Professional Documents
Culture Documents
MODEL S 42 SXG
WARNING
on
Do not stand
hopper grates.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Version
1.0.1
Revision date
06/07
Table of Contents
Introduction
Manufacturer’s Statement......................................................................... 12
Safety Alert Symbol and Signal Word Explanation .......................... 12
How to reach us .................................................................................. 13
How to order parts .............................................................................. 13
Model Number Nomenclature .................................................................. 14
ID Tags...................................................................................................... 15
Main ID tag ......................................................................................... 15
Boom ID and makeup pipe tag ........................................................... 16
How to order missing tags .................................................................. 16
Specifications
Concrete Pump Specifications .................................................................. 18
Boom Specifications ................................................................................. 20
Outrigger Specifications ........................................................................... 21
Assembled Unit Specifications ................................................................. 21
Hydraulic Pressure Specifications ............................................................ 22
Boom Folding and Slewing Specifications............................................... 24
Outrigger Extension and Slewing Specifications ..................................... 24
Safety
How to Order Additional Safety Manuals ................................................ 26
Warning Labels (Decals) .......................................................................... 29
Emergency Stop Switches......................................................................... 29
Other Safety Devices ................................................................................ 29
By-pass key switch ............................................................................. 30
Agitator automatic shut-off circuit...................................................... 30
E-Stop manifold .................................................................................. 31
Safety valves (pressure relief valve) ................................................... 32
Safety guards....................................................................................... 32
Fuses and circuit breakers................................................................... 32
Hydraulic safety devices - boom and outriggers................................. 32
Laminated Book Container ....................................................................... 33
Do Not Use a Crane to Extend Boom Reach............................................ 34
Product Overview
First Commissioning................................................................................. 36
Installation of your new unit ............................................................... 36
Concrete Pump Circuit.............................................................................. 37
Hydraulic Components ............................................................................. 38
Hi-flo pumpkit components ................................................................ 38
Twin-circuit switching (MPS) ............................................................ 38
Accumulator safety rules .................................................................... 39
Twin circuit switching ........................................................................ 40
Hydraulic pump drive ......................................................................... 43
Operation Manual - S 42 SX v
Table of Contents
Operation
Preparation ................................................................................................ 82
Arrive alert and on time. ..................................................................... 82
Use the right machine for the job........................................................ 82
Have the right equipment.................................................................... 82
Use your personal protective equipment............................................. 84
Truck and pump checklist................................................................... 85
On the truck......................................................................................... 85
On the pump........................................................................................ 85
Driving the unit ................................................................................... 86
Licensing............................................................................................. 86
Backing up .......................................................................................... 86
Changing lanes.................................................................................... 86
Towing the unit ................................................................................... 86
Loading the unit for shipment............................................................. 86
For ramp loading / unloading.............................................................. 86
For crane loading / unloading ............................................................. 87
Unit Setup ................................................................................................. 87
Selecting the proper setup location on the job site ............................. 87
Soil Considerations ............................................................................. 88
Calculating the outrigger load............................................................. 88
42 SX Model calculations................................................................... 89
Activating the outrigger hydraulics .................................................... 89
Setting the outriggers .......................................................................... 90
Shortrigging ........................................................................................ 94
Additional dos and don’ts of outrigger stabilization........................... 95
Releasing the boom tie-down strap..................................................... 96
Setting up the boom ............................................................................ 96
Releasing the tip hose ......................................................................... 97
Inspecting the tip hose ........................................................................ 98
Hanging extra system from the boom................................................. 99
Pouring directly out of the boom ...................................................... 100
Attaching the tip hose to a slickline.................................................. 100
Prepare for the Ready-Mix Trucks ......................................................... 100
Lubricating the Pipeline.......................................................................... 104
Pumping the Job...................................................................................... 106
Controlling the speed of the unit....................................................... 108
Pumping the job ................................................................................ 109
Boom Bounce .......................................................................................... 110
Time constraints................................................................................ 110
Cold weather pumping...................................................................... 110
Stop the dripping concrete while moving ......................................... 111
Moving the boom.............................................................................. 111
Delays ............................................................................................... 111
Keeping the concrete alive................................................................ 111
Maintenance
Filtration.................................................................................................. 134
General information .......................................................................... 134
Specific information.......................................................................... 134
External filtration .............................................................................. 135
Changing your hydraulic oil filters ................................................... 135
Changing high pressure water filter.................................................. 135
Hydraulic Oils......................................................................................... 135
General information .......................................................................... 135
Specific information.......................................................................... 136
When to change your hydraulic oil................................................... 136
Pressure, Hoses, and Fittings .................................................................. 136
General information .......................................................................... 136
Specific information.......................................................................... 137
Appendix
Hydraulic Oil Viscosity Chart ................................................................ 184
Torque Specifications for Metric Bolts................................................... 185
Recommended Emergency Hose Kit ...................................................... 189
Fitting Wrench Sizes............................................................................... 189
Grease Zerk Locations-Boom ................................................................. 191
Bearing Clearance Specifications ........................................................... 192
Maintenance Checklist............................................................................ 193
Weld-on Ends / Coupling Comparison ................................................... 194
Output Charts .......................................................................................... 195
Using the chart .................................................................................. 196
Using a Nomograph ................................................................................ 202
General information .......................................................................... 202
The quadrants.................................................................................... 204
Minimum Pipe Wall Thickness .............................................................. 210
Pictograms............................................................................................... 211
Glossary of Terms................................................................................... 212
Additional Reading Material............................................................. 217
List of Lubricants and Nitrogen.............................................................. 217
Hydraulic Schematic—Boom Circuit (1 of 2) ........................................ 221
Hydraulic Schematic—Boom Circuit (2 of 2) ........................................ 223
Hydraulic Schematic—Concrete Pump .................................................. 225
Output Chart ........................................................................................... 227
Nomograph ............................................................................................. 229
Operation Manual - S 42 SX ix
Table of Contents
WARNING
on
Do not stand
hopper grates.
S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
42SXside.eps
INTRODUCTION
Manufacturer’s Statement...................................................................... 12
Model Number Nomenclature................................................................ 14
ID Tags................................................................................................... 15
;;;;;;;;;;
To place an order for spare parts, you can call any of
DANGER the above numbers, or you can call our toll free parts
line from anywhere in the continental United States,
Hazard and consequence will be shown except Minnesota. Parts department hours are Monday
in this space. through Friday, 8:00 AM to 5:00 PM (central time).
Orders will also be accepted via fax, 24 hours/day.
D002.eps
• Spare Parts (small line) (0049)2325 - 987-0
WARNING •
•
Hazard and consequence will be shown
in this space.
•
Whenever you call the factory for spare parts or
W022.eps
service, always have the model number handy. You can
CAUTION find the model and serial number on the ID tag that is
mounted to the subframe of the unit (Figure 2).
Hazard and consequence will be shown For future reference, the model number and serial
in this space. number of your machine has been placed in the spaces
C008.eps
provided below.
CAUTION
Hazard and consequence will be shown
in this space.
C001.eps
Figure 1
Safety alert information boxes Model Number:
How to reach us
If you encounter a circumstance that is not covered by
this manual, Schwing Service Department
will be more than happy to assist you with all of your
parts and service needs. Serial Number:
.
•
•
•
•
•
•
BPL 2023-5
S 42 SX- 125
BP L 20 23 -5
S 42 / 38 SX -125
Schwing
Vertical reach (in meters)
Horizontal reach (in meters)
Super X outriggers
Diameter of boom pipeline (in millimeters)
In practical usage, this unit is referred to as the the same unit would become BPL 2525-6, S 42/38 -
“S 42 SX” or simply the “42.” 125. The code for hydraulic pump output is as follows:
The boom size generally determines the style of the -4 indicates that the pump is rated at 450 liters per
entire unit, because the structural requirements of the minute. -5 means 535 L/min, and -6, which is available
outrigger and tower dictate the design criteria to the only on the 2525, indicates that the pump will put out
engineers. Other pumpkits are available for this boom 636 L/min.
style, and using another pumpkit would change the The pumpkit has its own complete model number. You
model number of the unit. For example, if you ordered will find this used on the output charts and nomographs
the unit with a 2525-6 pumpkit, the model number of for specific machines. For example:
WARNING
on
Do not stand
hopper grates.
S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
42SXIDtaglocate.eps
Main ID tag
Figure 2
Location of main ID tag and stamped serial number
ID Tags the front outrigger. The boom ID tag and the odd-
length pipeline tag (Figure 4) is located on the
NOTE! passenger side of the #1 (main) boom, just behind the
ID tags and serial numbers shown in this hollow pin.
manual are for “REFERENCE ONLY”.
Locate each of the tags on your own unit to Main ID tag
determine specific information for your
pump. The main ID tag (Figure 3) gives information about the
There are two information tags on the unit. The main entire unit, the pumpkit, the hydraulic systems, and the
ID tag (Figure 3) of the machine is located on the year of manufacture. The unit serial number is stamped
driver side of the subframe (Figure 2), just forward of into the subframe immediately below this tag.
HERNE 2/ GERMANY
PHONE (02325) 7871
TELEX 820 348
MATERIAL
301733D
1 7 0 5 2 6 0 0 6
Figure 3
Main ID tag
30334197 C
produce a maximum material pressure of: (See parts book for standard lengths)
N/A PSI
BOOM MODEL: Maximum weight of boom pipeline MAIN 1630 mm
KVM S 42 SX WITHOUT CONCRETE is: 10.14 Lbs/ft
boomidtag.eps
1 7 2 0 3 0 0 6
Boom ID tag
WARNING
on
Do not stand
hopper grates.
S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
42SXboomIDtag.eps
Figure 4
Location of boom ID tag
WARNING
on
Do not stand
hopper grates.
S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
42SXside.eps
SPECIFICATIONS
Concrete Pump Specifications............................................................... 18
Boom Specifications .............................................................................. 20
Outrigger Specifications ........................................................................ 21
Assembled Unit Specifications .............................................................. 21
Hydraulic Pressure Specifications ......................................................... 22
Boom Folding and Slewing Specifications ............................................. 24
Outrigger Extension and Slewing Specifications ................................... 24
Specifications
Concrete Pump Specifications
.
Output (hydraulic pumps) 535 L/min (141 gpm) 636 L/min (168 gpm)
2525Hspc.eps
2 X 100 kw = 200 kw
Note: 2100 RPM is an example. Your 2100 RPM is needed here at the gearcase
output, but there is no access here to check
machine may have a different speed
the RPM. You can find out what the input
requirement, which is documented in speed must be to deliver 2100 RPM to the
the output chart included with your output by dividing the needed output speed
parts book and operation manual. by the gear ratio.
Output
RPM
Input
Ratio
RPM
A7VOside.eps
Boom Specifications
Placing Boom Model S 42/38 -125
aElectrical
wire and hydraulic hose limitations.
bApproximate; varies with truck model.
Outrigger Specifications
Design
front Fully hydraulic extension and jacking
rear Fully hydraulic slewing and jacking
Maximum outrigger force pounds
front 50,700
rear 52,900
Outrigger spread
front (side to side) 27 feet 3 inches
rear (side to side) 27 feet 3 inches
length 29 feet 0 inches
Outrigger footplate dimensions
front 11.81 inches x 13.78 inches
rear 11.81 inches x 13.78 inches
Maximum soil pressure (without any dunnage) PSI
front 313
rear 327
Maximum soil pressure (with supplied dunnage) PSI
front 88
rear 92
Concrete Pump
Main Pressure relief single circuit (2525H - 5) 350 bar (5076 PSI)
Main Pressure relief Twin circuit (2023 H -6) 320 bar (4641 PSI)
Main Pressure relief Twin circuit Hi-flo with A11VO 360 bar (5221 PSI)
Main Pressure relief Twin circuit Hi-flo with A7VO (2023 -4)350 bar (5076 PSI)
Main Pressure relief Twin circuit Hi-flo with 1418 2.5 310 bar (4496 PSI)
Outriggers
Outrigger main pressure relief (for most units) 280 bar (4061 PSI)
Outrigger main pressure relief (for 45/47) 300 bar (4351 PSI)
Outrigger main pressure relief (52/55) Check schematic
Outrigger main pressure relief (1418 2.5) 200 bar (2900 PSI)
Agitator
Relief 200 bar (2900 PSI)
Water pump
Relief 200 bar (2900 PSI)
Boom Pressures
Hydraulic pilot pressure (pre-set nonadjustable) 15 bar (508 PSI)
Pressure regulator (for 45/47, 52/55, & 58/61) 310 bar (4496 PSI)
Pressure regulator (for 32, 34, 39, & 42SX) 300 bar (4351 PSI)
Pressure regulator (for 24-4, 26-4, 28 & 42 290 bar (4206 PSI)
Pressure regulator (for 17 M) 280 bar (4061 PSI)
#1 down side relief (for 45/47 & 58/61) 230 bar (3336 PSI) + delta P
#1 down side relief (for 24-4, 26-4, 28, 32, & 34) 140 bar (2031 PSI)
#1 down side relief (for 17M) 170 bar (2466 PSI)
#1 down side relief (for 39, 52, 31, & 42) Is nonadjustable or doesn’t exist
#1 down side relief (for 42 SX) 90 bar (1305 PSI)
Notes:
1. Oil should be at 40˚ to 50˚ Celsius before testing
2. Specifications vary on different units. Always check hydraulic schematic for specific pressures on your unit.
Notes:
1. Oil must be at 40° - 50° Celsius before testing.
2. Times are without weights.
3. Boom times are considered within specifications at +/- 10 seconds.
on
Do not stand
hopper grates.
S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
42SXside.eps
SAFETY
How to Order Additional Safety Manuals .................................................. 26
Warning Labels (Decals) .......................................................................... 29
Emergency Stop Switches........................................................................ 29
Other Safety Devices ................................................................................ 29
Laminated Book Container ....................................................................... 33
Do Not Use a Crane to Extend Boom Reach ........................................... 34
Best Regards,
Robert Edwards
1015_06_5x1.fm
BY-PASS
NORM. BY-PASS
000196.eps
Figure 5
By-pass key switch
E-Stop manifold
The E-Stop manifold is located in an easily accessible
location on each unit. To locate the e-stop for your unit
check the overview section of this manual. A
description of how the E-Stop manifold is plumbed in
the system and how it is used is shown in Figure 6.
Boom
Y66
Concrete Pump
Y63 Y64
Accumulator
Figure 6
E-Stop manifold
Safety valves (pressure relief valve) activating the circuit again. Refer to the Vector System
The hydraulic pressures listed on hydraulic schematics Configuration Manual or the component location
are not nominal figures. They are the hydraulic diagram on the cover of the electrical control system
pressures that the concrete pump was designed to work for location and function of each fuse or circuit
with and that the components were designed to breaker.
accommodate.
Hydraulic safety devices - boom and
NOTE! outriggers
Under no circumstances should you raise
hydraulic pressures arbitrarily or because The holding valves on the boom and outriggers are
you “think it might help.” Conversely, intended to stop the cylinders from retracting if
lowering the hydraulic pressure settings hydraulic pressure is lost for any reason. A cylinder
may cause poor performance, heat, and would stop, for example, if a hydraulic hose or fitting
related premature component failure. In fails.
some extreme cases, raising or lowering
hydraulic pressures may cause dangerous The way the holding valves are designed, pressure
operation. Check with the Schwing Service must be applied to the holding valves from the
Department before changing any hydraulic hydraulic system before the cylinders can extend or
pressure settings. retract.
Safety guards There is a relief valve located in the holding valves to
prevent cylinder failure due to excessive pressure and
Safety guards are placed over moving parts. These
to prevent boom damage due to excessive forces.
were placed on the concrete pump unit for your
protection. Do not operate the concrete pump without NEVER adjust the relief valve setting on a holding
all of the safety guards in place. If they become valve while it is on the boom. There is no way to tell
damaged, lost, stolen, or inoperable, they must be what pressure setting you are making, and structural
replaced before operation continues. damage could result.
Two hydraulically unlockable check valves (counter-
Fuses and circuit breakers balance valve, holding valve, or H.E.R. valve) on each
Fuses and circuit breakers are devices that are intended boom cylinder prevent the boom from coming down
to protect against circuit overload. They do so by unintentionally (Figure 7). See the boom circuit -
melting or opening when the current in an electrical hydraulic schematic in the Appendix section of this
circuit becomes higher than it was designed for. Here manual for additional information on the counter-
are a couple of examples of causes of over current: balance valves.
• Short circuits (positive goes to negative
without resistance)
• Component malfunction (a coil that has to
move a sticky valve)
• Mechanical interference (a shovel handle stuck
through the oil cooler fan blade) 000367.eps
Vectorquickindex.eps
Figure 8
laminated book container (driver side tool box)
superboom.eps
Figure 9
Do not use a crane to extend the reach of a concrete pump
Do Not Use a Crane to Extend placing boom and may compromise its
integrity. The ultimate result of this could be
Boom Reach boom damage and potential failure.
It is the position of Schwing, in conjunction • In normal operating conditions, a concrete
with the Concrete Pumping Association as delivery line will have natural vibrations and
well as major crane manufacturers, that cranes must movements that can be transmitted to the crane
never be used to suspend a working concrete delivery through its suspension lines. Crane
line in an attempt to extend the horizontal reach of the manufacturers do not design their machinery
boom (Figure 9). There are many reasons for this with this intended application and continued
restriction; the main points are as follows: use has been shown to create structural
• The boom and the crane have differing pivot problems in the unit. As in the boom, the
points and modes of control. It is not possible ultimate result of this could be damage and
to continuously and accurately coordinate their potential failure.
movements. This will always result in loads If for reasons related to the site layout, pumping must
being imparted into the boom. Many of these be carried out over a greater horizontal distance or into
loads will violate the design intent of the inaccessible places, it must be performed in accordance
with operating instructions included in this manual.
on
Do not stand
hopper grates.
S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
42SXside.eps
PRODUCT OVERVIEW
First Commissioning ................................................................................. 36
Concrete Pump Circuit.............................................................................. 37
Hydraulic Components ............................................................................. 38
Function Diagrams.................................................................................... 44
Vector Control System .............................................................................. 52
Optional concrete shut-off valve ............................................................... 53
Safety Devices .......................................................................................... 61
Component Location and Identification .................................................... 64
This section provides an overview of the S 42 SXG in perfect synchronization. The Rock Valve is cycled
concrete pump circuit. It also identifies all of the unit’s back and forth by a third hydraulic cylinder called the
safety features and describes the functional Rock Valve slewing cylinder.
components of the truck cab, chassis, concrete pump, The method of getting the hydraulic cylinders to
and hopper area. change direction at the appropriate times is covered on
Schwing recommends that you read this section of the the following pages.
manual while you are near the unit so that you can
identify the components that are described. However, The hydraulic pumps that supply oil to the concrete
do not attempt to operate the concrete pump based on pumpkit adjust the amount of oil they deliver both by
information provided in this section alone. Read and internal pressure-sensing devices and by adjustment of
understand the entire manual before you attempt to external valves (the stroke limiter and/or the
operate the unit. dampener).
This operation manual deals primarily with the rock
type of concrete valve. If you have questions about
WARNING your concrete pump contact Schwing Service
Improper setup / operation creates
D-Herne.
hazards. Do not operate this machine
without training. Understand the
warnings in safety manuals and on
000099.eps
decals.
Differential
hydraulic
Concrete Pump Circuit cylinders
speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 37
Overview
Hydraulic Components
Soft switch
shutoff valve
Main pressure
gauge port
Soft switch
relief valve
000124.eps
Concrete pump
00
shutoff valve 01
03
.e
ps
Figure 11
Locations of the concrete pump and soft switch shutoff valves (top)
and relief valves (bottom)
circuit switching sequence is shown in the function charged with dry, not liquid, nitrogen. Complete
diagrams contained in this section of the manual. recharging instructions are found in the
Single-circuit switching does have one advantage over Maintenance section of this manual.
twin-circuit switching: when a single-circuit pump is 3. Never charge an accumulator with oxygen or
shut off, no pressure exists in the system. Certain compressed air. Under pressure, oxygen can
hydraulic lines could be safely opened with the engine contact some of the molecules of hydraulic oil and
running and the concrete pump in the OFF position lower the flash point of the oil to below room
(But don’t do it. ALWAYS shut off the engine before temperature. If the oil flashes, the accumulator will
working on hydraulics.) explode.
This is not the case with twin-circuit switching. 4. Never work on the accumulator, the rock valve
Whenever the engine is running, pressure is being cylinder, the cutting ring, or any other connected
stored in an accumulator. If a line is removed, oil will component with the engine running. After shutting
be discharged, which raises the possibility of injury to off the engine, remove the key and place it in your
bystanders. pocket. Then verify zero pressure on the
Accumulator safety rules accumulator gauge before opening or working on
any of these items.
Whenever you work with accumulators, be sure to
5. Never improvise the tools or equipment needed to
follow these simple Accumulator Safety Rules.
recharge the accumulator. The correct tools are
1. Never assume that the accumulator has no stored shown in the Maintenance section of this manual.
pressure. Check the gauge before removing any
6. If the accumulator develops a gas leak, an oil leak,
lines, valves, or fittings. Verify zero pressure, and
or a ruptured bladder, return it to Schwing Germany
periodically check that the gauge is in good
or to the manufacturer for repair. Do not attempt to
working order.
repair the accumulator yourself.
2. Recharge an accumulator (i.e., add nitrogen) only
after you read and understand all the instructions When in doubt, find out. Never make any assumptions
for recharging accumulators. Accumulators are regarding accumulators or the circuits they drive. If
you are not sure, call the Schwing Germany Service.
00
01
Accumulator
25
.e
ps
MPS manifold
000126.eps
Figure 12
MPS manifold and system accumulator
speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 39
Overview
;;
;; Emergency
stop
manifold
20
6 S3 boom
13
18
9A 16
14 15 17
9B
21
10A 10B
11
S2 7
S1 4
25
3
10C
23 12
22
2
24 10D 19
8A 8B
1
000130.eps
;;;
Figure 14
The Rock Valve slewing cylinder
(shown as item 5 in Figure 13)
Crossover position
Parallel position
Figure 15
“S” valve diagram explanation for S2 and S3 valves
(shown as items 6 and 7 in Figure 13)
speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 41
Overview
End stop
Rod
Rod Piston
side side
000131.eps
Figure 16
Differential hydraulic cylinder diagram explanation
(shown as items 8A and 8B in Figure 13)
The term “differential cylinder” refers to the fact that The switching valves (Figure 17) have a logic function,
each of the hydraulic cylinders that push the concrete in that they sense multiple pressures simultaneously
have an area difference (referred to as an “area and will route oil from the poppet end port to the
differential”) between the two sides of the piston. This output port ONLY if the pressure from the poppet end
area differential is due to the fact that the rod extends port exceeds the pressure at the spring end port by
only from one side of the piston and not the other. This more than 2:1.
is in contrast to the rock slewing cylinder, for example,
which has a rod extending from both sides of the piston
and, therefore, has the same area on both sides of the
piston.
Spring
Figure 17
Switching valve diagram explanation (shown as items 9A and 9B in Figure 13)
ps
96.e
0000
Figure 18
Distribution Gear case
speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 43
Overview
Function Diagrams • The oil that is forced out of the piston side of
the right differential cylinder (8A) flows
The following diagrams A through D show the through hoses into the piston side of the left
switching functions of the fully hydraulic pump control differential cylinder (item 8B). This oil is
system plumbed on ROD SIDE with simplified called rocking oil (orange).
schematics. The agitator, boom, and S-1 control • The rocking oil forces the left side differential
circuits are not shown. For information on ROD SIDE cylinder (8B) to extend. The cylinder rod
and PISTON SIDE configurations, see the pages extends, pushing concrete out of the material
following these function diagrams. cylinder, through the Rock Valve, and into the
pipeline. (This is called the pressure stroke.)
Phase A Hi-flo
• The oil from the rod side of the left differential
Please note that right and left refer to the orientation cylinder (8B) is routed back to the tank
you would have if you stood on the unit by the Rock through the return filter (12). The low pressure
Valve, looking toward the cab of the truck. oil is shown in green.
• As soon as you switch the unit distribution • The oil shown as blue, such as the oil in the
gearcase to the pumping position, the accumu- reservoir, is at rest, or pressureless.
lator hydraulic pump (20) begins pumping
high pressure oil (red) to charge the accumula-
tors (14).
• High pressure oil (red) continues to flow into
the accumulator circuit until the accumulators
(14) are charged to the pressure cut-off point of
the accumulator hydraulic pump (20). 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 pressure.
• The high pressure oil (red) from the accumula-
tor circuit flows through the S3 directional
control valve (6), which is in the parallel posi-
tion, into the extend side oil port of the rock
slewing cylinder (5).
• The rod of the rock slewing cylinder (5)
extends, if not already extended.
• The S1 directional control valve (4), which
controls whether the unit pumps in forward,
neutral, or reverse, is put into the forward posi-
tion.
• A pilot signal (high pressure oil) is routed from
the accumulator circuit to the end cap of the S2
directional control valve (7), which moves into
the parallel position.
• High pressure oil (red) flows from the main
hydraulic pump (2) through the parallel posi-
tion of the S2 valve (7) into the rod side of the
right side differential cylinder (8A). The cylin-
der retracts, which creates a vacuum in the
material cylinder. The right side material cylin-
der fills with concrete. (This is called the suc-
tion stroke.)
5
;;
;;
Phase A Hi-Flo
;; KEY
High Pressure
Rocking Oil Pressure
Low Pressure
Zero Pressure
(Tank, or oil at rest)
6
S3
14
To e-stop
manifold
9A 17
15 16 18
9B
23
10A 10B
11
S2 7
S1 4
26
3
10C
25
24
27 10D
8A 8B
2
12
20
1
000134.eps
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Operation Manual - S 42 SXG 45
Overview
5
;;
;;
Phase B Hi-Flo
;; KEY
High Pressure
Rocking Oil Pressure
Low Pressure
Zero Pressure
(Tank, or oil at rest)
6
S3
14
To e-stop
manifold
9A 17
15 16 18
9B
23
10A 10B
11
S2 7
S1 4
26
3
10C
25
24
27 10D
8A 8B
2
12
20
1
000135.eps
Phase B Hi-flo
Please note that right and left refer to the orientation
you would have if you stood on the unit by the Rock
Valve, looking toward 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 cylin-
der (8A) cannot retract to the bottom dead cen-
ter position, then oil is removed now through
check valve 10C.
• The right side differential cylinder (8A)
reaches bottom dead center. As the piston
reaches the guide bushing, it exposes a port to
the end cap of the reversing valve (9A), which
becomes connected to high pressure oil (red).
The left end cap of the reversing valve (9A) is
connected to low pressure oil (green), so the
reversing valve slides into the parallel position,
sending high pressure oil (red) toward the end
cap of the S3 valve (6).
• The pressure signal reaches the S3 valve end
cap (6), pushing the valve into the cross-over
position.
• The oil on the right end cap of the S3 valve (6)
flows back to tank (1).
• In the cross-over position, the S3 valve (6)
routes oil from the accumulators to the retract
port of the Rock Valve slewing cylinder (5).
The cylinder begins to retract.
• The oil from the extend side of the Rock Valve
slewing cylinder (5) is routed back to tank (1).
• Shown in beginning position in phase B sche-
matic. A pilot signal (high pressure oil) is
routed from the accumulator circuit to the left
side end cap of the S2 directional control valve
(7). The S2 valve slides into the cross-over
position.
• As the rock slewing cylinder (5) retracts,
pressure in the accumulator circuit falls. When
it drops below the set point of the accumulator
hydraulic pump cut-off pressure, the
accumulator hydraulic pump (20) increases the
flow of hydraulic oil to charge the accumulator
circuit (14).
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Operation Manual - S 42 SXG 47
Overview
Phase C Hi-flo
Please note that right and left refer to the orientation
you would have if you stood on the unit by the Rock
Valve, looking toward the cab of the truck.
• The Rock Valve slewing cylinder (5) reaches
the bottom dead center position.
• High pressure oil (red) continues to flow into
the accumulator circuit until the accumulators
(14) are charged to the pressure cut-off point of
the accumulator hydraulic pump (20). 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 pressure.
• The S2 valve (7) has finished sliding. Oil is
now routed from the main hydraulic pump (2)
to the rod side of the left hand differential cyl-
inder (8B).
• As the left hand differential cylinder (8A)
moves, rocking oil (gold) reaches the left end
cap of the reversing valve (9A). The valve
closes because of the pressure applied and the
force of the return spring. This removes the
pilot signal to the left side of the S3 directional
control valve (6).
• As the left side differential cylinder (8B)
retracts, it creates a void in the material cylin-
der and concrete begins to flow in to fill that
void. (Suction stroke)
• The oil from the piston side of the left side dif-
ferential cylinder (8B) travels through the
hoses to the piston side of the right hand differ-
ential cylinder (8A), forcing it to extend. In the
material cylinder, the concrete from stage A is
forced out into the delivery pipeline. (Pressure
stroke)
• The oil from the rod side of the right hand
differential cylinder (8A) is routed through the
S2 valve (7), through the return filter (12), and
back to tank (1).
5
;;
;;
Phase C Hi-Flo
;; KEY
High Pressure
Rocking Oil Pressure
Low Pressure
Zero Pressure
(Tank, or oil at rest)
6
S3
14
To e-stop
manifold
9A 17
15 16 18
9B
23
10A 10B
11
S2 7
S1 4
26
3
10C
25
24
27 10D
8A 8B
2
12
20
1
000136.eps
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Operation Manual - S 42 SXG 49
Overview
5
;;
;;
Phase D Hi-Flo
;; KEY
High Pressure
Rocking Oil Pressure
Low Pressure
Zero Pressure
(Tank, or oil at rest)
6
S3
14
To e-stop
manifold
9A 17
15 16 18
9B
23
10A 10B
11
S2 7
S1 4
26
3
10C
25
24
27 10D
8A 8B
2
12
20
1
000137.eps
Phase D Hi-flo
Please note that right and left refer to the orientation
you would have if you stood on the unit by the Rock
Valve, looking toward the cab of the truck.
• The left side differential cylinder (8B) retracts
to bottom dead center. The right side differen-
tial cylinder (8A) approaches top dead center.
• If there is not enough rocking oil to completely
extend cylinder 8A, rocking oil will now be
added through check valve 10D.
• When the left side differential cylinder is in the
top dead center position, pressure is applied to
the right end cap of the reversing valve 9B. The
left end cap of the reversing valve is connected
to low pressure, so the valve slides into the par-
allel position. The reversing valve routes the
pilot signal to the right side end cap of the S3
valve (6).
• The S3 valve (6) moves to the parallel position
in response to the pilot signal. The oil in the
left side end cap of the S3 valve (6) escapes to
tank.
• High pressure oil (red) is routed from the accu-
mulator circuit through the S3 valve (6) to the
extend port of the Rock Valve slewing cylinder
(5).
• The Rock Valve slewing cylinder (5) extends,
sending the retract side oil back to tank (1)
through the S3 valve (6).
• As the rock slewing cylinder (5) extends, pres-
sure in the accumulator circuit falls. When it
drops below the set point of the accumulator
hydraulic pump cut-off pressure, the accumu-
lator hydraulic pump (20) increases the flow of
hydraulic oil to charge the accumulator circuit
(14).
• At the same time that the Rock Valve cylinder
is extending, a high pressure pilot signal is sent
to the right end port of the S2 spool. It slides
into the parallel position. When it has com-
pleted the travel, oil is routed from the main
pump (2) to the rod side of the right hand dif-
ferential cylinder (8A).
• This brings us back to phase A. The machine
has made one complete cycle, which consists
of 2 suction strokes and 2 pressure strokes.
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Operation Manual - S 42 SXG 51
Overview
vectorcontrol.eps
Figure 20
Vector controller found in passenger side enclosure near hydraulic controls
pinchvalve.eps
Figure 21 slider.eps
Regulator
Figure 23
The concrete shut-off valve is designed to operate
Pressure regulator/control valve
normally at 40 PSI. Depending on the length of your
located in Vector controller enclosure
boom and the type of concrete you are pouring, the
pressure can be adjusted up or down to achieve the
desired performance of the valve. If concrete continues
to dribble out after the valve has inflated, you may wish
to increase the pressure in increments of five PSI until
it no longer drips. Pressure is adjusted by turning the
knob above the pressure gauge (Figure 22).
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Operation Manual - S 42 SXG 53
Overview
Options box The bottom switch (Figure 25) is used to control the
The “Options” electrical box is found on the wall of the function of the optional concrete shut-off valve.
enclosure housing the Vector controller. The three position switch allows the operator to control
the function of the valve in three different modes:
• Position number one is “Auto-mode”. This
mode should be used for normal operation.
The shut-off valve will work in relationship to
the concrete pump on-off switch. When the
machine is pumping, the concrete shut-off
valve is open, and when the pump is stopped,
power is removed from the solenoid and the
valve inflates to stop concrete from draining
out of the end hose. The valve can be
overridden via the remote box. If you are
standing near the boom with the remote box
and wish to drain the concrete from the boom,
activate the switch in Figure 25 to the down
position, which is the concrete shut-off valve
icon, and the valve will open. The switch is
located to the left of the E-stop button on the
remote box.
Concrete shut-off valve
disable switch
optionsbox.eps
Figure 24 shutoffswtch.eps
3036 2348
5 6
4
7
3
8
2
9
1
0 10
valveicon.eps
Figure 26
Switch on the remote box (left)
shut-off switch and valve icon (right)
lightswitch.eps
ANALOG 0 mA
PROPORTIONAL 00
1
0 to
Potentiometers
7.5 volts
20
Proportional
amplifiers
6 to 9 v olts TO
BOOM
DIGITAL 0 mA
00
1
PROPORTIONAL
0 to
Digital control
01010
system
(Comfort control)
1 10 1 0 110 TO
D/A Converters BOOM
000139.eps
Figure 27
Comparison of analog and digital systems
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Operation Manual - S 42 SXG 55
Overview
Controls and indication devices switch in the center disables the joysticks. Use this fea-
ture when you momentarily put the remote control box
down but want the concrete pump to continue. If you
∅=
27 mm
pushed the E-stop switch instead of centering the boom
speed switch, all functions would stop.
∅ = 47 mm ∅ = 47 mm
1
144P The emergency stop switch interrupts an
2
3 303623
49 active signal to the controller. This signal
303623
48
4
5 6
is always being sent, and when the con-
troller does not receive the signal, it acti-
7
3
8
2
9
1
estopswt.eps
0 10
Vectorr&fRadio.eps
vates the emergency stop circuit. The
machine has several emergency stop switches, which,
Figure 28 excluding the remote control box when the machine is
Omnex radio remote in the local mode, are all active.
cal, but there are some differences in the LED indica- The agitator switch controls agi-
tion messages. The Omnex radio remote box is shown tator on/off. The direction of the
in Figure 28. agitator shaft can be chosen by
selecting down to make it move
Remote control box functions forward and up to put it in
Here we will cover the purpose of each remote box reverse. vectoragit.eps
control function. We will begin with the concrete The status LEDs on the
shutoff valve disable switch, and move more or less remote box indicate the sta-
clockwise around the remote box. tus of the power, communica-
vectorboxleds.eps
8
2
toggle down to the “|” position activates or will stop the horn from sounding
the box. This switch is not used (or when it has been activated by a minor fault alarm.
vectorremoteon.eps
needed) on the cable remote control box. NOTE!
The boom speed selector and joy Major fault alarms cannot be addressed by
stick disable switch: use the fast this switch. If your horn continues to beep
speed (rabbit) when folding and after activating the switch to reset, you must
unfolding or when fast boom move-
vectorboomspeed.eps return to the main controller, located in the
ments are appropriate for the job tool box, and check the large LCD display to
conditions. Use the slow speed (snail) when job condi-
tions require precise boom movements. Positioning the
bmextup&dwn.eps
on the (+) switch to increase RPM, and
lift up on the (-) switch to decrease
RPM. Figure 29
Extension vs. direction
The vibrator/water pump switch con-
trols the hopper vibrator and water pump. we have added the boom #2 speed control switch.
To activate the vibrator, push the switch Your speed choices range from slow (|) to medium (||)
to the down position. The vibrator will to fast (|||).
run automatically when the concrete
vectorvibrator.eps These are the symbols for boom #1
pump is operating in the forward position. extend and retract joystick axis. See
To activate the water pump, push the switch to the up Figure 30 for the function location in
#1ext/rtrct.eps
position. The middle (0) position is off. relation to the other functions.
These are the symbols for boom slew-
Boom functions ing counterclockwise (CCW) and
Boom movements are shown as extend and retract clockwise (CW) joystick axis. Coun-
slewpicto.eps
instead of as up and down (Figure 29). terclockwise means rotating to the left at
The #2 boom section is acti- the top, and clockwise means rotating to the right at the
vated by depressing the joy- top.
stick handle pushbuttons.
#2rtract.eps
These are the symbols for boom #3
#2xtend.eps
The left and right joystick extend and retract joystick axis. See
each have a pushbutton which extends or retracts the #3ext/rtrct.eps
Figure 30 for the function location rela-
cylinder as indicated by the pictogram shown on each. tionship to the other functions.
Boom #2 is unique in that it does not
vectorbm2picto.eps These are the symbols for boom #4
have its own joystick axis. Instead, it extend and retract joystick axis. See
1 is activated by the pushbuttons on the Figure 30 for the function location rela-
#4ext/rtrct.eps
2
top of the joystick. The pushbuttons tionship to the other functions.
3
are not proportional. For this reason,
#1 UP #1 UP
NTT EXTEND NTT RETRACT PLUS PLUS
PLUS PLUS SLEWING CCW SLEWING CW
TIP EXTEND TIP TIP EXTEND #1
Figure 30 EXTEND UP
PUSH LEFT JOYSTICK DOWN PUSH RIGHT JOYSTICK DOWN
Joystick movement identification TO ACTIVATE SECTION #2 RETRACT TO ACTIVATE SECTION #2 EXTEND bignewjoystick I.D.eps
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Operation Manual - S 42 SXG 57
Overview
High pressure
Water Pump/Compressor Switch
Water Pump Switch Up = compressor
Up = Optional switch for future use Center = OFF
(Activates nothing at this time) Down = Activates pressure washer
Center = OFF
Down = activates water pump
while in local control HP Concrete Pump Switch
Up = forward
R Center = OFF
Vibrator/Hose shut-off Switch Down = reverse
Up = Optional ball injection P
clean out system
Down = Controls the vibrator in
vectorrearpanel.eps
“Auto” mode meaning vibrator is
on when pump is in forward only) Electric Stroke Limiter
Control Agitator Switch
Up = Decreases concrete Activates the agitator
pump strokes per minute Up = reverse (R)
Down = Increases concrete (Center OFF)
pump strokes per minute Down = (forward) pump mode (P)
Figure 31
Vector rear panel
The Vector rear panel houses nine switches with the information with, as inspectors, laborers, and redi-mix
noticeable absence of the local/remote switch, which is drivers could run you out of water before you need it to
now found on the main controller (Figure 32). clean out.
Figure 31, above, explains the location and function of vectorlclrmt.eps
one on the right activates the high pressure water NA 1350 U/min
Menu:[ENTER]=Ein
pump, while the switch on the left gives you the option
of activating the regular water pump while in either
‘local’ or ‘remote’ operation. Selecting the down HOME + HELP START
position of the left switch gives you continuous use of CLEAR - ENTER QUIT
Key
STARTUP SEQUENCE OFF ON FLASHING SLOW FLASHING FAST
STOP Power is on. An E-stop self-test is requested. Push the E-stop switch
to begin the self-test procedure. When the LED flashes faster, the test
is done. Release the E-stop switch. If the LED continues to flash fast,
the E-stop failed. Cycle E-stop. If not remedied, circuit failed.
OPERATION
STOP
STOP If the battery LED flashes red, the communications LED flashes
green, and the STOP LED is flashing fast, cycle power by removing
and replacing the battery. If LED’s continue to flash, open control box.
Check LED’s on base of joysticks. LED should flash every three
seconds; if not, the joystick module has failed. If the joystick is
operational, replace the transmitter board for the radio circuit.
If the battery LED is steady red, the communications LED is off, and
the STOP LED is flashing red, the micro board has failed. Cycle
power by removing and replacing the battery. If not remedied, replace
the transmitter board.
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Operation Manual - S 42 SXG 59
Overview
STOP
With power LED and communications LED both on steady, the unit
is indicating valid data, all functions are off, and unit is ready to
operate.
STOP
If power LED is on steady, communications LED flashes green, and
STOP LED flashes red, it means that some function is activated,
and the unit cannot reset. Return all functions to neutral, and recycle
the E-stop.
OPERATION
STOP
FAULT MESSAGES
STOP
When the power LED is on steady, the communications LED is off,
and the STOP LED is flashing red, the unit is indicating internal
interface failure. Cycle power by unplugging the cable and hooking it
back up. If not remedied, check for a faulty board or internal wiring.*
STOP
When the power LED is flashing, the communications LED is off*,
and the stop LED is flashing, the unit is indicating CAN-bus interface
failure. Check cable/truck wiring. If wiring is good, the problem could
be faulty wiring or circuitry on the 124-MC board.
STOP
When the power LED is flashing, the communication LED is
flashing, and the stop LED is flashing, the unit is indicating joystick
failure. Cycle the power by unplugging the cable and hooking it back
up. If not remedied, open box and check bottom of joystick. LED at
base of stick should flash every three seconds if functioning
properly.
* Note: the communications LED may also flash occasionally on a CAN-bus failure but not
with any constant pattern.
Safety Devices
The emergency stop switches (Figure 33) are located
This section lists the safety devices found on your on the main control panel, as well as on both control
pump. The items listed here must be kept in good boxes, on either side of the hopper, on the manual
working condition, or injury may result. Bypassing a boom control pedestal, near the water box and by each
safety device for servicing, emergency foldup, or set of outrigger controls. All eight emergency stop
cleanout should be done only by persons who know switches are wired in series, so they do exactly the
what systems are disabled by the bypass procedure. same thing. The emergency stop switch on the remote
Any safety devices that have been bypassed must be set control box does not work when the remote box is not
back to the original position upon completion of the plugged in.
service or emergency procedure.
NOTE!
Emergency stop switches Whenever the cable remote control or the
radio remote control are not plugged into
The emergency stop switches cut off electricity to the the control receptacle, you must install the
boom and concrete pump forward/reverse pilot valve. dummy plug, or the unit will not function!
In addition, they stop the electrical path to the (Details are found on page 75.)
“emergency stop manifold”.
Hopper grate interlock
The agitator hydraulic circuit runs through a normally
open directional control valve that routes oil directly
from the pump back to the tank if the following safety
conditions are compromised:
• electricity is lost on the unit
Manual • the hopper grate is raised
boom • the hopper grate is removed
Outrigger controls Although this safety device is good protection, you still
controls need to remember to never put your hands, arms, legs,
or anything other than concrete into the hopper when
Outrigger the hydraulic system is engaged.
controls
Safety valves (pressure-relief valves)
Water box The pressures listed on hydraulic schematics and in
manuals and literature are not nominal figures. They
are the pressures with which the machine was designed
to work and which the components were designed to
accommodate. In a very few instances, pressures may
be adjusted to accomplish certain things, but this may
be done only with the advice and step-by-step
Rear control
instructions of an authorized Schwing representative
panel familiar with the system and safety devices. Under no
circumstances should you raise pressures arbitrarily or
Beside because you believe it “might help.” In addition,
Beside
hopper lowering pressure settings may cause poor machine
hopper
performance, heat and premature component
degradation, and, in extreme cases, dangerous
Figure 33 operation.
Location of emergency stop switches other
than the two control boxes
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Operation Manual - S 42 SXG 61
Overview
Bypass
key switch
Figure 34
Emergency stop manifold bypasskey.eps
Emergency bypass procedure When the key is activated from normal to bypass, it
To fold up the boom after an electrical malfunction has supplies power to the dump valves and prevents them
opened the dump valves, the system is equipped with a from routing the oil back to tank. The bypass should be
manually operated bypass switch. This is a small key activated only if you have developed electrical
switch on the front wall of the enclosure that houses problems and must fold up the boom and outriggers to
the main controller (Figure 35). get to a location where repairs can be made. When any
dump valve is bypassed, the emergency stop switch is
not functional for that circuit.
Safety guards Never adjust the relief valve setting on a holding valve
In addition to the safety devices just discussed, there while it is on the boom. There is no way to tell what
are guards placed over moving parts: pressure setting you are making, and structural damage
could result.
• waterbox guards
• boom slewing gear drive
H.E.R. valves
• hopper grate
• water pump drive grate Two hydraulically unlockable check valves (H.E.R.
valves, or holding valves) on each boom cylinder
• slewing cylinder cover
(Figure 36) prevent the boom from coming down
These guards were placed for your protection. Do not unintentionally. See the boom schematic in the
operate the machine unless all the safety guards are in Appendix section of this manual for further details.
place. If they become damaged, lost, stolen, or
inoperable for any reason, they must be replaced before Fuses
operation continues.
Fuses are devices intended to protect against complete
system failure, fire, and dangerous operation. They do
Hydraulic safety devices—boom and
so by melting when the current in an electrical circuit
outriggers becomes higher than it is allowed to be. Some causes
The holding valves on the boom and outriggers stop the of overcurrent are shown in the following examples:
cylinders from retracting if hydraulic pressure is lost • short circuits (positive goes to negative without
for any reason, such as if a hydraulic hose or fitting resistance)
blows. Pressure must be applied to the holding valves • component malfunction (a coil that has to
from the hydraulic system before the cylinders can move a sticky valve)
extend or retract.
• mechanical interference (a shovel handle is
A relief valve is located in the holding valves to stuck through the oil cooler fan blade, for
prevent cylinder failure due to excessive pressures and example)
boom damage due to excessive forces.
000367.eps
Figure 36
Holding valves mounted on a hydraulic cylinder (H.E.R. Valves)
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Operation Manual - S 42 SXG 63
Overview
diagrams and lists on the fold-out brochure provided in Component Location and
the Appendix section of this manual. Then get the serial
number of the unit from the serial number plate, which Identification
is located on the subframe, behind the cab on the driver Location and identification of the operational
side, and call the Schwing Spare Parts. components of your concrete pump are discussed in the
The person taking the following pages. This information is for identification
order will make a note of the serial number of the unit only. Do not attempt to operate the machine from
for our files and send you the labels you need. You may information obtained from this section.
order complete sets or single labels. If the serial
number plate is missing or unreadable, the number is Truck cab component identification
stamped into the subframe just below the normal
location of the serial number plate. For installation Figure 37 shows the components in the truck cab. The
locations, see the decal location guide insert at the end components are usually mounted on a console to the
of the Appendix section. right of the driver’s seat or on the dash to the right of
the steering wheel.
PULL
TO APPLY
PARKING
BRAKE QUARTZ
PUSH TO 00000.1
RELEASE 1 HOURS
Figure 37
Truck cab components
Omnex receiver
smgrstim.eps
Autolube timers
Battery charger
vectoromnxrcvr.eps
Figure 38
Omnex receiver and battery charger
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Operation Manual - S 42 SXG 65
Overview
Passenger side outrigger controls • The Front Foot jacking handle controls the
The passenger side outrigger handles control the front jacking cylinder. Pull the handle to
slewing, extension, and jacking of the outriggers on the extend the cylinder, and push to retract the
passenger side. cylinder.
• The Front Extend/Retract handle activates
the hydraulic cable drive motor that extends
new45ps.eps
45 ps outrig latch.epsL
Figure 40
Passenger side outrigger controls
Locked
The E-stop and outrigger enable button are the same on
both sides; however, the control handles on the passenger Figure 41
side of the unit are configured differently than those on the Rear outrigger locking latch
driver side (Figure 42). (passenger side)
The front and rear outriggers have locking latches that
must be released before activation. The process of
setting the outriggers is described in the Operation
section of this manual. The functions of the controls
are as follows:
• The Outrigger pushbutton routes hydraulic • The Front Outrigger locking latch (Figure
oil from the boom control block to the 43) is positioned near the pivot point of the
outrigger control blocks. The outrigger front outrigger and is released by pulling the
pushbutton must be pushed and held during handle up to the open position.
any outrigger operation.
• The Rear slewing handle controls the rear
outrigger slewing cylinder extension and
retraction. Pull the handle to slew open, and
push to slew closed.
• The Rear Foot jacking handle controls the
rear jacking cylinder. Pull the handle to extend
the cylinder, and push to retract the cylinder.
Figure 43
30354500
Rear Slewing
• The Rear Outrigger locking latch (Figure
Front Extend/Retract
44) is released by lifting the pin and turning it
Front Foot Jacking Rear Foot Jacking to the unlocked position as shown.
Figure 42
Driver side outrigger controls
• The Outrigger Pushbutton routes hydraulic 45 rear ds outrig latch A.epsL
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Operation Manual - S 42 SXG 67
Overview
12 11
1 9
7 5 3 10
8 6 4 2
42sxgbmvlv2.eps
Figure 45
Manual boom controls
All functions of the 42 SXG which can be controlled 5. The boom #4 control handle is used to extend and
by use of the remote control can also be controlled retract section #4 by moving the control handle in
manually. The remote control should always be and out.
considered the primary method of control; however, the 6. The boom slewing control handle controls the
following pages will provide you with the location and direction of boom rotation by moving the handle in
identification of the manual controls which can be used and out.
if the remote control fails.
7. The water pump handle activates the water pump
when pushed in and the optional high pressure
Manual boom and pumpkit controls
washer when moved out.
The manual boom controls (Figure 45) are located in a 8. The boom/outrigger handle activates the boom
forward enclosure on the passenger side of the unit. control block when pushed in and the outrigger
1. The E-stop manifold houses the system dump control block when pulled out. Pulling this handle
valves. If you lose electricity to the controller for performs the same function as using the outrigger
any reason, including any emergency stop button pushbutton.
being pushed, the dump valves in the E-stop 9. The concrete pump handle operates the concrete
manifold will open. This will route oil from the pump forward when the handle is pushed in and
hydraulic pump directly back to the tank. operates the pump in reverse when the handle is
2. The boom #1 control handle is used to extend and pulled out.
retract section #1 by moving the control handle in 10. The agitator handle activates the agitator to the
and out. forward position when pushed in and to the reverse
3. The boom #2 control handle is used to extend and position when pulled out.
retract section #2 by moving the control handle in 11. The concrete pump pressure gauge indicates the
and out. hydraulic pressure being required for the concrete
4. The boom #3 control handle is used to extend and pump, and the faucet valve below it can be closed
retract section #3 by moving the control handle in to remove the gauge from the system.
and out.
Bypass
key switch
bypasskey.eps
Figure 46
Bypass key switch
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Operation Manual - S 42 SXG 69
Overview
Hopper area
45amhppr1.eps
8. Emergency stop
switch
2. Hopper grate
interlock switch
5. External spotlight
power receptacle
motor P
9. Rear control
panel
Figure 47
Hopper area components
The passenger side of the hopper area houses important to remember that you should never put
the components shown in Figure 47. any part of your body in the hopper or in the
1. Agitator motor. The agitator motor is a hydraulic concrete valve either from above (through the
motor that is directly coupled to the agitator shaft. hopper) or from below (through the outlet pipe or
Pressure required to run this circuit is 200 bar clean out door). You could be seriously injured.
(2900 PSI). 3. Horn alert button. If this button is pushed, the
2. Hopper grate interlock switch. The hopper grate warning horns on the unit will sound. The horn is
interlock switch is set on a cam system that is used for signaling and is spring-loaded to OFF.
activated only when the hopper grate is in the down 4. Vibrator power receptacle. This receptacle is
(pumping) position. When the hopper grate is present on your unit whether you ordered the
lifted, the concrete pump stops pumping, the vibrator option or not. If you decide to install a
agitator stops turning, and, on twin-circuit vibrator later, simply plug the unit into the
machines, the accumulator dumps. This switch receptacle. This is a 12-volt, 25-amp DC circuit.
differs from an emergency stop in that it has no 5. External spotlight power receptacle. This mates
effect on the boom or the water pump circuits. The with the plug on the end of the spotlight (described
interlock, like any mechanical device, is not fail in Schwing parts books as a “working reflector”).
safe, and, even with this switch installed, it is
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Operation Manual - S 42 SXG 71
Overview
Water tank
filler cap
Figure 49
Water tank filler cap
(top of passenger side
rear outrigger)
12
2
14
1
8
3 6
7 13
4
10
5 9
11
000169.eps
- .
.
.
.
.
Figure 50
Supplied accessories stored in passenger side toolbox
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Operation Manual - S 42 SXG 73
Overview
Fuel reservoir
The fuel reservoir (Figure 51) is in the driver side rear
outrigger and holds about 150 gallons of fuel. The fuel
reservoir filler cap is located on the top of the outrigger.
Fuel reservoir
filler cap
45fueltn.epsL
Figure 51
Fuel reservoir
vectorremoteplug.eps
Figure 52
Remote control cable receptacle
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Operation Manual - S 42 SXG 75
Overview
Vectorquickindex.eps
Figure 53
Safety Manual Quick Index pocket
Main hydraulic oil reservoir level gauge on the tank that indicates proper oil level
The main hydraulic oil reservoir houses the suction (Figure 54). This reservoir holds 169 gallons of
lines for all pump circuits, the return lines, the main hydraulic oil.
return filter, and all of the oil on the unit. There is a
oilgauge.eps
Oil Gauge
Figure 54
Hydraulic oil level gauge
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Operation Manual - S 42 SXG 77
Overview
42 Waterbox
WARNING
rs closed.
if
required.
ne/motor
s out of
Keep cove
Keep hand
.
Stop engi
access is
waterbox
WARNING
rs closed.
if
required.
ne/motor
s out of
Keep cove
Keep hand
.
Stop engi
access is
waterbox
Figure 55
Waterbox
(Covers removed for illustrative purposes)
Waterbox
The waterbox (Figure 55) is actually part of the pump
kit. The water in the box flushes the differential
cylinder rods and the back sides of the rubber rams,
keeping them cool. You must be very careful when
entering the waterbox area, as the hydraulic cylinders
that operate there are capable of tremendous forces.
Under no circumstances should you remove the covers
or guard when the pump is operating or ready to
operate. See the warnings in the Safety Manual
regarding the waterbox.
42 align.arrows.epsL
Figure 56
Boom alignment arrows
Alignment arrows
Boom alignment arrows are welded to the boom turret
and to the turret gear shrouding (Figure 56). The boom
turret turns, and the turret gear shrouding remains
stationary. By aligning the two arrows so they are
directly in line with one another when folding up, bring
the boom into the correct left/right position to be
lowered into the cradle. It is still wise to position
yourself so you can see the boom and A-frame as they
come together, so you can make minor adjustments. If
the arrows become damaged, it is critical to repair and
correctly realign them to avoid damage caused by
setting the boom on the A-frame.
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Operation Manual - S 42 SXG 79
Overview
52hornon.eps
45turret.epsL
Figure 57
Warning horns 3rd boom section (left) and turret (right)
Warning horns
Warning horns are located on the turret and third boom
section (Figure 57). They activate, producing a loud
blast, when the Vector control system recognizes any
fault, such as the oil temperature sensors detecting an
overheat condition or any number of a long list of
possible faults.
• Once the horn is activated, you can stop the
horn blasts by activating the “reset” to the “I”
position.
• If you discover that the fault is minor and you
can correct it later, activate “I” twice, and the
Vector controller will store the fault in memory
and allow you to proceed with the pour.
• The horns can be manually sounded when the hrnbtn.eps
WARNING
on
Do not stand
hopper grates.
S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
42SXside.eps
OPERATION
Preparation ............................................................................................... 82
Unit Setup ................................................................................................. 87
Prepare for the Ready-Mix Trucks .......................................................... 100
Lubricating the Pipeline .......................................................................... 104
Pumping the Job..................................................................................... 106
Cleanout ................................................................................................. 114
Special Pumping Situations .................................................................... 124
Emergency Procedures .......................................................................... 130
Other Things You Need to Know ............................................................. 132
• Clamp pins clamps and hoppers. Many pump operators remove the
• End hose dead plug wooden handle and install the hammer head on a steel
• Safety chains, cables, straps, or whipchecks for pipe. This makes it ideal for installing pipeline because
any and all devices that will hang over workers the handle can be used to pry clamp handles up or
or equipment down. Experienced pump operators never walk from
the pump to the pipeline without a hammer.
Inspect all pipes and pipe accessories for wall thickness
and condition, and have them loaded and secured for Finally, you will need all of the items required by law
travel before moving the unit. Keep in mind the for safe operation of a motor vehicle, as well as the
pressure rating of your unit when you inspect the necessary items needed for the job:
condition of the pipe accessories. Refer to the chart • Valid driver’s license
regarding pipe wall thickness and pressure in the • Fuel permit
Appendix section of this manual. • Cab card
In addition to the above, you will also need common, • Registration
everyday pumping accessories. Use the following list • Insurance card
for the minimum requirements of a normal pumping • First aid kit
job:
• Flares
• Shovel
• Reflector signs
• Barrel for mixing slurry (keep the barrel with
• Fire extinguisher
the unit at all times, even if you don’t plan to
use the barrel often.) • Job ticket
• Pipeline lubrication mixes; enough for the • Maps
day’s job—either commercial lubricating • Job site phone number and contact person
powder or portland cement for mixing slurry, if
required. (Sometimes slurry will be delivered
to you; at other times, the portland cement will
be supplied at the job site. You must always
know how your lubrication will be
accomplished before you leave the yard.)
• Grease gun and grease tubes
• Spray can filled with form oil or Kleen Kote
(not necessary, but very helpful)
• Cleanout balls or Go devil
• Water hose and nozzle
• Cleanout rake
• Working lamps for night work
• An approved air blowout cap (See the Safety
Manual for blowout cap requirements.)
• Five-gallon bucket
• Hand tools
• Hammer (2lb. to 4lb. wedged head works best)
Of all of these items, the hammer is the tool you will
need most often. It can be used to set up and remove
pipeline, to knock the wedges out of the tapered bend
for cleanout, to tap pipe to locate blockages (follow the
instructions in the Safety Manual), and it makes a good
device for knocking out concrete that has set up in
Use your personal protective equipment work that will protect your feet from lime and
accidental impact. The following protective clothing
(Figure 59) should always be worn to protect you from
WARNING chemical and all other job site hazards:
Personal injury hazard. Always wear • Protective rubber gloves and boots
safety gear when working with concrete • Hard hat
W018.eps
or equipment. • Safety goggles/glasses
• Safety vest
Concrete is made from lime, which is extremely • Snug-fitting work clothes
alkaline. If wet concrete stays on your skin long • Hearing protection
enough, it can cause severe burns. In extreme cases, it
• Breathing protection (when cement dust or
can cause the affected skin to fall off. When you work
exhaust fumes are present)
around concrete, wear water resistant gloves and boots.
When you work in concrete wear waterproof gloves • Full face shield (when around shotcrete or
and boots. In either case the boots should have steel other flying debris)
toes. There are boots made especially for concrete
HARD HAT
SAFETY HEARING
GOGGLES PROTECTION
BREATHING
MASK
SNUG
SAFETY FITTING
VEST CLOTHES
GLOVES
STEEL TOED
SHOES
SafegearWvest.eps
Figure 59
Wear personal protective equipment
Truck and pump checklist there is most likely a problem with the
integrity of the hydraulic seals somewhere
Check the following items each day before the machine in the system.
is taken from the yard:
Top off oil levels only with the same type of oil that is
On the truck in the reservoir. Do not mix name brands even if they
have the same viscosity. Each oil manufacturer uses a
• Truck engine oil level and condition
different additive package to accomplish anti-foaming,
• Antifreeze / coolant level in the radiator silt settling, anti-wear, etc. Mixing the different
• Battery fluid level and condition chemical additive packages may render them useless.
• Tire condition and proper air pressure Drain water from the hydraulic reservoir each morning.
• Brake system air pressure and condition (bleed This is done by opening the faucet located under the
water from air tanks) hydraulic reservoir and allowing the fluid to run into a
• Clean the windows of ice, frost, mud, and pan until the water stops and oil begins. (Water is
obstructions heavier than oil, so it sits on the bottom of the tank and,
• Clean the mirrors of ice, frost, and mud, and therefore, drains out first.)
align them properly for clear vision Fill your water tank before leaving, if it is allowed. In
• Keep the cab free of debris, especially on the some localities, filling the water tank may cause an
floor. Accidents can happen when foreign overweight condition for driving. If you cannot carry
objects get stuck between the clutch or brake water with you, be sure that there will be an ample
pedal and the fire wall supply of water at your destination. It is not possible
to pump a job without water! It is used in the
On the pump waterbox to cool the rubber rams and differential
Structural integrity of the unit is vital. Visually inspect cylinder rods, and it is necessary for cleanout. Ready-
the outriggers, boom, and tower areas. Look for cracks, mix trucks often carry more water than they need for
chipped paint, rust (especially under paint), and their own uses and will usually give the extra supply to
missing parts. Clean and repaint areas where the paint you. Verify this with the ready-mix company before
is chipped to prevent damage to the structural steel. you leave for the job.
Replace missing parts before using the unit. Report any NOTE!
structural abnormalities to Schwing Use only clean water to refill water tank.
Engineering Department before using the unit. If Never use reclaimer water.
Schwing’s engineers determine that repair is necessary Visually check the unit for hydraulic leaks, and repair
for safe operation, do not operate the unit until any leaks before operating the machine. Lost hydraulic
repairs are completed. Pipeline must be complete and oil harms the environment, and it is expensive to clean
free of dents, cracks, and holes. Pipe must have up and replace the lost oil.
sufficient wall thickness to handle the maximum
pressure of the pump. Inspect it weekly with an Be sure that everything on the unit is ready for road
ultrasonic thickness tester (see the Maintenance travel. This includes locking the outriggers, pinning the
section of this manual). All boom clamps must be outrigger pad holders, and securing all pipeline,
secure and pinned closed. All safety guards must be in pipeline accessories, and miscellaneous equipment.
place and secured for travel.
Check hydraulic oil level and condition. The oil should
be clear and clean looking. Milky-looking oil or oil
with many entrained air bubbles should be replaced
before the next job begins.
NOTE!
Oil that holds air bubbles overnight should
be replaced, but if it becomes bubbly on the
job, it is not an oil problem. In that case,
Driving the unit • It is always best to use the towing pin supplied
Many accidents involving concrete pumps are traffic by the truck manufacturer. On trucks that are
accidents. To avoid an accident when driving a so equipped, the towing pin is usually located
concrete pump truck, you must obey all traffic laws and inside the front bumper.
warning signs. A boom mounted truck is top heavy and • The 42 SXG is equipped with tow hooks on the
must be driven accordingly. front of the truck as well as on the rear
outriggers. If you are not able to use the
Licensing designated tow hooks for any reason, always
use extreme caution when selecting a place to
If you do not have a valid commercial driver’s license,
hook the towing cable. Be sure that the place
do not drive this unit.
you select has adequate room for the cable to
move without hitting or damaging other parts
Backing up
and that it is capable of handling the load of
You will be able to see the road behind you on the left towing the unit.
and right sides, but you will not be able to see • Use only undamaged towing straps or cables
directly behind you. If you must back up and there is capable of handling the load of towing the unit.
any chance that traffic or pedestrians are behind you, Never use chain for towing, because if a link
you must use a guide. A guide is a person who watches breaks, the chain will whip in both directions
for traffic, pedestrians, and other obstructions and away from the broken link with great force.
stands where you can see him or her giving you This could cause injury or property damage.
instructions. The backup warning device can give you
some measure of safety, but you cannot rely on it. For Loading the unit for shipment
example, a child walking behind your unit when you
begin to back up may become frightened by the backup If the unit will be transported by some means other
warning sound and freeze on the spot. than its own truck power (such as by railroad or ship),
care must be taken so that people and property are
If you are in an isolated area where there is no traffic or protected during the loading process. In these cases,
pedestrians, you can get out of the cab and look for remember the following points:
obstructions before you start to back up.
For ramp loading / unloading
Changing lanes
• Use only ramps that provide adequate and
When driving, you have blind spots on your right and stable support for loading and unloading
left sides. Unfortunately, many other drivers are purposes. Take precautions to prevent personal
unaware of these spots and will travel in them for injury in the event the unit were to tip or slip
extended time periods. You can avoid these blind spots off the ramps.
by using convex mirrors, which attach on or below the • You must use ramps that have a lesser slope
outside rearview mirrors. Before changing lanes, check than the gradient climbing ability of the
the convex mirrors for other drivers who may be vehicle.
“hiding” in your blind spots. Signaling well in advance
• If you are using guides to provide instructions,
will warn other drivers of your intention to change
they must not remain in the driving zone.
lanes.
• Secure the machine on the transport vehicle
Towing the unit against rolling, slipping, or tipping.
For crane loading / unloading removed. In the case of electrical wires, do not set
• Truck-mounted concrete pumps may be moved up in a position that gives you less than the 17 feet
by crane only if they have been equipped with of clearance required.
slinging rings designed for that purpose. 2. You must be able to fully extend the outriggers.
Slinging rings can be ordered from Schwing The stability calculations of the unit were made
for installation on new units or for with the outriggers fully extended. Anything less
field retrofits. than full extension could allow the unit to tip.
• Never hook lifting devices to standard pump 3. The soil must be able to support the forces imposed
parts such as the boom, concrete valve, or by the outriggers. Even solid granite has been
hopper. These parts were definitely not known to give way when the unit has been set up
designed to support the entire unit weight. improperly.
• Check the load-bearing capacity of any slings, 4. Stay back from the base edge of any excavation or
cables, or other lifting devices that will be used cliff (Figure 60) the same distance as the vertical
to lift the machine. Never exceed the rated drop of the excavation or cliff. For example, if the
working capacity of the lifting device. excavation is 25 feet deep, you must be 25 feet
• No one is allowed to walk, stand, or work back from the bottom edge. (This is known as the
under suspended loads. Keep the area free of one-to-one rule.)
personnel. 5. At least one ready-mix truck must be able to get
safely to and from your hopper.
Unit Setup In addition to the requirements mentioned above, it is
desirable that the setup point also have these features:
Selecting the proper setup location on the 1. Ability to handle the safe arrival and departure of
job site all ready-mix trucks with accessibility for two
trucks to be at the hopper simultaneously,
2. Fairly level terrain to facilitate bringing the
machine within 3° of level before unfolding the
WARNING boom, and
Improper setup causes job site accidents: 3. Out of the way of major traffic flow.
• Look for power lines before unfolding
• Be sure of unit's stability
W024.eps
1to1rule.eps
Figure 60
One to One rule
Soil pressure (PSI) = total outrigger force (lbs) ÷ area of soil contact (sq. in.)
Find the PSI on the soil type chart on page 88 to the outrigger leg. In this case, you would need 1,179
determine where you can safely set up your unit. square inches of cribbing. If you had a calculator
handy, you could use the square root function to
42 SX Model calculations determine what size cribbing square you would need.
The front outrigger decal on the 42 model shows a In this case, you would need a square 35 inches by 35
maximum force of 50,700 lb. The steel outrigger pads inches. For example, a 4 x 4 timber (actual width
are 11.81 in. by 13.78 in. (162 sq in.).Dividing 50,700 dimension of 3.5 inches) that is 40 inches long has 140
by 162 gives a soil pressure of 312 PSI: square inches of soil contact. Putting nine of these side
by side under the dunnage pad would give you 1,260
50,700 ÷162= 313
square inches of soil contact.
As you can see from the soil load bearing capacity
chart, the steel pads are not big enough to be used by Activating the outrigger hydraulics
themselves on any of the soil types listed. This is why To activate the hydraulics so you can set your
the unit comes equipped with dunnage pads. The pads outriggers:
are approximately 24 in. by 24 in. (576 sq in.). Now 1. Set the parking brake.
divide the maximum force of 50,700 by 576:
2. Depress the clutch.
50,700 ÷ 576 = 88 3. Select the proper pumping gear, as described on
the decal in the truck cab.
The pressure of 88 is suitable for firm, compacted
4. Select the pumping mode by pulling the PTO
gravel (more compacted, class V). If you had to set up
activation knob.
on virgin ground, asphalt, or one of the other soil types
listed, you would need to use additional cribbing 5. Slowly release the clutch until you feel the pump
(Figure 61). starting to engage, then depress the clutch again for
a second or two. Feathering in this way helps to
ensure that the gears engage properly. Now slowly
release the clutch again. If the engine lugs down,
immediately disengage the clutch, and verify that
you have selected the proper gear and that the PTO
activation knob is pulled all the way out. On most
trucks, the speedometer will register speed when
the pumps are turning properly.
Cribbing only.eps L 6. You should now have an illuminated warning lamp,
Figure 61 indicating that the PTO is engaged.
Add cribbing until you have adequate area 7. Get out of the truck cab and walk around the unit,
for the soil type unlocking the outrigger locking devices as you go.
(The locations are documented in the Product
Let’s assume that you had to set up on clay/silt soil, Overview section of this manual.) Double-check
which will bear a maximum of 43 PSI. If you divided that there are no obstructions or questionable soil
the maximum force by the pressure allowed (50,700 ÷ conditions while you are making this final safety
43) the answer would be how many square inches of check. If you see a problem, take care of it before
cribbing would have to be in contact with the soil under you set the outriggers.
Setting the outriggers The handles are all marked with decals (called
Start at the Vector controller located in the passenger pictograms), which present universal illustrations
side tool box. rather than text. You can find a complete display of the
pictograms in the Appendix section of this manual.
vectorlclrmt.eps
You may begin on either the driver side or the passenger
side of the unit. The E-stop and outrigger enable button
(Figure 63) are the same on both sides; however, the
control handles on the passenger side of the unit are
configured differently (see the Product Overview section
of this manual).
1 2
OK OFF
0 x1000 3
NA 1350 U/min
Menu:[ENTER]=Ein
30354500
Local/Remote/Ram change switches
Figure 62
Vector Controller local/remote switch Front Extend/Retract Rear Slewing
WARNING
Improper setup / operation creates
hazards. Do not operate this machine
without training. Understand the
warnings in safety manuals and on
decals.
W025.eps
outrigger slew/ext/jack.eps
1. Verify that you have already released the outrigger
lock.
Slewing
Jacking 2. Depress and hold the outrigger pushbutton while
you move the handle for front outrigger extend.
The outrigger will then begin its movement.
Pushing the handle slightly will cause the outrigger
Figure 64 to move slowly. Pushing it down farther will cause
Extending, jacking, slewing it to move faster. This is known as proportional
control. Continue watching while the outrigger is
For clarity, we will use these terms (Figure 64): moving.
extension and extending mean moving the outrigger
3. Extend the outrigger completely by watching the
horizontally (including the curved Super-X front
alignment arrows (Figure 66) on the front gate.
outriggers); jacking means moving the outrigger leg up
(See the information about shortrigging on page 94
or down; slewing means swinging the outriggers open
of this section.)
or closed from a pivot point (rear outriggers).
pose.2.epsR3.0 L
Figure 65
Watch the outriggers while they are moving
DANGER
Stay clear.
Contact will result in
death or serious injury
if the unit becomes
electrically charged.
WARNING
This machine is
remote controlled
and may start at any
time. Stop engine
before servicing unit.
otrgalin.eps
Figure 66
Front outrigger alignment arrows
pose.3.epsR3.0 L
Figure 67
After the outriggers are extended, center
the cribbing pads
4. If your outrigger will hit an obstruction or obstruct
other traffic by extending it completely, reposition 9. Again, look where the outrigger will be moving,
the unit. and push the outrigger pushbutton as you move the
handle for front outrigger jacking to the extend
5. When the outrigger is completely extended, release position. The outrigger leg will begin to move
the handle, and the handle will spring back to a down. Stop before the steel contacts the cribbing
neutral position. pad.
6. While continuing to depress the outrigger 10. Before jacking the steel pad onto the cribbing pad,
pushbutton, activate the rear outrigger slewing look under the unit (Figure 68) to see that no one
handle to the extend position, and slew the rear has approached the pad on the opposite side of the
outrigger until it is fully extended. truck. When possible, use a spotter. When an
7. Repeat the previous steps on the other side of the outrigger is jacked, the entire unit tips the opposite
unit. direction. This tipping causes the outrigger on the
8. After extending all four outriggers, walk around opposite side to become closer to the ground. The
the unit, centering the cribbing pads under the steel weight and force of this movement could easily
outrigger pads (Figure 67). crush anything that comes between the outrigger
and the ground. Be careful when jacking the
outriggers!
Looking under.eps L
Figure 68
Look at opposite
outrigger before
jacking.
11. When you are sure the area is clear, jack the incline, and the boom will slew by the force of
outrigger pad onto the dunnage pad. Repeat the gravity to the lowest point, which can cause
jacking steps for the other three outriggers. property damage or injury to personnel as well as
12. Bring the unit to within 3˚ of level (Figure 69) by damage to the boom.
observing the level bubble located near the When you have finished jacking the outriggers, the
outrigger controls. Failure to bring the unit within weight should be off of the truck tires, but they should
3˚ of level may result in premature boom brake still be in contact with the ground. There is no reason to
wear or the inability to slew the boom uphill. In lift the entire truck off of the ground. However, in
severe cases, it is possible that the boom brakes extreme cases, one side of the unit may have to be
will not be able to hold the boom on a steep lifted off of the ground to obtain levelling within 3˚.
Figure 69
3˚ = 6 inches of variance per
Max. 3°
each 10 feet of distance
between the widest two 6 inches per 10 feet between points
points of contact with the
ground.
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S 42 SX
Max. 3°
42SX 3 degrees.eps
Job to be
Never slew the boom outside of the grey area. pumped
Figure 70
Shortrigging
shrtrig2.eps
OUTRIGGER ART-pad.EPS
A B
C D
Figure 71
Dos and don’ts of outrigger stabilization
• Do not set the outrigger on uneven soil (Figure When you have finished setting the outriggers, return
71A). If necessary, reposition the unit or level the Vector control local/remote switch to the ‘remote’
the soil. position (Figure 72) and activate the “I” reset switch on
• Do not bridge a hole with outrigger cribbing the remote box.
(Figure 71B). If there is no soil contact over
the hole, the pressure on the ends of the pad is
much greater. The soil could give way or the
cribbing could break.
• Do not set the outrigger on a hill (Figure 71C).
The force of the machine weight must be
transmitted straight down. If you were to set up
as shown in this example, the outrigger load
would be partially down and partially
sideways, putting undue strain on the outrigger
leg.
• If you determine that you need five pieces of
cribbing to support the load but the foot vectorswitch.eps
ratc
het
UP.ep
s
Lock 1. Release lock.
hook.eps
Figure 73
(left) Unlocking the boom tie-down strap;
(right top) boom strap ratchet mechanism.
(right bottom) boom safety hook
;;;;;;;;;;
1. Pull the lock in the direction of the small white Setting up the boom
arrow until it is clear of the ratchet gear (Figure
;;;;;;;;;;
73).
DANGER
2. Pull out and up on the handle in the direction of the
curved arrow until it is positioned straight up. Now Electrocution hazard! Keep boom at
you can pull the strap out of the ratchet assembly. least 17 feet away from electrical wires.
D001.eps
Rele
asin
g
hos
e.ep
sL
Hos
e on
gro
u
nd.e
ps L
Figure 74
Releasing the tip hose
boomout-watch pads.eps
Figure 75
Slowly slew the boom around the unit and watch for outrigger sinking.
D001.eps
the maximum possible concrete pressure that the pump
can generate, so it is imperative that the hose be If you see that the outrigger is sinking into the soil,
capable of handling that pressure. The tip hose immediately slew the boom back to the position it
supplied by Schwing is rated to handle the pressure of came from, and fold it back up. Then, adjust the
the pump when the hose is new, but the pressure rating amount of dunnage under the cribbing pads until you
must be lowered as wear dictates. When the original tip have enough soil contact to hold the unit without
hose becomes worn, replace it with a tip hose of like sinking. Repeat the procedure for the other outriggers.
pressure rating and end type. Do not use the hose if the The stability of the unit must be ensured. Each time
steel braids are showing inside or out. Small pieces of you switch between operation of the boom and
braid showing through on the outside could be a operation of the outriggers, you must reselect the
puncture hazard to anyone coming in contact with it. correct switch position with the local / remote switch
The clamp and rubber gasket on the tip hose must be in (Figure 76) on the Vector controller (local for
like-new condition and should be free of old concrete outriggers and remote for controlling the boom with
buildup, as should the elbow at the end of the tip the remote box), and then activate the appropriate “I”
section. The raised end must be free of concrete. Check reset switch to regain control in either mode.
this on a daily basis. Be sure that the pin that keeps the
clamp closed is in place and in good condition. The
safety cable that is bolted to the end of the boom must
be secured to the tip hose on the supplied ring.
Remember, this hose will be hanging over workers. Be
absolutely certain that all components are safely Figure 76
attached and in excellent shape. Local/Remote
Switch on
After the tip hose has been released, continue to extend Vector controller
the boom. Before you extend the boom over the pour,
however, always test the stability of the unit. Unfold
the boom, and slowly slew to the side until it is
positioned directly over an outrigger (Figure 75). vectorswitch.eps
Hanging extra system from the boom If you will be removing the supplied tip hose and
replacing it with a combination of reducers and hoses,
Concrete weighs about 150 pounds per cubic foot, so you must pay close attention to the overall weight that
the total weight of the supplied tip hose and the the boom will lift. The entire assembly you attach must
concrete inside is 376 pounds. This is the total weight not exceed 376 pounds, including the weight of the
allowed to be hung from the boom. concrete. Exceeding this weight limit will cause the
metal in the boom to fatigue and can lead to cracks. All
pieces that hang from the boom must be in like-new
WARNING condition and must be securely clamped and pinned.
Safety cables or whipchecks must be used on each
Boom cracking hazard. Do not hang piece. The illustration below (Figure 77) is a typical
more than 376 pounds from the end of reducer/hose combination.
000068.eps
the boom.
Figure 77
Example of adapter/reducer/hose combination with weights
T
0
I
waterpumpswtch.eps vectorswitch.eps
• Clear the unit’s decks and walkways of debris • If you will be using portland cement and water
and ice or snow to prevent tripping and falling. to make your lubricating slurry, prepare for
that by positioning your barrel, shovel, and
• If the air temperature is above freezing, place
sack of portland cement on the ground behind
your water hose in a position where it will be
your hopper. Fill your barrel with 25 or 30
out of the way but still handy for washing
gallons of water (Figure 79). You can skip this
pipes and clamps and spraying down the
step if slurry will be delivered to you from the
hopper. If it is below freezing, keep the hose in
ready-mix company or if you are using
the heated cab until needed.
commercial slurry mix (slick pack).
• When using the hard wire control box, position
your remote box and cable in a place where it
won’t be in the way but where you will be able
to move around freely with it once the pour
begins. It is critical to be able to see the point
of discharge once the pour begins. If this is not
possible, arrange for a spotter at this time.
• Get your breathing mask ready for mixing the
slurry. Have all of your personal protective
devices on or nearby.
• Be sure the cleanout door is closed tightly.
• Fill your waterbox with water if it is not
already full. Secure the controls so no one can
turn it on without your knowledge.
Spraying water into barrel.eps
WARNING
Crushing/amputation hazard. Disable the
hydraulic system before removing
waterbox guards.
W007.eps
Figure 79
• To supply water to the water hose, you must Spray 25 or 30 gallons of water into
turn the quarter turn supply valve, which is the barrel
located near the operator’s access ladder. The
Shoveling.eps L
Figure 80
Put a couple of shovelfuls of sand in
the bottom of the hopper, over the
cleanout door.
1, 2, 3, 4, 5
zerks.eps L
Figure 81
Locations of the six Rock Valve greasing points (1–5, 7) and the
two agitator grease points (6, 8)
• Once again, if your unit is equipped with auto- functioning properly and to not check it on a
lube, greasing will be accomplished regular basis. If a port plugs or a pump stops
automatically. You will, however, need to set functioning, that particular grease point will
the proper times for each grease feeder by not receive any grease until you repair the
adjusting the timer settings in the cab. The problem.
timers are usually mounted on the top of the • You can keep your hopper and splash guard
doghouse between the seats. looking better and help yourself at cleanout
• The boom turret bearings must be greased time by spraying them with a release agent
daily. The auto-lube also takes care of that for before the pour begins. Schwing recommends
you automatically, but it is important for you to a product called Kleen Kote. This product is
check the grease tubs daily and to make certain specifically formulated to prevent concrete
that each grease point is actually receiving from sticking to forms. It also prevents
grease. The biggest drawback of the auto-lube concrete from sticking to any other surface.
system is the temptation to assume that it is Areas such as the tapered bend and elbows and
the back side of the outrigger beams are portland, and do not set like cement. If you use these
especially vulnerable to splashing concrete and products, pay close attention to the instructions and
should be sprayed. This will save you a warnings on the package.
considerable amount of time during your If you only have portland cement for lubricating your
cleanout process. pipeline, your options are mixing in a barrel or mixing
Be aware that release agents make for slippery footing, in the hopper, based on the job situation. Before you
so do not spray it directly on walking surfaces, and do begin to mix the slurry, put on your breathing mask and
not walk on surfaces that have been sprayed. If you do the rest of your personal protection equipment.
get over spray on a walking surface, clean it off
NOTE!
immediately.
Portland cement contains toxic chemicals.
Kleen Kote is a 100% water soluble formula used in Always wear your breathing mask and all
place of form oil or diesel fuel. It deposits a thin film other personal protective equipment when
that concrete, asphalt, dirt, or other debris will not stick mixing slurry.
to. Kleen Kote is environmentally safe and does not If you have a helper assigned to work at the pump, you
contain solvents, phosphates, or silicones. This product can mix the slurry in a barrel. This mixing method will
is biologically safe for use on all surfaces. Additionally, help you get good consistency and break up clumps of
Kleen Kote has an added rust inhibitor and is an cement that form in the slurry. However, you’ll need to
effective release alternative when diesel fuel and oils lift the barrel, which weighs 200 to 300 pounds, to pour
are not acceptable. This product is a non-hazardous the slurry into the hopper. Do not attempt to lift this
material and meets or exceeds all OSHA standards on barrel alone.
the MSDS Material Hazard Evaluation. Schwing is an To mix the slurry in a barrel, fill the barrel with about
authorized dealer of Kleen Kote which can be ordered 25 gallons of water. Lay a sack of portland cement on
in concentrate through the Spare Parts Department at top of the barrel. Break open the sack with a shovel
(0049) 2325-987-0. blade, and allow the cement to fall into the barrel
(Figure 82). When the bag is empty, set it off to the side
Lubricating the Pipeline and mix the cement and water with the shovel blade.
Break up any cement clumps and continue mixing until
When the ready-mix truck(s) arrive on the job, you can the mixture is smooth and creamy. Along with your
lubricate your pipeline. Schwing highly helper, pour the mixture into the hopper.
recommends that you prelubricate the boom or
separately laid pipeline each time you must pump into Make one barrel of slurry mix for each 100 feet of
dry pipe. In some parts of the United States and boom or separately laid pipeline that the concrete will
Canada, the concrete is so rich with cement fines that enter. Using the barrel method, you can add a little
operators do not prelubricate before beginning sand, if needed, to stretch the amount of slurry mixed.
pumping operations. This practice is not This would be helpful if you had to pump through 250
recommended. The amount of time you save by not feet of line and had only two sacks of cement. If you
prelubricating is far less than the time you’ll spend will be going through more than 200 feet of pipe
removing pipe sections from a separately laid pipeline however, arrangements should be made to have a grout
or, worse yet, removing the boom pipeline to unplug a mixture brought to you by the ready-mix plant.
rock jam caused by dry pipe. Most importantly, the If you have no one to help you lift the barrel, lay the
blockages caused by failure to lubricate can be sack of cement on the hopper grate, and break it open.
dangerous.
There are commercial products (slick packs) that will
lubricate a pipeline. These products usually come in WARNING
sandwich-size plastic bags and lubricate about 100 feet
Amputation/crushing hazard. Never
of 5-inch pipe per bag. Instructions for mixing vary by stand on hopper grate.
W013.eps
Stirring cement.eps L
Lifting barrel.eps L
;;;;;
;;;;;
;;;;;
;;;;;
;;;;;
;;;;;
;;;;;
Figure 82
Mixing the slurry in a barrel
Direct the spray of the water hose into the hopper, When enough slurry has been placed in the hopper to
aiming at the edge of the pile of cement. This will wash meet your lubrication requirements, back the first
the cement into the bottom of the valve housing. Try to ready-mix truck up to your hopper.
break up clumps of cement with the spray, but do not
put your hands or anything else into the hopper. Mix
enough slurry to lubricate the entire pipeline. When all WARNING
the cement has been washed to the bottom, cycle the
pump in reverse using the Rock Valve to blend the
portland and water. Do not put the pump in forward warn
.eps
bkup
until you have concrete to push the slurry into the open
cylinder and through the boom.
W002.eps
slurry is pushed into the open cylinder, you can put
the pump switch in the forward mode and begin
pumping.
4. Pump slowly (about 15 strokes per minute), and By putting the pump into reverse for several strokes,
watch the concrete pump circuit pressure gauge you release the pressure on the blockage. Understand
until the slurry starts to escape from the pipe or the safety rules for opening a blocked pipe as shown in
hose or the pump starts to pressure out (pressure the Safety Manual, which is a separate section of this
gauge approaches 300 bar). document.
5. If the pump does start to pressure out before The previous steps apply only to concrete passing
concrete is through the boom, immediately switch through the boom. If the blockage occurs in the slick
the pump to “reverse” mode, and notify the ready- line beyond the boom, the blockage most likely will
mix driver to stop dumping. Give the unit several not be freed by rocking back and forth, because you
strokes in reverse, then go back to forward. This need the assistance of gravity for that procedure to
“rocking” action will often pull a rock jam or work effectively. Once the concrete has passed the end
blockage from an elbow and reconfigure it enough of the boom, the blockage will need to be removed
to let it go through on the next attempt. If the from the pipeline manually.
concrete continues to slide without high pressure, 7. After concrete has emerged from the point of
continue pumping. discharge, stop pumping.
6. If pressure again rises toward the relief setting,
repeat the reverse cycle, but this time double the
number of strokes in reverse. That action might WARNING
cause the hopper to fill up and run concrete on the
ground, but if it causes the blockage to come free, Falling concrete hazard. Install a
it may save you from going through the slow blanking plug before swinging boom
process of breaking boom pipeline sections apart.
W014.eps
over workers or property.
This procedure works well if the boom is in the ‘A’
frame position (two sections up and two sections
down), because when you place the pump in 8. If you are pumping directly out of the boom, swing
reverse, you create a vacuum in the line. The the boom into the starting position, as directed by
combination of pump suction and gravity the hose handler or the concrete foreman. If you
sometimes works to pull the rock jam blockage will be moving the boom, which is now full of
loose; then when you push it through the highest concrete, over workers or property, attach the
set of elbows, gravity again will help by letting the blanking plug to the tip hose and secure it with the
separated rock free fall through the next two safety cable, or suck a ball into the tip hose by
sections and tip hose. Sometimes the plug will not putting the pump in reverse. Prevent the ball from
break loose, and you will need to find the source of falling out by putting the retainer pin in place
the blockage and remove it manually. before you move the boom. Be sure that the
blanking plug or ball and retainer are removed as
soon as the boom is in position.
9. If you are pumping into a slickline, wait for the
start signal before you begin to pour.
P
T
MG
P s
G .ep
jst
• The stroke limiter has an adjustment range of MY Y str
ka
cylinders.
original position and is no longer structurally sound.
Concrete must always cover the openings of the Wash the pipes, clamps, and gaskets with water as the
material cylinders or you will suck air into the pump. If day progresses and the crew removes pipe sections
this happens, concrete will blow back as compressed from the end of the slickline (Figure 86). If you do not
air escapes on the next shift of the Rock Valve. This wash the pipe sections until the pour is finished, you
can be dangerous, so warn the ready-mix driver to will not be able to get the hardened concrete out of
clear the area. If air has entered the material cylinders, them. This job can be done between loads of concrete
you can cushion the expulsion by stopping the concrete or by an oiler or laborer at almost any time. To
pump and filling the hopper with concrete before the conserve your water supply, you should ask to use the
next stroke. The mass of the concrete will prevent the ready-mix drivers’ water to wash out the pipe sections.
compressed air from pushing material out of the Washing Slick Line
Boom Bounce of level, and if possible have all of the unit’s tires in
contact with the ground after setting the outriggers. It is
vital that the outriggers are bearing the entire load but
that the tires are lightly touching the ground. The
friction created will prevent the chassis from swaying
when the Rock Valve shifts. Once you have set the
pump up properly, you must then put the boom in a
Distance "X"
A favorable position as shown in Figure 87. The reason
that example “B” has more boom bounce than example
“A” is due to vertical support at the pivots. This vertical
support is the same reason that houses have pitched
roofs and indoor stadiums have domes instead of flat
bmbounce.eps
roofs.
If the boom is still bouncing more than you prefer, the
only option you have left is to change the speed of the
Distance "X" concrete through the use of the stroke limiter.
B
Time constraints
Always keep the hopper at least half full, so if you
have trouble you will still be able to stroke the pump
Figure 87 periodically. If any problem arises with the unit while it
Two positions of the boom that result in the is pumping, you have just 15 to 30 minutes to solve it
same end hose location (Example “B” before the concrete will begin to set and possibly less
multiplies boom bounce) time than that if the temperature is extreme. You will
have less time with old concrete on a hot day and more
All booms bounce. A steady boom is one that simply time with fresh concrete on a cool, cloudy day. If you
doesn’t multiply its natural flex forces but, rather, know you will need more time, clean out before you
works against them. begin repairs. If the concrete is beginning to set, you
will have to clean out quickly and efficiently. Special
Every boom model has a “natural resonant frequency”
instructions for quick cleanout begin on page 124 of
that determines how it will perform under certain
this section. Keep moving, and you will usually be able
pumping conditions. Engineers can determine that a
to get the boom cleaned out. Old concrete and hot days
boom has an unsuitable resonant frequency for a
make for the worst conditions, in which the concrete
certain application after the fact, but predicting it in the
sets extremely quickly. This is called flashing, and if it
design stage is nearly impossible. Severe boom bounce
happens, you may lose some pipe.
is caused by taking the natural stiffening and relaxing
motion of the boom during the stroking of the pump
Cold weather pumping
and multiplying it. For example, when a stroke is
finished and the concrete valve is switching, the boom When you pump in very cold conditions (below 10°F),
relaxes with a downward droop. The worst case the concrete can freeze quickly. During a delay, the
scenario would be to repressurize the concrete as it machine might act like the concrete has set, but this is
reaches the limit of the droop and begins to “bounce” not necessarily the case. If your boom is not insulated,
upwards. When that happens, the natural spring of the the concrete may be frozen. As long as the concrete is
boom and the stiffening action of pressurizing the frozen, it cannot set. If this happens, you will be
concrete will work together to multiply the upward finished pumping for the day. If the concrete is frozen,
force. you may not be able to clean out the boom at the job
site, unless there is a heated area where you can move
To avoid these problems, some precautions must be
the pump for cleanout. If there is not, inform site
taken during setup. First you should make certain that
management and your company, gather up your things,
you have set up the pump on stable ground, within 3˚
and find a heated area to cleanout.
Figure 88
Concrete shut-off valves (left) and
blanking plug with safety cable (right)
and slowly pump the concrete from your hopper, Another thing you need to consider is the age of the
through the boom, and back into the hopper. If the concrete in the ready-mix trucks. If you have three or
concrete gets stiff while you are pumping, add water to four trucks lined up behind the pump and they have
the hopper. A word of caution: the concrete will been waiting with you, their concrete is also setting.
eventually set up regardless of what you do, unless you Let’s assume that you have been waiting for 45 minutes
add so much water that it will never be able to set. In while a form is being repaired. The ready-mix plant is
this case, it will be difficult to pump and will tend to 25 minutes from the job. A driver waited, on the job, to
segregate. This type of concrete cannot be used in the get to your pump for 35 minutes before the form broke.
pour. Put it on the ground when fresh concrete does His concrete is now an hour and 45 minutes old. If it is
arrive. If you have to wait so long that you reach this a hot day, you are risking a “boom party” by pumping
point, it is better to clean out and start over when fresh his concrete. Only you can make this call.
concrete arrives. If you are waiting while concrete is
Keep the waterbox full
Remember to check the water in the waterbox
regularly. The water is very important for cooling the
differential cylinders and for lubricating the rubber
rams.
WARNING
Crushing/amputation hazard. Disable the
hydraulic system before removing
waterbox guards.
W007.eps
Using the vibrator
If you are pouring stiff concrete that is not flowing well
through the hopper grate, turn on your vibrator. The
vibrator helps low-slump concrete fall through the
hopper grate by shaking the hopper itself or the grate.
truck.back view.epsR
If you didn’t buy a vibrator with your unit, you can
Figure 89 purchase one for field retrofit by calling Schwing Spare
Rotate the boom to the hopper to Parts Department at (0049)2325-987-0.
circulate the concrete
Keep the hopper grate in place
available, you can stroke the pump for a longer time
because the ready-mix truck can fill your hopper. If you WARNING
cannot dump concrete to the ground or into the form, or
if you must wait more than 20 minutes, many ready- Amputation/crushing hazard. Keep
mix drivers will allow you to turn the boom around so hopper grate in place during operation
you can pump the hopper out into their truck while the
W015.eps
and cleaning.
drum is charging. Stop the pump before exposing an
open cylinder and have them mix your old concrete Under no circumstances should you operate the
with the fresh concrete in the truck, then discharge the machine when the grate is not in place. If your grate is
drum and refill your hopper with fresh concrete. If the in place, it will catch all manner of troublesome
concrete begins to set while it is being pumped, you objects: mixer fins, clumps of unmixed cement, cats,
have only minutes to get the machine cleaned out. dogs, rebar, golf clubs, tools of all sorts, and more. If
any of these items were to enter your hopper, it would
be capable of causing a blockage, which is always strike the outside of the hose with the hammer.
dangerous. When operating your unit, always keep Again, do not damage the hose by striking it so
the grate over the hopper. hard that the steel braids inside get permanently
disfigured.
Disassembling pipeline to remove 5. After the blockage has been removed, clean up the
blockages clamp, gasket, and pipe end with a rag. If you must
If you have a blockage in your pipeline that you cannot wipe off the concrete with your hands, be sure to
remove by the backward/forward rocking motion wear gloves. If you have no gloves, be sure to rinse
described in step 5 on page 107, you will have to your hands immediately afterwards. Re-assemble
disassemble the pipeline to find it. You will almost the pieces, and pin the clamps if they will hang
always find the blockage in a reducer, hose, or elbow, overhead.
unless one of the delivery pipes has a hole in it or one 6. Return to the pump, and start pumping in forward
of the clamps has a bad gasket. again, slowly at first, until you are sure that there
are no more blockages. If you encounter another
blockage, remember to relieve the pressure again
WARNING by pumping in reverse for several strokes before
Expulsion hazard. Never open a
looking for the remaining blockages.
pressurized pipeline.
W002.eps
Balance load
Follow these steps to disassemble the pipeline: At the end of the pour, it is an unfortunate fact of
concrete pumping that you will often have to wait for a
1. Pump in reverse for several strokes to relieve
“balance load” of concrete to arrive at your job site.
pressure in the pipeline.
The balance load becomes necessary at the end of a
2. Use your hammer to locate the blockage by pour because the contractor is very seldom able to be
tapping the pipeline. (“Tapping” is a key word exact on his original order. The balance load usually
here. You can damage the pipe by striking it hard.) arrives late in the day, which gives you time to prepare
A pipeline that has been relieved sounds different for cleanout and to stow pipeline, clamps, and other
when tapped than a pipe that is pressurized. An equipment. This waiting time has one disadvantage
empty pipe has a definite reverberating “tong” however, in that the concrete in your machine will be
sound. A full pipe without pressure has a meaty getting old by the time the balance load arrives. This is
“thak” sound, and a pressurized pipe full of the most dangerous time for concrete setting in the
concrete has a thin “tik” sound because the forces machine. Be aware of this, and take any steps
on the steel do not allow the pipe to vibrate. necessary to keep the concrete alive. Clean out if you
Consider tapping your pipeline in each of these must, but remember that if you do and the balance load
configurations when there is no blockage, just to is very small, you may have only enough concrete to
become familiar with each sound. refill the hopper, material cylinders, and pipeline
3. After locating the blockage, carefully remove the without ever delivering concrete to the form. When the
clamps from the blocked pieces. If you are not balance load arrives, it is usually fresh concrete. That
wearing a full face shield, turn away from the means that if you pump at least 1 yard, your machine
clamp as you pull the handle. If you have relieved will be filled with fresh concrete for cleanout, which is
pressure by stroking in reverse, there should be no to your advantage. If it is a hot day and the balance
pressure, but some blockages can store pressure if load is less than a yard, you will not be able to get fresh
there is another blockage upstream or down concrete all the way through the boom when you pump
stream. After the clamps have been removed and the balance load, so the concrete that is in the end of
concrete is flowing from the force of gravity, the the boom for cleaning is as old as the next-to-last load.
danger of excessive pressure is past. With old concrete, it is imperative that the boom be
4. Displace the blocked piece enough so that you can cleaned immediately upon finishing the pour.
push a piece of rebar or another long poking device
into it. If the blockage is in a hose, it will help to
Figure 90
Positioning the boom for sucking the ball through the pipeline
Figure 91
Sucking the ball back 000183.eps
Set the stroke limiter to 50% or less before trying to the pump into reverse mode. The ball will be sucked
suck the ball back, because if the ball is brought back into the end of the pipe or hose. Continue pumping in
through the boom too quickly, it is possible to distort reverse.
the shape of the soft ball and not clean the boom as Position yourself on the deck of the pump, just forward
efficiently as when it comes through at a slower, steady of the hopper (Figure 92). Have the remote control box
pace. handy. When you hear the sound of the concrete falling
When the concrete has stopped dropping out of the through the #1 section pipeline and tower, start tapping
boom, walk to the end of the boom with the remote lightly on the pipeline. When the sound of the taps
control box and the sponge ball. Hold the cleanout changes from a “thak” sound to a “tong” sound, the
sponge ball up to the end of the delivery system with pipe is empty to your location. Give the pump one
the palm of your hand positioned flat (Figure 91). Put more stroke, which should bring the ball through the
reducer and into the reducing elbow; then shut the
pump off.
tapping pipe.eps L
Figure 92
Locate the cleanout ball by
tapping the deck pipe.
45turret.epsL
Figure 94
Boom slew alignment arrows
;;;;;;;;;;
box and the radio remote, as well as inside the
DANGER Vector controller itself. The device is a yellow,
adhesive backed sponge, about two inches high and
Electrocution hazard! Keep boom at two inches wide. It will require replacement every
least 17 feet away from electrical wires. two years. The maintenance schedule is detailed in
D001.eps
000240.eps
000241.eps
Figure 96 Figure 97
Parts identification for cleanout Remove the hairpin
000242.eps
000243.eps
Figure 98
Remove and store the wedge
Remove the hairpin, which is attached to a chain, from Knock the wedge from the pin on the tapered bend, and
the wedge (Figure 97) as well as the hairpin from the 6- store it in the wedge holder on the back of the hopper
inch clamp, and place the hairpin where you will be (Figure 98).
able to find it easily again. Remove the clamp (Figure
96) between the tapered bend and the first elbow or the
clamp between the 6-inch elbow and the reducer.
W011.eps
Tap on the “T” handle that opens the cleanout door on
the bottom of the hopper with your hammer (Figure
Swing the tapered bend open. Do not put your hands 99). When the door opens, the concrete at the bottom of
into the outlet pipe under any circumstances. If your the hopper should fall out. If it doesn’t, turn the pump
cleanout ball is inside the outlet pipe, it will get to the neutral, or “off,” position.
pumped out in the following procedure. Move out of
Aim your hammer upward and pound any material that
the way of the outlet pipe, and put the pump in forward
is lodged in the cleanout door. A couple of taps will
mode. When the tapered bend is open, you don’t have
probably free the material. If not, keep tapping until it
to worry about compressing the air that gets sucked
is free. You can minimize or eliminate this procedure
into the material cylinders, so you can let the machine
by putting sand in the bottom of the Rock Valve
cycle until the hopper is completely empty. Do not let
housing before you begin pumping, as explained
the machine cycle dry for an extended time, because,
earlier.
without concrete for lubrication, the rubber rams and
kidney seal will get hot and eventually be damaged.
Figure 99
Open cleanout door
Spraying hopper.eps L Stop the agitator from turning by centering the agitator
toggle switch on the rear panel (Figure 101). Do not
proceed to the next step until you have done so. You
will be able to visually confirm that the agitator has
stopped by looking in the hopper.
Poke any material that has set in the corners of your
hopper with a metal bar (Figure 102).
Do this procedure quickly, or the concrete may set up
in the Rock Valve and material cylinders. Concrete that
has set in the valve and cylinders is much harder to
remove later than concrete set in the hopper. If any
concrete in the hopper has set completely, you will
need to use a chipping hammer or another power tool
to remove it.
Figure 101 0
Stop agitator by placing
the switch in center HP
P
(neutral) position
agitatorswitch.eps
Figure 100
With the grate in place, clean the
agitator and hopper with water
When washing down the hopper, be sure of your
footing and keep the hopper grate in place (Figure
100). Stand on the tip down clean out step on either
side of the hopper. Spray water into the hopper from
above. Keep the agitator turning only until you have
sprayed the blades clean. Wash the material from the
hopper through the cleanout door on the bottom.
WARNING
Amputation/crushing hazard. Never use
the hopper grate interlock switch as an
ON-OFF switch! Switches can fail. Stop
engine and verify zero pressure in
gratewarn.eps
Figure 102
Remove built-up concrete with a bar
W015.eps
and cleaning.
WARNING
Amputation hazard. Stop pump before
cleaning the Rock Valve and hopper.
W011.eps
sprayOP.eps
Figure 104
Spray out the Rock Valve
and material cylinders.
• Be sure that your rake and everything else is Cleaning the waterbox
out of the valve area; then cycle the machine in
reverse for one more stroke. This will expose
the opposite material cylinder and completely
WARNING
extend its rubber ram. Pull any loose material Crushing/amputation hazard. Disable the
out with the cleanout rake, and then spray out hydraulic system before removing
the material cylinder as in the previous step. waterbox guards.
W007.eps
• By putting the pump in the “reverse” mode,
you are sucking from the direction of the
NOTE!
pipeline (which is not connected during the
The waterbox can now be cleaned and filled
cleanout procedure) and pumping into the without removing the cover. If for some
hopper. Because of this, you may find that you reason your waterbox cover is not securely
now have more material in the bottom of the in place, push the emergency stop button,
hopper, which needs to be rinsed out. which stops the pump and secures it against
unintentional starting. Then replace the
cover before restarting the pump.
To clean the waterbox:
1. Lower the truck RPM to an idle.
2. Leave the waterbox cover in place, open the drain
(Figure 106), and allow the water to flow out the
bottom of the waterbox.
3. When water stops flowing give the unit a few
sprayElb.eps
strokes in either forward or reverse. This will force
the water in the extended cylinder back into the
waterbox and, therefore, out the drain. The
waterbox is empty when no more water flows out
of the drain as the unit is cycled.
4. Close the drain and temporarily open the water
supply valve (Figure 106). Put the pump into
forward or reverse to clean any remaining cement
residue from the rams; then close the supply valve
sprayTB.eps
and open the drain to flush the remaining water
before returning the pump to the “off” position.
Figure 105
5. If you will be refilling the water box immediately
Washing the elbow and tapered bend
to start another pour, simply close the drain and
finish filling the water box.
6. A highly recommended practice is to not fill the
waterbox again until just before the next pour,
because when the water box is refilled immediately
• Spray out the tapered bend, the 6-inch elbow, after being dumped, the oil which is cooling in the
and the bottom of the 6-to-5-inch reducer, differential cylinders contracts and creates a
where the cleanout ball will not have touched vacuum behind the seals. This vacuum will pull
the sides (Figure 105). Pay attention to the flat water and other contaminants past the “v” shaped
surfaces and rubber parts because even small seals into the cylinder and will eventually destroy
pieces of debris will impede reassembly. the seals and score the cylinders.
• Spray off the clamps, gaskets, and wedges. It is especially important to drain the water box
• Close the hopper cleanout door, and reattach completely at the end of the day if the temperature is
the bungy cord, if used. below freezing
CAUTION
Pumpkit damage. Drain water out of
waterbox for transportation or storage in
freezing temperatures.
C003.eps
Waterbox drain
Waterbox supply
valve
wtrboxdrain.eps
Reassembling the unit 2. Replace the clamp between the 6-inch elbow and
To reassemble the concrete valve area, if it is feasible, the tapered bend or reducer. If you’re using the
you should move the truck ahead a few feet so you clamp between the elbow and the tapered bend,
don’t have to stand in the concrete and water left from orient the clamp with the opening on top and the
cleaning out. handle pointing rearward and down; that you may
have easier access when you need to remove it, and
Put the boom into the transport position before moving so it can’t be accidentally opened, as easily, by a
the unit even a few inches. mixer truck. You may have to tap the clamp with
your hammer to make it seat fully. This is normal
WARNING and ensures that you have a tight connection.
3. Replace the hairpins of the wedge and clamp.
Tipping/collision hazard. Do not move
the unit with the boom or outriggers
Be careful with acid
W016.eps
extended.
Do not drive for any distance with the concrete valve CAUTION
area still unassembled. It may be dangerous if the
tapered bend is swinging on its hinge while driving. In Chrome and rubber seal damage. Be very
careful when using aggressive cleaners
addition, the bumps, shaking, and turning forces may
Caution.eps
Preparing for travel Begin by attempting to clean the boom. If the ball will
To prepare your unit for travel: not come back, move to the hopper before dealing with
the boom.
1. Securely store your cleanout rake, sponge ball,
grease gun, hammer, shovel, and other accessories. Dump the hopper and material cylinders, and rake out
the bulk of the material from the concrete valve. If the
2. If you have been using the hard wire controls,
concrete is setting, don’t worry about getting each part
unhook your remote cable, and coil it neatly. Never
perfectly clean before moving on to the next area.
drive the unit with the remote box still attached to
When you have washed the bulk of the concrete from a
the pump. Store the cable and the control box in
component, the concrete will be thinned enough that it
the outside tool box of the truck. If you have been
will not set completely.
using the radio remote, it should also be placed in
one of the outside tool boxes. In the past we have If you were not able to suck the ball through the boom
advised storage of the box in the cab, but we have because the setting action was too far advanced, you
found that with extreme temperature changes, may be able to save some pipes and elbows by
condensation inside the box can cause internal disconnecting the elbows from each straight section.
corrosion, which can then cause electronic The elbows can be cleaned out by hand, and sometimes
component failure. For this reason, Schwing now straight sections of pipe will empty themselves by the
installs corrosion inhibitors in all locations that force of gravity, providing that the concrete doesn’t
contain an electronic circuit board. have to flow through an elbow. Use the boom to put the
straight sections of pipe in a vertical position after the
3. Before leaving the job, check to be sure that your
elbows are removed. Make sure that no one is standing
outriggers are closed and pinned, that your boom is
under the boom before raising or lowering, and don’t
secure in the cradle, and that the tie-down strap is
forget to watch for electrical wires or other
attached and tightened.
obstructions.
4. If you were collecting concrete delivery tickets on
your job, remember to give them to the concrete Do not use compressed air to clean single sections of
supervisor when you present your job ticket for pipe, because the concrete may develop very high
signing. velocity due to the relatively small mass. When the ball
or go devil exits the pipe under these conditions, it may
5. Before you get into the cab to drive, take a walk cause injury or property damage. Do not attempt to
around the truck. Look for items you may be remove sections of pipe from the boom by yourself if
forgetting, look under the unit for personnel and they are full of concrete. They will weigh more than
obstructions, and check the truck tires for air one person can safely handle alone.
pressure, as well as for anything that may be
protruding from them as a result of driving on the After the boom is clean, the remainder of the material
job site. Many driving accidents happen on the way in the hopper and valve can be chipped out if it will not
back to the shop after a job or on the way to a wash clean. Be sure to disable the hydraulic system on
second job. Think about your route, bearing in the unit by stopping the engine, putting the key in your
mind the time of day, road construction, and other pocket, putting a “Do Not Operate” tag on the ignition
factors. You want to begin driving with a fresh switch before entering the valve/hopper area for
attitude and a clear head. chipping.
After you have cleaned as much as possible, it may still
be worth while to try using a pressure washer to clean
Special Pumping Situations any unfinished components. If you know the location
of a pressure washer, drive there directly after leaving
Hurry up cleanout the job. Spraying concrete with a pressure washer
If concrete is setting up in your machine, you must usually results in sand, cement, and small rocks being
clean out in a hurry. Accidents happen when you panic, sent into the air as the water jet hits them, so do not
however, so remember to follow the safety rules as you attempt this procedure without wearing safety glasses
are working. Stay calm, and work as quickly as you can and, preferably, a full face shield.
without skipping any safety measures.
Moving the pump during a pour stretched out over another area that must be protected
If you have to move the pump during the pour, time from falling concrete, you may have to cap the hose
will be of the essence. If help is available, use it. with a blanking plug and fold it while it is still full of
Circulate the concrete, if possible, and add water to it. concrete. To fold up in this situation, you must be sure
that the concrete is fresh enough to remain stable
Fold up the boom after letting # 3 and #4 drain out in during your move. Because of the weight of the
the vertical position. Take a few strokes in reverse to concrete in the pipeline, the boom may have a hard
pull some of the concrete in #2 back toward the hopper. time pulling section #4 into section #3, as well as #3
Cap the tip hose with the blanking plug. If you don’t into #2. You can leave each section straight up until the
have a blanking plug, suck the cleanout ball several next section is fully retracted. As soon as sections #3
strokes into the boom and install a retainer pin, so you and #4 are in all the way against #2, you can fold up as
don’t drop any remaining concrete on personnel, normal. Leave the cap on the tip hose until you are
equipment, or your truck. extended again or at least until you can find a place
If the concrete is old, if temperatures are extreme, or if near the pump where it can be removed safely and the
you have to move a long distance, clean out the boom concrete allowed to drain out while the boom is in the
before moving. Position the boom in the “A” frame “A” frame position.
configuration, and suck the ball back according to the When you fold the boom for transport, bring it into a
instructions on page 114. Continue to stroke in reverse position that will allow the tip hose to catch in the
until the ball clears the deck pipe, take one more stoke, holding brackets (Figure 107). This position is reached
then stop the pump and quickly fold up the boom. when section #4 is retracted into section #3 and section
In some cases you may be forced to move without #3 is being brought into section #2.
being able to drain the boom of excess concrete. If, for
instance, you are pouring a deck with the boom
Figure 107
Seating the tip hose during boom foldup
If the boom is full of concrete and you have section #2 into a position that will allow you to physically reach
straight up and down while you are retracting section the fourth section and actually lift the tip hose into the
#3, the unit must be level for the hose to seat in the bracket assembly, where you can be certain that it is
holders. If it does not, you will have to put the boom locked into position inside the holders (Figure 108).
#2 section
#4 section
#3 section
Figure 108
Boom positioned to lock the tip hose into the holders
Once the boom is folded up, reposition the local/ When the unit is ready to move, bring the engine RPM
remote switch to the “local” position. Hold down the down to an idle, and take a look around before getting
outrigger pushbutton, and retract the outrigger pads in the cab. Be sure you have your shovel and barrel
from the cribbing. Have your assistant load the loaded, your remote box and cable stowed on the unit,
cribbing on the pump while you continue retracting the and the concrete tickets (if they are going to stay with
outriggers. If you will be moving only on the you). Generally, just make sure that you really are
construction site at low speeds, you can just lay the ready to move before you get into the cab.
cribbing on the truck. If you will be moving at higher
speeds or moving onto a public roadway at any time,
all loose items will have to be secured for travel. Be
sure that all outrigger pins are placed into the travel WARNING
position. Securing the unit for high speed or public
roadway travel will take considerably more time, so Tipping/collision hazard. Do not move
suck a cleanout ball through the boom and consider the unit with the boom or outriggers
W016.eps
whether or not you should also wash out the hopper extended.
and material cylinders. Remember, concrete is liquid
stone. If conditions are favorable for the concrete to
set, you will be much better off just cleaning out and
starting over when you have repositioned the machine. When you get into the cab, push in the clutch, take the
transmission out of gear, push in the PTO pull switch,
and be sure that the warning lamp in the dash goes off.
Listen for the telltale “clunk” that reveals whether the • If it is very cold, concrete can freeze in the
PTO has actually come out of gear. If you don’t hear boom while you are pumping.
the sound, make sure that you first attempt to move the • Concrete freezes in the hopper.
truck in a forward gear, because reverse will damage • The concrete may contain calcium chloride or
the hydraulic system if the PTO is still engaged. If you an equivalent accelerator which allows the
cannot get the PTO to respond to the pull switch, concrete to set before it freezes. This
instructions on getting it in and out of gear without the accelerates setting in much the same manner
air system can be obtained from Schwing that a hot day does.
Service Department.
• Anything you wash with water becomes coated
Remember to release the brake before you try to move. with ice, which will not melt and evaporate
When you arrive at the new setup spot, set your parking until the temperature rises above freezing.
brake, and get out of the cab to check over the new spot • Machine parts that you sometimes stand on or
for soil conditions, overhead power lines, obstructions, grasp with your hands become very slippery if
etc., just like you did for the original setup spot. If they contact any water.
something is not safe and you will need time to get the Some of these potential problems can be solved or
spot ready or find a new spot, finish cleaning out first. tolerated, while others cannot. The concrete will
Do not ignore safe procedure and common sense so usually be mixed using very hot water to keep the
that you can get back to pumping before the concrete from freezing during the delivery and waiting
concrete sets in the machine. On the other hand, it period.
doesn’t make sense to let the concrete set in the
machine while you are arranging for a safe setup spot. Here are some tips for cold-weather pumping:
If in doubt...clean out. 1. In locations that have cold winters, like the
There are many cases where you can fold up the boom northern United States and Canada, store the
and outriggers, move, safely setup, and be pumping machine indoors. If you do not have a heated shop
again in 10 or 15 minutes. Only hot or very cold for the winter, consider renting one.
weather conditions, old concrete, poor conditions for 2. If your unit does not have the optional, water tank
setup at the new location, and long drives make moving heater, do not put water in the water tank or the
without cleaning risky. Experienced operators should waterbox before driving to the job. If possible,
have no trouble recognizing if there is danger of contact the ready-mix company, and arrange for
concrete setting. Your job will be much easier if you the first driver to be loaded with hot water to fill
learn to understand the characteristics of concrete and your waterbox and to mix your slurry. Arrange for
make your decisions based on that knowledge. the last truck to be full of hot water for you to use
during cleanout. Many pump companies have
Cold weather pumping found that, if they insulate the water tank with
It is possible (and routine in some parts of the world) to styrofoam or large insulated construction blankets,
pump concrete with outside temperatures being they can fill the tank with hot water in the morning
subzero. This can present a variety of problems and have it still be warm for clean out. If you do
compared with pumping in moderate temperatures: this, however, you must be sure to keep an eye on
• Water in the water tank and waterbox can the tank for freezing, and leave the hose
freeze while you are driving to the job. disconnected and preferably stored in the heated
cab until clean out time.
• Moisture in the truck air system freezes,
effectively stopping air flow and freezing air- 3. You can prevent moisture in the air system from
operated components, including the PTO. freezing only by removing the moisture from the
• The boom and outrigger hydraulics are slow air. When temperatures are expected to be below
and sluggish to respond to your commands. freezing, drain the water from the air system each
day by opening the drain cock on the bottom of
• Slurry freezes in the boom when you are
each air tank. You should do this procedure at the
starting the pour.
end of the day, preferably in a warm shop. If cold-
weather operation is expected every day, you 9. If the concrete freezes in the hopper, you will also
should consider having an air dryer installed on the be done pumping. Find a warm place to bring the
truck air system. machine, and clean it as it thaws.
4. If you are expecting cold weather for extended 10. At the end of the cleanout procedure, open all drain
periods of time, such as winter in the northern cocks in the water supply system.
United States and Canada, you should change your
oil to a thinner viscosity type, such as an ISO VG Preheating the boom pipeline
32, which will give you a lower pour point. Be You can preheat your boom pipeline to help get the
aware, however, that this oil cannot protect the slurry through without freezing, but there is little you
components to as high a temperature as the can do about a separately laid pipeline that has laid
standard oil shipped with your unit (ISO VG 46). outside over night. In most cases, pours that require a
Another consideration is to preheat the hydraulic separate pipeline laid outside will cancel if it is very
oil before beginning the pour. This will require that cold. If they do not cancel, be certain that any pipeline
you arrive at the job early enough to do the laid outside is covered with insulated blankets and
procedure. Allow 10 or 15 extra minutes to preheat preferably not brought outside until just before the
the oil. pour (less than an hour prior). If not, there is a good
5. If the concrete contains calcium chloride or chance that you will not be able to get concrete through
another accelerator, you will have to keep the the line, because the slurry will freeze against the walls
concrete alive using the same techniques required of the pipe. Then the concrete will have to be pushed
for pumping on hot days. The calcium chloride through the pipe dry. This could result in a blockage
accelerates setting, but if the concrete does freeze, which we call flash freeze. If the motion of the concrete
the setting stops. When you begin to warm the is stopped in a frosted pipe, the heat will radiate from
machine, the concrete will begin to set again, even the concrete so quickly that the entire line can freeze
more quickly than on the job, because you are now completely in a matter of moments. Usually, if this
in a warm area. Do not waste time when cleaning a happens, the pour cannot be completed until the slick
machine under these circumstances. line is replaced, and the concrete sitting on the job will
6. Everything you wash on cold days will then have a be rejected before it can be placed. Many dollars are
layer of ice on it; be very careful when handling lost when this occurs.
these objects. Pipes and clamps could easily injure To preheat the boom pipeline:
you if they slip out of your hands. • Fully extend the outriggers as previously
7. Beware of slippery surfaces when pumping in cold described.
conditions. Don’t stand on ice coated pipes or other • Remove the wedge pin and the clamp from the
round objects. Some operators spray water on tapered bend to make an open path from the tip
decks and steps, allow it to freeze, then put a little hose to the hopper.
concrete on top of the ice for traction. The concrete • Look overhead for electrical wires or other
is easy to wash off when the machine is warmed obstructions.
because of the layer of ice that holds it away from
• Extend the boom and position it so that the tip
the steel. Be sure that you distribute concrete to all
hose slips over the exhaust stack of the truck
areas where you will be walking, if you choose to
engine and the exhaust is blowing into the
use this method.
hose. With an open path to the hopper, the
8. If the concrete does freeze in the boom, you will be exhaust should now travel through the
finished pumping until you have warmed up the pipeline, heating as it goes. Without an open
machine and cleaned out the boom. Fortunately, path, the hot air from the exhaust will be
the concrete will stop setting when it has frozen. forced backward and create excessive back
Once you bring the machine into a warm place, pressure on the engine of the truck.
you should be able to get it clean.
NOTE!
To prevent engine damage, the exhaust must
have a complete path to the hopper!
closed
s
ep
2.
o
its
ag
open
Figure 109
Agitator shutoff valve
To prevent concrete from freezing in the boom while move to the open position. Contact the Schwing
pumping, some companies wrap their boom pipeline Service Department if you have any questions
with insulation. In most cases, the insulation is a regarding installation.
styrofoam tube cut to accommodate the pipeline that is 2. Activate the agitator switch. The agitator will not
placed around the pipe, and taped together. The be able to turn, and the oil will be forced over the
styrofoam holds in the heat of the concrete. relief valve. At an idle (about 600 RPM), 4.5
horsepower is being converted to heat.
Minimum temperature for boom operation
3. When the temperature gauge shows 20˚C or higher,
is -40˚ open the shutoff valve.
Do not operate the boom if the temperature is colder
than -40˚. The material in this boom will become brittle Draining the water system
and likely to crack from normal boom bounce if
operated in temperatures colder than the minimum Drain the water system (when freezing)
temperature allowed for operation. The water pump and related plumbing on Schwing
-40˚ is the same temperature on both the Fahrenheit units may have several drain cocks installed along the
and Celsius scales (-40˚ F = -40˚C). water delivery system. After cleanout, it is very
important that you follow the water delivery line from
Preheating the hydraulic oil the pump to the outlet, open all drain cocks on your
unit, and then activate the water pump to be sure it isn’t
With load-sensing hydraulic systems and pressure cut-
holding water.
off hydraulic pumps, the hydraulic oil can no longer be
heated with the boom hydraulic system or the concrete NOTE!
pump hydraulic system. The agitator circuit must be It will not hurt the Hypro diaphragm pump
used to heat the hydraulic oil. to run it empty. After opening all drain
cocks and activating the pump, you may
To preheat the hydraulic oil, follow these steps: want to run the pump again to be sure all
1. Locate the agitator shutoff valve (Figure 109), and water has been removed.
close it. Note! If your unit does not have a shutoff
valve, you can order one, using part number
10004680 (shutoff valve) and number 30303432
(tube). Install the valve between the agitator hand
valve and the agitator motor. Position it so that if
the handle moves by the force of gravity, it will
Emergency Procedures
Disabling the entire unit in an emergency
If an emergency requires that the hydraulic system be
disabled completely—such as if a hose or fitting
breaks—you must stop the truck engine or at least take
the transmission out of gear. This can be done only
from the cab of the truck, unless you have purchased
the optional remote engine start/stop feature. If you are
faced with an emergency, first shut off the engine or
take the transmission out of gear, then investigate.
Keep one long length of each of the six possible
diameters of hose with the unit for such emergencies.
(For a list of the six hose diameters and the
recommended length of each, see the Appendix section
of this document.)
If there is an electrical malfunction in the E-stop
circuit, the dump valves (in the E-stop manifold) open.
This will route oil from the hydraulic pump directly
back to tank. This also happens when any emergency
stop button is pushed. To continue pumping, you will
have to find out what happened and fix it. If you cannot
find out what has happened within approximately 10
minutes, you will have to take action to prevent the
concrete from setting up or freezing. As discussed
earlier in this manual, the dump valves have a bypass
switch (Figure 110) located on the front wall of the tool
box containing the main controller.
By activating the dump valve bypass switch to the
‘bypass’ position, all electrical control of the unit is
lost. You should, however, be able to fold up the boom
and outriggers with the manual controls, so you can get
to a place where repairs are possible.
WARNING
Loss of emergency stop function.
Emergency stop switches are disabled
when manual override is activated.
W004.eps
BY-PASS Bypass
NORM. BY-PASS
key switch
by-pass2.eps
bypasskey.eps
Figure 110
Boom/Outrigger bypass switch (left)
Location of switch (right)
Do not operate the machine when: guide to their locations is shown in the Safety section of
• A crack or break in a boom, outrigger, or other this operation manual. There is no charge for warning
load-bearing structural member is discovered. labels.
• A guard is missing, damaged, or unusable.
Loss of radio remote signal
Loss of remote control If your radio remote stops functioning and the battery
The remote control box is considered the primary LED is off while the radio on/off switch is in the on
control source for the concrete pump and boom. If you position, the battery is probably dead. Remove the
lose the remote control for any reason, you can still battery from the remote box, and replace it with a fully
finish the job, but you must use extra caution. The charged battery. The dead battery should then be placed
manual control devices are shown in the Product in the charger (Figure 111). The charger is located in
Overview section of this document. Each manual the passenger side tool box which contains the main
control device does what its remote-control counterpart controller and the Omnex receiver (Figure 111).
does, but with less convenience. Get assistance, if
needed. The emergency override handles of hydraulic Disposal of spent batteries
valves are not always positioned at a work platform, so NiCd and NiMH batteries are recyclable. You can help
WATCH YOUR STEP if you need to access them. preserve our environment by returning your unwanted
batteries to the nearest location for collection,
Other Things You Need to Know recycling or proper disposal. Call 1-800-822-8837 toll
free for information about spent battery collection.
Reordering documentation or warning
labels CAUTION
To order replacement labels, operation manuals, safety Battery fluid is toxic. Do not handle
manuals, or any other unit documents, call the Schwing damaged or leaking batteries.
C006.eps
Spare Parts Department.
Have the serial number of the unit from the serial NOTE!
number plate handy when you call. Each safety label Do not dispose of nickel cadmium or nickel
has a part number on it. A complete list of labels and a metal hydride batteries in household or
business trash.
Omnex receiver
Figure 111
Omnex battery charger (left)
and location (right)
Battery charger
vectoromnxrcvr.eps
omnxchrg.eps
WARNING
on
Do not stand
hopper grates.
S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
42SXside.eps
MAINTENANCE
Filtration .................................................................................................. 134
Hydraulic Oils.......................................................................................... 135
Pressure, Hoses, and Fittings................................................................. 136
General Maintenance Tips...................................................................... 138
Maintenance Checklist............................................................................ 140
Daily Maintenance .................................................................................. 141
Weekly Maintenance .............................................................................. 142
Monthly Maintenance.............................................................................. 145
Setting Pressures ................................................................................... 149
Quarterly Maintenance ........................................................................... 159
Semiannual Maintenance ....................................................................... 160
Annual Maintenance ............................................................................... 162
Time-related Maintenance ...................................................................... 169
Unscheduled maintenance ..................................................................... 169
speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 135
Maintenance
recommend ISO VG 46 for the winter and ISO VG 68 Pressure, Hoses, and Fittings
or VG 100 for the summer, depending on how hot it
gets. The lower the ISO VG number, the thinner the oil
General information
is and the lower the pour point of the oil is. On the
other hand, the thinner the oil is, the lower the Most concrete pump hydraulic systems run with fairly
temperature will have to be before it breaks down the high pressures: in the 2000–5000 PSI range. The
lubricating film that protects your components. See the maximum pressure is determined by adjustment of the
chart in the Appendix section of this manual for help in main relief valve, and the machines are designed to
selecting the proper oil for your requirements. handle this pressure safely. Concrete pressure is just a
ratio of the hydraulic pressure.
The quality of the oil needed for use in a Schwing
machine is rated in the DIN system. The ratings have to If you lower the pressure at which the system runs, you
do with the chemical additive package that is can harm the system. For example, you ask the
introduced into the oil. Both the DIN rating HLP and machine to develop 3000 PSI of hydraulic pressure to
HV qualities are approved for use in our machines. push concrete. You want to replace a hydraulic hose
with a less expensive, lower pressure hose, so you
Specific information lower the relief valve setting from 4350 PSI to 2500
PSI. What happens? The concrete still requires 3000
All machines leave the Schwing factory filled with
PSI to get to where you want it to go, but your relief
Rando HD 46 hydraulic oil, which has an ISO viscosity
valve opens at 2500. Now the oil that should be
rating of VG 46. Rando HDZ 46, an extended-viscosity
pushing the concrete is traveling back to tank instead.
oil designed for use under severe conditions, is
All the horsepower it took to send the oil out of the
available on request. If you want your new machine
pumps at 2500 PSI is turned to heat, which boils the
filled with a different brand or different viscosity oil,
oil. The oil in this example loses its lubricating
you should specify it when ordering.
qualities at 80°C, so components begin to wear,
Many other brands of oil have been approved for use in sending debris downstream, which adds to the wear.
Schwing machines, including: The system would be destroyed in minutes if it
• Mobil DTE 25 continued to operate under these conditions.
• Shell Tellus oil If you raise the pressure at which the system runs, you
• BP Energol can also harm the system. Using a new example, the
• Aral Vitam concrete requires that the machine develop 5,200 PSI
• Esso Nuto hydraulic pressure to push it where you need it. Your
machine is factory set to run at a maximum of 5076
• Esso Univis
PSI (single circuit) so you raise the setting of the main
• Total Azolla relief to do the job. The hydraulic pump cannot
• Wintershall Wiolan withstand 5,200 PSI for more than a few minutes, and
The brands listed have been approved; however, any oil it breaks. Now you must replace a pump before you
that meets the quality and viscosity standards described can make another pour.
above can be used. If you leave the machine at the factory specifications,
you will not harm the system. It will give you years of
When to change your hydraulic oil dependable service. This means you should use only
Change your hydraulic oil at least once a year. If you fittings and hoses that have a sufficient working
use good filters and change them when they are dirty, pressure to handle the system requirements. If you take
the oil will be clean even after a year, but the chemical a job that needs more pressure than your machine is
additive packages that give the oil its properties will capable of handling, you should buy or rent a higher
break down with time and no amount of filtration will pressure machine.
bring them back.
TABLE 1
Hose, Fitting, and Tube Sizes, and Equal Connection Sizes
42SXhose/fittings chart.eps
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Operation Manual - S 42 SXG 137
Maintenance
A B
TORQUE/FORCE GRAPHS
Force
Force
Time Time
Figure 112
Effects of proper torque on bolts
x1000 3
Start OFF
Menu: [ENTER]=ON
Figure 114
Static cling tag for the windshield (left) and magnetic tag for the driver side door (right)
The manufacturer includes approved warning devices Store the labels in the glove box for future use.
with all new concrete pumps (Figure 114) and Before restarting the machine after performing
recommends the following procedure prior to maintenance, be sure to put away all tools, parts, and
performing any maintenance in an area of the unit that supplies, and clear the area of personnel.
would normally be guarded:
Concrete pumps are big enough to hide a man. Before
• Stop the truck engine.
starting the unit at any time, yell “Clear!” and allow
• Remove the key, and put it in your pocket. enough time for response before proceeding.
• Put the static cling “DO NOT OPERATE”
label on the inside of the windshield of the
truck. Place it in a location that is obvious to
anyone who enters the truck.
• After you leave the truck cab and close the
door, put the magnetic warning label “DO
NOT OPERATE” over the door handle. In this
way, no one can open the door without being
made aware that you are working on the
machine.
• Perform the needed service on the unit.
• Remove the labels, and reinstall the key.
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Operation Manual - S 42 SXG 139
Maintenance
Item D* W M Q SA A Page
Changing your hydraulic oil filters When fault message is received..............................135
Changing boom oil filter When you change main system filter.......................135
Changing high pressure water filter When you change main system filter.......................135
Check truck fluid levels X ..............................................................................141
Bleed moisture from air tanks X ..............................................................................141
Check truck tires X ..............................................................................141
Check hydraulic fluid X ..............................................................................141
Bleed moisture from hydraulic tank X ..............................................................................141
Check differential cyl. rod packing X ..............................................................................142
Inspect bolts on Rock Valve and rams X ..............................................................................142
Grease rock and agitator bearings X ..............................................................................142
Grease boom bearings and hollow pin X ..............................................................................142
Check the grease tubs of the auto-lube system. X ..............................................................................142
Inspect for damage and leaks X ..............................................................................142
Check if maintenance is due X ..............................................................................142
Grease boom zerks .......X .......................................................................142
Check pipe wall thickness .......X .......................................................................142
Check oil in optional air compressor .......X .......................................................................143
Check Rock Valve tension nut .......X .......................................................................143
Inspect cutting ring and rotate, if needed .......X .......................................................................143
Lubricate mechanical moving parts .......X .......................................................................145
Check tapered bend wedge bolt .......X .......................................................................145
Check boom slewing gearcase level ......... ...... ...X...........................................................145
Clean slewing gearcase breather ......... ... ......X...........................................................145
Check function of mech. boom brake ......... ... ......X...........................................................146
Clean and repack the Rollix gear ......... . ........X...........................................................147
Inspect the turret bolts for tightness ......... . ........X...........................................................147
Check fluid in distribution gearcase ......... . ........X...........................................................149
Check unit mounting hardware ......... . ........X...........................................................149
Check hydraulic pressures ......... . ........X...........................................................149
Clean oil cooler fins ......... . ........X...........................................................159
Check drive pinion bolts ................... .........X .................................................159
Change oil in optional compressor ................... .........X .................................................159
Change oil for temperature reasons ................... .................. X .......................................159
Change oil in distribution gearcase ................... .........Δ ...... ..........X............................ .160
Change oil in boom slewing gearcase ............................. ........ X....... ................................160
Test the dirty filter warning circuit ................... .................. X .......................................161
Change oil for age reasons ...................................... ......... X..............................169
Complete cleaning of optional compressor ...................................... ......... X..............................169
Inspect boom, outriggers, and tower Changes with unit age .............................................169
Change corrosion inhibitors ...................................... ......... X..............................169
Figure 116
Hydraulic oil level indicator
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Operation Manual - S 42 SXG 141
Maintenance
• Check the differential cylinder rod • Visually inspect the unit for damage or leaks
packings. The waterbox is fitted with a bolt- each day. Repairs should be made before the
down grate under the waterbox covers. To unit is operated.
check for rod packing wear, fill the waterbox • Once a day, check your maintenance
with water above the level of the differential checklist to see if any weekly, monthly,
cylinder rods (if no guards are installed) or semiannual, or annual maintenance is due.
above the bolt-down guards (if installed). Let it
sit for a few minutes. If oil begins to float to the If the auto-lube is not functioning:
top of the water, the rod packings are worn. • grease the Rock Valve and agitator bearings
Remember to let the water out after the check, as described in the Operation section of this
especially if freezing temperatures are manual.
expected. Failure to replace the rod packings • Grease the boom Rollix bearings and hollow
when they need it will result in contaminants pin as described in the Operation section of the
from the waterbox, including water, entering manual.
the hydraulic oil at the packings. This will
cause wearing on the rods, cylinder tubes,
guide bushings, pistons, and piston rings. The Weekly Maintenance
material that gets worn off these items also • Grease the boom. If you have an automatic
becomes a contaminant, accelerating wear. greaser installed, you must still remember to
Left unchecked, this wear will destroy a check each fitting to be certain that it is
differential cylinder. Under normal conditions, allowing grease to pass freely and to fill the
you are due for new packings after one to two grease pump reservoir as necessary. There are
years. many grease fittings on the boom, and each of
them should be pumped full of grease until
grease squirts out of the bearing area. The
WARNING location of each fitting is shown in the
Appendix section of this manual.
Changing cylinder rod packings can be
• Check the wall thickness of your boom
hazardous, including potential finger
amputation, hot oil burns, and oil
pipeline once a week. This should be checked
injections. You can remove the hazards by with an ultrasonic thickness tester (Figure
understanding the procedure. 117). These testers are available from suppliers
If you’re not familiar with the procedure, of quality control and testing equipment and
contact the Schwing Service Department from Construction Forms company
(Conforms). Conforms has its own brand and
000650.eps
before beginning.
model: the UT-100. Another common brand
• Visually inspect the bolts on the Rock Valve name is Krautkramer-Branson.
and the rubber rams each day. Notice if there is
any play. If you see something suspicious, shut
off the truck, put the key in your pocket, and
remove the hopper grate or waterbox covers
and guards, and inspect with a wrench. If you Figure 117
find that any bolts are loose, tighten with a Ultrasonic
torque wrench to the torque specifications thickness tester
found in the Appendix section of this manual. 000536.eps
Main areas of wear • Check the Rock Valve tension nut for play
Delivery pipeline tends to wear about 4 inches beyond once a week. To check this nut, remove the
the flange at the end concrete enters (Figure 118). keeper bolt, grasp the tension nut (Figure 121)
by hand, and turn clockwise. There are many
holes for the keeper bolt on the spacer behind
the tension nut. The object is to place the
keeper bolt in the farthest hole you can reach
when you turn the tension nut by hand. If the
tension nut will turn only enough to reach
fig1.eps
partway to a new bolt hole, then turn the nut
4” back to the previous hole. Do not use a
wrench on the tension nut to get it to go to a
Figure 118 new hole. The wrench flats are on the tension
End of boom pipe where concrete enters ring for loosening only. Overtightening the
tension nut will cause premature wear on the
Elbows tend to wear on the upstream side, or where kidney seal. The tension nut adjusts the free
concrete enters the elbow (Figure 119). play of the Rock Valve on the kidney seal end.
The pressure spring automatically
compensates for wear on the cutting ring end.
Replace and tighten the keeper bolt. You do
not have to tighten the keeper bolt according to
the torque specifications that are normally used
fig2.eps for that bolt size. Just be sure the bolt is tight
enough to not vibrate out.
• Inspect the cutting ring and rotate if needed.
When to rotate the cutting ring depends more
Figure 119 on the type of concrete and the number of
Elbow wearing as concrete enters cubic yards pumped than on a time schedule,
but you should check it for wear at least once a
week and rotate it as needed.
Extend the life of your system 45 rock valve assembly.eps L
Spacer
The lifetime of pipe and elbows can be extended by
Keeper bolt
rotating each on a regular basis. Turn each pipe as well Tension nut
as complete sets of elbows 180˚ so concrete enters the Wrench flats
opposite end. Wedge
Tapered bend
6-inch clamp
ps
Cover bolts
4.e
fig
Figure 121
Tension nut may look like the flat one
Figure 120 (above) or the cone shaped one (below)
Rotate pipe and
elbows 180˚
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Operation Manual - S 42 SXG 143
Maintenance
Spacer
Keeper bolt
Tension nut
Wrench flats
Wedge
Tapered bend
6-inch clamp
Cover bolts
Figure 122
Rock Valve assembly
Rotating the cutting ring little more, and then gently pry the Rock Valve
rearward a little more until it does. Rotate the ring
90° clockwise. (It doesn’t really matter which way
WARNING you rotate, but to keep from forgetting which way
Amputation/crushing hazard. Never work you went last time, Schwing recommends going
inside the hopper without disabling the clockwise each time.)
hydraulic system. 9. Be sure that the ring is centered in the Rock Valve.
W019.eps
• Lubricate mechanical moving parts with oil 5. Remove the dipstick plug (Figure 123).
or a WD-40 type of lubricant. This applies to The oil level should be visible on the dipstick
outrigger locking pins, hinges, valve handles, and should be near the full line. If needed, add
and other components. oil (90W gear lube). Do not replace the plug
• Once a week, check the bolt assembly that yet.
holds the tapered bend wedge. 6. Perform the steps listed in the following
procedure before replacing the pinion gear
cover.
Monthly Maintenance
• Clean the breather cap (Figure 123).
• Check the oil level in the boom slewing
1. Rinse both the breather and the dipstick
gearcase (Figure 123) by following these steps:
plug in cleaning solvent. In a pinch, brake
1. Be sure the machine is set up in a cleaner will work. Never use gasoline!
reasonably flat position.
2. Replace the dipstick plug, the breather cap,
2. Shut off the truck engine, and put the key and the pinion gear cover.
in your pocket.
3. Restart the unit. Slew the boom left and
3. Remove the boom slewing drive cover right several times, shut off the truck engine,
(Figure 123). Do not do this with the engine and put the key in your pocket. Then recheck
running because you will be exposing a pinch the oil.
point until the cover is replaced.
4. When oil level reaches the full line on the
4. Visually inspect the slewing pinion gear dipstick, replace the dipstick plug and pinion
(Figure 123) for wear. gear cover.
Breather cap
Dipstick
slewdip.eps
Figure 123
Check gearcase fluid level
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Operation Manual - S 42 SXG 145
Maintenance
42bmslew.epsL
Brake system
pressure gauge
Brake valve
manifold
Figure 124
Mechanical slewing brake system
The boom at rest is held by a multiple disk brake braking is accomplished by limiting how fast the oil
system (Figure 124), and stopping of the boom is can come out of the brake area. This is done with a
accomplished by hydraulic brake valves that are built throttle check valve. The throttle is preset at the factory
into the manifold shown in Figure 124. When the boom and should not be readjusted unless you first consult
is activated, pressure that turns the boom releases the the Schwing Service Department.
mechanical brake. When you are finished moving the Remember, if the reapplication of the brake is
boom, the mechanical brake must be reapplied slowly misadjusted, damage to the boom and the brakes
or damage could result to the brakes or the boom. Slow can occur!
• Check the mechanical brake reset time. the Schwing Service Department for advice on
1. Set up the unit as if pumping a boom job. how to proceed. This adjustment is critical. Do
Lift the boom far enough that it can be slewed not try to “wing” it.
back and forth without encountering any • Clean and repack the turret pinion gear and
obstacles or hazards. bolts.
2. With the engine running and the hydraulic 1. With the truck engine shut off, remove the
system engaged, stand with the remote box in a pinion gear cover to expose the Rollix ring
position where you can see the brake system gear (Figure 125).
pressure gauge (Figure 124).
NOTE!
3. Activate the boom slewing function either For the best maintenance of this gear,
left or right while watching the gauge. It remove the entire ring gear guard.
should go up to the top of the gauge as soon as
2. Clean the teeth of the gear with a thinning
you activate the function.
agent or cleaning solvent. Never use gasoline!
4. Let go of the boom function. The indicator
3. Apply fresh grease to the teeth. When
on the gauge should float down. If it takes
completed, replace the covers. Do not restart
more than 3 seconds or less than 1.5 seconds to
the unit until the covers are back in place.
float down, the throttle should be adjusted. If
the need for an adjustment is indicated, contact
Pinion gear
slwpngr.eps
Figure 125
Clean and repack the Rollix slewing gear
WARNING
Explosion hazard. Never use gasoline or
diesel fuel as a cleaning solvent.
W017.eps
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Operation Manual - S 42 SXG 147
Maintenance
Figure 126
Visually inspect the turret bolts for tightness.
(With boom in place, the top bolts must be
accessed through holes in turret.)
• Check the fluid level of the distribution If your unit is equipped with a Hi-flo pump kit and a
gearcase (Figure 127). 4400 Stiebel gearbox (Figure 128) you will find an oil
Be sure the truck is on reasonably level ground. With check plug on the side of the spline flange between the
the truck engine off, and the key in your pocket, hydraulic pumps and the gear box. The reservoir holds
remove the oil check plug (Figure 127). The oil should 90 weight oil and can be filled through the breather on
be at the level of the bottom of the hole in the gear top of the spacer. There is, however, no oil drain plug
case. If oil is needed, add it by removing the breather on the spline.
and pouring in the oil through the top. Your unit may be • Check the mounting hardware of the
equipped with one of two Stiebel gear boxes, 4194, or subframe, the oil and water tanks, the delivery
4400. The gearcase uses 90W gear lube. pipeline, the pumpkit, the differential
• Check the oil level in the spline flange. cylinders, the material cylinders, and the
driveline hardware. Check for bolt tightness,
cracks, and other abnormalities.
Breather filter
filler spout Breather grbx-5-6.eps
Oil check plug
Figure 127
Check fluid level of distribution gearcase Stiebel
box 4194 (left) or 4400 (right)
Figure 128
Oil check plug for spline flange cavity Oil check plug
(4400 gearcase) flange.eps
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Operation Manual - S 42 SXG 149
Maintenance
Setting Pressures 2. Activate the agitator. With the valve closed, the
agitator will not be able to turn, and the oil will be
The following pages provide the proper techniques for forced over the relief valve. At an idle (about 600
checking and setting hydraulic pressures of each RPM), 4.5 horsepower is being converted to heat.
system included on your unit.
more components. The specifications for each circuit
are shown on the hydraulic schematics found in the
Appendix of this manual. The hydraulic schematics are
the only documents in this manual that have been
updated specifically for your unit, by the serial number,
so in each of the following procedures you will be told
to refer to the schematic for the pressure required.
Figure 129
If you wish to order a CD ROM which explains the
Agitator shutoff valve
pressure setting procedure for a specific model (all
pumpkits), call Schwing Spare Parts Department
and request the CD using the following part
numbers:
• 61/58 meter . . . . . . . . . . . . . . . . . . . . . . .30365860
3. When the oil temperature gauge shows 50˚C, open
• 52 meter. . . . . . . . . . . . . . . . . . . . . . . . . .30354732
the shutoff valve.
• 45/47 meter . . . . . . . . . . . . . . . . . . . . . . .30356770
• 42 meter. . . . . . . . . . . . . . . . . . . . . . . . . .30355485 Setting pressures on Hi-flo -5 pumpkits
• 39 meter. . . . . . . . . . . . . . . . . . . . . . . . . .30365861 To set the pressure of the main relief valve on Hi-flo
• 34 meter. . . . . . . . . . . . . . . . . . . . . . . . . .30356772 pumpkits, if your unit is twin circut, you must first
• 32 meter. . . . . . . . . . . . . . . . . . . . . . . . . .30355486 disable the soft switch circuit. Simply locate the ball
• 31 meter. . . . . . . . . . . . . . . . . . . . . . . . . .30365862 cock for the soft switch circuit (Figure 130) and close it
by rotating the handle 90 degrees.
Preheat the hydraulic oil
The quarter turn shutoff valve for the concrete pump
Pressure settings must be made with the oil at normal (Figure 130) will also need to be closed during this
operating temperatures (40°− 60° C). In the past we procedure.
could pressure out a function in the boom or outrigger
system to create heat, but load sensing systems no NOTE!
longer allow maximum oil flow to be forced over relief. Main system adjustments are preset at the
factory. The following procedure begins
Because of this the agitator circuit must be used to heat with adjustment of the main relief cartridge
the hydraulic oil. and pressure cutoff. If proper pressures can
To preheat the hydraulic oil: not be obtained through these steps, contact
the Schwing Service Department for specific
1. Locate the agitator shutoff valve (Figure 129) and instructions on the adjustment of flow,
close it. horsepower, beginning of stroke regulation,
and Q-min.
NOTE!
If your unit does not have a shutoff valve, Pressure setting procedure:
order one from the Schwing Spare Parts
Department using part number 10004680
(valve), and number 30303432 (tube).
Contact the Service Department for
installation instructions.
Gauge port
Soft switch
shutoff valve
00
02
97
.ep
s
Concrete pump
hif
shutoff valve low
br
n.e
ps
Figure 130
Concrete pump and Soft switch shutoff valves
1. Be sure that the waterbox covers and guards are in with a 13mm wrench. Using a 4mm allen wrench,
place any time you will be working in the area turn the adjustment screw in (clockwise) one full
around the main control block. turn and tighten the jam nut. Restart the truck
2. Wear safety glasses when working around a engine.
concrete pump. 10. Adjust the engine RPM to maximum specification.
(See decal in truck cab)
NOTE!
It is vital that each adjustment screw be 11. Pressure out the system by activating the concrete
properly identified prior to making any pump forward switch on the rear panel. Using the
adjustment. All screw adjustments for the rear panel controls will allow you to read the
system relief must be made with the concrete pump main system pressure gauge, near
pumpkit in the neutral position and the e-stop manifold, from a safe distance.
adjustments for pressure cutoff must be
made with the engine shut off. NOTE!
3. Start the truck engine, and put the PTO in gear just Because you turned out the pressure relief
as you would to pump a job. cartridge in step 7, the system pressure
should read low at this time. If it does not
4. If you have not already closed the concrete pump and the gauge spikes to 320 bar or more,
shutoff valve (Figure 130) do so at this time. disengage the pump immediately. Turn the
5. Select “local” control with the “local/remote” relief cartridge out (counterclockwise)
more. For safety, it is important to adjust
switch and turn the electric stroke limiter knob the pressure up from below the specified
clockwise to maximum strokes per minute. target pressure rather than down from a
6. The main system control block pressure must be pressure which exceeds the target. Continue
set first to properly set the pressure cutoff on both this procedure until the main system
pressure gauge reads lower than the
pumps. Begin by backing off the jam nut of the specified target.
main relief cartridge (Figure 130) with a 9/16 inch
wrench. 12. To increase the pressure put the pump in the
neutral position and adjust the relief cartridge by
7. Using a 5/32 inch allen wrench, turn the turning it in (clockwise). When increasing the
adjustment screw out (counterclockwise) until you pressure, the adjustments should be made in
can feel no spring tension on the adjustment screw. quarter turn increments. If you make adjustments
8. Now, turn the screw back in (clockwise) two or to increase the pressure but the pressure does not
three full turns to give you a proper starting point come up, you are probably reading the pressure
and tighten the jam nut. cutoff of the pumps, if so proceed to the next step
9. Stop the truck engine and put the key in your otherwise skip to step 16.
pocket. Adjust the pressure cutoff screw (Figure
131) on each pump, by backing off the jam nut
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Operation Manual - S 42 SXG 151
Maintenance
13. Turn the relief cartridge adjustment screw back out until you achieve the desired pressure setting of
(counterclockwise) until you can no longer see a 350 bar (again, confirm the pressure specification
pressure drop and tighten the jam nut. with the hydraulic schematic).
14. Stop the truck engine, put the key in your pocket. 20. After pressure cutoff is set, return the pump to
15. Go to the pressure cutoff screw on both hydraulic neutral, bring engine RPM to idle, open the soft
pumps and back off the jam nut with a 13mm switch quarter turn valve, and either proceed to
wrench. Turn the adjustment screws in with a 4mm other pressure settings or take the transmission and
allen wrench one or two more turns, restart the PTO out of gear and shut off the truck.
engine and check the pressure again. Repeat this
procedure until the main system relief can be set to
the target pressure. 000336.eps
Load-sensing boom hydraulic controls to ensure that you have control when you need it. The
This unit is equipped with a load-sensing, proportional setting to maintain this minimum amount of oil is
boom hydraulic system. In a black-and-white system, called Q-min (pronounced “cue min”). To set the boom
the hydraulic pump puts out an unchanging amount of or outrigger hydraulic pressures on a load-sensing
oil, and speed control is done by restricting the oil to system, begin by setting ΔP and Q-min.
certain functions with orifices. In a load-sensing
system, the pump puts out more or less oil to respond
to the needs of the system. Generally, the pump puts
out enough oil to maintain 20 bar higher pressure at the WARNING
pump than the cylinders actually require. This 20 bar is
Entanglement hazard. Stop drive shafts
called delta P (ΔP). Additionally, we set the hydraulic before adjusting Delta P on A11VO pump.
W020.eps
pump so that it always puts out a small amount of oil,
even if no oil is needed for the system. This oil is used
pretension
only
33-35 bar
0-600 bar
gauge port
45bmcnbl.epsL
Figure 132
The 0–60 bar gauge port is located at the top of the boom control block, and the 0-600 bar
port is at the bottom.
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Operation Manual - S 42 SXG 153
Maintenance
pressreg.eps
bar. After achieving proper ΔP, tighten the jam nut Regulator pressure
adjustment
and bring the engine RPM up. If the pressure
gauge continues to read 20 bar, you are reading the T
true ΔP pressure and may move on to setting the Q- Adjustment for P pressure
min. If the pressure rises with the RPM, however, Delta-P
you may be reading the Q-min pressure instead of
true ΔP. If that happens, stop the engine, put the
key in your pocket, and place a “Do Not Operate”
sign on the windshield of the truck before
proceeding.
smdeltap.eps
Figure 133
Pressure regulator for A7VO boom pumps
(top) and A11VO pumps (bottom)
Q-min
Delta-P Pressure cut-off
adjustment screw
hifloreg.eps
Figure 134
Location of Q-min screw on the A7VO (left) and all adjustment screws of the A11VO (right)
6. Unscrew the Q-min screw (Figure 134) three full If pressure cannot be set correctly, there is a problem
turns. This step will help ensure that the pump either with the orifices in the base of the regulator or
produces only the amount of flow needed to with the regulator itself. Contact the Schwing Service
maintain ΔP pressure. Once all personnel are clear Department to determine how to continue.
of the truck, restart the engine, engage the pumps,
and recheck at an idle. Pressure should now read
17 bar. If it does not, go back and adjust ΔP until it
does.
If the boom does not run smoothly at 17 bar, you 1. If you unscrewed the Q-min screw as part of the ΔP
must fine tune the adjustment. Remove the gauge, and adjustment, begin by returning the screw to its
turn the ΔP adjustment screw until the boom is original position.
responsive and smooth. After adjusting, the gauge 2. All boom functions must be in neutral, and all
(reinstalled) must read between 14-25 bar. The emergency stop buttons should be up (not
electronics in the control system can also affect how engaged). Clear away all personnel, start the truck
the boom operates, so if ΔP adjustment does not seem engine, engage the pumps and bring engine RPM
to help, reset to 17 bar and check the electrical settings. to max. Read the pressure at the 0–600 bar main
Once electrical settings are verified, you could again boom gauge port (Figure 136) with a 0-100 bar
try to refine the boom action with the ΔP adjustment. gauge. Pressure should be at 30 bar. If no
NOTE! adjustment is needed, be sure the jam nut on the
Q-min screw is tight; then continue to set the rest
The pressure regulator (Figure 135) is of the boom and outrigger pressures. If adjustment
usually mounted on the inside of the
subframe, near the cab end of the is needed, continue to the next step.
differential cylinders. 3. Turn the Q-min screw (Figure 134) in to raise the
pressure. Turn it out to lower the pressure. Be sure
that you stop the drive shafts from turning each
time before making the adjustment. When pressure
is correct, tighten the jam nut on the adjustment
screw before continuing with the other procedures;
then recheck ΔP to make sure that it hasn’t
pressreg.eps
WARNING
Entanglement hazard. Stop drive shafts
before adjusting Q-min.
W009.eps
Setting Q-min
Check Q-min when the engine is at maximum specified
RPM. You must not adjust Q-min with the drive
shafts turning! Each time the Q-min screw must be
adjusted, the engine must be stopped or, at least, the
transmission must be taken out of gear so that the
drivelines stop turning.
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Operation Manual - S 42 SXG 155
Maintenance
Now that ΔP and Q-min are set, you can remove the 0-
100 bar pressure gauge and proceed to check and
adjust the main boom pressures.
1. Loosen jam nut of the boom pressure relief
cartridge (Figure 136) with a 30mm open end
wrench.
2. Turn the adjustment cartridge clockwise all the #1 down side
way in with a 32mm wrench. relief cartridge
3. Loosen the jam nut on the pressure relief screw of
the regulator (Figure 135) or the pressure cut-off Main boom pressure
(Figure 134), and tighten the screw all the way relief cartridge
down.
4. Identify the main boom pressure relief cartridge on
the boom control block (Figure 137) and loosen the
jam nut. Then unscrew the adjustment two full
turns.
Figure 137
5. Take engine RPM to full throttle and activate boom Main boom pressure adjustment and
retract for any boom section except #1. piston side relief
6. Now adjust pressure, which is read at the main cartridge (32mm) out, or counter clockwise, until
boom gauge port, to the setting found on the you achieve the pressure shown on the schematic,
schematic by turning the boom pressure relief for the boom pressure relief cartridge. When the
cartridge in, or clockwise, using no more than 1/4 proper pressure is achieved, lock the jam nut.
turn increments.
9. The next pressure setting is the regulator pressure.
7. When desired pressure is achieved, lock down the Locate the regulator adjustment screw (Figure 134)
jam nut. or pressure cut-off screw (Figure 135). Back off the
jam nut, and turn the screw counterclockwise until
you achieve the pressure shown on the schematic;
0-600 bar then lock the jam nut.
gauge port 10. The final boom pressure setting is the #1 boom rod
0.e
ps side relief setting. This relief cartridge is in close
60
top
es
proximity to the main boom relief (Figure 137), so
be sure to locate the proper adjustment. This
procedure should be performed with the outriggers
extended and the boom unfolded over the cab.
Boom pressure
Disconnect all gauges from gauge ports prior to
relief cartridge
operating any boom or outrigger functions.
Bring section #1 all the way down until the
cylinder bottoms out. Install a 0-600 bar gauge in
the main boom gauge port of the e-stop manifold
(Figure 136), and activate boom #1 down. The
pressure should read the setting shown on the
Figure 136 schematic. If adjustment is required, back off the
Boom pressure relief cartridge jam nut and turn the relief cartridge in or out as
8. The next step is to return to the e-stop manifold required until the desired pressure is achieved; then
boom pressure relief cartridge (Figure 136) and lock down the jam nut.
back off the jam nut (30 mm). Turn the relief
Setting outrigger pressure 4. The pressure should read the bar value shown on
After the boom circuit is properly set, you can set the the hydraulic schematic. Adjust by loosening the
outrigger pressure. Find the relief cartridge jam nut with a 9/16” open end wrench and turning
located on the front of the passenger side outrigger the cartridge (Figure 138) in or out with 5/32 allen
control valve (Figure 138). wrench. When the proper pressure is achieved, let
go of the handle and release the outrigger enable
button.
WARNING testport.eps
30354359
retraction of an outrigger jacking
W026.eps
cylinder.
CONCRETE PUMP
FORWARD/REVERSE
AGITATOR
Relief valve
Gauge port
Figure 139
Agitator component location
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Operation Manual - S 42 SXG 157
Maintenance
wrench.
1. Plug the 0–600 bar whip gauge into the gauge port
(Figure 139) for checking or setting agitator Cap Nuts
pressure.
2. Locate the agitator shutoff (Figure 140) valve and 3. Increase the throttle to any speed above idle.
close it. If your unit does not have a shutoff valve, Activate the agitator valve handle in either forward
order one from the Schwing Spare Parts or reverse, and read the gauge. If it does not read
Department using part numbers 10004680 (valve) the specified pressure, adjustment is required. Turn
and 30303432 (tube). Contact the Service the entire valve body (Figure 139) in to increase
Department for installation instructions, or if you pressure or out to decrease pressure.
can’t wait for a shutoff valve, you will need to 4. When the pressure is set, deactivate the agitator by
remove one of the hoses from the agitator motor placing the manual control handle in the neutral
and plug the hose and open fitting with approved position.
hydraulic dead plugs (Figure 141).
5. Remove the whip gauge.
NOTE! 6. Reopen the shutoff valve or remove the dead plugs
Do not jam the paddles to force the oil over and reconnect the capped hydraulic line.
relief by stopping the movement of the
agitator.
agitoff2.eps
Figure 140
Agitator shutoff valve
pinscrew.eps
Figure 142
Check the pinion gear mounting screw.
Cleaning oil cooler fins Change the oil for temperature reasons
Spray out the coils of the oil cooler with a high- Change hydraulic oil every six months if you live in a
velocity water nozzle or pressure washer. If you use a geographic location where seasonal temperature
pressure washer, be careful not to damage the electric changes are drastic. If you save the used oil in clean
motor or bend the cooler fins. barrels and properly store the barrels, you can reinstall
this oil when the weather changes back. You can use
the oil for a maximum of two six-month seasons.
Quarterly Maintenance
Caution! If you ignore proper storage procedures, the
Check the drive pinion and slewing joint oil will become contaminated and will cause damage to
1. With the truck engine turned off and the key in the machine if reused. Contact your hydraulic oil
your pocket, remove the pinion gear cover (Figure dealer to obtain clean barrels and proper storage
142). procedures. If you do not own a filter buggy for oil
2. Check the pinion gear mounting screw (Figure transfer, consider buying or renting one.
142). If it is loose, remove and clean it.
3. Apply Loc-tite or an equivalent primer to the
screw. When dry, apply Loc-tite 242 or equivalent.
4. Tighten the screw according to the torque chart in
the Appendix section of this manual.
5. Replace the pinion cover before restarting the unit.
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Operation Manual - S 42 SXG 159
Maintenance
Change oil in the distribution gearcase 2. Remove the breather filter and the drain plug
The oil in the distribution gearcase normally requires (Figure 143), and drain the old fluid into a drain
changing on an annual basis. The procedure is being pan.
shown in the Quarterly Maintenance section to remind 3. Clean the breather filter with cleaning solvent.
you that the oil should be changed for the first time Never use gasoline!
after a three month break-in period and annually 4. Rinse the case with clean hydraulic oil. Let the oil
thereafter. drain immediately out of the case. Dispose of this
Do this procedure when the oil is warm. When the oil oil; do not reuse it.
is cold, it does not drain as easily (Figure 143). 5. Replace the drain plug.
1. Park the truck in a level area. Place the “Do Not 6. Remove the full level plug or oil check plug
Operate” sticker on the window in front of the (Figure 143).
driver’s seat. Stop the engine, and put the key in 7. Refill through the filler spout (Figure 143) to the
your pocket. full level plug or oil check plug (Figure 143) with
90W gear lube. Replace the full level plug and the
breather filter.
Drain plug
Figure 143
Change distribution gearcase oil -Stiebel box 4194 (left) and 4400 (right)
Semiannual Maintenance Do not change oil when the temperature of the oil is
over 50˚C. Severe burns could result.
Change the oil in the boom slewing 1. Park the truck in a level area. Put the “Do Not
gearcase Operate” sticker on the window in front of the
Do this procedure (Figure 144) when the oil is warm. driver’s seat. Stop the engine, and put the key in
When the oil is cold, it does not drain easily, and it your pocket.
does not rinse dirt and contamination off the gears. You 2. Remove the boom slewing drive cover (Figure
must be sure, however, that the oil is not hot enough to 144). Do not do this with the engine running, as
burn you. you will be exposing a pinch point until the cover
is replaced.
3. Remove the breather filter and the dipstick/fill plug Test the dirty filter warning circuit
(Figure 144). Wash them both in solvent. Never All Vector units have two sensor switches to detect
use gasoline! dirty filters. One on the boom filter and one on the back
4. Remove one of the gearcase drain plugs (Figure of the oil cooler (Figure 145). Remove the connector
144), and let the old oil drain into a pan. plugs every 6 months. With the key switch in the “on”
5. Rinse the gear case with cleaning solvent or fresh position and the PTO selector knob in the “pumping”
hydraulic oil. Never use gasoline! Let it drain out mode, the fault warning horn should sound. If it does
immediately. Do not reuse this oil. not, contact Schwing Service Department
6. Replace the drain plug. for advice on how to proceed.
7. Fill the case to the proper line on the dipstick
(Figure 144). You will have to fill very slowly
because of the thickness of 90W gear lube.
8. Replace the breather filter, the dipstick/fill plug,
and the pinion gear cover.
boombrak.eps
filterswitch.eps
Breather cap
Dipstick
Figure 145
Dirty filter warning switches
shown in both locations
slewdip.eps
Figure 144
Change slewing gearcase oil
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Operation Manual - S 42 SXG 161
Maintenance
Annual Maintenance
Check the pre- charge of accumulators
Check the accumulator gas pre-charge as shown:
• 1st check-one week after first use
• 2nd check-three months after first use
• 3rd check-one year after first use
• 4th check and beyond-annually
If the accumulator requires charging, read all of the
instructions before beginning the job. Accumulators
must be charged only with dry nitrogen. Never use
compressed air or oxygen (Figure 146), as the
oxygen molecules will combine with the hydraulic oil
and lower the flash point of the oil to below room
temperature. You will create a major explosion by
using compressed air or oxygen to charge
accumulators. People have died using compressed air
or oxygen to charge accumulators. Use dry nitrogen,
not liquid nitrogen.
EXPLOSION CAUSED BY
WARNING
IMPROPER ACCUMULATOR
CHARGING CAN RESULT IN
DEATH OR SERIOUS INJURY!
* Follow the charging instructions exactly!
* Use ONLY dry nitrogen to charge the
accumulator!
* NEVER use oxygen or compressed air to
charge the accumulator! explosion warning.eps
Figure 146
Warning decal for accumulator charging
Regulator adjustment
Nitrogen bottle handle
100
1500
150
50
1000 2000
500 2500
PSI
bar 200
0
Hose
30341207
Charge valve assembly
30341201
BPL
Accumulator Charging Kit
HYDAC bladder
accumulator (Includes hose and charge valve assembly)
SCHWING PART NUMBER:
30338635 chargekit PN’s.eps
Figure 147
Accumulator charge kit for HYDAC bladder accumulators
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Operation Manual - S 42 SXG 163
Maintenance
ac
cu
m
ma
nif
old
.ep
s
Shutoff handle
Figure 148
Accumulator manifold bleed valves (Your unit should be equipped with one of the two
bleed valves shown above.)
4. Verify zero hydraulic pressure on the concrete 5. If there are multiple accumulators, charge one
pump’s accumulator gauge before beginning. The accumulator at a time. Leave the valve protection
accumulators should dump when the engine is caps (Figure 149) on the accumulators until you
stopped, but you still must verify it. If pressure actually begin the procedure.
remains, dump the accumulators using the manual 6. Remove the valve protection cap and the valve seal
bleed valve (Figure 148) on the manifold. cap from the accumulator that you will charge first.
(Figure 149)
HYDAC bladder
accumulator
accum closeup
100
1500
150
50
1000 2000 Pressure
500 2500 gauge
PSI
bar 200 Valve body
0
Figure 150
Charge vavle assembly T-handle
Gas chuck
Bleed valve
7. On the charge valve assembly, locate the T-handle 8. On the charge valve assembly, close the bleed
of the gas chuck (Figure 150). Rotate it valve (Figure 151), and disconnect the hose from
counterclockwise (outward) completely before the gas valve stem. This step closes the charge
attaching the swivel nut to the accumulator gas valve stem to prevent the gas pressure from
valve stem. escaping out of the hose and ensures that the initial
pressure reading is accurate.
100
1500
150
50
1000 2000
500 2500
PSI
bar 200
0
Figure 151
Close bleed valve and
Remove hose
disconnect hoses
charge assy/bleed/hose.eps
Bleed valve
Close valve
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Operation Manual - S 42 SXG 165
Maintenance
150
50
If the T-handle is turned in (clockwise) more 1000 2000
0
• If no adjustment is necessary, skip to step #18.
• If pressure is too high, skip to step #15.
• If pressure must be added, proceed to step #11.
251
>=H
read gauge.eps
!"
Figure 152
Attach swivel nut to
accumulator gas valve
High-pressure
regulator
Nitrogen supply
valve
Regulated pressure
adjustment handle Higher
Figure 154 Nitrogen bottle
Make connections between Lower
nitrogen bottle and charge kit
100
1500
150
50
1000 2000
500 2500
PSI
bar 200
Bleed valve
chargekithookup
11. Be sure that the nitrogen bottle supply valve is 14. Adjust the regulator handle clockwise, raising the
firmly closed. Attach the high-pressure regulator to regulated pressure. The accumulator will begin to
the nitrogen bottle; then attach the hose to the high- fill. Continue filling until the charge kit gauge
pressure regulator. Finally, attach the other end of reads the desired pressure of 1450 PSI. Close the
the hose to the valve assembly gas valve stem, as nitrogen bottle supply valve.
shown in Figure 154. Do not open the nitrogen 15. If you overcharge the nitrogen pressure, proceed as
bottle supply valve yet. follows:
12. Turn the regulated pressure adjustment handle on • Close the nitrogen bottle supply valve.
the high-pressure regulator counterclockwise to its • Slowly open the bleed valve on the charge kit.
minimum setting. Close the bleed valve when the correct
13. Crack open the nitrogen bottle supply valve pressure is reached.
(Figure 155). You will get a reading on the high-
NOTE!
pressure gauge side of the regulator. Note that if
there is not at least 1450 PSI showing on the high Never let nitrogen out of the accumulator by
pressing the gas valve pin with a foreign
pressure regulator gauge at this time, you will not object. The high pressure may rupture the
be able to charge the nitrogen to the 1450 PSI valve seat!
specification. If that is the case, you will need a
16. Let the nitrogen sit in the accumulator for 10 to 15
new bottle of nitrogen before proceeding. If there
minutes. This allows the gas temperature to
is enough pressure in the nitrogen bottle to do the
stabilize. Recheck the pressure on the charge kit
job, proceed to step #14.
gauge.
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Operation Manual - S 42 SXG 167
Maintenance
Figure 155
When the supply valve is open, bottle
pressure shows on the high pressure gauge
Nitrogen Bottle
Cracksupply.eps
EXPLOSION CAUSED BY
WARNING
IMPROPER ACCUMULATOR
CHARGING CAN RESULT IN
DEATH OR SERIOUS INJURY!
* Follow the charging instructions exactly!
* Use ONLY dry nitrogen to charge the
accumulator!
* NEVER use oxygen or compressed air to
charge the accumulator! explosion warning.eps
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Operation Manual - S 42 SXG 169
Maintenance
The designated person should determine whether b. proper operation of the adjusting nut, if so
conditions found during the inspection constitute a equipped;
hazard and whether a more detailed inspection is c. concrete preventing proper operation;
required. d. system compatibility.
4. Separately laid pipeline components for:
Frequent inspection of the boom and structural
a. sufficient wall thickness to withstand the
support system should include, as applicable:
maximum material pressure of the material
1. Safety devices, such as holding valves, guards and placement system, according to the
interlocks, for proper operation; manufacturers instructions.;
2. Boom controls for proper operation and b. dents, holes, or deformed ends;
engagement; c. the presence of old concrete inside the
3. Boom and outrigger hooks, straps, and latches for pipeline.
proper operation and engagement; 5. Cables or slings used to secure hanging system
components.
4. Hydraulic hoses for wear, rubbing and cracking;
6. Missing or damaged safety signs or operational
5. Hydraulic oil level;
labels.
6. Hydraulic oil leaks;
7. Remote control boxes and cables for proper
operation, exposed wires, broken controls, missing
control guards, or broken plugs;
8. Boom and outrigger structures for visible
deformations, cracks, and damage;
9. Boom and outrigger pins for visible wear, damage,
and missing hardware;
10. Tires for sufficient tread, proper inflation, cuts, and
loose lug nuts;
11. Proper loading of accessories to prevent loss while
traveling;
12. Proper lubrication of moving parts.
Frequent inspection of delivery system
components should include:
1. Boom Delivery system for:
a. minimum wall thickness to withstand the
maximum material pressure, according to the
manufacturer’s instructions;
b. dents or cracks;
c. missing locking pins;
d. leaking gaskets
2. Delivery system hoses for:
a. internal wear, according to the manufacturers
instructions;
b. separation of the ferrule from the hose;
c. bulges, kinks, soft spots, cuts, or abraded areas
which may indicate bad reinforcement;
d. presence of hardened concrete.
3. Couplings for:
a. cracked, broken, distorted, or missing
components;
W007.eps
estop.eps
machine is pushed. Unlock all E-stops.
Avoid changing rams with the motor running; you are
inviting trouble when you do so. However, if you are This symbol flashes in the upper right
working alone and must get the ram changed in a hurry, corner when the system is ready for start-
Start up.
you may need to let the truck engine run. If so, take the Istart.eps
following precautions to avoid amputation of hands, Start up the controller with this switch
arms, or fingers. shown as #4 in (Figure 157).
• Do not use the remote for this procedure.
Unplug it and store it. Iswitch.eps
Starting is confirmed by a brief beep and
• The on-off switch for the concrete pump and this symbol is displayed in the upper
the manual handle for activating the concrete OK right corner (Figure 157).
pump are located in positions that make them
The ram change position disables both
impossible for you to activate while your
local (rear panel) and remote control, brings the engine
hands are in the waterbox. If, however, another
to idle, reduces the stroke limiter to minimum output,
person has access to these devices, the danger
and gives complete concrete pump control to the
of accidental activation increases. Avoid
concrete pump fwd/rev switch located at the ram
changing rams in this situation.
change station (Figure 158).
• The chances of accidental amputation are
6
greatly increased when more than one person 1
is near the switch. You also have fewer 5
distractions when you are alone. If someone
approaches you when you are changing
2
1
OK OFF
0 x1000 3
PTO 1500 rpm 62˚C
2
Vector control HOME + HELP START
4
32ramchange.eps
Figure 158
The “Ram change station” on the rear boom
cradle houses the concrete pump fwd/reverse
switch.
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Operation Manual - S 42 SXG 171
Maintenance
Grooves lined up
with ports - open Concrete pump
open shutoff valve
Blckgrvs.eps
Removing old rams the waterbox, leaving about one and one-half
1. Close the shutoff valve (Figure 159), also known as inches of travel. This will allow you to remove the
the ball cock or quarter-turn valve. This allows you spacer coupling (dog bone).
to control the direction of travel of the differential 000308.eps
cylinders.
2. Drain the waterbox. Remove the waterbox covers
(Figure 160) and the bolt-down grate. Retract the
driver side differential rod almost all the way into
Figure 160
Retract all but about 1 1/2 inches of the driver
side rod into the waterbox.
the dog bone to prevent the assembly from turning. 6. Push an emergency stop button. Stop the engine,
You can rest the handle against the side of the and put the key in your pocket. Remove the dog
waterbox as shown in Figure 161. Unscrew the bone from the waterbox as shown in Figure 162.
four M20 bolts that hold the assembly together. 000310.eps
Figure 162
Remove the dog bone.
Figure 163
Removal bolt grooves on flanges
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Operation Manual - S 42 SXG 173
Maintenance
8. Push an emergency stop button. Stop the engine, Installing new rams
and put the key in your pocket. There is a groove in 1. Apply Loc-tite primer (or equivalent) to the M20
the ram flange that lines up with a groove in the bolts. Allow the primer to dry.
cylinder flange. An M12 x 45 bolt with nut will 2. While the primer is drying, apply a liberal coat of
drop into this groove and allow you to pull the ram clean grease to the new rams. There is no such
out (Figure 163). The fit should be snug, but there thing as too much grease here, because the excess
is no need to tighten the nut with tools. Note that, will be wiped off by the material cylinders during
for clarity, the ram flange and cylinder flange are installation.
shown outside the waterbox.
3. With the engine still stopped, hold the new ram up
9. Start the engine. Release the emergency stop to the cylinder flange. Line up the grooves, and
button, and slowly retract the cylinder rod (Figure drop your nut and bolt into place to hold the
164) until the ram is clear of the material cylinder. assembly together. Again, you should only tighten
10. Push an emergency stop button. Stop the engine, the nut finger-tight.
and put the key in your pocket. Remove the nut and 4. Start the engine. Release the emergency stop
bolt, and the ram will be free to come out of the button. Slowly extend the cylinder until the ram is
waterbox. installed in the material cylinder (Figure 165) but
11. Clean and inspect the bolts and cone washers, the the mounting flange is still exposed enough to
dog bone, and the cylinder flange. Replace any remove the nut and bolt.
damaged or worn parts with new ones. 5. Push an emergency stop button. Stop the engine,
and put the key in your pocket. Remove the nut and
bolt.
000313.eps
000312.eps
Figure 165
Figure 164 Slowly push the new ram into the
Slowly bring the ram into the waterbox. material cylinder
Figure 166
Slowly move the cylinder to
meet the dog bone
12. Open the shutoff valve. The unit will not cycle
when this valve is closed.
Upon completion of your work in the water box, it is
important that you remember to deactivate the O/I
switch on the ram change operation panel, which will
give control back to the local/remote switch on the
main panel.
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Operation Manual - S 42 SXG 175
Maintenance
Setting Vector Controller-Teach Mode 1. Go to the Vector controller and select ‘local’
control, but do not activate the reset “I” switch.
NOTE!
Setting the parameters in “Teach Mode” 2. Open the front cover and insert the “Teach Key”
should only be done by persons with a into the connector shown in Figure 168.
complete understanding of the Vector 3. The display window on the front cover should now
control system. be showing you the screen shown in Figure 167.
Teach mode offers the user the opportunity to teach the
main controller how he or she would prefer to have the
boom respond to the remote control joystick Restore parameters
movements by setting parameters for minimum and
maximum response times of each boom movement.
to factory setting OK
MIN is the amount of signal it takes to start boom
movement, and MAX is the signal required to make the
no yes
boom manual control handle travel all the way to the [CLEAR] [ENTER]
mechanical stop. Setting these parameters requires
setting up the unit and unfolding the boom. Be certain
that the boom has room to move safely during this Teach Mode E C
vectorrestore.eps
procedure.
Figure 167
NOTE! Vector display window for restoring
When the unit is in teach mode, the concrete to factory settings
pump and agitator are disabled to prevent
the operator from accidentally trying to
pump while the teach mode key is installed.
4. Push the ‘ENTER’ button to select yes. The
controller will then restore the parameters to the
values set in the Schwing Test Department. After
about 10 seconds, the system will reset itself.
WARNING NOTE!
When the system restart screen appears
Improper setup causes job site accidents: after setting the parameters, allow the
• Look for power lines before unfolding controller time to complete the process
• Be sure of unit's stability before performing any other system
W024.eps
1760 rpm 52 ˚C
OK
A B C D E
Teach
connectorlocation.eps mode!
Figure 168
Location of “Teach key” connector
Teach Mode
3. The display window on the controller cover will teachfunctionscreen.eps
show that the unit is in ‘Teach’ mode and the “I” in Figure 170
the upper right hand corner will be flashing, which Teach mode parameter screen
indicates that you need to activate the reset “I”
switch to start the “Teach mode” process (Figure 6. You are now ready to teach the controller what
169). parameters you prefer. We’ll use boom #1 as an
example. Before you activate the function to be
adjusted, you must decide which parameter you
1 2 want to adjust (MIN or MAX). The selection is
Start made with the “Rabbit/Off/Snail” switch. Choose
‘Rabbit’ for MAX or ‘Snail’ for MIN. So to set the
Teach #1 boom MIN, you must first place the switch to
0 x1000 3 mode! the ‘Snail’ position (Figure 171).
NA 1760 U/min 52˚C
Menu: [ENTER]=ON
teachmode.eps
snailspeed.eps
Figure 169
Teach mode screen Figure 171
Choose ‘Snail’ speed to set MIN
NOTE!
If the unit is in local control when the teach
key is inserted, the display will tell you that
you must change to remote control to enter
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Operation Manual - S 42 SXG 177
Maintenance
7. Start by holding down the “I” switch on the remote 9. If the boom is not moving, you should increase the
box while you activate the right hand joystick. percentage to this function by activating the
throttle switch to the “+” position (Figure 174).
Each time you tap the switch the duty cycle
percentage will increase by 1%.
activate"I".eps
vectorthrtlpicto.eps
Figure 172
Activate “I” switch and hold
NOTE!
Boom movement is not proportional in Figure 174
“Teach mode”, so the joystick can be moved Throttle switch on remote box
all the way to extend or half way; it doesn’t
matter as long as the boom function is
activated.
8. When the joystick is activated and the “I” switch is
still being held down, the display will show a bar
graph like the one shown in Figure 173, at which
time the “I” switch can be released. The joystick,
10. When the boom begins to move and you are
however, must remain activated, or the screen will
satisfied that the percentage of MIN is where you
revert to the one shown in Figure 170 and you will
need it to be, you will be required to push up on the
need to start over at the previous step. The
horn switch (Figure 172) to store the number. If
percentage shown on the graph indicates the duty
you release the joystick before beeping the horn,
cycle of this particular function. A reading of 45%
the percentage will revert to where it was when you
indicates that the duty cycle is on 45% of the time
began. After you store the information for “#1
and off 55%.
boom extend MIN”, the screen will display a single
mark in the “A” column as shown in Figure 175.
1760 rpm 52 ˚C
OK
A
15
45 %
50
Teach
mode!
1760 rpm
A B C
52 ˚C
D E
OK
Teach
45 mode!
Teach Mode
minparameterscreen.eps
11. If you felt that the boom took off too fast when the
joystick was activated and the percentage needs to
be decreased, tap the throttle switch (Figure 174)
to the “-” position until the boom responds as you
like, and store with the horn button as explained in
the previous step before releasing the joystick.
12. You should now activate the #1 boom joystick to
the retract position and adjust the percentage the
same way you did for the extend position. After
storing the parameter with the horn switch, the
s
V.ep
vlvR
display should look like Figure 176.
xbm
42s
1760 rpm 52 ˚C
OK Figure 178
A B C D E
Teach Manual boom control handles
mode!
14. Activate the “I” switch on the remote box, and hold
it down. Move the right hand joystick to the extend
Teach Mode position.
minretractstored.eps
speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 179
Maintenance
16. The handle on the boom valve should now have 17. Now activate the “I” switch again, and move the
moved to the extend position. Grab the handle, and right hand joystick to the retract position. Follow
pull or push it in the same direction it has already the same procedure, adjusting the manual control
moved. If the handle will not move any further, it handle to the mechanical stop on the opposite side.
has reached the mechanical stop. If you feel it is When the adjustment is complete and you have
solidly against the stop and should be backed off stored the information by sounding the horn,
slightly, tap the throttle switch to the “-” position release the joystick, and the display window should
until the pressure is relieved from the mechanical look like the one in Figure 181.
stop. If, on the other hand, the handle moves freely
and is not in contact with the mechanical stop, tap 1760 rpm 52 ˚C
the throttle switch to the “+” position until the
handle comes in light contact with the stop. When
OK
you feel that the handle is properly adjusted,
A B C D E
Teach
activate the horn button to store the parameter and
mode!
release the joystick. The display should now look
like the one in Figure 180.
NOTE! Teach Mode
With the apitech hand valve, it is necessary maxretractstored.eps
Teach Mode
Figure 180
Boom #1 MAX extend stored
maxextendstored.eps
no yes
?
[CLEAR] [ENTER]
Teach Mode E C
Storenew.eps
Figure 182
Window for storing new parameters
19. If you answer ‘yes’, the system will restart and seconds, and when completed the display
store the new parameters (Figure 183). If you will again show the screen below (Figure
answer no, the window will ask if you want to 184).
restore to the original factory settings. If you
answer ‘no’ to that question, the system will
remain unchanged.
1 2
Start
Figure 183
System restart screen will appear when the
local/remote switch is moved
NOTE!
When the system restart screen appears
after setting the parameters, allow the
controller time to complete the process
before performing any other system
functions in order to prevent losing your
stored information. The restart takes only
speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 181
Maintenance
NOTES
WARNING
on
Do not stand
hopper grates.
S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
42SXside.eps
APPENDIX
Hydraulic Oil Viscosity Chart .................................................................. 184
Torque Specifications for Metric Bolts..................................................... 185
Recommended Emergency Hose Kit...................................................... 189
Fitting Wrench Sizes ............................................................................... 189
Grease Zerk Locations-Boom................................................................. 191
Bearing Clearance Specifications........................................................... 192
Maintenance Checklist............................................................................ 193
Weld-on Ends / Coupling Comparison.................................................... 194
Output Charts ......................................................................................... 195
Using a Nomograph................................................................................ 202
Minimum Pipe Wall Thickness ................................................................ 210
Pictograms.............................................................................................. 211
Glossary of Terms................................................................................... 212
List of Lubricants and Nitrogen............................................................... 217
Hydraulic Schematic—Boom Circuit (1 of 2) .......................................... 221
Hydraulic Schematic—Boom Circuit (2 of 2) .......................................... 223
Hydraulic Schematic—Concrete Pump .................................................. 225
Output Chart ........................................................................................... 227
Nomograph ............................................................................................. 229
Water boils
VG
VG 2
VG 2
VG 6
VG 8
2
3
4
6
10
0
Optimum
Operating
Viscosity
temp chart.eps
Minimum permissible
viscosity
(°C) -40° -30° -20° -10° 0° 10° 20° 30° 40° 50° 60° 70° 80° 90° 100° 110° 120°
(°F) -40° -22° -4° 14° 32° 50° 68° 86° 104° 122° 140° 158° 176° 194° 212° 230° 248°
°C = degrees Celsius
°F = degrees Fahrenheit
Torque Specifications for Metric must be torqued to within 6% of the requirement. For
example, a bolt to be torqued to a 200 pound
Bolts requirement must be within the range of 208–192 foot
The following charts show the tightening torques pounds for a dial scale torque wrench.
specified for the bolts used on Schwing equipment. The Schwing equipment uses two different types of bolts;
charts are to be followed unless a different torque one has a black finish and the other has a Dacromet/
specification is indicated for a particular procedure. Geomet finish.
A torque wrench must be calibrated to within 1% of its Torque specifications are very important for proper
indicated value throughout its range. Bolts must be machine function. For more information on this
torqued to within 4% of the requirement if the wrench subject, refer to the section on bolt tightening in the
has a dial scale. If no dial scale is present, the bolts Maintenance section of this manual.
Note: This chart does not apply to slewing bearings or hydraulic cylinders.
Conversion: 1 N-m = 0.738 ft-lb; 1 ft-lb = 1.355 N-m. Revised 11/96
not
! "# " $$ %
&'(
Wrench Size
= 13 mm
DACROMET/GEOMET 500a Torque Specifications
For Metric NORMAL Thread
8.8 10.9 12.9
Wrench Hardness Hardness Hardness
Bolt Size Size (mm) ft-lb (N-m)b ft-lb (N-m) ft-lb (N-m)
Example M 8 x 1.25 13 13 (18) 20 (27) 23 (32)
M 10 x 1.5 17 27 (36) 39 (53) 46 (62)
M 12 x 1.75 19 46 (62) 66 (90) 80 (108)
M 14 x 2 22 73 (99) 106 (144) 126 (171)
Dia =
8 mm M 16 x 2 24 113 (153) 166 (225) 193 (261)
M 18 x 2.5 27 163 (221) 229 (311) 269 (365)
M 20 x 2.5 30 227 (308) 325 (441) 379 (513)
M 22 x 2.5 32 312 (423) 438 (594) 518 (702)
Pitch =
1.25 mm M 24 x 3 36 392 (531) 559 (758) 651 (882)
M 27 x 3 41 578 (783) 830 (1125) 963 (1305)
M 30 x 3.5 46 797 (1080) 1129 (1530) 1295 (1755)
Bolt torque-courseDACRO.eps
Note: This chart does not apply to slewing bearings or hydraulic cylinders.
a. DACROMET/GEOMET 500 means coated with Teflon and silver colored.
b. Conversion: 1 Nm = .738 ft-lb.
Note: This chart does not apply to slewing bearings or hydraulic cylinders.
a. DACROMET/GEOMET 500 means coated with Teflon and silver colored
b. Conversion: 1 Nm = .739 ft lb.
Recommended Emergency
Hose Kit
Schwing recommends that you carry one of each of the
following hoses on the unit in case you blow a hose on
the job. Each size listed represents the longest hose of
each diameter that is installed on the unit at the factory.
Keep the insides of the hoses clean until they are
needed by capping the ends and using tape to hold the
cap in place. Dirt introduced into your hydraulic
system through the installation of a hose that was not
kept clean will cause a variety of problems in the
operation of the unit.
45 6 hose lengths
12 22 19 7/8 3/4
16 30 27 1 3/16 1 1/16
20 36 32 1 7/16 1 1/4
25 46 41 1 13/16 1 5/8
30 50 46 2 1 13/16
38 60 55 2 3/8 1 13/16
new fitting wrench size.eps
Banjo fittings
1 + 1 1 + 1
1 + 1
1 + 1 1 BO
O
M
#2
KVM 42
1
1
1
1 + 1
#1
1
OM
#2 & 3 FEEDER
BO
10 GREASE POINTS
1 + 1 1 1 + 1
1 1
1
TURRET FEEDER 1
12 GREASE POINTS
1 1 + 1
4
M#
1 + 1
BOO
1
1 #3
2 + 2 M
B OO
2 hollow pins,
2 grease points on each
1 + 1 1
#3 & 4 FEEDER
1 + 1 11 GREASE POINTS
2 + 2 1 + 1
One grease point on each 42 greasing locations42.eps
side of each of the two pins KEY
Identifies which autolube feeder
} 4 is connected to the grease point
The number inside tells how many
To Rock
1 2 1 grease points are at the location
#1-#2
valve feeder Signifies that the grease point is not
1
Primary #3-#4 greased by any autolube system
feeder
Signifies that there is a grease point
Turret/#2-#3 1 + 1 1 + 1 on each side of the boom
.072
(hollow pin)
42 bearing clrnce.eps
.039 .039
.054
.054 .039 .039
.059 .035 .035
.059 .035
.054
.029
Bearing Clearance Specifications
.054 .035
.114
(hollow pin) .044
NOTE! ALL MEASUREMENTS ARE IN INCHES, AND REPRESENT MAXIMUM ALLOWABLE CLEARANCES.
Contact the Schwing service department if you have any questions.
revDate
Appendix
Maintenance Checklist
The following are the normal recommended maintenance schedules after the break-in period is completed.
Item D W M Q SA A page/
Changing your hydraulic oil filters When dirty filter lamp comes on ..............................135
Changing boom oil filter When you change main return filter.........................135
Changing high pressure water filter When you change main return filter.........................135
Check truck fluid levels X ............................................. ................................141
Bleed moisture from air tanks X ..............................................................................141
Check truck tires X ..............................................................................141
Check hydraulic fluid X ..............................................................................141
Bleed moisture from hydraulic tank X ..............................................................................141
Check differential cylinder rod packings X ..............................................................................142
Inspect bolts on Rock Valve and rams X ..............................................................................142
Grease rock and agitator bearings X ..............................................................................142
Grease boom bearings and hollow pin X ..............................................................................142
Fill auto greaser reservoir X ..............................................................................142
Inspect for damage and leaks X ..............................................................................142
Check if maintenance is due X ..............................................................................142
Grease the boom zerks ......... X.....................................................................142
Check pipe wall thickness ......... X.....................................................................142
Check oil in optional air compressor ......... X.....................................................................143
Check Rock Valve tension nut ......... X.....................................................................143
Inspect cutting ring and rotate, if needed ......... X.....................................................................143
Lubricate mechanical moving parts ......... X.....................................................................145
Check tapered bend wedge bolt ......... X.....................................................................145
Check boom slewing gearcase level ......... .........X...........................................................145
Clean slewing gearcase breather ......... .........X...........................................................145
Check function of mech. boom brake ......... .........X...........................................................146
Clean and repack the Rollix gear ......... .........X...........................................................147
Check turret bolts for tightness ......... .........X...........................................................148
Check fluid in distribution gearcase ......... .........X...........................................................149
Check unit mounting hardware ......... .........X...........................................................149
Check hydraulic pressures ......... .........X...........................................................150
Clean the oil cooler fins ......... .........X...........................................................159
Check drive pinion bolts ................... .........X .................................................159
Change oil in optional compressor ................... .........X .................................................159
Change oil for temperature reasons ................... .................. X .......................................159
Change oil in distribution gearcase ................... .........Δ ...... ..........X............................ .160
Change oil in boom slewing gearcase ............................. ........ X....... ................................160
Test the dirty filter warning circuit ................... .................. X .......................................161
Change oil for age reasons ...................................... ......... X..............................162
Complete cleaning of optional compressor ...................................... ......... X..............................162
Inspect boom, outriggers, and tower Changes with unit age .............................................162
Change corrosion inhibitors ...................................... ......... X..............................162
CONCRETE CONCRETE
BPL 1200 HDR-23 PRESSURE PRESSURE
Pumpkit model (PSI) (BAR) Concrete
2000 138
PERFORMANCE CHARACTERISTICS OF pressure is
PISTON SIDE
1800 124
shown here.
(bar)
(bar)
PUMP SPEED
2100 RPM
1700 117 Max. pressure
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110 is shown for
350
PISTON SIDE
1500 103
both piston
1400 97
Hydraulic oil and rod side
300 Piston side 1300 1285 88.6 90
pressure shown configurations
breakpoint 1200 83
Using the chart the 220 bar oil pressure marking on the rod side scale
Example 1—Checking flow at a given pressure (Item A in the example below). Draw a line straight
Your unit is configured on the rod side (standard from across the page until you intersect with the horsepower
the factory). You notice that your machine is not getting curve (Item B). Next, draw a straight line down from
as many strokes per minute as you are used to seeing. the intersection point until you pass through the rod
You count the strokes and see that you are getting side number of strokes scale, and read the strokes per
about 21 1/2 per minute. You check your pressure gauge minute. At 220 bar you should be getting a little more
and see that the hydraulic oil pressure is at 220 bar. To than 21 strokes per minute. Your unit is fine.
determine whether your unit is acting normally, locate
CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
output chart use.eps
2000 138
PERFORMANCE CHARACTERISTICS OF
PISTON SIDE
1800 124
(bar)
(bar)
PUMP SPEED
2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110
Example 2—Checking your hydraulic pumps of even a few RPM will give you a bad
To determine whether your pumps are still in good reading. Check the RPM of the drive shaft with
working condition, use the output chart and a flow a digital tachometer if one is available.
meter. Test one pump at a time, multiply the readings • Know how to use your flowmeter. Read the
by 2, and chart the result. You must multiply the instructions that came with it, and remember
readings, because the chart is based on the output of that a flowmeter must be calibrated
two pumps but we are only testing one at a time. periodically.
To test your pumps: • Make two copies of the output chart so you
• Be sure you are using the chart that applies to don’t ruin your original. You need one chart for
your unit. each pump tested.
• Select the proper gear for pumping (found on Read the flow at 0 bar, 100 bar, 150 or 200 bar, 250 bar,
the information plate mounted in the cab). and 300 bar. Also, document the breakpoint. The
• Set the pump speed (input drive shaft) RPM. breakpoint is where the flow drops off rapidly. You will
Pump speed information is found on line 16 of be able to notice it on the flowmeter. If you think it
the Delivery Inspection Report which arrived would be helpful, copy the chart below. Check which
with your unit when it was new. A difference reading you used (150 or 200 bar). The breakpoint will
be very close to either 150 or 200 bar, so it is not
necessary to take both readings. The breakpoint
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
CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
1checking output.eps
2000 138
PERFORMANCE CHARACTERISTICS OF
PISTON SIDE
1800 124
(bar)
(bar)
PUMP SPEED
2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110
1000 70
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 you have done the test incorrectly or are using
reasonably matches the specification plot on the wrong chart. In our example, the pump is
the chart, the pump is fine. If your line is to the okay. (See the plot that follows.)
lower left of the specification plot, the pump is
getting weak. If your line is to the upper right,
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)
CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
3checking output.eps
1200 83
ROD SIDE
300 bar
(bar)
1100 76
1000 70
250
600 41
200 500 34
400 28
150 200 bar
300 21
100 100 bar
50
WEAK 0 bar
200
100
14
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.)
(138) (204) (274) (332) (366)(390)
When you connect the dots, the line is completely If the plotted curve matches the specification plot for a
below the specifications. This pump is very weak and while but the breakpoint is too high or too low, it is
will completely stop pumping oil soon. You may notice possible to make an adjustment. Contact Schwing
high heat with this unit if you are pumping at high oil Service Department for the procedure.
pressures. There are many different possible pump kits and power
NOTE! settings for this unit. If you accidentally destroy your
Never try to make up for this weak pump by original output chart, please have your serial number
increasing the speed of the engine. If the handy when you call to get a replacement. Also, please
pump turns faster than specification, it will advise us if you have changed differential cylinders,
not be able to draw oil as fast as it is turning material cylinders, or hydraulic pumps, because you
(“cavitation”), and immediate failure could may need a different output chart than the one that was
result.
originally shipped with the unit.
Using a Nomograph power rating (in Kw) is shown for the engine or electric
motor. With a truck-mounted pump that uses a PTO
from the truck engine, the power rating reflects the
General information
power output of the hydraulic pumps only. (All the
If you have read the original Schwing power from the truck engine is normally not available
publication Nomographs—A Guide to Usage, you will to the concrete pump and should not be used for power
notice several changes in this document. Because not calculations.) If you know the required output for the
all of the power from the truck engine can be used for job, the nomograph will help you calculate the required
the concrete pump, the TK number of the engine has no pressure. If you know the output and pressure, you can
meaning. Therefore, this section about using calculate the power requirement.
nomographs is being adapted especially for boom The nomograph was developed by extensive trial-and-
pumps. We can still figure out the TK of the job to do, error testing and has proven to be accurate to ±10% in
but the suitability of the pump has to be determined in nearly all pumping applications. The original
a different manner. To make the pump numbers and job nomographs used “spread measure” of fresh concrete
numbers match, we will use a “Power Factor Number,” instead of slump, and the two are not directly
which takes into account the power of the hydraulic interchangeable. Some approximations are used in
pumps 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 cubic meters but the ±10% accuracy still applies. In all cases, it is
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
1. the amount of power available, you know that the concrete will be hard to feed into the
cylinders, you should adjust the output requirement to
2. the maximum concrete output available, and
compensate for incomplete filling. For example, if you
3. the maximum concrete pressure available. will need 50 cubic yards per hour into the form but the
To estimate the power a pump requires to complete a concrete is so stiff that it will fill the cylinders only
particular job and to determine which pump is 80%, you should multiply the required output by 1.25
appropriate, a nomograph is used. (1÷80%).
With a concrete pump that is driven by its own prime The nomograph is divided into four quadrants (Figure
mover, such as a trailer-mounted concrete pump or a 185).
truck-mounted pump with a separate drive engine, the
Q in yd3/hr.
80
Pistonside 67
60
40
100
200
2"
Lower left quadrant Lower right quadrant300
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
The upper left quadrant is the beginning and end point To use the nomograph, you begin at output required
of the graph, and it shows maximum output, pressure, and move clockwise until you encounter the lines that
and power for a specific machine. The upper right represent your job situation. Each time you meet the
quadrant accounts for the relationship between line that applies, you make a 90° turn until you come to
concrete output and pipeline diameters. The lower right a point on the bottom of the upper left quadrant that
quadrant accounts for the resistance to flow of the shows pressure required (Figure 186).
entire pipeline system. The lower left quadrant
accounts for the 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 186
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
1. We will need an average output of 75 cubic yards pump 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
3. We will need the following pipeline lengths:
vertical run, we will have to add 1.1 times 70 ft =
Separately laid pipeline: 77 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
particular model of concrete pump (Figure 187).
Power factor
number
TK number does not apply to truck mounted units. (replaces TK)
Curve shown is Power Factor number (PF). 72600
200
boom-upper left quad-eps
Q in yd3/hr.
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
140
Figure 187
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 output must always be less than or equal to the PF. For
number of the job, example, if you needed 50 cubic yards per hour and
• the maximum output required by the job must determined that this will require 750 PSI, you can
be available from the pump, and multiply 50 by 750, which equals 37,500. Any pump
you select must have a PF of 37,500 or greater. If you
• the maximum pressure required by the job
are using a nomograph that has been converted to
must 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 for bar to PSI
able to go from rod side to piston side, maximum is 18.966. For all practical purposes, you can use 19.
pressure and output can be exchanged—that is, you can For 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 the pipeline and forms a slippery layer on which
determined by the size of the hydraulic pumps, the the bulk of the concrete slides. While it is true that
number of strokes per minute, and the size of the a 6-inch pipeline has 49 percent more surface area
differential and material cylinders. The unit is usually to coat than a 4-inch pipeline, the volume of
designed so maximum output can be achieved only at concrete that can move on the layer is increased by
less than maximum pressure. 125 percent, which results in lower velocity of the
Maximum pressure (abbreviated as max P) is concrete (in feet per second), lower friction, and,
determined by the size of the differential and material therefore, lower pressure. A pump that may not be
cylinders and the setting of the main relief valve. To be capable of completing a difficult job through 4- or
sure that the unit will handle the job, be careful to 5-inch pipe may be able to do it easily through 6-
notice max P and max Q. Here is an example of why inch pipe. Experience has taught us that 5-inch is
that is important: You contract to pump a job that the optimum pipeline size for lengthy vertical
requires only 20 yards per hour, but you calculate that runs, such as those found on high-rise buildings. It
you will need 2100 PSI pressure. The PF of this job is is large enough for most aggregate but small
42,000 (20 x 2100). The pump shown in Figure 187 enough that you minimize the amount of concrete
has a TK of 72,600, so there is enough power available. that slides back into the hopper when the concrete
However, the maximum pressure available from the valve cycles, which we call backwash. You must
pump is only 1570 PSI. This pump would not do the also consider the people at the point of placement.
job. Very few hose handlers, if any, can move 6-inch
hose on a slab all day. There is no provision in the
2. Follow the chart in a straight line from required
nomograph for mixing pipeline sizes. For example,
output into the upper right quadrant until you
if you will be reducing from 5-inch to 4-inch pipe,
come to the size of the pipeline that you will use. A
you should calculate the chart as if you were using
good rule of thumb for sizing pipeline is to use the
4-inch pipe for the entire distance. This will not be
largest diameter pipeline that you can. It takes less
completely accurate, but you will be safe in your
force to move concrete through a 6-inch pipeline
pressure calculation. In our example, we use 5-inch
than, for example, a 4-inch pipeline. When
pipeline (Figure 188).
pressure is exerted on concrete in a pipeline, a
paste of water and cement fines coats the inside of
Pipeline diameter in inches
Q in yd3/hr.
4"
Figure 188
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 188. • each 30° or 45° bend with a radius of 1 meter
3. The lower right quadrant refers to the or 250 mm = 3 feet
proportional value of your pipeline. It is a way of • each section of rubber hose causes three times
taking into account not only the length of the as much resistance as the same length of steel
pipeline, but also the number of bends, the pipe (e.g., 12 ft of rubber hose has the same
increased resistance of flow in rubber hose, and resistance as 36 ft of pipeline)
other factors. It is more a measure of the resistance • Figure all horizontal and vertical distances
to flow than a measure of length. In calculating the equally. The increased pressure required to
proportional value of your pipeline, always apply push concrete vertically is accounted for by
the following criteria: adding pressure, not distance. An example
• each 90° bend with a radius of 250 mm (boom pipeline is shown below (Figure 189).
elbow) = 3.5 feet
boom 4 nomo.eps
40 ft.
hose
150 ft. pipe
70 ft.
level
difference
NOTE!
Proportional value of the 42 boom and deck pipe system is 260 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 = 260 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 = 530 feet.
Round down to 500 feet to make it easy to use the chart (Figure 190).
Figure 189
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 previously, we are using 500
right quadrant until it intersects with the line that feet as our proportional value (Figure 190).
represents your pipeline. When you reach the
lwr rght quad-eps
100
200
300
400
Make a 90° turn when
you intersect with the
500
proportional value that
applies to your job.
600
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI
As you can see by the chart in Figure 191, we are PF = (627 x 100)
reentering the upper left quadrant through the pressure PF = 62,700
scale at about 550 PSI. Remember, we now have to add
The unit must have a PF over 62,700, and it must be
the head pressure for our vertical rise. At 1.1 PSI per
able to pump 100 yd3/hr and 627 PSI simultaneously.
foot of level difference and our 70-foot vertical run, we
Look at the pump shown in our sample nomograph
must now add 1.1 x 70 = 77 PSI to the 550 PSI from
(Figure 192).
the chart.
• Can the unit pump at 627 PSI? Yes
550 PSI + 77 PSI = 627 PSI
• Can the unit pump 100 yd3/hr? Yes
NOTE!
• Can the unit pump both simultaneously? No!
When calculating the head pressure from
vertical runs, it doesn’t matter if the This unit will not do the job.
pipeline runs straight up and down or if it The engine is a little too small. The intersection of 100
runs uphill at an angle. Only the level yards3/hr and 627 PSI has been plotted for visual
difference in feet is needed for the pressure representation, but you can see immediately that the PF
calculation. If the pipeline is running
downhill, the operator will need special of the job (62,700) is bigger than the PF of the unit
knowledge, but you don’t need to add any (56,650). The curved black line represents the PF of the
head pressure to the nomograph. unit. If the unit is going to be able to handle the job, the
The nomograph is now complete. The PF of our job intersection of pressure and yd3/hr will be to the right
can be calculated like this: and down from the curved line. Anything to the left or
above the line is beyond the power of the hydraulic
PF = PSI x yd3/hr
pumps. If we could order this same unit with the pumps
We need a unit that is capable of 627 PSI and 100 yd3/ set to a higher Kw, the PF of the higher Kw unit would
hr. The PF of this job is: be 72,600, which would be sufficient.
56,650
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 192
Is this unit sufficient for the job?
Plotting the intersection of our hypothetical job again, • Pump the top of the building at 85 yd3/hr
you can see that it falls within the power zone of the
instead of 100 yd3/hr.
hydraulic pumps with a higher Kw (Figure 193).
• Pump the top of the building at a 6-inch slump
Bearing in mind that the nomograph should only be instead of 5-inch. (This would still be within
considered accurate to within ±10 percent, you should specifications.)
always calculate conservatively, and allow for the
• Remove some of the rubber hose at the end of
graph tolerance. In the case of the pump in Figure 193,
the horizontal run. Normally, with job
we should still be safe even if the pressure required
circumstances that did not require a substantial
were 10% greater (690 PSI).What if you already own
vertical run, you could also use 6-inch instead
the pump shown in Figure 192? Is there anything that
of 5-inch-diameter pipeline. But in our
can be done to the job specifications to make the unit
example, the entire vertical run was made with
with the less powerful pumps work? You could use the
the boom. The boom can never support 6-inch
smaller PF unit shown in Figure 192 if you can get
pipeline.
permission to do any of the following things:
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
up lft 132Kw Qwad 2000R-eps
P (in PSI)
Figure 193
Same model pump with larger Kw hydraulic pumps
D
4200 290
ED
ATE
m
D
EAT
te
ATE
TRE
280
ys
4000
“s
T TR
TRE
ED
4.4
EAT
270
AT
m
A
AT
ste
RE
4“ H
” HE
)
HE
3800
TED
m
TT
sy
260
5m
4.4
em
“
“
EA
4.9
4.0
EA
2
(1
st
m
H
250 ste
TR
sy
3600
”&
m
6“
te sy
8“
AT
ys
4.8
5“
4.
240 )s
HE
e
3400 ug
5“
230 ga m
, 11 ste
3200 220 ,9 sy
“ (7 6“
210 4.9
3000
200
2800
190
2600 180
MATERIAL PRESSURE
170
2400
160
2200 150
2000 140
130
1800
120
1600 110
100
1400
pipewallvsPress2.eps
90
1200 80
1000 70
60
800
50
600 40
400 30
20
0.120”
0.150”
0.177”
0.188”
0.250”
200
10
0 0
PSI BAR
0 .050" .100" .150" .200" .250" .300" .350"
.025" .075" .125" .175" .225" .275" .325" .375"
1. This chart assumes a safety factor of 2:1. Higher safety factors may be required in some circumstances.
2. Wear reduces wall thickness. Thickness must be checked on a regular basis.
3. Pressures may be limited even more by clamp style or pipe end used.
4. The chart is based on 62,000 PSI tensile strength. Heat-treated calculations are based on 120,000 PSI tensile strength.
5. The chart is for pressure calculations ONLY. There is no allowance for mechanical forces other than pressure, and thicker
walls may be needed for mechanical strength because of support or restraint considerations.
6. The chart does not take into account metal fatigue caused by pressure cycles.
Note! This chart is intended as a guide for concrete pumping applications and is subject to the notes,
assumptions, and conditions listed above. Any other use of this chart is not recommended.
This chart does not apply to double-wall pipe. Double wall pipe can be checked by inspecting the inside of the pipe. If the insert is intact, the pipe is
okay. If the insert is worn through, the pipe must be replaced. Contact your pipe supplier for the pressure capacity of your double-wall pipe.
Pictograms
Shown below are the pictograms used on Schwing
pumps and their accessories, along with a brief
description of each.
Boom #1 (main) Boom #2 Boom #2 speed control Boom #3 Boom #4 (tip) Boom slewing
slow
medium
extend retract extend retract fast extend retract extend retract clockwise counter-
(CW) clockwise
(CCW)
Remote box ON / OFF Truck engine ON / OFF Engine throttle Electric vibrator Concrete pump
off Decrease off On reverse
on Increase Off
automatic
(Not functional on 45 SX) On forward
Electric vibrator Water pump / Compressor Concrete pump Truck engine ON / OFF
Manual ON Water pump ON On reverse off
OUTRIGGERS
4552pcto.eps
Extend (DS front) Extend (PS front) Slewing (DS rear) Slewing (PS rear) Jacking
Extend Retract Extend Retract Slewing open Slewing closed Slewing open Slewing closed extend (down) retract (up)
Electrocution Guide
Made by combining the words “electric” + An assistant brought in to help with backing up a
“execution.” It means “death by electricity.” See truck or trailer or with other circumstances in
also: Conductors which the driver cannot see enough to ensure
safety. See also: Spotter
EN 287-1 / PREN 288-3
The code for structural welding with steel as High Voltage
defined by the European Norm. See also: For the purposes of this manual, any current over
Certified Welder 120 volts AC is considered high voltage. In the
United States, electrically driven concrete pumps
Expert normally operate the motors at 480 volts AC
As used in this manual, an expert is defined as a (high voltage) and the controls at 24 volts DC
person who, on the basis of specialized training (low voltage). With electric wires in residential or
and experience, has developed a high degree of industrial areas, the voltage is approximately
knowledge and skill in the areas of concrete 8000 volts to ground or 13,800 volts from phase
pumps, concrete pumping, cleanout procedures, to phase (distribution voltage). When dealing
generally accepted engineering norms, and with electric wires that are mounted high above
safety regulations to the extent of being able to the ground on steel towers, the voltage ranges
evaluate equipment and processes as they relate from 100,000 to 1,000,000 volts (transmission
to job safety. Experts demonstrate their voltage).
knowledge and abilities by passing the
certification testing and experience requirements Hopper Grate
of the Concrete Pumping Association. A meshwork typically made from steel bars and
Other experts may include master mechanics placed over the concrete hopper. It serves to
and after-sales service technicians of the keep human body parts away from the agitator
manufacturer. See also: Certified Operator (when left in its proper position) and to keep
large foreign objects from falling into the hopper,
Fast Switch which could cause blockages if they were
A secondary hydraulic circuit added to single- pumped. The hopper grate must be secured in
circuit machines to disable the stroke limiter position in order to be effective.
during the switch of the Rock Valve cylinder,
thereby making the Rock Valve switch quickly. Jacking the Outriggers
This circuit is not needed or available on twin- Adjustment of the outriggers in the vertical
circuit machines. direction. With boom-mounted concrete pumps,
you should strive to make the adjustments so
Foreign Material that the unit sits within 3° of level.
Material that was never intended to be pumped
but ends up in the concrete hopper. Examples of Licensed Electrician
foreign material include small animals, hammers, A qualified electrician licensed by the state,
ready-mix truck fins, unmixed clumps of cement, county, or municipality where the connections
hardened concrete that breaks away from ready- are to be made. In some locations, electricians
mix truck fins, and soft drink cans. Many of these are not required to be licensed, but the work
items can create a blockage if they are pumped should still be completed by a competent
through the system. professional. Under no circumstances should
high-voltage connections be made by a concrete
pump operator or related personnel.
Maintenance OSHA
All procedures for servicing, inspection, and Occupational Safety and Health Administration.
repair of concrete pumps and related equipment A branch of the U. S. federal government that
and devices. Maintenance and inspection are deals with job safety. It establishes and enforces
methods of maintaining the desired state of the safety regulations for industry and business. One
equipment. Repair is the method of restoring the of the areas over which it has authority is
desired state of the equipment. construction job sites and workshops.
Maximum Pressure Personal Protective Apparel
When talking about a hydraulic system, Things you can wear to protect yourself from
maximum pressure refers to the highest pressure potential dangers in a concrete placing
that can be achieved with the settings of the environment. Examples are:
circuit relief valves. When discussing concrete • snug-fitting work clothes
output, maximum pressure refers to the pressure • steel-toed work boots
that will be developed if the hydraulic system • lime-resistant gloves
pressure reaches the relief valve setting. • safety glasses
Concrete pressure is always the force at which • ear muffs or ear plugs
the differential cylinders are moving, divided by • rubber boots for when you have to stand in
the cross-sectional area of the concrete cylinder. concrete
Maximum concrete pressure, then, is developed • hard hat
when the differential cylinders are moving with
Point of Discharge
maximum force, which is determined by the
The location on the machine from which concrete
hydraulic system relief valve setting. During
is expelled from a delivery system. This can be
normal pumping, the resistance of moving the
the point of placement (the actual form that is
concrete through the pipe or boom creates the
being filled with concrete) or the cleanout area
pressure needed by the pump and is well under
after completion of a job.
the maximum pressure. See Also: Concrete
Pressure Pour
Used by the concrete pumping industry and in
Minimum Safety Distance
this manual as a noun. It is the specific job for the
In this manual, the term “minimum safety
pump during any given time period, e.g. “We’ll
distance” refers to the closest distance that you
grab lunch right after the pour.”
are allowed to approach an object or electrical
wires while leaving room for errors in human Prime Mover
judgment or machine malfunction. The distance The primary power source for a hydraulic
from electrical wires in the United States is 17 system. The term “prime mover” denotes neither
feet, as recommended by the Concrete an internal combustion engine nor an electric
Pumping Association. This distance may have motor.
other values in different countries.
Proportional
Murphy’s Law Proportional movement means the speed that a
An old adage that says: “Anything that can go boom or outrigger travels is proportional to the
wrong, will go wrong, and at the worst possible amount of movement on the control handle
moment.” (joystick or outrigger handle).
Operational Area PTO
The area around a working piece of equipment (Power Take Off) A switchable output from the
or point of discharge where dangers can be transmission or an intermediate gearcase. On a
encountered because of the nature of the concrete pump, the PTO is used to divert the
machinery or process in use. For safety reasons, power from the engine and drive train to turn the
do not allow unauthorized presence in the hydraulic pumps.
operational area.
Truck fluid levels See owners manual for your specific truck
Grease for
Optimoly Paste White T - 250 grams
spline and couplers
Hydraulic Oils
ISO viscosity VG 32 = winter in northern US and Canada
ISO viscosity VG 46 = summer in northern US and Canada
ISO viscosity VG 68 = tropical areas, desert summers, indoor uses .
The following table shows the characteristics of Rando HD 46. You may use this information for
comparison with other brands.
ISO Viscosity Viscosity Flash Pour Foam, Seq II
Viscosity cST @ cST @ Viscosity Gravity point point ml foam @ 0/10
Class 40 C 100 C Index API F F minutes
VG 32 30.1 5.3 106 30.7 385 -25 20/0
VG 46 46.2 6.9 105 29.3 425 -20 20/0
VG 68 65.5 8.7 103 28.6 445 -20 20/0
Some oil manufacturers offer vegetable-based hydraulic oils, which are considered environmentally
friendly (the additive packages are not inert, however). These vegetable-based oils must NEVER be
mixed with mineral-based oils. A complete flush of the hydraulic system must be performed when
changing to this type of fluid. See the list below for a sample of the available oils and viscosities.
Gearcase Oils
A) for distribution gearcases
The order of the list is meaningless. Any oil that meets the DIN quality designation and ISO
viscosity specification may be used.
The lubricants listed above are suitable for continuous ambient (outside) temperatures of -10 C (14
F) to +40 C (104 F). For conditions outside of this range, contact the oil manufacturer for
recommendations.
Viscosity class 220 roughly corresponds to SAE 90.
Compressor Oils
Use VG 100 oil when ambient (outside) temperature is 0 to 10 C (32 to 50 F).
Use VG 150 oil when ambient temperature is above 10 C (50 F).
Grease
The order of the list is meaningless. Any grease that meets the quality designation and viscosity
specification may be used.
OM19A
Output Chart
Nomograph
WARNING
on
Do not stand
hopper grates.
S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
42SXside.eps
ALPHABETICAL INDEX
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Operation Manual - S 42 SXG 233
Alphabetical Index
L
G
laborers and oilers, safety rules . . . . . . 100
glossary of terms, alphabetical . . . . . . 212
laminated book container . . . . . . . . 33
greasing
license required to drive . . . . . . . . . 86
agitator bearings . . . . . . . . . . 102
list of lubricants and nitrogen . . . . . . . 217
boom zerk location chart . . . . . . . 191
local/remote switch
list of lubricants . . . . . . . . . . 217
vector controller . . . . . . . . . . 90
rock valve . . . . . . . . . . . . . 102
location
concrete shut-off valve . . . . . . . . 54
H options box . . . . . . . . . . . . 54
h.e.r. valve (holding valve) . . . . . . 32, 63 lock out - tag out
hi-flo pumpkit procedure . . . . . . . . . . . . . 139
components . . . . . . . . . . . . .38 lubrication . . . . . . . . . . . . . . 104
hi-flo pumpkit components . . . . . . . .38 boom pipe . . . . . . . . . . . . . 100
hopper quantity of slurry needed . . . . . . . 104
cleanout . . . . . . . . . . . . . 118 slickline . . . . . . . . . . . . 100, 104
removing hardened material . . . . . 120 slurry . . . . . . . . . . . . . . . 107
spraying with kleen kote . . . . . . . 103 with commercial lubricant . . . . . . 104
horn, warning . . . . . . . . . . . . . .80 with portland cement . . . . . . . . 104
hose shut-off with ready mix grout . . . . . . . . . 104
use . . . . . . . . . . . . . . . 111 without slurry . . . . . . . . . . . 104
how to reach us . . . . . . . . . . . . .13
hurry up cleanout . . . . . . . . . . . 124 M
hydraulic components . . . . . . . . . .38 machine
hydraulic pump drive, distribution gearcase . .43 selection . . . . . . . . . . . . . 82
hydraulic system maintenance
pressure specifications . . . . . . . . .22 filtration
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Operation Manual - S 42 SXG 235
Alphabetical Index
R
P
radio
parts, see spare parts
loss of remote signal . . . . . . . . . 132
personal protective equipment . . . . .84, 101
ram changing . . . . . . . . . . . . . 171
pictograms . . . . . . . . . . . . . . 211
ready-mix drivers
pinch valve
pointing out warning horn . . . . . . . 109
concrete shut-off . . . . . . . . . . .53
safety rules . . . . . . . . . . . . 100
pipe
reassembling the unit . . . . . . . . . . 123
makeup . . . . . . . . . . . . . . .16
reducers, remove for cleaning . . . . . . . 114
pipe ends, dissimilar . . . . . . . . . . 100
releasing the tip hose . . . . . . . . . . 97
pipeline, see slickline
remote box
placing crew, safety rules . . . . . . . . 100
led status messages . . . . . . . . . 59
pre-checks
loss of signal . . . . . . . . . . . . 132
importance of . . . . . . . . . . . .82
omnex . . . . . . . . . . . . . . 56
on pump . . . . . . . . . . . . . .85
remote control, cable receptacle . . . . . . 75
preheating the boom pipeline . . . . . . . 128
reordering
preparation
documentation . . . . . . . . . . . 132
for pumping . . . . . . . . . . . . .82
warning labels . . . . . . . . . . . 132
prechecks . . . . . . . . . . . .85
reservoir
rock valve . . . . . . . . . . . 102
fuel . . . . . . . . . . . . . . . 74
selecting a set-up location . . . . . .87
hydraulic oil . . . . . . . . . . . . 77
spraying the hopper . . . . . . . 103
water . . . . . . . . . . . . . . . 72
for travel
rock valve
after cleanout . . . . . . . . . . 124
cleaning . . . . . . . . . . . . . . 121
boom tie-down strap . . . . . . . .96
grease . . . . . . . . . . . . . . 102
pressure relief valves . . . . . . . . . . .61
preparation for concrete . . . . . . . 102
pressure setting
slewing cylinder diagrams . . . . . . 41
agitator . . . . . . . . . . . . . . 158
boom circuit . . . . . . . . . . . . 152
boom control block . . . . . . . . . 156 S
boom redundant relief . . . . . . . . 156 s valve diagram explanation . . . . . . . 41
delta p . . . . . . . . . . . . . . 153 safety
main concrete pump . . . . . . . . . 150 arranging for a spotter . . . . . . . . 101
outrigger . . . . . . . . . . . . . 157 blockages . . . . . . . . . . . . . 113
q-min . . . . . . . . . . . . . . 155 devices . . . . . . . . . . . . . . 61
pressure specifications agitator shut-off . . . . . . . . . 61
hydraulic . . . . . . . . . . . . . .22 blanking plug . . . . . . . . . . 107
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Operation Manual - S 42 SXG 237
Alphabetical Index
wetting . . . . . . . . . . . . . . 114 W
spotter . . . . . . . . . . . . . . 101, 109 warning . . . . . . . . . . . . . . . 12
stability of the unit . . . . . . . . . . . .98 warning horn
stroke limiter instructions . . . . . . . . . . . . 109
manual adjustment . . . . . . . . . 108 location . . . . . . . . . . . . . . 80
switch, emergency stop . . . . . . . . . .71 warning labels
locations . . . . . . . . . . . . . .61 decal location guide . . . . . . . . . 29
switching valve diagram . . . . . . . . .42 reorder . . . . . . . . . . . . . . 63
waterbox
T cleaning . . . . . . . . . . . . . . 122
tank filling . . . . . . . . . . . . . . . 101
fuel . . . . . . . . . . . . . . . .74 keeping it full . . . . . . . . . . . 112
hydraulic oil . . . . . . . . . . . . .77 safety . . . . . . . . . . . . . . . 78
water . . . . . . . . . . . . . . . .72
teach mode Z
vector controller zerks
setting parameters . . . . . . . . 175 agitator . . . . . . . . . . . . . . 102
time constraints . . . . . . . . . . . . 110 boom . . . . . . . . . . . . . . . 191
tip hose rock valve . . . . . . . . . . . . . 102
inspecting . . . . . . . . . . . . . .98
removal for cleaning . . . . . . . . 114
towing the unit (driving) . . . . . . . . .86
troubleshooting
checking your hydraulic pumps . . . . 197
loss of boom and outriggers . . . . . . 130
loss of electricity . . . . . . . . . . 130
time constraints . . . . . . . . . . 110
U
unfolding the boom . . . . . . . . . . .96
unit setup, location . . . . . . . . . . . .87
unlocking the tip hose . . . . . . . . . .97
V
valve . . . . . . . . . . . . . . . . .42
vector control
controls and indication devices . . . . .56
explanation . . . . . . . . . . . 52, 55
rear panel operation . . . . . . . . . .58
vector controller
local/remote switch . . . . . . . . . .90
teach mode . . . . . . . . . . . . 175
voltage converter, duvac ii . . . . . . . . .76