50
Placing boom hydraulic pumps .................................. 14 Phase H .......................................................................51
Concrete pump hydraulic pumps ............................... 14 Phase I ........................................................................52
Phase J ........................................................................53
Fixed Displacement Pump ................................................ 15
Phase K .......................................................................54
Rexroth A2F20 ........................................................... 15
Troubleshooting .................................................................55
Variable Displacement Pump ............................................ 15
Rexroth A7VO ........................................................... 15 High-Flow Single Circuit 2020/2023 ................................61
High-Flow Single Circuit Schematic ..........................62
Variable Displacement Axial Piston Pump ....................... 16
Concrete Pump Control Block ....................................63
RexrothA10VO .......................................................... 16
Switching Manifold ....................................................64
RexrothA11VO .......................................................... 16
Stroke Limiter with Fast Switch/Dampner .................64
Rexroth A11VO Adjustments .................................... 17
Phase A .......................................................................66
Transfer Cases ................................................................... 18 Phase B .......................................................................68
Relief Valves ..................................................................... 19 Phase C .......................................................................70
Safety Relief Valves .......................................................... 20 Phase D .......................................................................72
Pressure Relief Valve Type DB ................................. 20 Twin Circuits .....................................................................74
Pressure Relief Valves Type DBW ............................ 20 1200 Twin Circuit with Switching Valves ........................75
Hydraulic Symbols ............................................................ 21 Twin Circuit Schematic w/Soft Switch ......................76
Hydraulic Symbols (Cont.) ............................................... 22 Concrete Pump Control Block ....................................77
S3 Control Block ........................................................77
Hydraulic Symbols (Cont.) ............................................... 23
Soft Switch .................................................................78
Hydraulic Symbols (Cont.) ............................................... 24 Accumulator Unloader Valve .....................................78
Hydraulic Symbols (Cont.) ............................................... 25 Accumulator Control Block/Dump Valve ..................79
Hydraulic Symbols (Cont.) ............................................... 26 Phase A .......................................................................80
Phase B .......................................................................82
Hydraulic Symbols (Cont.) ............................................... 27
Phase C .......................................................................84
Formulas ............................................................................ 28 Phase D .......................................................................86
1200 Twin Circuit with MPS .............................................89
Pumpkits Twin Circuit with MPS/Soft Switch ...........................90
Concrete Pump Control Block ....................................91
800 Gate Valve .................................................................. 30 S3 Control Block ........................................................91
801 Gate Valve .................................................................. 31 MPS ............................................................................92
801 Pumpkit Schematic ............................................. 32 Accumulator Control Block/Dump Valve ..................93
Concrete Pump Control Block ................................... 33 Soft Switch .................................................................94
Stroke Limiter ............................................................ 34 Phase A .......................................................................96
Training Manual
Table of Contents
Phase B .......................................................................98 Using a Nomograph ........................................................ 159
Phase C .....................................................................100 General information ................................................. 159
Phase D .....................................................................102 The quadrants ........................................................... 161
Twin Circuit with Variable displacement Minimum Pipe Wall Thickness ....................................... 167
accumulator pump Schematic 104
Preventative Maintenance ............................................... 168
Model Number Nomenclature .........................................105 Scheduled Maintenance ........................................... 168
Hi-Flow Pumpkits (2023-2525) ......................................106 Filtration .......................................................................... 170
Hi-Flow Pumpkits (2525H) .............................................107 General information ................................................. 170
Hi-Flow Pumpkits Schematic ...................................108 Specific information ................................................. 170
Concrete Pump Control Block .................................109 Changing hydraulic oil filters .................................. 170
Main Relief/Soft Switch Block ................................110 Changing high pressure water filter ......................... 171
MPS ..........................................................................111 Hydraulic Oils ................................................................. 171
S3 Control Block - Machined ...................................112 General information ................................................. 171
S3 Control Block - Cast ...........................................113 Specific information ................................................. 172
2023 Circuit diagram ................................................114 When to change your hydraulic oil .......................... 172
Phase A .....................................................................114
Phase B .....................................................................116
Phase C .....................................................................118 Electrical
Phase D .....................................................................120 Introduction ..................................................................... 173
What is Electricity? ......................................................... 173
Booms Amperage ........................................................................ 176
Black & White .................................................................123 Voltage ............................................................................ 177
Electric/Air/Oil .........................................................123 Resistance ........................................................................ 177
Electric/Oil/Oil .........................................................123
Basic Circuits .................................................................. 179
Proportional .....................................................................125
Schematics ...................................................................... 181
Boom Holding Valves .....................................................126
Circuit Types ................................................................... 181
28X B&W Boom .............................................................127
Ohm’s Law ...................................................................... 183
Load Sense Hydraulic Circuits ........................................131
Series Circuit Laws ......................................................... 185
Overview ..................................................................131
Components ..............................................................132 Parallel Circuit Laws ....................................................... 186
Basic Principles - Simple Circuit .............................133 Series – Parallel Circuits ................................................. 188
Basic Principles - Orifice .........................................134 Circuit Faults ................................................................... 189
Basic Principles - Without Relief Valve ..................135
Using Test Equipment ..................................................... 190
Basic Principles - With Relief Valve .......................136
The Troubleshooting Process ................................... 195
Basic Principles - Delta-P ........................................137
Basic Principles - Delta-P ........................................138 Electrical Symbols .......................................................... 196
Basic Principles - Pressure Cut-Off .........................139 Electrical Symbols .......................................................... 197
Basic Principles - Shuttle Valves .............................140 Electrical Symbols .......................................................... 198
Basic Principles - Pressure Regulator ......................141
Controller Systems .......................................................... 199
A7 Variable Displacement Hydraulic Pump Training ....142 Analog ...................................................................... 199
All Functions in Neutral ...........................................142 Digi-Prop (Microwave) ............................................ 199
Cylinder Extend Function Initiated ..........................144 Comfort Control ....................................................... 199
Hydraulic Cylinder Extending .................................146 C32 ........................................................................... 200
Hydraulic Cylinder Fully Extended Pump ...............148 CPC .......................................................................... 200
Fixed Displacement Pump Training ................................150 CPC II ...................................................................... 200
All Function in Neutral ............................................150 Vector - Current Production ..................................... 201
Boom Function Activated ........................................151 28X Truck and Pumpkit Circuit ...................................... 203
Cylinder Pressurized at the End of Stroke ...............152
28X Boom Circuit ........................................................... 204
Output Charts ...................................................................153
Using the Chart ................................................................154
Training Manual
SERVICE TRAINING
Table of Contents
Misc Procedures
Material Cylinder Alignment .......................................... 205
Pumping on piston side ................................................... 207
(Available on some units only) ................................ 207
Shimming the Differential Cylinders .............................. 208
Determining the proper shimm size ......................... 208
Dimension A ............................................................ 208
Dimension B ............................................................ 208
Formula .................................................................... 209
Apitech Control Chamber Air Bleed Procedure ............. 210
Hydraulic Pump Adjustments ......................................... 213
Main System Pumps A11VO ................................... 213
Setting the Flow Rate ............................................... 213
Horsepower Setting .................................................. 214
Q-min Output Flow .................................................. 214
Check all hydraulic pressures. ................................. 215
Setting pressures on Hi-flo -6 pumpkits .................. 215
Pressure setting procedure: ...................................... 216
Setting the soft switch relief pressure ...................... 217
Accumulator Bypass Retrofit .......................................... 219
Service Bulletin 1001-03 ......................................... 219
Trouble Shooting Kit ...................................................... 220
Training Manual
Table of Contents
Training Manual
SERVICE TRAINING
Training Manual 1
SERVICE TRAINING
machining center, which is home of the new Forrest every surface with high quality acrylic urethane in an
Line machining Center. endless array of colors and paint schemes. Climate
For the year 2000, Schwing America, Inc. has added a controlled conditions assure proper curing and drying
75,000 sq. ft paint booth. This state-of-the-art time. A new solvent recovery system keeps the Super
behemoth is the largest building in the surrounding Booth environmentally friendly.
communities. Dubbed the “Super Booth” by industry
insiders. This is the largest facility for painting Today Schwing America has over 326,000 square feet
concrete pumps in the world. The six-story structure of manufacturing space and employs over 400 people.
combines with retractable roof panels to accommodate
unfolded booms. Painters will use catwalks to cover
N S
2 Training Manual
SERVICE TRAINING
Hydraulic Training
General Principles
1. Hydraulic pressure always takes path of least
resistance.
Pascal's Law
Training Manual 3
SERVICE TRAINING
Seals
Hydraulic Cylinder
Water Box
6 bar
4 Training Manual
SERVICE TRAINING
0 GPM 10 GPM
10 gallon maximum
capacity cylinder
10 inch of area on
cylinder piston
1000 PSI
Training Manual 5
SERVICE TRAINING
U.S.
F = FORCE (in pounds) (lb)
P = PRESSURE
(in pounds per square inch) (P.S.I.)
F F=PxA
A = AREA (in square inches) (in2)
P = F/A
P A METRIC
A = F/P
F = FORCE (in kilograms) (Kg)
P = PRESSURE
(in kilograms per square centimeter) (Kg/cm2)
A = AREA (in square centimeters) (cm2)
GENERAL
Q = FLOW RATE
QxP (unit of volume per time period)
POWER = P = PRESSURE
CONSTANT
(unit of force per unit of area)
U.S.
HP = HORSEPOWER
GPM x PSI GPM = GALLONS PER MINUTE
HP =
1714
PSI = POUNDS PER SQUARE INCH
1714 = KNOWN CONSTANT
METRIC
KW = KILOWATTS
LPM x BAR
KW = LPM = LITERS PER MINUTE
600
BAR = METRIC UNIT OF PRESSURE
600 = KNOWN CONSTANT
6 Training Manual
SERVICE TRAINING
2. develops a pressure of
10 pounds per square inch(psi)
(.69 bar) (68.94 kilopascals)
throughout the container.
100 lb.
(444.82 N)
10 lb.
(44.48 N)
Transfer of Energy
ENERGY CAN NEITHER BE CREATED NOR DESTROYED
1. Moving the small piston 10 in. 2. 10 cu. in. (163.8 cm3) of liquid
0.25 m) displaces 10 cu. in. will move the larger piston only
(163.87 cm3) of liquid. 1 in. (2.54 cm)
(1 sq. in. x 10 in. =10 cu. in.) (10 sq. in. x 1 in. = 10 cu. in.)
(6.45 cm2 x 25.40 cm = 163.87 cm3) (64.52 cm x 2.54 cm = 163.87 cm )
100 lb.
10 lb. (444.82 N)
(44.48 N)
1 sq. in.
(6.45 cm2) 10 sq. in.
(64.51 cm2)
1 in
(0.02 m)
10 in
(0.25 m)
Training Manual 7
SERVICE TRAINING
Hydraulic Jack
HYDRAULIC
8"
ROD
PISTON
MOTOR
PUMP
LOAD
PUMP
TO RESERVOIR ROTARY
DRIVE SHAFT
8 Training Manual
SERVICE TRAINING
Check Valve
Throttle Valve
Switching Valve
Training Manual 9
SERVICE TRAINING
CARTRIDGE CARTRIDGE
W/SEALS W/SEALS
P/N 30333032 P/N 30333033
TORQUE TORQUE
SPECIFICATION SPECIFICATION
55 ft/lbs. 200 ft/lbs.
10 Training Manual
SERVICE TRAINING
Shuttle Valve
B
A shuttle valve is used where the higher of the two
pressures must be selected, while blocking the lower
pressure input. A C
A C
The valve has two inlet, ports “A” and “C”, and one
output port “B”. When either port A or C is
pressurized, a ball automatically seals the other inlet
and allows the higher pressure fluid to flow to port “B”.
B B
A C A C
Greater pressure from "A" port Greater pressure from "C" port
39000145.ai
Training Manual 11
SERVICE TRAINING
5 4 3 1 6 2
5 4 6 5 4 6
12 Training Manual
SERVICE TRAINING
SPRING
GUIDE
SPRING
GUIDE
SPRING
POPPET
Training Manual 13
SERVICE TRAINING
PumpKit Pumps
Boom Pump
Accumulator Pump
Agitator Pump
Stiebel 4194 Stiebel 4400
PumpKit Pumps
Proportional Boom Pump PumpKit Pumps
Accumulator Pump
14 Training Manual
SERVICE TRAINING
Q min
Q max
Q min
0ß
25ß -
Q max
Training Manual 15
SERVICE TRAINING
Q min
Q max
16 Training Manual
SERVICE TRAINING
Pressure Cut-Off
Pressure Cut-Off
Delta P
Q min Q min
Load Sense Port
Q max
Q max
Horsepower Control
*Stroke *Stroke Regulation
Regulation **Pressure Cut-Off
Pressure Cut-Off
Horsepower
Control
Style #1
***Pressure Cut-Off
Q min
Horsepower
Q min Control
*Stroke Regulation
Style #2
* The beginning of stroke regulation has been increased from 5-7 ** Pressure Cut-Off / Style #1
bar to 8-10 bar on pumps with the following serial numbers: Turn Clock-wise to increase the pressure
Turn Counter-Clock-wise to decrease the pressure
A11VO 130 - 21034174, dated 08/22/05
A11VO 190 - 21006318, dated 08/01/05
*** Pressure Cut-Off / Style #2
Pumps with serial numbers below these should also have Turn Counter-Clock-wise to increase the pressure
beginning of stroke regulation pressure set to 8-10 bar. Turn Clock-wise to decrease the pressure
Training Manual 17
SERVICE TRAINING
Transfer Cases When you are operating the unit, the distribution
gearcase interrupts the power to the rear ends, and
Hydraulic pumps for the concrete pump, placing boom, transmits it to internal gears that turn the hydraulic
agitator, etc., are usually mounted on a distribution pumps. Changing between travel and pumping modes
gearcase. When you are driving the truck, the power of is accomplished by means of an air switch in the truck
the truck engine is transmitted through the truck cab.
transmission, through a propeller shaft, through the
bottom of the distribution gearcase, through another
propeller shaft, and into the rear end(s) of the truck.
4194 4195
4400
18 Training Manual
SERVICE TRAINING
Pressure Pressure
Tank
Tank
Pressure
Pressure
Tank
Tank
Training Manual 19
SERVICE TRAINING
VENT
LINE
20 Training Manual
SERVICE TRAINING
Hydraulic Symbols
LINE, WORKING
P = R 1/2"
T = R 1/2"
SP = R 3/4"
Nitrogen pressure set at 55 bar G = R 3/8"
(800 PSI) AC = R 11/2"
Y = R 3/8"
G
1.9 mm
LINE, JOINING
S3 ("T" FITTING)
P T
NG
10 10 Filter
Agitator
A LINE, PLUGGED
P R
RESTRICTION, FIXED
(orifice, nozzle)
100 G Y
bar
0.7 mm
12 Filter
A11VO
LINE, WORKING
LINE, PASSING
LINE, PLUGGED
LINE, JOINING
("T" FITTING)
1.3 1.3
RESTRICTION, FIXED
(orifice, nozzle) OR
Training Manual 21
SERVICE TRAINING
X1
M X2
A
A1
PRIME MOVER,
ELECTRIC MOTOR
PUMP, SINGLE
VARIABLE DISPLACEMENT,
SHOWING HORSEPOWER S
CONTROL CIRCUITS.
PRIME MOVER,
INTERNAL COMBUSTION ENGINE
(Diesel shown..."G" if gas.) MOTOR, ROTARY,
FIXED DISPLACEMENT
MOTOR, ROTARY,
FIXED DISPLACEMENT
BI - DIRECTIONAL
22 Training Manual
SERVICE TRAINING
ACCUMULATOR,
GAS CHARGED
FILTER OR STRAINER
Training Manual 23
SERVICE TRAINING
320 BAR
HYDRAULICALLY UNLOCKABLE
CHECK VALVE WITH INTEGRAL
RELIEF VALVE.
(H.E.R. BOOM HOLDING VALVE)
NORMALLY OPEN
A 2.0
CHECK VALVE, FIXED FORCE
(SPRING FORCE INDICATED) 300 bar
PRESSURE RELIEF VALVE
WITH EXTERNAL DRAIN
(SHOWN WITH A NORMALLY
OPEN SOLENOID VALVE...
MANY OTHER POSSIBILITIES
ARE AVAILABLE).
24 Training Manual
SERVICE TRAINING
P 0-55 bar A
Y(T)
A
PRESSURE REDUCING VALVE ACCUMULATOR P Y T
MANUAL (STROKE LIMITER) OR UNLOADING VALVE
DAMPNER
B 70 bar 300
0-50 bar
bar
A
PRESSURE REDUCING VALVE
(ELECTRIC STROKE LIMITER) P
ACCUMULATOR DUMP VALVE
P
(ELECTRIC)
T T
A 55 bar
T
P
T
MG Pressure
P
G
reducing valve A
MY Y
Electric
stroke limiter
1.5
P P
A
A
P
Training Manual 25
SERVICE TRAINING
X1
X2
A
A1
COMPONENT ENCLOSURE
BRAKE VALVE
(BERINGER) X A
(USED ON #1 SECTION
DOWN FUNCTION)
BALL COCK
(SHUT OFF VALVE,
QUARTER TURN VALVE)
B
BRAKE VALVE
(COUNTERBALANCE VALVE)
(USED ON ALL SECTIONS KVM 52 & 55)
X A
B
R Z
X A Y
BRAKE VALVE (SAUER)
(USED ON #1 SECTION
DOWN FUNCTION)
Z VENTED RESERVOIR
(TANK)
26 Training Manual
SERVICE TRAINING
SPRING
DIRECTIONAL VALVE
3 POSITION, 4 WAY, CLOSED CENTER
MANUAL
DIRECTIONAL VALVE (HANDLE OR PUSHBUTTON)
3 POSITION, 4 WAY, OPEN CENTER
DETENT
DIRECTIONAL VALVE
3 POSITION, 4 WAY
CLOSED PRESSURE CENTER
HAND LEVER
DIRECTIONAL VALVE
3 POSITION, 4 WAY, TANDEM CENTER
(REQUIRES A HOLLOW SPOOL) EXAMPLES OF COMBINATIONS OF METHODS
X OR
PRESSURE REGULATOR P
(REGULATES DELTA P) A T
USED ON LOAD SENSING SYSTEMS
Training Manual 27
SERVICE TRAINING
Formulas
5 2.5
10,000
Pounds
To move this load it will take To move this load it will take
about 510 psi about 680 psi
5100 6800
= 2.975 HP = 3.967 HP
1714 1714
28 Training Manual
SERVICE TRAINING
Pumpkits
Single Circuit Pumpkits Twin Circuit Pumpkits
Training Manual 29
SERVICE TRAINING
30 Training Manual
SERVICE TRAINING
Training Manual 31
SERVICE TRAINING
5
Pipe Gate
Hopper Gate
9B
9A 6
4 3
7
300
bar
10A 10B
D
12A 12B 11C 2 2
32 Training Manual
SERVICE TRAINING
9B T P1
9A
9B
T
6
S3
S1 4
1.5 mm
hole drilled
through spool 300 B
7
bar
A
S2
3
8 9A
S-1
S-2
S-3
39000155.eps
Training Manual 33
SERVICE TRAINING
Stroke Limiter
1
P
2 A
4 T
P
3
4 0-50
BAR
1
3
2 T
A
39000158.eps
494 Block
A
agitator
5 motor
3 B
6
P
1 Agitator H2O pump
pressure* motor
2
3 6 A
2 B
H2O
pressure*
1
4
2 1
4
39000157.eps
CA B
34 Training Manual
SERVICE TRAINING
C
B
A
B
C
B 2
1
A
1
C
0.7 2
mm
39000160.eps
Gate Valve
A 1 B D
1
A C
2
D
2
C 39000163.eps
Training Manual 35
SERVICE TRAINING
36 Training Manual
SERVICE TRAINING
Single Circuit
Training Manual 37
SERVICE TRAINING
10A 10B 11
7 3
4
10D
10C
10E D
9A
2 2
8A 8B
9B 12
10F
38 Training Manual
SERVICE TRAINING
P1
S3 P2
X
10B
P
1.5 mm
T
hole drilled
through spool
6
S1 4
X
R
B
7
300 bar
3 A
S2
10A
Port size
limits flow
S-1
S-2
S-3
39000147.eps
Training Manual 39
SERVICE TRAINING
Stroke Limiter
1
P
2 A
4 T
P
3
4 0-50
BAR
1
3
2 T
A
39000158.eps
494 Block
A
agitator
5 motor
3 B
6
P
1 Agitator H2O pump
pressure* motor
2
3 6 A
2 B
H2O
pressure*
1
4
2 1
4
39000157.eps
CA B
40 Training Manual
SERVICE TRAINING
Switching Valve
C
C
B B
2
1
A
2
1
39000161.eps
A7VO
1
A
2 Q min
1
2
B
Q max
X1 A B X1
X2 X2
A A
1 1
A1 A1
D
2 2
To
Boom
Circuit
S S 39000162.eps
Training Manual 41
SERVICE TRAINING
Rock Valve
1
2
D
A B C
2
A
1
E F GH
B
C
D
F
G
H E
39000164.eps
42 Training Manual
SERVICE TRAINING
Training Manual 43
SERVICE TRAINING
KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
12 13 18
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
44 Training Manual
SERVICE TRAINING
End of first working stroke * NOTE: If the left hand differential has not fully
extended at this point due to not enough loop oil, high
The differential cylinders have reached the end of their
pressure oil will continue to flow through check valve
stroke position*. Switching valve (5) is sending a high
(17) on the right hand differential until the left hand
pressure signal to the left hand end cap of S3 valve (3).
differential is fully extended.
Oil from the right hand end cap of the S3 valve (3) is
relieved via check valve (15), the S2 valve (2), S1 valve
KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
12 13 18
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 45
SERVICE TRAINING
Phase C cylinder (4) is changed and the right hand side of the
cylinder is getting oil so that the cylinder will extend.
Rock valve cylinder getting oil to extend
Oil from the left hand side of the rock valve shift
High pressure oil from switching valve (5) has now cylinder is routed to tank via valves (3, 1) and filter (7).
shifted the S3 valve (3) fully to the right hand position.
At this point the pressure oil to the rock valve shift
KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
12 13 18
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
46 Training Manual
SERVICE TRAINING
Phase D rock valve shift cylinder (4). As the S2 valve (2) shifts
to the right oil from the right hand end cap of the S2
S2 valve getting signal to shift
valve (2) is routed to the hydraulic tank via check valve
The rock valve shift cylinder (4) has now fully (13), valves (3, 1) and the filter (7).
extended. At this point a signal is sent to the left hand
end cap of the S2 valve (2) from a signal port on the
KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
12 13 18
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 47
SERVICE TRAINING
KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
12 13 18
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
48 Training Manual
SERVICE TRAINING
Phase F via the loop hose. The oil on the rod side of the right
hand differential is going through valves (2 and 1),
Middle of the second working stroke (diagram 6) filter (7) and back to the tank. Oil directed through the
Pressure oil is being routed through the S1 valve (1) S3 valve has the rock valve shift cylinder held in the
and S2 valve (2) to the rod side of the left hand extended position so that concrete from the right hand
differential cylinder causing it to retract. Oil from the material cylinder is being pushed into the delivery pipe
piston side of the left hand differential cylinder is line and concrete from the hopper is being sucked into
passed to the piston side of the right hand differential the left hand material cylinder.
KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
12 13 18
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 49
SERVICE TRAINING
Phase G (3) is relieved via check valve (14), the S2 valve (2), S1
valve (1), filter (7) and back to the hydraulic tank.
End of second working stroke (diagram 7) * NOTE: If the left hand differential cylinder has not
The left hand differential cylinder has now fully fully retracted at this point because of to much loop oil,
retracted*. Switching valve (6) is sending a high high pressure oil will continue to flow through check
pressure signal to the right hand end cap of the S3 valve (16) and back to the hydraulic tank until the left
valve (3). Oil from the left hand end cap of the S3 valve hand differential cylinder is fully retracted.
KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
12 13 18
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
50 Training Manual
SERVICE TRAINING
KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
12 13 18
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 51
SERVICE TRAINING
Phase I the rock valve shift cylinder (4). As the S2 valve (2)
shifts to the left oil from the right hand end cap of the
S2 valve getting signal to shift
S2 valve (2) is routed to the hydraulic tank via check
The rock valve shift cylinder (4) has now fully valve (12), valves (3, 1) and filter (7).
retracted. At this point a signal is sent to the right hand
end cap of the S2 valve (2) from a signal port on the on
KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
12 13 18
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
52 Training Manual
SERVICE TRAINING
KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
12 13 18
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
Training Manual 53
SERVICE TRAINING
Phase K
First working stroke
Refer to diagram 1 for explanation of first working
stroke.
KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
12 13 18
3 S3
1.5 mm
hole drilled
through spool S1
300
1 bar
2 S2 10
15
14
20
16
7
5 8
M
6
17 6 bar
54 Training Manual
SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
A
OPEN B
S3
1.5 mm
hole drilled
through spool S1
300
bar
S2
6 bar
Training Manual 55
SERVICE TRAINING
Before rock valve shifts to the right the differential continues to get pressure oil to the rod side
unit builds high pressure, left differential so that the excess rocking oil can be exhausted through
continues to move, right differential has check valve (A). As soon as the left hand differential
stopped. has fully retracted a signal will be sent out of the
switching valve to S3 valve.
The unit has too much rocking oil and the right hand
differential has reached it’s stop. The left hand
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
S3
1.5 mm
hole drilled
through spool S1
300
bar
S2
6 bar
56 Training Manual
SERVICE TRAINING
Rock valve shifts and as soon as the right hand differential for the start of the next stroke.
differential cylinder shifts the rock valve However since check valve (A) is stuck open and the
shifts again (machine gunning). pressure oil shifts the S3 valve to the right causing the
rock valve to shift to the left. (See diagram 3B).
The rock valve has shifted to the right and a signal
from the rock valve has shifted the S valve to the left.
The pressure oil is supposed to go to the rod side of the
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
S3
1.5 mm
hole drilled
through spool S1
300
bar
S2
B
A
Note:
Stuck Open
6 bar
Training Manual 57
SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
S3
1.5 mm
hole drilled
through spool S1
300
bar
S2
B
A
Note:
Stuck Open
6 bar
58 Training Manual
SERVICE TRAINING
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
S3
1.5 mm
hole drilled
through spool S1
300
bar
S2
B
A
Note:
Stuck Open
6 bar
Training Manual 59
SERVICE TRAINING
Rock valve shifts to the right and then the NOTE: If the ball cock was partially closed the
machine builds high pressure. machine would continue to stroke, however there
would be a pressure spike between the time the rock
After the rock valve is done shifting to the right a valve is done shifting and the differential cylinders start
signal is supposed to be sent to the right hand end cap moving.
of the S2 to shift it to the left, however the signal will
not reach the S2 end cap because the ball cock is
closed.
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
Ball Cock
S3
1.5 mm
hole drilled
through spool S1
300
bar
S2
Note:
Stuck Open
6 bar
60 Training Manual
SERVICE TRAINING
Single Circuit
S3 shifting by signal from Switching valve
Training Manual 61
SERVICE TRAINING
5 1
T SP
9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B
X3
A2 B2
A3 B3
10C S3 6 10D
XA1 XB3
1.5
A B
A1 B1
S2 7
XA XB
11 PR
PP
S1 4
XR XP
P2 P1
MP
10E
1.8 T2 T1
1.2
12
3 1.4
300 bar
8A X1
8B 10F
T
1.8
2 2
1
62 Training Manual
SERVICE TRAINING
A2 B2
A3 B3
6
XA1 S3 XB3 X1 MP P2
T2
P
1.5
R
A B
T
X
R
A1 B1
X
7
A
S2
XA XB
P1
T1
X
A
PR
1
PP
P
P
S1 4
XR XP
P2 P1
XP
X
B
A3
1
MP
T2 T1
XB A2
12 1.2 4
3 B2
5
XB B3
1.4
300 bar
X1
3
T
5 6
Training Manual 63
SERVICE TRAINING
Switching Manifold
10B T SP
9A
3.5MM Orifice 1.3MM Orifice
ZS2 1.3 ZS1
9C 9B
9C
XA XB
A 3.5 3.5 B
10A 10B
9A
9B X3
MPS_SC.eps
MG2 G2 6
4
Reversing Valve 11
(for Fast Switch) Dampner 3
6 7 20 0.7
bar
0-30
bar
1 9 X1
8 MX1
3.5-40 8
12 bar
2 10 MG1 5
4
2 0.7
MP 3.5-40
bar
9
12
PBP PZ T
10
5
11
1
3
SC_FastSwitchDampner.eps
64 Training Manual
SERVICE TRAINING
Training Manual 65
SERVICE TRAINING
Phase A
• Pressure oil (red) flows through the S3 valve (6)
(cross-over position) into the retract side oil port
of the rock slewing cylinder (5).
66 Training Manual
SERVICE TRAINING
T SP
9A
ZS2 1.3 ZS1
9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B
10A 10B
X3
10C A2 B2 10D
A3 B3
S3 6
XA1 XB3
1.5
A B
A1 B1
S2 7
11 XA XB
PR
PP
S1 4
XR XP
P2 P1
MP
10E
1.8 T2 T1
1.2 12
8A 8B
3 1.4
300 bar
X1
2 2
1.8
T 1
10F
Training Manual 67
SERVICE TRAINING
Phase B
• The right side differential cylinder (8B) reaches
bottom dead center. If there is not enough rocking
oil in the loop to bring the left side cylinder to the
top dead center position, oil will be added now
through check valve 10F.
68 Training Manual
SERVICE TRAINING
T SP
9A
ZS2 1.3 ZS1
9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B
10A 10B
X3
10C A2 B2 10D
A3 B3
S3 6
XA1 XB3
1.5
A B
A1 B1
S2 7
11 XA XB
PR
PP
S1 4
XR XP
P2 P1
MP
10E
1.8 T2 T1
1.2 12
8A 8B
3 1.4
300 bar
X1
2 2
1.8
T 1
10F
Training Manual 69
SERVICE TRAINING
Phase C
• The rock valve slewing cylinder (5) reaches the
top dead center position.
70 Training Manual
SERVICE TRAINING
T SP
9A
ZS2 1.3 ZS1
9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B
10A 10B
X3
10C A2 B2 10D
A3 B3
S3 6
XA1 XB3
1.5
A B
A1 B1
S2 7
11 XA XB
PR
PP
S1 4
XR XP
P2 P1
MP
10E
1.8 T2 T1
1.2 12
8A 8B
3 1.4
300 bar
X1
2 2
1.8
T 1
10F
Training Manual 71
SERVICE TRAINING
Phase D
• The left side differential cylinder retracts (8A) to
bottom dead center. The right side differential
cylinder extends to top dead center (shown in their
new positions).
72 Training Manual
SERVICE TRAINING
T SP
9A
ZS2 1.3 ZS1
9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B
X3
10C A2 B2 10D
A3 B3
S3 6
XA1 XB3
1.5
A B
A1 B1
S2 7
11 XA XB
PR
PP
S1 4
XR XP
P2 P1
MP
10E
1.8 T2 T1
1.2 12
8A 8B
3 1.4
300 bar
X1
2 2
1.8
T 1
10F
Training Manual 73
SERVICE TRAINING
Twin Circuits the oil to change directions, oil is also routed to the
valve that changes the direction of the differential
Beginning in 1995, most units became available with cylinders. If the rock valve cylinder has enough
optional twin circuit switching. “Twin Circuit” refers pressure available to switch, it will do so. If not, it will
to the fact that there is one hydraulic circuit to move wait. As soon as the differential cylinders have changed
the differential cylinders, and another separate circuit directions, one of the following things will happen:
to switch the rock valve. On single circuit units, the
If the rock valve has already switched, concrete will
main hydraulic pumps move the main differential
immediately be drawn from the hopper, and pushed
cylinders AND the rock valve.
into the pipeline, which is just a normal stroke.
There are certain advantages to having a separate
hydraulic circuit to switch the rock valve. For example, If the rock valve has NOT already switched, concrete
under the single circuit system, if you were pumping a will begin to be drawn from the pipeline and pushed
stiff, lean mix and pressure was running high, it would into the hopper. This reduces the pressure in the
also take quite a bit of pressure to switch the rock pipeline to zero. As soon as pressure in the pipeline is
valve. There were even a few isolated cases where the relieved, the rock valve switches across. It doesn’t slam
rock valve wouldn’t switch because there wasn’t and it doesn’t pound, it just moves. As soon as the rock
enough pressure available, usually when pumping valve has moved, concrete is accelerating out of the
straight up. The reason that it was hard to switch the unit like normal.
rock valve was because the valve had to try to dislocate The concrete is not actually pumped in reverse,
a column of concrete that still had pressure on it from because as soon as the pressure in the pipeline drops to
the stroke. The next stroke could not begin until the zero, the rock valve switches. A complete description
rock valve had completed it’s travel. of the twin circuit switching sequence is found in this
When using twin circuit, the differential cylinders do chapter starting on page 56. This system has the added
not have to wait for the rock valve before they change benefit of reducing wear on the cutting ring, the
directions and begin the next stroke. As soon as the S-3 spectacle plate, the kidney seal and kidney plate, as
spool changes directions, which gives the rock valve well as the rock valve slewing cylinder.
S1
Single Circuit
S2 Twin Circuit
S1
S2
S3
S3
74 Training Manual
SERVICE TRAINING
Accumulator oil switches the rock Rock may or may not shift at the
same time as the differential cylinders
Training Manual 75
SERVICE TRAINING
14
5 1
11 19
S3 6 15
16
8A 8B 17
9A
18
10C
1
10D 1
9B
22 NG
10B 10A 10 13
23
7 1
4
S2
S1 3
0.7 mm
21
24 12
2 20
1
76 Training Manual
SERVICE TRAINING
P1
P2
X
P
S1 4
T
7 3
300 bar
B
X
S2
R
Port size
A
limits flow
S-1
2
S-2
39000148.eps
S3 Control Block
6
S3
39000149.eps
Training Manual 77
SERVICE TRAINING
Soft Switch
2
4
3
1
0.7 mm
3 2
80
bar
Soft switch
39000151.eps
A
2
1
1
2
P Y T
39000153.eps
78 Training Manual
SERVICE TRAINING
1
2
Nitrogen pressure set
7 at 100 bar (1450 PSI)
4 2 300 1
3 bar
5
6
6
T Y P
5
7
39000152.eps
Accumulator Pump
200 bar
A11 A10
39000154.eps
1
Training Manual 79
SERVICE TRAINING
The following diagrams A through D show the • The oil that is forced out of the piston side of the
switching functions of the concrete pumpkit plumbed right differential cylinder (8B) flows through
on the ROD SIDE with simplified schematics. The hoses into the piston side of the left differential
agitator, boom, and S-1 control circuits are not shown. cylinder (Item 8A). This oil is called rocking oil
(orange).
Phase A
• The rocking oil forces the left side differential
• As soon as you switch the unit distribution cylinder (8A) to extend. The cylinder rod extends,
gearcase to the pumping position, the accumulator pushing concrete out of the material cylinder,
hydraulic pump (20) begins pumping high through the rock valve, and into the pipeline. (This
pressure oil (red) to charge the accumulator circuit is called the pressure stroke.)
(14).
• The oil from the rod side of the left differential
• The high pressure oil (red) from the accumulator cylinder (8A) is routed back to the tank through
circuit charges the accumulator (14). When the the return filter (12). The low pressure oil is shown
accumulator pressure reaches the setting of the in green.
accumulator dump valve (13), the accumulator
dump valve opens and routes the oil from the • The oil shown in blue, such as the oil in the
accumulator charge pump (20) back to the reservoir, is at rest, or pressureless.
reservoir (1).
80 Training Manual
SERVICE TRAINING
6.3
Phase A Twin Circuit
mm
14
Nitrogen pressure
5 1 set at 100 bar
6.3 (1450 PSI)
mm
19
11
S3 15
16
8A 8B 17
9A 6 300
bar
18
10C
1
10D 1
9B
22 NG
10 13
10B 10A
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
S1 320 3
0.7 mm bar
21
KEY
High Pressure
12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
Training Manual 81
SERVICE TRAINING
Phase B
• The oil from the left side of the rock valve slewing
cylinder (5) is routed back to tank (1).
82 Training Manual
SERVICE TRAINING
6.3
Phase B Twin Circuit
mm
14
Nitrogen pressure
5 1 set at 100 bar
6.3 (1450 PSI)
mm
11 19
S3 15
16
8A 8B 17
9A 6 300
bar
18
10C
1
10D 1
9B
P
22 NG
10B 10A 10 13
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
S1 320 3
0.7 mm bar
21
KEY
High Pressure
12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
28X 1200 TCphaseAoriginal
Training Manual 83
SERVICE TRAINING
Phase C
• The rock valve slewing cylinder (5) reaches the
top dead center position.
84 Training Manual
SERVICE TRAINING
6.3
Phase C Twin Circuit
mm
14
Nitrogen pressure
5 1 set at 100 bar
6.3 (1450 PSI)
mm
11 19
S3 15
16
8A 8B 17
9A 6 300
bar
18
10C
1
10D 1
9B
22 NG
10B 10A 10 13
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
S1 320 3
0.7 mm bar
21
KEY
High Pressure
12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
28X 1200 TCphaseAoriginal
Training Manual 85
SERVICE TRAINING
Phase D
86 Training Manual
SERVICE TRAINING
6.3
Phase D Twin Circuit
mm
14
Nitrogen pressure
5 1 set at 100 bar
6.3 (1450 PSI)
mm
11 19
S3 15
16
8A 8B 17
9A 6 300
bar
18
10C
1
10D 1
9B
22 NG
10B 10A 10 13
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
S1 320 3
0.7 mm bar
21
KEY
High Pressure
12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
Training Manual 87
SERVICE TRAINING
88 Training Manual
SERVICE TRAINING
Training Manual 89
SERVICE TRAINING
14
5 1
19
11
S3 15
16
8A 8B 17
6
9A
18
10C
1
10D 1
9B
22
23 NG
10 13
10B 10A
25
7 4 1
S2
S1
0.7 mm 3
21
12
24
2 20
1
90 Training Manual
SERVICE TRAINING
P1
P2
X
P
S1 4
T
7 3
300 bar
B
X
S2
R
Port size
A
limits flow
S-1
2
S-2
39000148.eps
S3 Control Block
6
S3
39000149.eps
Training Manual 91
SERVICE TRAINING
MPS
1 5
3
2 4
S3
1
3
3
2 4 NG
10
5 5
92 Training Manual
SERVICE TRAINING
1
2
Nitrogen pressure set
7 at 100 bar (1450 PSI)
4 2 300 1
3 bar
5
6
6
T Y P
5
7
39000152.eps
Accumulator Pump
200 bar
A11 A10
39000154.eps
1
Training Manual 93
SERVICE TRAINING
Soft Switch
2
4
3
1
0.7 mm
3 2
80
bar
Soft switch
39000151.eps
94 Training Manual
SERVICE TRAINING
Training Manual 95
SERVICE TRAINING
The following diagrams A through D show the • The oil that is forced out of the piston side of the
switching functions of the concrete pump kit plumbed right differential cylinder (8B) flows through
on ROD SIDE with simplified schematics. The agitator, hoses into the piston side of the left differential
boom, and S-1 control circuits are not shown. cylinder (item 8A). This oil is called rocking oil
(orange).
Phase A
• The rocking oil forces the left side differential
• As soon as you switch the unit distribution cylinder (8A) to extend. The cylinder rod extends,
gearcase to the pumping position, the accumulator pushing concrete out of the material cylinder,
hydraulic pump (20) begins pumping high through the rock valve, and into the pipeline. (This
pressure oil (red) to charge the accumulator circuit is called the pressure stroke.)
(14).
• The oil from the rod side of the left differential
• The high pressure oil (red) from the accumulator cylinder (8A) is routed back to the tank through
circuit charges the accumulator (14). When the the return filter (12). The low pressure oil is shown
accumulator pressure reaches the setting of the in green.
accumulator dump valve (13), the accumulator
dump valve opens and routes the oil from the • The oil shown as blue is at rest, or pressureless,
accumulator charge pump (20) back to the such as the oil in the reservoir.
reservoir (1).
96 Training Manual
SERVICE TRAINING
9B
To e-stop
manifold
22 P
NG 250 bar
23
10 13
10B 10A
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
320
bar
3
S1
0.7 mm
21
KEY
High Pressure 12
Rocking Oil Pressure
Low Pressure 20
2
Zero Pressure
(Tank, or oil at rest) 1
Training Manual 97
SERVICE TRAINING
Phase B
• The right side differential cylinder (8B) reaches
bottom dead center. If there is not enough rocking
oil in the loop to bring the left side differential
cylinder (8A) to the top dead center position, oil is
added now through check valve 10D.
• The oil from the left side of the rock valve slewing
cylinder (5) is routed back to tank (1).
98 Training Manual
SERVICE TRAINING
9B
To e-stop
manifold
22 P
NG 250 bar
23
10 13
10B 10A
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
320
bar
3
S1
0.7 mm
To e-stop
manifold
21
KEY
High Pressure 12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
Training Manual 99
SERVICE TRAINING
Phase C
• The rock valve slewing cylinder (5) reaches the
top dead center position.
9B
To e-stop
manifold
22 P
NG 250 bar
23
10 13
10B 10A
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2
320
bar
3
S1
0.7 mm
21
KEY
High Pressure 12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
Phase D
9B
To e-stop
manifold
22 P
NG 250 bar
23
10 13
10B 10A
T
200
bar
Y P
0.7 0.7
2.5 mm
7 2.5 mm
mm mm
1
4
S2
320
bar
3
S1
0.7 mm
21
KEY
High Pressure 12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
6.3
mm 14
Nitrogen pressure
set at 100 bar
(1450 PSI)
5 1
6.3
mm
19
11
S3 15
16
8A 8B 17
6 300
9A bar
T P
18
B A 1.0
mm
10C
1.0 1
T P mm 10D 1
B A
9B
To e-stop
manifold
22
NG 250 bar
23
10
10B 10A
0.7 0.7
2.5 mm
7 2.5 mm
mm mm
1
4
S2
S1 320 3
bar
To e-stop
manifold
21
12
2 20
1
TCVariable.ai
S 58 SX- 125
Boom pipe diameter in millimeters
Outrigger design Super X
Vertical Boom reach in meters
Manufacture Schwing
S3 6
13
16 14 17
15 18
P
9A
9B
20
10A 10B
11
S2 7
S1 4
24
3
10C
22 12
21
1.1 23 10D 2
8A 8B
T
19
1
A B
A1 B1
3.0 3.0
mm
XA S2 XB mm
PR
7 PP
0.7
mm
X3 P2
T2
0.7 4
mm
XR
S1 XP
P X
R R
P2 P1
MP T
X1
T2
24
1.2
T1
P1
P
A 1.4 MX
P
350 bar
3 22
X1
X2
XA
80 bar
A
X3
21
B
1.1
23
XB
T
24
A 3
23
21
The standard Schwing control block has used up to 560 for compact simpler design
LPM of oil. We have developed a new control block The twin circuit machines with G-3 control block will
designed for 800 LPM of oil. Called G-3 for 3rd also use the condensed version accumulator (only one
Generation Control Block and is also known as the Hi- larger one).
Flow Brain.
This block incorporates the soft switch into the relief
valve and the accumulator manifold valve into the S-3,
1 1.4 MX
350 bar
X1
2
6 X2
80 bar
X3
4 1.1
5
6
4
5
1
39000213.eps
MPS
10B
9C
9B
9C
9A 10A 10B
9B
The MPS system is an important part of the twin circuit cylinders to switch with a minimum delay. The S3
system incorporated in the Hi-flo pump kit. The MPS block and the system accumulator are separated from
system consists of three small directional control the main control block and located above the hopper
valves mounted in a manifold. This replaced the two end of the material cylinders. Access to these
switching valves that were located on the passenger components is facilitated by removing the decking
side differential cylinder. The main pressure that is between the water box and the rear boom rest.
supplied to these directional control valves is supplied
by the accumulator. This means we are using
accumulator pressure to switch the S3 valve. The end
result is a faster, more consistent switch.
The faster switch of the S3 valve allows the differential
A B
B
A1 B1
X
1
B
1
XA S3 XB B
A
T
1
A
7 8.0
1
P
S
M
mm
P
Psp
M
Mp1
X
2.0 T
mm 6 300 Mp
bar
T
P
3 4 5
P
PS
2
3
6
2 4
S0153.eps
1
B
X
3
B
A3 A2 B2 B3
B
XA1
1
S3 A
XB1
2
P
1 A
S
T3
3
P
S
M
P
M
MSP3
T
A
6 6.5
X
SP mm MSP2
SP
2 2.0 5
bar mm 7 MSP1
TUV
3 2 330
P 4 bar
P P1
MP
T T MS
1
7
5
S0154.eps
2023 Circuit diagram • High pressure oil (red) flows from the main
hydraulic pump (2) through the parallel position
The following diagrams A through D show the of the S2 valve (7) into the rod side of the right
switching functions of the fully hydraulic pump control side differential cylinder (8A). The cylinder
system plumbed on ROD SIDE with simplified retracts, which creates a vacuum in the material
schematics. The agitator, boom, and S-1 control cylinder. The right side material cylinder fills with
circuits are not shown. concrete. (This is called the suction stroke.)
Phase A • The oil that is forced out of the piston side of the
right differential cylinder (8A) flows through
Please note that right and left refer to the orientation hoses into the piston side of the left differential
you would have if you stood on the unit by the rock cylinder (item 8B). This oil is called rocking oil
valve, looking towards the cab of the truck. (orange).
• As soon as you switch the unit distribution gear
case to the pumping position, the accumulator • The rocking oil forces the left side differential
hydraulic pump (20) begins pumping high cylinder (8B) to extend. The cylinder rod extends,
pressure oil (red) to charge the accumulators.(14). pushing concrete out of the material cylinder,
through the rock valve, and into the pipeline. (This
is called the pressure stroke.)
• Shown in the beginning position in phase A
schematic. High pressure oil (red) continues to
• The oil from the rod side of the left differential
flow into the accumulator circuit until the
cylinder (8B) is routed back to the tank through
accumulators (14) are charged to the pressure cut-
the return filter (12). The low pressure oil is shown
off point of the accumulator hydraulic pump (20).
in green.
When the cut-off point is reached, the
accumulator pump reduces the hydraulic oil flow
until there is just enough to maintain the cut-off • The oil shown as blue, such as the oil in the
pressure. reservoir, is at rest, or pressureless.
Phase A Hi-Flo
KEY
5 High Pressure
Rocking Oil Pressure
Low Pressure
Soft Switch Pressure
Zero Pressure
6 S3
(Tank, or oil at rest)
14
17 15 18
16
P
9A
9B
23
10A 10B
11
S2 7
S1 4
26
3
10C
25 12
24
1.1 27 10D 2
8A 8B
T
20
1
hiflo A.eps
Phase B
Please note that right and left refer to the orientation
you would have if you stood on the unit by the rock
valve, looking towards the cab of the truck.
• The left side differential cylinder (8B) reaches top
dead center. If there is so much rocking oil in the
loop that the right side differential cylinder (8A)
cannot retract to the bottom dead center position,
then oil is removed now through check valve 10C.
Phase B Hi-Flo
KEY
5 High Pressure
Rocking Oil Pressure
Low Pressure
Soft Switch Pressure
Zero Pressure
6 S3
(Tank, or oil at rest)
14
17 15 18
16
P
9A
9B
23
10A 10B
11
S2 7
S1 4
26
3
10C
25 12
24
10D 2
1.1
27
8A 8B
T
20
1
hiflo A.eps
Phase C
Phase C Hi-Flo
KEY
5 High Pressure
Rocking Oil Pressure
Low Pressure
Soft Switch Pressure
Zero Pressure
6 S3
(Tank, or oil at rest)
14
17 15 18
16
P
9A
9B
23
10A 10B
11
S2 7
S1 4
26
3
10C
25 12
24
10D 2
1.1
27
8A 8B
T
20
1
hiflo A.eps
Phase D Hi-Flo
KEY
5 High Pressure
Rocking Oil Pressure
Low Pressure
Soft Switch Pressure
Zero Pressure
6 S3
(Tank, or oil at rest)
14
17 15 18
16
P
9A
9B
23
10A 10B
11
S2 7
S1 4
26
3
10C
25 12
24
10D 2
1.1
27
8A 8B
T
20
1
hiflo D.eps
Booms
Black & White Proportional
39000168.eps
Electric/Oil/Oil
39000167.eps
39000169.eps
Proportional
Electric/Oil/Oil - Variable
To:Outrigger Function
P1
1PM
M P4
T
T
P3
P2
39000165.eps
To:Outrigger Function
P1
1PM
M P4
T
T
P3
P2
39000166.eps
Boom Holding Valves If you should have a problem with a boom section
creeping, position the boom in an area which still
Schwing uses a specially-designed hydraulically produces pressure in the corresponding cylinder but
unlockable check valve on all hydraulic cylinders leaves the holding valve in an accessible area. Loosen
which operate placing boom sections. These valves the fitting of the pressure connection of the working
seal the hydraulic cylinder to prevent it from creeping line and the leakage oil connection. With the hydraulic
or moving until pressure is applied to it. A holding pump not turning, you will be able to see which portion
valve is installed at both ends of the hydraulic cylinder of the valve is leaking.
to prevent movement and limit pressure in either
direction. If oil flowing out uniformly from the leakage oil
connection, this indicates that the auxiliary safety valve
is not properly sealing. If this holding valve is on boom
TRUCK-MOUNTED AND SEPARATE
PLACING BOOM HYDRAULIC CYLINDER HOLDING VALVES section 1 cylinder, holding valve replacement is
necessary.
UNLOCKABLE
CHECK RETURN OIL If hydraulic oil is flowing out uniformly from the
CONNECTION
(LEAKAGE OIL) working line, this indicates that the check valve is not
sealing properly, or debris in the oil has caused the
RELIEF (NON-ADJUSTABLE) unlocking system to hang up and not allow the check
SAFETY VALVE
valve ball to seat. If there are any questions concerning
CONTROL LINE CONNECTION holding valves or other areas of your Schwing
(CONNECTED WITH WORKING LINE
OF THE OPPPOSITE SIDE) equipment that you need answered, contact your local
Schwing dealer or Schwing America, Inc. for more
information.
PORT X
BLOCK A BLOCK B
LINE B
CYLINDER
LINE A PORT Y
CYLINDER ROD
140 bar
1.7 2.0
Training Manual
1.3 1.0 1.7 1.3 1.3 1.3
A4 B4 A3 B3 A2 B2 A1 B1
P T
B A P1
280 bar
T T
300 bar
AIR TANK
28X B&W Boom
T P
KVM 28 Neutral
W/ MONSUN - TISON HANDVALVES 5 - 7 bar
196101
10/91
RE
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure (Tank, or oil at rest)
BOOM #3 (Tip) BOOM #2 BOOM #1 (MAIN) SLEWING CYLINDERS
Outrigger Jacking Cylinders 270 BAR 270 BAR
SERVICE TRAINING
Training Manual
1.3 1.0 1.7 1.3 1.3 1.3
A4 B4 A3 B3 A2 B2 A1 B1
B A P1 T
P
280 bar
300 bar T T
T P
KVM 28 AIR TANK
W/ MONSUN - TISON HANDVALVES
196101 #3 Extend Only
10/91
RE 5 - 7 bar
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure (Tank, or oil at rest)
128
129
BOOM #3 (Tip) BOOM #2 BOOM #1 (MAIN) SLEWING CYLINDERS
Outrigger Jacking Cylinders 270 BAR 270 BAR
270 BAR 270 BAR
SERVICE TRAINING
140 bar
1.7 2.0
Training Manual
1.3 1.0 1.7 1.3 1.3 1.3
A4 B4 A3 B3 A2 B2 A1 B1
B A P1 T
P
280 bar
300 bar T T
T P
KVM 28 AIR TANK
W/ MONSUN - TISON HANDVALVES
196101 #1 Retract
10/91
RE #3 Extend 5 - 7 bar
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure (Tank, or oil at rest)
PRINT # 329324
BOOM #3 (Tip) BOOM #2 BOOM #1 (MAIN) SLEWING CYLINDERS
Outrigger Jacking Cylinders
270 BAR 270 BAR
SERVICE TRAINING
Training Manual
35 bar
1.3 1.0 1.7 1.3 1.3 1.3
B A P1
A4 B4 A3 B3 A2 B2 A1 B1
T
P
300 bar
T P 280
bar
T T
A 5-7
bar
T P
KVM 28
W/ MONSUN - TISON HANDVALVES
190321
130
SERVICE TRAINING
Load Sense Hydraulic Circuits When activating a function by remote on a “black &
white” system, the handvalve spool is fully activated
and a signal is sent to the hydraulic pump to send the
Overview required amount of oil to run that function.
C2 C1
G1/2
39000178.eps
X3
39000177.eps
GPM x PSI Orifice created between the spool and valves walls
HP =
1714
Q-Maximum(Q-max): The highest volumetric flow
LPM x BAR
KW = rate possible from the hydraulic pump. Adjusted with a
600
39000182
mechanical stop screw. Turn screw inward to decrease
and outward to increase.
Delta Pressure (Delta-P):The pressure differential Q-Minimum(Q-min): The lowest volumetric flow rate
between two given points in a hydraulic circuit. possible from the hydraulic pump. Adjusted with a
mechanical stop screw. Turn screw inward to increase
and outward to decrease.
Q-Min Screw
1000 PSI
68.95 bar Q-Max Screw
Q-Max Q-Min
Section
Compensator
C1
X3
P 39000183.eps
T
C2
Section
Compensator
39000186.eps
10,000 lbs
10”
1000 psi
10 GPM
39000187.eps
0 psi
200 psi
10 GPM
39000188.eps
10,000 lbs
10”
1000 psi
1200 psi
10 GPM
39000189.eps
10,000 lbs
10,000 lbs
10”
10”
2000 psi
10 GPM 10 GPM
39000190.eps
10”
0 psi
Delta P
The pressure differential
between two given points
in a hydraulic circuit
200 psi
2000 psi
X
X3
P
A T
39000191a.eps
Basic Principles - Delta-P P). The pump is only supplying the amount of oil
required to maintain the (Delta-P). In this case, 5 gpm.
In this diagram, the cylinder will take exactly 2
If the size of the orifice increases, the flow rate will be
minutes to extend. There will be a pressure of 1000 psi
increased by the Delta-P regulator. That will increase
at the cylinder and a pressure of 1200 psi at the pump.
the speed of the cylinder.
The orifice caused a drop in pressure (Delta-P). The
regulator has been adjusted to maintain 200 psi (Delta-
10”
1000 psi
Delta P
The pressure differential
between two given points
in a hydraulic circuit
1200 psi
X3
P
A T
39000191.eps
Basic Principles - Pressure Cut-Off The regulator has been adjusted to a pressure limit of
3000 psi. The pump is only supplying the amount of oil
In this diagram, the cylinder is at the end of it’s stroke.
required to maintain 3000 psi.
There will be a pressure of 3000 psi at the cylinder and
a pressure of 3000 psi at the pump. The orifice does
NOT cause a drop in pressure because there is no flow.
10,000 lbs
10”
4350 psi
4350 psi
X3
P
A T
39000192.eps
Basic Principles - Shuttle Valves have been replaced by the proportional handvalves.
The regulator has been adjusted to a pressure limit of
In this diagram, the cylinder with the highest load
3000 psi. If any one cylinder reaches the end of it’s
(2500 psi) will be monitored at the regulator. The
stroke, the main pressure will be 3000 psi.
regulator will maintain the 200 psi delta-P above that
load. The orifices, needed to cause a drop in pressure,
X3
P
A T
39000193.eps
Δ P regulator Δ P regulator
X
20 Pressure
Regulator
bar Δ P 300 bar
ΔP
Regulator
20 bar
300
X
bar A T
0 bar
ORIFICE
KVM 36X . . . . 1.6 mm
P 0.8 mm
0-15 Bar
KVM 36 LW . . 1.6 mm
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
P
A T
Pressure Regulator
(300 bar)
ΔP Regulator
(20 bar)
39000219.eps
X 300
bar
C2 C1
39000197.eps
A T
20 bar spring
P
20 bar spring
C2
C1
A T
X
A1 This will create a pressure drop on the piston side of
20
bar Δ P
the Control Piston Chamber, allowing the spring on rod
T
side of the chamber to decompress. As the spring
300
bar decompresses the angle of the rotary group will
X3
increase. The pump will displace more oil, until 20 bar
A T
P 39000194.eps (Delta-P) reached.
Not enough pressure to hold back the spring
A
A1
+20 bar pressure pushing on spool X
20
bar Δ P
Compressed Spring T
300
bar
X3
P 39000200.eps
A
P
T
A T
X3
P
spool. The spring will decompress, moving the spool to X3
the left.
Not enough pressure to hold back the spring
KEY
High Pressure
1.0 mm
Reduced Pressure
320 bar
Control Pressure 330 bar
320 bar
310 bar
Low Pressure
Δ P regulator A7 VO Pump A
A1
3 X
20
bar Δ P T
300
bar
X3
P
A T
Δ P regulator A7 VO Pump
A1
Q-MIN
Pressure
Regulator
300 bar
ΔP
Regulator A
20 bar
X 0 bar
A T
ORIFICE
KVM 36X . . . . 1.6 mm
P 0.8 mm
KVM 36 LW . . 1.6 mm
0-15 Bar Q-MAX
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
X3
HT001.ai
Cylinder Extend Function Initiated This will create a pressure drop allowing the spring on
rod side to decompress, thus changing the angle of the
The directional valve has been moved to the "cylinder
rotary group to displace enough oil to extend the
extend" position. Oil travels through the handvalve and
hydraulic cylinder.
to the boom holding valve. A signal is also sent from
the handvalve to the Delta P regulator, via the “X” port.
Decompressed Spring
The pressure from the “X” port plus the 20 bar spring A
is greater than the pressure on the “A” port side of the X
A1
spool. This will move the spool to the left, creating a 20 + Load
bar Δ P T
passage way for the oil in the Control Piston Chamber
of the hydraulic pump to tank. 300
bar
X3
1 P
A T 39000202.eps
Pressure + 20 bar
spring signal from Rotary Group
handvalve pushing
on spool
A A T
A1 P
X
X3
20 + Load
bar Δ P T
Not enough pressure to hold back the spring
300
bar
X3 Oil enters the holding valve. The hydraulically
A T
unlockable check valve “opens” allowing oil to enter
P
C1
Open Relief
1.0 mm
320 bar
330 bar
320 bar
310 bar
X
A T
P
1.0 mm
Control Piston Chamber X3
39000201.eps
Open Checkvalve
39000203.eps
KEY
High Pressure
1.0 mm
Reduced Pressure
320 bar
Control Pressure 330 bar
320 bar
310 bar
Low Pressure
Δ P regulator A7 VO Pump A
A1
X
20 + Load
bar Δ P T
300
bar
X3
P
A T
Δ P regulator A7 VO Pump
A1
Q-MIN
Pressure
Regulator
300 bar
ΔP
Regulator A
20 bar
X 0 bar
A T
ORIFICE
KVM 36X . . . . 1.6 mm
P 0.8 mm
KVM 36 LW . . 1.6 mm
0-15 Bar Q-MAX
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
X3
HT002.ai
Hydraulic Cylinder Extending ‘X” port pressure on the spring side of the 20 bar spool
is greater than the “A” port pressure. The spool will
The hydraulic pump is only putting out enough oil to
move to the left, creating a larger passageway for the
extend the hydraulic cylinder. Depending upon the load
Control Piston Chamber oil to escape to tank.
requirements, the signal line pressure will increase or
decrease accordingly. If the signal line pressure The farther left the spool moves,
increases, the 20 bar Delta P spool will open, allowing the larger the opening back to tank
allowing a larger passageway for the Control Piston
Chamber oil to escape to tank. This will decrease the X
pressure on the piston side of the Control Piston A
20 + Load
Chamber, allowing the spring on the rod side to A T
bar Δ P
decompress and the angle of the rotary group to 39000206.eps
increase, creating more flow to meet the load
requirements.
Example: With a larger passageway to tank, pressure decreases in
Load requirements for a particular function increse. the Control Piston Chamber.
1.0 mm
A T
320 bar
330 bar
A1
320 bar
310 bar
T
1.0 mm
39000204.eps
X3
C2 C1
Spring decompresses, rotary group angle increases,
more flow created.
C2
C1
X
X A
20
A T
bar Δ P
39000205.eps
KEY
High Pressure
1.0 mm
Reduced Pressure
320 bar
Control Pressure 330 bar
320 bar
310 bar
Low Pressure
Δ P regulator A7 VO Pump A
A1
X
20
bar Δ P T
300
bar
X3
P
A T
Δ P regulator A7 VO Pump
A1
Q-MIN
Pressure
Regulator
300 bar
ΔP
Regulator A
20 bar
X 0 bar
A T
ORIFICE
KVM 36X . . . . 1.6 mm
P 0.8 mm
KVM 36 LW . . 1.6 mm
0-15 Bar Q-MAX
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
X3
HT002.ai
Hydraulic Cylinder Fully Extended Pump If pressure reaches over 300 bar. The spring on the 300
bar spool will compress. Creating a passageway for oil
The cylinder has fully extended.
from the “A” port to pass through the spool and flow to
the piston side of the Piston Control Chamber.
300+ pressure
A
A1
1.0 mm
X
320 bar
T
330 bar
300
320 bar
bar
310 bar X3
1.0 mm
P
39000211.eps
39000209.eps
(Delta P) spool.
A T
P
X3
C2 C1
C1
Equal pressure A
A1
X
A
A1 20
X bar Δ P T
300
T
bar
300 X3
bar
P
X3 39000212.eps
P
A T
A T
P
X
X3
A T
KEY
High Pressure
1.0 mm
Reduced Pressure
320 bar
Control Pressure 330 bar
320 bar
310 bar
Low Pressure
Δ P regulator A7 VO Pump A
A1
X
20
bar Δ P T
300
bar
X3
P
A T
Δ P regulator A7 VO Pump
A1
Q-MIN
Pressure
Regulator
300 bar
ΔP
Regulator A
20 bar
X 0 bar
A T
ORIFICE
KVM 36X . . . . 1.6 mm
P 0.8 mm
KVM 36 LW . . 1.6 mm
0-15 Bar Q-MAX
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
X3
HT003.ai
EB
∅1.0
B2 B1
320 bar
330 bar
290 bar
300 bar
A2 A1
∅1.0
EA
C1 C2 C1 C2 PP
G1/2 G1/2
15
bar
0.2
mm
300
bar
.061 mm P
T
LS
KEY
High Pressure
Reduced Pressure
Pretension Pressure
High pressure filter
Low Pressure
Zero Pressure
(Tank, or oil at rest)
2.0
atmospheres
EB
∅1.0
B2 B1
320 bar
330 bar
290 bar
300 bar
A2 A1
∅1.0
EA
C1 C2 C1 C2 PP
G1/2 G1/2
15
bar
0.2
mm 300
bar
.061 mm
P
T
LS
KEY
High Pressure
Reduced Pressure
Pretension Pressure
Low Pressure High pressure filter
Zero Pressure
(Tank, or oil at rest)
2.0
atmospheres
EB
∅1.0
B2 B1
320 bar
330 bar
290 bar
300 bar
A2 A1
∅1.0
EA
C1 C2 C1 C2 PP
G1/2 G1/2
15
bar
0.2
mm 300
bar
.061 mm
P
T
LS
KEY
High Pressure
Reduced Pressure
Pretension Pressure
Low Pressure High pressure filter
Zero Pressure
(Tank, or oil at rest)
2.0
atmospheres
(bar)
2100 RPM
1700 117 pressure is
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110 shown for
350
PISTON SIDE
1500 103 both piston
1400 97
Hydraulic oil pres- and rod side
300 Piston side 1300 1285 88.6 90
sure shown here, 1200 83
configurations
breakpoint
ranging from zero to 250
1100 76
OIL PRESSURE (BAR)
1000 70
the relief valve set-
ROD SIDE 900 62
ting. 200 350 Rod side
800 55
300 breakpoint 700
758 52
48
150 250
Concrete out-
600 41
200 500 34
put is shown
100
150 400 28 here, with max
100
300 21 shown for both
50 200 14
piston and rod
50 7
100
The breakpoint side configura-
breakpoint 0 13 26 39 52 65 78 92
105 118 131 144 157 170 183 196
specification is 178 bar
103 170.5
tions.
listed here. CONCRETE OUTPUT (cu yd / h)
26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
Hydraulic liters per 15.5
PISTON 5 10 15 20 25 30 NUMBER OF STROKES
minute and the cor- SIDE (stroke / min.) Information
OIL VOLUME
responding strokes 100 200 300 400 500 (liter / min.) about the
per minute for both Differential Hydraulic Cylinder Material Cylinders Hydraulic Pumps
pumpkit and
piston and rod side. Bore dia. / Rod dia. x Stroke length Bore dia. x Stroke length Type / KW
hydraulic
125 mm / 80 mm x 2000 mm 230mm x 2000 mm 2 x A7VO-107
output chart explain.eps
2 x 66KW pumps is
Slewing cylinder 80 / 45 x 185 shown here.
Using the Chart the 220 bar oil pressure marking on the rod side scale
(item A in the example below). Then draw a line
Example 1—Checking flow at a given pressure straight across the page until you intersect with the
Your unit is configured on the rod side (standard from horsepower curve (Item B). Next, draw a straight line
the factory). You notice that your machine is not getting down from the intersection point until you pass through
as many strokes per minute as you are used to seeing. the rod side number of strokes scale, and read the
You count the strokes and see that you are getting strokes per minute. At 220 bar you should be getting a
about 21 1/2 per minute. You check your pressure gauge little more than 21 strokes per minute. Your unit is fine.
and see that the hydraulic oil pressure is at 220 bar. To
determine whether your unit is acting normally, locate
CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
output chart use.eps
2000 138
PERFORMANCE CHARACTERISTICS OF
1900 131
PISTON SIDE
(bar)
2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110
Example 2—Checking your hydraulic pumps by 2, and chart the result. You multiply the readings
To determine whether your pumps are still in good because the chart is based on the output of two pumps,
working condition, use the output chart and a flow but we are only testing one at a time.
meter. Test one pump at a time, multiply the readings
To test your pumps: • Make two copies (one for each pump tested) of
• Use use the chart that applies to your unit (see the Output Chart located in the Appendix of the
Output Chart in the Appendix of your Operation Operation Manual. Don’t use the original copy,
Manual). you will need additional copies of the original for
• Select the proper truck transmission gear for future tests.
pumping (found on the information plate mounted
in the truck cab). Read the flow at 0 bar, 100 bar, 150 or 200 bar, 250 bar,
• Set the pump speed (input drive shaft) RPM. and 300 bar. Also document the breakpoint. The
Pump speed information is found on line 16 of the breakpoint is where the flow drops off rapidly. You will
Delivery Inspection Report which arrived with be able to notice it on the flowmeter. If you think it
your unit when it was new. A difference of even a
would be helpful, copy the chart below. Check which
few RPM will give you a bad reading. Check the
RPM with a digital tachometer if one is available. reading you used (150 or 200 bar). The breakpoint will
• Know how to use your flowmeter. Read the be very close to either 150 or 200 bar, so it is not
instructions that came with it. A flowmeter must necessary to take both readings. The breakpoint
be calibrated periodically. specification is shown on each output chart.
100 bar x2 x2
breakpoint x2 x2
breakpoint
150 or 200 bar x2 x2
250 bar x2 x2
300 bar x2 x2
checking output form
Plot the readings on the output chart. Take a clean • Turn the ruler sideways and draw a light line up
output chart and proceed as follows: the page from the liters/minute reading you took
• Lay a straight edge horizontally across the page at at that pressure. (Remember to multiply the
the pressure point you are plotting. Draw a light reading by 2.) In our example, we measured 276
line across the chart. In the example below, we use liters at 250 bar.
the rod side scales and curve (you could use the • Put a dot at the point where the two lines intersect.
piston side scale and curve instead). The ruler is
shown ready to draw a line at 250 bar hydraulic • Do the same thing with each pressure reading. You
pressure. should end up with six dots.
CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
1checking output.eps
2000 138
PERFORMANCE CHARACTERISTICS OF
1900 131
PISTON SIDE
(bar)
2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110
1000 70
300 21
100
50 200 14
50 7
100
breakpoint 0 13 26 39 52 65 78 92
105 118 131 144 157 170 183 196
178 bar 103 170.5
CONCRETE OUTPUT (cu yd / h)
26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
15.5
PISTON 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
100 200 300 400 500 (liter / min.)
• Connect the dots. If your plotted line reasonably the upper right of the spec, you have done the test
matches the specification plot on the chart, the incorrectly, or you are using the wrong chart. In
pump is fine. If your line is to the lower left of the our example, the pump is okay. (See the plot
spec, the pump is getting weak. If your line is to which follows.)
CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
2checking output.eps
1200 83
ROD SIDE
300 bar
(bar)
1100 76
1000 70
250
600 41
200 500 34
7
100
26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
(234) (276) (338) (388) (398)
(392)
When you connect the dots, the line is completely handy when you call to get a replacement. Also, please
below the specifications. This pump is very weak and advise us if you have changed differential cylinders,
will completely stop pumping oil soon. You may notice material cylinders, or hydraulic pumps, because you
high heat with this unit, if you are pumping at high oil may need a different output chart than the one that was
pressures. originally shipped with the unit.
NOTE!
Never try to make up for this weak pump by
increasing the speed of the engine. As the
pump turns faster than specifications, it will
not be able to suck oil as fast as it is turning
(it is called “cavitation” if this happens),
and immediate failure could results.
If the plotted curve matches the spec for a while, but
the breakpoint is too high or too low, it is possible to
make an adjustment. Contact the Schwing America
Service Department for the procedure.
There are many different possible pumpkits and power
settings for this unit. If you accidentally destroy your
original output chart, please have your serial number
Using a Nomograph With a concrete pump that is driven by its own prime
mover, such as a trailer-mounted concrete pump or a
truck-mounted pump with a separate drive engine, the
General information power rating (in Kw) is shown for the engine or electric
motor. With a truck-mounted pump that uses a PTO
NOTE! from the truck engine, the power rating reflects the
If you have read the original Schwing Amer- power output of the hydraulic pumps only. (All the
ica publication, Nomographs—A Guide to power from the truck engine is normally not available
Usage, you will notice several changes in this to the concrete pump and should not be used for power
document. Because not all of the power calculations.) If you know the required output for the
from the truck engine is used for the con-
crete pump, the TK number of the engine job, the nomograph will help you calculate the required
has no meaning. Therefore, this section pressure. If you know the output and pressure, you can
about using nomographs has been adapted calculate the power requirement.
especially for boom pumps. You can still fig- The nomograph was developed by extensive trial-and-
ure out the TK of the job to do, but the suit- error testing and has proven to be accurate to ±10% in
ability of the pump has to be determined in
a different manner. To make the pump num- nearly all pumping applications. The original
bers and job numbers match, we will use a nomographs used “spread measure” of fresh concrete
“Power Factor number,” which takes into instead of slump, and the two are not directly
account the power of the hydraulic pumps interchangeable. Some approximations are used in
instead of the engine and is easy to use with translating the charts from spread measure to slump,
cubic yards per hour and PSI instead of but the ±10% accuracy still applies. In all cases, it is
cubic meters per hour and bar.
assumed that you will receive fresh, high-quality
Concrete pumps are limited in what jobs they can do concrete on your job and that the concrete will be
by three factors: plastic enough to flow into the material cylinders. If
you know that the concrete will be hard to feed into the
1. The amount of power available. cylinders, you should adjust the output requirement to
2. The maximum concrete output available. compensate for incomplete filling. For example, if you
will need 50 cubic yards per hour into the form but the
3. The maximum concrete pressure available. concrete is so stiff that it will fill the cylinders only
80%, you should multiply the required output by 1.25
To estimate the power a pump requires to complete a (1÷80%).
particular job and to determine which pump is
appropriate, a nomograph is used. The nomograph is divided into four quadrants
.
Figure 1
Quadrants
The upper left quadrant is the beginning and end point To use the nomograph, you begin at output required
of the graph and shows maximum output, pressure, and and move clockwise until you encounter the lines that
power for a specific machine. The upper right quadrant represent your job situation. Each time you meet the
accounts for the relationship between concrete output line that applies, you make a 90° turn until you come to
and pipeline diameters. The lower right quadrant
a point on the bottom of the upper left quadrant that
accounts for the resistance to flow of the entire pipeline
system. The lower left quadrant accounts for the shows pressure required (Figure 2).
pumpability of the concrete.
Q in yd3/hr.
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
6" 5" 4.5"
140
4"
120 116
Rod side
100
80
Piston side 67
60
40
132 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI 1566 870
100
200
2"
300
400
2.5"
500
600
3"
4" 5" 6" Pumpkit Model: 120/80 x 1600:200 3000 2500 2000 1800 1500 1200 1000 800
Slump of fresh concrete in inches Power: 132 KW Proportional value of pipeline in feet
Figure 2
Moving around a nomograph
To illustrate the use of a nomograph, we will use a Boom pipe, elbows, and deck system.
hypothetical job situation with the following • 13 ft of 5-in. rubber hose
specifications. • 144 ft of 5-in. steel pipe (on the boom and pump
1. We will need an average output of 75 cubic yards deck)
per hour, but we will be pumping only 75% of the • 5.25 ft of 6–to–5-in. reducer (on the pump)
time. The rest of the time will be spent moving • 4 5-in. 45° elbows, radius 250 mm
hose, removing pipe lengths, waiting for concrete
• 11 5-in. 90° elbows, radius 250 mm
trucks, and taking care of miscellaneous jobs. This
means that when we are actually pumping, we will • 2 6-in. 90° elbows, radius 250 mm
need an output rate of 75 ÷.75 = 100 yd3/hr. 4. We will specify a slump of 5-6 in. and use the 5-in.
line on the chart.
2. We will use 5-in.-diameter pipeline.
5. In addition, when we add the pressure for the verti-
3. We will need the following pipeline lengths: cal run, we will have to add 1.1 times 70 ft = 77
Separately laid pipeline. PSI.
• 40 ft of 5-in. rubber hose All of these criteria will be explained in detail as we go
• 150 ft of 5-in. horizontal steel pipe through the individual quadrants.
The quadrants
1. The upper left quadrant describes the power
curve of a given hydraulic pump Kw rating and the
maximum output and maximum pressure of a par-
ticular model of concrete pump (Figure 3).
Power factor
56,650
Power factor number (PF) number
upper left quad-eps
English to Metric Conversion Factor is PF Ö 18.966 (replaces TK)
200
Q in. yd3/hr.
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
140
Example Job
Working power (in kW)
120
Power curve 100
Maximum output and
80maximum pressure
of a specific unit
60
Kw rating
40
103 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI
Figure 3
Upper left quadrant
Any concrete pump selected for a job must meet three efficiency factors figured in. When using an
technical parameters: Americanized nomograph (pressure in PSI and flow in
• The power factor number of the pump must be cubic yards per hour), the pressure multiplied by the
equal to or greater than the power factor number output must always be less than or equal to the PF of
of the job. the pump. For example, if you needed 50 cubic yards
• The maximum output required by the job must be per hour and determined that this will require 750 PSI,
available from the pump. you can multiply 50 by 750, which equals 37,500. Any
pump you select must have a PF of 37,500 or greater. If
• The maximum pressure required by the job must
you are using a nomograph that has been converted to
be available from the pump.
metric units of measure (pressure in bar and output in
It is important to notice the pump maximum pressure cubic meters per hour), you can still multiply the
and maximum output, even if the power factor number pressure by the output, but you must multiply the
of the pump is larger than the job requires. These answer by the conversion factor between metric and
parameters are decided during the design stage of the English units of measure to get the PF. The conversion
unit and cannot be adjusted on the job. If the unit is factor for cubic yards to cubic meters and bar to PSI is
able to go from rod side to piston side, maximum 18.966. For all practical purposes, you can use 19. For
pressure and output can be exchanged—that is, you can example, if you need 50 cubic meters per hour and
decrease one while increasing the other the same determine that your job setup will require 65 bar, you
amount. can multiply 50 by 65, which equals 3250. Multiply
The power factor number (PF) replaces the TK this by 19, and you find that your PF requirement is
number on a truck-mounted unit. It is the Kw 61,750. Again, any pump you select for the job in this
multiplied by a constant (550) that has several example should have a PF of 61,750 or greater.
The maximum output (abbreviated as max Q) is line and forms a slippery layer on which the bulk of
determined by the size of the hydraulic pumps, the the concrete slides. While it is true that a 6-inch
number of strokes per minute, and the size of the pipeline has 49 percent more surface area to coat
differential and material cylinders. The unit is usually than a 4-inch pipeline, the volume of concrete that
designed so maximum output can be achieved only at can move on the layer is increased by 12 percent,
less than maximum pressure. which results in lower velocity of the concrete (in
Maximum pressure (abbreviated as max P) is feet per second), lower friction, and therefore lower
determined by the size of the differential and material pressure. A pump that may not be capable of com-
cylinders and the setting of the main relief valve. To be pleting a difficult job through 4- or 5-inch pipe may
sure that the unit will handle the job, be careful to be able to do it easily through 6-inch pipe. Note!
notice max P and max Q. Here is an example of why Experience has taught us that 5-inch is the opti-
that is important: You contract to pump a job that mum pipeline size for lengthy vertical runs such
requires only 20 yards per hour, but you calculate that as those found on high-rise buildings. It is large
you will need 2100 PSI pressure. The PF of this job is
enough for most aggregate, but small enough
42,000 (20 x 2100). The pump shown in Figure 3 has a
that you minimize the amount of concrete that
TK of 72,600, so there is enough power available.
However, the maximum pressure available from the slides back into the hopper when the concrete
pump is only 1570 PSI. This pump would not do the valve cycles, which we call backwash. You must
job. also consider the people at the point of place-
ment. Very few hose handlers, if any, can move
6. Follow the chart in a straight line from required
output into the upper right quadrant until you 6-inch hose on a slab all day. There is no provi-
come to the size of the pipeline that you will use. A sion in the nomograph for mixing pipeline sizes.
good rule of thumb for sizing pipeline is to use the For example, if you will be reducing from 5-inch to
largest-diameter pipeline that you can. It takes less 4-inch, pipe, you should calculate the chart as if
force to move concrete through a 6-inch pipeline you were using 4-inch pipe for the entire distance.
than, for example, a 4-inch pipeline. When pres- This will not be completely accurate, but you will
sure is exerted on concrete in a pipeline, a paste of be safe in your pressure calculation. In our example
water and cement fines coats the inside of the pipe- (Figure 4) we use 5-inch pipeline.
Figure 4
Upper right quadrant—Pipeline diameter
When the output line intersects the pipeline diameter • Each 90° bend with a radius of 1 meter (long
that corresponds to your job, draw a line straight down sweep) = 10. feet.
into the lower right quadrant, as shown in Figure 4. • Each 30° or 45° bend with a radius of 1 meter or
7. The lower right quadrant refers to the propor- 250 mm = 3 feet.
tional value of your pipeline. It is a way of taking • Each section of rubber hose causes three times as
into account not only the length of the pipeline, but much resistance as the same length of steel pipe
also the number of bends, the increased resistance (e.g., 12 feet of rubber hose has the same
of flow in rubber hose, and other factors. It is more resistance as 36 feet of pipeline).
a measure of the resistance to flow than a measure • Figure all horizontal and vertical distances
of length. In calculating the proportional value of equally. The increased pressure required to push
your pipeline, always apply the following criteria: concrete vertically is accounted for by adding
• Each 90° bend with a radius of 250 mm (boom pressure, not distance.
elbow) = 3.5 feet. • An example pipeline is shown below (Figure 5).
boom 4 nomo.eps
40 ft.
hose
150 ft. pipe
70 ft.
level
difference
Note!
Proportional value of the 39X boom and deck pipe system is 261 feet.
This value includes elbows, reducer, and tip hose.
Example: You must go 150 feet out through the deck and boom pipe, including the tip hose, then
through 40 feet of rubber hose. Calculate the proportional value as follows:
all boom system = 261. feet (includes a 12-ft long, 5-in. tip hose)
15 10-foot pipe sections = 150. feet
40 x 3 = 120. feet (for the rubber hose)
Total = 531. feet.
Round the total to 500 feet to make it easy to use the following chart (Figure 6).
Figure 5
Calculating proportional values
Once you have calculated the proportional value of intersection, make a 90° turn clockwise, into the lower
your pipeline, extend your line down from the upper left quadrant. As noted above, we are using 500 feet as
right quadrant until it intersects with the line that our proportional value (Figure 6).
represents your pipeline. When you reach the
8. The lower left quadrant refers to the pumpability right quadrant until it intersects with the 5-inch
of the concrete. If the concrete specifications allow slump line, then make a 90° turn clockwise. This
a range in slump (for example 5–6 in.), always use will lead you back into the upper left quadrant
the lower end to be safe. In our example, we use 5- through the pressure scale (Figure 7).
inch slump. You extend the line from the lower
Figure 7
Lower left quadrant—
pumpability of the
concrete
As you can see by the chart in Figure 7, we are The nomograph is now complete. The PF of our job
reentering the upper left quadrant through the pressure can be calculated like this:
scale at about 550 PSI. Remember, we now have to add PF = PSI x yd3/hr
the head pressure for our vertical rise. At 1.1 PSI per
We need a unit that is capable of 627 PSI, and 100 yd3/
foot of level difference, and our 70-foot vertical run,
hr. The PF of this job is:
we must now add 1.1 x 70 = 77 PSI to the 550 PSI
from the chart. PF = (627 x 100)
PF = 62,700
550 PSI + 77 PSI = 627 PSI
The unit must have a PF over 62,700 and it must be
NOTE! able to pump 100 yd3/hr and 627 PSI simultaneously.
When calculating the head pressure from Look at the pump shown in our sample nomograph
vertical runs, it doesn’t matter if the pipe- (Figure 8).
line runs straight up and down, or if it runs
uphill at an angle. Only the level difference • Can the unit pump at 627 PSI? Yes
in feet is needed for the pressure calculation. • Can the unit pump 100 yd3/hr? Yes
If the pipeline is running downhill, the oper- • Can the unit pump both simultaneously? No! This
ator will need special knowledge, but you unit will not do the job.
don’t need to add any head pressure to the
nomograph.
56,650
Power factor number (PF)
upper left quad-eps
English to Metric Conversion Factor is PF Ö 18.966
200
Q in. yd3/hr.
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
140
Example Job
Working power (in kW)
120
100
80
60
40
103 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI
Figure 8
Is this unit sufficient for the job?
The engine is a little too small. The intersection of 100 pumps set to a higher Kw? The PF of the higher Kw
yards3/hr and 627 PSI has been plotted for visual unit is 72,600. This should work. Plotting the
representation, but you will see immediately that the intersection of our hypothetical job again, you will see
PF of the job (62,700) is bigger than the PF of the unit that it falls within the power zone of the hydraulic
(56,650). The curved black line represents the PF of the pumps (Figure 9)
unit. If the unit is going to be able to handle the job, the
intersection of pressure and yd3/hr will be to the right
and down from the curved line. Anything to the left or
above the line is beyond the power of the hydraulic
pumps. What if we could order this same unit with the
The nomograph should only be considered accurate to • Pump the top of the building at 85 yd3/hr instead
within ±10 percent. You should always calculate of 100 yd3/hr.
conservatively, and allow for the graph tolerance. In the • Pump the top of the building at a 6-inch slump
case of the pump in Figure 9, we should still be safe instead of 5-inch. (This would still be within
even if the pressure required were 10 percent greater specifications.)
(690 PSI).What if you already own the pump shown in • Remove some of the rubber hose at the end of the
horizontal run. Normally, with job circumstances
Figure 8? Is there anything that can be done to the job
that did not require a substantial vertical run, you
specifications to make the unit with the less powerful could also use 6-inch instead of 5-inch-diameter
pumps work? You could use the smaller PF unit shown pipeline, but in our example, the entire vertical run
in Figure 8 if you can get permission to do any of the was made with the boom. The boom can never
following things: support 6-inch pipeline.
72,600
Power Factor number (PF)
English to Metric Conversion factor is PF 18.966
200
Q (in yd3/hr)
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
Working power (in kW)
140
120
100
Example Job 80
60
40
132 kW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
up1ft 132Kw Quad 2000R.eps
P (in PSI)
Figure 9
Same model pump with larger Kw hydraulic pumps
Scheduled Maintenance
Semi-annually
As Indicated
Quarterly
Annually
Monthly
Weekly
Daily
Task
Semi-annually
As Indicated
Quarterly
Annually
Monthly
Weekly
Daily
Task
Δ = Breakin period
back to the shop, or order the filter so it can be replaced General information
soon. Remember, unfiltered oil wears out every
hydraulic component on the concrete pump. Hydraulic oils are rated for viscosity, heat dissipation,
foaming characteristics, pour point, antiwear additives,
Your concrete pump may be equipped with a main anticorrosive additives, lubricating qualities,
return oil filter mounted on top of the hydraulic oil compressibility, temperature range, temperature
reservoir or an inline filter located on the passenger stability, and other functions. Although many different
side just above the hydraulic oil cooler. (Both types of brands of oil meet these specifications, they may use
filter are shown in. different chemical additive packages to achieve the end
t
result. For this reason, you should not mix two
The boom/outrigger circuit is equipped with an in-line
different brands of oil. The additive package from one
high-pressure filter. This filter is in a canisters rated to
brand may be incompatible with the additive package
handle the pressure that is felt by this circuit. There is
from the other, rendering both packages useless.
no integral bypass in this filter. The filter is not fitted
with a ΔP switch, so you should change it whenever Recently a few manufacturers have introduced
the return filter light comes on. The rating on the biodegradable hydraulic oils onto the market. These
filter is β25 = 200. We install this filter to catch large oils are based on vegetable extracts instead of mineral
particles that may cause a boom valve or holding valve extracts. They are considered safer for the environment
to stick in an open position. Because the boom circuit in the event of a spill, although the additive packages
gets its oil from the same tank as the return filter, the are not inert. One brand, Mobil EAL 224-H, has been
oil should be clean anyway. accepted for use in Schwing pumps, and other brands
The oil tank breather filter is mounted on top of the are under consideration and testing. These oils must
hydraulic oil tank. This filter should be changed when not be mixed with mineral-based hydraulic oils, even in
the main return oil filter is changed. very small amounts. If you will be pumping a job in an
environmentally sensitive location and want to use this
The high pressure oil filter is located on the passenger type of hydraulic oil, please contact the Schwing
side of the unit. Service Department at (651) 429-0999 for instructions
The type of filters installed on your unit are the result on making the change from mineral oil.
of years of experience and testing. We recommend that Viscosity of hydraulic oil is similar in concept to the
you do not change the housing or element to some different weights of motor oil. For example, in the
other type. You may learn that in the long run, cheaper winter you may run 5W-30 in your car, while in the
is more expensive. summer you run 10W-40. The same is true for
hydraulic systems. If you live in a climate where the
Changing high pressure water filter weather is changing from extremely hot conditions to
extremely cold conditions, you should consider
The optional high pressure water pump has an inline
changing the weight of the hydraulic oil that you use
filter between the water tank and the optional high
by the season. The International Standards
pressure water pump. This filter needs to be inspected,
Organization (ISO) has developed a method of grading
cleaned, or replaced at the same time hydraulic oil
hydraulic oils for viscosity. For summer in northern
filters are changed. This filter will also need inspection
North America, we recommend ISO VG 46 weight oil,
and cleaning if water is not flowing through the high
while in the winter we recommend ISO VG 32 or even
pressure water system. The part number for the filter
VG 22, depending on how cold it gets in your area. For
element is in the Parts List manual supplied with your
southern North America and Central America, we
concrete pump.
recommend ISO VG 46 for the winter and ISO VG 68
or VG 100 for the summer, depending on how hot it
Hydraulic Oils gets. The lower the ISO VG number the thinner the oil
and the lower the pour point of the oil. On the other
General information relates to all hydraulic oils. hand, the thinner the oil, the lower the temperature will
Specific information contains hydraulic oil have to be before it breaks down the lubricating film
recommendations for Schwing concrete pumps. that protects your components.
Specific information
• Mobil DTE
• BP Energol
• Aral Vitam
• Esso Nuto
• Esso Univis
• Total Azolla
• Wintershall Wiolan
Electrical Introduction
This guide will help you learn how to service current
Electrons (13) and future Schwing electrical systems. Even if you
- have little or no experience with electrical repairs, this
-
guide will help. It begins with the basic definition of
electricity and continues all the way through the
- -
troubleshooting process. It will show you how to use
Ohm’s law, identify series, parallel and series-parallel
- - - - circuits, and troubleshoot circuits using various testers.
It’s a fairly complete journey from concepts to
applications.
- - - -
-
Nucleus
What is Electricity?
(w/13 Protons) Electricity is the flow or displacement of electrons.
Normally, the atoms in a substance are balanced in an
electrically neutral state. They’re made up of equal
Figure 1. Aluminum atom (Neutral state) numbers of positively-charged protons and negatively-
charged electrons.
-
However, it is possible to strip electrons from atoms.
This creates areas of positive and negative charge in a
-
One Electron Is substance: positive charge where there are atoms
- - Forced From without the normal number of electrons, and negative
The Atom Leaving charge where there are excess electrons. As you might
Only 12
- - - - have guessed, these two oppositely charged areas
attract each other. Why? Because the unbalanced atoms
and stray electrons always want to return to the
- - - - balanced, or electrically neutral, state. On the other
- hand, areas with the same charge repel.
Figure 7. AC current flow periodically AC and DC. Two types of electric currents exist; AC,
reverses direction for Alternating Current, and DC, for Direct Current.
+ resistance.
Amperage
Seconds
0 Amperage describes the rate of current flow. It is
measured in amps, using an ammeter. The higher the
3 1 amperage, the greater the number of electrons flowing
past a single point in one second.
2
1 Amp
Current flow and heat are related. As amperage
Figure 9. Amperage is the rate of current flow increases, more electrons flow and more heat is
generated. Any electrical component that carries
Low Current Flow current, generates heat. For this reason, the wires in a
Low Heat Schwing concrete pump are sized according to the
amount of current they must carry. Thick wires carry
large currents, while thin wires are used for small
currents. Thick wires can handle a large current
without burning up because they are made up of more
atoms with more available electrons. They therefore
resist the flow of current less than thin wires.
Voltage
Allows Less Voltage is the force that moves electrons through a
Flow (Amps) circuit. It’s also known as “electromotive force,” or
“EMF”. Technically, it is the potential difference in
1000 electron pressure between any two points. Voltage is
measured in volts, using a voltmeter.
Allows More The higher the voltage, the more force is available to
Flow (Amps) cause electrons to flow. The lower the voltage, the less
available force.
10
Figure 13. A resistence is a restriction Voltage is like the water pressure in a pipe. At 10 psi of
pressure, water flows through a pipe at a certain rate. At
20 psi, the water will flow almost twice as fast. The
relationship is similar in an electrical circuit. For
example, at 12 volts, current flows through a particular
Allows Less
Flow (Amps) circuit at a rate of 12 amps. At 24 volts, however,
current flow through that same circuit at a rate of 24
amps.
Infinite
Resistance
Allows More
Flow (Amps) Resistance descries how much a component or circuit
resists, or restricts, current flow. Think of it as a kind of
0 electrical friction. The greater the resistance, the less
current flows. The less the resistance, the greater the
current flow. Resistance is measured in ohms, using an
Figure 14. The two extremes of resistence ohmmeter.
20
2000
200u conductors in a Schwing electrical circuit.
m 20m
200m
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V Besides the thickness of a wire, several other factors
COM V mA
affect the resistance of a conductor. They include
condition, length and temperature. For instance, a wire
in poor condition with a partially cut core, has
increased resistance because the narrower width at the
cut restricts the movement of electrons. In fact, the
Figure 15. Copper conductor partially cut wire operates in a circuit as if its entire
length were of the reduced diameter at the point of the
cut.
Short Wire Offers
Less Resistence
The length of the conductor also affects its resistance.
A longer wire offers more resistance than a shorter
wire (of the same diameter) because the voltage has to
move the electrons through it farther.
200
1000
500 200 BATT
9V
with another conductor. Glass, rubber, and ceramic are
20
2000
m
200u
20m
other examples of typical insulators.
200m
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V
COM V mA
Basic Circuits
Figure 19. Circuit breakers Circuit protection devices such as fuses and circuit
breakers are designed to protect a circuit’s wiring and
components by cutting off current flow when it
becomes too high. They do this by switching off or
melting. This opens, or breaks, the circuit.
20
2000
m
200u
20m
loose or corroded connections. If the voltage drop
200m
2000k
2000
200m
200
across a wire or connection is sever enough, the circuit
200k
200 mA FUSED
500V max
500V
COM V mA
dim, cranking slows, or the battery discharges
frequently.
Figure 20. Measuring voltage drop
200u
2000
m 20m
200m
200m
2000k
2000
200 Other types of controls vary the function of a load by
200k
20k
200 mA FUSED
500V max
500V
increasing or decreasing current flow. Variable
COM V mA
resistors, do this by allowing you to vary the amount of
resistance in the circuit. So, in a light dimming circuit,
for example, the higher the resistance, the dimmer the
lights, and the less resistance, the brighter the lights.
Figure 21. Rheostat A ground is a return for current flow to the voltage
source. Ultimately, the negative battery terminal serves
as the ground for all the circuits in Schwing concrete
pumps. However, since the frame and engine are also
connected to this terminal and are conductors, most
ground connections are made to them, not the battery
terminal.
-
2 3 +
TRANSMITTER
DIN ANSI
OR T 1K
(both DIN)
BATTERY Control Relays these numbers DIN ANSI
) show the location
shown (ANSI "ladder" drawing (line number)
TAS
Pivot point of the switch - contacts
CURRENT FLOWS
line indicates of the
N.O. IN THIS DIRECTION
below the activation Relay terminal Relay coil
°C that the relay coil
120V 120V
would be DIODE Primary
that the contact lever FUNCTION WHEN TEMPERATU numbers
60 HZ 60 HZ
drawn towards contact
#2 in the RE SWITCH will operateBLOCKED
CURRENT
"ON" position
ACTIVATED "ON" IN THIS DIRECTION
TAS
TRANSFORMER
line numbers
CHASSIS GROUND OR N.C.
CR 1 CR 2 °C 2
3 Secondary
d during 13 8, 9 12V
as Spring is compresse 1 5 9LIGHT EMITTING DIODE 12V
"OFF" position activated, activation, indicating
that it will 7 9 1 CR
DIN ANSI
indicated by solid line (L.E.D.) DIN
return to "O" when released ANSI
50a N.O. contact N.C. contacts
N.C. contact
OVER-CURR wire are underlined
30 ENT SWITCH numbers
(Always normally closed) SHIELDED CABLE
ON O OFF 1 CR 3 N.C. OL
BRIDGE RECTIFIER
In this example, 14 (Show all conductors
contact is made
1
5 9 (A.C. to D.C. converter)
STARTER between terminals 8 STARTER inside shield)
DIN ANSI
1 and 3 in the which relay
these numbers denote
"OFF" position
coil will operate the contact FS 21 21 22 22 DIN ANSI
ON OFF
31 TERMINAL CONNECTORS
N.O.
2 3 Q
CR 3 CR 2 2
FLOAT SWITCH 15
16
G CAPACITOR
1
1 2 8
9 (Oil 9
Level) FS (VALUE INDICATED
POSITIVE NEGATIVE IN
common TERMINALS
FARADS)TERMINALS
shown ELECTRIC MOTOR M N.C.
2 μF
Pivot point of the switch common Q neutral
(μ = micro or 1 millionth) 2 μF
line indicates hot
below the activation DIN
that the contact lever
would be FUNCTION WHEN DIN ANSI ANSI
#3 in the
pushed towards contact ACTIVATED "OFF"
"OFF" position
Figure 22. Typical electrical symbols Figure 24. Typical parallel circuit
- +
POWER
500 200 BATT
12V
1000
200 9V
20 200u
2000
m 20m
200m
- +
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V
COM V mA
12V
- + POWER
1000
500 200 BATT
200 9V
20 200u
12V 2000
m
200m
200m
20m
2000k 200
200k 2000
-
20k
+ 200 mA FUSED
500V max
500V
COM V mA
Ohm’s Law
I= E Amperage, voltage, and resistance are related in a
R circuit. Ohm’s law describes this relationship and can
be used to find a missing value when the other two are
known.
E=IxR
The basic equation of the law is I equals E divided by
R= E R. I is the current in amps, E is the voltage, and R is the
I resistance in ohms.
I R
You should memorize the different forms of Ohm’s law
because you’ll need them when troubleshooting
Figure 29. Memory aid for Ohm’s Law circuits.
12 ohm load
POWER
500 200 BATT
1000
200 9V
20 200u
2000
m 20m
200m
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V
COM V mA
+
- 0V=0 Amp x 12
12 ohm load
POWER
500 200 BATT
1000
200 9V
20 200u
2000
m 20m
200m
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V
COM V mA
20 200u
2000
200m
200m
2000k 200
200k
20k
2000
200 mA FUSED
500V max
500V
it’s the same throughout the circuit, you can use Ohm’s
COM V mA law:
12 volts/12 ohms = 1 amp.
Figure 36. Total resistence in series circuit
+
- 1Amp= 12V
12
+
- 4V=1 Amp x 4 This result also agrees with the rule that current is the
same throughout the circuit. If you plug the voltage
drop and resistance of one load into Ohm’s law, you get
the same current value: 4 volts/4 ohms = 1 amp of
current flow.
POWER
500 200 BATT
1000
200 9V
20 200u
2000
m 20m
200m
2000k
200k 2000
200m
200 The third rule also proves out. Each 4 ohm load causes
20k
200 mA FUSED
500V max
500V a 4 volt drop, and 4 volts + 4 volts + 4 volts = 12 volts –
COM V mA
the source voltage.
Figure 38. Voltage drop of one load in series
circuit
POWER
1000
500 200 BATT
• Second, the total amperage in a parallel circuit is
20
2000
200 9V
200m
2000k
200m
200
amperages. This means you can treat each
individual branch of the circuit as a series circuit,
200k 2000
20k
200 mA FUSED
500V max
500V
20 200u
2000
m 20m
200m
2000k
2000
200
200m
200 mA FUSED
500V max circuit, you plug numbers into the total resistance
Figure 41. Measuring total amperage in a equation. See Figure 42 for an illustration of how to
parallel circuit solve the equation for this example. The total resistance
in this circuit is 4 ohms. This number also agrees with
Total the 3 amps of total current: Using Ohm’s law, 12 volts/
Resistance
4 ohms = 3 amps.
1 = 1 1 = 1x 4 = 4
1 + 1 + 1 3 1 1 An important difference between parallel and series
12 12 12 12 4 circuits is that as you add more branches to a parallel
circuit, its total resistance decreases instead of
Add Fractions increases. And this, of course, increases the current in
Find a Common Invert
Denominator, If Simplify Fraction and the circuit. For instance, add another 12 ohm load in
Necessary Fraction Multiply parallel with the previous circuit, and the total
resistance goes down to 3 ohms, while the amperage
Figure 42. Calculating total resistance in a increases to 4 amps.
parallel circuit
+
+ -
-
POWER
500 200 BATT
1000
200 9V
POWER 20 200u
200k 2000
20k
COM V mA
200 mA FUSED
500V max
500V
Figure 43. Measuring total resistance in a Figure 44. Total total resistance in a parallel
parallel circuit circuit
12 V
- +
Circuit Faults
200
1000
500 200 BATT
9V
operate and no heat is generated. As a result, an
20
2000
m
200u
20m
ammeter will not give a reading, but a voltmeter,
depending on where it is placed, may or may not show
200m
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V a voltage reading.
Figure 48. Voltage reading before opne
Unwanted Resistances. Opens are one extreme of
unwanted added resistance. But problems also occur
when any unwanted, but less then infinite, resistance is
added in series to a circuit. This may be caused by a
wire of incorrect size or material, a damaged wire,
+ loose or dirty connectors, or corroded connections or
- terminals.
20
2000
m
200u
20m
starter motor turns too slowly or the lights dim, for
200m
2000k
2000
200m
200
instance.
200k
20k
200 mA FUSED
500V max
500V
Figure 49. Voltage reading after open Shorts. A short circuit occurs when previously
unconnected conductors touch one another allowing
current to bypass a part of a circuit. Shorts may occur
within a component, such as a starter motor or relay
coil, or across conductors in one or more circuits.
+
-
Figure 52. Short voltage across switch However, jumper wires and self-powered and
unpowered test lights are also useful troubleshooting
Jumper Wire tools, but can cause other problems if not used
correctly.
CAUTION
Unpowered Test Light. An unpowered
Figure 54. Jumper wire bypassing an opening testlight is simply a bulb with leads attached
to the bulb’s terminals. A 12 volt light is
Test Light "On" used on 12 volt systems, a 6 volt light on 6
volt systems. This type of test light must be
used in a powered, or active, circuit, since
the only way the bulb will light is when cur-
rent flows from the circuit and through the
+ light to ground.
-
You can check for voltage in a circuit by
touching one lead to ground and probing
the circuit with the other lead. This type of
testing, however, only tells you where volt-
age is present. To find out how much, you
must use a voltmeter.
+
- Self-Powered Test Light. A self-powered test light has
its own battery, so it must be used in an unpowered
circuit. You use it to check for continuity.
+
-
+
-
200m
200m
20 200u
thousandths).
2000
m 20m
200m
200m
2000k 200
200k 2000
20k
200 mA FUSED
500V max
500V
COM V mA
3 3 3 3
It is important to remember how to connect a
mulitmeter to obtain the proper reading and prevent
damage to the meter or sensitive electronic circuit.
First, read and follow the instructions that come with Figure 63. Converting units of measure
POWER
500 200 BATT
Conductors should have almost no voltage drop. A
1000
20
2000
200 9V
200u
drop greater than 0.1 volt in a low-current conductor, or
0.3 volts in a high-current conductor (such as a battery
m 20m
200m
200m
2000k 200
200k
20k
2000
200 mA FUSED
500V max
500V
cable) indicates a damaged conductor or a poor
COM V mA connection.
Electrical Symbols
LINE
MAGNET COIL
FOR HYDRAULIC VALVE
CONNECTOR DIN ANSI
HORN
LINES, JOINING
(Letter
LAMP WITH BULB R indicates
lens color)
DIN ANSI
LINES, PASSING
31 D-
+ OIL TEMPERATURE
TRANSMITTER OR T
(both DIN)
BATTERY
- CURRENT FLOWS
IN THIS DIRECTION
DIODE
CURRENT BLOCKED
IN THIS DIRECTION
CHASSIS GROUND OR
LIGHT EMITTING DIODE
(L.E.D.)
50a
30
SHIELDED CABLE
(Show all conductors
STARTER STARTER inside shield)
21 21 22 22
31 TERMINAL CONNECTORS
POSITIVE NEGATIVE
TERMINALS TERMINALS
ELECTRIC MOTOR M
Electrical Symbols
SWITCHES RELAYS
KEY: N.O. = Normally open N.C. = Normally closed KEY: N.O. = Normally open N.C. = Normally closed
ON OFF
30 85
2 3
OR
Component
Component Contacts (2 N.O.
Dashed lines = enclosure
enclosure contacts shown).
available positions
of switch
86 87a 87
AS DRAWN
("O" POSITION) K3
85 30
contact is made CR 3
1 14
between terminals 8 5 9
1 and 3 in the
"OFF" position these numbers denote which relay
ON OFF
coil will operate the contact
2 3
CR 3 CR 2
1 15 16 2
Pivot point of the switch shown
9 9 1 2 8 G
below the activation line indicates
common common
that the contact lever would be hot neutral
pushed towards contact #3 in the
FUNCTION WHEN
"OFF" position ACTIVATED "OFF"
Electrical Symbols
MOMENTARY CONTACT
N.C.
CIRCUIT BREAKER /
DIN ANSI DISCONNECT
SWITCH
PS.
N.O.
N.C.
MISC. DEVICES
TGS.
0 1 2
D.P.D.T. RESISTOR
2.5 K
0,1,2 (VALUE INDICATED IN OHMS)
(K = 1000)
DIN ANSI
POT
MECHANICAL SWITCH 1K
(Hopper Grate Switch) NONE POTENTIOMETER
AVAILABLE (Value indicated)
1K
DIN ANSI DIN ANSI
TAS
120V 120V
N.O. Primary 60 HZ 60 HZ
¡C
TEMPERATURE SWITCH TRANSFORMER
TAS
N.C. Secondary
¡C 12V 12V
OVER-CURRENT SWITCH OL
(Always normally closed) N.C. BRIDGE RECTIFIER
(A.C. to D.C. converter)
DIN ANSI
DIN ANSI
FS
N.O.
Q CAPACITOR
FLOAT SWITCH FS
(VALUE INDICATED IN
(Oil Level) N.C.
FARADS) 2 F 2 F
Q ( = micro or 1 millionth) DIN ANSI
DIN ANSI
Controller Systems
Analog
39000170.eps
Digi-Prop (Microwave)
40 60 0 0 0 0 0 1
10
80
20 100
C
HOURS
VDO
P
Filter
C
in Bypass
15 20 MAT
10 U/minx100 25
5 30
0 35
OIL
COOLER
ON
OFF
3034
1803
30339533
5 6
4
7
3
8
2
9
1
0 10
39000171.eps
Comfort Control
0
0 0
0
0
0 0
! 3034
1221
30339533
5 6
4
7
3
8
2
9
1
0 10
39000172.eps
C32
O
N
NO
RE
START PWM
T O P E R AT E
3_
D Z O N E!
5 30
POWER
4_
MAX PWM
REAR CTR 0 35
5_
UMB CTR
6_ RAMP UP
RADIO CTR
40 60
ALARM 80
20 100
E-STOP C
STORE
VDO
3034
1803
5 6
4
7
3
30339533
8
2
L1357-01 5
9
1
4 6
0 10
7
3
8
2
9
1
0 10
30339530
39000173.eps
CPC
2_
3_ START PWM
POWER RPM 4_
MAX PWM
REAR CTR
5_
UMB CTR
6_ RAMP UP
RADIO CTR
LINK
C
NORMAL BYPASS
ALARM
E-STOP
STORE
3034
Reset 8540
30345602
L1357-01 4
5 6 7
3
8
2
9
1
0 10
39000174.eps
30351405A
CPC II
2_
3_ START PWM
POWER RPM 4_
MAX PWM
REAR CTR
5_
UMB CTR
6_ RAMP UP
RADIO CTR
ALARM
E-STOP
STORE
∅ ∅
WHEN WELDING ANYWHERE ON UNIT
POWER CABLE MUST BE DISCONNECTED
Reset
5 6
4
L1357-01
7
3
8
2
9
1
0 10
CPC 2 30357944
39000175.eps
2
1
OK OFF
0 x1000 3
PTO 1500 rpm 62˚C
Menu: [ENTER]=ON
1
HOME + HELP START 2
30356534 C
HP
30362348
CLEAR - ENTER QUIT R 4
5 6
7
3
8
2
9
1
0 10
39000176.eps
202
2
6 - 6 SQ. MILS
(wire size)
Non-joining lines
Training Manual
2
1.5 - 1.5 SQ. MILS
all 3 wires
SERVICE TRAINING
JunctionBox
(see boom orange
Trouble Light brown
2 1 schematic)
Receptacle at Tachometer
Operator’s Panel Panel
Panel Light Light
G
to Pin 2/5 + brown brown G
brown brown
from Pin 1/11 red red
orange
brown Remote
thermometer for Remote thermometer
Emergency
stop button
Pass. Side oil tank for Driver’s side oil tank
orange
= 10 gauge
= 12 gauge grey brown brown
= 16 gauge red G G
Small
All fuses On-Off
20 amp switch brown brown
(AGC size) orange
red
black purple
white purple
USA 28M
black stripe
white with
1/94 GRP
electric oil
white cooler only
green yellow
red white
25 A
In line
fuse
25 A
H
purple
purple
purple
yellow
white & black stripe
black
white
Tachometer Trouble Light Dirty hyd. oil Passenger side Driver’s side
12 volt sending unit Receptacle filter pressure hyd. oil hyd. oil
+ (proximity switch) at Center of switch 35 PSID temperature temperature
Unit (2.4 bar) sending unit sending unit
STOP
25 A
A B C D E F G H G+ G- S O P
2
2/7 2/9
6 10 12
1 2 3 4 5 6 7 8 9 11
1 2 3 4 5 6 7 8 9
10
11
12
7 +
12 Volt
1 1 1 1 1 1 1 1 1 1 1 1
2 A2 B2 C2 D 2 E2 F2 G2 H 2 + 2 - 2 P2 S -
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
#1 BOOM UP
#1 BOOM DOWN
SLEWING CCW
SLEWING CW
#3 BOOM EXTEND
#3 BOOM RETRACT
#2 BOOM EXTEND
#2 BOOM RETRACT
THROTTLE UP
THROTTLE DOWN
CONCRETE PUMP
FORWARD RELAY
CONCRETE PUMP
REVERSE RELAY
CONCRETE PUMP
FORWARD
CONCRETE PUMP
REVERSE
Components 2 thru 5
BYPASS VALVE
2/90 RE
Misc Procedures
Material Cylinder Alignment
1. To visually inspect the alignment, put a trouble
light in the waterbox, at the opening to the cylinder
being aligned (See Figure 66). Be careful with
fingers and hands in the waterbox. Put the trouble
light in the waterbox, then remove your hand
BEFORE proceeding to the next step.
Figure 67
Material Cylinder Alignment Tool
LIGHT RAYS
CYLINDER WALL
ALIGNMENT TOOL
Figure 66 Figure 68
Placing a spot light in the waterbox Light rays in material cylinder
2. Select the “forward” mode of the S1 valve, AT If the alignment tool should contact the cyl-
THE SLOWEST POSSIBLE SPEED! Look into inder wall at any time, return the pump to
the material cylinder from the valve end. The gap neutral immediately! Damage may occur to
between the alignment tool (See Figure 67) and the cylinder wall.
cylinder wall should be seen as even rays of light
(See Figure 68). When the cylinder gets fully
extended, the alignment tool may drop a small
amount or even barely touch the material cylinder
wall.
3. If, for example, the alignment tool contacts the cyl- NOTE!
inder on the lower side, loosen the mounting bolts If a squeaking sound indicates the align-
at the waterbox a little bit, then tighten the ment tool is dragging on the material cylin-
LOWER bolts first (See Figure 69). This will lower der, turn off the pump IMMEDIATELY!
the bottom of the material cylinder. When the 9. If there is no dragging, you may proceed to step 11.
alignment is close, tighten the top bolts and If dragging does happen, repeat the visual checks.
recheck the alignment. When the alignment is 10. Loosen the bolts on the material cylinders and
within specification, the alignment tool will travel valve housing, and at the machine frame, and
the entire length of the cylinder without touching repeat the alignment procedure.
the cylinder wall. If the alignment tool is not 11. Check the mounting of the pump kit and its mount-
always located exactly in the middle of the cylinder ing to the pump kit frame.
during the travel, but DOES NOT TOUCH, then
12. Tighten all bolts.
realignment is not necessary. Minor misalignments
are compensated for with the rubber ram. Repeat 13. Complete the reassembly of valves, and install the
procedure for the other cylinder. rubber rams.
NOTE!
If proper alignment cannot be achieved oth-
erwise, tightening torques may be exceeded
by 10% over the charts specs. If further
alignment problems persist, please contact
the Schwing Service Department.
MOUNTING
BOLTS
Figure 69
Mounting bolts
4. Grease new o-rings and insert in the valve housing.
5. Carefully slide the valve housing onto the material
cylinders, and rest the valve housing on the
machine frame.
6. Bolt the valve housing and material cylinder
flanges together making sure that the alignment is
being maintained.
7. Bolt the valve housing to the machine frame.
8. Check alignment with the tool once more, at slow-
est possible speed.
Add hose
and fittings
to each side
Loosen for
rotation
Dimension A
Tape
Using a caliper measure the distance from the top of
the bushing down to the bushing seal recess. See Figure Figure 71
70. Compacting the Cherevon seals
Use the caliper to measure the distance between the top
and the bottom of the compacted cheveron seals. See
Figure 72.
Dimension A = 57.12 mm
Tension Ring
Bushing Dimension B
Dimension B
Figure 70
Measuring for dimension A Figure 72
Measuring for dimension B
Dimension B
Leave the tape around the cheveron seals to hold them
into place. On a solid flat surface place the Tension ring
on top of the cheveron seals. This will compact the
cheveron seals to the proper size. See Figure 71.
Formula
A should equal B
B - A = shims required
In this example:
57.40
- 57.12
.28 mm (.011")
Figure 73
Formula for determining shimm size
In this example, we would need to add 1 - 0.5mm
shimm to the Tension ring. This will ensure that the
cheveron seals will not expand, thus preventing wear
on the cylinder rod.
NOTE!
A maximum of 5 shimms can be used.
NOTE!
Dimension B can never be greater than
dimension A or cylinder rod damage can
occur.
Figure 77
Bleeding the PC2 control chamber
Figure 75 • The PC1 control chamber (handle side) is bled
Normal Horizontal Position by loosening the port plug several turns (Figure
If the valve is mounted with the main spool horizontal 78). Then supply a pilot signal to the end chamber
and the solenoids (Figure 76) are below the main spool, by energizing the solenoid closest to the port plug
then the following must be done: with a 100% input signal. Once there is no more air
Port Plug
PC2 Control
Chamber
Figure 80
Bleeding the PC2 control chamber
• The PC1 control chamber (handle side) is bled
by loosening the spool plug with flow limiter sev-
Figure 78 eral turns in order for the O-ring to disengage with
Bleeding the PC1 control chamber the lead-in surface of the SAE port (Figure 81).
Then supply a pilot signal to the end chamber by
If the valve is mounted with the main spool horizontal
energizing the solenoid closest to the plug with
and the solenoids are to the left or the right of the main
100% input signal. Once there is no more air exit-
spool in the same horizontal plane (Figure 79), then the
ing from the threads of the plug, turn the plug into
following must be done:
the valve housing until the O-ring contacts the
lead-in surface. Then remove the pilot signal and
any other positive pressure from the valve. Tighten
the plug into the valve housing to 10 - 30 ft. lbs. of
torque.
NOTE!
Solenoid Solenoid Due to the internal core of the casting, it
may be necessary to slightly tilt either the
Spool valve or the equipment in which the valve is
mounted on, so that the end plug is the high-
Figure 79 est point of the valve section, in order to
remove all the air from the control chamber.
Spool Horizontal - Solenoids to the left and
right of main spool
• The PC2 control chamber (spring side) is bled
by loosening the spool plug with flow limiter sev-
eral turns in order for the O-ring to disengage with
the lead-in surface of the SAE port (Figure 80).
Then supply a pilot signal to the end chamber by
energizing the solenoid closest to the plug with
100% input signal. Once there is no more air exit-
ing from the threads of the plug, turn the plug into
the valve housing until the O-ring contacts the
lead-in surface. Then remove the pilot signal and
any other positive pressure from the valve. Tighten
the plug into the valve housing to 10 - 30 ft. lbs. of
torque.
Figure 81
O-ring
Bleeding the PC1 control chamber
If the valve is mounted with the main spool vertical
(Figure 82), then the following must be done:
Upper Control
Chamber
Upper Chamber
Figure 83
Bleeding the upper control chamber using
spool plug with flow limiter
O-ring
Upper Control
Figure 82 Chamber
Vertically mounted handvalve
• Only the upper control chamber needs to be Figure 84
bled since the air in the lower control chamber will Air bleeding the upper control chamber using
rise and the air will purge out of the control cham- the port plug
ber through the clearance around the main spool
(Figure 83 or Figure 84 depending upon the orien-
tation of the valve).The upper control chamber is
bled by loosening the spool plug with flow limiter
several turns in order for the O-ring to disengage
with the lead-in surface of the SAE port. Then sup-
ply a pilot signal to the end chamber by energizing
the solenoid closest to the plug with 100% input
A11VO130 / A11VO130
Q-max Screws
A11VO130 / A11VO190
Q-max Screws
Horsepower Setting
Adjustment Knob
After the flow rate is set, the horsepower setting then
must be done. The horsepower break point must be set
to the proper specifications per the output chart.
CONCRETE
BPL 2023-5 PRESSURE
350 or 400 HP truck PSI Bar
2000 138
Piston Side
Bar
PUMP SPEED
E 2100 RPM
HYDRAULIC RELIEF VALVE IS SET AT
350 BAR MAX. PRESSURE (5075 PSI).
1700
1600
1500
117
110
103
T
P
G
P
MG
PL
1400 97
MY Y
1300 90
4500
300
OIL PRESSURE
4000 800 55
250 700 48
3500
3000 600 41
200
SA
2500
2000
150
500
400
34
27
Figure 88
1500
1000
100 300
200
21
14
Stroke Limiters (two generations)
50
500
0
100 7
3. Increase the engine Rpm's to the maximum setting
Break Point 208
180 Kw = 182 bar
200 KW = 202 bar
At 350 bar
180 Kw = 278 l/m
10 20
7.5 15
30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220
23 30.5 38 46 53.5 61 69 76.5 84 92 99 107 114 122 130 137 145 153 160 168
cu yd / h
cu meters/ h
and while watching the flow meter scale, slowly
200 Kw = 309 l/m
CONCRETE OUTPUT
32
turn the stroke limit potentiometer to the minimum
5 10 15 20 25 30 Number of strokes
until the reading is correct or if it is to low, turn the 1. Locate the agitator shutoff valve and close it.
Q min screw in until the reading is correct. When NOTE! If your unit does not have a shutoff valve,
the Q min has been set, the flow meter can now be order one from the Schwing Spare Parts Depart-
removed. ment using part number 10004680 (valve), and
number 30303432 (tube). Contact the Service
A11VO190 Department for installation instructions.
14. Activate the agitator. With the valve closed the agi-
tator will not be able to turn and the oil will be
A11VO130 forced over the relief valve. At an idle (about 600
RPM), 4.5 horsepower is being converted to heat.
Q min Screw 0
Q min Screw
Figure 89
Q-min screw locations
agitoff.eps
2. Repeat steps 2 through 6 on the second main
system pump before attempting to set the pressure
cut-off on both pumps. Figure 90
Agitator shutoff valve
NOTE!
15. When the oil temperature gauge shows 50˚C, open
All screw adjustments with the system
relief’s and pressure cut-off must be done the shutoff valve.
while the unit (pumpkit) is in the neutral
position. Setting pressures on Hi-flo -6 pumpkits
Check all hydraulic pressures. a. To set the pressure of the main relief valve on Hi-
Changes in pressures can indicate trouble in one or flo pumpkits, you must first disable the soft switch
more components. The specifications for each circuit circuit. Simply locate the ball cock for the soft
are shown on the hydraulic schematics found in the switch circuit (Figure 91) and close it by rotating
Appendix of this manual. The hydraulic schematics are the handle 90 degrees.
the only documents in this manual that have been b. The quarter turn shutoff valve for the concrete
updated specifically for your unit, by the serial number,
pump (Figure 91) will also need to be closed
so in each of the following procedures you will be told
during this procedure.
to refer to the schematic for the pressure required.
• Preheat the hydraulic oil NOTE!
Pressure settings must be made with the oil at normal Main system adjustments are preset at the
operating temperatures (40°− 60° C). In the past we factory. The following procedure begins
could pressure out a function in the boom or outrigger with adjustment of the main relief cartridge
system to create heat, but load sensing systems no and pressure cutoff. If proper pressures can
longer allow maximum oil flow to be forced over relief. not be obtained through these steps, refer to
Because of this the agitator circuit must be used to heat the beginning of this procedure for specific
instructions on the adjustment of flow,
the hydraulic oil. horsepower, beginning of stroke regulation
To preheat the hydraulic oil: and Q-min.
Pressure setting procedure: 23. Stop the truck engine and put the key in your
pocket. Adjust the pressure cutoff screw (Figure
Soft switch 92) on each pump, by backing off the jam nut with
shutoff valve a 13mm wrench. Using a 4mm allen wrench, turn
the adjustment screw in (clockwise) one full turn
Main Pressure
Gauge port and tighten the jam nut. Restart the truck engine.
24. Adjust the engine RPM to maximum specification.
(See decal in truck cab)
25. Pressure out the system by activating the concrete
Concrete pump
pump forward switch on the rear panel. Using the
shutoff valve hif
lob
rn
rear panel controls will allow you to read the con-
.e
ps
crete pump main system pressure gauge, near the e-
stop manifold, from a safe distance.
Figure 91
Concrete pump and Soft switch shutoff valves NOTE!
Because you turned out the pressure relief
1. Be sure that the waterbox covers and guards are in cartridge in step 21., the system pressure
place any time you will be working in the area should read low at this time. If it does not
around the main control block. and the gauge spikes to 320 bar or more,
16. Wear safety glasses when working around a con- disengage the pump immediately. Turn the
relief cartridge out (counterclockwise)
crete pump. more. For safety, it is important to adjust
NOTE! the pressure up from below the specified
target pressure rather than down from a
It is vital that each adjustment screw be pressure which exceeds the target. Continue
properly identified prior to making any this procedure until the main system pres-
adjustment. All screw adjustments for the sure gauge reads lower than the specified
system relief must be made with the pump- target.
kit in the neutral position and adjustments
for pressure cutoff must be made with the 26. To increase the pressure put the pump in the neutral
engine shut off. position and adjust the relief cartridge by turning it
17. Start the truck engine, and put the PTO in gear just in (clockwise). When increasing the pressure, the
as you would to pump a job. adjustments should be made in quarter turn incre-
ments. If you make adjustments to increase the
18. If you have not already closed the soft switch shut- pressure but the pressure does not come up, you are
off valve and the concrete pump shutoff valve (Fig- probably reading the pressure cutoff of the pumps,
ure 91) do so at this time. if so proceed to the next step otherwise skip to step
19. At the rear panel, select “local” control with the 29.Turn the relief cartridge adjustment screw back
“local/remote” switch and turn the electric stroke out (counterclockwise) until you can no longer see
limiter knob clockwise to maximum strokes per a pressure drop and tighten the jam nut.
minute. 27. Stop the truck engine, put the key in your pocket.
20. The main system control block pressure must be 28. Go to the pressure cutoff screw on both hydraulic
set first to properly set the pressure cutoff on both pumps (Figure 92) and back off the jam nut with a
pumps. Begin by backing off the jam nut of the 13mm wrench. Turn the adjustment screws in with
main relief cartridge (Figure 93) with a 9/16 inch a 4mm allen wrench one or two more turns, restart
wrench. the engine and check the pressure again. Repeat
21. Using a 5/32 inch allen wrench, turn the adjustment this procedure until the main system relief can be
screw out (counterclockwise) until you can feel no set to the target pressure.
spring tension on the adjustment screw. 29. When the proper main relief pressure is achieved,
22. Now, turn the screw back in (clockwise) two or pressure cutoff can be set. Shut off the engine, put
three full turns to give you a proper starting point the key in your pocket and install 0-600 bar gauges
and tighten the jam nut. with whip hoses to the “M1” gauge ports on the
31. Always stop the truck engine and put the key in
your pocket before making any adjustment on the
hydraulic pump. If the cutoff on one pump is set Concrete pump
higher than the other, that pump will be more dom- shutoff valve hif
lob
rn
.e
ps
When you put the pump in forward now, the main con-
crete pump pressure gauge should read the pressure
shown on the schematic for soft switch. If adjustment
is needed, loosen soft switch relief valve jam nut (Fig-
ure 93) with a 9/16 open end wrench, and use a 5/32
allen wrench to adjust the pressure. Turn the adjust-
ment screw in (clockwise) to raise the pressure or out
(counter clockwise), to lower the pressure. When you
attain the required pressure, tighten the jam nut while
holding the allen wrench to keep the pressure from ris-
ing. Be sure to open the concrete pump shutoff valve
on the side of the brain (Figure 93) when you are fin-
ished. The unit will not stroke with this valve closed
ACCUMULATOR
SYSTEM
11 1
2 3 4
7 Figure 2
6
5
Plugging the hose and pump
B B
E-STOP AGITATOR Close the 1/4 turn valve on the accumulator system and
VALVE CLOSED FOR
BYPASS
stroke the machine with water in the hopper. The
9 A A
10 2.0 bar
accumulator gauge should respond very similar as it
8 39000214.eps does with the accumulator pump. Also, you must
ACCUMULATOR confirm that the e-stop manifold does de-energize the
PUMP
accumulator system.
Training Manual
SERVICE TRAINING
Table of Contents
Service Manual
Visual Inspection
General Instructions
NOTE!
The following pages contain suggestions
about what to look for during routine visual
inspections. A complete structural
inspection must still be done according to
the manufacturers recommended schedule.
Periodic Maintenance
A complete structural inspection of the concrete pump,
Figure 2
boom, and outrigger assembly should be performed by
Visible rust, indicating a possible crack.
a qualified boom inspector, at the following intervals:
• The first five years - at least once per year. If paint is found to have split and rust is coming
through, remove the paint and do a close visual
• Five to ten years - every 6 months
inspection. If a crack is found a Schwing approved
• Ten years and older - every 500 working hours, boom inspector must be called in for analysis. Please
or at least once per year, whichever occurs contact SAI Engineering if you have any questions.
first.
At least once per week the unit should have a complete
visual inspection. The unit should be clean and dry
prior to inspection including inside the tower.
Freshly painted units aren’t likely to show cracks (paint
covers them up). Cracks typically won’t show up until
at least 150 pumping hours after painting. Visual
inspection of all components, however, must still be
done each week. Check safety decals for proper
positioning. Remember that safety decals and labels
are available, free of charge, from the SAI Spare Parts
Department. Order replacements whenever these labels
are damaged or missing. Please have the serial number Figure 3
of the unit available when you call Spare Parts. Crack on a welded joint.
Figure 1 Figure 4
Paint crack - may indicate a crack in the metal. Dented corners, indicating damage.
Training Manual 3
Safety Decals from the diagrams and lists, get the serial number of
Each machine is equipped with a set of warning labels the unit from the serial number plate, and call Schwing
specific to the model, boom style and installed options. America at (800) 328-9635. The person taking the
Safety decals MUST be replaced if they are damaged, order will make a note of the serial number of the unit
faded, missing, or unreadable for any reason. for our files and send you the labels you need. You may
Ultraviolet radiation, rain, steam cleaning, and other order complete sets or single labels. If the serial
factors cause these labels to fade in time. Sets include number plate is missing or unreadable, the number is
outrigger load labels, but they do not include metal stamped into the subframe just below the normal
plates, which can be ordered separately. For installation location of the serial number plate.
locations, see the decal location guide insert found in
the Appendix section of the Operation manual. To get
replacement labels, identify which label(s) you need
58p6.eps
WARNING IMPORTANT
WARNING SAFETY INSTRUCTIONS
WARNING
Falling hazard.
Not a work
platform.
DANGER The hydraulic oil filters on this unit are disposable.
Cleaning and re-use is not possible. It is time to
replace the filter if the oil is at normal operating
temperature and the "dirty filter" indicator light is
Do not use the
boom as a crane
1. Operation of this machine requires training. You must read all warning labels on the unit -
items covered on specific warning labels are not covered here. There are
other hazards and safety rules that are ONLY covered in the safety manual or
operation manual.
is cold the "dirty filter" lamp may illuminate even if 3. Safety devices and guards must NOT be altered or removed.
3 4 5. NEVER try to finish the operation with the emergency stop dump valves bypassed.
at least 17 feet 6. You must always be able to see the point of discharge. If this is impossible, an assistant
(spotter) MUST be used. The spotter must be positioned to see both the
Stand clear of operator and point of discharge for the purpose of giving instructions to the
CAUTION
When light is on, hydraulic pumps are
(5 meters). outriggers when
operator.
Factory-filled with 9. DO NOT unfold the boom unless the outriggers are fully extended and properly jacked.
SAFETY INSTRUCTIONS Rando HDZ Shortrigging is NEVER allowed on the side of the pour.
P/N 30345427
TEXACO
ERICAN 1. Release tie-down strap before lifting boom. 10. Maintain a safe distance from excavations or cliffs. Stay as far back from the edge as the
AM
2. Lower boom into cradle and reattach tie down strap depth of the excavation or cliff. (This is the one to one rule).
CONCRET
TION
Factory-filled with
before transport.
Rando HD
C IA
SLIDE-PLATE 11. Never retract the outriggers until the boom is folded into the transport position.
SO
P/N 30345426
TEXACO
E
PU S
MP ING A
1. TO RELEASE, PULL 30355887
IMPORTANT 12. Be sure outriggers are retracted and pinned before driving the unit.
SLIDE-PLATE DOWN AND Use
TIE-DOWN Change all filter elements if the dirty filter lamp illuminates when oil is
1.
BOOM UP
2. 3.
BOOM DOWN BOOM LEFT
4.
BOOM RIGHT
5.
OPEN OR
6.
CLOSE OR
EXTEND BOOM RETRACT BOOM
STRAP AND
RATCHET
PIVOT HANDLE OUT AND UP
COMPLETELY.
Mobil DTE® 25
A MOBIL PRODUCT 11 above 20 C. If unit does not have electrical filter lamp, change the filter
elements every 13,000 yds or every 6 months, whichever occurs first.
13. NEVER drive the unit with extended outriggers or an unfolded placing boom! Not even a
few feet.
HANDLE
10
14. The supplied safety cable MUST be used to secure the discharge hose or reducer to the
DATE OF LAST CHANGE DATE OF LAST CHANGE DATE OF LAST CHANGE
tip section.
15. DO NOT overload the boom. The maximum allowable weight from hose or reducer/hose
WARNING combination is 376 pounds, which is equivalent to one 12 foot long 5 inch
hose, OR a 5 inch to 4 inch reducer and one 12 foot long 4 inch hose. NEVER
use the boom as a hoist or crane. NEVER attach a structural extension to the
Do not operate at boom.
pressures exceeding
16. In the event of a thunderstorm or high winds (over 48 MPH), the boom must be folded into
the rating of the
7. 8. 9. 10.
STOP BOOM START PUMP SLOW PUMP STOP PUMP
11.
LITTLE BIT
12.
ADD WATER
13.
ALL DONE
2. TO REATTACH, PULL 2" PUMP THE HANDLE PUSH HANDLE entire material 6 the transport position.
14 17 feet (5 meters).
Stay clear. SAFE ZONE
(During operation, tip
hose must always
This product is covered by one or more of the following U.S. patents:
3,409,334 4,057,373 4,392,510 4,708,288 5,257,912 Re. 32,041
Contact will result in be in this zone)
HAZARD ZONE
TM
3,580,696
3,640,303
4,178,142
4,191,513
4,437,817
4,465,441
4,852,467
4,978,073
5,263,828
5,281,113
Re. 32,657
Re. 32,719
death or serious injury (During operation, tip
20
WARNING 18 19 Boom may float down without warning if tip is brought into hazard zone.
Stop engine/motor if
time. Stop engine reverse strokes.
access is required. 1.
before servicing unit. 22 Keep covers closed.
21 24
2. Raise #1 boom.
Keep hands out
WARNING CUIDADO WARNING
of hopper and
WARNING
CAUTION IMPORTANT Electrocution hazard.
You can order additional operation manuals, spare Keep covers closed.
WHEN PERFORMING ANY WELDING parts books, safety manuals and decal sets by manual if access machine without
ON THIS UNIT IT IS NECESSARY TO contacting us at: is required. training. Understand
DISCONNECT ALL THE WIRING FROM
Schwing America, Inc.
1-(800)-328-9635
SAFETY
39 41 24 Volts
Here 30A 40A
+ - + -
Do not touch
hydraulic oil leaks. SAFETY INSTRUCTIONS
Stand clear of Get immediate
+ - + -
Extend outriggers until striped
outriggers when radio or cable remote plug medical attention if decals are visible, as shown in
24 Volts Here
activating. (shown on control receptacle)
+ - + -
Put all remote
control functions
40 oil penetrates skin.
illustrations.
38 SAFETY INSTRUCTIONS
30350982 A
59
bed out of the system. Accumulator
57
NO!
Make repairs before Concrete pump system plumbing WARNING
47 reusing the machine.
system plumbing
30353078 IMPORTANT!
WARNING
Do not insert solid
SAFETY INSTRUCTIONS Clear discharge area when Stop agitator before objects into waterbox SAFETY INSTRUCTIONS
OVERRIDE OF EMERGENCY STOP MANIFOLD
• Use ONLY for emergency foldup and cleaning.
• Emergency stop buttons DO NOT WORK when procedure is used.
first starting the pump,
restarting after moving, or
putting any solid
object in hopper. 56 cleanout holes.
NEVER PARTIALLY EXTEND OUTRIGGERS
whenever air is present in Explosion / fire 1. Outriggers must NEVER be partially extended when the boom will be used,
1. Pull override handle and hold. If control is
restored, there is a control system electrical problem. You can fold up and
clean out by holding the override handles. Be careful where you position
yourself when lowering the boom and closing the outriggers. If control is not
the delivery system. See
Safety Manual.
hazard. Stop engine
before refueling.
Fire extinguisher
inside.
30354741
55 WARNING
or when the truck will be raised. The forces transmitted to the outriggers must
be absorbed by the outrigger reinforcements. Partial extension defeats the
reinforcements.
53 54
restored, there is a
hydraulic problem;
proceed to step 2.
Boom/outrigger
Accumulator
system plumbing
51 SAFETY INSTRUCTIONS
2.
3.
Outriggers must be fully extended or fully retracted.
If the outrigger is fully retracted (shortrigged), different hazards are present.
See the Safety Manual, or your Operation Manual for information regarding
2. F o r a system plumbing
hydraulic problem, the
inlet plumbing to the Concrete pump
Closed WARNING
nonworking system
must be plumbed out of
system plumbing ATTENTION! NO! OK
Tipping hazard.
the manifold. With the Boom/outrigger
engine stopped, circuit override Serial #: Additional cribbing
handle Open Outrigger
disconnect the Was built according to these drawings. needed for many soil
plumbing for the
Inner Box
Agitator shutoff valve electric:
nonworking system at Concrete pump, Reinforcements
Outrigger types, including
the fitting pointed out at accumulator
override handle • Shutoff valve - open for normal operation. hydraulic: Do not partially Outrigger Reinforcements asphalt. See manual.
right. Plug both open
fittings that result, using extend outriggers. Outer Box Aligned 30359230
30354564 hyd. boom: Reinforcements
• Shutoff valve - closed to preheat hydraulic See Safety
Figure 5
Sample decal location guide. See your Operation Manual
for your specific unit.
4 Training Manual
General Items
Items to check:
• Boom Tie Down Straps
• Rear Steps
• Bearings and Pins Greased
• Tie Down Plates/Channels to Chassis
• Tower Tie-Down Bolts and Detach Tower Pins
• Hopper Grate
• Water Box Covers
• Clearance at Front Boom Rest (See SAIE
5158)
Figure 8
Make sure all bearings and pins are greased.
Figure 6
Check for frayed edges and a working locking
mechanism on the boom tie-down strap. Figure 9
Check for cracks on the Tie Down Plates/
Channels
Figure 7
Check for damaged or missing steps.
Figure 10
On SPB booms, make sure the detach tower
pins are in place and not damaged.
Training Manual 5
Figure 11 Figure 12
Check the hopper grate for damage. Make Make sure the water box covers and safety
sure the hopper grate switch works properly. grates are in place.
Correct Incorrect
In the transport position, each boom rest should be in contact with the boom and
slightly compressed, (approximately 1/16 to 3/32 of an inch compression of the
rubber rest). The load of the boom should not be on the boom hook. Maintain some
clearance between the boom hook and the boom hook pin.
6 Training Manual
Outriggers
Items to check:
• Structural members and welded seams for
cracks, deformation and wear
• Operation/Functions
• Outrigger Tubes
• Outrigger Pads
• Pins, Pin Bores and Safety Devices
Figure 15
Check for cracks on the outrigger pin, also
make sure the pin is in place and functioning
properly.
Figure 13
Check for cracks on the outrigger structure.
Figure 16
Check for damage on all 4 outrigger pads.
Figure 14
Make sure the outriggers are functioning properly.
Check for proper vertical alignment. Outrigger
tubes must be replaced if wear is greater than 10 Figure 17
percent of original wall thickness. Check for cracks on outrigger tube, pay special
attention to all welded seams
Training Manual 7
Do not partially extend outriggers
Structural damage could result.
NO!
s
.ep
58
00
04
Force
Fulcrum
Outrigger
Inner Box
Reinforcements
Outrigger 1. Outrigger fully retracted.
Outer Box No lever action.
Reinforcements Force absorbed by reinforcements.
Force must be low, or unit will tip.
Figure 18
Transparent outrigger shows reinforcement Fulcrum
areas (curved outriggers have the same
limitations)
Force
CAUTION
Force
Structural damage to outriggers is Fulcrum
possible. Do not jack outriggers unless
they are either fully extended or fully
000467.eps
retracted.
Force
Fulcrum
NO!
3. Outrigger partially extended.
Lever action present, but force transmitted to
areas with no reinforcements.
Outrigger bends, bottom plate dents, or both.
000459.eps
8 Training Manual
Tower
Items to check:
• Structural members and welded seams for
cracks, deformation and wear
• Tie-Down Bolts
• Rubber Dust Cover
• Hydraulic Hoses
• Slewing Cylinders
• Tower Bolts, Bushing and Main Column
Figure 21
Crack on subframe inside bottom corner.
(view from under tower.)
Figure 19
Cracks on tower gussets
Figure 22
Check tie-down bolts and plates for damage.
Figure 20
Crack on upper tower plate
Figure 23
Check for missing or worn rubber dust cover.
Training Manual 9
Figure 24 Figure 26
Check for damaged or worn hydraulic lines. Check for missing or damaged tower bolts. It
is recommended that the anchor bolts for the
tower be replaced every three years.
Figure 25
Make sure the cover for the slewing cylinders
is in place and not damaged.
10 Training Manual
Turret
Items to check:
• Structural members and welded seams for
cracks, deformation and wear
• Hollow Pin Mounting Bolts and Snap Ring
• Internal Structure
Figure 29
Pipeline clamp rubbing on hollow pin.
Figure 27
Damage on tower.
Figure 30
Dislodged hollow pin bushing. Damaged
retaining ring.
Figure 28
Improper hollow pin mounting bolt.
Figure 31
Cracks inside the turret
Training Manual 11
Slewing Gear
Items to check:
• Structural members and welded seams for
cracks, deformation and wear
• Bolts Tight
• Drive Gear Wear or Deterioration
• Slewing Bearing Gear Wear or Deterioration
Figure 34
Excessive Wear on slew drive
Figure 32
Check for wear or deterioration on slew drive
Figure 33
Check tightness of bolts
12 Training Manual
Boom Sections
Items to check:
• Structural members and welded seams for
cracks, deformation and wear
• Articulated Joints and Guide Levers Bearing
• Pins and Safety Devices
• Latch Hook and Assembly, Hook Support
• Hydraulic Lines
• Hydraulic Cylinder
• Threaded Pins
Figure 37
Crack on side plate
Figure 35
Damaged head section
Figure 38
Crack on the end plate
Figure 39
Figure 36 Check for cracks and damage on the guide
Crack on bottom plate levers.
Training Manual 13
Figure 40
Bent keeper bolt Figure 43
Check for leaks and damage on boom
cylinder. Make sure the boom cylinder is
operating properly.
Figure 41
Make sure the boom hook is working properly.
Figure 44
Damage on threaded pin
Figure 42
Check for damaged hydraulic lines on boom
section
14 Training Manual
Concrete Delivery Pipeline
Items to check:
• Mounting Hardware - U-Bolts/Nuts/Saddles
• Clamps with Safety Devices
• Reducer safety cable/nylon choker
• End Hose Safety Cable
Figure 47
Check pipeline clamps for damage.
Figure 45
Make sure all U-bolts and related hardware are
in place and are not damaged.
Figure 48
Make sure nylon choker and safety cable are
in place and are not damaged.
Figure 46
Damaged U-Bolts
Figure 49
Check for broken or damaged pipe arm
clamps.
Training Manual 15
16 Training Manual
SAIE 5158
Standard: 5158
SAIE STANDARD Page: 1 of 5
Subject: Procedures for Setting Boom Rests
The following procedures are for Schwing America personal to follow and adhere to in regards to the set-
ting of the boom rests for the following units: KVM 17, KVM 23, KVM 26, KVM 28X, 31 EZ, KVM 32
XL, KVM 34X, KVM 36 X, KVM 39 X AND THE KVM 42, S 45/47 SX, KVM 52/55, S 58/61 SX and
an others.
3 Section Booms
1. The boom must be folded up unto the main rest and all four outriggers must be raised off the ground
so there is no outrigger contact with the ground
2. Raise the #1 boom section enough that the #2 boom section is off the A-Frame boom rest :A:. Then
make sure that all boom sections are folded together. Each boom rest section should be folded into the
mating boom section rest without causing the boom section to bow.
3. Then lower the #1 boom section until the #2 boom section comes in contact with the A-frame boom
rest rubber “A”. The #2 boom section should come in contact with the rubber rest enough to be
slightly compressed, approximately 1/16 to 3/32 of an inch compression of the rubber rest.
4. Position the #2 front boom rest “B” to have a 1/8 of an inch clearence with the #2 boom section. The
key to this setting must be when the #2 boom section is in the rear A-frame rest and the #2 boom is
extended (lowered) to touch the front boom rest, there is still clearence between the boom hook and
the boom hook pin. The load of the boom should never be on the boom hook while in the traveling
position.
Training Manual 17
Standard: 5158
SAIE STANDARD Page: 2 of 5
Subject: Procedures for Setting Boom Rests
2. Raise the #1 boom section enough that the #2 boom section is off the A-frame boom rest “A”. Then
make sure that all boom sections are folded together. Each boom rest section should be folded into the
mating boom section rest without causing the boom to bow.
3. Then lower the #1 boom section until the #2 boom section comes in contact with the A-frame boom
rest rubber “A’. The #2 boom section should come in contact with the rubber rest enough to be slghtly
compressed, approximately 1/16 to 3/32 of an inch compression of the rubber rest.
4. Install the #4 boom rest “D” for a 1/4 to 3/8 of an inch gap between the rubber rest and the #4 boom
section.
5. After the #4 boom rest “D” is installed, lower the #4 boom section to just come in contact with the 34
boom rest “D’.
6. Then position the rear #4 boom rest “B” to touch the #4 boom section. At this time, both #4 boom
rests should be in contact with the #4 boom section.
7. Position the #2 boom rest “C” to have a 1/8 of an inch clearance with the #2 boom section. The key to
this setting must be when the #2 boom section is in the rear A-frame rest and the #2 boom is extended
(lowered) to touch “A” the front boom rest, there is still clearance between the boom hook and the
boom hook pin. The load of the boom should never be on the hook while in the traveling position.
18 Training Manual
Standard: 5158
SAIE STANDARD Page: 3 of 5
Subject: Procedures for Setting Boom Rests with preload
The boom should be completely folded so that all hydraulic cylinders are retracted to their furthermost
position. The #2 boom should be in the main rear rest. All four outriggers must be raised off the ground so
there is no outrigger contact with the ground. The front #4 boom rest dimension should be taken from the
bottom of the folded #4 boom., to the top of the tower plate on the pedestal weldment. The dimesion
should be noted and 1-1/2” added to that dimension this will be the overall length for the front boom rest
with the rubber pad bolted on. Then the #4 rear boom rest should be measured from the bottom of the
folded #4 boom, to the top of the rear pedestal boom rest. Again this dimension should be noted this time
1” should be added. This will be the overall length for the rear boom rest with the rubber pad bolted on.
Training Manual 19
Standard: 5158
SAIE STANDARD Page: 4 of 5
Subject: Procedures for Setting Boom Rests
20 Training Manual
Standard: 5158
SAIE STANDARD Page: 5 of 5
Subject: Procedures for Setting Boom Rests
Training Manual 21
22 Training Manual
SERVICE TRAINING
Table of Contents
Schematics
Output Chart - Sample .........................................................2
Nomograph - Sample ...........................................................3
Accumulator Bypass Retrofit - Reference ...........................4
800 ........................................................................................5
801 ........................................................................................6
900 ........................................................................................7
900 w/o FAST SWITCH ......................................................8
900 WITH FAST SWITCH .................................................9
900 WITH FAST SWITCH and DAMPNER ....................10
1200 TC WITH SWITCHING VALVES ..........................11
1200 TC WITH MPS .........................................................12
HI-FLOW - SINGLE CIRCUIT ........................................13
2023-4 ................................................................................14
2023-5 ................................................................................15
2525H .................................................................................16
KVM 31 EZ Boom .............................................................17
KVM 32XL ........................................................................18
32XLG ...............................................................................19
34 XG .................................................................................20
KVM 39X ..........................................................................21
S 39/41 SX .........................................................................22
S 42 SX ..............................................................................23
S 42 SX ..............................................................................24
S 45 SX ..............................................................................25
S 45 SX ..............................................................................26
52 M ...................................................................................27
52 M ...................................................................................28
S 58 SX ..............................................................................29
S 58 SX ..............................................................................30
Training Manual
Table of Contents
Training Manual
Output Chart - Sample
CONCRETE CONCRETE
BPL 1200 HDR-23 PRESSURE PRESSURE
(PSI) (BAR)
2000 138
PERFORMANCE CHARACTERISTICS OF
1900 131
PISTON SIDE
THE AXIAL PISTON HYDRAULIC PUMP
ROD SIDE
PUMP SPEED 1800 124
(bar)
(bar)
2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110
Breakpoint 0 13 26 39 52 65 78 92
105 118 131 144 157 170 183 196
=178 bar
@ 300 bar 103 170.5
=238 l/m
CONCRETE OUTPUT (cu yd / h)
26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
15.5
PISTON 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
100 200 300 400 500 (liter / min.)
Training Manual 2
Nomograph - Sample
Q in yd3/hr.
320 l/m
For vertical placing, 180
Max Q
add 1.105 PSI per foot
of level difference. 160
6" 5" 4.5"
Number:
012
140
4"
120 116
Rodside
100
80
Pistonside 67
60
40
132 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI 1566 870
100
200
2"
300
400
2.5"
500
600
3"
4" 5" 6" 3000 2500 2000 1800 1500 1200 1000 800
Slump of fresh concrete in inches Proportional value of pipeline in feet
Training Manual 3
Accumulator Bypass Retrofit - Reference
A1 A B B1 T
FOR REFERENCE ONLY
SERVICE BULLETIN 1001-03
200 bar
ACCUMULATOR
XA
1.5 mm
S3
SYSTEM
XB Agitator
This line must return
11 1 to tank by itself
T
2 3 4
2nd agitator with Shut-Off* Truck air supply
7
Valve
Nitrogen pressure set at Psp 6.0 mm long rock and
Mp1
100 bar (1450 PSI) sloped side units
6 2.0 mm A
300 Mp 5-7 bar
bar 5
B
Accumulator control device B T
B 10 bar
E-STOP P
AGITATOR T(A)
P(B)
VALVE CLOSED FOR
BYPASS
Emergency stop
9 A A manifold
T SP MP2 MP3
10
T
1.3
mm
2.0 bar P2
ZK2 8 ZK1
0.9
P3
P P
ACCUMULATOR G Y
SYSTEMA B
11 1
A1 B1 2 3 4
3.0 3.0 X1
mm 7 S2
XA XB
mm
Y3
PR 6 A
PP A1
S1 5
XR XP B B
E-STOP P2 AGITATOR
P1 2.0 bar See boom
schematic
1.8 T M
mm
S
Hyd. oil cooler
w/elec fan
Training Manual 4
800
Training Manual 5
801
A
agitator
motor
B
Pipe Gate
B
M
0-50
BAR Position 1 =
Spring Return
T 2 1 Position 2 =
Detent
S3
S1 A
CA B
1.5 mm
hole drilled
through spool 5.5 bar
300 *Agitator pressure =
bar with gearcase 70 bar
with direct drive 200 bar
S2 *Waterpump pressure =
with agitator gearcase 200 bar
with direct drive agitator 210 bar
X2 X2
M A A
A1 A1
0.7 To
mm Boom
6 bar Circuit
Training Manual 6
900
PRINT # 329325 A
B
M
P
P
0-50
BAR 210 bar
T
Position 1 =
Spring Return
A 2 1 Position 2 =
Detent
S3
S1
T1 T CA B
1.5 mm
hole drilled
through spool 5.5 bar
300
bar
S2
X1 X1
X2 X2
A A
A1 A1
D
M
To
Boom
6 bar Circuit
S S
Training Manual 7
900 w/o FAST SWITCH
Note:
Pressures are set to the 200 bar
accuracy of the gauge as
received from the P Hydraulic style
manufacturer. remote throttle
actuation
AIR TANK
Change
Y3
A A
A1 A1
D
M
To
Boom
35 PSI P
Rev.061198
Circuit
SAIE 10057
initials
S S
Training Manual 8
900 WITH FAST SWITCH
Remote controlled
stroke limiter T
A
Remote Throttle
T Agitator Actuation (hyd. version)
B
P
Change
70
B bar
P
P
A
0-55 bar T
Y(T) BPL 900 HDR 6
bar
Release
STROKE A KVM 28X 200 bar
LIMITER P
KVM 26-4
with Single Gauge Port
Rev.032697
SAIE 10038
0-400 bar
initials
Circuit Switching,
fast switch,
FAST
SWITCH P and 344780 (12v) or
T
Compressor
344781 (24v) E-stop manifold
(Optional)
X
A B AIR TANK
Water
NG 6 pump
5 - 7 bar A T B
0.7 mm
Note:
Pressures are set to the
S3 accuracy of the gauge as
received from the
manufacturer.
1.5 mm
hole drilled
through spool S1 C P
T
210 bar
P
A
300 bar B
S2
T Concrete Pump
For. / Neut. / Rev.
See boom
schematic
D C B A
X1 X1
Port size
250
limits flow Y3 Y3 bar
A A
A1 A1
A7VO-80 LR S S A7VO-80 LR
Training Manual 9
900 WITH FAST SWITCH and DAMPNER
Change
P
T
0-55 bar 70
Y(T)
B bar
STROKE A A
LIMITER
A 200 bar
Release
P
Gauge Port
0-400 bar
Rev.082797
SAIE 10055
BPL 1200 HDR
initials
KVM 28X / 26-4 / 32 XL Compressor
(Optional)
FAST
with Single Circuit Switching, Water
pump
SWITCH P T 4 or 5 place b & w boom manifold,
DAMPENER X
NG 6
30344780 (12v) or
A B 30344781 (24v) E-stop manifold A T B
P
0.7 mm
0-55
bar
Y(T)
A
0.7 mm
AIR TANK
C P
1.5 mm
hole drilled
through spool S1
See boom
schematic
A D C B A
B
300 bar
S2 250
bar F
T
Concrete Pump
For. / Neut. / Rev. E
X1 X1
Port size
limits flow Y3 Y3
A A
A1 A1
Note: D
Pressures are set to the
M accuracy of the gauge as
received from the
To
manufacturer. Boom
3.5 bar Circuit
5.5 bar
A7VO-107 LR S S A7VO-107 LR
Training Manual 10
1200 TC WITH SWITCHING VALVES
Remote controlled
Nitrogen pressure set at 100 bar stroke limiter
(650 PSI) SAIE 10026 Change
T Rev.112596 Release
initials
P
P 70
0-55 B bar BPL 900-1200 KVM 36X
bar
TWIN CIRCUIT
A with electric over air pilot
Y(T) Note:
Pressures are set to the
300 A accuracy of the gauge as
S3 bar Manual stroke received from the
limiter manufacturer.
Accumulator control device
P
C P
This line must
return to tank Accumulator pump
by itself. unloading valve Concrete Pump
Forward/Neutral/Reverse
T
200
bar AIR TANK
Y P B
NG
10 A 6 bar
250 bar T
0.7 0.7
mm mm
S2
B A
200
bar
S1
320
bar
P T
Port size
0.7 mm limits flow
X1 X1 Remote Throttle
A2F-23 A2F-10 Actuation (hyd. version)
Y3 Y3
A A
120 Hyd. oil cooler
A1 A1
bar w/elec fan
Soft switch M P
35 psi T
ΔP
6
bar
1200 = A7VO-107 LR S See boom schematic S 1200 = A7VO-107 LR
900 = A7VO-80 LR 900 = A7VO-80 LR
Training Manual 11
1200 TC WITH MPS
,,
Nitrogen pressure set
A Note:
Pressures are set to the
Y(T) accuracy of the gauge as
received from the
300 A manufacturer.
S3 bar Manual stroke
limiter
Accumulator control device
T P
B A 1.0 mm
P
C P
T P This line must
1.0 mm
return to tank Accumulator pump
by itself. unloading valve Concrete Pump
B A
Forward/Neutral/Reverse
A A T
200
bar AIR TANK
Y P B
NG
10 A 6 bar
0.7 0.7
mm mm
S2
B A
200
bar
S1
320
bar
P T
Port size
0.7 mm limits flow
X1 X1 Remote Throttle
A2F-23 A2F-10 See boom
Actuation (hyd. version)
schematic
Y3 Y3
A A
80 Hyd. oil cooler
A1 A1 D C B A
bar w/elec fan
250 bar
Soft switch M P
35 psi T
E
ΔP
6
Emergency stop F bar
1200 = A7VO-107 LR S See boom schematic S 1200 = A7VO-107 LR manifold
900 = A7VO-80 LR 900 = A7VO-80 LR
Training Manual 12
HI-FLOW - SINGLE CIRCUIT
SAIE 10207 Change
P Rev. 102901 Release.
T
initials
Truck air supply 200 bar
330
bar
3
1.6
2
1
2020-4, 2023-4
5-7 bar P1
See boom schematic
0.9
KVM 32 XG
A
MP1
HI-FLOW - SINGLE CIRCUIT
B with Rexroth A7VO hydraulic pumps
1.6 3
and cartridge type MPS manifold
P(B) P3
Agitator T(A) 2
1
P2 0.9
Emergency stop
manifold
T
MP3 MP2
A
T SP Concrete Pump
Forward/Off/Reverse
B
MG2
20
bar
XA XB G2
PBP
A 3.5 3.5 B 3.5-40
bar
X3
PZ
3.5-40 0.7
bar
0.7
T
A2 B2
0-30
A3 B3 bar
1.5
A B X1
A1 B1
Y3
A
XA S2 XB
A1
PR
PP
S1
XR XP
P2 P1
M
10 bar
S
1200 or 2020/2023 = A7VO-107 LR
1.8 900 = A7VO-80 LR
Training Manual 13
2023-4
Change
T 5-7 bar
A
A1 A B B1 Agitator
B
2nd agitator with B Concrete Pump
XA
1.5
mm
S3
XB
long rock and
sloped side units A
Forward/Off/Reverse 2020-4, 2023-4
T
KVM 34 X
Rev. 120798
SAIE 10115
Nitrogen pressure set at
100 bar (1450 PSI)
6.0 mm
MPS - TWIN CIRCUIT
Psp Mp1
with Rexroth A7VO hydraulic pumps
Note:
initials
2.0 This line must return
mm 300 Mp to tank by itself Pressures are set to the and cartridge type MPS manifold
Accumulator control device bar 200 bar accuracy of the gauge as
T P received from the
manufacturer.
P
G2
MG2
T SP
MP5 T MP2
Remote Throttle Emergency stop P4
0-30
Actuation (hyd. version manifold bar
ZK2 ZK1 0.9 P3
used when engine not X1
electronically controlled) P2
1 2 1.6 MX1
3 3.5-55
ZS2 ZS1 260 bar
bar
MG1
MP1
P
0.9
XA XB
A B
A1 B1
3.0 3.0 X1
mm S2 mm
XA XB
Y3
PR 0.7 A
mm
PP A1
0.7
mm S1
XR XP
P2 P1 See boom
schematic
MP
T2 T1 S 1200 = A7VO-107 LR
1.2 900 = A7VO-80 LR
X1
X1
Y3
1.8 80 X2 A
bar Hyd. oil cooler A1
w/elec fan
A7VO-LRDH
X3 M
Hydraulic pumps are
1.1 used only on -4 machines
35 psi 200 bar
T ΔP
1.8
S 1200 = A7VO-107 LR
900 = A7VO-80 LR
Training Manual 14
2023-5
Change
Note:
P
A1 A B B1
T
XA S3 XB 200 bar
This line must return
to tank by itself
T
Nitrogen pressure set at
100 bar (1450 PSI) 6.0
Rev. 110499
SAIE 10139
mm Agitator
Psp Mp1 Truck air supply
2.0
mm 300 Mp 2nd agitator with A
initials
Acumulator control device bar long rock and
T sloped side units B 5-7 bar
P
T(A)
P(B)
Emergency stop
manifold 2023-5
T SP
MP5 T MP2 KVM 39X, 34X
P4
0.9
X3
P
A B
A1 B1 T
3.0 3.0
mm S2 mm
XA XB Pressure P
reducing
PR 0.7 valve 55 bar
PP
mm T
0.7
mm S1 A
XR XP
P2 P1 Y T2 R T1 G Z A M Y T2 R T1 G Z A M
A
MP Electric
stroke limiter
see see
T2 T1 note note
1.2
See boom
X1 schematic
1.8
mm
80 X2
bar
35 psi
M
T P Note: A11VO-LRDH
1.8 Hydraulic pumps are 200 bar
mm limited to 350 bar
by pressure cutoff.
Training Manual 15
2525H
Change
2nd agitator with
long rock and With switching signal
sloped side units
from waterbox end
A1 A B B1
Note:
Pressures are set to the
accuracy of the gauge as
XA S3 XB received from the
This line must return
to tank by itself 200 bar manufacturer.
T
P
Nitrogen pressure set at
100 bar (1450 PSI) 6.0
Rev. 110399
SAIE 10143
Psp mm Mp1
2.0
mm 300 Mp
initials
Acumulator control device bar
T
P
MP5 T MP2
P4
0.9 P3 C P
P2
1 2 1.6
3
Remote Throttle 260
bar
T Actuation (hyd. version
used when engine not MP1
1.1
electronically controlled) Truck air supply
0.9
1.2
T1 T2
MP P
P1 P2 T
0.7 mm XP XR 55 bar
S1 A
PP
PR 0.7 mm Pressure
3.0 mm
reducing valve
XB XA 3.0 mm
S2
B1 A1
B A
T
M A Z G T1 R T2 Y M A Z G T1 R T2 Y
X3 2.0 mm
5.5 bar
Electric
XA XB stroke limiter
See boom
schematic
ZS1 ZS2 Hyd. oil cooler
w/elec fan
1.3
mm
M
ZK1 ZK2
1.3 35 psi S M1 S M1
mm ΔP
SP T A11VO-LRDH
Hydraulic pumps are
limited to noted pressure 200 bar
by pressure cutoff.
Training Manual 16
KVM 31 EZ Boom
300 bar
280 bar
330 bar
310 bar
160 bar
320 bar
290 bar
320 bar
300 bar
150 bar
T T T T T
180 bar
270 bar
230 bar
220 bar
240 bar
190 bar
300 bar
240 bar
210 bar
250 bar
T P B A B A B A B A C
9 A1 X B1 125 125 125 125
B2
1.0 mm
B1 A2
1.0 mm
A1 A2
1.0 mm
A1 A2
1.0 mm
A1 B2
1.0 mm
B1 0 - 16
bar bar bar bar
3
bar
EB EA EA EA EB
150 bar 150 bar
13
150 bar
14 bar
T1
21
T
A B
Front of Unit
Water Optional HP Optional
pump water pump air compressor
or
2
280
bar T1
35 l/m
180 bar
C1 22 14
125 125 125 125
C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 MPS bar bar bar bar
G1/2
1 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2
T P B A B A B A B A C
10 10
140 bar
30
bar 15
1 1 1 1 1 1 1 1 bar
P2
18
350 ∅ 0.55
bar
P
T
LS
T
14 P
HYDRAULIC SCHEMATIC
1.5
KVM 31 EZ boom 11 20 bar
P2 P3 P1
MP3
20 bar Δ P
330
bar 17
Note:
Pressures are set to the MP2 MP1
Z To concrete pump circuit
accuracy of the gauge as 2.0 0.3
bar bar hydraulic pump, port Z.
received from the
manufacturer. 310 bar
T Not used without 3-circuit
Emergency stop
manifold control.
Training Manual 17
KVM 32XL
Driver Side
BOOM #1 (MAIN) BOOM #2 BOOM #3 BOOM #4 (TIP) Optional air Water
200/125 x 1030 180/110 x 1300 150/90 x 800 110/70 x 670 SLEWING (LEFT - RIGHT) compressor pump HOME
X E X E X E X E
X E X E X E X E
P2 P1 P2 P1 P2 P1 P2
P1
P
14 bar
140 80 140 80 T
T bar bar bar bar
A B
80 140 80 140
bar bar bar bar
P
P1 280
bar
T
140 bar
C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 MPS
G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2
30
bar 15
bar
Outrigger Extension Cylinders
Rear Front
60/40 x 1520 70/50 x 2300
MP Outrigger Jacking Cylinders
90/60 x 650
350 P2
bar
P
T
LS
HYDRAULIC SCHEMATIC St
KVM 32XL
w/meter out spools
0
applies to proportional units only 2.0 I
and E-stop manifold number 10181606 (12v) See concrete High pressure filter atmospheres
or 10181607 (24v) pump schematic
P3 P2 MP1 P1
MP2
Note: 330 bar P regulator A
Pressures are set to the A1
A
X X
accuracy of the gauge as MP5
P
received from the T 20
T
bar P To LS port
manufacturer. T of Apitech
300
0.9 0.9
SAIE 10188 Change bar
1.6 1.6 X3
Rev. 061900 Release
Emergency 2 2
stop P
initials manifold A T
1 3 1 3
System when equipped with Rexroth hydraulic pump System when equipped with Voac hydraulic pump
Training Manual 18
32XLG
10151785
HOME
10151785 10151785 10151785
Water
310 bar 310 bar 310 bar 310 bar Tank
320 bar 320 bar 320 bar 320 bar SR
SR1
320 bar 320 bar 320 bar 320 bar
Water High pressure
310 bar 310 bar 310 bar 310 bar
pressure water (optional)
0 - 16
10151785 10151785 10151785 bar
10151785
Driver Side
14 bar
Outrigger Extension Cylinder Outrigger Jacking Cylinders Outrigger Extension Cylinder
T Rear 125/100 x 550 Front
70/50 x 2300 60/40 x 1520
A B
140 80 140 80 T
140 bar bar bar bar bar
C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 MPS
G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2
15
bar
80 140 80 140
0.76 bar bar
mm bar bar
P
P1 280
bar
0.2 mm
300
bar
0.61
mm T
P
T
LS
initials
Training Manual 19
34 XG
HOME
BOOM #1 (MAIN) BOOM #2 BOOM #3 BOOM #4 (TIP)
225/125 x 880 180/125 x 151 0 150/100 x 1173 110/60 x 805 SLEWING (LEFT - RIGHT)
Grayed components represent
EA EB EB EB
optional equipment
140 bar
M
∅1.0 ∅1.0 ∅1.0 ∅1.0
A1 A2 B2 B1 B2 B1 B2 B1
B
Water
Tank
320 bar
320 bar
320 bar
310 bar
330 bar 320 bar 330 bar 330 bar
A
T T T T
290 bar
180 bar
320 bar
280 bar
190 bar 330 bar 290 bar 300 bar
T
B1 B2 A2 A1 A2 A1 A2 A1
Water pump HP water pump
∅1.0 ∅1.0 ∅1.0 ∅1.0
EB EA EA EA Water High pressure
pressure water
A1 X B1
0 - 16
bar
Driver Side
Outrigger Extension Outrigger Jacking Cylinders Outrigger Extension
Cylinder 125/100 x 550 Cylinder
14 bar
A B Rear Front
Compressor 70/50 x 2300 60/40 x 1520
P
140 bar
140 80 140 80 T
bar bar bar bar
C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 PP
G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2
15
bar
80 140 80 140
bar bar bar bar
P
280
bar
0.2
mm
300
bar
.061 mm P
T
T
LS
HYDRAULIC SCHEMATIC
34 XG
w/fixed displacement boom pump and
proportional control valve
330 bar
Note: Outrigger Extension Outrigger Extension
Pressures are set to the Cylinder Cylinder
High pressure filter
accuracy of the gauge as Rear Outrigger Jacking Cylinders Front
received from the 70/50 x 2300 125/100 x 550 60/40 x 1520
manufacturer.
Passenger Side
Training Manual 20
KVM 39X
Driver Side
BOOM #1 (MAIN) BOOM #2 BOOM #3 BOOM #4 (TIP) Optional air Water
240/180 x 1080 200/140 x 1620 150/80 x 1173 120/70 x 805 SLEWING (LEFT - RIGHT) compressor pump
HOM
10151786
Outrigger Extension Cylinder Outrigger Jacking Cylinders Outrigger Extension Cylinder
Rear 100/65 x 650 Front
1.0 mm 70/50 x 2075 95/82 + 58/44 X 3561
1.0 mm 1.0 mm 1.0 mm
320 bar
320 bar
320 bar
320 bar
330 bar
330 bar 330 bar 330 bar
320bar 310 bar 320 bar
300 bar
310bar
320 bar
310 bar
310 bar
P
14 bar
140 80 140 80 T
T bar bar bar bar
A B
80 140 80 140
bar bar bar bar
P
P1 280
bar
200 bar
T
C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 MPS
G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2
30
bar 15
bar
Outrigger Extension Cylinder Outrigger Extension Cylinder
Rear Front
70/50 x 2075 95/82 + 58/44 X 3561
MP Outrigger Jacking Cylinders
100/65 x 650
350 P2
bar
P
T
LS
HYDRAULIC SCHEMATIC
KVM 39X
w/slewing motor manifold,
2.0
Apitech control block, and emergency stop manifold
See concrete pump atmospheres 10181606 (12 volt) or 10181607 (24 volt)
High pressure filter
schematic Emergency stop
P1 manifold
P3 P2 MP1 Note:
MP3
330 Δ P regulator A Pressures are set to the
bar A1 accuracy of the gauge as
X received from the
MP2
T
20 manufacturer.
bar Δ P T
300
bar SAIE 10162 Change
X3
Rev. 120299 E-stop manifold symbol corrected.
P
A T initials
System when equipped with Rexroth hydraulic pump
Training Manual 21
S 39/41 SX
14.03.2006
HOME
Training Manual 22
S 42 SX
HOME
Driver Side
Outrigger Jacking Cylinders Outrigger Extension Cable
Outrigger Slewing Cylinder 110/80 x 750
100/40 x 327
Rear Front Front
Rear
A1 B1 A2 B2 A3 B3 A4 B4 T
P
350 T1
bar 200
bar
300
350 bar
200
bar
bar
P1
C
T A4 B4 A3 B3 A2 B2 A1 B1
HYDRAULIC SCHEMATIC
KVM 42 SX
applies to units w/ symetrical outrigger
valves, and Apitech boom control valves.
initials
Training Manual 23
S 42 SX
P1 P2 P2 P2
0 - 16
bar X E X E X E
X E X E X E
Grayed components represent A1 X B1
P1 P2 P2 P2
optional equipment
14 bar
T
#1 Down - brake valve B
Water pump HP water pump
A B
0.35
T1
0.35
T2
X Y A
P1
PP C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1
15
bar
30bar
P2
350
bar
T LS
see concrete
pump schematic HYDRAULIC SCHEMATIC
P3 P2 MP1 P1
MP3 High pressure filter KVM 42 SX
320 bar W/ Apitech boom control valves,
and e-stop manifold 10181607
MP2
Δ P regulator
T A
X
A1 Note:
Pressures are set to the
20 accuracy of the gauge as
0.9 0.9 bar Δ P T received from the
1.6 1.6
300
manufacturer.
2 2
bar
atmospheres
X3 Change
1 3 1 3 SAIE 10233-2/2
P Rev. 090904 Release
A T
2.0
Emergency stop manifold Boom hydraulic pump
initials
Training Manual 24
S 45 SX
HOME
Driver Side
Outrigger Jacking Cylinders Outrigger Slewing Cylinder Outrigger Extension Cable
110/80 x 750 100/40 x 327
A1 B1 A2 B2 A3 B3 A4 B4 T
P
T1
350 200
bar bar
T2
300
200 350 bar
bar bar
P1
C
T A4 B4 A3 B3 A2 B2 A1 B1
HYDRAULIC SCHEMATIC
KVM 45 SX
applies to unit SN 70526011, 170526002 and later
Training Manual 25
S 45 SX
HOME Water Optional air BOOM #4 (TIP) BOOM #3 BOOM #2 BOOM #1 (MAIN)
SLEWING (LEFT - RIGHT) pump compressor 115/70 x 995 200/110 x 1200 260/160 x 1990 340/115 x 2290
HYDRAULIC SCHEMATIC
KVM 45 SX 10151788
320 300
T
10151786
330 320
T
10151785
320 310
T 10151784
350 330
T
applies to unit SN 70526011, 170526002 and later bar bar bar bar bar bar bar bar
P2 P2 P2 P2
0 - 16
P1 X E P1 X E P1 X E P1 X E
bar
Note:
Pressures are set to the
A1 X B1
accuracy of the gauge as
received from the
manufacturer.
P1 X E P1 X E P1 X E P1 X E
200 bar 200 bar P2 P2 P2 P2
A B
A4 B4 A3 B3 A2 B2 A1 B1
P
P
X
Y
Ls
L Pv
Ls
160 - 200 μ
T1
T2
a' a b b' 35
230 bar
bar
Dr2-a'
Dr1-b'
P1 350
bar
40
bar
A B b a A B A B
200
bar X Y b4 a4 b3 a3 b2 a2 b1 a1
D-G 1-b4
D-G 3-a4
C-G 2-b3
C-G 4-a3
B-G 3-b2
B-G 1-a2
A-G 2-b1
A-G 4-a1
30 l
max. LS
see concrete
pump schematic
MP2
T PST P
D-G 1-b4
D-G 3-a4
C-G 2-b3
C-G 4-a3
B-G 1-a2
B-G 3-b2
A-G 2-b1
A-G 4-a1
Dr 1-b'
Dr 1-a'
P regulator
A MP3
A1
1 2 1 3 2 4 1 3 2 4 X
20 P3
bar P T MP1
310
bar P1
X3
P T P T P T
330
bar
P
A T
Emergency stop manifold T 2.0
Boom hydraulic pump
atmospheres
Training Manual 26
52 M
A1 B1 A2 B2 A3 B3 A4 B4 T
350 350 50
bar bar bar
T1
P1
150
bar 350 350 50
bar bar bar
P C
A1 B1 A2 B2 A3 B3 A4 B4 T
HYDRAULIC SCHEMATIC
KVM 52
1 of 2 (outrigger circuit)
Note:
Pressures are set to the
accuracy of the gauge as
received from the
manufacturer.
initials
Passenger Side
Training Manual 27
52 M
HYDRAULIC SCHEMATIC
Water BOOM #1 (MAIN) BOOM #2 BOOM #3 BOOM #4 (TIP)
KVM 52 pump 350/160 x 2730 280/160 x 2100 SLEWING (LEFT - RIGHT) 210/110 x 1173 130/80 x 1069
initials
14 bar
T
M B B M M B B M
A B M B B M M B B M
A A A A
A A A A
See SAIE 10079 A X X A A X X A
A X X A A X X A
page 1 of 2
P1 1.5
adjusted to 20 bar
dynamic pressure
T1 adjusted to 20 bar
dynamic pressure
T2
adjusted to 20 bar
dynamic pressure
Pst
Pst
50 adjusted
bar to 20 bar
dynamic
30 pressure
bar
a4 A4 B4 a5 A5 B5 a6 A6 B6 a1 A1 B1 a2 A2 B2 a3 A3 B3
P L(T) b1 b1 a1 a1 b2 b2 a2 a2 b3 b3 a3 a3 b4 b4 a4 a4 b5 b5 a5 a5 b6 b6 a6 a6
T T
190 190
bar bar
350 bar
10146289 10146290
X (LS) X (LS)
P P
b4 b5 b6 b1 b2 b3 T
a1
b2
a2
b3
a3
b4
a4
b5
a5
b6
a6
4 3 2 1 4 3 2 1 4 3 2 1
filter filter
20 bar
T P
A1
A
310
MP5 0.9 0.9 bar
T
P T P T P T 1.6 1.6
Emergency 2 2
stop X3 P
T A
manifold 5.5
1 3 1 3 bar
Boom hydraulic pump
Training Manual 28
S 58 SX
330 bar
330 bar
330 bar
260 bar
320 bar
320 bar
320 bar
250 bar
T T T T
240 bar
260 bar
330 bar
310 bar
250 bar
270 bar
340 bar
320 bar
B1 X A1
0 - 16 A2 A1 A2 A1 A2 A1 B2 B1
bar 1.0 mm 1.0 mm 1.0 mm 1.0 mm
EA EA EA EB water tank
250 bar 250 bar
water HP
output water
M output
14 bar
B A 240 bar
P1
T1
0.55 mm
A B A B A B A B A B B A B A B Z R M LS T P
T2
300 bar
300 bar
R1
a a a a a a a
360 bar
o o o o o o o
A
A
b b b b b b 280 bar b 20
bar
B
230 bar 180 bar B
HYDRAULIC SCHEMATIC
S 58, 61 SX boom T2 T1 X G A M
Training Manual 29
S 58 SX
Driver Side
HOME
Outrigger Slewing Cylinder Outrigger Jacking Cylinders Outrigger Extension Cable Outrigger Roller
130/60 x 445 130/70 x 800 22 x 33
Rear Rear Front Front
A A
B B
A1 B1 A2 B2 A3 B3 A4 B4 T
P
P1
350 210 210
bar bar bar
200 200
T1 bar bar
T2
200 200
350 bar bar
bar 310
210 210 bar
bar bar
T A4 B4 A3 B3 A2 B2 A1 B1
HYDRAULIC SCHEMATIC
S 58, 61 SX
A A
page 2 of 2
B B
Note:
Pressures are set to the
accuracy of the gauge as
received from the
Rear Rear Front Front manufacturer.
Outrigger Slewing Cylinder Outrigger Jacking Cylinders Outrigger Extension Cable Outrigger Roller
130/60 x 445 130/70 x 800 22 x 33
initials
Passenger Side
Training Manual 30