Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
HOME PRINT
OR
1-888-292-0262
OR
Branches
Florida............................................................. 1-813-985-8311
Northern California........................................ 1-925-371-8595
Southern California ....................................... 1-562-493-1012
Georgia ........................................................... 1-678-560-9801
Texas .............................................................. 1-972-245-5166
HOME PRINT
SERVICE TRAINING
Table of Contents
Service Manual
HOME PRINT
SERVICE TRAINING
Table of Contents
Power Regulator With Hydraulic Stroke Limiter (LRH) .... 61 Set the agitator pressure ......................................................123
Voac Variable Displacement Axial Piston Pump .................... 62 S 31 XT ......................................................................................125
Check all hydraulic pressures .............................................125
Preheat the hydraulic oil .....................................................125
Pressure Settings Check the concrete pump pressure -4 pumpkits .................126
General ........................................................................................ 63 To check or set the concrete pump pressure
Stroke Limiter Adjustment .................................................. 63 adjustments, follow these steps: .................................126
Check the accumulator Pre-Charge ..................................... 64 Setting the main relief valve ...............................................126
Setting the soft switch circuit relief pressure ......................128
To check or adjust the soft switch pressure setting,
Hydraulic Pump Adjustments proceed as follows: .....................................................128
Setting pressures on load-sensing booms ...........................128
Main System Pumps A11VO .................................................... 69
Preheat the oil .....................................................................128
Setting the Flow Rate ........................................................... 69
About proportional boom systems ......................................128
Horsepower Setting .............................................................. 70
Setting DP ...........................................................................129
Setting Stroke Limitation ..................................................... 70
Setting Q-min .....................................................................131
Q-min Output Flow .............................................................. 70
Setting boom pressures .......................................................131
Check all hydraulic pressures. ............................................. 71
There are several devices on the boom circuit which
Setting pressures on Hi-flo -6 pumpkits .............................. 71
control boom pressure (Figure 45): ............................131
Pressure setting procedure: .................................................. 72
Raise the pressure of the lowest circuit ..............................132
Setting the soft switch relief pressure .................................. 73
Setting the outrigger pressures ...........................................132
BPL 500 ....................................................................................... 75 To set the 280 bar relief valve for the outrigger
BPL 2000 ..................................................................................... 81 circuit: .........................................................................132
BPL 4000 ..................................................................................... 85 Setting 15 bar pretension ....................................................134
KVM 17M ................................................................................... 97 To check or set pretension, follow these steps: ..................134
Setting concrete pump pressure ........................................... 98 Setting the agitator circuit pressure ....................................135
Setting the soft switch circuit relief pressure ..................... 100 Setting accumulator circuit pressure ...................................136
Setting accumulator E-Stop manifold pressure 32XL Single Circuit ..................................................................139
(original production) .......................................................... 100 Check hydraulic pressures ..................................................139
Setting the accumulator unloading valve Preheat the hydraulic oil .....................................................139
(original production) .......................................................... 101 Check the concrete pump pressure (900 or 1200) ..............139
Setting accumulator E-Stop manifold pressure Setting boom pressures .......................................................140
(current production) ........................................................... 101 Preheat the oil .............................................................140
Setting the accumulator unloading valve About proportional boom systems ..............................141
(current production) ........................................................... 102 Setting DP ...........................................................................141
Setting the boom E-Stop manifold pressure ...................... 102 Setting Q-min .....................................................................142
Setting the boom/outrigger pressure .................................. 103 Setting boom pressures .......................................................143
Setting the outrigger pressure ............................................ 103 Setting the 140 bar down side relief valve pressure ...........144
Setting the boom pressures ................................................ 104 Setting the outrigger
Set boom section #1 down pressure ................................... 105 pressures (7 place boom valve systems) .............................146
Setting water pump pressure .............................................. 106 Setting 15 bar pretension ....................................................148
Setting the agitator pressure ............................................... 107 To set the agitator circuit pressure: .....................................148
KVM 28X .................................................................................. 109 32 XL Twin Circuit ...................................................................151
Check all hydraulic pressures ............................................ 109 Units up to 450 l/m .....................................................151
Set the concrete pump main relief valve ............................ 111 Check hydraulic pressures ..................................................151
Set the concrete pump main relief valve ............................ 112 Preheat the hydraulic oil .............................................151
Set the soft switch circuit relief pressure ....113 Check the concrete pump pressure
Set accumulator circuit hydraulic oil pressure ................... 113 (900-1200 - MPS pumpkits) ...............................................151
Setting the outrigger pressure ............................................ 115 Setting the soft switch circuit relief pressure ......................153
Pressure reducing valve ..................................................... 116 Setting the boom pressures .................................................153
Electric stroke limiter ......................................................... 116 Load-sensing boom pressures .............................................155
Load-sensing boom pressures ............................................ 116 Preheat the oil .............................................................155
Check or set P .................................................................. 118 About proportional boom systems ..............................155
Check or set Q-min ............................................................ 119 Setting DP ...........................................................................156
Set boom pressures ............................................................ 119 Setting Q-min .....................................................................158
Set the down side relief valve pressure .............................. 121 Setting boom pressures ...............................................158
Set 15 bar pretension .......................................................... 122 Setting the 140 bar down side relief valve pressure ...........160
Set water pump pressure .................................................... 122
Service Manual
HOME PRINT
SERVICE TRAINING
Table of Contents
Setting the outrigger Check the concrete pump pressure
pressures (7 place boom valve system) .............................. 160 (2020, 2023, 2525 pumpkits) ..............................................205
Setting the water pump hyd. pressure ................................ 162 Setting the main relief valve on -4 pumpkit .......................206
To set the agitator circuit pressure: .................................... 162 Setting the soft switch circuit relief pressure ......................208
32 XL Hi-Flow B&W ............................................................... 165 Setting boom pressures .......................................................209
Units up to 450 l/m ............................................................ 165 140 bar down side relief .....................................................209
Check hydraulic pressures ................................................. 165 Setting the outrigger pressures ...........................................209
Preheat the hydraulic oil ............................................ 165 Setting the water pump hydraulic pressure .........................210
Location of pressure setting/checking devices .......... 166 Setting 15 bar pretension ....................................................210
Check the concrete pump pressure Setting the agitator circuit pressure ....................................211
(2020, 2023, 2525 pumpkits) ............................................. 167 Setting accumulator circuit pressure ...................................213
Setting the main relief valve .............................................. 168 S 34 X .........................................................................................217
Setting the soft switch circuit relief pressure ..................... 169 Check hydraulic pressures ..................................................217
Setting the boom pressures ................................................ 169 Preheat the hydraulic oil .............................................217
Setting the 140 bar down side relief valve pressure .......... 172 Check the concrete pump pressure
Setting the outrigger pressures (2020, 2023, 2525 pumpkits) ......................................217
(7 place boom valve systems) ............................................ 173 Setting the main relief valve .......................................218
To set the agitator circuit pressure: .................................... 175 Setting the soft switch circuit relief pressure ..............220
32 XL High Flow Proportional ............................................... 177 Load-sensing boom pressures .....................................221
Units up to 450 l/m ............................................................ 177 Preheat the oil .............................................................221
Check hydraulic pressures ................................................. 177 About proportional boom systems ..............................221
Check the concrete pump pressure Setting DP ...................................................................221
(2020, 2023, 2525 pumpkits) ............................................. 177 Setting Q-min .............................................................223
Setting the main relief valve .............................................. 178 Setting boom pressures
Setting the soft switch circuit relief pressure ..................... 180 (Load sensing proportional booms.) ...........................223
Load-sensing boom pressures ............................................ 180 Setting the 140 bar down side relief valve pressure ...224
Preheat the oil ............................................................ 181 Setting the outrigger pressures ...................................225
About proportional boom systems ............................. 181 Setting the water pump hydraulic pressure .................226
Setting DP .......................................................................... 181 Setting 15 bar pretension ............................................226
Setting Q-min ..................................................................... 183 Setting the agitator circuit pressure ............................227
Setting boom pressures ...................................................... 183 Setting accumulator circuit pressure ...........................228
Setting the 140 bar down side relief valve pressure .......... 185 KVM 36X-42M (pre-1998) .......................................................231
Setting the outrigger pressures ........................................... 185 Pressure Settings for KVM 36X
Setting the water pump hyd. pressure ................................ 187 Proportional Load Sensing .................................................231
Setting 15 bar pretension ................................................... 187 Component Location Guide KVM 36 X
To set the agitator circuit pressure: .................................... 188 W/Rexroth Handvalves .......................................................232
32 XL Hi-Flow Prop, A11VO .................................................. 191 Pressure Settings for KVM 36X Proportional
Units above 450 l/m (-5 and -6 units) ................................ 191 Load Sensing ......................................................................233
Check hydraulic pressures ................................................. 191 Pressure Regulator Cutaway ...............................................234
Preheat the hydraulic oil .................................................... 191 Pressure Settings for Regulator and Releif Valves .............235
Check the concrete pump pressure KVM 36 LW & 36 X W/Rexroth Boom Handvalve ..........236
(2020, 2023, 2525 pumpkits) ............................................. 191 Pressure Settings for KVM 42
Setting the main relief valve .............................................. 193 (B&W Load sensing and Proportional Load Sensing ........237
Setting the soft switch circuit relief pressure ..................... 194 Component Location Guide KVM 42
Setting boom pressures ...................................................... 194 W/Rexroth Handvalves .......................................................238
Preheat the oil ............................................................ 195 Pressure Settings for KVM 42LW Proportional
About proportional boom systems ............................. 195 Load Sensing ......................................................................239
Setting DP .......................................................................... 195 Pressure Regulator Cutaway ...............................................240
Setting Q-min ..................................................................... 197 Pressure Settings for Regulator and Relief Valves
Setting boom pressures ...................................................... 197 KVM 42 ..............................................................................241
Setting the 140 bar down side relief valve pressure .......... 199 KVM 42 LW, W/Rexroth BoomHandvalve .......................242
Setting the outrigger KVM 36X ...................................................................................243
pressures (7 place boom valve systems) 200 Set the concrete pump main relief valve (single- circuit) ...244
Setting 15 bar pretension ........................................... 202 Setting the soft switch circuit relief pressure ......................247
To set the agitator circuit pressure: .................................... 202 Set accumulator circuit .......................................................248
KVM 32 XG .............................................................................. 205 Units with a pressure- compensated pump .................248
Check hydraulic pressures ...................................................... 205 Setting the outrigger pressure .............................................249
Preheat the hydraulic oil .................................................... 205 Check or set P ...................................................................252
Service Manual
HOME PRINT
SERVICE TRAINING
Table of Contents
Set boom pressures ............................................................ 253 Setting concrete pump pressure (single-circuit units) ........303
(load sensing proportional booms) ............................ 253 Setting boom circuit pressures ............................................306
Set 15 bar pretension .......................................................... 255 Load-sensing boom hydraulic controls ...............................306
Set water pump pressure .................................................... 255 Setting DP ...........................................................................306
Set the agitator pressure ..................................................... 255 Setting Q-min .....................................................................308
KVM 39X .................................................................................. 257 Setting boom pressure ........................................................309
Check all hydraulic pressures ............................................ 257 Set the #1 down side pressure .............................................310
Set the concrete pump main relief valve (twin circuit) ...... 259 Setting outrigger pressure ...................................................311
Setting the soft switch circuit relief pressure ..................... 260 Set accumulator circuit hydraulic oil pressure
Set accumulator circuit ...................................................... 261 (units with accumulator unloading valves) .........................314
(units with a pressure- compensated pump) .............. 261 S 45/47SX ...................................................................................317
Set the outrigger pressure .................................................. 262 Setting Pressures .......................................................................317
Check or set P .................................................................. 265 Check all hydraulic pressures. ............................................317
Check or set Q-min ............................................................ 265 Setting pressures on Hi-flo -6 pumpkits .............................317
Set boom pressures ............................................................ 266 Setting the soft switch relief pressure .................................320
(load sensing proportional booms) ............................ 266 Setting boom circuit pressures ............................................320
Boom holding valves ......................................................... 267 Load-sensing boom hydraulic controls ...............................320
Set 15 bar pretension .......................................................... 268 Setting delta P pressure .......................................................321
Set water pump pressure .................................................... 268 Setting Q-min .....................................................................323
Set the agitator pressure ..................................................... 268 Setting boom pressures .......................................................323
S 42SX ....................................................................................... 271 Setting outrigger pressure ...................................................324
Setting Pressures ................................................................ 271 Set the agitator pressure ......................................................325
Check all hydraulic pressures ............................................ 271 Set accumulator circuit pressure .........................................326
Preheat the hydraulic oil ............................................ 271 S 45SX Hi-Flow - 6 ....................................................................329
Setting pressures on Hi-flo -6 pumpkits ............................ 272 Setting Pressures .......................................................................329
Setting the soft switch relief pressure ................................ 274 Check all hydraulic pressures. ............................................329
Setting boom circuit pressures ........................................... 274 Setting the main relief pressure and pressure cutoff on
Load-sensing boom hydraulic controls .............................. 274 Hi-flo -6 pumpkits ..............................................................330
Setting delta P pressure ...................................................... 275 Setting the soft switch relief pressure .................................332
Setting Q-min ..................................................................... 277 Setting boom circuit pressures ............................................332
Setting boom pressures ...................................................... 277 Load-sensing boom hydraulic controls ...............................332
Setting outrigger pressure .................................................. 278
KVM 52M (pre-1998) ...............................................................333
Setting the agitator pressure ............................................... 279
Pressure Settings for KVM 52 Proportional
Setting accumulator circuit pressure .................................. 280
Load Sensing ......................................................................333
KVM 42M - Proportional (Apitech) Single Circuit .............. 283 Component Location Guide- KVM 52 ...............................334
Check hydraulic pressures ................................................. 283 Pressure Settings for KVM 52 Proportional
Preheat the hydraulic oil .................................................... 283 Load Sensing ......................................................................334
Setting concrete pump pressure (single-circuit units) ........ 283 Pressure Regulator Cutaway KVM 52 ...............................336
Setting boom circuit pressures ........................................... 286 Pressure Settings for Regulator and Releif Valves
Load-sensing boom hydraulic controls .............................. 286 KVM 52 ..............................................................................337
Setting DP .......................................................................... 286 Setting Pretension Pressure(Refer to Figure 5) ..................337
Setting Q-min ..................................................................... 288 Control Block 1 for KVM 52 Boom 3, Boom 4,
Setting boom pressure ........................................................ 288 & Slewing 338
Setting pretension .............................................................. 291 Control Block 2 for KVM 52 Boom 1, Boom 2,
KVM 42M - Proportional (Apitech) Twin Circuit ............... 293 & Outriggers .......................................................................339
Check hydraulic pressures ................................................. 293 Pre-Control Block 1-A for KVM 52 ..................................340
Preheat the hydraulic oil .................................................... 293 Pre-Control block 1-B for KVM 52 ..................................341
Setting concrete pump pressure (High-flow pumpkits) ..... 293 Pre-Control Block 1-C for KVM 52 ..................................342
Setting the soft switch circuit relief pressure ..................... 295 Pre-Control Block 2-A for KVM 52 ..................................343
reheat the oil to check pressures ........................................ 296 Pre-Control Block 2-B for KVM 52 ..................................344
Load-sensing boom hydraulic controls .............................. 296 Electric Bypass Valve for KVM 52 ....................................345
Setting DP .......................................................................... 297 S 52 SX .......................................................................................347
Setting Q-min ..................................................................... 299
Setting Pressures .......................................................................347
Setting boom pressure ........................................................ 299
Check and adjust all hydraulic pressures ............................347
Setting 15 bar pretension ................................................... 301
Preheat the hydraulic oil .............................................347
KVM 42M - Proportional (Rexroth) ...................................... 303 Setting pressures on Hi-flo -6 pumpkits .............................348
Check hydraulic pressures ................................................. 303 Pressure setting procedure: .........................................348
Preheat the hydraulic oil .................................................... 303
Service Manual
HOME PRINT
SERVICE TRAINING
Table of Contents
Setting the soft switch relief pressure ................................ 350 Electrical Information
Setting boom circuit pressures ........................................... 350
Load-sensing boom hydraulic controls .............................. 350 Boom Control Systems and the Advantages of Each ............397
Setting Delta P pressure ..................................................... 351 Boom Control Systems .............................................................399
Setting Q-min ..................................................................... 352 Introduction to Proportional Controls ...................................400
Setting boom pressures ...................................................... 353 The Joystick with Potentiometer ........................................400
Setting main pressure ................................................. 353 The Proportional Amplifier ................................................401
Setting boom pressure (redundant) relief ................... 353 The Solenoid Valves ...........................................................401
Setting pressure cut-off .............................................. 354 The Proportional Amplifier in Use with the Radio ...............402
Setting slewing pressure ............................................ 354
Motherboard for Proportional Units ......................................403
Setting outrigger pressure ................................................. 355
Setting the agitator pressure ............................................... 355 Power Supply - Slot 9 ...............................................................404
Setting accumulator circuit pressure .................................. 356 Proportional Amplifier - Slot 1,2,3 ..........................................405
KVM 52M ................................................................................. 359 Calibration of Proportional Amplifier Cards ........................406
Setting relief pressure and pressure cutoff on Linear Signal Diagram .............................................................407
Hi-flo -6 pumpkits ............................................................. 359 Decal of Proportional Motherboard .......................................408
Setting the soft switch circuit relief pressure ..................... 362 Wiring Diagram - DUVAC II 12V / 24V Transformer .........409
Set boom circuit pressures ................................................. 362
Wiring Diagram - DUVAC II 12V / 24V Transformer .........410
Checking and Setting DP pressure ..................................... 363
Set Q-min ........................................................................... 364 Digital Proportional - Overview (1 of 5) .................................411
Checking boom pressures .................................................. 365 Overview ............................................................................411
Setting main boom circuit pressures .................................. 366 M.A.T. ................................................................................412
Checking pretension pressure ............................................ 367 Processor Unit .....................................................................413
Set the outrigger pressure .................................................. 368 Card Functions ....................................................................414
Set the agitator pressure ..................................................... 369 Control System Arrangement .............................................415
KVM 55M ................................................................................. 371 Digital Proportional - Programming ......................................416
Check all hydraulic pressures ............................................ 371 Programming ......................................................................416
Preheat the hydraulic oil .................................................... 371 MAT Operation ..................................................................416
Setting relief pressure and pressure cutoff on Menu Structure ...................................................................417
Hi-flo -6 pumpkits ............................................................. 372 Moving Through The Menu Survey ...................................418
Setting the soft switch circuit relief pressure ..................... 375 Access The Service Menu ..................................................419
Setting boom circuit pressures ........................................... 375 Identifying the Entries and Parameters ...............................420
Checking and setting DP pressure ..................................... 375 SCV Card Main Menus ...................................................420
Setting Q-min ..................................................................... 377 ?PAR Main Menu ...........................................................420
Checking boom pressures .................................................. 377 Submenus Functions and Parameters .................................421
Setting main boom circuit pressures .................................. 378 ?SELECT
Checking pretension pressure ............................................ 379 Submenu Functions and Parameters
Setting the outrigger pressure ............................................ 380 (In Service Menu Only!) .....................................................422
Set the agitator pressure ..................................................... 381 ?V24 Submenu Functions and Parameters ......................423
Set accumulator circuit pressure ........................................ 382 ?DIN Main Menu ............................................................423
?RACK Submenu Functions and Parameters ................424
S 58/61SX .................................................................................. 385
?BDI A Submenu Functions and Parameters .................425
Check all hydraulic pressures ............................................ 385
?BDI F Submenu Functions and Parameters .................426
Preheat the hydraulic oil ............................................ 385
?SOUT" Main Menu .........................................................427
Setting pressures on Hi-flo -6 pumpkits ............................ 385
?POUT Main Menu .........................................................428
Pressure setting procedure: ........................................ 385
?DIAG Main Menu .........................................................429
Setting the soft switch relief pressure ................................ 388
?SYSTEM Main Menu ..................................................429
Setting boom circuit pressures ........................................... 388
?GERAET Main Menu (In Service Menu Only!) ...........430
Load-sensing boom hydraulic controls .............................. 388
V2.4 Menus ........................................................................430
Setting Delta P pressure ..................................................... 389
Software Versions ...............................................................431
Setting Q-min ..................................................................... 390
Setting boom pressures ...................................................... 391 Digital Proportional - Balancing Valve Currents ..................453
Setting main pressure ................................................. 391 Hysteresis ............................................................................455
Setting boom pressure (redundant) relief ................... 391 Diagnostic Signal ................................................................455
Setting pressure cut-off .............................................. 392 Setting Valve Currents ........................................................455
Setting slewing pressure ............................................ 392 Digital Proportional - Troubleshooting ..................................457
Setting outrigger pressure ................................................. 393 Troubleshooting procedure 1 ..............................................459
Setting the agitator pressure ............................................... 393 Troubleshooting procedure 2 ..............................................459
Setting accumulator circuit pressure .................................. 394 Troubleshooting procedure 3 ..............................................459
Service Manual
HOME PRINT
SERVICE TRAINING
Table of Contents
Troubleshooting procedure 4 ............................................. 459 Bypass mode ...............................................................518
Troubleshooting The Radio ............................................... 460 Options box .........................................................................519
Operation ........................................................................... 461 Night light switch .......................................................519
Emergency Stop ................................................................. 462 Concrete shut-off valve switch ...................................519
Automatic Shut down ........................................................ 462 Control and monitoring components ..................................520
Trouble-shooting ................................................................ 463 Controller cabinet (Figure 13) ....................................520
Troubleshooting tables ....................................................... 464 Display window (Figure 14) .......................................520
Control status indications ...........................................520
Operating mode display ..............................................520
Comfort Control Manual Menu control .......................................................................521
1.0 Working with the info & diagnosis system ................. 468 Basic functions of the keys (Figure 15) ......................521
1.1 Introduction into the info & diagnosis system ..... 468 Fast selection/abbreviated function keys (shortcuts): .521
1.2 Menu structure info & diagnosis system / Local control .......................................................................522
Operation data display ....................................................... 470 Remote control ...................................................................523
1.2.1 Standard display & malfunction messages ....... 470 Menu overview - Main menu .............................................524
1.2.2 Main menu ........................................................ 471 Menu overview - Main menu (continued) ..........................525
1.2.3 "PUMP VPUME" sub-menu ............................. 472 Menu overview - submenus ................................................528
1.2.4 "OPERATION DATA" sub-menu .................... 472 Menu operation - Example: ................................................529
1.2.5 "MALFUNCTION LIST" sub-menu ................ 473 Diagnostic system/Fault handling ...................................530
1.2.6 "LUBRICATION-UNIT" sub-menu ................ 473 Display language ........................................................531
1.2.7 "I/O DISPLAY" sub-menu ............................... 473 Acknowledging messages ...........................................532
1.2.8 SCROLLING" sub-menu .................................. 474 Acknowledging faults .........................................................532
2.0 Concrete pump efficiency parameter setting / Fault definition ...................................................................532
Central lubrication / Prop characteristics ........................... 475 Low level fault ............................................................532
2.1 Password entry and parameter selection menu .... 475 High level faults ..........................................................532
2.2 Setting the concrete pump efficiency for Silent diagnostic .........................................................533
pumped volume determination .................................. 476 Reporting and acknowledging of faults ......................534
2.3 Adjusting the central lubrication .................................. 477 Acknowledging of several faults ................................539
2.4 Adjusting the proportional parameters for boom Switching off the control system ................................539
functions ............................................................................. 478 Summary of messages ........................................................540
Proportional characteristics adjustment for the Heat the oil first ..................................................................552
BOOM SLEW function with PROP valve types : ............. 479 Restore original factory settings .................................552
Proportional characteristics adjustment for the Setting parameters ......................................................553
BOOM 1 function with PULSAR valve types : ................ 480
3.0 I/O status display - signals & references ..................... 481
3.1 Machine control ................................................... 481 Radio Remotes
3.2 Concrete pump control ......................................... 483 Cross Reference Wiring Chart ................................................559
3.3 Boom control ....................................................... 484
3.4 Rear panel ............................................................ 486
3.5 Extension module ................................................ 487 Radio Control FW 18
4.0 Fault messages and fault causes ................................... 488
Table of Contents ......................................................................561
4.1Introduction ........................................................... 488
4.2 Control diagnosis electronic modules 1. Safety and Accident Prevention Regulations .....................561
Fault code S !) ............................................................ 489 Safety Regulations - Concrete Pumps with
4.3 Remote-control system diagnosis (fault code F!) 490 placing booms .....................................................................562
4.5 Engine/PTO Diagnosis (fault code D!) ................ 493 Traveling .............................................................................562
4.6 Concrete pump diagnosis (fault code B!) ............ 494 Jacking ................................................................................562
4.7 Boom control diagnosis (fault code M!) .............. 495 Concrete Pump ...................................................................562
4.8 Central lubrication/extension diagnosis (fault code Z/ Placing Boom .....................................................................562
E!) 497 Pipelines ..............................................................................563
5.0 Output signal interdependence list ............................... 498 Remote Controls .................................................................563
Electrical Connections .........................................................563
Part 1 Operation ...................................................................... 514
Commissioning .................................................................. 514 2. Short Instructions .................................................................564
Selecting local control ....................................................... 515 Preparing the Commissioning ............................................564
Selecting remote control .................................................... 516 Making Ready for Operation ..............................................564
Ram change mode: ............................................................. 517 Operating Mode ..................................................................564
Emergency stop buttons ..................................................... 518 Reasons for Automatic Switch-off .....................................564
Override of the E-stop manifold ........................................ 518 3. Preface ...................................................................................564
Service Manual
HOME PRINT
SERVICE TRAINING
Table of Contents
4. Extract from the Terms of Warranty ................................ 565 Troubleshooting: Receiver LEDs .......................................598
5. Model Plates ......................................................................... 566 Troubleshooting Controller (MC1) ....................................600
6. Technical Data ...................................................................... 566 Troubleshooting Table: Transmitter LEDs ......................601
7. Brief Description .................................................................. 566 16. Maintenance ........................................................................602
Transmitter ......................................................................... 566 Replacing of Fuses ..............................................................602
Receiver ............................................................................. 567 17. Repair ..................................................................................603
8. Control and Monitoring Equipment .................................. 568
Radio Remote .................................................................... 568
Receiver ............................................................................. 569
Radio Control FW 24
9. Commissioning ..................................................................... 570 Table of Contents ......................................................................605
Preparations ....................................................................... 570 Safety Instructions ....................................................................606
Ready for operation ........................................................... 570 Scope of Application .................................................................607
10. Operating the Radio Remote Control .............................. 571 Start-Up .....................................................................................608
Transmitter mode ............................................................... 571 Operation ...................................................................................611
Transmitter range ............................................................... 572
Charging the Battery ................................................................612
Putting out of Operation .................................................... 573
Changeover to Cable Remote Control ............................... 573 Maintenance ..............................................................................613
12. Safety Facilities .................................................................. 574 Operation Fault Indicators ......................................................614
Fuses .................................................................................. 574
13. Maintenance Works and Checks ...................................... 575 C32/CPC Radio Remote
Changing the transmitter battery ........................................ 575
Charging the transmitter battery ........................................ 575 Spread Spectrum Technology ..................................................617
Mounting the Receiver Antenna: ............................................618
Transmitter Operation .............................................................619
Radio Control FW 20 Remote Radio Controller .........................................................622
Table of Contents ..................................................................... 577
2. Short Operating Instructions .............................................. 578
Preparations ....................................................................... 578 Omnex Radio Control System
Ready-for-Operation State ................................................. 578 1. Introduction ..........................................................................627
Emergency Shut-Off .......................................................... 578 2. Physical Mounting ................................................................628
Automatic Shut-Off ........................................................... 578
3. Considerations for Electrowelding ......................................628
Interruptions of Work ........................................................ 578
4. Receiver Connector Assignments ........................................629
3. Foreward ............................................................................... 579
5. Cable Unit Connector Assignments ....................................630
4. Designated Use ..................................................................... 579
6. Fuses .......................................................................................630
Non Designated Use ................................................................. 579
7. Operations .............................................................................631
Extract from Terms of Warranty ........................................... 580
7.1 Receiver ........................................................................631
5. Safety Rules and Accident Prevention Regulations .......... 581 7.1.1 Receiver Lights - General Function ...................631
7. Short Description ................................................................. 582 7.1.2 Receiver Lights - Error Conditions ...................631
8. Technical Data: .................................................................... 583 7.1.3 Operator Adjustments: .......................................632
Transmitter ......................................................................... 583 7.2 Transmitter ....................................................................633
Receiver ............................................................................. 584 7.2.1 Transmitter Lights .............................................633
9. Monitoring-, Warning-, and Control Elements ................ 585 7.2.2 Operator Controls: .............................................634
7.3 Cable Unit .....................................................................634
10. Pre-Operational Instructions ............................................ 588
7.3.1 Cable Unit Lights ...............................................634
11. Operation ............................................................................ 592 7.3.2 Operator Controls: .............................................635
Battery Capacity ................................................................ 592
8. Troubleshooting Information ..............................................635
Disturbances ....................................................................... 593
8.1 I24-MC Board ...............................................................635
Frequency Change ............................................................. 593
8.2 Receiver TPCB-1527-01 Board ....................................635
12. Emergency Shut-Off .......................................................... 593
13. Interruptions of Work/End of Operation ........................ 594
14. Replacing the Battery ........................................................ 595 Conversion Charts
Recharging of Battery ........................................................ 595 Fluid Power Formulas ..............................................................642
15. Malfunctions ....................................................................... 596 Torque Specifications ...............................................................644
Message Interference ......................................................... 597
Torque Specification: Slewing Roller Bearing Bolts .............647
Trouble Shooting ...................................................................... 598
WP Number Codes ...................................................................652
Service Manual
HOME PRINT
SERVICE TRAINING
Table of Contents
BP Model Number Codes ........................................................ 653
Outrigger Spreads and Loads ................................................. 654
Boom Pin Clearances ............................................................... 655
Nozzle Chart ............................................................................. 665
Boom Times/Without Weights ................................................ 666
Boom Pressures & Nozzle Chart Size .................................... 667
Boom Pressures & Nozzle Chart Size .................................... 668
Rotek Bearing Clearance Instructions - SAIE - 5114 ........... 669
Special Tools
Hydraulic Trouble Shooting Kits ........................................... 679
Hydraulic Oil Filter Cart ........................................................ 679
Flow Meters and Accesories .................................................... 680
Flow Meter Y223 Model HT200 ............................... 680
Specifications: ............................................................ 680
Accessories: ............................................................... 680
Material Cylinder Alignment Tool ......................................... 681
Piston Installation Tools for Differential Cylinders ............. 682
Gland Packing Installation Tools ........................................... 683
Seal Replacement Tools ........................................................... 684
Piston Seal Guide Tool ...................................................... 684
Piston Seal Form Tool ....................................................... 684
Bushing Installation Tool ........................................................ 684
Rock Shaft Bushing Installation Tool ................................ 684
Accumulator Charging Kit ..................................................... 685
Adjustment Meters for Analog Proportional Cards ............. 685
Analog Adjustment Meter ................................................. 685
Technition Support Kit ........................................................... 685
Electrical Tools and Accessories ............................................. 686
Spanner Socket Tools for Boom Pins ..................................... 687
Truck Engine Tools ................................................................. 688
Pro-Link 9000 .................................................................... 688
Micellaneous Tools ................................................................... 688
Whip Hose and Fittings ..................................................... 688
Rock Valve Cover Alignment ............................................ 688
Service Manual
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Semi-annually
As Indicated
Quarterly
Annually
Monthly
Weekly
Daily
Task
Service Manual 1
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Semi-annually
As Indicated
Quarterly
Annually
Monthly
Weekly
Daily
Task
2 Service Manual
HOME
PRINT
Service Manual
Check if maintenance is due
Perform post-trip inspection
SERVICE TRAINING
S0167.eps
3
Maintenance, Lubrication Schedules, etc.
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
SCREEN SIZES
U.S. SIEVE NUMBER OPENING (micro-meters) OPENING (inches)
50 297 0.0117
60 238 0.009
70 210 0.0083
100 149 0.0059
140 105 0.0041
200 74 0.0029
270 53 0.0021
325 44 0.0017
PAPER 10 0.00039
PAPER 5 0.00019
149 mm
(100 Mesh)
SIZES IN MICRO-METERS
(Magnification 500x) 74 mm
(200 Mesh)
44 mm
(325 Mesh)
25 mm
10 mm
5 mm
2 mm
S0022.eps
4 Service Manual
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
X = 200
{
example: 12 = 200.
This means that for every 200 particles of
HOW BETA WORKS 12 microns or larger that hit the
media, 1 will make it through.
IN OUT = IN
OUT
FLOW S0024.eps
Service Manual 5
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
S0025.eps
6 Service Manual
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Handling, Storing & Dispensing and snow. The proper storing position of an oil drum
is: drum should be laid on its side with the bungs
Lubricating fluids approximately horizontal and at the lowest point. In
To obtain optimum performance from oil, proper this position, water and moisture cannot collect in the
handling, storing and dispensing is required. These chime and because the bungs are below the level of the
steps are necessary to preserve the integrity of the drums contents, the incidence of water being drawn
product. It is uneconomic to buy a high quality into the drum from normal breathing is greatly
lubricant and then permit degradation through reduced. For maximum protection, drums should be
contamination. stood on end with bungs down on a well-drained
surface. In circumstances when all the aforementioned
Unless simple precautions are observed, contamination
storing methods are impractical, drum covers should be
of lubricants can occur during storage; or during
used. Covers are available in both metal and plastic.
transfer of oil from the original container to the
Drums with a bung on the side should be stored either
dispensing equipment; or during dispensing of oils to
on their end, or on their side with the bung facing
the equipment to be lubricated. Pumps, oil cans,
down. Regardless of the position, drums should
measures, funnels and other dispensing equipment
always be placed on blocks or racks several inches
must be kept clean at all times and covered when not in
from the ground to avoid contact with moisture or
use.
standing water.
Storing oil drums, fill carts, or other containers outside
When drums must be stored outside with the bung end
of climate controlled areas is a poor practice. Water
upward, they should be blocked up in a manner that
and moisture may get into the drum around the bungs
will keep the drum teetered to provide sufficient
and contaminate or destroy the drums contents. A
draining of water. The drum should be rotated on the
drum standing on end with the bungs facing up can
blocks so that any water collecting on the top of the
collect rain water or condensation inside the chime.
drum surface does not come in contact with or
This water can gradually be drawn in around the bungs
submerge the bung openings.
by the breathing of the drum as the ambient
temperature rises and falls. This can occur even with Before opening a drum that has been stored outside, the
bungs drawn tight and the tamper-proof seals in place. bung and chime areas should be cleaned thoroughly to
In addition, the dirt and rust that can accumulate inside eliminate the hazard of collected rust, scale and dirt
the chime and around the bungs may contaminate the from falling into the drum.
drums contents when the drum is opened for use. Always use the oldest oil first. The probability of
As a general rule, lubricants in drums smaller than 16 oxidation, contamination and attack by heat and cold,
gallon capacity should never be stored outside. increase with age. If the oil quality is suspect due to
However if drums must be stored outside, a temporary long periods of storage, have the oil analyzed before
shelter or lean-to, and/or a waterproof tarpaulin is using it.
highly recommended for protecting the drum from rain
SUN
standing
RAIN
water
chime bungs
Service Manual 7
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Hydraulic Oils gets. The lower the ISO VG number the thinner the oil
and the lower the pour point of the oil. On the other
General information relates to all hydraulic oils. hand, the thinner the oil, the lower the temperature will
Specific information contains hydraulic oil have to be before it breaks down the lubricating film
recommendations for Schwing concrete pumps. that protects your components.
The quality of the oil needed for use in a Schwing
General information concrete pump is rated in the DIN system. The ratings
Hydraulic oils are rated for viscosity, heat dissipation, have to do with the chemical additive package that is
foaming characteristics, pour point, antiwear additives, introduced into the oil. Both the DIN rating HLP and
anticorrosive additives, lubricating qualities, HV qualities are approved for use in our concrete
compressibility, temperature range, temperature pumps.
stability, and other functions. Although many different
brands of oil meet these specifications, they may use Specific information
different chemical additive packages to achieve the end All concrete pumps leave the Schwing factory filled
result. For this reason, you should not mix two with Texaco Rando HD 46 hydraulic oil, which has an
different brands of oil. The additive package from one ISO viscosity rating of VG 46. Rando HDZ 46, an
brand may be incompatible with the additive package extended-viscosity oil designed for use under severe
from the other, rendering both packages useless. conditions, is available on request. If you want your
Recently a few manufacturers have introduced new concrete pump filled with a different brand or
biodegradable hydraulic oils onto the market. These different viscosity oil, you should specify it when
oils are based on vegetable extracts instead of mineral ordering.
extracts. They are considered safer for the environment Many other brands of oil have been approved for use in
in the event of a spill, although the additive packages Schwing concrete pumps, including:
are not inert. One brand, Mobil EAL 224-H, has been
accepted for use in Schwing pumps, and other brands Mobil DTE
are under consideration and testing. These oils must Shell Tellus oil
not be mixed with mineral-based hydraulic oils, even in BP Energol
very small amounts. If you will be pumping a job in an
Aral Vitam
environmentally sensitive location and want to use this
type of hydraulic oil, please contact the Schwing Esso Nuto
Service Department at (651) 429-0999 for instructions Esso Univis
on making the change from mineral oil.
Total Azolla
Viscosity of hydraulic oil is similar in concept to the
Wintershall Wiolan
different weights of motor oil. For example, in the
winter you may run 5W-30 in your car, while in the The order of the brands listed is not significant. Any oil
summer you run 10W-40. The same is true for that meets the quality and viscosity standards described
hydraulic systems. If you live in a climate where the above can be used.
weather is changing from extremely hot conditions to
extremely cold conditions, you should consider
changing the weight of the hydraulic oil that you use
by the season. The International Standards
Organization (ISO) has developed a method of grading
hydraulic oils for viscosity. For summer in northern
North America, we recommend ISO VG 46 weight oil,
while in the winter we recommend ISO VG 32 or even
VG 22, depending on how cold it gets in your area. For
southern North America and Central America, we
recommend ISO VG 46 for the winter and ISO VG 68
or VG 100 for the summer, depending on how hot it
8 Service Manual
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Hydraulic Oils When to change your hydraulic oil
VG 32 = Winter application conditions in Central Change your hydraulic oil at least once a year. If you
Europe. use good filters, and change them when they are dirty,
VG 46 = Summer application conditions in Central the oil will be clean even after a year. The chemical
Europe. additive packages that give the oil its properties will
break down with time, however and no amount of
VG 68 = Excessive heat indoors application or in the
filtration will bring them back.
Tropics.
Service Manual 9
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Hydraulic Oil Viscosity Chart The minimum permissible viscosity represents the
warmest temperature at which the oil will still be
The illustration below shows the relationship between thick enough to provide lubrication and sealing.
the oil temperature and its viscosity. As you can see, Anything warmer, and the components will have
the oil gets thicker when the temperature is low and metal-to-metal contact (thermal breakdown).
thinner as the temperature rises. The optimum operating viscosity is the range of oil
The cold start limit represents the coldest thickness at which the oil works best (thin enough
temperature at which the oil is thin enough to flow to flow easily yet thick enough to protect the
into the hydraulic pumps. Anything colder, and system components).
the pumps would not be able to suck in the oil An example of how to read a chart for VG-46 oil is
(cavitation). given in the chart below. The chart shows the cold start
limit as -8C (18F) and the minimum permissible
viscosity as 90C (194F). The optimum range is 50-
76C.
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)
(F)
C = degrees Celsius
F = degrees Fahrenheit S0027.eps
10 Service Manual
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Service Manual 11
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Lubrication Recomendations
Industrial Gear Lubricant Oil
BI -
MOBIL MOBILUBE HD
The gear lubricant oils Industrial and Motor Vehicle are Under extreme conditions, please inquire as to
suitable for continuous ambient temperatures of suitability. The viscosity class ISO-VG 220 roughly
approximately -10 C to approximately +40 C. corresponds to SAE 90.
12 Service Manual
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Compressor Oil
VG 100 = AMBIENT TEMPERATURE 0 C to +10 C
VG 150 = AMBIENT TEMPERATURE ABOVE +10 C
Operating the compressor below 0 C may only be For an explanation of the various lubricant prefix codes
done according to manufacturers specifications. for determining suitable lubricant substitutes, refer to
page 11 of this section in this Service Manual.
Service Manual 13
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Filling Capacities
Hydraulic Reservoirs
BPL 4000
S 17 130 gallons
KVM 23M
KVM 25
KVM 26M
KVM 26-4
S 28 X 98 gallons
S 31 XT 127 gallons
S 34 X 127 gallons
14 Service Manual
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
S 42 SX 169 gallons
S 52 SX 153 gallons
Slew Drives
Transmissions
Service Manual 15
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Gear Boxes
16 Service Manual
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Service Manual 17
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
TE-ML 10
APPROVED LUBRICANTS
TRANSMISSION FOR SERVICE FILL
16 S 151 +WSK 4 S 120 GP +WSK Engine oils
16 S 160 (A) +WSK 4 S 150 GP (A) +WSK - API CD / CE / CF / SF / SG
16 S 190 (A) +WSK S 6-65 +WSK - MIL-L-2104C / -D / -E
16 S 220 (A) +WSK S 6-90 +WSK - MIL-L-46152C / -D / -E
16 S 221 +WSK 9 S 75 +WSK -SAE 20W-20
16 S 251 +WSK 9 S 109 +WSK
16 S 150 +WSK
Add Add
Dip Stick
Oil Level
Indicator Plug
Drain Drain
Drain Drain
16 S 190 A 4 S-150 GPA S0029.eps
18 Service Manual
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Steyr Gear Boxes Remove the level checking plug at position #3, if
no oil comes from the port, start to dispense new
oil into the filling port until oil starts to over-flow
Lubrication Specs
out the checking port, then replace all plugs and
1. Steyr specifies 85-140 weight gear oil and strongly tighten.
advises a change of gear oil on all their transfer
5. With this method, proper oil filling is achieved
cases every 3300 hours or once per year.
without over-filling.
2. Whenever leakage of gear oil is discovered,
preventative measures must be taken. Transfer Case Gear Oil Capacities are as
3. Operating the transfer case with too low an oil Follows:
level WILL result in severe damage to the unit. Model VG2000 w/o cooler ...........2.25gal/8.5 liters
4. IMPORTANT! A proper oil level check can only Model VG2000 w/cooler ..............2.50gal/9.5 liters
be done by dispensing new oil into the filling port
at position #1, be sure that vehicle is on level
surface before removing any port plugs.
4 - Breather
Service Manual 19
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Stiebel Gear Boxes 5. Subsequent oil changes should occur every 2000
operating hours or at least, every 12 months.
Lubrication Specs 6. The oil type and quality approved by Stiebel is
determined by the following index. In situations
1. Reducers are supplied without oil. For filling
when an oil from this index cannot be acquired, use
capacity, please see data on the gear plate.
EP SAE 90 with viscosity 220 cST at 40 C.
2. Refilling is only necessary in case of oil leakage
7. Special conditions and applications will require
due to defective seals or defective gear case
special lubricants. Consult the gear manufacturer
gaskets. Such defects should be repaired
for special recommendations.
immediately.
GEAR OIL SAE 90 (or as we call it: 90W) IS A
3. First change of oil should be after 200 operating
SINGLE RANGE OIL.
hours.
GEAR OIL SAE 85-90 IS A MULTIGRADE OIL.
4. Drain the old oil immediately after the stopping of
EITHER OF THESE OILS MAY BE USED
reducer operation, while oil is still warm. Prior to
refilling the gear case, dispense some new oil into
the top of case to flush remaining old oil out.
ARAL Aral Degol BG 220, or Aral Degol BMB 220, or Aral Getriebeol EP 90
CHEVRON Universal Gear Lubricant E SAE 85W-90, or Non-Leaded Gear Compound 220
ESSO SPARTAN EP 220, or ESSO GETRIEBEOEL GP-D 90, or ESSO GEAR OIL GP 90
TEXACO Meropa 220, or Geartex EP-D SAE 85W/90, or Geartex EP-A SAE 85W/90
20 Service Manual
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Service Manual 21
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
TE-ML 09
APPROVED LUBRICANTS
VERSION FOR SERVICE FILL
TE-ML 14
APPROVED LUBRICANTS RECOMMENDED
VERSION ALTERNATIVES
FOR SERVICE FILL
22 Service Manual
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Features Uses
inhibits fretting corrosion and false brinelling Assembly paste with universal application range
clean handling due to its clean handling and long-term separating
facilitates assembly and disassembly and lubrication effect. Superior to lack assembly
lubricants in performance test for a variety of
good separating effect for all types of contact
applications.
resistant to cold and hot water
Prevents fretting corrosion on bearing seals, spline
excellent rust protection even in salt water shafts, torque loaded connections.
white, almost colorless in thin layer
easy application (spray-without CFC)
temperature application range: -30C/-22F to
+250C/+482F
USDA-H2 approval
Service Manual 23
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
S0100.ai
24 Service Manual
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Check Outrigger Cylinder for: 2. Check the lever position with the respective
1. Any missing or damaged parts, then check for cylinder movements. Test is to be carried out while
leakage of shut-off valves or cylinder seals. you have an operating oil temperature of
2. With no load applied to the outrigger cylinder, approximately 30 to 50 (86 to 122 F.)
close the shut-off valve and remove the hydraulic 3. Check the #1 boom down relief - Refer to Service
line between this valve, and the outrigger cylinder. Bulletin G-103-89 for checking this function.
Engage control valve for the outrigger cylinder to 4. Check boom slewing cylinders for:
level position, front to extend the outrigger a. Exterior damage of cylinders tubes and mount-
cylinder. If the valve is leaking, oil will run out of ing flanges.
the shut-off valve. b. Leakage and correct movement.
3. Slew the extended boom over the outrigger 5. Check the hydraulic tank for:
cylinder which is to be checked. Close the shut-off
a. Proper oil level and leakage
valve and remove the hydraulic line between this
valve and the boom control block. Mark the b. Contamination and oil purity. (if necessary,
cylinder rod (with a felt tip pen) and observe. If the take an oil sample for evaluation).
cylinder retracts and no oil runs out of the shut-off 6. Check boom operation speed (too fast / too slow),
valve, then the piston sealing is leaking. with unstressed boom as per Boom Time Chart.
7. Check remote control motions with all switch
Check the control block for:
functions and operation symbols.
1. Any missing parts (knobs, symbol of switching
8. Check remote control safety switch (emergency
levers, etc.), damaged or leaking parts, and
stop button) for proper operation.
cleanliness.
S0099.eps
Service Manual 25
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Lubrication Specs for Schwing equivalent with the below listed minimum
characteristics:
Placing Booms Base Type....................................................Lithium
Maintenance of the collar bearing, step bearing on NLG1 No. ..............................................................2
the shorter booms and rollix bearing for the slew- cSt @ 40 C (104 F) ........320 summer, 150 winter
ing gear of longer booms should be lubricated
Molybdenum disulfide.......................3% minimum
daily.
ASTM dropping point (degrees F..... 350 degrees F
The boom should be rotated while grease is applied
minimum
to achieve adequate lubrication.
The outriggers and boom should be greased
monthly. 2. All other bearings must be greased with a lithium
The grease recommendations are as follows: grease such as Mobil Grease HP, CM-S, or an
equivalent.
1. The bronze tower or column bushings must be
greased with a moly additive which has a minimum In order to ensure that the grease is uniformly
of 3% molybdenum disulfide. distributed on the bearing surface, you must lubricate
while slowly rotating the boom.
Greases such as Lubriplate Mo-Lith No. 2, Texaco
Molytex EP2, Mobil Grease CM-P may be used or an
Greasing zerks.eps L
S102.eps
26 Service Manual
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
S0162.eps
Service Manual 27
HOME PRINT
SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
TODAY S DATE: / /
COMPANY:
STREET ADDRESS:
CONTACT: PHONE: ( )
SERVICE DEPARTMENT
SCHWING AMERICA INC.
5900 CENTERVILLE ROAD
WHITE BEAR, MN 55127
FAX: 651/429-2112
SAISVC 018REV05/03/00
28 Service Manual
HOME PRINT
SERVICE TRAINING
Pumpkits
PUMPK I T PUMP DIFFERENTAL MAX. CONCRETE MAX. PRESS. MAX. THEORY STROKE
CYL. CYLINDER OUTPUT ON CONCRETE STROKES/MIN LENGTH
(Dia) (Diameter) ROD PISTON ROD PISTON ROD PISTON (IN.)
(cu. Yd/hr) (cu. Yd/hr) (psi) (psi)
500-18x 7 3.1 - 75 - 870 - 27 55
900 HDR 8 4.7 (120mm) 117 67 870 1565 30 17 63
1250 7 3.14 - 95 - 942 - 34 55
1200 HDR-20 8
1200 HDR-23 9
2023-4 9 5.1 (130mm) 170 - 1007 - 26 - 79
2023-5 9 5.1 (130mm) 209 - 1007 - 32 - 79
2023H-6 9 4.7 (120mm) 182 - 1233 - 28 - 79
2525H-5 10 4.7 (120mm) 181 - 1169 - 18 - 98
2525H-6 10 4.7 (120mm) 213 - 1169 - 22 - 98
750-18R 7 3.1 - 69 - 870 - 34 39
Service Manual 29
HOME PRINT
SERVICE TRAINING
Pumpkits
ramctrl.eps
30 Service Manual
HOME PRINT
SERVICE TRAINING
Pumpkits
Soft switch
shutoff valve
Figure 3
Retract the drivers side rod into the
waterbox all but about an inch and a half
5. A 55mm open end wrench and a 24 - 30 mm box
end wrench were supplied with the unit; you will
need them for this step. Locate the 55mm wrench
Concrete pump on the dog bone to hold the assembly from turning.
39
shutoff valve hif
low
.ep You can rest the handle against the side of the
s
waterbox (Figure 4). Unscrew the 4 M20 bolts that
hold the assembly together.
Figure 2
Concrete pump shutoff valve
dogbone2.eps
Figure 4
Remove the bolts from the dogbone
Service Manual 31
HOME PRINT
SERVICE TRAINING
Pumpkits
dogbone3.eps
Figure 6
Removal bolt grooves on flanges
32 Service Manual
HOME PRINT
SERVICE TRAINING
Pumpkits
will be wiped off by the material cylinders during 8. Start the engine. Release the emergency stop
installation. button. Slowly move the cylinder down to where
3. With the engine still stopped, hold the new ram up the flange butts up to the dogbone. Be careful not
to the cylinder flange. Line up the grooves, and to go too far! (Figure 9).
drop your nut and bolt into place to hold the assem-
bly together. Again, you should only tighten the nut
finger tight. ram install fig 3
Figure 9
Slowly move the cylinder to meet
the dogbone
Service Manual 33
HOME PRINT
SERVICE TRAINING
Pumpkits
34 Service Manual
HOME PRINT
SERVICE TRAINING
Pumpkits
5. In order to move the second piston to the bottom Rock Valve section of this book for rebuilding
dead center position without re-extending the first instructions.
cylinder, we must drain out the rocking oil. 12. Support each material cylinder with the lifting
NOTE! device. Remove the bolts at the waterbox. If an
When opening the hydraulic system, which impact wrench is used, you must use an impact
we have to do to drain the rocking oil, make socket and wear eye protection.
certain of absolutely clean conditions. 13. Detach the material cylinders and remove in a
6. To drain the rocking oil rod side: downward direction.
a. Disconnect one end of the rocking oil hose and
NOTE!
hold the hose into a clean container.
Take care not to damage hoses and tubes
b. Start the engine. that may be positioned under the material
c. Select I (ON = ram change mode). Put the S1 cylinders
in reverse mode by holding the Pump Forward/
Reverse switch in the reverse position. When
the piston reaches bottom dead center (B.D.C.)
position. The rocking oil will be expelled,
through the hose.
\
S0168.eps
Figure 14
Draining the rocking oil
7. Stop the engine Figure 15
8. Remove the hopper and outlet piping from the Removing bolts at the waterbox
concrete valve 14. Remove the split rings and mounting flanges. If
9. Carefully support the differential cylinders spacing rings are used on the unit, remove them at
cylinders to avoid unintentional movement of the this time.
pumpkit after the material cylinders have been
removed. for example, wedge wooden blocks
between the cylinders and across of the subframes.
10. Mark for identification, then remove the hydraulic
hoses from the rock slewing cylinder.
NOTE!
Plug the open hydraulic lines with dead
plugs.
Service Manual 35
HOME PRINT
SERVICE TRAINING
Pumpkits
S0171 S0172.eps
Figure 16
Removing the Split Rings Figure 17
15. Clean, check and grease the mounting parts and all Grease new o-rings
mounting surfaces at the waterbox and rock 19. Carefully slide a pre-completed material cylinder
housing. into the waterbox, and give a ballpark alignment.
16. Clean the mounting surfaces of the new material 20. Screw in the mounting bolts and washers and
cylinders thoroughly, remove primer, and grease. tighten crosswise, using the torques specified in the
17. Install mounting flanges and split rings. At this table.
time mount spacing rings removed in step 12, if
any
NOTE!
Please remember not to interchange the
flanges and split rings, and spacing rings
from the waterbox to concrete valve end.
The cylinder themselves can go either way.
18. Grease the new o-rings and insert into the lead in
rings of the waterbox
S0168.eps
Figure 18
Tightening bolts at the waterbox
36 Service Manual
HOME PRINT
SERVICE TRAINING
Pumpkits
S0174.eps
Figure 19
Mount the alignment tool, to the differential
cylinder rod.
Service Manual 37
HOME PRINT
SERVICE TRAINING
Pumpkits
Figure 22
Mounting bolts on waterbox
28. Grease new o-rings and insert in the valve housing.
29. Carefully slide the valve housing onto the material
cylinders, and rest the valve housing on the
Uneven rays around alignment tool machine frame.
30. Bolt the valve housing and material cylinder
flanges together making sure that the alignment is
Figure 21
being maintained.
NOTE! 31. Bolt the valve housing to the machine frame.
If the alignment tool should contact the cyl-
inder wall at any time, release the Concrete 32. Check alignment with the tool once more, by using
Pump Forward/Reverse switch immedi- the Ram Change Mode switch.
ately! Damage may occur to cylinder wall. NOTE!
If a squeaking sound indicates the align-
27. If, for example, the alignment tool contacts the ment tool is dragging on the material cylin-
cylinder on the lower side, loosen the mounting der, turn off the pump IMMEDIATELY!
bolts at the waterbox a little bit, then tighten the
LOWER bolts first. This will lower the bottom of 33. If there is no dragging, you may proceed to step 36.
the material cylinder. When the alignment is close, If dragging does happen, repeat the visual checks.
tighten the top bolts and recheck the alignment. 34. Loosen the bolts on the material cylinders and
When the alignment is within specification, the valve housing, and at the machine frame, and
alignment tool will travel the entire length of the repeat the alignment procedure.
cylinder without touching the cylinder wall. If the 35. Check the mounting and shimming of the pump kit
alignment tool is not always located exactly in the and its mounting to the pump kit frame.
middle of the cylinder during the travel, but DOES
NOT TOUCH, then realignment is not necessary. 36. Tighten all bolts.
Minor misalignments are compensated for with the 37. Complete the reassembly of valves, and install the
rubber ram. Repeat procedure for the other rubber rams.
cylinder. 38. Reopen the 1/4 turn valve.
NOTE!
If proper alignment cannot be achieved oth-
erwise, tightening torques may be exceeded
by 10% over the charts specs. If further
alignment problems persist, please contact
the Schwing Service Department.
38 Service Manual
HOME PRINT
SERVICE TRAINING
Pumpkits
Rod Diameter
Ordering Chart
Rod Cylinder Item
Diameter Diameter Number Pumpkit Model Number
Figure 23
Alignment Tool Chart
Service Manual 39
HOME PRINT
SERVICE TRAINING
Pumpkits
Pumping on piston side When changing the hoses from the rod side port to the
piston side port, you must cross them. This keeps the
Piston side pumping changes your concrete pump from machine in the same sequence of events as when it is
a low-pressure, high-volume machine into a high hooked up for rod side pumping. Failure to cross the
pressure, low-volume machine. This would be handy, hoses will result in pumping in reverse whenever you
for example, to pump long distances horizontally or select forward.
vertically.
When you have finished with the need for piston side
Piston side operation dramatically raises the maximum operation, change it back to rod side immediately.
pressure on the concrete. For this reason, it is crucial
When you are configured on the piston side, the safety
that your entire material delivery system be rated to
rules for the following topics become even more
handle the available pressure and be maintained in like-
important:
new condition. Remember that pipe wall thickness
wears with each yard of concrete pumped. Inspect the Opening lines under pressure
wall thickness regularly. The maximum material Sucking back plugged lines before opening
pressure available on the piston side depends on which Pressure-handling capacity of pipes, hoses, and
differential and material cylinders you purchased with clamps in your delivery system
your unit. The maximum material pressure is recorded The dangers of blockages
on the main ID tag.
All of these items are covered in the Safety Manual.
To convert your machine to piston side operation, you Understand the rules and live by them.
must have some additional hoses and fittings, plus the
tools to install them.
Loosen for Add dead
rotation plugs
(1200s only)
This hose
1200s only
Add hose
and fittings
to each side
Loosen for
rotation
40 Service Manual
HOME
PRINT
The following steps must be followed to ensure proper installation of the sealing glands (rod packings) on
differential cylinders:
GUIDE BUSHING
SCRAPER
PISTON ROD
SEALING GLAND SET
Sealing Gland Replacement
FIGURE 1
Service Manual
assembled (Figure 2, Dimension B).
SAIE STANDARD
The packings must never be under compression from the tension ring. If the packings are under
compression from the tension ring, it is possible that the cylinder rod may become scored after a short
1
period of time during operation. Therefore when Dimension A is subtracted from Dimension B, the
Date: 12-19-95
dimension of the spacing disks must equal the difference with a tolerance of minus nothing, plus 1 mm or
No.: SAIE - 5221
of 1
.039 inch.
Rev.: D
41
Pumpkits
HOME PRINT
SERVICE TRAINING
Pumpkits
Dimension A
Using a caliper measure the distance from the top of Tape
the bushing down to the bushing seal recess.
Figure 25
See Figure 1.
Compacting the Cherevon seals
Use the caliper to measure the distance between the top
and the bottom of the compacted cheveron seals.
See Figure 3.
Dimension A = 57.12 mm
Tension Ring
Bushing Seal Recess
Bushing
Dimension B
Dimension B
Figure 24
Measuring for dimension A
Figure 26
Dimension B Measuring for dimension B
Leave the tape around the cheveron seals to hold them
into place. On a solid flat surface place the Tension ring
on top of the cheveron seals. This will compact the
cheveron seals to the proper size. See Figure 2.
42 Service Manual
HOME PRINT
SERVICE TRAINING
Pumpkits
Formula
A should equal B
B - A = shims required
In this example:
57.40
- 57.12
.28 mm (.011")
Figure 27
Formula for determining shim size
In this example, we would need to add 1 - 0.5mm shim
to the Tension ring. This will ensure that the cheveron
seals will not expand, thus preventing wear on the
cylinder rod. See Figure 4
NOTE!
A maximum of 5 shims can be used.
NOTE!
Dimension B can never be greater than
dimension A or cylinder rod damage can
occur.
Service Manual 43
HOME PRINT
SERVICE TRAINING
Pumpkits
44 Service Manual
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
Service Manual 45
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
PumpKit Pumps
Accumulator Pump
Agitator Pump
Oil Cooler Pump Stiebel 4194
PumpKit Pumps
Accumulator Pump
Agitator Pump
Stiebel 4400
S0064.eps
46 Service Manual
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
Fixed Displacement Pump the fixed displacement of the pump. The pump is
suitable for use in mobile and industrial applications.
A2FO
Fixed displacement axial piston pumps of bent axis
design for use in hydrostatic drives in open circuits.
The output flow is proportional to the input speed and
Service Manual 47
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
48 Service Manual
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
P max
350
A (B) R
Operating pressure PB (bar)
setting range
200
G
100
50
0
Flow Q (L/min.)
S
Figure 28 - Pressure Setting Ranges Figure 30 - Schematic of a A7V Variable
Displacement Pump
Summation HP control is made possible by means of
throttles via port G.
A (B) R
T
X3 A
S T
Service Manual 49
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
A (B) R
X2
G
X1
S
Q min
Q max
S0098.eps
50 Service Manual
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
0
25 -
Service Manual 51
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
V = constant
p B = operating pressure
pB g
V = pump displacement
g
350
Operating pressure p B (bar)
300
A (B) R
250
220 bar
200
Adjust. range
G
150
Start of control
100
50 50 bar
0
0 0.2 0.4 0.6 0.8 1.0
V Displacement V
g min g max
S A7VO-107 LR
52 Service Manual
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
40
35
0
30
25 -
25
pilot press. PSt in bar
20
setting range
15
Q max
10
Service Manual 53
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
Setting range from 50 to 350 bar. Setting range for remote control 50 to 315 bar
max. 10 bar
P max
350
315
300
150
Operating pressure PB (bar)
setting range
200
100
50
0
Flow Q (L/min.)
P regulator
High pressure filters
X
20
A bar P
A1
290
bar
P
A T
X3
54 Service Manual
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
Service Manual 55
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
DR Pressure Control
The pressure control serves to maintain a constant
pressure in the hydraulic system, within the control
range of the oump. The pump therefore supplies only
the amount of hydraulic fluid required by the actuators.
Pressure may be smoothly set at the pilot valve.
56 Service Manual
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
Service Manual 57
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
p B = operating pressure
pB V = constant
g
V = pump displacement
M A G T1 R T2
g
350
Operating pressure p B (bar)
250
220 bar
200 Setting range
150 Start of control
100 Vg max Vg min
50 50 bar
0
0 0.2 0.4 0.6 0.8 1.0
V Displacement V
g min g max
15
the rocker arm to determine the power setting.
setting range
10
4
Should the operating pressure exceed the set spring
force, the pilot control valve is operated via the rocker 0 0,5 1,0
Vg min Vg Vg max
arm, allowing the pump to swivel towards zero output. Displacement Vg max
This in turn reduces the effective moment on the arm of
the rocker, thus allowing the operating pressure to rise Figure 45 - A11VO Variable Displacement Output
in the same ratio by which the output flow is reduced Chart
(pB Vg = constant).
Variation: Hydraulic Stroke Limiter (LRH...)
The hydraulic stroke limiter allows the maximum
displacement to be infinitely varied or limited as
required.
58 Service Manual
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
M A G T1 R T2 Y
Stroke Regulation
Horsepower Control
Pressure Cut-Off
Stroke Regulation
Pressure Cut-Off
Horsepower
Control
Q min
Vg max Vg min
Q min
s M1
Service Manual 59
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
Linde Hydraulik BPR 105 from 3.06 to 15.86 cid. Pressure ratings are 5000 psi
intermittent and 3000 psi continuous duty.
Our BPR, bent-axis, variable displacement pumps are
self-priming units primarily for use in open circuit
applications. Six sizes are available with displacement
60 Service Manual
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
Q L P P Y X
L P P Y
U T
Figure 47 - Schematic of a BPR 105 Variable
Displacement Pump With Stroke Limiter
Service Manual 61
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
Voac Variable Displacement desired displacement flow. The setting range can be
mechanically limited by setting screws. The position of
Axial Piston Pump the swash plate can be controlled via a visual
Variable displacement pumps work according to the mechanical indicator. The latest knowledge and
swash plate pricipal: 9 pistons operate in a rotating experience with regard to noise reduction has been
cylinder barrel where they fulfill one suction and one used in the development of V30D. All components
presssure stroke per rotaiton. The axial movement of used in the V30D are manufactured from high grade
the pistons is provided by an adjustable swash plate. he materials and machined with close tolerances.
setting angle (0-17) is varied in proportion to the
Horsepower Control
Q min Q max
Pressure Cut-off
VOAC Boom Pump
62 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Pressure Settings
General
Stroke Limiter Adjustment
Override
Button
B P A
Remote controlled
stroke limiter
P
Output to hydraulic pumps 70
A
A
B
C
Adjustment Procedure
1. Disconnect line at A port of shuttle valve and install a 0-200 bar gauge in the end of the hose.
2. Push override button in all the way.
3. Pressure out pumpkit.
4. Set relief valve to 70 bar.
5. Set max. pressure on computer card for 35-40 bar with override button de-activated and the stroke limit
knob on remote box at min. strokes.
Pressure Settings
Check the accumulator Pre-Charge
After charging an accumulator that has had no initial
gas pre-charge, allow 20 to 30 minutes for the gas
temperature and pressure to stabilize. Recheck the gas
WARNING
pre-charge pressure and adjust if necessary.
EXPLOSION CAUSED BY
After the accumulator has been put in service it is
important that the pre-charge pressure is checked at
IMPROPER ACCUMULATOR
least once in the first week to verify the initial pre- CHARGING CAN RESULT IN
charge has not changed due to temperature and DEATH OR SERIOUS INJURY!
pressure stabilization. If the check reveals no loss in
pressure, the pre-charge should be checked on the * Follow the charging instructions exactly!
following schedule: * Use ONLY dry nitrogen to charge the
1st Check - 1 week accumulator!
* NEVER use oxygen or compressed air to
2nd Check - 3 months
charge the accumulator!
3rd Check - 1 year
4th Check and continued - yearly
Read all instructions for charging accumulators before
beginning the charging procedure. Accumulators must
be charged only with dry nitrogen. Compressed air and
oxygen must never be used, because oxygen molecules
combine with hydraulic oil, lower the flash point of the
oil to less than room temperature, and cause an
explosion. Workers have died using compressed air or
oxygen to charge accumulators (Figure 49). Use only
dry nitrogen, never liquid nitrogen.
explwarn.eps
Figure 49
Charging accumulators
improperly can cause injury or
death
revDate
64 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Nitrogen Bottle
1500 2000
1000 2500
50 200
3000
500
3500
hose
0 250
30355456
accuman1.eps
BPL
ACCUMULATOR CHARGING KIT
HYDAC bladder (Includes hose and charge valve assy)
Accumulator
SCHWING PART NUMBER:
30355436
chargkit.eps
Figure 50
Accumulator charge kit for HYDAC
bladder accumulators
.
ps
S0106.eps
Figure 51
Accumulator manual bleed valves
Pressure Settings
Tank Regulated
Pressure Pressure
Nitrogen Supply Valve
Regulator Adjustment
Handle
Nitrogen Bottle
Push Button
Pressure Gauge
100 150
Charge Valve Stem
1500 2000
1000 2500
50 200
3000
500
3500
0 250
HYDAC bladder
Accumulator
chgvalve.eps
Figure 52
Charge valve assembly
revDate
66 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
5. Remove the valve protection cap and the valve seal 9. Be sure that the nitrogen bottle supply valve is
cap from the accumulator (Figure 53). Leave the firmly closed. Attach the high-pressure regulator to
valve protection cap on the accumulator until you the nitrogen bottle, then attach the hose to the high-
actually begin the procedure. pressure regulator. Finally, attach the other end of
the hose to the charge valve stem on the charge
valve assembly (Figure 52.
10. Do not open the nitrogen bottle supply valve yet.
Valve Protection Cap Turn the regulator adjustment handle on the high-
pressure regulator (Figure 52) counter clockwise to
its minimum setting (closed).
11. Slowly open the nitrogen bottle supply valve
(Figure 52). You will get a reading on the tank
Valve Seal Cap pressure gauge side of the regulator. If there is
enough pressure in the nitrogen bottle to do the
job, proceed to Step 13.
Valve Stem NOTE!
O-ring
If there is not at least 1450 PSI in the
nitrogen bottle (as shown on the regulator
gauge at this time), you will not be able to
charge the accumulator nitrogen to the 1450
PSI specification. If that is the case, you will
need a new bottle of nitrogen before
HYDAC bladder proceeding.
Accumulator 12. Adjust the regulator adjustment handle clockwise,
accum closeup
raising the regulated pressure. The accumulator
will begin to fill. Continue filling until the charge
Figure 53 valve assembly pressure gauge (Figure 52) reads
Detail of accumulator the desired pressure of 1450 PSI. Close the
gas valve area nitrogen bottle supply valve.
13. If you overcharge the nitrogen pressure, refer to
(Figure 52) and proceed as follows:
6. On the charge valve assembly (Figure 52, close the
bleed valve (turn it clockwise all the way in). If a Close the nitrogen bottle supply valve.
hose is connected to the charge valve stem, Depress the push button on the top of the charge
disconnect the hose from the charge valve stem. valve assembly.
This step closes the charge valve stem to prevent Slowly open the bleed valve on the charge kit.
the gas pressure from escaping out of the hose. It Close the bleed valve when the correct pressure is
ensures that the initial pressure reading is accurate. reached on the charge valve pressure gauge.
7. Find the swivel nut on the charge valve assembly NOTE!
(Figure 52). Screw the swivel nut onto the Never let nitrogen out of the accumulator by
accumulator gas valve. Tighten to 1015 in./lb. pressing the gas valve pin with a foreign
8. After the swivel nut is attached, depress the push object. The high pressure may rupture the
button on the top of the charge valve assembly valve seal!
(Figure 52). This presses a pin into the accumulator 14. Let the nitrogen sit in the accumulator for 10 to 15
gas valve and opens it. Read the pressure on the minutes. This allows the gas temperature to
charge valve assembly pressure gauge. The stabilize. Depress the push button on top of the
pressure should read 100 bar (1450 PSI). charge valve assembly. Recheck the pressure on
If pressure must be added, proceed to Step 10. the charge valve assembly pressure gauge.
If pressure is too high, skip to Step 14.
If no adjustment is necessary, skip to Step 17.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 67
HOME PRINT
Pressure Settings
15. Add or release nitrogen until the pressure is
correct. Be sure that the bleed valve is closed
before adding pressure and that the nitrogen bottle
supply valve is closed before releasing pressure.
16. When the correct pressure is reached, refer to
(Figure 52) and proceed as follows:
Close the nitrogen bottle supply valve.
Open the charge valve assembly bleed valve.
This releases the pressure in the hose, charge
valve assembly, and regulator.
While holding the charge valve assembly on
the accumulator, unscrew the charge valve
swivel nut.
Remove the charge valve assembly.
If you are finished with the charge valve
assembly, remove the hose and regulator.
54. Make a bubbly mixture from soap and water.
Spread the mixture around the accumulator gas
valve to check for gas leaks. Gas leaks will push
the bubbles away from the area of the leak. If you
find a leak, replace the accumulator or have it
repaired by qualified personnel. Never repair an
accumulator yourself.
55. Replace the gas valve seal cap (tighten to 22 ft/lb),
and hand-tighten the valve protection cap.
56. If your concrete pump has two accumulators,
repeat this procedure for each accumulator.
revDate
68 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Hydraulic Pump
Adjustments Adjustment Knob
P
to the tandem A11VO main system hydraulic pumps, T
MG
P
the following steps must be done in order that they are MY Y
G
listed;
Q-max Screws
A11VO130 / A11VO190
Q-max Screws
Pressure Settings
Horsepower Setting
Adjustment Knob
After the flow rate is set, the horsepower setting then
must be done. The horsepower break point must be set
to the proper specifications per the output chart.
CONCRETE
BPL 2023-5 PRESSURE
350 or 400 HP truck PSI Bar
2000 138
Piston Side
Bar
PUMP SPEED
E
2100 RPM 1700 117 P
T
HYDRAULIC RELIEF VALVE IS SET AT 1600 110
350 BAR MAX. PRESSURE (5075 PSI). MG
1500 103 P
G
PL
1400 97
MY Y
1300 90
4500
300
OIL PRESSURE
4000 800 55
250 700 48
3500
3000 200
600 41
Figure 60
SA
2500 500 34
150
2000
1500 100
400
300
27
21
Stroke Limiters (two generations)
1000
500
50
200
100
14
7
3. Increase the engine Rpm's to the maximum setting
Break Point
180 Kw = 182 bar
200 KW = 202 bar
0
10 20 30 40 50 60 70 80
208
90 100 110 120 130 140 150 160 170 180 190 200 210 220 cu yd / h
and while watching the flow meter scale, slowly
At 350 bar
180 Kw = 278 l/m
200 Kw = 309 l/m
7.5 15 23 30.5 38 46 53.5 61 69 76.5 84 92 99 107 114 122 130 137 145 153 160 168
CONCRETE OUTPUT
cu meters/ h
turn the stroke limit potentiometer to the minimum
5 10 15 20 25 30
32
Number of strokes
(stroke / min.)
material output until the maximum flow rate begins
100 200 300 400 500 535
Oil volume
(liter / min.) to drop.
Break Points
4. When the flow rate begins to drop, stop turning the
Figure 58 potentiometer and read the pressure on the 0 to 40
Sample output chart bar gauge. The reading that is seen is the
beginning of stroke limitation. The reading should
Setting Stroke Limitation be between 5 to 7 bar. If it is not, then adjust the
beginning of stroke limitation screw accordingly to
Now that the maximum flow rate and horsepower
achieve the proper pressure reading.
settings have been made, the beginning of stroke
limitation can be set. Adjust the supplement system a. If the pressure is too high, then turn the screw
pressure to the maximum pressure of 50 bar. counter-clockwise (out) to reduce the pressure.
1. Make sure the stroke limit potentiometer at the rear b. If the pressure is too low, then turn the screw
operation panel or remote box is at the maximum clockwise (in) to increase the pressure.
material output setting.
Q-min Output Flow
Once the beginning of stroke limitation is set, the next
step is to check the Q min output flow.
1. With the 0 to 40 bar gauge still in the electric
stroke limit line going to the Y port of the hydraulic
pumps. Increase the engine Rpm's to the
maximum setting and while watching the flow
meter scale, turn the stroke limit potentiometer to
the minimum material output. The 0 to 40 bar
gauge should be reading approximately 25 bar
Figure 59
more than the beginning of stroke limitation setting
Stroke Limiter Potentiometer
to ensure the hydraulic pumps are all the way to the
2. Install a 0 to 40 bar gauge in the electric stroke minimum against the Q min stop. The Q min
limit line going to the Y port of the hydraulic reading should be between 15 to 25 liters per
pumps, at this time the reading on the gauge should minute. If it is too high, turn the Q min screw out
be 0. until the reading is correct or if it is to low, turn the
revDate
70 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Q min screw in until the reading is correct. When Parts Department using part number 10004680
the Q min has been set, the flow meter can now be (valve), and number 30303432 (tube). Contact the
removed. Service Department for installation instructions.
2. Activate the agitator. With the valve closed the
A11VO190
agitator will not be able to turn and the oil will be
forced over the relief valve. At an idle (about 600
RPM), 4.5 horsepower is being converted to heat.
A11VO130
agitoff2.eps
Q min Screw
Q min Screw
Figure 61
Q-min screw locations Figure 62
2. Repeat steps 2 through 6 on the second main Agitator shutoff valve
system pump before attempting to set the pressure 3. When the oil temperature gauge shows 50C, open
cut-off on both pumps. the shutoff valve.
NOTE!
All screw adjustments with the system Setting pressures on Hi-flo -6 pumpkits
reliefs and pressure cut-off must be done a. To set the pressure of the main relief valve on
while the unit (pumpkit) is in the neutral Hi-flo pumpkits, you must first disable the soft
position. switch circuit. Simply locate the ball cock for
the soft switch circuit (Figure 63) and close it
Check all hydraulic pressures.
by rotating the handle 90 degrees.
Changes in pressures can indicate trouble in one or b. The quarter turn shutoff valve for the concrete
more components. The specifications for each circuit pump will also need to be closed during this
are shown on the hydraulic schematics found in the procedure.
Appendix of this manual. The hydraulic schematics are
the only documents in this manual that have been NOTE!
updated specifically for your unit, by the serial number, Main system adjustments are preset at the
so in each of the following procedures you will be told factory. The following procedure begins
with adjustment of the main relief cartridge
to refer to the schematic for the pressure required. and pressure cutoff. If proper pressures can
Preheat the hydraulic oil not be obtained through these steps, refer to
Pressure settings must be made with the oil at normal the beginning of this procedure for specific
instructions on the adjustment of flow,
operating temperatures (40 60 C). In the past we horsepower, beginning of stroke regulation
could pressure out a function in the boom or outrigger and Q-min.
system to create heat, but load sensing systems no
longer allow maximum oil flow to be forced over relief.
Because of this the agitator circuit must be used to heat
the hydraulic oil.
To preheat the hydraulic oil:
1. Locate the agitator shutoff valve (Figure 62) and
close it. NOTE! If your unit does not have a
shutoff valve, order one from the Schwing Spare
Pressure Settings
Pressure setting procedure: 7. Stop the truck engine and put the key in your
pocket. Adjust the pressure cutoff screw (Figure
Soft switch 64) on each pump, by backing off the jam nut with
shutoff valve a 13mm wrench. Using a 4mm allen wrench, turn
the adjustment screw in (clockwise) one full turn
Main Pressure and tighten the jam nut. Restart the truck engine.
Gauge port
8. Adjust the engine RPM to maximum specification.
(See decal in truck cab)
9. Pressure out the system by activating the concrete
pump forward switch on the rear panel. Using the
Concrete pump
shutoff valve hif
lob
rn.
rear panel controls will allow you to read the
ep
s concrete pump main system pressure gauge, near
Figure 63 the e-stop manifold, from a safe distance.
Concrete pump and Soft switch shutoff valves NOTE!
1. Be sure that the waterbox covers and guards are in Because you turned out the pressure relief
place any time you will be working in the area cartridge in step 7, the system pressure
around the main control block. should read low at this time. If it does not
and the gauge spikes to 320 bar or more,
2. Wear safety glasses when working around a disengage the pump immediately. Turn the
concrete pump. relief cartridge out (counterclockwise)
more. For safety, it is important to adjust
NOTE! the pressure up from below the specified
It is vital that each adjustment screw be target pressure rather than down from a
properly identified prior to making any pressure which exceeds the target. Continue
adjustment. All screw adjustments for the this procedure until the main system pres-
system relief must be made with the pump- sure gauge reads lower than the specified
kit in the neutral position and adjustments target.
for pressure cutoff must be made with the 1. To increase the pressure put the pump in the
engine shut off.
neutral position and adjust the relief cartridge by
1. Start the truck engine, and put the PTO in gear just
turning it in (clockwise). When increasing the
as you would to pump a job.
pressure, the adjustments should be made in
2. If you have not already closed the soft switch quarter turn increments. If you make adjustments
shutoff valve and the concrete pump shutoff valve to increase the pressure but the pressure does not
(Figure 63) do so at this time. come up, you are probably reading the pressure
3. At the rear panel, select local control with the cutoff of the pumps, if so proceed to the next step
local/remote switch and turn the electric stroke otherwise skip to step 15.Turn the relief cartridge
limiter knob clockwise to maximum strokes per adjustment screw back out (counterclockwise)
minute. until you can no longer see a pressure drop and
4. The main system control block pressure must be tighten the jam nut.
set first to properly set the pressure cutoff on both 2. Stop the truck engine, put the key in your pocket.
pumps. Begin by backing off the jam nut of the 3. Go to the pressure cutoff screw on both hydraulic
main relief cartridge (Figure 65) with a 9/16 inch pumps (Figure 64) and back off the jam nut with a
wrench. 13mm wrench. Turn the adjustment screws in with
5. Using a 5/32 inch allen wrench, turn the a 4mm allen wrench one or two more turns, restart
adjustment screw out (counterclockwise) until you the engine and check the pressure again. Repeat
can feel no spring tension on the adjustment screw. this procedure until the main system relief can be
6. Now, turn the screw back in (clockwise) two or set to the target pressure.
three full turns to give you a proper starting point 4. When the proper main relief pressure is achieved,
and tighten the jam nut. pressure cutoff can be set. Shut off the engine, put
the key in your pocket and install 0-600 bar gauges
with whip hoses to the M1 gauge ports on the
bottom of the two hydraulic pumps (Figure 64).
revDate
72 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
You must be able to read both gauges
simultaneously to ensure that one pump is not
more dominant than the other.
NOTE!
The gauges in the M1 ports will read consid-
erably less than the cutoff pressure of the
pump. On a -6 (190/130 pump combination)
the 190 will usually read 85 to 90 bar while
the 130 reads about 110 bar. They could
read the same however, at approximately
110 bar, but the 190 must never read higher
than the 130. The actual cutoff pressure will
130ajst.eps
be read on the concrete pump main system
pressure gauge near the e-stop manifold. Figure 64
1. Activate concrete pump forward to pressure out the Adjustment screw locations
pump and read the pressure on the two gauges in
the M1 ports. Soft switch
shutoff valve
2. Always stop the truck engine and put the key in
your pocket before making any adjustment on the Main Pressure
hydraulic pump. If the cutoff on one pump is set Gauge port
higher than the other, that pump will be more
dominant. The pressure gauge in the M1 port of the
dominant pump will however, read lower than the
other. To equalize the two pumps you must either
Concrete pump
adjust the cutoff screw in (clockwise) to increase shutoff valve hif
lob
rn.
ep
the pressure of the pump showing the higher s
Pressure Settings
is needed, loosen soft switch relief valve jam nut
(Figure 65) with a 9/16 open end wrench, and use a 5/
32 allen wrench to adjust the pressure. Turn the
adjustment screw in (clockwise) to raise the pressure or
out (counter clockwise), to lower the pressure. When
you attain the required pressure, tighten the jam nut
while holding the allen wrench to keep the pressure
from rising. Be sure to open the concrete pump shutoff
valve on the side of the brain (Figure 65) when you are
finished. The unit will not stroke with this valve closed
revDate
74 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
BPL 500
Soft Switch
Accumulator Unload-
ing Manifold Valve
Concrete Pump
and Gauge Port
Pressure Gauge
Manual (forward/reverse)
Agitator Hand Valve Control Lever.
and Gauge Port
Main Control Panel
Agitator Shutoff Valve
Figure 66
General location of components used
to set hydraulic pressures
Heating hydraulic oil. Pressure settings must be horsepower is being converted to heat. Shut off the
made with the oil at normal operating temperatures concrete pump when the temperature gauge on the
(40 60C). The agitator circuit must be used to operators panel shows 50C.
heat the hydraulic oil. Do not jam the paddles to 3. Open the agitator shutoff valve or remove plug and
force the oil over the relief valve by stopping the reconnect hose to agitator motor.
movement of the agitator. To preheat the
hydraulic oil using the agitator circuit, follow these NOTE!
instructions. If your unit does not have a shutoff valve,
order one, using part #10004680 (valve),
1. Locate the agitator shutoff valve and close it
and #30303432 (tube). Contact the Schwing
(Figure 67). The general location of the agitator
Service Department for installation instruc-
shutoff valve is shown in Figure 66.
tions. If you cant wait for a shutoff valve,
2. Position the agitator hand valve in the forward or you will need to remove one of the hoses
reverse position. The agitator will not be able to from the agitator motor and plug the hose
turn, and the oil will be forced over the relief valve. and open fitting with approved hydraulic
At idle speed (about 600 RPM), about 4.5
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 75
HOME PRINT
Pressure Settings
dead plugs. Do not substitute other plugs, 6. Using the concrete pump forward/neutral/
such as a steel bearing inside a cap fitting. reverse control lever, put the concrete pump into
You will need: the forward position. The unit will cycle one
- Qty 2 VS-16S locking plugs, part number stroke, then the rock valve cylinder will retract. Oil
10016803 will have nowhere to go except over the main relief
- Qty 1 GS-16S straight fitting, part number valve.
10008088 7. Read the pressure on the concrete pump gauge,
- Qty 2 16S capnuts, part number 10001743. located on the main control block. It should read
300 bar. If no adjustment is needed, skip to Step
12.
agit.shutoff.eps
CLOSED
8. If adjustment is required, loosen the jam nut on the
main relief valve adjusting screw (requires a 13-
mm spanner wrench).
9. Turn the knob on the relief valve to adjust the
pressure. Screw the handle in to raise pressure, out
to lower the pressure.
10. Retighten the jam nut. (Tightening the jam nut
tends to raise the pressure. If it becomes a problem,
Valve is shown in the hold the knob while tightening the jam nut)
OPEN position .
17mainreliefvalv
Figure 67
Agitator shut off valve
NOTE!
Pressure setting shown in these procedures
are for the BPL 500 HDR-18. Pressure set-
ting will be different for each type of pump
kit. Refer to the hydraulic schematic in the
Appendix of your Operation manual for the
correct pressure settings.
Set the concrete pump pressure. The Schwing
concrete pump circuit on the BPL 500 is designed Jam nut
to be operated at a maximum pressure of 300 bar
(4350 PSI). It is controlled by the main relief Relief Valve
valve, which is located at the rear of the main
control block (Figure 68).
To check or set the main relief pressure:
1. Be sure that the waterbox covers are installed on
the waterbox. We do not recommend using the
remote control box for the following procedure. Figure 68
2. Wear safety glasses when setting pressures.
3. Close the concrete pump shutoff valve and the soft 11. Put the concrete pump into the forward position
switch shutoff valve (Figure 6-77). again. The machine will not stroke this time, but
will again develop maximum pressure. Read the
4. Put the operators panel remote/local switch into pressure on the gauge. If more adjustment is
the local position. needed, return the pump to neutral, then repeat
5. Using the switch on the operators panel, rev the steps 9. thru 11. until the pressure is at 300 bar.
engine up to full RPM. Return the pump to the neutral position.
revDate
76 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
2. High-pressure the concrete pump. The control
block pressure gauge should read 100-bar (1450
17valves.epsL
Concrete pump
PSI) instead of 300 bar. If adjustment is needed,
shutoff valve loosen the 2.5-mm allen screw on the face of the
soft switch relief valve cartridge (Figure 69). Using
a screwdriver, adjust the pressure up or down as
needed, and lock into place with the 2.5-mm allen
screw. Use a screwdriver, if necessary, to prevent
the cartridge from turning while tightening the
allen screw. Be sure to open the concrete pump
shutoff valve when you are finished. The unit will
not stroke with this valve close
Setting accumulator E-Stop manifold pressure.
The accumulator E-Stop manifold pressure circuit
;@;@ @
; @
; @
; @
; ;@;@;@;@;@;@;@;@;@;@ is set to a maximum of 260-bar (3771 PSI) by its
;@ @
; @; @
@; @
@; @
@
; ;@ ;@@
; @
@;
@;@;@;@;@;@
@;
Soft switch relief valve on the emergency stop manifold. To
;@;@
;
Q
@
@
;
Q @;
;
Q
@
;
Q
;
Q
;
Q
@
@;
;
Q
@
;
Q
;
Q
@
@;
;
Q
@
;
Q
@
;
Q
@
@;
@
;
Q
;
Q
@
;
Q
@
; @
;
Q
@;@;@
@
;
Q
@
;
Q
@
; @
;
Q
@
;
Q@
;@
;
Q
@
;
Q
;
Q
@
;
@ ;
@
;
Q
;
Q
;
Q
@
; @;@;@;@;@
shutoff valve check the setting of the valve with the highest
pressure, you must first raise the pressure of the
lower three:
Soft Switch closed
1. Locate the accumulator unloading valve and its
Relief Valve relief valves (Figure 70).
Blckgrvs.eps
open
Figure 69
Concrete pump shut off valves 170-bar
138-bar
NOTE!
If you cannot adjust the pressure up to 300
bar, you have a problem. To ensure that the
pressure will not be to high when the prob-
230-bar
lem is found, turn the main relief knob OUT
several turns to lower the pressure. Contact
Schwing Americas service department for 17accum.eps
Pressure Settings
3. Loosen the jam nut of the open valve (170-bar) and 3. Turn the open valve (170-bar) adjustment screw
the close valve (138-bar) pressure adjustment out two-and-a-half turns or until the gauge on the
screws. With an allen wrench turn both adjustment accumulator unloading valve reads 170-bar
screws in two-and-a-half turns. This will raise the (Figure 70).
pressure on both valves above 260-bar. 4. Turn the close valve (138-bar) adjustment screw
4. Connect the whip hose of a 0400 or 0600 bar out two-and-a-half turns or until the gauge on the
gauge into the gauge port of the E-Stop manifold accumulator unloading valve reads 138-bar
(Figure 71). (Figure 70
5. Tighten the jam nuts on all three adjustment
17estopman.eps
screws.
Set the water pump/agitator pressures. You will
need an assistant to perform this procedure. The
location of all the components needed for this
procedure are shown in (Figure 66). This hydraulic
circuit has a maximum pressure of 200 bar (2900
PSI), limited by the relief valve on the water pump
handvalve.
To set the water pump/agitator hydraulic circuit
pressures perform the following steps.
Relief valve
1. Stop the unit, and put the key in your pocket.
Gauge port 2. Install the whip hose of a 0400 or 0600 bar
gauge on to the gauge port located on the
waterpump handvalve. The location of the water
pump hand valve if shown in Figure 66. Make sure
the whip hose connection is tight.
3. To check or set the highest pressure of this circuit,
you must first raise the pressure of the agitator
Figure 71 relief valve. Turn the body of the relief valve in
E-Stop manifold accumulator relief valve (clockwise) one and one half turns on the agitator
hand valve. (The location of the water pump and
5. High-pressure the concrete pump. The pressure the agitator hand valve are shown in Figure 66.)
gauge should read 260-bar (3771 PSI) This will increase the circuit pressure over the 200
6. If adjustment is needed, loosen the jam nut and bars needed to set the water pump relief valve.
with a allen wrench turn the adjustment screw on 4. Start the unit engine and set the transmission and
the relief valve (Figure 71). Turn in to raise PTO as you would to pump concrete.
pressure, turn out to lower pressure. 5. Locate the relief valve on the water pump hand
7. Repeat steps (5) and (6) until the gauge reads 260- valve. It will be on the bottom, passenger side, of
bar. the water pump handvalve.
8. Tighten the jam nut on the adjustment screw, 6. Be sure that all personnel are clear.
remove the whip hose and gauge from the gauge 7. Bring the engine to full RPM.
port, and replace the cap on the gauge port. 8. Locate the agitator shutoff valve and close it
Setting the accumulator unloading valve. Use an (Figure 67) The general location of the agitator
allen wrench to make these adjustments shutoff valve is shown in Figure 66.
1. High-pressure the concrete pump. 9. Position the agitator hand valve in the forward or
2. Turn the high pressure (230-bar) adjustment screw reverse position. The agitator will not be able to
out one-and-a-half turns or until the gauge on the turn, and the oil will be forced over the water pump
accumulator unloading valve reads 230-bar relief valve.
(Figure 70).
revDate
78 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
10. The gauge attached to the water pump hand valve pressure at which the valve relieves can be seen on
should read 200 bar. the pressure gauge attached to the agitator hand
11. To adjust the pressure, turn the outside body of the valve. It should read 150 bar (2175 PSI).
water pump pressure relief valve (shown in Figure 20. To adjust the pressure, turn the outside body of the
58) clockwise to increase, or counterclockwise to agitator pressure relief valve, located on the bottom
decrease until 200 bar is showing the pressure of the agitator hand valve. It is the smaller of the
gauge. two cartridges extending from the bottom of the
valve (Figure 72). Turn the body of the relief valve
clockwise to increase or counter clockwise to
Turn body of valve decrease until 150 bar is showing the pressure
200 bar to adjust. gauge.
Higher
Relief Valve Lower
PS
7.E
lv1
m pv
p/c
pm
wtr
Figure 72
Water pump relief valve
Pressure Settings
revDate
80 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
BPL 2000 4. Wear safety glasses when setting pressures.
5. Start the engine.
NOTE!
6. Close the concrete pump shut-off valve (also
Pressure settings must be made with the
known as the ballcock or quarter-turn valve). (See
hydraulic oil at normal operating tempera-
Figure 74.)
tures (4060C).
7. Put the operators panel remote / local switch
To heat the oil to operating temperature use one of the into the local position.
following procedures:
8. Using the switch on the operators panel, rev the
1. When the oil is very cold (at or below the pour engine up to full RPM.
point of your hydraulic oil), bring engine RPM to
an idle. Let the engine idle until the temp. gauge on 9. Using the concrete pump forward / neutral /
the operators panel reads 40C. reverse handle, put the concrete pump into the
forward position. The unit will stroke no more
2. If your concrete pump unit has an agitator shutoff than once, then the rock cylinder will retract. Oil
valve, refer to Preheating the hydraulic oil in the will have nowhere to go except over the main relief
Operation section of this manual. valve.
Set the concrete pump pressure. The Schwing
10. Read the pressure on the concrete pump gauge,
concrete pump circuit on the BPL 2000 is designed
located on the main control panel. It should read
to be operated at a maximum pressure of 300 bar
300 bar. Return the pump to neutral whether in
(4350 PSI). It is controlled by the main relief
needs adjustment or not. If no adjustment is
valve, which is located on the top of the main
needed, skip to Step 13.
control block (Figure 73). To check or set the main
relief pressure: 11. If adjustment is required, loosen the jam nut on the
relief valve adjusting screw (requires a 13 mm
spanner wrench).
12.
13. Turn the knob on the relief valve to adjust the
pressure. Screw the handle in to raise pressure, out
to lower the pressure.
14. Retighten the jam nut. (This step is necessary
because tightening the nut tends to raise the
pressure. If it becomes a problem, hold the knob
while tightening the jam nut).
15. Put the concrete pump into the forward position
again. The machine will not stroke this time, but
will again develop maximum pressure. Read the
pressure on the gauge. If more adjustment is
needed, return the pump to neutral, then repeat
steps i. thru l. until the pressure is at 300 bar.
Lower Raise Return the pump to the neutral position.
pressure pressure 16. Open the quarter turn valve.
17. Return the RPM to an idle and go on to the other
gray valve.eps L pressure settings, as required.
Figure 73
Concrete pump circuit
main relief valve
Pressure Settings
Closed
Figure 74
Concrete pump shutoff valve
Relief Valve
OU
TR
IG
GE
R
R
ET
RA
CT
E
XT
EN
D
Figure 75
Outrigger handvalve
Pressure Settings
revDate
84 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
BPL 4000
Accumulator Unload-
ing Manifold Valve
Concrete Pump
and Gauge Port
Pressure Gauge
Figure 76
General location of components used
to set hydraulic pressures (original
production)
Pressure Settings
Figure 77
General location of components used
to set hydraulic pressures (current
production)
agit.shutoff.eps
CLOSED
Valve is shown in
the OPEN
position
Figure 78
Agitator shut off valve
Set the concrete pump pressure (original located at the front of the main control block
production) - The concrete pump circuit on the (Figure 79). To check or set the main relief
BPL 4000 is designed to be operated at a pressure perform the following steps.
maximum pressure of 320 bar (4640 PSI). It is
controlled by the main relief valve, which is
relieflocMPS.eps
Lower Raise
pressure pressure
Concrete pump
shutoff valve gray valve.eps L
Figure 79
Concrete pump shutoff valve
and main relief valve
1. Be sure that the waterbox covers are installed on 2. Wear safety glasses when setting pressures.
the waterbox. We do not recommend using the
remote control box for the following procedure.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 87
HOME PRINT
Pressure Settings
3. Close the concrete pump shutoff valve (Figure 6-
88) and the soft switch shutoff valve (FigureFigure
81).
Closed
Figure 80
Concrete pump shutoff valve
Pressure Settings
Soft switch
shutoff valve
Pressure
Concrete pump control
hif
shutoff valve low
brn
.ep
s
position
(closed)
Groove lined
up with ports - open
grooves.eps
Groove at 90
to ports - closed
Figure 82
Concrete pump shutoff valve and soft switch shutoff valve
3. Close the concrete pump shutoff valve and the soft 7. Read the pressure on the concrete pump pressure
switch shutoff valve (Figure 82). gauge, located on the main control block (Figure
4. Position the remote / local switch, on the main 82.) It should read 320 bar. Position the throttle
control panel, to the local position. switch to the neutral position. If no adjustment is
needed, skip to Step 12.
5. Use the throttle switch, on the main control panel,
to rev the engine up to full RPM. 8. If adjustment is required, loosen the 9/16 inch jam
nut on the main relief valve (Figure 82).
6. Use the concrete pump forward / neutral /
reverse switch to put the pump into the forward 9. Use a 5/32 inch allen wrench to adjust the pressure
position. The unit will stroke only once, then the to 320 bar. Turn the adjustment screw in to raise
rock cylinder will retract. Oil will have nowhere to pressure, out to lower the pressure.
go except over the concrete pump main relief
valve.
revDate
90 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
10. Retighten the jam nut. (tightening the jam nut the pump to neutral, then repeat Steps 1. through
tends to raise the pressure. If this happens, hold the 6. until the pressure is at 80 bar. Position the
allen wrench in position while tightening the jan throttle switch to the neutral position.
nut). 8. Be sure to open the concrete pump shutoff valve
11. Put the concrete pump into the forward position when you are finished. The unit will not stroke
again. The machine will not stroke this time, but with the shutoff valve closed.
will develop maximum pressure. Read the pressure Set accumulator circuit hydraulic oil pressure
on the gauge. If more adjustment is needed, return (units with pressure- compensated pumps) - You
the pump to neutral, then repeat Steps 8. through will need an assistant for parts of this procedure.
11. until the pressure is at 320 bar. Position the To check or adjust the hydraulic pressure in the
throttle switch to the neutral position. accumulator circuit, perform the following steps:
NOTE! 1. Stop the truck, put the key in your pocket, and
If you cannot adjust the pressure up to 320 place a Do Not Operate sign on the windshield.
bar, you have a problem. In this case, turn 2. Loosen the jam nut on the pressure regulator of the
the adjustment knob out by several turns so accumulator hydraulic pump. Turn the screw in
that your pressure isnt too high once the two-and-a-half turns. This will raise the regulator
problem is found. Contact Schwing Amer- pressure above 300 bar (Figure 83).
icas service department for advice on how .
to continue.
12. If you are not setting the soft switch pressure, open
both shutoff valves. The unit will not stroke with
the shutoff valves closed.
Setting the soft switch circuit relief pressure
(current production) - To check or adjust the soft
switch pressure setting, perform the following Accumreg.eps
steps:
1. Open the soft switch shutoff valve. Close the
concrete pump shutoff value (Figure 82.)
2. Use the throttle switch, on the main control panel,
to rev the engine up to full RPM.
Accumulator pump
3. Use the concrete pump forward / neutral / pressure regulator
reverse switch to put the pump into the forward
position. The control block pressure gauge should
read 80-bar (1160 PSI) instead of 320 bar.
Figure 83
4. If adjustment is required, loosen the 9/16 inch jam
Accumulator pump pressure regulator
nut on the soft switch relief valve (Figure 82).
5. Use a 5/32 inch allen wrench to adjust the pressure
to 80 bar. Turn the adjustment screw in to raise 3. Connect the whip hose of a 0-600 bar gauge into
pressure, out to lower the pressure. the gauge port of the E-Stop manifold (Figure 84).
6. Retighten the jam nut. (tightening the jam nut 4. Loosen the jam nut on the accumulator relief valve,
tends to raise the pressure. If this happens, hold the located on the E-Stop manifold. Turn the screw in
allen wrench in position while tightening the jan two turns. This will raise the relief setting above
nut). 300 bar (Figure 84).
7. Put the concrete pump into the forward position
again. The machine will not stroke this time, but
will develop maximum pressure. Read the pressure
on the gauge. If more adjustment is needed, return
Pressure Settings
e-stop/left.epsL 45s3blck.epsL
Relief Valve
Figure 84
Figure 85
E-Stop manifold accumulator relief valve
Accumulator manifold pressure relief
valve
5. Clear all personnel away from the drive lines, start
the truck engine, engage the pumps, and bring 8. You will need an assistant for this step. With the
engine RPM to maximum. engine still running, adjust the relief valve of the E-
6. Read the pressure on the accumulator circuit gauge Stop manifold. Back out the adjustment screw
located just between the hopper and the A-frame. until pressure reads 260 bar (3770 PSI) on the
Pressure should read 300 bar (4350 PSI). If no gauge connected to the E-Stop manifold.
adjustment is needed, skip to (Step 8).
7. If additional pressure adjustment is needed, locate
the accumulator manifold pressure relief valve
(Figure 85). Loosen the jam nut, and turn the screw WARNING
in to increase pressure, or out to decrease pressure.
Tighten the jam nut when pressure is at 300 bar. Stop the truck engine before proceed-
ing to the next Step. Entanglement
hazard
revDate
92 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
screw in to increase pressure, or out to decrease
pressure. Lock the jam nut when pressure is e-stop/left.epsL
correct.
Set accumulator circuit hydraulic oil pressure Relief Valve
(units with accumulator unloading valves) - You and Gauge Port
will need an assistant for parts of this procedure.
To check or adjust the hydraulic pressure in the
accumulator circuit, follow these steps:
1. Stop the truck, put the key in your pocket, and
place a Do Not Operate sign on the windshield.
2. Connect the whip hose of a 0-600 bar gauge into
the gauge port of the E-Stop manifold (Figure 87).
3. Locate the accumulator unloading valve. The
location of this valve on the pump unit may vary.
Loosen the jam nut on the accumulator unloading
valve. Turn the screw in two-and-a-half turns. This
will raise the pressure above 300 bar (Figure 86). Figure 87
E-Stop manifold accumulator
relief valve
Adjustment Screw
Figure 86
Accumulator unloading valve
Pressure Settings
. 2. Install the whip hose of a 0400 or 0600 bar
gauge on to the gauge port located on the
45s3blck.epsL
;;;;;;;;
@@@@@@@@
;;;
@@@
Higher
Relief Valve Lower
@@@@@@@@ ;;;
;;;;;;;;
4Kpsoutr.eps
@@@
@@@@@@@@ ;;;
;;;;;;;; @@@
WARNING
IN Clear area
RETRACT
before activating
OUTRIGGER
outriggers
OUT
EXTEND
S
.EP
4K
vlv
/cmp
p mp
wtr
Outrigger
Figure 89 Relief Valve
Water pump relief valve and Gauge
Port
10. Return the outrigger handvalve to the neutral
position.
Figure 90
11. Turn the body of the relief valves out (counter Outrigger relief valve
clockwise) one and one half turns on the agitator
hand valve and the passenger side outrigger hand
valve. This will return the these relief valves to 18. Return the outrigger handvalve to the neutral
their original settings. position.
12. Remove the pressure gauge from the water pump 19. Remove the pressure gauge from the passenger
hand valve and replace the cap nut on the gauge side outrigger hand valve and replace the cap nut
port. on the gauge port.
13. Install the whip hose of a 0400 or 0600 bar 20. Close the agitator shutoff valve (Figure 91).
gauge on to the gauge port located on the 21. Install the whip hose of a 0400 or 0600 bar
passenger side outrigger hand valve. Make sure the gauge on to the gauge port located on the drivers
whip hose connection is tight.(Figure 65). side agitator hand valve (Figure 92). Make sure the
14. Be sure that all personnel are clear. whip hose connection is tight.
15. Rev the engine to full RPM.
16. Activate the passenger side outrigger handvalve in
the retract position. Hold the handvalve in retract
position to cause the outrigger to bottom out in the
retract position. This will send the oil against the
high-pressure plug. The oil will return to the tank
over the relief valve in the outrigger hand valve.
The pressure at which the valve relieves can be
seen on the pressure gauge attached to the
outrigger pump hand valve. It should read 200 bar
(2900 PSI).
Pressure Settings
WARNING 4Kdshppr.epsL
agit.shutoff.eps
CLOSED
Do not stand on
hopper grates.
SAFETY INSTRUCTIONS
HOPPER GRATE OR
BEFORE REMOVING
SERVICE:
PERFORMING ANY
Engines Electric Motors
Gasoline or Diesel motor.
1. Stop the electric
1. Stop the engine.
place it 2. Lock out the power an
2. Remove the key, source according to
put
in your pocket, and approved lockout-tagout
a "DO NOT OPERATE" program.
tag on the switch.
3. Check accumulator
3. Check accumulator circuit pressure gauge
circuit pressure gauge (if so equipped) to
verify
verify
(if so equipped) to zero system pressure.
zero system pressure.
Gauge Port
@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;
QQQQQQQQQQQQQQQQQQQQ
@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;
QQQQQQQQQQQQQQQQQQQQ
@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;
QQQQQQQQQQQQQQQQQQQQ
Valve shown in the @@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;
QQQQQQQQQQQQQQQQQQQQ
@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;
QQQQQQQQQQQQQQQQQQQQ
SUBSIDIARY OF F. W. GMBH.
AMERICA INC.
HERNE 2/ GERMANY
AGITATOR
WHITE BEAR, MINNESOTA
OPEN position
PHONE (02325)7871
PHONE 612-429-0999 TELEX 820 348
TWX: 910-563-3539
4.373.875
U. S. PATENTS: 3.146.721; 3.640.303; 3.409.334; REVERSE - FORWARD
5,346,368
before activating 3,741,691
3,829,251
4,343,598
4,373,225
4,556,370
4,621,375
4,681,022
5,106,225
5,106,272
5,224,654
5,401,140
4,019,839 4,373,875
outriggers
Figure 91 IN
RETRACT
OUTRIGGER
OUT
EXTEND
Agitator Relief
22. Be sure that all personnel are clear. Valve
23. Rev the engine to full RPM.
24. Hold the agitator lever in the forward or reverse Figure 92
position. This will send the oil against the high- Agitator relief valve
pressure plug. The oil will return to the tank over
the relief valve in the agitator hand valve. The 26. Return the agitator handvalve to the neutral
pressure at which the valve relieves can be seen on position.
the pressure gauge attached to the agitator hand 27. Remove the pressure gauge from the outrigger
valve. It should read 200 bar (2900 PSI). hand valve and replace the cap nut on the gauge
25. To adjust the pressure, turn the outside body of the port.
agitator pressure relief valve, located on the bottom
of the agitator hand valve. It is the smaller of the
two cartridges extending from the bottom of the
valve (Figure 92). Turn the body of the relief valve
clockwise to increase or counter clockwise to
decrease until 200 bar is showing the pressure
gauge.
revDate
96 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 17M
Check hydraulic pressures. Check all hydraulic
pressures. Changes in pressures can indicate
trouble in one or more components. The
specifications for all circuits are shown on the
Hydraulic Schematics in the Appendix of this
manual.
Pressure settings must be made with the oil at normal
operating temperatures (40C 60C). The agitator
circuit must be used to heat the hydraulic oil. Do not
jam the paddles to force the oil over relief by stopping
the movement of the agitator. To preheat the hydraulic
oil using the agitator circuit, follow these instructions.
1. Locate the agitator shutoff valve and close it
(Figure 107). The general location of the agitator
shutoff valve is shown in Figure 93.
NOTE!
If your unit does not have a shutoff valve,
order one, using part #10004680 (valve),
and #30303432 (tube). Contact the Schwing
Service Department for installation instruc-
tions. If you cant wait for a shutoff valve,
you will need to remove one of the hoses
from the agitator motor and plug the hose
and open fitting with approved hydraulic
dead plugs. Do not substitute other plugs,
such as a steel bearing inside a cap fitting.
2. Position the agitator lever in the forward or reverse
position (Figure 107). The agitator will not be able
to turn, and the oil will be forced over the relief
valve.
3. At idle speed (about 600 RPM), about 4.5
horsepower is being converted to heat. Shut off the
concrete pump when the temperature gauge on the
operators panel shows 50C.
4. Open the agitator shutoff valve or remove plug and
reconnect hose to agitator motor.
The general location of the components used to check
or set hydraulic pressures in shown in Figure 93.
Pressure Settings
Boon/Outrigger
Hand Valve and Gauge E- Stop Manifold Valves
Port and Gauge Ports
30347529 A
Gauge
Figure 93
General location of components
used to set hydraulic pressures
revDate
98 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
8. Read the pressure on the control block pressure
17mainreliefvalve.eps
gauge, shown in Figure 68. It should read 300-bar.
Return the pump control to neutral, whether it
needs adjustment or not. If no adjustment is
needed, skip to Step 13.
17valves.eps
Shutoff valve
Jam nut
Relief Valve
Figure 94
Concrete pump main relief valve
Pressure Settings
12. High-pressure the concrete pump again. Read the
pressure on the control block pressure gauge. If
more adjustment is needed, return the concrete
pump switch to neutral, then repeat Steps (5)
through (8) until the pressure is correct.
NOTE!
If you cannot adjust the pressure up to spec- 170-bar
ification, you have a problem. In this case,
unscrew the adjustment knob several turns 138-bar
so that your pressure is not too high when
you find the problem. Contact Schwing
Americas Service Department at (651) 429-
0999 for advice on how to continue. 230-bar
13. If you will not be setting the soft switch pressure,
open the shutoff valves. The unit will not stroke
17accum.eps
with closed shutoff valves.
Figure 96
Setting the soft switch circuit relief Accumulator unloading valve
pressure (original production)
To check or adjust the soft switch pressure setting,
1. Locate the accumulator unloading valve (Figure
perform the following steps.
96).
1. Open the soft switch shutoff valve. The rest of the
2. Loosen the jam nut of the high pressure valve
unit should still be set up as if you were going to
(230-bar) adjustment screw. With an allen wrench
check or set concrete pump pressure.
turn the adjustment screw in one-and-a-half turns.
2. High-pressure the concrete pump. The control This will raise the pressure on the valve above 260-
block pressure gauge should read 100-bar (1450 bar.
PSI) instead of 300 bar. If adjustment is needed,
3. Loosen the jam nut of the open relief valve (170-
loosen the 2.5-mm allen screw on the face of the
bar) and on the close valve (138-bar) pressure
soft switch relief valve cartridge (Figure 95). Using
adjustment screws. With an allen wrench turn both
a screwdriver, adjust the pressure up or down as
adjustment screws in two-and-a-half turns. This
needed, and lock into place with the 2.5-mm allen
will raise the pressure on the valve above 260-bar.
screw. Recheck. Use a screwdriver, if necessary, to
prevent the cartridge from turning while tightening 4. Connect the whip hose of a 0400 or 0600 bar
the allen screw. Be sure to open the concrete pump gauge into the gauge port of the E-Stop manifold
shutoff valve when you are finished. The unit will (Figure 97).
not stroke with this valve close
revDate
100 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
4. Turn the close valve (138-bar) adjustment screw
17estopman.eps out two-and-a-half turns or until the gauge on the
accumulator unloading valve reads 138-bar (Figure
96).
5. Tighten the jam nuts on all three adjustment
screws.
17accum2.eps
@@@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;;;
;@Q ;@Q ;@Q;@Q ;@Q;@Q ;@Q;@Q ;@Q;@Q ;@Q
;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q
@@@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;;;
Q
@
Q
@
;
Q
@
;
Q
@
;
;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q
;
@@@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;;; ;@Q ;@Q ;@Q ;@Q ;@Q
;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q
@@@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;;;
Figure 97 @@@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;;;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
; ;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q
@@@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;;;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
Q
@
;
E-Stop manifold accumulator relief valve ;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q
@@@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;;; ;@Q;@Q;@Q ;@Q;@Q;@Q ;@Q;@Q;@Q ;@Q;@Q ;@Q;@Q ;@Q;@Q ;@Q
;@Q;@Q;@Q ;@Q;@Q;@Q ;@Q;@Q;@Q ;@Q;@Q;@Q;@Q ;@Q;@Q;@Q;@Q ;@Q;@Q;@Q ;@Q;@Q;@Q
@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;
5. High-pressure the concrete pump. The pressure @@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;
gauge should read 260-bar (3771 PSI). @@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;; Gauge
@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;
6. If adjustment is needed, loosen the jam nut and @@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;
230-bar relief
@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;
with a allen wrench turn the adjustment screw on @@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;
170-bar relief
@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;
the relief valve (Figure 97). Turn in to raise @@@@@@@@@@@@@@@@@@@@@@
;;;;;;;;;;;;;;;;;;;;;;
pressure, turn out to lower pressure. Figure 98
7. Repeat steps (5) and (6) until the gauge reads 260- Accumulator unloading valve
bar. (current production
8. Tighten the jam nut on the adjustment screw,
1. Locate the accumulator unloading valve (Figure
remove the whip hose and gauge from the gauge
98).
port, and replace the cap on the gauge port
2. Loosen the jam nut of the high pressure valve
Setting the accumulator unloading valve (230-bar) adjustment screw. With an allen wrench
(original production) turn the adjustment screw in one-and-a-half turns.
This will raise the pressure on the valve above 260-
Use an allen wrench to make these adjustments bar.
1. High-pressure the concrete pump. 3. Loosen the jam nut of the open relief valve (170-
2. Turn the high pressure (230-bar) adjustment screw bar.) With an allen wrench turn the adjustment
out one-and-a-half turns or until the gauge on the screw in two-and-a-half turns. This will raise the
accumulator unloading valve reads 230-bar (Figure pressure on the valve above 260-bar.
96). 4. Connect the whip hose of a 0400 or 0600 bar
3. Turn the open valve (170-bar) adjustment screw gauge into the gauge port of the E-Stop manifold
out two-and-a-half turns or until the gauge on the (Figure 99.)
accumulator unloading valve reads 170-bar (Figure
96).
Pressure Settings
Setting the boom E-Stop manifold
17estopman.eps
pressure
The boom E-Stop manifold pressure circuit is set to a
maximum of 350-bar (5076 PSI) by its relief valve on
the emergency stop manifold. To check the setting of
the valve with the highest pressure, you must first raise
the pressure of the lower two:
1. Locate the boom/outrigger hand valve (Figure
101).
Relief valve 2. Turn the outside body of the 300-bar relief valve
that is located at the bottom of the boom/outrigger
Gauge port hand valve in two-and-one-half turns. This will
raise the pressure on the valve above 350-bar.
3. Locate the boom hand valves (Figure 101).
4. Turn the outside body of the (280-bar) relief valve
that is located at the back of the boom hand valve
in two-and-one-half turns. This will raise the
pressure on the valve above 350-bar.
Figure 99 5. Connect the whip hose of a 0400 or 0600 bar
E-Stop manifold accumulator relief valve gauge into the gauge port of the boom E-Stop
manifold valve (Figure 100).
5. High-pressure the concrete pump. The pressure
gauge should read 260-bar (3771 PSI)
6. If adjustment is needed, loosen the jam nut and 17e-stop.eps
GREASE TOWER BEARINGS
GREASE TOWER BEARINGS ONLY GREASE WHICH HAS
THE FOLLOWING CHARACTERISTICS. USE LUBRIPLATE
7. Repeat steps (5) and (6) until the gauge reads 260- manifold block.
Emergency stop
switches do NOT
function when
= manual bypass is
depressed.
bar.
8. Tighten the jam nut on the adjustment screw,
remove the whip hose and gauge from the gauge
port, and replace the cap on the gauge port.
cato E!
r light
temp hydr whe POS GE."
erat aulic n indi SIBL
g
CAR pped
atin
TRID
N!
is cold if
LAC AND PAP is equi
.
n oil ace
IO
GE NOT
flash Do is at
NT
ER
r
TRID SE IS
ANIN E-W oil filte
whe
TE
and
G
The
es
REP
WARNING
Do not operate at
pressures exceeding
the rating of the
entire material
delivery system.
revDate
102 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
8. If adjustment is needed, loosen the jam nut and 1. Connect the whip hose of a 0400 or 0600 bar to
turn the adjustment screw on the relief valve that is the gauge port of the boom/outrigger hand valve.
located on the boom E-Stop manifold valve (Figure 2. If this is not already done, start the truck engine
100). Turn in to raise pressure, turn out to lower and set the transmission and PTO as you would for
pressure. a pumping job.
9. Repeat steps (4) thorough (6) until the gauge reads 3. Locate the 300-bar relief valve on the bottom of
350-bar. the boom/outrigger hand valve.
10. Tighten the jam nut on the boom E-Stop manifold 4. Set the engine RPM to maximum.
adjustment screw, remove the whip hose and gauge
5. Push the outrigger enable pushbutton located next
from the gauge port, and replace the cap on the
to the outrigger hand valves. Hold the outrigger
gauge port.
hand valve lever in the retract position. The oil
11. Turn the outside body of the 300-bar relief valve coming from the pump has nowhere to go but over
that is located at the bottom of the boom/outrigger the relief valve on the boom/outrigger hand valve.
hand valve out two-and-one-half turns.
NOTE!
12. Turn the outside body of the (280-bar) relief valve
You cannot use the outrigger extend posi-
that is located at the back of the boom hand valve
tion for this adjustment because extend has
out two-and-one-half turns.
nonadjustable secondary relief functions
13. Set or reset the boom and the outrigger hydraulic built into the valve.
pressures.
6. The pressure on the pressure gauge should read
300-bar.
Setting the boom/outrigger pressure
7. If adjustment is needed, turn the outside body of
The outrigger circuit is set to a maximum of 300-bar
the relief valve that is located at the bottom of the
(4350 PSI) by the relief valve on the boom/outrigger
boom/outrigger hand valve. Turn in to raise
hand valve. This handvalve is located on the drivers
pressure, turn out to lower pressure.
side of the turret (Figure 101). Due to the location of
the boom/outrigger handvalve and the outrigger control 8. Activate the enable pushbutton and the hand valve
lever used in this procedure, you will need an assistant and read the pressure on the gauge again. Repeat
to make the adjustments and read the gauge. steps (7) and (8) until the gauge reads 300-bar.
9. When the pressure is 300-bar, release the enable
pushbutton and the outrigger hand valve.
Turn body of valve 10. Remove the whip gauge from the boom/outrigger
to adjust. hand valve, and replace the cap on the gauge port.
300 bar Higher
Relief Valve Lower Setting the outrigger pressure
The outrigger circuit is set to a maximum of 280-bar
(4060 PSI) by the relief valve located on the drivers
side outrigger hand valve assembly (Figure 102). The
valve routes the oil to the two outrigger hand valve
banks, one on each side of the unit. A relief valve
inside the drivers side bank limits the entire outrigger
circuit to 280-bar.
PS
X.E
-28
lve
va
oom
tr ig/b
ou
Figure 101
Boom/outrigger hand valve
Pressure Settings
8. Activate the enable pushbutton and the hand valve
;;;;;;;;;;;;;
@@@@@@@@@@@@@
and read the pressure on the gauge again. Repeat
@@@@@@@@@@@@@
;;;;;;;;;;;;; WARNING 17dshopper.epsL
@@@@@@@@@@@@@
;;;;;;;;;;;;; steps (7) and (8) until the gauge reads 280-bar.
@@@@@@@@@@@@@
;;;;;;;;;;;;;
@@@@@@@@@@@@@
;;;;;;;;;;;;; 9. When the pressure is 280-bar, release the enable
@@@@@@@@@@@@@
;;;;;;;;;;;;;
Do not stand on
hopper grates.
@@@@@@@@@@@@@
;;;;;;;;;;;;; SAFETY INSTR
UCTIONS pushbutton and the outrigger hand valve.
@@@@@@@@@@@@@
;;;;;;;;;;;;;
OR
HOPPER GRATE
BEFORE REMOVING
ANY SERVICE:
PERFORMING
Electric Motors
Engines
Gasoline or Diesel 1. Stop the electric
motor.
@@@@@@@@@@@@@
;;;;;;;;;;;;;
1. Stop the engine. power
2. Lock out the
10. Remove the whip hose and gauge from the boom
key, place it to an
2. Remove the and put
source according t
in your pocket, approved lockout-tagou
a "DO NOT OPERATE" program.
tag on the switch.
@@@@@@@@@@@@@
;;;;;;;;;;;;;
3. Check accumulatorgauge
3. Check accumulator circuit pressure
gauge to verify
circuit pressure (if so equipped)
to verify
(if so equipped) zero system pressure.
zero system pressure.
WARNING
Stored hydraulic energy.
Release all hydraulic
pressure and verify zero
pressure on gauge
@@@@@@@@@@@@@
;;;;;;;;;;;;; hand valve, and replace the cap on the gauge port.
before servicing.
30308020 C
Release all hydraulic
pressure and verify zero
pressure on gauge
before servicing. PSI) by the relief valve on the boom hand valve
WARNING
Clear area
before activating
assembly (Figure 103).
outriggers
17bmcntl.epsL
Relief Valve
Figure 102
Outrigger hand valve
1. Connect the whip hose of a 0400 or 0600 bar
gauge into the gauge port on the drivers side
outrigger hand valve.
2. If this is not already done, start the truck engine
and set the transmission and PTO as you would for
a pumping job.
3. Locate the 280-bar relief valve on the back of the ;;;;;;;;;;;
@@@@@@@@@@@
;;;;;;;;;;;
@@@@@@@@@@@
Ele DA
Sta ctro
vo y ba cu
NG
ER
;;;;;;;;;;;
@@@@@@@@@@@
17 ltage ck tion
fe
et wir fromhaza
;;;;;;;;;;;
@@@@@@@@@@@
W
Do
m not
AR
ac
tra hi oper NIN
in Figure 102.
;;;;;;;;;;;
@@@@@@@@@@@
ne
th inin w ate G
e
m warg. Unithou this
an
ua ning ders t
ls
an s in tand
d
on safe
de ty
;;;;;;;;;;;
@@@@@@@@@@@
ca
ls.
revDate
104 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
s
.ep
17
lblk
ntr
omc
bo
Figure 104
Boom control relief valve
4. Pressure out any boom cylinder except #1 in a possibility of an inattentive operators causing damage
retract position. You can pressure out a cylinder by to the boom or the A frame when folding into the
retracting a fully retracted cylinder or extending a transport position. To prevent this, there is a secondary
fully extended cylinder. The oil will have nowhere relief valve that regulates only the pressure on the #1
to go but over the relief valve. retract function. The #1 boom down pressure should be
5. Have your assistant read the pressure on the gauge 170-bar (2465 PSI). To check or adjust the down side
at the boom hand valve. It should read 280-bar. If relief valve:
no adjustment is needed, skip to Step 8. You have to raise the boom and rotate it for this
6. To adjust the boom pressure, locate the relief valve procedure, so you must set the outriggers as you would
on the back of the boom control block (Figure to pump a job. Release the boom strap. To adjust the
104). valve, you will need a 2.5 mm allen wrench and a
7. If adjustment is needed, turn the outside body of standard screwdriver.
the relief valve that is located at the back of the 1. Connect the whip hose of a 0-400 or 0600-bar
boom hand valve. Turn in to raise pressure, turn gauge into the gauge port shown in Figure 105.
out to lower pressure.
8. When the pressure is 280-bar, release the boom
hand valve.
9. Remove the whip hose and gauge from the boom
hand valve, and replace the cap on the gauge port.
Pressure Settings
170-bar gauge
port
170-bar relief
valve
;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@
@;
@;
DA
@;@;@;@;@;@;@;@;@;@;@;@;
Ele
Sta ctr NG
@;
;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@
vo y oc
17 ltag bac utio ER
fe e w k fr n h
et o a
(5 ires m zard
m h
ete at le igh .
rs as
). t
@;@;@;@;@;@;@;@;@;@;@;@;
;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@
W
Do
m no
AR
a
tra chint op NIN
th inin e w erate
m e wa g. U ith
an o this
G
ua rnin nde ut
ls g rs
an s in tan
;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@
d
on safe d
;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@
@;@;@; @;(Hoses @;@;@; @; abbreviated for clarity)
Figure 105
Section #1 down relief valve
revDate
106 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
To set the water pump circuit pressure perform the
following steps: Turn body of valve
1. Stop the unit, and put the key in your pocket. to adjust.
200 bar Higher
2. Connect the whip hose of a 0-400 or 0-600 bar
gauge to the gauge port on the water pump hand
Relief Valve Lower
valve.
3. If your unit does not have a compressor, skip to
Step 6.
4. If your unit has a compressor remove one of the
hoses from the water pump motor and plug the
hose and the open fitting with approved hydraulic
dead plugs. Do not improvise on these plugs. If
you dont have any, contact Schwings Spare Parts
Department and order them before continuing with
this procedure. You will need: pv
lv1
7.E
PS
p/cm
Qty 2 VS-16S locking plugs, part number wtrpm
10016803
Qty 1 GS-16S straight fitting, part number Figure 106
10008088 Water pump relief valve
Qty 2 16S capnuts, part number 10001743 9. If adjustment is needed, turn the outside body of
All of these fittings and many, many more the relief valve that is located at the bottom of the
extremely useful items are included in the water pump/compressor hand valve. Turn in to
Troubleshooting Kit, part number 30308553. raise pressure, turn out to lower pressure.
We highly recommend purchase of this kit. It 10. When the pressure is set to 200-bar, stop the engine
will pay for itself many times over. and remove the key.
5. Be sure that one of the locking plugs and capnuts 11. Remove the dead plugs and store in a clean area or
are tightened on the straight fitting and that the in a plastic bag or something similar to keep dirt
dead plugs are securely tightened to the hose and from entering the fittings. Re-attach the hose to the
the open motor fitting. water pump motor fitting and tighten securely.
6. Locate the relief valve on the water pump hand (Torque is correct if you make one complete
valve. It comes out of the valve body toward the revolution after feeling initial resistance increase.)
ground, and it is the smaller of the two cartridges 12. Remove the whip hose and pressure gauge.
that youll see. Replace the gauge port cover.
7. Be sure that any personnel are clear, and restart the
engine. Setting the agitator pressure
8. Activate the water hand valve by pushing or The agitator circuit has a maximum pressure of 150-
pulling the handle. This will send the oil against bar (2175 PSI), limited by the relief valve located in
the high pressure plug. The oil will have nowhere the agitator hand valve (Figure 107). There is a gauge
to go, so it will return to the tank over the relief port for checking or setting the pressure. The port is
valve in the water pump hand valve. The pressure located on the agitator hand valve.
at which it relieves can be seen on the gauge. It 1. Stop the unit, and put the key in your pocket.
should read 200-bar. If no adjustment is needed,
2. Connect the whip hose of 0-400 or a 0600-bar
skip to Step 10.
gauge to the gauge port on the agitator hand valve.
3. If your unit is equipped with a agitator shut off
valve, close it (Figure 107). Skip to Step 6.
Pressure Settings
valve in the agitator hand valve. The pressure at
which it relieves can be seen on the gauge. It
should read 150-bar.
agit.shutoff.eps
Pressure Settings
NOTE! The general location of the components used to check
Depending on the type of pumpkit and or set hydraulic pressures are shown in Figure 2.
original or current production, your
concrete pump unit may or may not have all
the components shown in Figure 2
Figure 2
General location of components
used to set hydraulic pressures
revDate
110 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Set the concrete pump main relief valve 8. Use the concrete pump forward/neutral/reverse
(single- circuit) switch to put the pump into the forward position.
The unit will stroke only once, then the rock
The BPL 1200 concrete pump is designed to operate at cylinder will retract. Oil will have nowhere to go
a maximum pressure of 300 bar (4350 PSI). It is except over the concrete pump main relief valve.
controlled by the main relief valve (Figure 3). The
9. Read the pressure on the concrete pump pressure
main relief valve is located at the front of the control
gauge, located on the main control block. It should
block (towards the truck cab). To check or set the main
read 300 bar. Position the throttle switch to the
relief pressure, perform the following steps:
neutral position. If no adjustment is needed, skip
to Step 12.
grooves2.eps
gray valve.eps
Figure 3
Main relief valve (single circuit)
1. Be sure that the waterbox covers are installed on
the waterbox. We do not recommend using the
remote control box for the following procedure.
2. Wear safety glasses when setting pressures.
3. Close the concrete pump shutoff valve (Figure 80).
quarter turn.eps
Pressure Settings
12. Retighten the jam nut. (Tightening the jam nut 3. Close the concrete pump shutoff and soft switch
tends to raise the pressure. If this happens, hold the shutoff valves (Figure 5).
adjustment knob while tightening the jam nut.) 4. Position the remote / local switch on the rear
13. Put the concrete pump into the forward position control panel to the local position.
again. The machine will not stroke this time, but 5. Use the throttle switch on the rear control panel to
will develop maximum pressure. Read the pressure rev the engine up to full RPM.
on the control block pressure gauge. If more
6. Use the concrete pump forward/neutral/reverse
adjustment is needed, return the pump to neutral;
switch to put the pump into the forward position.
then repeat Steps 8 through 11 until the pressure is
The unit will stroke only once, then the rock
at 300 bar. Position the throttle switch to the
cylinder will retract. Oil will have no where to go
neutral position.
except over the concrete pump main relief valve.
14. Open the shutoff valve. The unit will not stroke
7. Read the pressure on the concrete pump pressure
with the shutoff valve closed.
gauge located on the main control block. It should
NOTE! read 350 bar. Position the concrete pump switch to
If you cannot adjust the pressure up to 300 the off (neutral) position. If no adjustment is
bar, you have a problem. In this case, turn needed, skip to Step 11.
the adjustment knob out by several turns so
that your pressure isnt too high once the 8. If adjustment is needed, use a 9/16 inch spanner
problem is found. Contact Schwing wrench, to loosen the jam nut on the main relief
Americas Service Department for advice on valve adjusting screw (Figure 5).
how to continue. 9. Insert a 5/32 inch allen wrench in the adjustment
screw. Turn the screw in to raise pressure or out to
Set the concrete pump main relief valve
lower the pressure.
(twin circuit) 10. Once the pressure is correct (350 bar) retighten the
The main relief valve is the primary pressure control jam nut. Tightening the nut tends to raise the
device on units equipped with Rexroth A7VO pressure, so check pressure again after tightening.
hydraulic pumps. This pump is designed to operate at a Verify the correct pressure setting (350 bar).
maximum pressure of 350 bar (5075 PSI). 11. Open the concrete pump shutoff valve and soft
switch shutoff valves. The unit will not stroke with
these valves closed.
WARNING
Hot oil expulsion hazard. Stand away
from pumpkit when checking hydraulic
pressures.
W008.eps
NOTE!
The main relief valve is set to very high
pressure (at least 350 bar). Use the controls
on the rear control panel when checking the
pressure of the main relief valve, so you will
be out of the way if a hose or a fitting
malfunctions.
Refer to Figure 5 for the location of the components
used to set the concrete pump pressures. Use the
following steps to set the main relief valve pressure:
1. Be sure that the waterbox covers are installed on
the waterbox. We do not recommend using the
remote control box for the following procedure.
2. Wear safety glasses when setting pressures.
revDate
112 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
w
Gauge port
Hif
lrv
vw
.ep
s
Soft switch
relief valve
grooves2.eps
Figure 5
Location of the main relief valve
Set the soft switch circuit relief pressure 3. If adjustment is needed, loosen the jam nut on the
To check or adjust the soft switch pressure setting, soft switch relief valve with a 9/16 inch spanner
proceed as follows: wrench. Adjust the pressure up or down, as needed,
using a 5/32 inch Allen wrench. When the correct
1. Close the concrete pump shutoff valve. Open the pressure is achieved, re-lock the jam nut.
soft switch shutoff valve. The rest of the unit
should still be set up as though you were going to 4. Be sure to open the concrete pump shutoff valve
check concrete pump pressure. when you are finished. The unit cannot stroke with
this valve closed.
2. Increase the engine RPM to pressure out the
concrete pump. The pressure gauge should read 80 Set accumulator circuit hydraulic oil
bar (check your schematic). If no adjustment is
pressure
needed, skip to Step 4.
(units with a pressure- compensated pump)
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 113
HOME PRINT
Pressure Settings
You will need an assistant for parts of this procedure. .
To check or adjust the hydraulic pressure in the
accumulator circuit, perform the following steps:
1. Stop the truck, put the key in your pocket, and
place a Do Not Operate sign on the windshield.
2. Loosen the jam nut on the pressure regulator of the
accumulator hydraulic pump. Turn the screw in
Accumreg.eps
two-and-a-half turns. This will raise the regulator
pressure above 300 bar (Figure 83).
NOTE!
If your unit is a current production model
(Figure 6), skip Steps 3,4, and 8 of this
procedure.
Accumulator pump
pressure regulator
Figure 7
Accumulator pump pressure regulator
estopleft.epsL
Figure 8
E-Stop manifold relief valve
accumulator circuit (original
production)
WARNING
Entanglement hazard. Stop drive shafts
before adjusting the accumulator pump
pressure regulator.
W010.eps
9. After the truck engine is stopped, back out the
accumulator circuit hydraulic pump pressure
regulator two-and-a-half-turns. This restores the
pressure regulator to its original setting (Figure
83).
10. Clear all personnel from the drive line area, start
the truck, and rev the engine RPM to maximum.
11. Read the pressure on the accumulator gauge. It
Figure 9 should read 200 bar (2900 PSI).
Accumulator pressure gauge 12. If additional adjustment is needed, you must stop
the truck engine each time you approach the
accumulator circuit hydraulic pump (Figure 83).
7. If additional pressure adjustment is needed, locate
Adjust the accumulator pump pressure regulator
the accumulator manifold pressure relief valve
screw in to increase pressure or out to decrease
(Figure 85). Loosen the jam nut, and turn the screw
pressure. Lock the jam nut when pressure is correct
in to increase pressure or out to decrease pressure.
(200 bar).
Tighten the jam nut when pressure is at 300 bar.
Setting the outrigger pressure
45s3blck.eps
Pressure Settings
6. When the pressure on the gauge connected to the
outrigger hand valve is 280-bar, release the enable
280 bar push button and the outrigger hand valve.
Lower Relief Valve 7. Remove the whip hose and gauge from the
outrigger hand valve, and replace the cap on the
gauge port.
Higher Pressure reducing valve
This valve is preset at the factory. Contact Schwing
Turn body of valve Americas Service Department at (651) 429-0999 for
to adjust. information on checking or setting this valve.
cylinder.
with orifices. In a load-sensing system, the pump puts
out more or less oil to respond to the needs of the
3. Set the engine RPM to maximum.
system. Generally, the pump puts out enough oil to
4. Push the outrigger enable pushbutton located next maintain a 20 bar higher pressure at the pump than
to the outrigger hand valve (passenger side). Hold what the cylinders actually require. This 20 bar is
an outrigger hand valve lever in the jacking-retract called delta P (P). Additionally, we set the hydraulic
position. The oil coming from the pump has pump so that it always puts out a small amount of oil,
nowhere to go but over the outrigger relief valve. even if no oil is needed for the system. This oil is used
NOTE! to ensure that you have control when you need it. The
You cannot use the extend position for this setting to maintain this minimum amount of oil is
adjustment because extend has a called Q-min (pronounced cue min). To set the boom
nonadjustable secondary relief function or outrigger hydraulic pressures on a load-sensing
built into the valve. system, begin by setting Q-min and P.
5. Turn the outside body of the relief valve cartridge The general locations of the components used to set
that is located at the back of the passenger side boom hydraulic pressures is shown in Figure 12.
outrigger hand valve (Figure 11). Turn in
(clockwise) to raise pressure; turn out (counter NOTE!
clockwise) to lower pressure. Do not adjust P or Q-min if your boom is
operating as you like it. The pressure setting
procedure uses a standard starting point
revDate
116 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
and must be fine tuned from there. It was NOTE!
fine tuned at the factory and should not be Each time the Q-min screw must be
adjusted unless absolutely necessary. adjusted, the engine must be stopped, or at
least the transmission must be taken out of
gear so that the drive lines stop turning.
WARNING
Entanglement hazard. Stop drive shafts
before adjusting Q-min.
W009.eps
Figure 12
Location of components used to
check or set boom pressures
Pressure Settings
boom control
ps
block relief valve
v.e
itprd
ap
15 bar pretension
adjustment screw
Figure 13
Boom hand valves
WARNING
Entanglement hazard. Stop drive shafts
before adjusting Q-min.
W009.eps
W009.eps
Department if you are unable to adjust the pressure
to specification.
NOTE!
If the boom does not operate smoothly at 20
bar, you must fine tune the adjustment.
9. Remove the gauge, and adjust P until the boom is
responsive and smooth. When done, the gauge
3. Read the pressure on the 0 - 600 gauge. If the
(reinstalled) must read between 14 and 25 bar. The
pressure reads less than 100 bar, return the engine
electronics in the control system can also affect
RPM to idle speed and install a 0 -100 bar gauge. If
how the boom operates, so if P adjustment does
the pressure reads more than 100 bar, stop the drive
not seem to help, reset to 20 bar and check the
shafts from turning, and turn the Q-min adjustment
electrical settings. Once electrical settings are
screw in until the pressure is below 100 bar, then
verified, you could again refine the boom action
install the 0 - 100 bar gauge.
with the P adjustment. Caution! Do not operate
any functions while setting P. 4. Bring the engine RPM to maximum. Q-min
pressure should read 40 - 45 bar.
10. When P has been set, remove the 0-100 gauge.
5. If no adjustment is needed, stop the drive lines
from turning. Tighten the jam nut on the Q-min
adjustment screw. Remove the 0-100 gauge.
6. If adjustment is needed, continue to Step 7.
deltaPvlv.eps
Pressure Settings
Now that P and Q-min are set, you can check or set 2. The redundant relief valve located in the
the boom valve pressures. There are three pressure emergency stop manifold, set at 320 bar (4640
settings on the boom circuit (Figure 16): PSI).
1. Pressure regulator (the high-pressure adjustment 3. The boom control block relief valve, set at 350 bar
screw on the P regulator valve), set at 290 bar (5075 PSI).
(4205 PSI).
P Regulator Valve
(high pressure
adjustment screw)
0-400 bar
gauge port
0-60 bar
gauge port
s deltaPvlv.eps
.ep
nly
ipo
ap
boom control T
block relief valve
estop/right.eps
E-Stop Manifold
Redundant Relief Valve
ps
rt.e
ca
no
Original Production
Current Production
Figure 16
Boom hydraulic pressure adjustment components
Pressure Settings
140 bar
gauge port
Figure 17 0.e
ps
it14
140 bar relief valve and gauge ap
port
Pretension
gauge port
Figure 18 .ep
s
rtn
itp
Pretension adjustment screw ap
Set 15 bar pretension 3. If adjustment is needed, loosen the jam nut on the
To check or set pretension, follow these steps: pretension valve (Figure 18). Turn the screw in to
raise pressure and out to lower pressure. When the
1. Stop the truck engine. Plug the 0 - 40 bar gauge pressure is correct, retighten the jam nut.
into the pretension check port of the Apitech
handvalve (Figure 18). 4. Stop the engine, and remove the 0 - 40 bar gauge.
Pretension setting is complete.
2. Start the truck engine, but leave it at an idle.
Pretension adjustment is made at an idle to Set water pump pressure
establish the minimum pressure setting. (Note: As
RPM is increased, pretension pressure will rise.) With a seven place hand valve, the water pump
Read the pressure on the gauge. If it reads 15 bar hydraulic control is inside the boom control block.
1 bar, the pressure is set correctly. There is not a separate relief valve for this circuit and,
therefore, nothing that must be set.
revDate
122 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Set the agitator pressure fittings and many, many more extremely useful
The agitator circuit has a maximum pressure of 200 bar items are included in the Troubleshooting Kit, part
(2900 PSI), limited by the relief valve located on the number 30308553. We highly recommend
passenger side of the main control block (Figure 19). purchase of this kit. It will pay for itself many
times over. You will need:
Agitator Relief Valve Turn body of valve - Qty 2 VS-16S locking plugs, part number
10016803
Gauge port to adjust
Higher - Qty 1 GS-16S straight fitting, part number
10008088
Lower - Qty 2 16S capnuts, part number 10001743
5. Be sure that one of the locking plugs and capnuts
are tightened on the straight fitting and that the
dead plugs are securely tightened to the hose and
the open motor fitting.
6. Locate the relief valve on the back of the agitator
hand valve.
itrlf
2.e
ps 7. Be sure that all personnel are clear, and restart the
ag
engine.
8. Activate the agitator hand valve by pushing or
Figure 19 pulling the handle. This will send the oil against
Agitator hand valve the high pressure plug. The oil will have nowhere
to go, so it will return to the tank over the relief
1. Stop the unit, and put the key in your pocket. valve in the agitator hand valve. The pressure at
2. Connect the whip hose of a 0-400 or a 0600-bar which it relieves can be seen on the gauge. It
gauge to the gauge port on the agitator hand valve should read 200-bar.
(Figure 19). 9. If adjustment is needed, turn the outside body of
3. If your unit is equipped with an agitator shutoff the relief valve that is located at the back of the
valve, close it (Figure 20). Skip to Step 5. agitator hand valve. Turn in to raise pressure or
52qrttrn.epsL
turn out to lower pressure.
Closed 10. When the pressure is set at 200-bar, stop the engine
and remove the key. Open the shutoff valve or
remove the dead plugs, and store them in a clean
area like a plastic bag or something similar in order
to keep dirt from entering the fittings. Reattach the
hose to the agitator motor fitting, and tighten
securely. (Torque is correct if you make one
Shown in the complete revolution after feeling initial resistance
open position increase.)
11. Remove the whip hose and pressure gauge.
Replace the gauge port cover.
Figure 20
Agitator shutoff valve
Pressure Settings
revDate
124 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
S 31 XT handle as well as on the handle itself, which will
indicate the open or closed configuration of the
valve (Figure 108). If the handle is removed from
Check all hydraulic pressures
the agitator shutoff valve (Figure 108) or the
Changes in pressure can indicate trouble in one or concrete pump shutoff valve (Figure 110) and
more components and will serve as early warning replaced in a different configuration, the grooves in
indicators if you check them on a regular basis. The the handle may no longer indicate the proper open/
specifications for each circuit are shown on the closed orientation of the valve. The grooves in the
hydraulic schematics found in the Appendix section of shaft give the only true indication of the valves
this manual. The hydraulic schematics are the only position.
documents in this manual that have been updated
specifically for your unit, by the serial number, so in NOTE!
each of the following procedures you will be told to If your unit is an early production model
refer to the schematic for the pressure required. and does not have an agitator shutoff valve,
order one from the Schwing Spare Parts
Preheat the hydraulic oil Department, using part number 10004680
(valve) and number 30303432 (tube).
Pressure settings must be made with the oil at normal
Contact the Service Department for
operating temperatures (50 to 60 C). In the past we
installation instructions.
could pressure out a function in the boom or outrigger
system to create heat, but today, load sensing systems 2. Activate the agitator. With the valve closed, the
no longer allow maximum oil flow to be forced over agitator will not be able to turn and the oil will be
relief. Because of this, the agitator circuit must be used forced over the relief valve. At an idle (about 600
to heat the hydraulic oil. RPM) you will be converting 4.5 horsepower to
To heat the oil to operating temperature: heat.
1. Locate the agitator shutoff valve (Figure 108), and 3. When the oil temperature gauge shows 50 C, open
close it. The quarter turn shutoff valve has a the shutoff valve.
grooved line on the shaft or pivot point of the
Motor Open
Mounting screw and washer
removed for illustration
Figure 108
Agitator shutoff valve (left) and Open/closed orientation of shutoff valve (right)
Pressure Settings
Check the concrete pump pressure -4 8. Place the concrete pump forward / neutral /
pumpkits reverse switch on the rear control panel into the
forward position. The unit will stroke no more
than once, then the rock cylinder will retract. Oil
leaving the hydraulic pumps will be blocked in the
WARNING brain. This is called high-pressuring the concrete
pump.
Wear safety glasses any time you check 9. Read the pressure on the gauge. The target pressure
or set pressures. Oil expulsion hazard!
000438.eps
for the concrete pump circuit main relief valve is
shown on the hydraulic schematic in the Appendix
section of this manual. Return the pump control to
neutral whether the pressure needs adjustment or
Because the Hi-flow pumpkits have the ability to create
not. If no adjustment is needed, skip to step 14. If
high pressure on the concrete, the pressure settings
adjustment is needed, proceed to next paragraph.
have to be tailored specifically for each model. This
means that we cannot simply list a pressure
Setting the main relief valve
specification for all units. The correct pressure
specifications for your unit are shown on the hydraulic The main relief valve is the primary pressure control
schematic in the Appendix, section of this manual. device on units equipped with Rexroth A7VO
hydraulic pumps.
NOTE!
If the main relief valve needs adjustment, proceed as
Do not use the remote control box for the
follows:
following pressure setting procedure.
1. Wear safety glasses when checking or adjusting
To check or set the concrete pump pressure pressures.
adjustments, follow these steps:
2. Using a 9/16 spanner wrench, loosen the jam nut
1. Be sure that the waterbox covers and guards are
on the main relief valve adjusting screw (Figure
installed on the waterbox.
111).
2. Start the truck engine, and put the PTO and
transmission into gear just as you would to pump a Gauge port
job.
3. Locate and close the concrete pump shutoff valve 00
02
97
.ep
and the soft switch shutoff valve (Figure 110). s
revDate
126 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
4. Once the pressure is correct to the hydraulic 5. If you will not be setting the soft switch pressure,
schematic, retighten the jam nut. Tightening the open the shutoff valves. The unit will not stroke
nut tends to raise the pressure, so check pressure with closed shutoff valves.
again after tightening.
Soft switch
shutoff valve
Main Pressure
Gauge port
Concrete pump
shutoff valve 00
02
74
.e
ps
Figure 110
Showing the concrete pump and soft switch shutoff
valves
Open
5/32" Allen head
Mounting screw and washer
removed for illustration 9/16" jam nut
Figure 111
Shutoff valve open / closed orientation
Pressure Settings
Setting the soft switch circuit relief
pressure
Gauge port
00
04
32
.ep
s
Figure 112
Location of the Main relief valve
main relief valve
Soft switch
relief valve
To check or adjust the soft switch pressure setting, Preheat the oil
proceed as follows:
When you set pressures for any circuit on any unit, the
1. Open the soft switch shutoff valve (Figure 111). hydraulic oil should be at normal operating
The rest of the unit should still be set up as though temperature (40 - 60 C). Instructions for heating the
you were going to check concrete pump pressure. hydraulic oil are found on page 371.
2. High pressure the concrete pump. The pressure
gauge should read 60 or 80 bar (check your About proportional boom systems
schematic). If adjustment is needed, proceed to In a black and white boom system, the hydraulic pump
step (3). If no adjustment is needed, skip to step puts out an unchanging amount of oil, and speed
(4). control is done by restricting the oil to certain functions
3. Loosen the jam nut on the soft switch relief valve with orifices. In a load-sensing system, the pump puts
(Figure 5) with a 9/16 spanner wrench. Adjust the out more or less oil to respond to the needs of the
system. Generally, the pump puts out enough oil to
pressure up or down, as needed, using a 5/32 Allen
maintain a 20 bar higher pressure at the pump than
wrench. When the correct pressure is achieved, what the cylinders actually require. This 20 bar is
tighten the jam nut. called delta P (P). Additionally, we set the hydraulic
4. Be sure to open the concrete pump shutoff valve pump so that it always puts out a small amount of oil,
(Figure 111) on the side of the brain when you are even if no oil is needed for the system. This oil is used
finished. The unit cannot stroke with this valve to ensure that you have control when you need it. The
closed. setting to maintain this minimum amount of oil is
called Q-min (pronounced cue min). To set the boom
Setting pressures on load-sensing booms or outrigger hydraulic pressures on a load-sensing
If your unit has a load-sensing proportional system, it system, begin by setting Q-min and P.
will have different pressure adjustments than if it is Read all of the instructions before beginning any
equipped with a black and white boom system. The pressure settings. General locations of the components
following instructions are for seven place, load-sensing for the following procedures are shown in Figure 113.
proportional systems. If you have a unit equipped with You will need an assistant for parts of the procedure.
a black and white boom system, contact Schwing You and any assistants should wear eye protection
Service for the correct instruction pages. when checking or setting pressures.
revDate
128 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Figure 113
Locations of
components used to
check and set boom
pressures 000433.eps
000442.eps
procedure. Gauge damage possible!
Each time the Q-min screw is adjusted, the engine must
be stopped, or at least the transmission must be taken
out of gear so that the drive lines stop turning. To check
or set P, follow these steps:
Boom control
block relief valve
0-400 bar (non-adjustable)
gauge port
30 bar
pilot pressure 448
.ep
s
000
relief cartridge
140 bar downside
relief cartridge (non-adjustable)
Figure 114
Location of the boom circuit pressure devices (Hoses removed for clarity.)
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 129
HOME PRINT
Pressure Settings
Q-min
adjustment screw
000434.eps
Q-max
Figure 115
Location of the Q-min adjustment screw on A11VO (left)
and A7VO (right)
3. To be sure that the pump is putting out only enough wrench) and adjusting the screw (3mm Allen
oil to maintain P, we need to change the setting of wrench) clockwise to increase pressure or counter
the Q-min screw. Q-min is adjusted by a screw on clockwise to decrease it.
the boom hydraulic pump (Figure 115). Unscrew 5. The delta P adjustment screw on the A11VO boom
the Q-min screw three full turns. Make sure that all pump, also shown in Figure 44 below, requires a
emergency stop switches are in the up (not 13mm open end wrench and a 4mm allen wrench.
activated) position. Check that all personnel are
clear of the truck; then restart the engine, engage NOTE!
the pumps, and leave the engine at an idle. Pressure If the boom is not smooth at 20 bar, you
can be read on the 0 - 40 bar gauge that you must fine tune the adjustment. In that case,
installed. Pressure should read 20 bar. If no REMOVE THE GAUGE and adjust P
adjustment is needed, simply reset the Q-min until the boom is responsive and smooth.
screw as described on page 223. If adjustment is The gauge (reinstalled) must now read
needed, continue to step (4). between 14 and 25 bar. The electronics in
the control system can also affect how the
4. Delta P is adjusted on the bottom (smaller) screw
boom operates, so if P adjustment does not
of the pressure regulator shown in Figure 44 below.
seem to help, reset to 20 bar and check the
If your unit has an A7VO boom pump, you can do
electrical settings. Once electrical settings
so by loosening the jam nut (10mm open end
are verified, you could again refine the boom
action with the P adjustment.
Delta-p
000435.eps
T
P adjustment screw
000281.eps
Figure 116
Location of the delta P adjustment screw for a unit
with A7VO pump (left) and A11VO pump (right)
revDate
130 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting Q-min each time before making the adjustment. When
Check Q-min pressure when the engine is at the pressure is correct, tighten the jam nut on the
maximum specified RPM, but the engine must be adjustment screw before continuing with the other
stopped to adjust the screw. procedures.
1. If you unscrewed the Q-min screw as the first step Setting boom pressures
of P adjustment, begin by returning the screw to
its original position (Figure 115). (Load sensing proportional booms)
2. Remove the 0 - 40 bar gauge from the 0 - 400 bar Now that P and Q-min are set, you can check or set
gauge port, and install the 0 - 600 bar gauge in its the boom valve pressures.
place.
There are several devices on the boom circuit
3. Clear all personnel away from the drive lines, start which control boom pressure (Figure 45):
the truck engine, engage the pumps, and bring 1. Pressure regulator (the high-pressure adjustment
engine RPM to max. All boom functions must be in
screw on the P regulator valve on units with
neutral, and all emergency stop buttons should be
A7VO boom pumps), set at 300 bar.
up (not engaged).
2. Pressure cut-off on units with A11VO pumps.
4. Read the pressure on the 0 - 600 bar gauge.
Pressure should be at 40 - 45 bar. If no adjustment 3. The boom control block relief valve, pre-set at 350
is needed, stop the drive lines from turning, be sure bar.
the jam nut on the Q-min screw is tight, and NOTE!
proceed to Setting boom pressures. If adjustment is This relief valve is nonadjustable. If
needed, continue to the next step. pressure is not maintained with the
5. Turn the Q-min screw in to raise the pressure specification limits, the valve must be
(Figure 115). Turn it out to lower the pressure. Be replaced.
sure that you stop the drive shafts from turning
Boom control
block relief valve
0-400 bar (non-adjustable)
000436.eps
gauge port
T High pressure
adjustment screw
30 bar
pilot pressure 448
.ep
s
000
relief cartridge
140 bar downside
relief cartridge (non-adjustable)
Figure 117
The boom pressure devices
Pressure Settings
Raise the pressure of the lowest circuit Setting the outrigger pressures
To check the setting of the valve with the highest After the boom pressures are set, you can set the
pressure, you must first raise the pressure of the lower: outrigger pressure.
1. Loosen the jam nut of the high pressure adjustment The boom, outriggers, water pump, and compressor
screw (Figure 117) of the P regulator. Turn the circuits have all been put together in the boom valve
screw in two-and-a-half turns. This will raise the manifold. When the outrigger selector push button is
pressure on the regulator above 350 bar. pushed, the boom/outrigger control handle is activated
2. Pressure out any boom cylinder except #1 down by (Figure 117), which routes oil to the two outrigger
activating the control handle. To pressure out a hand valve banks (one on each side of the unit). A
cylinder, retract a fully retracted cylinder or extend relief valve inside the passenger side bank limits the
a fully extended cylinder. The oil is then forced entire outrigger circuit to 280 bar (4060 PSI) instead of
over the relief valve. the 300 bar (4350 PSI) of the boom relief valve.
The telltale hiss of an open relief valve should be
To set the 280 bar relief valve for the outrigger
coming from the Apitech control block relief valve circuit:
now. If it isnt, raise the setting of the delta P
regulator a little more until the hiss originates at
the Apitech control block relief valve. Read the
pressure on the gauge. It should read 350 bar. If
pressure is correct, proceed to the next step.
WARNING
NOTE!
Although the pressure specification for the Wear safety glasses any time you check
Apitech relief valve is 350 bar, you may or set pressures. Oil expulsion hazard!
000438.eps
continue to use the relief valve as long as the
cartridge maintains at least 330 bar. If you
must replace the valve and dont have one
on hand, proceed to the next step before 1. Plug the whip hose of a 0-400 or 0-600 bar gauge
using the machine again. Redo this entire (Figure 46) into the gauge port.
procedure when you have installed the new 2. If not already done, start the truck engine and set
valve. If pressure on the Apitech relief valve the transmission and PTO as you would for a
is below 290 bar, you should not use the pumping job.
machine until the valve is replaced. 3. Locate the 280 bar relief valve (Figure 118) on the
back of the outrigger valve.
3. You will need a helper for this step. While
pressuring out any boom cylinder except #1 down, 4. Set the engine RPM to maximum.
have your helper adjust the high pressure screw of 5. Select outrigger with the outrigger push button.
the P regulator out (lowering the pressure) until This will route oil to the outrigger handvalves.
the gauge reads 300 bar. Release the pressurized 6. With the outriggers folded into the travel position,
function, and lock the jam nut. The boom pressures activate the passenger side hand valve jacking
are now set. If you did not get the readings cylinder retract for either the front or rear
specified after following the instructions, contact outrigger.
Schwing Americas Service Department at (651)
429-0999 for advice on how to continue.
NOTE!
You will get an incorrect reading if you select any
other outrigger function. The handles are spring
loaded and will return to neutral as soon as you let
go.
revDate
132 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
000452.eps
0-400 bar
gauge port
Boom/Outrigger
control handle
AGITATOR
CONCRETE PUMP
Boom 1
Boom 2
Boom 3
Boom 4
Boom 1 Telescope
Slewing
Boom / Outrigger
Water / Compressor
10189517
DANGER WARNING
s Electrocution hazard.
.ep
Do not operate this
Stay back from high machine without
451
voltage wires at least training. Understand
17 feet (5 meters).
000
the warnings in safety
manuals and on decals.
Figure 118
Position of the 0-400 bar gauge port and boom/outrigger control handle
7. Read the pressure on the gauge. It should read 280 10. When the pressure is correct, either go on to other
bar (4060 PSI). If no adjustment is needed, skip to pressure settings or remove the whip hose and
step 10. gauge, and cap the gauge port with the attached
8. If adjustment is needed, turn the outside body of cap.
the relief valve that is located at the back of the 11. Return the RPM of the truck to an idle, take the
outrigger valve. Turn in to raise pressure and out to transmission and PTO out of gear, and shut off the
lower pressure. There is no jam nut on this valve. truck, or go on to the other pressure settings as
9. Activate the outrigger jacking retract hand valve, required.
and read the pressure on the gauge again. Repeat
steps (8) and (9) until the gauge reads 280 bar.
000453.eps
280 bar
Relief valve
AGITATOR
CONCRETE PUMP
Boom 1
Boom 2
Boom 3
Boom 4
Boom 1 Telescope
Slewing
Boom / Outrigger
Water / Compressor
10189517
DANGER WARNING
Electrocution hazard.
4 Stay back from high
Do not operate this
machine without
voltage wires at least
WARNING
Clear area
before activating
outriggers
00
04
40
.ep
s
Figure 119
Location of the 280 bar outrigger pressure relief valve
(Hoses removed for clarity)
Pressure Settings
Setting 15 bar pretension 2. Start the truck engine, but leave it at an idle.
(Pretension adjustment is made at an idle to
establish the minimum pressure setting. As RPM is
CAUTION increased, pressure will rise. Damage to the 0 - 40
bar gauge is possible if RPM is raised while the
Truck engine must be at idle to set
gauge is connected.)
000439.eps
pretension. Gauge damage possible!
3. If the pressure reads 15 bar 1 bar, the pressure is
set correctly. If adjustment is needed, proceed to
To check or set pretension, follow these the next step.
steps: 4. Loosen the jam nut on the pretension valve. Turn
1. Stop the truck engine. Plug the 0 - 40 bar gauge the screw in to raise pressure and out to lower
into the 0-60 bar pretension check port of the pressure. When the pressure is correct, retighten
Apitech hand valve (Figure 118). the jam nut.
5. Stop the engine, and remove the 0 - 40 bar gauge.
Pretension setting is complete.
15 bar pretension
adjustment screw
0-60 bar
gauge port
s
.ep
450
000
Figure 120
Pretension adjustment screw
and gauge port
revDate
134 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting the agitator circuit pressure
000447.eps
Lower
AGITATOR
CONCRETE PUMP
10189517
DANGER WARNING
Electrocution hazard.
4 Stay back from high
Do not operate this
machine without
voltage wires at least training. Understand
17 feet (5 meters). the warnings in safety
3
Agitator
1
manuals and on decals.
Fwd/Reverse WARNING
Clear area
before activating
outriggers
Concrete pump REAR EXTEND REAR JACKING FRONT JACKING FRONT EXTEND
Fwd/Reverse 88
.ep
s
02
00
Figure 121
Agitator hand valve (location right, blowup left)
agitator relief valve limits the pressure in the agitator shutoff valve (open position)
circuit to 200 bar (2900 PSI). There is a gauge port for
checking or setting the pressure in this circuit. The port
is located on the agitator hand valve block and shown
on top in Figure 49. The gauge port may be mounted
on the side of the block on some units. To check or set
the agitator pressure, follow these steps:
Motor
1. Unscrew the cover from the gauge port. Plug in the
0-600 bar gauge and whip hose that came in the Figure 122
toolbox. The agitator shutoff valve
2. Start the engine if its not already running. 4. Activate the agitator, and read the pressure on the
3. Close the agitator shutoff valve (Figure 62). gauge.
NOTE! 5. If adjustment is needed, put your wrench on the
body of the relief valve (Figure 49), which is
If your unit does not have a shutoff valve,
located on the back of the agitator hand valve.
you can order one using part number
While reading the gauge, turn the body in to raise
10004680 (valve) and part number
pressure or out to lower pressure until 200 bar is
30303432 (tube). Contact Schwing
achieved.
Americas Service Department at (651) 429-
0999 for installation instructions. 6. Put the agitator handle in neutral.
7. Remove the whip hose and pressure gauge.
Replace the gauge port cover.
Pressure Settings
Setting accumulator circuit pressure 4. Read the pressure on the accumulator circuit
To check or adjust the hydraulic pressure in the pressure gauge (Figure 124). The pressure should
accumulator circuit: read the value shown on the hydraulic schematic. If
no adjustment is needed, skip to step (7). If
1. Stop the truck, put the key in your pocket, and additional pressure adjustment is needed, continue
place a Do Not Operate sign on the windshield. with step (5).
2. Loosen the jam nut on the pressure regulator of the
@@@@@@@@
;;;;;;;;
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
000292.eps
;;;;;;;;
@@@@@@@@
QQQQQQQQ
3. Clear all personnel away from the drive lines, start
@@@@@@@@
;;;;;;;;
QQQQQQQQ
the truck engine, engage the pumps, and bring the
;;;;;;;;
@@@@@@@@
QQQQQQQQ
engine RPM to maximum.
;;;;;;;;
@@@@@@@@
QQQQQQQQ
Figure 124
Accumulator circuit pressure gauge
000289.eps
Figure 123
Accumulator pump pressure regulator for
A7VO (above) and for A11VO (below) Manual bleed
valve
Boom Pump
Accumulator Pump
Pressure relief
cartridge
Accumulator Pump
Pressure Regulator Figure 125
Accumulator manifold pressure relief
Standby 000446.eps cartridge and manual bleed valve
Pressure Screw hgacugc.psd
revDate
136 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
WARNING
Entanglement hazard. Stop drive shafts
before adjusting the accumulator pump
000075.eps
pressure regulator.
NOTE!
The accumulator circuit hydraulic pump
pressure regulator is sometimes referred
to as the pressure cut-off.
Pressure Settings
revDate
138 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
32XL Single Circuit 2. Turn on the agitator. The agitator will not be able
to turn, and the oil will be forced over the relief
valve.
Check hydraulic pressures
3. At an idle (approx. 600 rpm), about 5.4 horsepower
Check all hydraulic pressures. Changes in pressures
is being converted to heat. Shut off the concrete
can indicate trouble in one or more components.
pump when the temperature gauge on the rear
Pressure settings must be made with the oil at normal
control panel shows 40 C.
operating temperatures (40 to 60 C).The
specifications for all circuit pressures are found on the
Check the concrete pump pressure (900 or
hydraulic schematics in the appendix section of this
1200)
manual.
The Schwing concrete pump circuit on the BPL 900 or
Preheat the hydraulic oil 1200, KVM 32 XL is designed to be operated at a
maximum pressure of 300 bar (4350 PSI). Pressure is
Because of the new load sensing and pressure cutoff
limited by the main relief valve which is located on the
regulated hydraulic systems, you cant use the concrete
forward (towards the truck cab) end of the main control
pump or boom circuit to preheat the hydraulic oil (they
block. To check or set the main relief pressure: (See
stop putting out oil if you try). To heat the oil to
Figure 126).
operating temperature:
1. Locate the agitator shutoff valve and close it. Note!
If your unit does not have a shutoff valve, you can
order one using part number 10004680 (valve) and
part number 30303432 (tube). Install as shown in
figure 50 on page 6-228.
s
.ep
in2
Bra
Pressure gauge
Main relief valve
Jam nut
Lower Raise
pressure pressure
Adjustment
handle scmnrlf2.eps
Figure 126
The main relief valve, concrete pump
Pressure Settings
1. Be sure that the waterbox covers are installed on 3. Start the truck engine, and put the PTO and
the waterbox. Use of the remote control box for the transmission into gear just as you would to pump a
following procedure is NOT recommended. job.
2. Wear safety glasses when checking or setting 4. See figure 127. Close the shutoff valve (also known
pressures. as the ball cock or quarter turn valve).
Figure 127
Showing the concrete pump shutoff valve
5. Put the rear control panel switch remote / local bar, there is a hydraulic problem. In this case,
into the local position. unscrew the adjustment knob by several turns so
6. Using the switch on the rear control panel, rev the that your pressure isnt too high once the problem
truck engine up to full RPM. is found. Contact Schwing Americas Service
Department at (651) 429-0999 for advice on how
7. Using the concrete pump forward / neutral /
to continue.
reverse switch on the rear control panel, put the
concrete pump into the forward position. The 13. Return the pump to the neutral position.
unit will stroke no more than once, then the rock 14. Open the shutoff valve.
cylinder will retract. Oil will have nowhere to go 15. Return the RPM of the truck to an idle, take the
except over the main relief valve. transmission and PTO out of gear, and shut off the
8. Read the pressure on the gauge, as shown. It truck, or go on to the other pressure settings, as
should read 300 bar. Return the pump to neutral required.
whether in needs adjustment or not. If no
adjustment is needed, skip to step 14. Setting boom pressures
9. Loosen the jam nut on the relief valve adjusting (7 place proportional circuit) If your unit has a load-
screw (requires a 13 mm spanner wrench). sensing proportional system, it will have different
10. Turn the knob on the relief valve to adjust the pressure adjustments than if it is equipped with a black
pressure. Screw the handle in to raise pressure, out and white boom system. The following instructions are
to lower the pressure. for load-sensing proportional systems. If your unit is
11. Retighten the jam nut. (This step is necessary equipped with a black and white boom system, these
because tightening the nut tends to raise the instructions will be wrong. Contact Schwing Americas
pressure. If it becomes a problem, hold the knob Service Department to obtain correct instructions.
while tightening the jam nut). Preheat the oil
12. Put the concrete pump into the forward position
NOTE!
again. The machine will not stroke this time, but
will again develop maximum pressure. Read the Whenever you set pressures for any circuit
pressure on the gauge. If more adjustment is on any unit, the hydraulic oil should be at
needed, return the pump to neutral, then repeat normal operating temperature (40 - 60 C).
steps 8. thru 12. until the pressure is at 300 bar. Instructions for heating he hydraulic oil
NOTE! If you cannot adjust the pressure up to 300 are found in section on page 6-139.
revDate
140 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
About proportional boom systems called delta P (P). Additionally, we set the hydraulic
In a black and white boom system, the hydraulic pump pump so that it always puts out a small amount of oil,
puts out an unchanging amount of oil, and speed even if no oil is needed for the system. This oil is used
control is done by restricting the oil to certain functions to ensure that you have control when you need it. The
with orifices. In a load-sensing system, the pump puts setting to maintain this minimum amount of oil is
out more or less oil to respond to the needs of the called Q-min (pronounced cue min). To set the boom
system. Generally, the pump puts out enough oil to or outrigger hydraulic pressures on a load-sensing
maintain a 20 bar higher pressure at the pump than system, begin by setting Q-min and P. See figure 130.
what the cylinders actually require. This 20 bar is
Figure 128
Locations of components
CONCRETE PUMP
REV FWD
s
.ep
used to check and set
loc
XL
32
boom pressures
E-Stop manifold
Pressure Settings
boom control
ps
block relief valve
v.e
itprd
ap
15 bar pretension
adjustment screw
Figure 129
Showing the location of the boom circuit pressure devices
(Hoses removed for clarity.)
Q-min
adjustment screw
Qminscrew.eps
Q-max
Figure 130
Location of the Q-min adjustment screw
Setting Q-min 2. Clear all personnel away from the drive lines, start
You must check Q-min pressure when the engine is at the truck engine, engage the pumps, and bring
the maximum specified RPM, but you must adjust it engine RPM to max. All boom functions must be in
with the engine stopped. neutral, and all emergency stop buttons should be
up (not engaged).
1. If you unscrewed the Q-min screw as the first step
of P adjustment, begin by returning the screw to 3. Read the pressure on the 0 - 600 gauge. Pressure
its original position (see Figure 130).Remove the 0 should be at 40 - 45 bar. If no adjustment is needed,
- 40 bar gauge from the 0 - 400 bar gauge port, and stop the drivelines from turning, be sure the jam
install the 0 - 600 bar gauge in its place. nut on the Q-min screw is tight, then continue to
revDate
142 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
CAUTION
Do not operate any functions while setting P.
000435.eps
T Figure 131
P adjustment screw The P regulator valve
paragraph to check the rest of the boom and 5. Loosen the jam nut of the adjustment screw of the
outrigger pressures. If adjustment is needed, redundant relief valve in the emergency stop
continue to step (5.). manifold. Turn the screw in one-and-a-half turns.
4. Turn the Q-min screw in to raise the pressure This will raise the pressure setting of the relief
(Figure 130). Turn it out to lower the pressure. Be valve to above 350 bar.
sure that you stop the drive shafts from turning 6. Pressure out any boom cylinder except #1 down by
each time before making the adjustment. When pushing or pulling the control handle. To pressure
pressure is correct, tighten the jam nut on the out a cylinder, retract a fully retracted cylinder or
adjustment screw before continuing with the other extend a fully extended cylinder. The oil is forced
procedures. over the relief valve.
Setting boom pressures The telltale hiss of an open relief valve should be
(Load sensing proportional booms.) Now that P and coming from the Apitech control block relief valve
Q-min are set, you can check or set the boom valve now. If it isnt, raise the setting of the other
pressures. pressure devices until the hiss originates at the
Apitech control block relief valve. Read the
There are three pressure settings on the boom circuit: pressure on the gauge. It should read 350 bar. If
(see Figure 132) pressure is correct, proceed to step (4.).
1. Pressure regulator (the high-pressure adjustment
screw on the P regulator valve), set at 300 bar. NOTE! Although the pressure specification for the
2. The redundant relief valve located in the Apitech relief valve is 350 bar, you may continue
emergency stop manifold, set at 330 bar. to use the relief valve as long as the cartridge
3. The boom control block relief valve, set at 350 bar. maintains at least 330 bar. If you must replace the
NOTE! This relief valve is nonadjustable. If valve, proceed to step (4.) before using the
pressure is not maintained with the specification machine again, and redo this entire procedure
limits, the valve must be replaced. when you have installed the new valve. If pressure
on the Apitech relief valve is below 290 bar, you
To check the setting of the valve with the highest
should not use the machine until the valve is
pressure, you must first raise the pressure of the
replaced.
lower two:
7. Screw out the e-stop manifold redundant relief
4. Loosen the jam nut of the high pressure adjustment
valve adjustment screw one-and-a-half turns.
screw of the P regulator. Turn the screw in two- Pressure out any boom cylinder except #1 down,
and-a-half turns. This will raise the pressure on the and read the gauge. Pressure should read 330 bar.
regulator above 350 bar. If it does not, turn the screw in to raise pressure, or
out to lower pressure until it is set at 330 bar. If the
location of this valve causes you to be near the accessing the valve.
drivelines, be sure to stop them from turning before
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 143
HOME PRINT
Pressure Settings
Redundant
relief valve
000436.eps
T High pressure MP
1
adjustment screw
TT
M
10
16
78
P1
92
-7.
ep
s
P4
P2
P3
0-400 bar
gauge port
0-60 bar
gauge port
s
.ep
nly
ipo
ap
boom control Figure 132
block relief valve The three boom pressure
8. You will need a helper for this step. While again. Remember, the emergency stop switches do
pressuring out any boom cylinder except #1 down, nothing if the e-stop manifold is plumbed out of
have your helper adjust the high pressure screw of the system.
the P regulator out (lowering the pressure) until 9. Remove the whip hose from the 300 bar gauge
the gauge reads 300 bar. Release the pressurized port. Before folding up the boom, proceed to the
function and lock the jam nut. The boom pressures instructions for setting the 140 bar down side relief
are now set. If you did not get the readings valve.
specified after following the instructions it is
possible that there is a problem with the emergency Setting the 140 bar down side relief valve
stop manifold (see Figure 133). You can plumb the pressure
malfunctioning circuit out of the system to test it.
Set the pressure of the 140 bar down side relief valve.
Use only approved hydraulic dead plugs to plug
This valve is a secondary relief valve for #1 cylinder
the inlet hose to the malfunctioning circuit. If
retract function. Proper adjustment ensures that the #1
pressure can now be achieved, the e-stop manifold
boom and the A-frame wont be damaged by putting
is the source of the problem. If pressure still cannot
the boom in the cradle. (See figure 134.) To adjust this
be achieved, the problem is elsewhere. Contact
valve (requires a 2.5 mm Allen wrench and a standard
Schwing Americas Service Department for advice
screwdriver):
on how to continue. If the problem was found to be
the e-stop manifold, repair it before using the unit 1. Install a 0 - 400 bar or 0 - 600 bar gauge into the
140 bar gauge port (shown in Figure 134).
revDate
144 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Outlet to tank
Boom /
Outriggers
Pilot drain
S
MP
Boom/outrigger
T circuit dump
valve
S
MP
P3
ps
s.e
oppre
est
P2
Boom
P4 P1
override
button
Boom/outrigger
inlet port
Figure 133
Emergency stop manifold
original production (top), current production
2. Unfold the #2 section from #1 until it is straight. 3. Bring #1 down until the cylinder is completely
For the following procedure we must bring #1 all bottomed out. The cylinder does NOT bottom out
the way down until the cylinder bottoms out. if you are setting the folded boom into the A-frame
Position the boom so this can be done without (travel position).
hitting the truck or any other obstacle.
Pressure Settings
4. Activate the #1 down (retract) handvalve The reads just under 140 bar. Retightening the set screw
boom will not be able to move because the cylinder will raise the pressure slightly. Recheck the
is already bottomed out. Read the pressure on the pressure, and readjust if needed.
gauge that you just installed. It should read 140 6. When the pressure is set at 140 bar with the set
bar. If no adjustment is necessary, skip to step 6. screw tight, you can remove the whip hose gauge
5. If adjustment is needed, loosen the set screw of the and replace the cap on the gauge port.
140 bar relief valve with the 2.5 mm Allen wrench. 7. The boom pressure setting sequence is complete. If
While you activate #1 down, adjust the relief you are done with the boom, slew it back into the
cartridge with the screwdriver until the pressure transport position, and lower #1 into the cradle.
Reattach the boom strap.
140 bar
gauge port
ps
0.e
it14
ap
Figure 134
location of the 140 bar relief
valve and gauge port
Setting the outrigger 1. Wear safety glasses whenever you check or set
pressures (7 place boom valve systems) pressures.
After the boom pressures are set, you can set the 2. Plug the whip hose of a 0 - 400 or 0 - 600 bar
outrigger pressure. gauge into the gauge port. Location is shown in
In this system, the boom, outriggers, water pump, figure 46.
and compressor circuits have all been put together 3. If not already done, start the truck engine and set
in the boom valve manifold. (See Figure 46). When the transmission and PTO as you would for a
the outrigger selector push-button is activated, the pumping job.
outrigger valve routes oil to the two outrigger 4. Locate the 280 bar relief valve on the back of the
handvalve banks, one on each side of the unit. A outrigger valve, as shown in Figure 47.
relief valve inside the passenger side bank limits 5. Set the engine RPM to maximum.
the entire outrigger circuit to 280 bar (4060 PSI)
6. Select outrigger with the outrigger pushbutton.
instead of the 300 bar (4350 PSI) of the boom
This will route oil to the outrigger handvalves.
relief valve.
To set the 280 bar relief valve for the outrigger
circuit: (See Figure 46 and Figure 47).
revDate
146 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Gauge port
Figure 135 hd
.ep
s
itor
ap
Position of the outrigger selector valve
Outrigger handle
32Porct5.eps
Figure 136
Location of the passenger
side outrigger control block
Pressure Settings
280 bar
Lower Relief Valve
PS
oc
bb
ck.
Higher ep
s
7. Assuming that the outriggers are folded into the 1. Stop the truck engine. Plug the 0 - 40 bar gauge
travel position, activate the passenger side into the pretension check port of the Apitech
handvalve jacking cylinder retract for either the handvalve (Figure 138).
front or rear outrigger. Note! You will get an 2. Start the truck engine, but leave it at an idle.
incorrect reading if you select extension cylinder (Pretension adjustment is made at an idle to
retract by mistake. If you select extend by establish the minimum pressure setting. As RPM is
mistake, the outriggers will extend instead of increased, pressure will rise. Damage to the 0 - 40
reading the relief valve setting. The handles are bar gauge is possible if RPM is raised while the
spring loaded and will return to neutral as soon as gauge is connected.)
you let go.
3. Read the pressure on the gauge. If it reads 15 bar
8. Read the pressure on the gauge. It should read 280 1 bar, the pressure is set correctly. If adjustment is
bar (4060 PSI). If no adjustment is needed, skip to needed, proceed to step (4.).
step 10.
4. Loosen the jam nut on the pretension valve. Turn
9. If adjustment is needed, turn the outside body of the screw in to raise pressure, and out to lower
the relief valve that is located at the back of the pressure. When the pressure is correct, retighten
outrigger valve. Turn in to raise pressure, turn out the jam nut.
to lower pressure. There is no jam nut on this
5. Stop the engine, and remove the 0 - 40 bar gauge.
valve.
Pretension setting is complete.
10. Activate the outrigger jacking retract handvalve
and read the pressure on the gauge again. Repeat To set the agitator circuit pressure:
steps 8. and 9. until the gauge reads 280 bar.
The agitator relief valve is located in the agitator
11. When the pressure is correct, either go on to other forward / neutral / reverse handvalve, at the rear of the
pressure settings, or remove the whip hose and unit on the drivers side. The relief valve limits the
gauge, and cap the gauge port with the attached pressure in the agitator circuit to 200 bar (2900 PSI).
cap. (See Figure 49). There is a gauge port for checking or
12. Return the RPM of the truck to an idle, take the setting the pressure in this circuit. The port is located
transmission and PTO out of gear, and shut off the on the agitator handvalve. To check or set the agitator
truck, or go on to the other pressure settings, as pressure, follow these steps:
required. 1. Remove the aluminum diamond plate cover from
over the agitator handvalve.
Setting 15 bar pretension
2. Unscrew the cover from the gauge port. Plug in the
To check or set pretension, follow these steps: 0 - 600 bar gauge and whip hose that came in the
toolbox.
revDate
148 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
CAUTION
Truck engine must be at an idle while setting pretension.
Pretension
gauge port
s
.ep
rtn
itp
ap
Figure 138
Pretension adjustment screw and gauge
agitator pressure check.eps L
Figure 139
Showing the agitator handvalve
and gauge port
(Diamond plate removed
for this illustration.)
3. Start the engine, if not already running. 6. If adjustment is needed, put your wrench on the
4. Close the agitator shutoff valve. (See Figure 140.) body of the relief valve, which is located on the
Note! If your unit does not have a shutoff valve, back of the agitator handvalve. While reading the
you can order one using part number 10004680 gauge, turn the body in to raise pressure, or out to
(valve) and part number 30303432 (tube). Contact lower pressure until 200 bar is achieved.
Schwings Service Department at (651) 429-0999 7. Put the agitator handle in neutral.
for installation instructions. 8. Remove the whip hose and pressure gauge.
5. Activate the agitator in forward. Read the pressure Replace the gauge port cover.
on the gauge. 9. Replace the aluminum diamond plate over the
agitator handvalve.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 149
HOME PRINT
Pressure Settings
closed
s
ep
o.
its
ag
open
Figure 140
The agitator shutoff valve
revDate
150 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
32 XL Twin Circuit off, and the key in your pocket, remove the plug
(item 2). The oil should be at the level of the
Units up to 450 l/m bottom of the hole in the case. If oil is needed, add
Check the fluid level of the distribution gearcase. by removing the breather (item 1) and pouring in
(See Figure 141). Be sure the truck is on through the top. This gearcase uses 90W gearlube.
reasonably level ground. With the truck engine
2
4194.e
ps
Figure 141
Check, drain and fill ports of the Stiebel 4194
Check the mounting hardware of the subframe, the 1. Locate the agitator shutoff valve and close it. There
oil and water tanks, the delivery pipeline, the is a picture of the location on page 6-228. Note! If
pumpkit, the differential cylinders, the material your unit does not have a shutoff valve, you can
cylinders and the driveline hardware. Check for order one using part number 10004680 (valve) and
bolt tightness, cracks and other abnormalities. part number 30303432 (tube). Contact Schwings
Service Department at (651) 429-0999 for
Check hydraulic pressures installation instructions.
Check all hydraulic pressures. Changes in 2. Turn on the agitator. The agitator will not be able
pressures can indicate trouble in one or more to turn, and the oil will be forced over the relief
components. Pressure settings must be made with valve.
the oil at normal operating temperatures (40 to 3. At an idle (approx. 600 rpm), about 5.4 horsepower
60 C).The specifications for all circuit pressures is being converted to heat. Shut off the agitator
are found on the hydraulic schematics in the when the temperature gauge on the rear control
appendix section of this manual. panel shows 40 C. Dont forget to open the shutoff
Preheat the hydraulic oil
valve when the procedure is finished.
Because of the new load sensing and pressure cut-
Check the concrete pump pressure (900-
off regulated hydraulic systems, you cant use the
1200 - MPS pumpkits)
concrete pump or boom circuit to preheat the
hydraulic oil (they stop putting out oil if you try). Schwing concrete pumps with MPS pumpkits are
To heat the oil to operating temperature: designed to be operated at a maximum pressure of 320
bar (4640 PSI). Pressure is limited by the main relief
valve which is located on the forward end (towards the
Pressure Settings
truck cab) of the main control block. (See Figure 142). 9. Read the pressure on the gauge, located as shown
To check or set the concrete pump relief pressure, in figure 142. It should read 320 bar. Return the
follow these steps: pump control to neutral whether the pressure
needs adjustment or not. If no adjustment is
needed, skip to step 14.
1. Wear safety glasses when checking or setting
pressures. 10. Using a 13 mm spanner wrench, loosen the jam nut
on the relief valve adjusting screw (Figure 142).
2. Be sure that the waterbox covers and guards are
installed on the waterbox. Use of the remote 11. Turn the knob on the relief valve to adjust the
control box for the following pressure setting pressure. Screw the handle in to raise pressure, out
procedure is NOT recommended. to lower the pressure.
3. Start the truck engine, and put the PTO and 12. Retighten the jam nut. Tightening the nut tends to
transmission into gear just as you would to pump a raise the pressure. If the pressure rise becomes a
job. problem, hold the knob while tightening the jam
nut.
4. See Figure 127. Close the concrete pump shutoff
valve, and the soft switch shutoff valve. (These 13. High pressure the concrete pump again. Read the
valves are also known as quarter turn valves). pressure on the gauge. If more adjustment is
needed, return the pump control to neutral, then
5. Put the rear control panel switch remote / local
repeat steps (8.) thru (13.) until the pressure is
into the local position.
correct. NOTE! If you cannot adjust the pressure
6. Be sure that all emergency stop switches are in the up to specification, there is a hydraulic problem. In
up (not activated) position. Reset the e-stop circuit. this case, unscrew the adjustment knob several
7. Using the switch on the rear control panel, rev the turns so your pressure isnt too high when you find
truck engine up to full RPM. the problem. Contact Schwing Americas Service
8. Put the concrete pump forward / neutral / reverse Department for advice on how to continue.
switch on the rear control panel into the forward 14. If you will not be setting the soft switch pressure,
position. The unit will stroke no more than once, open the shutoff valves. The unit will not stroke
then the rock cylinder will retract. Oil leaving the with closed shutoff valves.
hydraulic pumps will be forced over the main relief
valve. This is called high-pressuring the concrete
pump.
relieflocMPS.eps
Pressure
Gauge Jam Nut
Adjustment
Handle
Lower Raise
pressure pressure
gray valve.eps
Figure 142
The main relief valve, concrete pump circuit.
revDate
152 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
soft switch.epsL
Figure 143
Showing the concrete pump shut-off valve (left) and soft switch shutoff valve (right)
grooves.eps
Groove at 90 to ports
- closed
Figure 144
Shutoff valve orientation
Setting the soft switch circuit relief 3. Be sure to open the concrete pump shutoff valve on
pressure the side of the brain (shown in Figure 143) when
To check or adjust the soft switch pressure setting, you are finished. The unit cannot stroke with this
proceed as follows: valve closed.
1. Open the soft switch shutoff valve, as shown in
Setting the boom pressures
figures 143 and 144. The rest of the unit should
still be set up as though you were going to check (7 place black and white circuit) If your unit has a
concrete pump pressure. black and white boom system, it will have different
pressure adjustments than if it is equipped with a load-
2. High pressure the concrete pump. The pressure
sensing proportional system. The following
gauge should read 80 bar (1160 PSI) instead of 320
instructions are for black and white systems. If you
bar. If adjustment is needed, loosen the set screw
have a proportional unit, skip to page 6- 221. To set the
on the face of the relief valve cartridge with a 2.5
300 bar boom circuit relief valve proceed as follows:
mm allen wrench. Using a screwdriver, adjust the
(See Figure 145)
pressure up or down as needed, and lock the set
screw into place with the 2.5 mm allen wrench. 1. We have to raise the boom and rotate it 180 for
Recheck. Use a screwdriver, if necessary, to this procedure, so you must set the outriggers as
prevent the cartridge from turning while tightening you would to pump a job. Be sure that you set up
the allen screw. well away from electrical wires and other
obstructions.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 153
HOME PRINT
Pressure Settings
7plcpres.eps
Use #2, 3, or 4
140 bar port
3
140 bar relief
300 bar port SECTION 1 SECTION 2 SECTION 3 SECTION 4 SLEWING AIR / WATER BOOM / OUTRIG.
Lower
300 bar
Relief Valve
Figure 145
Showing the location of the boom ep
s
m.
oo
circuit pressure devices. 7p
lcb
2. Once the outriggers are set, unlock the boom strap, 6. If adjustment is needed, put your wrench on the
and raise the #1 boom far enough that you wont 300 bar relief valve at the back of the boom control
hit anything on the truck. Leave the rest of the valve bank. While you are holding the function in
boom folded. Rotate the boom so that you have retract mode, adjust the cartridge in or out until the
safe and easy access to the boom control valves. pressure reads 300 bar.
3. Remove the control block cover, held on by 2 M6 7. If you cannot achieve 300 bar, it is possible that
screws. there is a problem with the emergency stop
4. Install the whip hose of a 0-400 or 0-600 bar gauge manifold (see Figure 146). You can plumb the
in the 300 bar gauge port (Item 1 in Figure 145). malfunctioning circuit out of the system to test it.
Use only approved hydraulic dead plugs to plug
5. Assuming that your boom is completely folded up
the inlet hose to the malfunctioning circuit. If
(except for #1), select a handle, and retract #2, #3
pressure can now be achieved, the e-stop manifold
or #4 section. Do NOT use #1 retract, slewing left
is the source of the problem. Contact Schwing
right, outrigger, water pump, or any extend
Americas Service Department for advice on repair
function. (Again, when you try to retract a fully
of the e-stop manifold. Repair the e-stop manifold
retracted cylinder, the oil has no where to go except
before using the unit again. Remember, the
over the relief valve - this allows us to read the
emergency stop switches do nothing if the e-stop
relief valve setting on a gauge). Read the pressure
manifold is plumbed out of the system. Remove
on the whip gauge that you installed in step 4,
the whip hose from the 300 bar gauge port. Before
above. It should read 300 bar. If no adjustment is
folding up the boom, proceed to the instructions
necessary, skip to step 7.
for setting the 140 bar down side relief valve.
revDate
154 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Outlet to tank
Boom /
Outriggers
Pilot drain
S
MP
Boom/outrigger
T circuit dump
valve
S
MP
P3
s
.ep
ppres
esto
P2
Boom
P4 P1
override
button
Figure 146
Emergency stop manifold
Boom/outrigger
original production (top),
inlet port
current production (bottom)
Pressure Settings
with orifices. In a load-sensing system, the pump puts even if no oil is needed for the system. This oil is used
out more or less oil to respond to the needs of the to ensure that you have control when you need it. The
system. Generally, the pump puts out enough oil to setting to maintain this minimum amount of oil is
maintain a 20 bar higher pressure at the pump than called Q-min (pronounced cue min). To set the boom
what the cylinders actually require. This 20 bar is or outrigger hydraulic pressures on a load-sensing
called delta P (P). Additionally, we set the hydraulic system, begin by setting Q-min and P. See figure 149.
pump so that it always puts out a small amount of oil,
CONCRETE PUMP
REV FWD
sp
loc.e
XL
32
E-Stop manifold
Figure 147
Locations of components used to check and set boom pressures
Setting P
Note! Do not adjust P or Q-min if your boom is
running as you like it. The pressure setting procedure
uses a standard starting point and must be fine tuned
from there. It was fine tuned at the factory, and should
not be adjusted unless absolutely necessary.
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. To check or set P, follow
these steps:
1. Stop the truck engine and place a Do Not
Operate sign on the truck windshield.
revDate
156 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar
gauge port of the manual boom handvalves. Take
care not to accidently install the gauge in the 0-60
bar port. (See Figure 145.)
boom control
ps
block relief valve
v.e
itprd
ap
15 bar pretension
adjustment screw
Figure 148
Showing the location of the boom circuit pressure devices.
(Hoses removed for clarity.)
3. To be sure that the pump is putting out only enough boom or outrigger functions, you will damage
oil needed to maintain P, we need to change the the 0 - 40 bar gauge. Make sure that all
setting of the Q-min screw. Q-min is adjusted by a emergency stop switches are in the up (not
screw on the boom hydraulic pump (see Figure activated) position. Pressure can be read on the 0 -
149). Unscrew the Q-min screw three full turns. 40 bar gauge that you installed. Pressure should
Check that all personnel are clear of the truck, then read 20 bar. If no adjustment is needed, simply
restart the engine, engage the pumps, and leave the reset the Q-min screw as described in . If
engine at an idle. CAUTION! If you activate any adjustment is needed, continue to step (4.).
Q-min
adjustment screw
Qminscrew.eps
Q-max
Figure 149
Location of the Q-min adjustment screw
Pressure Settings
4. Delta P is adjusted by the P screw on the P boom is responsive and smooth. When done, the
regulator (see Figure 150). Loosen the jam nut and gauge (reinstalled) must read between 14 and 25
adjust the screw inward to increase pressure, or bar. The electronics in the control system can also
outward to decrease pressure until it is set at 20 bar affect how the boom operates, so if P adjustment
(1). Contact Schwing Americas Service does not seem to help, reset to 20 bar and check the
Department if you are unable to adjust the pressure electrical settings. Once electrical settings are
to spec. NOTE! If the boom is not smooth at 20 verified, you could again refine the boom action
bar, you must fine tune the adjustment. In that case, with the P adjustment.
REMOVE THE GAUGE, and adjust P until the
CAUTION
Do not operate any functions while setting P.
000435.eps
T
P adjustment screw
Figure 150
The P regulator valve
revDate
158 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
3. The boom control block relief valve, set at 350 bar.
NOTE! This relief valve is nonadjustable. If
pressure is not maintained with the specification
limits, the valve must be replaced.
Redundant
relief valve
000436.eps
MP
1
T High pressure
adjustment screw TT
M
10
16
78
P1
92
-7.
ep
s
P4
P2
P3
0-400 bar
gauge port
0-60 bar
gauge port
Figure 151
s
.ep
a pip
o nly
The three boom pressure devices
boom control
block relief valve
To check the setting of the valve with the highest over the relief valve.
pressure, you must first raise the pressure of the
lower two: The telltale hiss of an open relief valve should be
1. Loosen the jam nut of the high pressure adjustment coming from the Apitech control block relief valve
screw of the P regulator. Turn the screw in two- now. If it isnt, raise the setting of the other
and-a-half turns. This will raise the pressure on the pressure devices until the hiss originates at the
regulator above 350 bar. Apitech control block relief valve. Read the
pressure on the gauge. It should read 350 bar. If
2. Loosen the jam nut of the adjustment screw of the
pressure is correct, proceed to step (4.).
redundant relief valve in the emergency stop
manifold. Turn the screw in one-and-a-half turns.
This will raise the pressure setting of the relief NOTE! Although the pressure specification for the
valve to above 350 bar. Apitech relief valve is 350 bar, you may continue to
use the relief valve as long as the cartridge maintains at
3. Pressure out any boom cylinder except #1 down by
least 330 bar. If you must replace the valve, proceed to
pushing or pulling the control handle. To pressure
step (4.) before using the machine again, and redo this
out a cylinder, retract a fully retracted cylinder or
entire procedure when you have installed the new
extend a fully extended cylinder. The oil is forced
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 159
HOME PRINT
Pressure Settings
valve. If pressure on the Apitech relief valve is below 5. If adjustment is needed, loosen the set screw of the
290 bar, you should not use the machine until the valve 140 bar relief valve with the 2.5 mm Allen wrench.
is replaced. While you activate #1 down, adjust the relief
4. Screw out the e-stop manifold redundant relief cartridge with the screwdriver until the pressure
valve adjustment screw one-and-a-half turns. reads just under 140 bar. Retightening the set screw
Pressure out any boom cylinder except #1 down, will raise the pressure slightly. Recheck the
and read the gauge. Pressure should read 330 bar. pressure, and readjust if needed.
If it does not, turn the screw in to raise pressure, or 6. When the pressure is set at 140 bar with the set
out to lower pressure until it is set at 330 bar. If the screw tight, you can remove the whip hose gauge
location of this valve causes you to be near the and replace the cap on the gauge port.
drivelines, be sure to stop them from turning before 7. The boom pressure setting sequence is complete. If
accessing the valve. you are done with the boom, slew it back into the
5. You will need a helper for this step. While transport position, and lower #1 into the cradle.
pressuring out any boom cylinder except #1 down, Reattach the boom strap.
have your helper adjust the high pressure screw of
the P regulator out (lowering the pressure) until Setting the outrigger
the gauge reads 300 bar. Release the pressurized pressures (7 place boom valve system)
function and lock the jam nut. The boom pressures After the boom pressures are set, you can set the
are now set. If you did not get the readings outrigger pressure.
specified after following the instructions, contact
In this system, the boom, outriggers, water pump,
Schwing Americas Service Department at (651)
and compressor circuits have all been put together
429-0999 for advice on how to continue.
in the boom valve manifold. (See Figure 46). When
the outrigger selector pushbutton is activated, the
Setting the 140 bar down side relief valve
outrigger valve routes oil to the two outrigger
pressure handvalve banks, one on each side of the unit. A
Set the pressure of the 140 bar down side relief valve. relief valve inside the passenger side bank limits
This valve is a secondary relief valve for #1 cylinder the entire outrigger circuit to 280 bar (4060 PSI)
retract function. Proper adjustment ensures that the #1 instead of the 300 bar (4350 PSI) of the boom
boom and the A-frame wont be damaged by putting relief valve.
the boom in the cradle. (See figure 134.) To adjust this To set the 280 bar relief valve for the outrigger
valve (requires a 2.5 mm Allen wrench and a standard circuit: (See Figure 154).
screwdriver):
1. Install a 0 - 400 bar or 0 - 600 bar gauge into the
140 bar gauge port (shown in Figure 152). 1. Wear safety glasses whenever you check or set
2. Unfold the #2 section from #1 until it is straight. pressures.
For the following procedure we must bring #1 all 2. Plug the whip hose of a 0-400 or 0-600 bar gauge
the way down until the cylinder bottoms out. into the gauge port. Location is shown as item 1 in
Position the boom so this can be done without figure 46.
hitting the truck or any other obstacle. 3. If not already done, start the truck engine and set
3. Bring #1 down until the cylinder is completely the transmission and PTO as you would for a
bottomed out. The cylinder does NOT bottom out pumping job.
if you are setting the folded boom into the A-frame 4. Locate the 280 bar relief valve on the back of the
(travel position). outrigger valve, as shown in Figure 154.
4. Activate the #1 down (retract) handvalve The 5. Set the engine RPM to maximum.
boom will not be able to move because the cylinder 6. Select outrigger with the outrigger pushbutton.
is already bottomed out. Read the pressure on the This will route oil to the outrigger handvalves.
gauge that you just installed. It should read 140
bar. If no adjustment is necessary, skip to step 6.
revDate
160 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
7plc140.eps
DANGER WARNING
Electrocution hazard. Do not operate this
Stay back from high machine without
training. Understand
voltage wires at least SAFETY
140 bar
gauge port
ps
0.e
it14
ap
Figure 152
location of the 140 bar relief valves and gauge
ports. - B & W (top)
proportional (bottom)
7. Assuming that the outriggers are folded into the 8. Read the pressure on the gauge. It should read 280
travel position, activate the passenger side bar (4060 PSI). If no adjustment is needed, skip to
handvalve jacking cylinder retract for either the step 10.
front or rear outrigger. Note! You will get an 9. If adjustment is needed, turn the outside body of
incorrect reading if you select extension cylinder the relief valve that is located at the back of the
retract by mistake. If you select extend by outrigger valve. Turn in to raise pressure, turn out
mistake, the outriggers will extend instead of to lower pressure. There is no jam nut on this
reading the relief valve setting. The handles are valve.
spring loaded and will return to neutral as soon as
you let go.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 161
HOME PRINT
Pressure Settings
7plcORhndl.eps
Outrigger handle
1
Gauge port
DANGER WARNING
Electrocution hazard. Do not operate this
Stay back from high machine without
training. Understand
voltage wires at least SAFETY
1
Gauge port
Figure 153
.ep
s Position of the outrigger selector valve
hd
itor
ap Monsun-Tyson black & white (top right)
Outrigger handle Apitech proportional (bottom left)
10. Activate the outrigger jacking retract handvalve pressure in the agitator circuit to 200 bar (2900 PSI).
and read the pressure on the gauge again. Repeat (See Figure 155). There is a gauge port for checking or
steps 8. and 9. until the gauge reads 280 bar. setting the pressure in this circuit. The port is located
11. When the pressure is correct, either go on to other on the agitator handvalve. To check or set the agitator
pressure settings, or remove the whip hose and pressure, follow these steps:
gauge, and cap the gauge port with the attached 1. Remove the aluminum diamond plate cover from
cap. over the agitator handvalve.
12. Return the RPM of the truck to an idle, take the 2. Unscrew the cover from the gauge port. Plug in the
transmission and PTO out of gear, and shut off the 0-600 bar gauge and whip hose that came in the
truck, or go on to the other pressure settings, as toolbox.
required. 3. Start the engine, if not already running.
4. Close the agitator shutoff valve. (See Figure 156.)
Setting the water pump hyd. pressure
Note! If your unit does not have a shutoff valve,
With a seven place handvalve, the water pump you can order one using part number 10004680
hydraulic control is inside the boom control block. (valve) and part number 30303432 (tube). Contact
There is not a separate relief for this circuit. Schwings Service Dept. for installation
instructions.
To set the agitator circuit
5. Activate the agitator in forward. Read the pressure
pressure:
on the gauge.
The agitator relief valve is located in the agitator
forward / neutral / reverse handvalve, at the rear of the
unit on the drivers side. The relief valve limits the
revDate
162 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
32Porct5.eps
280 bar
Lower Relief Valve
PS
oc
bb
ck.
Higher ep
s
Figure 154
Location of the 280 bar outrigger
pressure relief valve.
(Hoses removed for clarity).
agitator pressure check.eps L
Pressure Settings
closed
s
ep
o.
its
ag
open
Figure 156
The agitator shutoff valve
revDate
164 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
32 XL Hi-Flow B&W off, and the key in your pocket, remove the plug
(item 2). The oil should be at the level of the
bottom of the hole in the case. If oil is needed, add
Units up to 450 l/m
by removing the breather (item 1) and pouring in
Check the fluid level of the distribution gearcase. through the top. This gearcase uses 90W gearlube.
(See Figure 141). Be sure the truck is on
reasonably level ground. With the truck engine
Figure 157
Check, drain and fill ports of the Stiebel 4194 gearcase.
Check the mounting hardware of the subframe, the part number 30303432 (tube). Contact Schwings
oil and water tanks, the delivery pipeline, the Service Department at (651) 429-0999 for
pumpkit, the differential cylinders, the material installation instructions.
cylinders and the driveline hardware. Check for 2. Turn on the agitator. The agitator will not be able
bolt tightness, cracks and other abnormalities. to turn, and the oil will be forced over the relief
valve.
Check hydraulic pressures
3. At an idle (approx. 600 rpm), about 5.4 horsepower
Check all hydraulic pressures. Changes in is being converted to heat. Shut off the agitator
pressures can indicate trouble in one or more when the temperature gauge on the rear control
components. Pressure settings must be made with panel shows 40 C. Dont forget to open the shutoff
the oil at normal operating temperatures (40 to valve when the procedure is finished.
60 C).The specifications for all circuit pressures
are found on the hydraulic schematics in the
appendix section of this manual.
Pressure Settings
Location of pressure setting/checking devices eral location of the devices needed to check pressures
See Figure 158. The illustration below shows the gen- on the concrete pump, boom, and outriggers,
Boom control
block
32
prs
loc
.ep
s
E-Stop manifold
Ball cock
CONCRETE PUMP
REV
FWD
(quarter-turn valve)
Outrigger pushbutton
Outrigger pushbutton
Passenger side
outrigger controls
Driver's side
outrigger controls
Figure 158
Location of the pressure setting devices
revDate
166 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Check the concrete pump pressure (2020, model. This means that we cannot simply list a
2023, 2525 pumpkits) pressure specification for all units. The correct
Because the Hi-flo pumpkits have the ability to pressure specifications for your unit are shown on
create high pressure on the concrete the pressure the hydraulic schematic in section 7 of this
settings have to be tailored specifically for each manual..
Gauge port
Hif
lrv
vw
.ep
s
Soft switch
relief valve
Figure 159
Location of the concrete pump circuit main relief
valve and soft switch relief valve
To check or set the concrete pump pressure 5. Install a 0 - 400 or 0 - 600 bar gauge in the gauge
adjustments, follow these steps: port.
6. Put the rear control panel switch remote / local
1. Wear safety glasses when checking or setting into the local position.
pressures. 7. Be sure that all emergency stop switches are in the
2. Be sure that the waterbox covers and guards are up (not activated) position. Reset the e-stop circuit.
installed on the waterbox. Use of the remote 8. Using the switch on the rear control panel, rev the
control box for the following pressure setting truck engine up to full RPM.
procedure is NOT recommended. 9. Put the concrete pump forward / neutral / reverse
3. Start the truck engine, and put the PTO and switch on the rear control panel into the forward
transmission into gear just as you would to pump a position. The unit will stroke no more than once,
job. then the rock cylinder will retract. Oil leaving the
4. See figures 38, 161, and 162. Locate and close the hydraulic pumps will be blocked in the brain. This
concrete pump shutoff valve, and the soft switch is called high-pressuring the concrete pump.
shutoff valve. (These valves are also known as
quarter turn valves).
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 167
HOME PRINT
Pressure Settings
Soft switch
shutoff valve
Concrete pump
shutoff valve
hif
lob
r2.
ep
s
Figure 160
Showing the concrete pump and soft switch shutoff valves
grooves.eps
Groove at 90 to ports
- closed
Figure 161
Orientation of the concrete pump shutoff valve open/closed positions
10. Read the pressure on the gauge. Pressure shown on valve so you will be out of the way if a hose or fitting
the gauge should be the same as the specification blows. See Figure 162. If the main relief valve needs
for the concrete pump circuit on the hydraulic adjustment, proceed as follows:
schematic. Return the pump control to neutral 1. Always wear eye protection when checking or
whether the pressure needs adjustment or not. If no setting pressures.
adjustment is needed, skip to step (14.) on page 6-
218. If adjustment is needed, proceed to step (1.). 2. Using a 9/16 spanner wrench, loosen the jam nut
on the main relief valve adjusting screw (Figure
Setting the main relief valve 162).
The main relief valve is the primary pressure control 3. Insert a 5/32 Allen wrench in the adjustment
device on units equipped with Rexroth A7VO screw. Turn the screw in to raise pressure, out to
hydraulic pumps. lower the pressure. Always go back to the rear
CAUTION! The main relief valve is set to very high panel before checking the pressure.
pressure (at least 350 bar). Use the rear control panel
switch when checking the pressure of the main relief
revDate
168 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
op
n-c
lsd
2.e
ps
closed
open
Figure 162
Orientation of the soft switch valve open/closed positions
4. Once the pressure is correct to the hydraulic 4. Be sure to open the concrete pump shutoff valve on
schematic, retighten the jam nut. Tightening the the side of the brain (shown in Figure 163) when
nut tends to raise the pressure, so check pressure you are finished. The unit cannot stroke with this
again after tightening. valve closed.
5. If you will not be setting the soft switch pressure,
open the shutoff valves. The unit will not stroke Setting the boom pressures
with closed shutoff valves. (7 place black and white circuit) If your unit has a
black and white boom system, it will have different
Setting the soft switch circuit relief pressure adjustments than if it is equipped with a load-
pressure sensing proportional system. The following
To check or adjust the soft switch pressure setting, instructions are for black and white systems. If you
proceed as follows: have a proportional unit, contact Schwing Americans
1. Open the soft switch shutoff valve, as shown in Service Department at (651) 429-0999 for correct
figure 162. The rest of the unit should still be set up instructions.
as though you were going to check concrete pump To set the 300 bar boom circuit relief valve proceed as
pressure. follows: (See Figure 164)
2. High pressure the concrete pump. The pressure 1. The boom must be raised and rotated 180 for this
gauge should read 60 or 80 bar (check your procedure, so you must set the outriggers as you
schematic). If adjustment is needed, proceed to would to pump a job. Be sure that you set up well
step (3), below. If no adjustment is needed, skip to away from electrical wires and other obstructions.
step (4.). 2. Once the outriggers are set, unlock the boom strap,
3. Loosen the jam nut on the soft switch relief valve and raise the #1 boom far enough that you wont
hit anything on the truck. Leave the rest of the
with a 9/16 spanner wrench. Adjust the pressure up boom folded. Rotate the boom so that you have
or down, as needed, using a 5/32 Allen wrench. safe and easy access to the boom control valves.
When the correct pressure is achieved, re-lock the 3. Remove the control block cover, held on by 2 M6
jam nut. screws.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 169
HOME PRINT
Pressure Settings
Gauge port
Hif
lrv
2.e
ps
Soft switch
relief valve
Figure 163
Location of the main relief valve
4. Install the whip hose of a 0 - 400 or 0 - 600 bar 7. If you cannot achieve 300 bar, it is possible that
gauge in the 300 bar gauge port (see Figure 165). there is a problem with the emergency stop
5. Assuming that your boom is completely folded up manifold (see Figure 166). You can plumb the
(except for #1), select a handle, and retract #2, #3 malfunctioning circuit out of the system to test it.
or #4 section. Do NOT use #1 retract, slewing left Use only approved hydraulic dead plugs to plug
right, outrigger, water pump, or any extend the inlet hose to the malfunctioning circuit. If
function. (Again, when you try to retract a fully pressure can now be achieved, the e-stop manifold
retracted cylinder, the oil has no where to go except is the source of the problem. Contact Schwing
over the relief valve; this allows the relief valve Americas Service Department for advice on repair
setting to be read on a gauge). Read the pressure on of the e-stop manifold. Repair the e-stop manifold
the whip gauge that you installed in step 4, above. before using the unit again. Remember, the
It should read 300 bar. If no adjustment is emergency stop switches do nothing if the e-stop
necessary, skip to step 8. manifold is plumbed out of the system.
6. If adjustment is needed, put your wrench on the
300 bar relief valve at the back of the boom control
valve bank. While you are holding the function in
retract mode, adjust the cartridge in or out until the
pressure reads 300 bar.
revDate
170 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
7plcpres.eps
Use #2, 3, or 4
140 bar port
300 bar port SECTION 1 SECTION 2 SECTION 3 SECTION 4 SLEWING AIR / WATER BOOM / OUTRIG.
DANGER WARNING
Electrocution hazard. Do not operate this
Stay back from high machine without
training. Understand
voltage wires at least SAFETY
Figure 164
Showing the location of the boom circuit pressure devices.
(Hoses removed for clarity.)
Lower
300 bar
Relief Valve
s
ep
m.
oo
lcb
7p
Figure 165
Location of the boom relief valve
Pressure Settings
8. Remove the whip hose from the 300 bar gauge
port. Before folding up the boom, proceed to the
instructions for setting the 140 bar down side relief
valve on page 172.
S
MP
Boom/outrigger
T circuit dump
valve
S
MP
P3
ps
res.e
opp
est
P2
Boom
P4 P1
override
button
Boom/outrigger
inlet port
Figure 166
Emergency stop manifold
Setting the 140 bar down side relief valve 3. Bring #1 down until the cylinder is completely
pressure bottomed out. The cylinder does NOT bottom out
if you are setting the folded boom into the A-frame
Set the pressure of the 140 bar down side relief valve.
(travel position).
This valve is a secondary relief valve for #1 cylinder
retract function. Proper adjustment ensures that the #1 4. Activate the #1 down (retract) handvalve The
boom and the A-frame wont be damaged by putting boom will not be able to move because the cylinder
the boom in the cradle. (See figure 167.) To adjust this is already bottomed out. Read the pressure on the
valve (requires a 2.5 mm Allen wrench and a standard gauge that you just installed. It should read 140
screwdriver): bar. If no adjustment is necessary, skip to step 6.
1. Install a 0 - 400 bar or 0 - 600 bar gauge into the 5. If adjustment is needed, loosen the set screw of the
140 bar gauge port (shown in Figure 134). 140 bar relief valve with the 2.5 mm Allen wrench.
While you activate #1 down, adjust the relief
2. Unfold the #2 section from #1 until it is straight.
cartridge with the screwdriver until the pressure
For the following procedure we must bring #1 all
reads just under 140 bar. Retightening the set screw
the way down until the cylinder bottoms out.
will raise the pressure slightly. Recheck the
Position the boom so this can be done without
pressure, and readjust if needed.
hitting the truck or any other obstacle.
revDate
172 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
6. When the pressure is set at 140 bar with the set 7. The boom pressure setting sequence is complete. If
screw tight, you can remove the whip hose gauge you are done with the boom, slew it back into the
and replace the cap on the gauge port. transport position, and lower #1 into the cradle.
Reattach the boom strap.
7plc140.eps
DANGER WARNING
Electrocution hazard. Do not operate this
Stay back from high machine without
training. Understand
voltage wires at least SAFETY
Figure 167
location of the 140 bar relief valve and gauge port
Setting the outrigger pressures (7 place 2. Plug the whip hose of a 0 - 400 or 0 - 600 bar
boom valve systems) gauge into the gauge port. Location is shown in
figure 46.
After the boom pressures are set, you can set the
outrigger pressure. 3. If not already done, start the truck engine and set
In this system, the boom, outriggers, water pump, the transmission and PTO as you would for a
and compressor circuits have all been put together pumping job.
in the boom valve manifold. (See Figure 46). When 4. Locate the 280 bar relief valve on the back of the
the outrigger selector pushbutton is activated, the outrigger valve, as shown in Figure 47.
outrigger valve routes oil to the two outrigger 5. Set the engine RPM to maximum.
handvalve banks, one on each side of the unit. A 6. Select outrigger with the outrigger pushbutton.
relief valve inside the passenger side bank limits This will route oil to the outrigger handvalves.
the entire outrigger circuit to 280 bar (4060 PSI)
7. Assuming that the outriggers are folded into the
instead of the 300 bar (4350 PSI) of the boom
travel position, activate the passenger side
relief valve.
handvalve jacking cylinder retract for either the
To set the 280 bar relief valve for the outrigger front or rear outrigger. Note! You will get an
circuit: (See Figure 170). incorrect reading if you select extension cylinder
retract by mistake. If you select extend by
mistake, the outriggers will extend instead of
1. Wear safety glasses whenever you check or set
reading the relief valve setting. The handles are
pressures.
spring loaded and will return to neutral as soon as
you let go.
Pressure Settings
7plcORhndl.eps
Outrigger handle
Gauge port
DANGER WARNING
Electrocution hazard. Do not operate this
Stay back from high machine without
training. Understand
voltage wires at least SAFETY
Figure 168
Position of the outrigger selector valve
32Porct5.eps
Figure 169
Location of the passenger side outrigger control block
revDate
174 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
280 bar
Lower Relief Valve
PS
oc
bb
ck.
Higher ep
s
Figure 170
Location of the outrigger relief valve
8. Read the pressure on the gauge. It should read 280 2. Unscrew the cover from the gauge port. Plug in the
bar (4060 PSI). If no adjustment is needed, skip to 0 - 600 bar gauge and whip hose that came in the
step 10. toolbox.
9. If adjustment is needed, turn the outside body of 3. Start the engine, if not already running.
the relief valve that is located at the back of the 4. Close the agitator shutoff valve. (See Figure 172.)
outrigger valve. Turn in to raise pressure, turn out Note! If your unit does not have a shutoff valve,
to lower pressure. There is no jam nut on this you can order one using part number 10004680
valve. (valve) and part number 30303432 (tube). Contact
10. Activate the outrigger jacking retract handvalve Schwings Service Dept. for installation
and read the pressure on the gauge again. Repeat instructions.
steps 8. and 9. until the gauge reads 280 bar. 5. Activate the agitator in forward. Read the pressure
11. When the pressure is correct, either go on to other on the gauge.
pressure settings, or remove the whip hose and 6. If adjustment is needed, put your wrench on the
gauge, and cap the gauge port with the attached body of the relief valve, which is located on the
cap. back of the agitator handvalve. While reading the
12. Return the RPM of the truck to an idle, take the gauge, turn the body in to raise pressure, or out to
transmission and PTO out of gear, and shut off the lower pressure until 200 bar is achieved.
truck, or go on to the other pressure settings, as 7. Put the agitator handle in neutral.
required.
8. Remove the whip hose and pressure gauge.
Replace the gauge port cover.
To set the agitator circuit pressure:
9. Replace the aluminum diamond plate over the
The agitator relief valve is located in the agitator agitator handvalve.
forward / neutral / reverse handvalve, at the rear of the
unit on the drivers side. The relief valve limits the
pressure in the agitator circuit to 200 bar (2900 PSI).
(See Figure 171). There is a gauge port for checking or
setting the pressure in this circuit. The port is located
on the agitator handvalve. To check or set the agitator
pressure, follow these steps:
1. Remove the aluminum diamond plate cover from
over the agitator handvalve.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 175
HOME PRINT
Pressure Settings
Figure 171
Showing the agitator handvalve and gauge port.
(Diamond plate removed for this illustration.)
closed
s
ep
o.
its
ag
open
Figure 172
The agitator shutoff valve
revDate
176 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
32 XL High Flow Proportional engine off, and the key in your pocket,
remove the plug (item 2). The oil should be at
the level of the bottom of the hole in the case.
Units up to 450 l/m If oil is needed, add by removing the breather
5.3-6 Check the fluid level of the distribution gear- (item 1) and pouring in through the top. This
case. (See Figure 173). Be sure the truck is on gearcase uses 90W gearlube.
reasonably level ground. With the truck
2
4194.e
ps
Figure 173
Check, drain and fill ports of the Stiebel 4194 gearcase
Check the mounting hardware of the subframe, the 1. Locate the agitator shutoff valve and close it. There
oil and water tanks, the delivery pipeline, the is a picture of the location on page 6-228. Note! If
pumpkit, the differential cylinders, the material your unit does not have a shutoff valve, you can
cylinders and the driveline hardware. Check for order one using part number 10004680 (valve) and
bolt tightness, cracks and other abnormalities. part number 30303432 (tube). Contact Schwings
Service Department at (651) 429-0999 for
Check hydraulic pressures installation instructions.
Check all hydraulic pressures. Changes in 2. Turn on the agitator. The agitator will not be able
pressures can indicate trouble in one or more to turn, and the oil will be forced over the relief
components. Pressure settings must be made with valve.
the oil at normal operating temperatures (40 to 3. At an idle (approx. 600 rpm), about 5.4 horsepower
60 C).The specifications for all circuit pressures is being converted to heat. Shut off the agitator
are found on the hydraulic schematics in the when the temperature gauge on the rear control
appendix section of this manual. panel shows 40 C. Dont forget to open the shutoff
Preheat the hydraulic oil
valve when the procedure is finished.
Because of the new load sensing and pressure cut-
Check the concrete pump pressure (2020,
off regulated hydraulic systems, you cant use the
2023, 2525 pumpkits)
concrete pump or boom circuit to preheat the
hydraulic oil (they stop putting out oil if you try). Because the Hi-flow pumpkits have the ability to
To heat the oil to operating temperature: create high pressure on the concrete the pressure
settings have to be tailored specifically for each
model. This means that we cannot simply list a
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 177
HOME PRINT
Pressure Settings
pressure specification for all units. The correct manual. (See Figure 37).
pressure specifications for your unit are shown on
the hydraulic schematic in Section 7 of this
Gauge port
Hif
lrv
vw
.ep
s
Soft switch
relief valve
Figure 174
Location of the concrete pump circuit main
relief valve and soft switch relief valve
To check or set the concrete pump pressure 9. Put the concrete pump forward / neutral / reverse
adjustments, follow these steps: switch on the rear control panel into the forward
position. The unit will stroke no more than once,
then the rock cylinder will retract. Oil leaving the
1. Wear safety glasses when checking or setting
hydraulic pumps will be blocked in the brain. This
pressures.
is called high-pressuring the concrete pump.
2. Be sure that the waterbox covers and guards are
10. Read the pressure on the gauge. Pressure should
installed on the waterbox. Use of the remote
read as shown for the concrete pump circuit main
control box for the following pressure setting
relief valve setting on the hydraulic schematic.
procedure is NOT recommended.
Return the pump control to neutral whether the
3. Start the truck engine, and put the PTO and pressure needs adjustment or not. If no adjustment
transmission into gear just as you would to pump a is needed, skip to step (14.) on page 6-218. If
job. adjustment is needed, proceed to step (10.).
4. See Figure 174. Locate and close the concrete
pump shutoff valve, and the soft switch shutoff Setting the main relief valve
valve. (These valves are also known as quarter The main relief valve is the primary pressure control
turn valves). device on units equipped with Rexroth A7VO
5. Install a 0 - 400 or 0 - 600 bar gauge in the gauge hydraulic pumps.
port. CAUTION! The main relief valve is set to very high
6. Put the rear control panel switch remote / local pressure (at least 350 bar). Use the rear control panel
into the local position. switch when checking the pressure of the main relief
7. Be sure that all emergency stop switches are in the valve so you will be out of the way if a hose or fitting
up (not activated) position. Reset the e-stop circuit. blows. See Figure 5. If the main relief valve needs
8. Using the switch on the rear control panel, rev the adjustment, proceed as follows:
truck engine up to full RPM.
revDate
178 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Soft switch
shutoff valve
Main pressure
gauge port
Concrete pump
shutoff valve hif
low
br
n.
ep
s
Figure 175
Showing the concrete pump and soft switch shutoff
closed
Groove at 90 to ports
- closed
op
n-c
lsd
.ep
s
Figure 176
Shutoff valve open / closed orientation
Pressure Settings
Gauge port
Hif
lrv
vw
.ep
s
Soft switch
relief valve
Figure 177
Location of the main relief valve
revDate
180 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Preheat the oil system. Generally, the pump puts out enough oil to
Note! Whenever you set pressures for any circuit on maintain a 20 bar higher pressure at the pump than
any unit, the hydraulic oil should be at normal operat- what the cylinders actually require. This 20 bar is
ing temperature (40 - 60 C). Instructions for heating called delta P (P). Additionally, we set the hydraulic
the hydraulic oil are found in section on page 217. 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
About proportional boom systems to ensure that you have control when you need it. The
In a black and white boom system, the hydraulic pump setting to maintain this minimum amount of oil is
puts out an unchanging amount of oil, and speed called Q-min (pronounced cue min). To set the boom
control is done by restricting the oil to certain functions or outrigger hydraulic pressures on a load-sensing
with orifices. In a load-sensing system, the pump puts system, begin by setting Q-min and P. See figure 180.
out more or less oil to respond to the needs of the
CONCRETE PUMP
REV FWD
s
.ep
loc
XL
32
Figure 178
Locations of components
used to check and set
boom pressures
E-Stop manifold
Setting P
Note! Do not adjust P or Q-min if your boom is
running as you like it. The pressure setting procedure
uses a standard starting point and must be fine tuned
from there. It was fine tuned at the factory, and should
not be adjusted unless absolutely necessary.
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. To check or set P, follow
these steps:
1. Stop the truck engine and place a Do Not
Operate sign on the truck windshield.
2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar
gauge port of the manual boom handvalves. Take
care not to accidently install the gauge in the 0-60
bar port. (See Figure 179.)
Pressure Settings
boom control
ps
block relief valve
v.e
itprd
ap
15 bar pretension
adjustment screw
Figure 179
Location of the boom circuit pressure devices
(Hoses removed for clarity.)
3. To be sure that the pump is putting out only enough boom or outrigger functions, you will damage
oil needed to maintain P, we need to change the the 0 - 40 bar gauge. Make sure that all
setting of the Q-min screw. Q-min is adjusted by a emergency stop switches are in the up (not
screw on the boom hydraulic pump (see Figure activated) position. Pressure can be read on the 0 -
180). Unscrew the Q-min screw three full turns. 40 bar gauge that you installed. Pressure should
Check that all personnel are clear of the truck, then read 20 bar. If no adjustment is needed, simply
restart the engine, engage the pumps, and leave the reset the Q-min screw as described in . If
engine at an idle. CAUTION! If you activate any adjustment is needed, continue to step (4.).
Q-min
adjustment screw
Q-minscrew.eps
Q-max
Figure 180
Location of the Q-min adjustment screw
4. Delta P is adjusted by the P screw on the P outward to decrease pressure until it is set at 20 bar
regulator (see Figure 181). Loosen the jam nut and (1). Contact Schwing Americas Service
adjust the screw inward to increase pressure, or Department if you are unable to adjust the pressure
revDate
182 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
to spec. NOTE! If the boom is not smooth at 20 affect how the boom operates, so if P adjustment
bar, you must fine tune the adjustment. In that case, does not seem to help, reset to 20 bar and check the
REMOVE THE GAUGE, and adjust P until the electrical settings. Once electrical settings are
boom is responsive and smooth. When done, the verified, you could again refine the boom action
gauge (reinstalled) must read between 14 and 25 with the P adjustment.
bar. The electronics in the control system can also
CAUTION
Do not operate any functions while setting P.
000435.eps
T
P adjustment screw
Figure 181
The P regulator valve
Pressure Settings
3. The boom control block relief valve, set at 350 bar.
NOTE! This relief valve is nonadjustable. If
pressure is not maintained with the specification
limits, the valve must be replaced.
MP
1
TT
M
10
16
78
P1
92
-7.
ep
s
P4
P2
P3
0-400 bar
gauge port
0-60 bar
gauge port
.ep
s Figure 182
nly
ipo
ap
boom control The three boom pressure devices
block relief valve
To check the setting of the valve with the highest over the relief valve.
pressure, you must first raise the pressure of the
lower two: The telltale hiss of an open relief valve should be
4. Loosen the jam nut of the high pressure adjustment coming from the Apitech control block relief valve
screw of the P regulator. Turn the screw in two- now. If it isnt, raise the setting of the other
and-a-half turns. This will raise the pressure on the pressure devices until the hiss originates at the
regulator above 350 bar. Apitech control block relief valve. Read the
pressure on the gauge. It should read 350 bar. If
5. Loosen the jam nut of the adjustment screw of the
pressure is correct, proceed to step (4.).
redundant relief valve in the emergency stop
manifold. Turn the screw in one-and-a-half turns.
NOTE! Although the pressure specification for the
This will raise the pressure setting of the relief
Apitech relief valve is 350 bar, you may continue
valve to above 350 bar.
to use the relief valve as long as the cartridge
6. Pressure out any boom cylinder except #1 down by maintains at least 330 bar. If you must replace the
pushing or pulling the control handle. To pressure valve, proceed to step (4.) before using the
out a cylinder, retract a fully retracted cylinder or machine again, and redo this entire procedure
extend a fully extended cylinder. The oil is forced when you have installed the new valve. If pressure
revDate
184 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
on the Apitech relief valve is below 290 bar, you 5. If adjustment is needed, loosen the set screw of the
should not use the machine until the valve is 140 bar relief valve with the 2.5 mm allen wrench.
replaced. While you activate #1 down, adjust the relief
7. Screw out the e-stop manifold redundant relief cartridge with the screwdriver until the pressure
valve adjustment screw one-and-a-half turns. reads just under 140 bar. Retightening the set screw
Pressure out any boom cylinder except #1 down, will raise the pressure slightly. Recheck the
and read the gauge. Pressure should read 330 bar. pressure, and readjust if needed.
If it does not, turn the screw in to raise pressure, or 6. When the pressure is set at 140 bar with the set
out to lower pressure until it is set at 330 bar. If the screw tight, you can remove the whip hose gauge
location of this valve causes you to be near the and replace the cap on the gauge port.
drivelines, be sure to stop them from turning before 7. The boom pressure setting sequence is complete. If
accessing the valve. you are done with the boom, slew it back into the
8. You will need a helper for this step. While transport position, and lower #1 into the cradle.
pressuring out any boom cylinder except #1 down, Reattach the boom strap.
have your helper adjust the high pressure screw of
the P regulator out (lowering the pressure) until Setting the outrigger pressures
the gauge reads 300 bar. Release the pressurized After the boom pressures are set, you can set the
function and lock the jam nut. The boom pressures outrigger pressure.
are now set. If you did not get the readings In this system, the boom, outriggers, water pump,
specified after following the instructions, contact and compressor circuits have all been put together
Schwing Americas Service Department at (651) in the boom valve manifold. (See Figure 46). When
429-0999 for advice on how to continue. the outrigger selector pushbutton is activated, the
outrigger valve routes oil to the two outrigger
Setting the 140 bar down side relief valve handvalve banks, one on each side of the unit. A
pressure relief valve inside the passenger side bank limits
Set the pressure of the 140 bar down side relief valve. the entire outrigger circuit to 280 bar (4060 PSI)
This valve is a secondary relief valve for #1 cylinder instead of the 300 bar (4350 PSI) of the boom
retract function. Proper adjustment ensures that the #1 relief valve.
boom and the A-frame wont be damaged by putting To set the 280 bar relief valve for the outrigger
the boom in the cradle. (See figure 183.) To adjust this circuit: (See Figure 46 & Figure 47).
valve (requires a 2.5 mm Allen wrench and a standard
screwdriver):
1. Install a 0 - 400 bar or 0 - 600 bar gauge into the 1. Wear safety glasses whenever you check or set
140 bar gauge port (shown in Figure 183). pressures.
2. Unfold the #2 section from #1 until it is straight. 2. Plug the whip hose of a 0-400 or 0-600 bar gauge
For the following procedure we must bring #1 all into the gauge port. Location is shown as item 1 in
the way down until the cylinder bottoms out. figure 46.
Position the boom so this can be done without 3. If not already done, start the truck engine and set
hitting the truck or any other obstacle. the transmission and PTO as you would for a
3. Bring #1 down until the cylinder is completely pumping job.
bottomed out. The cylinder does NOT bottom out 4. Locate the 280 bar relief valve on the back of the
if you are setting the folded boom into the A-frame outrigger valve, as shown in Figure 185.
(travel position). 5. Set the engine RPM to maximum.
4. Activate the #1 down (retract) handvalve The 6. Select outrigger with the outrigger pushbutton.
boom will not be able to move because the cylinder This will route oil to the outrigger handvalves.
is already bottomed out. Read the pressure on the
gauge that you just installed. It should read 140
bar. If no adjustment is necessary, skip to step 6.
Pressure Settings
140 bar
gauge port
ps
0.e
it14
ap
Figure 183
Location of the 140 bar relief valve and gauge port
1
Gauge port
s
.ep
hd
itor
ap
Outrigger handle
Figure 184
Position of the outrigger selector valve on units
equipped with Apitech proportional valves
revDate
186 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
280 bar
Lower Relief Valve
32Porct5.eps
PS
oc
bb
ck.
Higher ep
s
Figure 185
Location of the 280 bar outrigger
pressure relief valve.
(Hoses removed for clarity).
7. Assuming that the outriggers are folded into the 11. When the pressure is correct, either go on to other
travel position, activate the passenger side pressure settings, or remove the whip hose and
handvalve jacking cylinder retract for either the gauge, and cap the gauge port with the attached
front or rear outrigger. Note! You will get an cap.
incorrect reading if you select extension cylinder 12. Return the RPM of the truck to an idle, take the
retract by mistake. If you select extend by transmission and PTO out of gear, and shut off the
mistake, the outriggers will extend instead of truck, or go on to the other pressure settings, as
reading the relief valve setting. The handles are required.
spring loaded and will return to neutral as soon as
you let go. Setting the water pump hyd. pressure
8. Read the pressure on the gauge. It should read 280 With a seven place handvalve, the water pump
bar (4060 PSI). If no adjustment is needed, skip to hydraulic control is inside the boom control block.
step 10. There is not a separate relief for this circuit, and
9. If adjustment is needed, turn the outside body of therefore nothing that must be set.
the relief valve that is located at the back of the
outrigger valve. Turn in to raise pressure, turn out Setting 15 bar pretension
to lower pressure. There is no jam nut on this To check or set pretension, follow these steps:
valve.
1. Stop the truck engine. Plug the 0 - 40 bar gauge
10. Activate the outrigger jacking retract handvalve into the pretension check port of the Apitech
and read the pressure on the gauge again. Repeat handvalve (Figure 183).
steps 8. and 9. until the gauge reads 280 bar.
2. Start the truck engine, but leave it at an idle.
(Pretension adjustment is made at an idle to
establish the minimum pressure setting. As RPM is
Pressure Settings
CAUTION
Truck engine must be at an idle while setting pretension.
increased, pressure will rise. Damage to the 0 - 40 3. Read the pressure on the gauge. If it reads 15 bar
bar gauge is possible if RPM is raised while the 1 bar, the pressure is set correctly. If adjustment is
gauge is connected.) needed, proceed to step (4.).
Pretension
gauge port
s
.ep
rtn
itp
ap
Figure 186
Pretension adjustment screw and gauge port
4. Loosen the jam nut on the pretension valve. Turn 2. Unscrew the cover from the gauge port. Plug in the
the screw in to raise pressure, and out to lower 0-600 bar gauge and whip hose that came in the
pressure. When the pressure is correct, retighten toolbox.
the jam nut. 3. Start the engine, if not already running.
5. Stop the engine, and remove the 0 - 40 bar gauge. 4. Close the agitator shutoff valve. (See Figure 188.)
Pretension setting is complete. Note! If your unit does not have a shutoff valve,
you can order one using part number 10004680
To set the agitator circuit pressure: (valve) and part number 30303432 (tube). Contact
The agitator relief valve is located in the agitator Schwing Americas Service Department at (651)
forward / neutral / reverse handvalve, at the rear of the 429-0999 for installation instructions.
unit on the drivers side. The relief valve limits the 5. Activate the agitator in forward. Read the pressure
pressure in the agitator circuit to 200 bar (2900 PSI). on the gauge.
(See Figure 187). There is a gauge port for checking or 6. If adjustment is needed, put your wrench on the
setting the pressure in this circuit. The port is located body of the relief valve, which is located on the
on the agitator handvalve. To check or set the agitator back of the agitator handvalve. While reading the
pressure, follow these steps: gauge, turn the body in to raise pressure, or out to
1. Remove the aluminum diamond plate cover from lower pressure until 200 bar is achieved.
over the agitator handvalve. 7. Put the agitator handle in neutral.
8. Remove the whip hose and pressure gauge.
Replace the gauge port cover.
revDate
188 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Figure 187
Showing the agitator handvalve and gauge port.
(Diamond plate removed for this illustration.)
closed ag
its
o.
ep
s
open
Figure 188
The agitator shutoff valve
Pressure Settings
revDate
190 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
32 XL Hi-Flow Prop, A11VO off, and the key in your pocket, remove the plug
(item 2). The oil should be at the level of the
bottom of the hole in the case. If oil is needed, add
Units above 450 l/m (-5 and -6 units)
by removing the breather (item 1) and pouring in
Check the fluid level of the distribution gearcase. through the top. This gearcase uses 90W gearlube.
(See Figure 189). Be sure the truck is on
reasonably level ground. With the truck engine
Breather / filler
grbx-5-6.eps
Check port
Figure 189
Drain port
Check, drain and fill ports of the Stiebel
gearcase.
Main ports (left illustration)
Spline flange ports (right illustration)
Check the mounting hardware of the subframe, the part number 30303432 (tube). Contact Schwings
oil and water tanks, the delivery pipeline, the Service Department at (651) 429-0999 for
pumpkit, the differential cylinders, the material installation instructions.
cylinders and the driveline hardware. Check for 2. Turn on the agitator. The agitator will not be able
bolt tightness, cracks and other abnormalities. to turn, and the oil will be forced over the relief
valve.
Check hydraulic pressures
3. At an idle (approx. 600 rpm), about 5.4 horsepower
Check all hydraulic pressures. Changes in is being converted to heat. Shut off the agitator
pressures can indicate trouble in one or more when the temperature gauge on the rear control
components. Pressure settings must be made with panel shows 40 C. Dont forget to open the shutoff
the oil at normal operating temperatures (40 to valve when the procedure is finished.
60 C).The specifications for all circuit pressures
are found on the hydraulic schematics in the Check the concrete pump pressure (2020,
appendix section of this manual. 2023, 2525 pumpkits)
Preheat the hydraulic oil Because the Hi-flow pumpkits have the ability to create
high pressure on the concrete the pressure settings have
Because of the new load sensing and pressure cut-
to be tailored specifically for each model. This means
off regulated hydraulic systems, you cant use the
that we cannot simply list a pressure specification for
concrete pump or boom circuit to preheat the
all units. The correct pressure specifications for your
hydraulic oil (they stop putting out oil if you try).
unit are shown on the hydraulic schematic in section 7
To heat the oil to operating temperature:
of this manual. (See Figure 37). Additionally, the
1. Locate the agitator shutoff valve and close it. There pressure is not limited by the main relief valve, but
is a picture of the location on page 6-228. Note! If rather by a pressure cutoff adjustment on the concrete
your unit does not have a shutoff valve, you can
order one using part number 10004680 (valve) and
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 191
HOME PRINT
Pressure Settings
pump circuit hydraulic pumps.
To check or set the concrete pump pressure
adjustments, follow these steps:
Gauge port
Hif
lrv
vw
.ep
s
Soft switch
relief valve
Figure 190
Location of the concrete pump circuit
main relief valve and soft switch relief
Soft switch
shutoff valve
Main pressure
gauge port
Concrete pump
shutoff valve hif
low
br
n.
ep
s
closed
Groove lined up with ports
- open
grooves.eps
Groove at 90 to ports
- closed
open
Figure 191
Showing the concrete pump and soft switch shutoff valves
and their open/closed orientation op
n-c
lsd
.ep
s
pressure. Turn the screw on each pump an equal Setting the main relief valve
amount. On these screws, very small adjustments The main relief valve is not the primary pressure con-
make a big pressure difference. trol device on units with Hi-flo pumpkits.
Pressure cut-off adjustment screws CAUTION! The main relief valve is set to very high
pressure (at least 350 bar). Use the rear control panel
switch when checking the pressure of the main relief
valve so you will be out of the way if a hose or fitting
blows. Always wear eye protection when setting
pressures! See Figure 5. If the main relief valve needs
adjustment, proceed as follows:
1. If you ever need to check or adjust the main relief
valve, you must first screw in the pressure cut-off
screws on the hydraulic pumps by 1 turn each.
A11ctoff.eps
Then, when you high pressure the concrete pump,
Figure 192 you will be reading the setting of the main relief
Location of the pressure cut- valve.
off adjustment screws
Pressure Settings
Gauge port
Hif
lrv
vw
.ep
s
Soft switch
relief valve
Figure 193
Location of the main relief valve
2. Using a 9/16 spanner wrench, loosen the jam nut 2. High pressure the concrete pump. The pressure
on the main relief valve adjusting screw (Figure gauge should read 60 or 80 bar (check your
193). schematic). If adjustment is needed, proceed to
step (4), below. If no adjustment is needed, skip to
3. Insert a 5/32 allen wrench in the adjustment screw. step (4.).
Turn the screw in to raise pressure, out to lower the 3. Loosen the jam nut on the soft switch relief valve
pressure. Always go back to the rear panel before
with a 9/16 spanner wrench. Adjust the pressure up
checking the pressure.
4. Once the pressure is correct to the hydraulic or down, as needed, using a 5/32 allen wrench.
schematic, retighten the jam nut. Tightening the When the correct pressure is achieved, re-lock the
nut tends to raise the pressure, so check pressure jam nut.
again after tightening. Dont forget to turn the 4. Be sure to open the concrete pump shutoff valve on
pressure cut-off adjustment screws back out 1 turn the side of the brain (shown in Figure 191) when
each and verify the correct pressure setting before you are finished. The unit cannot stroke with this
unplugging the gauge. valve closed.
5. If you will not be setting the soft switch pressure,
open the shutoff valves. The unit will not stroke Setting boom pressures
with closed shutoff valves. (7 place proportional circuit) If your unit has a load-
sensing proportional system, it will have different
Setting the soft switch circuit relief pressure adjustments than if it is equipped with a black
pressure and white boom system. The following instructions are
To check or adjust the soft switch pressure setting, for load-sensing proportional systems. If your unit is
proceed as follows: equipped with a black and white boom system, these
1. Open the soft switch shutoff valve, as shown in instructions will be wrong. Contact Schwing Americas
figure 191. The rest of the unit should still be set up Service Department at (651) 429-0999 to obtain
as though you were going to check concrete pump correct instructions.
pressure.
revDate
194 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Preheat the oil out more or less oil to respond to the needs of the
Note! Whenever you set pressures for any circuit on system. Generally, the pump puts out enough oil to
any unit, the hydraulic oil should be at normal maintain a 20 bar higher pressure at the pump than
operating temperature (40 - 60 C). Instructions for what the cylinders actually require. This 20 bar is
heating the hydraulic oil are found in section on page called delta P (P). Additionally, we set the hydraulic
6-217. 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
About proportional boom systems to ensure that you have control when you need it. The
In a black and white boom system, the hydraulic pump setting to maintain this minimum amount of oil is
puts out an unchanging amount of oil, and speed called Q-min (pronounced cue min). To set the boom
control is done by restricting the oil to certain functions or outrigger hydraulic pressures on a load-sensing
with orifices. In a load-sensing system, the pump puts system, begin by setting Q-min and P. See figure 41.
CONCRETE PUMP
REV FWD
Figure 194
Locations of components
used to check and set 32XLHF+.eps
boom pressures
E-Stop manifold
Pressure Settings
the gauge (reinstalled) must read between 14 and and check the electrical settings. Once electrical
25 bar. The electronics in the control system can settings are verified, you could again refine the
also affect how the boom operates, so if P boom action with the P adjustment.
adjustment does not seem to help, reset to 20 bar
Q-min.
adjustment screw
Hi
pm
pb
m.
ep
s
Figure 195
Boom pump adjustment screws
CAUTION
Do not operate any functions while setting P.
boom control
ep
s
block relief valve
itprdv.
ap
15 bar pretension
adjustment screw
Figure 196
Showing the location of the boom circuit pressure devices.
(Hoses removed for clarity.)
revDate
196 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting Q-min 4. With the drive shafts stopped, loosen the jam nut of
You must check Q-min pressure when the engine the high pressure adjustment screw of the boom
is at the maximum specified RPM, but you must hydraulic pump pressure regulator. Turn the screw
adjust it with the engine stopped. in two-and-a-half turns. This will raise the pressure
of the regulator above 350 bar.
1. If you unscrewed the Q-min screw as the first step
of P adjustment, begin by returning the screw to 5. Loosen the jam nut of the adjustment screw of the
its original position (see Figure 195). redundant relief valve in the emergency stop
manifold. Turn the screw in one-and-a-half turns.
2. Remove the 0 - 40 bar gauge from the 0 - 400 bar
This will raise the pressure setting of the relief
gauge port, and install the 0 - 600 bar gauge in its
valve to above 350 bar.
place.
3. Clear all personnel away from the drive lines, start Pressure out any boom cylinder except #1 down by
the truck engine, engage the pumps, and bring pushing or pulling the control handle. To pressure out a
engine RPM to max. All boom functions must be in cylinder, retract a fully retracted cylinder or extend a
neutral, and all emergency stop buttons should be fully extended cylinder. The oil is forced over the relief
up (not engaged). valve.
4. Read the pressure on the 0 - 600 gauge. Pressure The telltale hiss of an open relief valve should be
should be at 40 - 45 bar. If no adjustment is needed, coming from the Apitech control block relief valve
stop the drivelines from turning, be sure the jam now. If it isnt, raise the setting of the other pressure
nut on the Q-min screw is tight, then continue to devices until the hiss originates at the Apitech control
paragraph to check the rest of the boom and block relief valve. Read the pressure on the gauge. It
outrigger pressures. If adjustment is needed, should read 350 bar. If pressure is correct, proceed to
continue to step (5.). step (4.).
5. Turn the Q-min screw in to raise the pressure
(Figure 44). Turn it out to lower the pressure. Be NOTE! Although the pressure specification for the
sure that you stop the drive shafts from turning Apitech relief valve is 350 bar, you may continue to
each time before making the adjustment. When use the relief valve as long as the cartridge maintains at
pressure is correct, tighten the jam nut on the least 330 bar. If you must replace the valve, proceed to
adjustment screw before continuing with the other step (4.) before using the machine again, and redo this
procedures. entire procedure when you have installed the new
valve. If pressure on the Apitech relief valve is below
Setting boom pressures 290 bar, you should not use the machine until the valve
(Load sensing proportional booms.) Now that P is replaced.
and Q-min are set, you can check or set the boom valve 6. Screw out the e-stop manifold redundant relief
pressures. valve adjustment screw one-and-a-half turns.
There are three pressure settings on the boom Pressure out any boom cylinder except #1 down,
circuit: (see Figure 197) and read the gauge. Pressure should read 330 bar.
1. Pressure regulator (the high-pressure adjustment If it does not, turn the screw in to raise pressure, or
screw on the boom hydraulic pump), set at 300 bar. out to lower pressure until it is set at 330 bar. If the
location of this valve causes you to be near the
2. The redundant relief valve located in the
drivelines, be sure to stop them from turning before
emergency stop manifold, set at 330 bar.
accessing the valve.
3. The boom control block relief valve, set at 350 bar.
7. With the truck engine off, adjust the high pressure
NOTE! This relief valve is nonadjustable. If
screw of the boom hydraulic pump regulator out
pressure is not maintained with the specification
(lowering the pressure) two-and-a-half turns. Start
limits, the cartridge valve must be replaced.
the engine, pressure out any boom cylinder except
To check the setting of the valve with the highest #1 down, and read the pressure on the gauge. It
pressure, you must first raise the pressure of the should read 300 bar. If not, repeat step (7.),
lower two: adjusting the screw a small amount each time, until
the gauge reads 300 bar when a cylinder is
pressured out.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 197
HOME PRINT
Pressure Settings
Redundant
relief valve
MP
1
TT
M 0-400 bar
gauge port
10
16
78 0-60 bar
P1
92
-7.
ep
s
gauge port
P4
P2
P3
s
.ep
nly
ipo
ap
boom control
block relief valve
Pressure Cut-off
adjustment screw
ILbmpmp.eps
Figure 197
The three boom pressure devices
8. With the truck engine off, lock the jam nut on the
high pressure screw you were adjusting in step (7.).
The boom pressures are now set. If you did not get
the readings specified after following the
instructions it is possible that there is a problem
with the emergency stop manifold (see Figure
198). You can plumb the malfunctioning circuit out
of the system to test it. Use only approved
hydraulic dead plugs to plug the inlet hose to the
malfunctioning circuit. If pressure can now be
achieved, the e-stop manifold is the source of the
problem. If pressure still cannot be achieved, the
problem is elsewhere. Contact Schwing Americas
Service Department for advice on how to continue.
If the problem was found to be the e-stop manifold,
repair it before using the unit again. Remember, the
emergency stop switches do nothing if the e-stop
revDate
198 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
manifold is plumbed out of the system. Remove
the whip hose from the 300 bar gauge port. Before
folding up the boom, proceed to the instructions
for setting the 140 bar down side relief valve.
S
MP
Boom/outrigger
T circuit dump
valve
S
MP
P3
ps
res.e
opp
est
P2
Boom
P4 P1
override
button
Setting the 140 bar down side relief valve 5. If adjustment is needed, loosen the set screw of the
pressure 140 bar relief valve with the 2.5 mm allen wrench.
While you activate #1 down, adjust the relief
Set the pressure of the 140 bar down side relief valve.
cartridge with the screwdriver until the pressure
This valve is a secondary relief valve for #1 cylinder
reads just under 140 bar. Retightening the set screw
retract function. Proper adjustment ensures that the #1
will raise the pressure slightly. Recheck the
boom and the A-frame wont be damaged by putting
pressure, and readjust if needed.
the boom in the cradle. (See figure 199.) To adjust this
valve (requires a 2.5 mm Allen wrench and a standard 6. When the pressure is set at 140 bar with the set
screwdriver): screw tight, you can remove the whip hose gauge
and replace the cap on the gauge port.
1. Install a 0 - 400 bar or 0 - 600 bar gauge into the
140 bar gauge port (shown in Figure 199). 7. The boom pressure setting sequence is complete. If
you are done with the boom, slew it back into the
2. Unfold the #2 section from #1 until it is straight.
transport position, and lower #1 into the cradle.
For the following procedure we must bring #1 all
Attach the boom strap.
the way down until the cylinder bottoms out.
Position the boom so this can be done without
hitting the truck or any other obstacle.
3. Bring #1 down until the cylinder is completely
bottomed out. The cylinder does NOT bottom out
if you are setting the folded boom into the A-frame
(travel position).
4. Activate the #1 down (retract) handvalve The
boom will not be able to move because the cylinder
is already bottomed out. Read the pressure on the
gauge that you just installed. It should read 140
bar. If no adjustment is necessary, skip to step 6.
Pressure Settings
140 bar
gauge port
ps
0.e
it14
ap
Figure 199
location of the 140 bar relief valve and gauge port.
Setting the outrigger 3. If not already done, start the truck engine and set
pressures (7 place boom valve systems) the transmission and PTO as you would for a
pumping job.
After the boom pressures are set, you can set the
outrigger pressure. 4. Locate the 280 bar relief valve on the back of the
In this system, the boom, outriggers, water pump, outrigger valve, as shown in Figure 201.
and compressor circuits have all been put together 5. Set the engine RPM to maximum.
in the boom valve manifold. (See Figure 199). 6. Select outrigger with the outrigger pushbutton.
When the outrigger selector push-button is This will route oil to the outrigger handvalves.
activated, the outrigger valve routes oil to the two 7. Assuming that the outriggers are folded into the
outrigger handvalve banks, one on each side of the travel position, activate the passenger side
unit. A relief valve inside the passenger side bank handvalve jacking cylinder retract for either the
limits the entire outrigger circuit to 280 bar (4060 front or rear outrigger. Note! You will get an
PSI) instead of the 300 bar (4350 PSI) of the boom incorrect reading if you select extension cylinder
relief valve. retract by mistake. If you select extend by
To set the 280 bar relief valve for the outrigger mistake, the outriggers will extend instead of
circuit: (See Figure 201). reading the relief valve setting. The handles are
spring loaded and will return to neutral as soon as
you let go.
1. Wear safety glasses whenever you check or set
8. Read the pressure on the gauge. It should read 280
pressures.
bar (4060 PSI). If no adjustment is needed, skip to
2. Plug the whip hose of a 0-400 or 0-600 bar gauge step 10.
into the gauge port. Location is shown as item 1 in
figure 201.
revDate
200 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
7plcORhndl.eps
Outrigger handle
Gauge port
1
Gauge port
SECTION 1 SECTION 2 SECTION 3 SECTION 4 SLEWING AIR / WATER BOOM / OUTRIG.
DANGER WARNING
Electrocution hazard. Do not operate this
Stay back from high machine without
training. Understand
voltage wires at least SAFETY
1
17 feet (5 meters). MANUAL
manuals and on decals.
Figure 200
h d.e
ps Position of the outrigger selector valve
itor
ap
Monsun-Tyson black & white (right)
Outrigger handle Apitech proportional (left)
280 bar
Lower Relief Valve
32Porct5.eps
PS
oc
bb
ck.
Higher ep
s
Figure 201
Location of the 280 bar outrigger
pressure relief valve.
(Hoses removed for clarity).
Pressure Settings
9. If adjustment is needed, turn the outside body of
the relief valve that is located at the back of the
outrigger valve. Turn in to raise pressure, turn out Setting 15 bar pretension
to lower pressure. There is no jam nut on this To check or set pretension, follow these steps:
valve. 1. Stop the truck engine. Plug the 0 - 40 bar gauge
10. Activate the outrigger jacking retract handvalve into the pretension check port of the Apitech
and read the pressure on the gauge again. Repeat handvalve (Figure 202).
steps 8. and 9. until the gauge reads 280 bar. 2. Start the truck engine, but leave it at an idle.
11. When the pressure is correct, either go on to other (Pretension adjustment is made at an idle to
pressure settings, or remove the whip hose and establish the minimum pressure setting. As RPM is
gauge, and cap the gauge port with the attached increased, pressure will rise. Damage to the 0 - 40
cap. bar gauge is possible if RPM is raised while the
12. Return the RPM of the truck to an idle, take the gauge is connected.)
transmission and PTO out of gear, and shut off the 3. Read the pressure on the gauge. If it reads 15 bar
truck, or go on to the other pressure settings, as 1 bar, the pressure is set correctly. If adjustment is
required. needed, proceed to step (4.).
CAUTION
Truck engine must be at an idle while setting pretension.
Pretension
gauge port
4. Loosen the jam nut on the pretension valve. Turn setting the pressure in this circuit. The port is located
the screw in to raise pressure, and out to lower on the agitator handvalve. To check or set the agitator
pressure. When the pressure is correct, retighten pressure, follow these steps:
the jam nut. 1. Remove the aluminum diamond plate cover from
5. Stop the engine, and remove the 0 - 40 bar gauge. over the agitator handvalve.
Pretension setting is complete. 2. Unscrew the cover from the gauge port. Plug in the
0-600 bar gauge and whip hose that came in the
To set the agitator circuit pressure: toolbox.
The agitator relief valve is located in the agitator 3. Start the engine, if not already running.
forward / neutral / reverse handvalve, at the rear of the 4. Close the agitator shutoff valve. (See Figure 204.)
unit on the drivers side. The relief valve limits the Note! If your unit does not have a shutoff valve,
pressure in the agitator circuit to 200 bar (2900 PSI). you can order one using part number 10004680
(See Figure 203). There is a gauge port for checking or
revDate
202 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Figure 203
Showing the agitator handvalve and
gauge port.
(Diamond plate removed
for this illustration.)
closed
s
ep
o.
its
ag
open
Figure 204
The agitator shutoff valve
Pressure Settings
revDate
204 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 32 XG Check the concrete pump pressure (2020,
2023, 2525 pumpkits)
Because the Hi-flow pumpkits have the ability to create
Check hydraulic pressures high pressure on the concrete, the pressure settings
The following pages provide the proper techniques for have to be tailored specifically for each model. This
checking and setting hydraulic pressures of each means that we cannot simply list a pressure
system included on units up to 450 l/m. specification for all units. The correct pressure
Check all hydraulic pressures. Changes in pressures specifications for your unit are shown on the hydraulic
can indicate trouble in one or more components. schematic in the Appendix, section of this manual.
Pressure settings must be made with the oil at normal If you wish to order a CD ROM which explains the
operating temperatures (40 to 60 C). The pressure setting procedure for a specific model (all
specifications for all circuit pressures are found on the pumpkits), call SAI Spare Parts Department at (800)
hydraulic schematics in the Appendix section of this 328 - 9635 and request the CD using the following part
manual. numbers:
61/58 meter . . . . . . . . . . . . . . . . . . . . . . .30365860
Preheat the hydraulic oil 52 meter . . . . . . . . . . . . . . . . . . . . . . . . . .30354732
Because of the new load-sensing hydraulic systems 45/47 meter . . . . . . . . . . . . . . . . . . . . . . .30356770
regulated by pressure cut-off, you cant use the 42 meter . . . . . . . . . . . . . . . . . . . . . . . . . .30355485
concrete pump or boom circuit to preheat the hydraulic
39 meter . . . . . . . . . . . . . . . . . . . . . . . . . .30365861
oil (they stop putting out oil rather than send it over
relief). To heat the oil to operating temperature: 34 meter . . . . . . . . . . . . . . . . . . . . . . . . . .30356772
32 meter . . . . . . . . . . . . . . . . . . . . . . . . . .30355486
1. Locate the agitator shutoff valve (Figure 36) and
close it. Note! If your unit does not have a shutoff 31 meter . . . . . . . . . . . . . . . . . . . . . . . . . .30365862
valve, you can order one using part number NOTE!
10004680 (valve) and part number 30303432 Use of the remote control box for the
(tube). Contact the Schwing Service Department at following pressure setting procedure is NOT
(651) 429-0999 for installation instructions. recommended.
2. Turn on the agitator. The agitator will not be able To check or set the concrete pump pressure
to turn, and the oil will be forced over the relief adjustments, follow these steps:
valve.
3. At an idle (approximately 600 rpm), about 5.4 WARNING
horsepower is being converted to heat. Shut off the
agitator when the temperature gauge on the rear Wear safety glasses any time you check
or set pressures. Oil expulsion hazard!
000438.eps
control panel shows 40 C. Dont forget to open
the shutoff valve when the procedure is finished.
1. Be sure that the waterbox covers and guards are
agitoff.eps
installed on the waterbox.
2. Start the truck engine, and put the PTO and
transmission into gear just as you would to pump a
job.
3. Locate and close the concrete pump shutoff valve
and the soft switch shutoff valve (Figure 38 next
page). (These valves are also known as quarter
Agitator quarter turn turn valves).
shutoff valve (open position) Motor 4. If your concrete pump pressure gauge is not
already plumbed into the gauge port (Figure 37),
install a 0 - 400 or 0 - 600 bar gauge in the gauge
Figure 21 port.
Agitator shutoff valve
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 205
HOME PRINT
Pressure Settings
5. The local/remote switch located on the controller If your unit has any pumpkit other than a
cover must be in the local position. Hi-flo -4, call SAI Service Department and
ask for the proper pressure setting
6. Be sure that all emergency stop switches are in the procedures for your specific pumpkit.
up (not activated) position. Reset the E-stop circuit.
The main relief valve is the primary pressure control
7. Using the throttle switch on the rear control panel, device on units equipped with Rexroth A7VO
bring the truck engine up to full RPM. hydraulic pumps.
8. CAUTION! The main relief valve (Figure 39) is
If the main relief valve needs adjustment, proceed as
set to very high pressure (at least 350 bar). Use the
follows:
rear control panel switch when checking the
pressure of the main relief valve, so you will be out 1. Wear safety glasses when checking or adjusting
of the way if a hose or fitting blows. pressures.
9. Place the concrete pump forward / neutral / reverse 2. Using a 9/16 spanner wrench, loosen the jam nut
switch on the rear control panel into the forward on the main relief valve adjusting screw (Figure
position. The unit will stroke no more than once; 37).
then the rock cylinder will retract. Oil leaving the
3. Insert a 5/32 allen wrench in the adjustment screw.
hydraulic pumps will be blocked in the brain. This
is called high-pressuring the concrete pump. Turn the screw in to raise pressure and out to lower
the pressure. Always go back to the rear panel
10. Read the pressure on the gauge. The target pressure
before checking the pressure.
for the concrete pump circuit main relief valve is
shown on the hydraulic schematic in the Appendix 4. Once the pressure is correct to the hydraulic
section of this manual. Return the pump control to schematic, retighten the jam nut. Tightening the
neutral whether the pressure needs adjustment or nut tends to raise the pressure, so check pressure
not. If no adjustment is needed, skip to step 14 of again after tightening.
the next procedure. If adjustment is needed, 5. If you will not be setting the soft switch pressure,
proceed to next paragraph. open the shutoff valves. The unit will not stroke
with closed shutoff valves.
Setting the main relief valve on -4 pumpkit
NOTE!
Gauge port
Hif
lo_
4.e
ps
Soft switch
relief valve
Figure 22
Location of the concrete pump circuit main relief
valve and soft switch relief valve
revDate
206 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Soft switch
shutoff valve
Main Pressure
Gauge port
Concrete pump
hif
shutoff valve low
br
n.
ep
s
Figure 23
Showing the concrete pump and soft switch shutoff
valves
Open
5/32" Allen head
Mounting screw and washer
removed for illustration 9/16" jam nut
Figure 24
Shutoff valve open / closed orientation
Pressure Settings
Setting the soft switch circuit relief 3. Loosen the jam nut on the soft switch relief valve
pressure (Figure 5) with a 9/16 spanner wrench. Adjust the
To check or adjust the soft switch pressure setting, pressure up or down, as needed, using a 5/32 Allen
proceed as follows: wrench. When the correct pressure is achieved,
1. Open the soft switch shutoff valve (Figure 38). The tighten the jam nut.
rest of the unit should still be set up as though you 4. Be sure to open the concrete pump shutoff valve
were going to check concrete pump pressure. (Figure 38) on the side of the brain when you are
2. High pressure the concrete pump. The pressure finished. The unit cannot stroke with this valve
gauge should read 60 or 80 bar (check your closed.
schematic). If adjustment is needed, proceed to
step (3) below. If no adjustment is needed, skip to
step (4).
Gauge port
Hif
lo_
4.e
ps
Soft switch
relief valve
Figure 25
Location of the main relief valve
revDate
208 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
0-400 bar
gauge port Boom control
block relief valve
Redundant
relief valve
p s
e.e
alv
oo mv
34b newestop.eps
Setting boom pressures 5. The boom control block relief valve can then be
There are two pressure settings on the boom circuit: the turned out with the handle still activated until the
redundant relief valve and the boom control block gauge reads 300 bar.
relief (Figure 45). NOTE!
1. Install 0-400 or 0-600 bar gauge in the 0-400 bar The gauge will always read the lowest relief
gauge port (Figure 45). setting in the system; therefore, we turn the
pressure up on the boom control block in
2. The redundant relief valve located in the step #3 to assure that it is higher than the
emergency stop manifold (Figure 45) should first 330 bar required for the redundant relief
be turned out two turns by loosening the jam nut valve.
with a 9/16 open end wrench and turning the
140 bar down side relief
cartridge out with a 4 mm Allen wrench.
The down side relief is now a non-adjustable, internal
3. The boom control block relief valve (Figure 45),
valve which is verified at the factory and should not
should then be turned in one turn by using a 1/8 require further attention. If you feel you need to verify
allen wrench to remove the cover guard and a 5/32 the down side relief call Schwing Service Department
allen wrench to turn in the screw. and ask about the proper procedure for doing so.
4. The redundant relief valve, located in the
Setting the outrigger pressures
emergency stop manifold, should be set at 330 bar.
Activate any boom cylinder, except #1, to the boom After the boom pressures are set, you can set the
in or boom down position. The gauge should be outrigger pressure.
reading lower than the target 330 bar. Turn the In this system, the boom, outriggers, water pump, and
screw in until it reaches 330 bar. compressor circuits have all been put together in the
boom valve manifold. When the outrigger selector
pushbutton is pushed, the outrigger valve handle is
activated, which routes oil to the two outrigger
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 209
HOME PRINT
Pressure Settings
0-400 bar Outrigger handle
gauge port
15 bar pretension
adjusment screw
Figure 27
Position of the outrigger selector valve on units ghn
dl.e
ps
otr
new
equipped with Apitech proportional valves
handvalve banks (one on each side of the unit). A relief 8. If adjustment is needed, turn the outside body of
valve inside the passenger side bank limits the entire the relief valve that is located at the back of the
outrigger circuit to 280 bar (4060 PSI) instead of the outrigger valve. Turn in to raise pressure; turn out
300 bar (4350 PSI) of the boom relief valve. to lower pressure. There is no jam nut on this
To set the 280 bar relief valve for the outrigger circuit: valve.
9. Activate the outrigger jacking retract handvalve
and read the pressure on the gauge again. Repeat
WARNING steps (8) and (9) until the gauge reads 280 bar.
Wear safety glasses any time you check 10. When the pressure is correct, either go on to other
or set pressures. Oil expulsion hazard! pressure settings or remove the whip hose and
000438.eps
34manco3.eps
WARNING
Clear area
before activating
outriggers
otr
gb
lk.e
ps
200
100 300
bar 400
WIKA
280 bar
Relief valve
Figure 28
Location of the 280 bar outrigger
pressure relief valve.
(Hoses removed for clarity).
CAUTION
Truck engine must be at idle to set
000439.eps
3. If the pressure reads 15 bar 1 bar, the pressure is Setting the agitator circuit pressure
set correctly. If adjustment is needed, proceed to The agitator relief valve is located in the agitator
the next step. forward / neutral / reverse handvalve (Figure 49). The
4. Loosen the jam nut on the pretension valve. Turn relief valve (not completely visible in Figure 49) limits
the screw in to raise pressure, and out to lower the pressure in the agitator circuit to 200 bar (2900
pressure. When the pressure is correct, retighten PSI). There is a gauge port (not visible in Figure 49)
the jam nut. for checking or setting the pressure in this circuit. The
5. Stop the engine, and remove the 0 - 40 bar gauge. port is located on the agitator handvalve. To check or
Pretension setting is complete. set the agitator pressure, follow these steps:
Pressure Settings
1. Unscrew the cover from the gauge port. Plug in the 2. Start the engine, if its not already running.
0-600 bar gauge and whip hose that came in the
toolbox.
0-60 bar
gauge port
15 bar pretension
adjusment screw
Figure 29
Pretension adjustment screw
ps
n.e
and gauge port new
pre
tns
Relief valve
Gauge Port
34agithandvalve.eps
Figure 30
Agitator handvalve
3. Close the agitator shutoff valve (Figure 50). 30303432 (tube). Contact Schwing
Americas Service Department at (651) 429-
NOTE! 0999 for installation instructions.
If your unit does not have a shutoff valve,
you can order one using part number 4. Activate the agitator, and read the pressure on the
10004680 (valve) and part number gauge.
revDate
212 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
5. If adjustment is needed, put your wrench on the 6. Put the agitator handle in neutral.
body of the relief valve (Figure 49), which is 7. Remove the whip hose and pressure gauge.
located on the back of the agitator handvalve. Replace the gauge port cover.
While reading the gauge, turn the body in to raise
pressure or out to lower pressure until 200 bar is
achieved.
agitoff.eps
Pressure Settings
Setting accumulator circuit pressure
45Accreg.eps
Accumulator pump
pressure regulator Redundant
Relief cartridge
Figure 32
Accumulator pump pressure regulator for newredun.eps
revDate
214 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
8. After the truck engine is stopped, go back to the
accumulator circuit hydraulic pump pressure
regulator (Figure 51), and turn the screw back out
two-and-one-half turns. This restores it to its
accuman1.eps
original setting.
9. Clear all personnel from the drive line area, start
the truck, and bring the engine RPM up to
maximum.
10. Read the pressure on the accumulator gauge. It
should read the proper accumulator system
pressure.
11. If adjustment is needed, you must stop the truck
engine, or a least stop the drive lines from turning,
each and every time you approach the accumulator
Pressure Relief Cartridge circuit hydraulic pump. Turn the screw in to
Manual bleed valve increase the pressure or out to decrease pressure.
Lock the jam nut when the pressure is correct.
NOTE!
The accumulator circuit hydraulic pump
pressure regulator is sometimes referred to
as the pressure cut-off.
Figure 35
Accumulator manifold pressure
relief cartridge
WARNING
Entanglement hazard. Stop drive shafts
before adjusting the accumulator pump
000075.eps
pressure regulator.
Pressure Settings
revDate
216 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
S 34 X Check the concrete pump pressure (2020, 2023,
2525 pumpkits)
Check hydraulic pressures Because the Hi-flow pumpkits have the ability to create
high pressure on the concrete, the pressure settings
The following pages provide the proper techniques for have to be tailored specifically for each model. This
checking and setting hydraulic pressures of each means that we cannot simply list a pressure
system included on units up to 450 l/m. specification for all units. The correct pressure
Check all hydraulic pressures. Changes in pressures specifications for your unit are shown on the hydraulic
can indicate trouble in one or more components. schematic in Appendix, Section 7 of this manual.
Pressure settings must be made with the oil at normal If you wish to order a CD ROM which explains the
operating temperatures (40 to 60 C). The pressure setting procedure for a specific model (all
specifications for all circuit pressures are found on the pumpkits), call Schwing Spare Parts Department at
hydraulic schematics in the Appendix section of this (800) 328 - 9635 and request the CD using the
manual. following part numbers:
Preheat the hydraulic oil 61/58 meter . . . . . . . . . . . . . . . . . . . . . . .30365860
Because of the new load-sensing hydraulic systems 52 meter . . . . . . . . . . . . . . . . . . . . . . . . . .30354732
regulated by pressure cut-off, you cant use the 45/47 meter . . . . . . . . . . . . . . . . . . . . . . .30356770
concrete pump or boom circuit to preheat the hydraulic 42 meter . . . . . . . . . . . . . . . . . . . . . . . . . .30355485
oil (they stop putting out oil rather than send it over 39 meter . . . . . . . . . . . . . . . . . . . . . . . . . .30365861
relief). To heat the oil to operating temperature: 34 meter . . . . . . . . . . . . . . . . . . . . . . . . . .30356772
1. Locate the agitator shutoff valve (Figure 36) and 32 meter . . . . . . . . . . . . . . . . . . . . . . . . . .30355486
close it. Note! If your unit does not have a shutoff 31 meter . . . . . . . . . . . . . . . . . . . . . . . . . .30365862
valve, you can order one using part number
10004680 (valve) and part number 30303432 NOTE!
(tube). Contact the Schwing Service Department at Use of the remote control box for the
(651) 429-0999 for installation instructions. following pressure setting procedure is NOT
recommended.
2. Turn on the agitator. The agitator will not be able
to turn, and the oil will be forced over the relief To check or set the concrete pump pressure
valve. adjustments, follow these steps:
3. At an idle (approximately 600 rpm), about 5.4
horsepower is being converted to heat. Shut off the WARNING
agitator when the temperature gauge on the rear
control panel shows 40 C. Dont forget to open Wear safety glasses any time you check
or set pressures. Oil expulsion hazard!
000438.eps
the shutoff valve when the procedure is finished.
agitoff.eps
Pressure Settings
5. The remote / local switch located on the rear Setting the main relief valve
control panel must be in the local position. The main relief valve is the primary pressure control
6. Be sure that all emergency stop switches are in the device on units equipped with Rexroth A7VO
up (not activated) position. Reset the E-stop circuit. hydraulic pumps.
7. Using the throttle switch on the rear control panel, If the main relief valve needs adjustment, proceed as
bring the truck engine up to full RPM. follows:
CAUTION! The main relief valve (Figure 39) is set to 10. Wear safety glasses when checking or adjusting
very high pressure (at least 350 bar). Use the rear pressures.
control panel switch when checking the pressure of the
11. Using a 9/16 spanner wrench, loosen the jam nut
main relief valve, so you will be out of the way if a
hose or fitting blows. on the main relief valve adjusting screw (Figure
37).
8. Place the concrete pump forward / neutral /
reverse switch on the rear control panel into the 12. Insert a 5/32 Allen wrench in the adjustment
forward position. The unit will stroke no more screw. Turn the screw in to raise pressure and out
than once, and then the rock cylinder will retract. to lower the pressure. Always go back to the rear
Oil leaving the hydraulic pumps will be blocked in panel before checking the pressure.
the brain. This is called high-pressuring the 13. Once the pressure is correct to the hydraulic
concrete pump. schematic, retighten the jam nut. Tightening the
9. Read the pressure on the gauge. The target pressure nut tends to raise the pressure, so check pressure
for the concrete pump circuit main relief valve is again after tightening.
shown on the hydraulic schematic in the Appendix 14. If you will not be setting the soft switch pressure,
section of this manual. Return the pump control to open the shutoff valves. The unit will not stroke
neutral whether the pressure needs adjustment or with closed shutoff valves.
not. If no adjustment is needed, skip to step 14. If
adjustment is needed, proceed to next paragraph.
Gauge port
Hif
lo_
4.e
ps
Soft switch
relief valve
Figure 37
Location of the concrete pump circuit main relief
valve and soft switch relief valve
revDate
218 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Soft switch
shutoff valve
Main Pressure
Gauge port
Concrete pump
hif
shutoff valve low
br
n.
ep
s
Figure 38
Showing the concrete pump and soft switch shutoff
valves
Open
5/32" Allen head
Mounting screw and washer
removed for illustration 9/16" jam nut
Figure 39
Shutoff valve open / closed orientation
Pressure Settings
Setting the soft switch circuit relief pressure 3. Loosen the jam nut on the soft switch relief valve
To check or adjust the soft switch pressure setting, (Figure 5) with a 9/16 spanner wrench. Adjust the
proceed as follows: pressure up or down, as needed, using a 5/32 Allen
1. Open the soft switch shutoff valve (Figure 38). The wrench. When the correct pressure is achieved,
rest of the unit should still be set up as though you tighten the jam nut.
were going to check concrete pump pressure.
4. Be sure to open the concrete pump shutoff valve
2. Pressure out the concrete pump. The pressure (Figure 38) on the side of the brain when you are
gauge should read 60 or 80 bar (check your finished. The unit cannot stroke with this valve
schematic). If adjustment is needed, proceed to closed.
step (3) below. If no adjustment is needed, skip to
step (4).
Gauge port
Hif
lo_
4.e
ps
Soft switch
relief valve
Figure 40
Location of the main relief valve
revDate
220 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Load-sensing boom pressures Setting P
If your unit has a load-sensing proportional system, it NOTE!
will have different pressure adjustments than if it is Do not adjust P or Q-min if your boom is
equipped with a black-and-white boom system. The running as you like it. The pressure setting
following instructions are for seven place, load-sensing procedure uses a standard starting point
proportional systems. If you have a unit equipped with and must be fine tuned from there. It was
a black-and-white boom system, contact Schwing fine tuned at the factory and should not be
adjusted unless absolutely necessary.
Service for the correct instruction pages.
Do not adjust Q-min with the drive shafts turning!
Preheat the oil Each time the Q-min screw is adjusted, the engine must
NOTE! be stopped, or at least the transmission must be taken
out of gear, so that the drivelines stop turning. To check
Whenever you set pressures for any circuit
on any unit, the hydraulic oil should be at or set P, follow these steps:
normal operating temperature (40 - 60 C). 1. Stop the truck engine, and place a Do Not
Instructions for heating the hydraulic oil Operate sign on the truck windshield.
are found on page 217.
2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar
About proportional boom systems gauge port (Figure 42) of the manual boom hand
In a black-and-white boom system, the hydraulic pump valves. Take care not to accidently install the gauge
puts out an unchanging amount of oil, and speed in the 0-60 bar port.
control is done by restricting the oil to certain functions CAUTION! If you activate any boom or outrigger
with orifices. In a load-sensing system, the pump puts functions, you will damage the 0 - 40 bar gauge.
out more or less oil to respond to the needs of the 3. To be sure that the pump is putting out only enough
system. Generally, the pump puts out enough oil to oil to maintain P, we need to change the setting of
maintain a 20 bar higher pressure at the pump than the Q-min screw. Q-min is adjusted by a screw on
what the cylinders actually require. This 20 bar is the boom hydraulic pump (Figure 43). Unscrew the
called delta P (P). Additionally, we set the hydraulic Q-min screw three full turns. Make sure that all
pump so that it always puts out a small amount of oil, emergency stop switches are in the up (not
even if no oil is needed for the system. This oil is used activated) position. Check that all personnel are
to ensure that you have control when you need it. The clear of the truck; then restart the engine, engage
setting to maintain this minimum amount of oil is the pumps, and leave the engine at an idle. Pressure
called Q-min (pronounced cue min). To set the boom can be read on the 0 - 40 bar gauge that you
or outrigger hydraulic pressures on a load-sensing installed. Pressure should read 20 bar. If no
system, begin by setting Q-min and P. adjustment is needed, simply reset the Q-min
Read all of the instructions before beginning any screw as described on page 223. If adjustment is
pressure settings. General locations of the components needed, continue to step (4).
for the following procedures are shown in Figure 41.
You will need an assistant for parts of this procedure.
You and any assistants should wear eye protection
when checking or setting pressures.
Manual boom handvalves,
Delta P adjustment
and E-Stop manifold
Figure 41
Locations of
components used to
check and set boom
pressures 34cmploc.eps
Pressure Settings
15 bar pretension
adjustment screw 140 bar gauge port (use 0-400
bar gauge when checking)
0-60 bar
gauge port
0-400 bar
gauge port
Figure 42
Location of the boom circuit
pressure devices boom control 140 bar downside
(Hoses removed for clarity.) block relief valve relief cartridge 34blck.eps
CAUTION Q-min
adjustment screw
Do not operate any function during this
000442.eps
Figure 44
The P regulator valve
revDate
222 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting Q-min 5. Turn the Q-min screw in to raise the pressure
Check Q-min pressure when the engine is at the (Figure 43). Turn it out to lower the pressure. Be
maximum specified RPM, but the engine must be sure that you stop the drive shafts from turning
stopped to adjust the pressure. each time before making the adjustment. When
pressure is correct, tighten the jam nut on the
1. If you unscrewed the Q-min screw as the first step
adjustment screw before continuing with the other
of P adjustment, begin by returning the screw to
procedures.
its original position (Figure 43).
2. Remove the 0 - 40 bar gauge from the 0 - 400 bar Setting boom pressures (Load sensing
gauge port, and install the 0 - 600 bar gauge in its proportional booms.)
place. Now that P and Q-min are set, you can check or set
3. Clear all personnel away from the drive lines, start the boom valve pressures.
the truck engine, engage the pumps, and bring There are three pressure settings (Figure 45) on the
engine RPM to max. All boom functions must be in boom circuit:
neutral, and all emergency stop buttons should be
1. Pressure regulator (the high-pressure adjustment
up (not engaged).
screw on the P regulator valve), set at 300 bar.
4. Read the pressure on the 0 - 600 bar gauge.
Pressure should be at 40 - 45 bar. If no adjustment 2. The redundant relief valve located in the
is needed, stop the drivelines from turning, be sure emergency stop manifold, set at 330 bar.
the jam nut on the Q-min screw is tight, and 3. The boom control block relief valve, set at 350 bar.
proceed to Setting boom pressures. If adjustment is NOTE!
needed, continue to the next step. This relief valve is nonadjustable. If
pressure is not maintained with the
specification limits, the valve must be
replaced.
15 bar pretension
adjustment screw 140 bar gauge port (use 0-400
bar gauge when checking)
0-60 bar
newestop.eps
gauge port
0-400 bar
gauge port
Figure 45
The three boom pressure
boom control 140 bar downside
block relief valve
devices
relief cartridge 34blck.eps
Pressure Settings
1. Loosen the jam nut of the high pressure adjustment specified after following the instructions, contact
screw (Figure 45) of the P regulator. Turn the Schwing Americas Service Department at (651)
screw in two-and-a-half turns. This will raise the 429-0999 for advice on how to continue.
pressure on the regulator above 350 bar.
Setting the 140 bar down side relief valve pressure
2. Loosen the jam nut of the adjustment screw of the
redundant relief valve (Figure 45) in the Set the pressure of the 140 bar (Figure 45) down side
emergency stop manifold. Turn the screw in one- relief valve. Down side relief is a secondary relief valve
and-a-half turns. This will raise the pressure setting for #1 cylinder retract function. Proper adjustment
of the relief valve to above 350 bar. ensures that the #1 boom and the A-frame wont be
damaged by putting the boom in the cradle. To adjust
3. Pressure out any boom cylinder except #1 down by
this valve (requires a 2.5 mm Allen wrench and a
activating the control handle. To pressure out a
standard screwdriver):
cylinder, retract a fully retracted cylinder or extend
a fully extended cylinder. The oil is then forced 1. Install a 0 - 400 bar or 0 - 600 bar gauge into the
over the relief valve. 140 bar gauge port shown in Figure 45.
The telltale hiss of an open relief valve should be 2. Unfold the #2 section from #1 until it is fully
coming from the Apitech control block relief valve extended. For the following procedure we must
now. If it isnt, raise the setting of the other bring #1 all the way down until the cylinder
pressure devices until the hiss originates at the bottoms out. Position the boom so this can be done
Apitech control block relief valve. Read the without hitting the truck or any other obstacle.
pressure on the gauge. It should read 350 bar. If 3. Bring #1 down until the cylinder is completely
pressure is correct, proceed to the next step. bottomed out. The cylinder does NOT bottom out
NOTE! if you are setting the folded boom into the A-frame
Although the pressure specification for the (travel position).
Apitech relief valve is 350 bar, you may 4. Activate the #1 down (retract) handvalve. The
continue to use the relief valve as long as the boom will not be able to move because the cylinder
cartridge maintains at least 330 bar. If you is already bottomed out. Read the pressure on the
must replace the valve and dont have one
on hand, proceed to the next step before gauge that you just installed. It should read 140
using the machine again. Redo this entire bar. If no adjustment is necessary, skip to step 6.
procedure when you have installed the new 5. If adjustment is needed, loosen the set screw of the
valve. If pressure on the Apitech relief valve 140 bar relief valve (Figure 45) with the 2.5 mm
is below 290 bar, you should not use the
machine until the valve is replaced. Allen wrench. While you activate #1 down, adjust
the relief cartridge with the screwdriver until the
4. Screw out the E-stop manifold redundant relief pressure reads just under 140 bar. Retightening the
valve (Figure 45) adjustment screw one-and-a-half set screw will raise the pressure slightly. Recheck
turns. Pressure out any boom cylinder except #1 the pressure, and readjust if needed.
down, and read the gauge. Pressure should read
6. When the pressure is set at 140 bar with the set
330 bar. If it does not, turn the screw in to raise
screw tight, you can remove the whip hose gauge
pressure or out to lower pressure until it is set at
and replace the cap on the gauge port.
330 bar. If the location of this valve causes you to
be near the drivelines, be sure to stop them from 7. The boom pressure setting sequence is complete. If
turning before accessing the valve. you are done with the boom, fold it back into the
transport position, and reattach the boom strap.
5. You will need a helper for this step. While
pressuring out any boom cylinder except #1 down,
have your helper adjust the high pressure screw of
the P regulator out (lowering the pressure) until
the gauge reads 300 bar. Release the pressurized
function, and lock the jam nut. The boom pressures
are now set. If you did not get the readings
revDate
224 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting the outrigger pressures
Outrigger handle
0-400 bar
gauge port
otrghndl.eps
Figure 46
Position of the outrigger selector valve on units
equipped with Apitech proportional valves
After the boom pressures are set, you can set the 4. Set the engine RPM to maximum.
outrigger pressure. 5. Select outrigger with the outrigger pushbutton.
In this system, the boom, outriggers, water pump, and This will route oil to the outrigger handvalves.
compressor circuits have all been put together in the 6. Assuming that the outriggers are folded into the
boom valve manifold. When the outrigger selector travel position, activate the passenger side
pushbutton is pushed, the outrigger valve handle is handvalve jacking cylinder retract for either
activated, which routes oil to the two outrigger the front or rear outrigger.
handvalve banks (one on each side of the unit). A relief
valve inside the passenger side bank limits the entire NOTE!
outrigger circuit to 280 bar (4060 PSI) instead of the You will get an incorrect reading if you
select any other outrigger function. The
300 bar (4350 PSI) of the boom relief valve. handles are spring loaded and will return to
To set the 280 bar relief valve for the outrigger circuit: neutral as soon as you let go.
7. Read the pressure on the gauge. It should read 280
bar (4060 PSI). If no adjustment is needed, skip to
WARNING step 10.
Wear safety glasses any time you check 8. If adjustment is needed, turn the outside body of
or set pressures. Oil expulsion hazard! the relief valve that is located at the back of the
000438.eps
Pressure Settings
34manco3.eps
280 bar
10 9 Relief valve
2 4 6 8
AGITATOR
3 5 7
CONCRETE PUMP
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SLEWING
AIR / WATER
BOOM / OUTRIG.
DANGER WARNING
Electrocution hazard.
4 Stay back from high
Do not operate this
machine without
voltage wires at least training. Understand
17 feet (5 meters). the warnings in safety
3
WARNING
Clear area
before activating
outriggers
otr
gb
lk.e
ps
200
100 300
bar 400
WIKA
Figure 47
Location of the 280 bar outrigger
pressure relief valve
(Hoses removed for clarity)
10. When the pressure is correct, either go on to other Setting the water pump hydraulic pressure
pressure settings or remove the whip hose and With a seven place handvalve, the water pump
gauge and cap the gauge port with the attached hydraulic control is inside the boom control block.
cap. There is not a separate relief for this circuit and,
11. If there are not other pressure settings required, therefore, nothing that must be set.
return the RPM of the truck to an idle, take the
transmission and PTO out of gear, and shut off the Setting 15 bar pretension
truck. To check or set pretension, follow these steps:
1. Stop the truck engine. Plug the 0 - 40 bar gauge
into the (0 - 60 bar) pretension check port of the
Apitech handvalve (Figure 48).
revDate
226 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
CAUTION
Truck engine must be at idle to set
000439.eps
pretension. Gauge damage possible!
2. Start the truck engine, but leave it at an idle. Setting the agitator circuit pressure
(Pretension adjustment is made at an idle to The agitator relief valve is located in the agitator
establish the minimum pressure setting. As RPM is forward / neutral / reverse handvalve (Figure 49).
increased, pressure will rise. Damage to the 0 - 40 The relief valve (not completely visible in Figure 49)
bar gauge is possible if RPM is raised while the limits the pressure in the agitator circuit to 200 bar
gauge is connected.) (2900 PSI). There is a gauge port (not visible in Figure
3. If the pressure reads 15 bar 1 bar, the pressure is 49) for checking or setting the pressure in this circuit.
set correctly. If adjustment is needed, proceed to The port is located on the agitator handvalve. To check
the next step. If not skip to step (5). or set the agitator pressure, follow these steps:
4. Loosen the jam nut on the pretension valve. Turn 1. Unscrew the cover from the gauge port. Plug in the
the screw in to raise pressure and out to lower 0-600 bar gauge and whip hose that came in the
pressure. When the pressure is correct, retighten toolbox.
the jam nut. 2. Start the engine if its not already running.
5. Stop the engine, and remove the 0 - 40 bar gauge.
Pretension setting is complete.
15 bar pretension
adjustment screw
0-60 bar
gauge port
Figure 48
Pretension adjustment screw
and gauge port
pretnsn.eps
Pressure Settings
34manco3.eps
agitator
handvalve 10 9
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SLEWING
AIR / WATER
BOOM / OUTRIG.
DANGER WARNING
Electrocution hazard.
4 Stay back from high
Do not operate this
machine without
voltage wires at least training. Understand
17 feet (5 meters). the warnings in safety
1
manuals and on decals.
AGITATOR s
ep WARNING
dv.
forward/reverse agit
han Clear area
before activating
outriggers
CONCRETE PUMP
forward/reverse
200
100 300
Figure 49
bar 400
WIKA
Agitator handvalve
5. If adjustment is needed, put your wrench on the 6. Put the agitator handle in neutral.
body of the relief valve (Figure 49), which is 7. Remove the whip hose and pressure gauge.
located on the back of the agitator handvalve. Replace the gauge port cover.
While reading the gauge, turn the body in to raise
pressure or out to lower pressure until 200 bar is
achieved.
agitoff.eps
Setting accumulator circuit pressure To check or adjust the hydraulic pressure in the
You will need an assistant for parts of this procedure. accumulator circuit:
There are three relief settings for the accumulator 1. Stop the truck, put the key in your pocket, and
circuit. place a Do Not Operate sign on the windshield.
revDate
228 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
45Accreg.eps
newredun.eps
Figure 51 Figure 52
Accumulator pump pressure regulator for Accumulator redundant relief cartridge
A7VO (above) and for A11VO (below)
@@@@@@@@
;;;;;;;;
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
45acumpr.epsL
@@@@@@@@
;;;;;;;;
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
Figure 53
Accumulator circuit pressure gauge
Pressure Settings
8. After the truck engine is stopped, go back to the
accumulator circuit hydraulic pump pressure
regulator (Figure 51) and turn the screw back out
two-and-one-half turns. This restores it to its
accuman1.eps
original setting.
9. Clear all personnel from the drive line area, start
the truck, and bring the engine RPM up to
maximum.
10. Read the pressure on the accumulator gauge. It
should read the proper accumulator system
pressure.
11. If adjustment is needed, you must stop the truck
engine, or a least stop the drive lines from turning,
each and every time you approach the accumulator
Pressure Relief Cartridge circuit hydraulic pump. Turn the screw in to
Manual bleed valve increase the pressure or out to decrease pressure.
Lock the jam nut when the pressure is correct.
NOTE!
The accumulator circuit hydraulic pump
pressure regulator is sometimes referred to
as the pressure cut-off.
Figure 54
Accumulator manifold pressure
relief cartridge
WARNING
Entanglement hazard. Stop drive shafts
before adjusting the accumulator pump
000075.eps
pressure regulator.
revDate
230 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 36X-42M (pre-1998) As mentioned earlier before we check or adjusts
settings of the pressure limit valve or the two relief
valves, we must make sure the Delta-P and Q-
Pressure Settings for KVM 36X
minimum settings are correct.
Proportional Load Sensing
NOTE!
NOTE:All pressure settings must be done
when the hydraulic oil is at 50 to 70 degrees
Celsius.
Please read all instructions before attempting to check
or set pressures.
There is a pressure limit valve and two different relief
valves in the KVM 36X boom circuit. Before checking
or setting these 3 valves, you should make sure that the
Delta-P setting on the pressure regulator and the Q
minimum setting on the hydraulic pump are properly
set. In order to help you better understand this, we will
describe the functions of each valve and the hydraulic
pump before attempting to set or check pressures.
Refer to Illustration 1on Page- D2 for the location of
each item as it is mounted on the unit.
Figure 1 of this page, is called the pressure regulator.
Adjusting screw (item 4) is the pressure limit function
of the pressure regulator. Adjusting screw (item 3) is
the Delta-P function of the regulator. The Delta-P
function senses pressure on both sides of the boom
handvalve, and adjusts the output flow of the hydraulic
pump.
Figure 2 of this page is the "normally open" relief
valve. (Normally open denotes that unless the coil is
energized, the relief valve will not develop any
pressure). This is the valve that opens and vents your
boom circuit to tank when you hit the red emergency
shut off button on your remote control box or
operations panel.
Figure 3 of this page is the boom handvalve. (Item
10) is pointing to the relief valve located on the
handvalve. It's function is to protect the handvalves
from any pressure spikes that might be in the system.
(Item G2) is a gauge port.
Figure 4 of this page is the boom circuit hydraulic
pump. This style of hydraulic pump has a variable
output depending on the requirements of the boom,
which is controlled by the pressure regulator described
in Figure 1 (above).
Pressure Settings
Component Location Guide KVM 36 X W/
Rexroth Handvalves
1200 / 36 X
Illustration 1
item
4
item 3
FIGURE 1
item
2
item
STOP for Q min 1
FIGURE 4 FIGURE 2
item
10
24V
item
G2
24V
FIGURE 3
revDate
232 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Pressure Settings for KVM 36X 2. Q Minimum setting: the Q minimum stop on the
Proportional Load Sensing hydraulic pump, (Figure 4, item 1).
1. 1.Delta-P setting on the pressure regulator. With all boom functions in the neutral position,
(Figure 1, Item 3) emergency stop buttons up, the engine at
With all boom functions in the neutral position, maximum specified RPM's, the pressure on the
emergency stop buttons up, the engine at minimum main gauge (0-600 bar) should be:
RPM's (idle), the pressure that will be read on both
a) . . . KVM 32 & 36 = 40 Bar;
the pretension gauge and the main pressure gauge
b) . . . KVM 42 = 40-45 Bar;
is either Delta-P or an idle Q-minimum. To
determine what indeed is creating this pressure, we c) . . . KVM 52 = 50-55 Bar.
must do at least ONE of the three following If the pressure is incorrect, the Q-min. screw on the
procedures: hydraulic pump must be adjusted accordingly. Turn
a. A.Back off the Q-min. screw at least 3 turns on the Q-min screw inward to increase the pressure and
the hydraulic pump to insure that it is only outward to decrease the pressure.
producing the amount of flow that the regulator
is requiring to maintain Delta-P pressure. Now
read an accurate Delta-P pressure on either the
pretension gauge or the main pressure gauge.
This requires that the Q-min. be re-adjusted;
(refer to paragraph 2. for Q minimum setting).
b. B.While observing the pretension or the main
pressure gauge you increase the engine RPM
by 300 RPM in 3 increments of 100 RPM
each, making sure that the pressure does not
increase. This will assure that you are indeed
observing accurate Delta-P. If the pressure
does increase, then the pressure observed is an
idle Q-min. and not a true Delta-P. You should
then follow the procedures in paragraph 1. A.
c. C.Install a high pressure (0-600 Bar) gauge in
the X port of the regulator with a "T" fitting.
While operating a boom function, monitor the
pressure between the main pressure gauge and
the gauge at the X port of the regulator. There
should be exactly 20 Bar less pressure at the X
port continuously.
Adjusting Delta-P: The Delta-P pressure should be 20
Bar plus or minus 1 Bar; (this is the same for KVM 32,
KVM 36X, KVM 42 and KVM 52 machines). If the
Delta-P pressure is incorrect, then the regulator must
be adjusted accordingly. Turn the small screw (Figure
1, item 3) on the regulator inward to increase or
outward to decrease the Delta-P pressure. If the Delta-
P pressure cannot be adjusted to proper pressure, then
the regulator is probably defective. Do not replace the
regulator until the orifices in the base plate have been
checked to make sure they are not obstructed or
improperly sized. Refer to Figure 5 on Page - D4 for
proper orifice sizes.
Pressure Settings
Pressure Regulator Cutaway
Pressure
Regulator
P
Regulator
X
A T
P 0.8 mm
ORIFICE
KVM 36X . . . . 1.6 mm
KVM 36 LW . . 1.6 mm
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
Figure 205
revDate
234 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Pressure Settings for Regulator and Releif
Valves
Now that we know our delta-P and Q-minimum are set
correct we can check and reset the pressure limit and
two relief valves. The correct pressure settings are as
follows:
1. PRESSURE REGULATOR (Figure 1, item 4)310
Bar
2. NORMALLY OPEN BYPASS VALVE (Figure 2,
item 2)330 Bar
3. HANDVALVE RELIEF (Figure 3, item 10)340
Bar
In order to reset the valve with the highest pressure, we
must first raise the pressure of the other two valves.
a. A.Install a 0-600 Bar gauge in the gauge port
(Figure 3, item G2) of the handvalve.
b. B.To set the pressure regulator (Figure 1),
loosen the lock nut (Item 4), and turn the
adjusting screw inward approximately two
turns. This will raise the pressure of this valve
higher than 340 bar.
c. C.To set the normally open bypass valve
(Figure 2), loosen the lock nut (Item 2), and
turn the adjusting screw inward approximately
one turn. This will raise the pressure of this
valve higher than 340 bar.
d. D.Pressure out any boom section except main
down. The pressure can now be read on the 0-
600 Bar gauge that you have installed on the
handvalves. The gauge should read 340 Bar. If
it does not, adjust the relief valve on the boom
handvalves (Figure 3, item 10). After you
have this relief set to 340 Bar you can lock the
locknut and move on to the normally open
bypass valve.
e. E.While you continue to hold a function
pressured out you can adjust the normally open
bypass valve (Figure 2, item 2), until the
pressure gauge now reads 330 Bar. After this
pressure is set and the locknut is locked,
proceed to the pressure regulator.
f. F.While still holding a function pressured out
you can now adjust the pressure regulator (Fig.
1, Item 4), until the pressure gauge reads 310
Bar. When this pressure has been set and the
locknut is locked, you are finished setting the
main circuit pressures on the boom.
236
Handvalve
PRINT
5 3 1 1 1 1
24V
3 - SWING RIGHT SPEED
Service Manual
7 - OUTRIGGER SPEED 10 10
8 - PRETENTION VALVE
24V
9 - PRETENTION RELIEF G2
revDate
HOME PRINT
SERVICE TRAINING
Pressure Settings
Pressure Settings for KVM 42 (B&W Load
sensing and Proportional Load Sensing
NOTE!
NOTE:All pressure settings must be done
when the hydraulic oil is at 50 to 70 degrees
Celsius.
Please read all instructions before attempting to check
or set pressures.
There is a pressure limit valve and two different relief
valves in the KVM 42 boom circuit. Before checking
or setting these 3 valves, you should make sure that the
Delta-P setting on the pressure regulator and the Q
minimum setting on the hydraulic pump are properly
set. In order to help you better understand this, we will
describe the functions of each valve and the hydraulic
pump before attempting to set or check pressures.
Refer to Illustration 2 on Page- D8 for the location of
each item as it is mounted on the unit.
Figure 1 of this page, is called the pressure regulator.
Adjusting screw (item 4) is the pressure limit function
of the pressure regulator. Adjusting screw (item 3) is
the Delta-P function of the regulator. The Delta-P
function senses pressure on both sides of the boom
handvalve, and adjusts the output flow of the hydraulic
pump.
Figure 2 of this page is the "normally open" relief
valve. (Normally open denotes that unless the coil is
energized, the relief valve will not develop any
pressure). This is the valve that opens and vents your
boom circuit to tank when you hit the red emergency
shut off button on your remote control box or
operations panel.
Figure 3 of this page is the boom handvalve. (Item 9)
designates the main pressure relief valve located on the
handvalve. It's function is to protect the handvalves
from any pressure spikes that might be in the system.
(Item 11) designates the relief valve for the main
section down.
Figure 4 of this page is the boom circuit hydraulic
pump. This style of hydraulic pump has a variable
output depending on the requirements of the boom,
which is controlled by the pressure regulator described
in Figure 1 (above).
As mentioned earlier before we check or adjusts
settings of the pressure limit valve or the two relief
valves, we must make sure the Delta-P and Q-
minimum settings are correct.
Pressure Settings
Component Location Guide KVM 42 W/
Rexroth Handvalves
Illustration 2
item
4
item 3
FIGURE 1
item
2
item
STOP for Q min 1
FIGURE 4 FIGURE 2
item 11
item 9
FIGURE 3
revDate
238 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Pressure Settings for KVM 42LW 2. Q Minimum setting: the Q minimum stop on the
Proportional Load Sensing hydraulic pump, (Figure 4, item 1).
1. Delta-P setting on the pressure regulator. (Figure With all boom functions in the neutral position,
1, Item 3) emergency stop buttons up, the engine at
With all boom functions in the neutral position, maximum specified RPM's, the pressure on the
emergency stop buttons up, the engine at minimum main gauge (0-600 bar) should be:
RPM's (idle), the pressure that will be read on both
a) . . . KVM 32 & 36 = 40 Bar;
the pretension gauge and the main pressure gauge
b) . . . KVM 42 = 40-45 Bar;
is either Delta-P or an idle Q-minimum. To
determine what indeed is creating this pressure, we c) . . . KVM 52 = 50-55 Bar.
must do at least ONE of the three following If the pressure is incorrect, the Q-min. screw on the
procedures: hydraulic pump must be adjusted accordingly. Turn
a. A.Back off the Q-min. screw at least 3 turns on the Q-min screw inward to increase the pressure and
the hydraulic pump to insure that it is only outward to decrease the pressure.
producing the amount of flow that the regulator
is requiring to maintain Delta-P pressure. Now
read an accurate Delta-P pressure on either the
pretension gauge or the main pressure gauge.
This requires that the Q-min. be re-adjusted;
(refer to paragraph 2. for Q minimum setting).
b. B.While observing the pretension or the main
pressure gauge you increase the engine RPM
by 300 RPM in 3 increments of 100 RPM
each, making sure that the pressure does not
increase. This will assure that you are indeed
observing accurate Delta-P. If the pressure
does increase, then the pressure observed is an
idle Q-min. and not a true Delta-P. You should
then follow the procedures in paragraph 1. A.
c. C.Install a high pressure (0-600 Bar) gauge in
the X port of the regulator with a "T" fitting.
While operating a boom function, monitor the
pressure between the main pressure gauge and
the gauge at the X port of the regulator. There
should be exactly 20 Bar less pressure at the X
port continuously.
Adjusting Delta-P: The Delta-P pressure should be 20
Bar plus or minus 1 Bar; (this is the same for KVM 32,
KVM 36X, KVM 42 and KVM 52 machines). If the
Delta-P pressure is incorrect, then the regulator must
be adjusted accordingly. Turn the small screw (Figure
1, item 3) on the regulator inward to increase or
outward to decrease the Delta-P pressure. If the Delta-
P pressure cannot be adjusted to proper pressure, then
the regulator is probably defective. Do not replace the
regulator until the orifices in the base plate have been
checked to make sure they are not obstructed or
improperly sized. Refer to Figure 5 on Page - D10 for
proper orifice sizes.
Pressure Settings
Pressure Regulator Cutaway
Pressure
Regulator
P
Regulator
X
A T
P 0.8 mm
ORIFICE
KVM 36X . . . . 1.6 mm
KVM 36 LW . . 1.6 mm
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
Figure 206
Regulator Valve
revDate
240 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Pressure Settings for Regulator and Relief e. While still holding a function pressured out
Valves KVM 42 you can now adjust the pressure regulator
(Figure 1, Item 4), until the pressure gauge
Now that we know our delta-P and Q-minimum are set
reads 310 Bar on Black & White units or 290
correct we can check and reset the pressure limit and
Bar on Proportional units. When this pressure
two relief valves. The correct pressure settings are as
has been set and the locknut is locked, you are
follows:
finished setting the main circuit pressures on
1) PRESSURE REGULATOR (Figure the boom.
1, item 4): f. There is also a relief valve for the main boom
down function (Figure 3, item 11); (this relief
KVM 42 B&W 310 Bar valve is either located in the handvalve housing
KVM 42 Prop. 290 Bar directly in front of the manual hand lever for
the main section), or: (is Td into the steel tube
2) NORMALLY OPEN BYPASS VALVE that comes out of the "A" port on the frontside
(Figure 3, item 2): of the main section handvalve). Before setting
All 42 Meters 320 Bar the downside relief valve, you must bring the
boom to its fully retracted position. This is
3) HANDVALVE HIGH PRESSURE best accomplished with the boom swung off to
RELIEF (Figure 3, item 9): the side of the truck with the outriggers fully
extended. While holding the main section
All 42 Meters 330 Bar
pressured out in the fully retracted position,
you can now adjust the downside relief
In order to reset the valve with the highest pressure, we cartridge until you read 100 Bar on the 0-600
must first raise the pressure of the other two valves. Bar gauge.
242
KVM 42LW BOOM HANDVALVE
(Waterpump/Compressor,Throttle, & Outrigger)
PRINT
24V
Service Manual
7
O-ring O-ring
8 8
10
Filter Orifice
24V
2 2 2 2 4 6
revDate
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 36X 1. Locate the agitator shutoff valve, and close it
(Figure 10). The general location of the agitator
Check all hydraulic pressures shutoff valve is shown in Figure 93.
Pressure Settings
The general location of the components used to
check or set hydraulic pressures in shown in Fig-
ure 93.
36Xdside.eps
Boom (Section #1) Down
Pressure Relief Valve and Boom Hand Valves and
Gauge Port Gauge Port
Figure 11
General location of components
used to set hydraulic pressures
Set the concrete pump main relief valve valve is located at the front of the control block
(single- circuit) (towards the truck cab). To check or set the main relief
pressure perform the following steps:
The BPL 1200 concrete pump is designed to operated
at a maximum pressure of 300 bar (4350 PSI). It is
controlled by the main relief valve (Figure 79), which
revDate
244 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
grooves2.eps
Lower Raise
pressure pressure
gray valve.eps L
Figure 12
Concrete pump main relief valve
Pressure Settings
with the shutoff valve closed. 7. Read the pressure on the concrete pump pressure
gauge located on the main control block. It should
NOTE!
read 350 bar. Position the concrete pump switch to
If you cannot adjust the pressure up to 300
the off (neutral) position. If no adjustment is
bar, you have a problem. In this case, turn
needed, skip to Step 11.
the adjustment knob out by several turns so
that your pressure isnt too high once the 8. If adjustment is needed, use a 9/16 inch spanner
problem is found. Contact Schwing Amer- wrench, loosen the jam nut on the main relief valve
icas Service Department for advice on how adjusting screw (Figure 5).
to continue. 9. Insert a 5/32 inch allen wrench in the adjustment
Set the concrete pump main relief valve (twin screw. Turn the screw in to raise pressure or out to
circuit) lower the pressure.
10. Once the pressure is correct (350) bar retighten the
The main relief valve is the primary pressure control
jam nut. Tightening the nut tends to raise the
device on units equipped with Rexroth A7VO
pressure, so check pressure again after tightening.
hydraulic pumps. This pump is designed to operate at a
Verify the correct pressure setting (350 bar).
maximum pressure of 350 bar (5075 PSI).
11. Open the concrete pump shutoff and soft switch
valves. The unit will not stroke with theses valves
closed.
WARNING
Hot oil expulsion hazard. stand away
from pumpkit when checking hydraulic
pressures.
W008.eps
Gauge port
39
hif
lw1
.ep
s
Soft switch
relief valve
grooves2.eps
Figure 14
Location of the main relief valve
Setting the soft switch circuit relief 2. High pressure the concrete pump. The pressure
pressure gauge should read 60 or 80 bar (check your
schematic). If no adjustment is needed, skip to Step
To check or adjust the soft switch pressure setting,
4.
proceed as follows:
3. If adjustment is needed, loosen the jam nut on the
1. Close the concrete pump shutoff valve. Open the
soft switch relief valve with a 9/16 inch spanner
soft switch shutoff valve. The rest of the unit
wrench. Adjust the pressure up or down, as needed,
should still be set up as though you were going to
using a 5/32 inch Allen wrench. When the correct
check concrete pump pressure.
pressure is achieved, re-lock the jam nut.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 247
HOME PRINT
Pressure Settings
4. Be sure to open the concrete pump shutoff valve
when you are finished. The unit cannot stroke with
e-stop/right.epsL
this valve closed.
Relief Valve and
Gauge Port
Set accumulator circuit
Units with a pressure- compensated pump
You will need an assistant for parts of this procedure.
To check or adjust the hydraulic pressure in the
accumulator circuit, perform the following steps:
1. Stop the truck, put the key in your pocket, and
place a Do Not Operate sign on the windshield.
2. Loosen the jam nut on the pressure regulator of the
accumulator hydraulic pump. Turn the screw in
two-and-a-half turns. This will raise the regulator
pressure above 300 bar (Figure 83).
. Figure 16
revDate
248 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting the outrigger pressure
SAFETY INSTRUCTIONS
Accumulator Safety Rules
2. Always relieve the
the system is relieved
of oil pressure.
1. Never assume that hydraulic system of pressure before
dis-assembly for clean
out, repair, or maintenance.
WARNING
Stored hydraulic energy.
With a seven place hand valve, the boom/outrigger
circuit pressure gauge
to verify zero
Release all hydraulic
36accum.eps
Lower
Figure 17 Turn body of valve
Accumulator manifold pressure relief Higher
to adjust.
valve
8. You will need an assistant for this step. With the 280 bar
engine still running, adjust the relief valve of the E-
Stop manifold. Back out the adjustment screw Relief Valve
until pressure reads 260 bar (3770 PSI) on the
gauge connected to the E-Stop manifold.
WARNING
Entanglement hazard. Stop drive shafts
before adjusting the accumulator pump
pressure regulator.
W010.eps
Figure 18
Outrigger hand valve
9. After the truck engine is stopped, back out the
accumulator circuit hydraulic pump pressure regu-
lator two-and-a-half-turns. This restores the pres-
sure regulator to its original setting (Figure 83). 1. Connect the whip hose of a 0400 or 0600 bar to
10. Clear all personnel from the drive line area, start the gauge port on the right side of the outrigger
the truck, and rev the engine RPM to maximum. hand valve.
11. Read the pressure on the accumulator gauge. It 2. If it is not already done, start the truck engine and
should read 200 bar (2900 PSI). set the transmission and PTO as you would for a
pumping job.
12. If additional adjustment is needed, you must stop
the truck engine each time you approach the accu- 3. Set the engine RPM to maximum.
mulator circuit hydraulic pump (Figure 83). Adjust 4. Push the outrigger enable pushbutton located next
the accumulator pump pressure regulator screw in to the outrigger hand valve (passenger side). Hold
to increase pressure or out to decrease pressure. one of the outrigger hand valve levers in the
Lock the jam nut when pressure is correct (200 jacking-retract position. The oil coming from the
bar). pump has nowhere to go but over the outrigger
relief valve.
NOTE!
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 249
HOME PRINT
Pressure Settings
You cannot use the extend position for this boom hydraulic pressures is shown in Figure 19.
adjustment because extend has a nonadjust-
NOTE!
able secondary relief functions built into the
Do not adjust P or Q-min if your boom is
valve.
running as you like it. The pressure setting
5. Turn the outside body of the relief valve that is procedure uses a standard starting point
located at the back of the passenger side outrigger and must be fine tuned from there. It was
hand valve (Figure 102). Turn in to raise pressure fine tuned at the factory and should not be
or turn out to lower pressure. adjusted unless absolutely necessary.
6. When the pressure on the gauge connected to the
outrigger hand valve is 280-bar, release the enable
push button and the outrigger hand valve.
7. Remove the whip hose and gauge from the
WARNING
outrigger handvalve, and replace the cap on the
Entanglement hazard. Stop drive shafts
gauge port before adjusting Q-min.
W009.eps
Pressure reducing valve
This valve is preset at the factory. Contact Schwing
Americas Service Department at (651) 429-0999 for
information on checking or setting this valve. Each time the Q-min screw must be
adjusted, the engine must be stopped, or at
Electric stroke limiter
least the transmission must be taken out of
This valve is preset at the factory. Contact Schwing gear so that the drivelines stop turning.
Americas Service Department at (651) 429-0999 for
information on checking or setting this valve
Load-sensing boom pressures (7 place
proportional circuit)
If your unit has a load-sensing proportional system, it
will have different pressure adjustments than if it is
equipped with a black and white boom system. The
following instructions are for load-sensing proportional
systems. If you have a unit equipped with a black and
white boom system, contact Schwing Service
Department for the correct instruction pages.
In a black and white boom system, the hydraulic pump
puts out an unchanging amount of oil, and speed
control is done by restricting the oil to 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 a 20 bar higher pressure at the pump than
what the cylinders actually require. This 20 bar is
called delta P (P). Additionally, we set the hydraulic
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
to ensure that you have control when you need it. The
setting to maintain this minimum amount of oil is
called Q-min (pronounced cue min). To set the boom
or outrigger hydraulic pressures on a load-sensing
system, begin by setting Q-min and P.
The general locations of the components used to set
revDate
250 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
36Xdside.eps
Figure 19
Location of components used to
check or set boom pressures
0-400 bar
gauge port
0-60 bar
gauge port
boom control
block relief valve
s
ep
dv.
itpr
ap
36
15 bar pretension
adjustment screw
Figure 20
Boom hand valves
Pressure Settings
Check or set P Remove the gauge, and adjust P until the boom is
To check or set P follow these steps: responsive and smooth. When done, the gauge
(reinstalled) must read between 14 and 25 bar. The
1. Stop the truck engine, and place a Do Not electronics in the control system can also affect how
Operate sign on the truck windshield. the boom operates, so if P adjustment does not seem
2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar to help, reset to 20 bar and check the electrical settings.
gauge port of the manual boom handvalves. Take Once electrical settings are verified, you could again
care not to accidently install the gauge in the 0-60 refine the boom action with the P adjustment.
bar port (Figure 20). CAUTION! Do not operate any functions while
3. To be sure that the pump is putting out only enough setting P.
oil needed to maintain P, we need to change the
setting of the Q-min screw. Q-min is adjusted by a
screw on the boom hydraulic pump (Figure 21).
Unscrew the Q-min screw three full turns. Check
deltaPvlv.eps
that all personnel are clear of the truck, then restart
the engine, engage the pumps, and leave the engine
at an idle. CAUTION! If you activate any boom P adjust
T
or outrigger functions, you will damage the 0 - screw
40 bar gauge. Make sure that all emergency stop
switches are in the up (not activated) position. Figure 22
Pressure can be read on the 0 - 40 bar gauge that P regulator valve
you installed. Pressure should read 20 bar. If no Check or set Q-min
adjustment is needed, simply reset the Q-min
screw as described in the Check or set Q-min steps. You must check Q-min pressure when the engine is at
If adjustment is needed, continue to Step 4. the maximum specified RPM, but you must adjust it
with the engine stopped. To check or set the Q-min
follow these steps:
Q-min
adjustment screw 1. If you unscrewed the Q-min screw as the first step
of P adjustment, begin by returning the screw to
its original position (Figure 21).
2. Remove the 0 - 40 bar gauge from the 0 - 400 bar
gauge port, and install the 0 - 600 bar gauge in its
place (Figure 20).
3. Clear all personnel away from the drive lines, start
Q-minscrew.eps
the truck engine, engage the pumps, and bring
Q-max engine RPM to max. All boom functions must be
in neutral, and all emergency stop buttons
should be up (not engaged).
Figure 21
Q-min adjust screw 4. Read the pressure on the 0 - 600 gauge. Pressure
should be at 40 - 45 bar. If no adjustment is needed,
4. Delta P is adjusted by the P screw on the P stop the drive lines from turning, be sure the jam
regulator (Figure 22). Loosen the jam nut, and nut on the Q-min screw is tight, then continue to
adjust the screw inward to increase pressure or Set boom pressures to check the rest of the boom
outward to decrease pressure until it is set at 20 bar pressures.
(1). Contact Schwing Americas Service 5. If adjustment is needed, turn the Q-min screw in to
Department if you are unable to adjust the pressure raise the pressure (Figure 21). Turn it out to lower
to specification. the pressure. Be sure that you stop the drive shafts
from turning each time before making the
NOTE! adjustment. When pressure is correct, tighten the
If the boom does not operate smoothly at 20 jam nut on the adjustment screw before continuing
bar, you must fine tune the adjustment. with the other procedures.
revDate
252 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Set boom pressures
(load sensing proportional booms)
Now that P and Q-min are set, you can check or set
the boom valve pressures.There are three pressure
settings on the boom circuit (Figure 23).
1. Pressure regulator (the high-pressure adjustment
screw on the P regulator valve), set at 290 bar 0-400 bar
(4205 PSI). gauge port
2. The redundant relief valve located in the 0-60 bar
gauge port
emergency stop manifold, set at 320 bar (4640
PSI). boom control
3. The boom control block relief valve, set at 350 bar block relief valve
(5075 PSI). Bo
om
Va
.eps
36
e-stop/right.epsL
E-Stop Manifold
Redundant Relief Valve
Figure 23
Boom hydraulic pressure adjustment
components
Pressure Settings
two: pressurized function and lock the jam nut. The
1. Loosen the jam nut of the high pressure adjustment boom pressures are now set. If you did not get the
screw of the P regulator. Turn the screw in two- readings specified after following the instructions,
and-a-half turns. This will raise the pressure on the contact Schwing Americas Service Department at
P regulator above 350 bar. (651) 429-0999 for advice on how to continue.
2. Loosen the jam nut of the adjustment screw on the
E-stop manifold redundant relief valve. Turn the
screw in one-and-a-half turns. This will raise the
pressure setting of the relief valve to above 350 bar.
3. Pressure out any boom cylinder except #1 down by
pushing or pulling the control handle. To pressure
out a cylinder, retract a fully retracted cylinder or
extend a fully extended cylinder. The oil is forced
over the relief valve.
4. The tell tale hiss of an open relief valve should be
coming from the Apitech control block relief valve
now. If it isnt, raise the setting of the other
pressure devices until the hiss originates at the
Apitech control block relief valve. Read the
pressure on the gauge connected to the 0-400 bar
gauge port on the boom hand valve block. It should
read 350 bar. If pressure is correct, proceed to Step
5.
NOTE!
Although the pressure specification for the
Apitech relief valve is 350 bar, you may con-
tinue to use the relief valve as long as the
cartridge maintains at least 330 bar. If you
must replace the valve, proceed to Step 5
before using the concrete pump again, and
redo this entire procedure when you have
installed the new valve. If pressure on the
Apitech relief valve is below 290 bar, you
should not use the concrete pump until the
valve is replaced.
5. Screw out the E-Stop manifold redundant relief
valve adjustment screw one-and-a-half turns.
Pressure out any boom cylinder except #1 down,
and read the gauge. Pressure should read 320 bar.
If it does not, turn the screw in to raise pressure or
out to lower pressure until it is set at 320 bar. If the
location of this valve causes you to be near the
drive lines, be sure to stop them from turning
before accessing the valve.
6. You will need a helper for this step. While
pressuring out any boom cylinder (except #1
down) have your helper adjust the high pressure
screw of the P regulator out (lowering the
pressure) until the gauge reads 290 bar. Release the
revDate
254 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
0-400 bar
gauge port
0-60 bar
gauge port
boom control
block relief valve
s
ep
dv.
itpr
ap
36
15 bar pretension
adjustment screw
Figure 24
Pretension adjustment screw
and gauge port
Set 15 bar pretension valve is inside the boom control block. There is not a
To check or set pretension, follow these steps: separate relief valve for this circuit and, therefore,
nothing that must be set.
1. Stop the truck engine. Plug the 0 - 40 bar gauge
into the 0-60 bar gauge port of the Apitech hand Set water pump pressure
valve (Figure 24).
With a seven place hand valve, the water pump
2. Start the truck engine, but leave it at an idle.
hydraulic control is inside the boom control block.
(Pretension adjustment is made at an idle to
There is not a separate relief valve for this circuit and,
establish the minimum pressure setting. As RPM is
therefore nothing that must be set.
increased, pressure will rise. Read the pressure on
the gauge. If it reads 15 bar 1 bar, the pressure is
Set the agitator pressure
set correctly.
The agitator circuit has a maximum pressure of 200 bar
NOTE! (2900 PSI), limited by the relief valve located in the
Damage to the 0 - 40 bar gauge is possible if agitator hand valve (Figure 117). The gauge port for
RPM is raised while the gauge is connected. checking or setting the agitator pressure is located on
3. If adjustment is needed, loosen the jam nut on the the agitator hand valve.
pretension valve (Figure 24). Turn the screw in to
raise pressure and out to lower pressure. When the
pressure is correct, retighten the jam nut.
4. Stop the engine, and remove the 0 - 40 bar gauge.
#1 boom down - brake valve
With a seven place hand valve, the #1 down brake -
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 255
HOME PRINT
Pressure Settings
AgitHdVl.eps
All of these fittings and many, many more
extremely useful items are included in the
Troubleshooting Kit, part number 30308553. We
highly recommend purchase of this kit. It will pay
for itself many times over. You will need:
Relief Valve - Qty 2 VS-16S locking plugs, part number
10016803
- Qty 1 GS-16S straight fitting, part number
10008088
- Qty 2 16S capnuts, part number 10001743
6. Be sure that one of the locking plugs and capnuts
Gauge Port are tightened on the straight fitting and that the
dead plugs are securely tightened to the hose and
the open motor fitting.
7. Locate the relief valve on the agitator hand valve.
8. Be sure that all personnel are clear, and restart the
engine.
9. Activate the agitator hand valve by pushing or
Figure 25 pulling the handle. This will send the oil against
Agitator hand valve the high pressure plug. The oil will have nowhere
to go, so it will return to the tank over the relief
1. Stop the unit, and put the key in your pocket.
valve in the agitator hand valve. The pressure at
2. Connect the whip hose of 0-400 or a 0600-bar which it relieves can be seen on the gauge. It
gauge to the gauge port on the agitator hand valve should read 200-bar.
(Figure 117).
10. If adjustment is needed, turn the outside body of
3. If your unit is equipped with an the relief valve that is located at the back of the
4. agitator shut off valve, close it (Figure 20). Skip to agitator hand valve. Turn in to raise pressure or
Step 6. turn out to lower pressure.
11. When the pressure is set at 200-bar, stop the engine
52qrttrn.epsL and remove the key. Open the shut off valve or
remove the dead plugs and store them in a clean
Closed
area or in a plastic bag or something similar to
keep dirt from entering the fittings. Reattach the
hose to the agitator motor fitting and tighten
securely. (Torque is correct if you make one
complete revolution after feeling initial resistance
Shown in the increase.)
open position 12. Remove the whip hose and pressure gauge.
Replace the gauge port cover.
Figure 26
Agitator shutoff valve
5. If your unit is not equipped with an agitator shut
off valve, remove one of the hoses from the
agitator motor and plug the hose and the open
fitting with approved hydraulic dead plugs. Do not
improvise on these plugs. If you dont have any,
contact the Schwings Spare Parts Department and
order them before continuing with this procedure.
revDate
256 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 39X
52qrttrn.epsL
Closed
Check all hydraulic pressures
Check all hydraulic pressures. Changes in pressures
can indicate trouble in one or more components.
NOTE!
Hydraulic pressure settings shown in the
following procedures are for a 2023 twin
circuit pump kit. However, because Shown in the
different pump kits may be used in this unit, open position
all pressure settings should be verified with
the pressure settings shown on the Figure 27
applicable hydraulic schematic. The Agitator shutoff valve
hydraulic schematics for your pump kit are
in the Appendix of this manual.
Read all of the instructions before beginning any
pressure settings. You will need an assistant for parts of
the procedure.
You and any assistants should wear eye protection
when checking or setting pressures.
Be sure that the waterbox covers are installed on the
waterbox.
We do not recommend using the remote control box for
the following procedures.
Wear safety glasses when setting pressures.
Position the remote/local switch on the rear control
panel to the local position.
Pressure settings must be made with the oil at normal
operating temperatures (40C 60C). The agitator
circuit must be used to heat the hydraulic oil. Do not
jam the paddles to force the oil over relief by stopping
the movement of the agitator. To preheat the hydraulic
oil using the agitator circuit, follow these instructions.
1. Locate the agitator shutoff valve, and close it
(Figure 10). The general location of the agitator
shutoff valve is shown in Figure 93.
2. Position the agitator lever in the forward or reverse
position. The agitator will not be able to turn, and
the oil will be forced over the relief valve.
3. At idle speed (about 600 RPM), about 4.5
horsepower is being converted to heat. Position the
agitator lever to the off (center) position when the
temperature gauge on the rear control panel
indicates 50C.
4. Open the agitator shutoff valve or remove the plug,
and reconnect the hose to the agitator motor.
Pressure Settings
The general location of the components used to 61/58 meter. . . . . . . . . . . . . . . . . . . . . . . 30365860
check or set hydraulic pressures is shown in Figure 52 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30354732
93. 45/47 meter. . . . . . . . . . . . . . . . . . . . . . . 30356770
If you wish to order a CD ROM which explains the 42 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30355485
pressure setting procedure for a specific model (All 39 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30365861
pumpkits), call SAI Spare Parts Department at (800) 34 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30356772
328 - 9635 and request the CD using the following part 32 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30355486
numbers:
31 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30365862
39Xtop.eps
Hydraulic Controls
Enclosure
Boom Hand Valves
Soft Switch Shutoff Valve and Gauge Port
(twin circuit) Forward/Reverse
Hand Valve
Agitator Hand
Valve and Gauge
Port
Main Relief Valve E-Stop Manifold
Soft Switch Relief Valve and Gauge port
Pilot Air Regulator
Concrete Pump Shutoff Stroke Limiter
Valve
Figure 28
General location of components
used to set hydraulic pressures
revDate
258 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Set the concrete pump main relief valve 9. Insert a 5/32 inch allen wrench in the adjustment
(twin circuit) screw. Turn the screw in to raise pressure or out to
lower the pressure.
The main relief valve is the primary pressure control
device on units equipped with Rexroth A7VO 10. Once the pressure is correct (350 bar) retighten the
hydraulic pumps. This pump is designed to operate at a jam nut. Tightening the nut tends to raise the
maximum pressure of 350 bar (5075 PSI). pressure, so check pressure again after tightening.
Verify the correct pressure setting (350 bar).
11. Open the concrete pump shutoff valve and soft
WARNING switch shutoff valve. The unit will not stroke with
these valves closed.
Hot oil expulsion hazard. Stand away
from pumpkit when checking hydraulic
pressures.
W008.eps
Pressure Settings
w
Gauge port
39
hif
lw1
.ep
s
Soft switch
relief valve
grooves2.eps
Figure 29
Location of the main relief valve
Setting the soft switch circuit relief bar (check your schematic). If no adjustment is
pressure needed, skip to Step 4.
To check or adjust the soft switch pressure setting, 3. If adjustment is needed, loosen the jam nut on the
proceed as follows: soft switch relief valve with a 9/16 inch spanner
wrench. Adjust the pressure up or down, as needed,
1. Close the concrete pump shutoff valve. Open the
using a 5/32 inch Allen wrench. When the correct
soft switch shutoff valve. The rest of the unit
pressure is achieved, re-lock the jam nut.
should still be set up as though you were going to
check concrete pump pressure. 4. Be sure to open the concrete pump shutoff valve
when you are finished. The unit cannot stroke with
2. Increase the engine RPM to high pressure the
this valve closed.
concrete pump. The pressure gauge should read 80
revDate
260 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Set accumulator circuit .
e-stop/right.epsL
Figure 32
E-Stop manifold relief valve,
accumulator circuit (original
production)
5. Clear all personnel away from the drive lines, start
the truck engine, engage the pumps, and bring the
engine RPM to maximum.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 261
HOME PRINT
Pressure Settings
6. Read the pressure on the accumulator circuit gauge 11. Read the pressure on the accumulator gauge. It
located below the rear control panel. Pressure should read 200 bar (2900 PSI).
should read 300 bar (4350 PSI). If no adjustment is 12. If additional adjustment is needed, you must stop
needed, skip to Step 8. the truck engine each time you approach the accu-
7. If additional pressure adjustment is needed, locate mulator circuit hydraulic pump (Figure 83). Adjust
the accumulator manifold pressure relief valve the accumulator pump pressure regulator screw in
(Figure 85). Loosen the jam nut, and turn the screw to increase pressure or out to decrease pressure.
in to increase pressure or out to decrease pressure. Lock the jam nut when pressure is correct (200
Tighten the jam nut when pressure is at 300 bar. bar).
45s3blck.epsL
Set the outrigger pressure
With a seven place hand valve, the boom/outrigger
selector valve is inside the boom control block. This
valve is activated when the outrigger enable push
button is pushed. There is not a separate relief for this
circuit and, therefore, nothing that must be set.
The outrigger circuit is set to a maximum of 280-bar
(4060 PSI) by the relief valve located on the passenger
side outrigger hand valve assembly (Figure 102). The
valve routes the oil to the two outrigger hand valve
banks, one on each side of the unit. A relief valve
inside the passenger side bank limits the entire
Relief Valve
outrigger circuit to 280-bar.
Figure 33 Lower
Accumulator manifold pressure relief Turn body of valve
Higher
valve to adjust.
WARNING
Entanglement hazard. Stop drive shafts
before adjusting the accumulator pump
Figure 34
pressure regulator.
W010.eps
W026.eps
cylinder.
puts out an unchanging amount of oil, and speed
control is done by restricting the oil to certain functions
1. Connect the whip hose of a 0400 or 0600 bar to with orifices. In a load-sensing system, the pump puts
the gauge port on the right side of the outrigger out more or less oil to respond to the needs of the
hand valve. system. Generally, the pump puts out enough oil to
2. If it is not already done, start the truck engine and maintain a 20 bar higher pressure at the pump than
set the transmission and PTO as you would for a what the cylinders actually require. This 20 bar is
pumping job. called delta P (P). Additionally, we set the hydraulic
3. Set the engine RPM to maximum. 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
4. Push the outrigger enable pushbutton located next
to ensure that you have control when you need it. The
to the outrigger hand valve (passenger side). Hold
setting to maintain this minimum amount of oil is
one of the outrigger hand valve levers in the
called Q-min (pronounced cue min). To set the boom
jacking-retract position. The oil coming from the
or outrigger hydraulic pressures on a load-sensing
pump has nowhere to go but over the outrigger
system, begin by setting Q-min and P.
relief valve.
The general locations of the components used to set
NOTE! boom hydraulic pressures is shown in Figure 19.
You cannot use the extend position for this
adjustment because extend has NOTE!
nonadjustable secondary relief functions Do not adjust P or Q-min if your boom is
built into the valve. running as you like it. The pressure setting
procedure uses a standard starting point
5. Turn the outside body of the relief valve that is
and must be fine tuned from there. It was
located at the back of the passenger side outrigger
fine tuned at the factory and should not be
hand valve (Figure 102). Turn in to raise pressure
adjusted unless absolutely necessary.
or turn out to lower pressure.
6. When the pressure on the gauge connected to the
outrigger hand valve is 280-bar, release the enable WARNING
push button and the outrigger hand valve.
7. Remove the whip hose and gauge from the Entanglement hazard. Stop drive shafts
outrigger handvalve, and replace the cap on the before adjusting Q-min.
W009.eps
gauge port.
Pressure reducing valve Each time the Q-min screw must be
This valve is preset at the factory. Contact Schwing adjusted, the engine must be stopped, or at
Americas Service Department at (651) 429-0999 for least the transmission must be taken out of
information on checking or setting this valve. gear so that the drivelines stop turning.
Electric stroke limiter
The stroke limiter valve is preset at the factory. Contact
Schwing Americas Service Department at (651) 429-
0999 for information on checking or setting this valve.
Load-sensing boom pressures (7 place propor-
tional circuit)
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 263
HOME PRINT
Pressure Settings
39Xtop.eps
Figure 35
Location of components used to
check or set boom pressures
0-400 bar
gauge port
0-60 bar
gauge port
boom control
block relief valve
s
.ep
rdv
a pitp
36
15 bar pretension
adjustment screw
Figure 36
Boom hand valves
revDate
264 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Check or set P bar, you must fine tune the adjustment.
To check or set P follow these steps: Remove the gauge, and adjust P until the boom is
1. Stop the truck engine, and place a Do Not responsive and smooth. When done, the gauge
Operate sign on the truck windshield. (reinstalled) must read between 14 and 25 bar. The
electronics in the control system can also affect how
2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar
the boom operates, so if P adjustment does not seem
gauge port of the manual boom handvalves. Take
to help, reset to 20 bar and check the electrical settings.
care not to accidently install the gauge in the 0-60
Once electrical settings are verified, you could again
bar port (Figure 20).
refine the boom action with the P adjustment.
3. To be sure that the pump is putting out only enough CAUTION! Do not operate any functions while
oil needed to maintain P, we need to change the setting P.
setting of the Q-min screw. Q-min is adjusted by a
screw on the boom hydraulic pump (Figure 21).
Unscrew the Q-min screw three full turns. Check
that all personnel are clear of the truck, then restart
deltaPvlv.eps
the engine, engage the pumps, and leave the engine
at an idle. CAUTION! If you activate any boom
or outrigger functions, you will damage the 0 - P adjust
T
40 bar gauge. Make sure that all emergency stop screw
switches are in the up (not activated) position.
Pressure can be read on the 0 - 40 bar gauge that Figure 38
you installed. Pressure should read 20 bar. If no P regulator valve
adjustment is needed, simply reset the Q-min
screw as described in the Check or set Q-min steps.
Check or set Q-min
If adjustment is needed, continue to Step 4.
You must check Q-min pressure when the engine is at
Q-min the maximum specified RPM, but you must adjust it
adjustment screw with the engine stopped. To check or set the Q-min
follow these steps:
1. If you unscrewed the Q-min screw as the first step
of P adjustment, begin by returning the screw to
its original position (Figure 21).
2. Remove the 0 - 40 bar gauge from the 0 - 400 bar
gauge port, and install the 0 - 600 bar gauge in its
Q-minscrew.eps
place (Figure 20).
Q-max 3. Clear all personnel away from the drive lines, start
the truck engine, engage the pumps, and bring
Figure 37 engine RPM to max. All boom functions must be
Q-min adjust screw in neutral, and all emergency stop buttons must
be up (not engaged).
4. Read the pressure on the 0 - 600 gauge. Pressure
4. Delta P is adjusted by the P screw on the P should be at 40 - 45 bar. If no adjustment is needed,
regulator (Figure 22). Loosen the jam nut, and stop the drive lines from turning, be sure the jam
adjust the screw inward to increase pressure or nut on the Q-min screw is tight, then continue to
outward to decrease pressure until it is set at 20 bar Set boom pressures to check the rest of the boom
(1). Contact Schwing Americas Service pressures.
Department if you are unable to adjust the pressure 5. If adjustment is needed, turn the Q-min screw in to
to specification. raise the pressure (Figure 21). Turn it out to lower
NOTE! the pressure. Be sure that you stop the drive shafts
If the boom does not operate smoothly at 20 from turning each time before making the
Pressure Settings
adjustment. When pressure is correct, tighten the screw on the P regulator valve), set at 300 bar
jam nut on the adjustment screw before continuing (4350 PSI).
with the other procedures. 3. The redundant relief valve located in the
emergency stop manifold, set at 330 bar (4786
Set boom pressures PSI).
(load sensing proportional booms) NOTE!
Now that P and Q-min are set, you can check or set The boom control block relief valve is
the boom valve pressures. There are three pressure nonadjustable. If pressure is not maintained
settings on the boom circuit (Figure 39 and Figure 23). within the specification limits, the valve
1. The boom control block relief valve, set at 350 bar must be replaced.
(5075 PSI).
2. Pressure regulator (the high-pressure adjustment
e-stop/right.epsL
E-Stop manifold
redundant relief valve
ps
rt.e
ca
no
E-Stop manifold
redundant relief
valve
Figure 39
E-Stop manifold (current production left - original production right
revDate
266 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
now. If it isnt, raise the setting of the other
pressure devices until the hiss originates at the
Apitech control block relief valve. Read the
pressure on the gauge connected to the 0-400 bar
gauge port on the boom hand valve block. It should
read 350 bar. If pressure is correct, proceed to Step
0-400 bar
5.
gauge port
0-60 bar NOTE!
gauge port Although the pressure specification for the
Apitech control block relief valve is 350 bar,
boom control
block relief valve you may continue to use the concrete pump
.eps
as long as the relief valve cartridge
Va
om
36
Bo
maintains at least 330 bar. If pressure on the
15 bar pretension relief valve is below 290 bar, you should not
adjustment screw
use the concrete pump until the relief valve
is replaced. If you need to replace the relief
valve, repeat this entire procedure before
P Regulator Valve
using the concrete pump again.
(high pressure
adjustment screw) 5. Screw out the E-Stop manifold redundant relief
valve adjustment screw one-and-a-half turns.
Pressure out any boom cylinder except #1 down,
and read the gauge. Pressure should read 330 bar.
If it does not, turn the screw in to raise pressure or
out to lower pressure until it is set at 330 bar. If the
deltaPvlv.eps
Pressure Settings
0-400 bar
gauge port
0-60 bar
gauge port
boom control
block relief valve
s
ep
dv.
itpr
ap
36
15 bar pretension
adjustment screw
Figure 41
Pretension adjustment screw
and gauge port
Set 15 bar pretension valve is inside the boom control block. There is not
To check or set pretension, follow these steps: a separate relief valve for this circuit and,
therefore, nothing that must be set.
1. Stop the truck engine. Plug the 0 - 40 bar gauge
into the 0-60 bar gauge port of the Apitech hand Set water pump pressure
valve (Figure 24).
With a seven place hand valve, the water pump
2. Start the truck engine, but leave it at an idle.
hydraulic control is inside the boom control block.
(Pretension adjustment is made at an idle to
There is not a separate relief valve for this circuit and,
establish the minimum pressure setting. As RPM is
therefore nothing that must be set.
increased, pressure will rise. Read the pressure on
the gauge. If it reads 15 bar 1 bar, the pressure is
Set the agitator pressure
set correctly.
The agitator circuit has a maximum pressure of 200 bar
NOTE! (2900 PSI), limited by the relief valve located on the
Damage to the 0 - 40 bar gauge is possible if back of the agitator hand valve (Figure 117). The gauge
RPM is raised while the gauge is connected. port for checking or setting the agitator pressure is
3. If adjustment is needed, loosen the jam nut on the located on top of the agitator hand valve.
pretension adjustment screw (Figure 24). Turn the
screw in to raise pressure and out to lower
pressure. When the pressure is correct, retighten
the jam nut.
4. Stop the engine, and remove the 0 - 40 bar gauge.
With a seven place hand valve, the #1 down brake -
revDate
268 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
39Xcont3.eps
52qrttrn.epsL
Closed
Shown in the
open position
Figure 43
Agitator shutoff valve
Agitator Hand Valve
4. Be sure that one of the locking plugs and capnuts
39Xcontr.eps
are tightened on the straight fitting and that the
dead plugs are securely tightened to the hose and
the open motor fitting.
5. Locate the relief valve on the back of the agitator
hand valve.
6. Be sure that all personnel are clear, and restart the
AGITATOR CONCRETE PUMP
SECTION 1 SECTION 2 SECTION 3 SECTION 4 SLEWING AIR / WATER BOOM / OUTRIG. engine.
7. Activate the agitator hand valve by pushing or
DANGER WARNING
Do not operate this
Electrocution hazard. machine without
Stay back from high training. Understand
voltage wires at least SAFETY
the warnings in safety
17 feet (5 meters). MANUAL
manuals and on decals.
Pressure Settings
Lower
ps
2.e
itrlf
ag
Figure 44
Agitator relief valve
revDate
270 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
S 42SX 2. Activate the agitator. With the valve closed, the
agitator will not be able to turn, and the oil will be
forced over the relief valve. At an idle (about 600
Setting Pressures
RPM), 4.5 horsepower is being converted to heat.
The following pages provide the proper techniques for
3. When the oil temperature gauge shows 50C, open
checking and setting hydraulic pressures of each
the shutoff valve.
system included on your unit.
Pressure Settings
Setting pressures on Hi-flo -6 pumpkits 4. If you have not already closed the soft switch
To set the pressure of the main relief valve on Hi-flo shutoff valve and the concrete pump shutoff valve
pumpkits, you must first disable the soft switch circuit. (Figure 56) do so at this time.
Simply locate the ball cock for the soft switch circuit 5. At the rear panel, select local control with the
(Figure 56) and close it by rotating the handle 90 local/remote switch and turn the electric stroke
degrees. limiter knob clockwise to maximum strokes per
minute.
The quarter turn shutoff valve for the concrete pump
(Figure 56) will also need to be closed during this 6. The main system control block pressure must be
procedure. set first to properly set the pressure cutoff on both
pumps. Begin by backing off the jam nut of the
NOTE! main relief cartridge (Figure 58) with a 9/16 inch
Main system adjustments are preset at the wrench.
factory. The following procedure begins
with adjustment of the main relief cartridge 7. Using a 5/32 inch allen wrench, turn the
and pressure cutoff. If proper pressures can adjustment screw out (counterclockwise) until you
not be obtained through these steps, contact can feel no spring tension on the adjustment screw.
the Schwing Service Department for specific
instructions on the adjustment of flow, 8. Now, turn the screw back in (clockwise) two or
horsepower, beginning of stroke regulation, three full turns to give you a proper starting point
and Q-min. and tighten the jam nut.
Pressure setting procedure: 9. Stop the truck engine and put the key in your
pocket. Adjust the pressure cutoff screw (Figure
Soft switch 57) on each pump, by backing off the jam nut with
shutoff valve
a 13mm wrench. Using a 4mm allen wrench, turn
the adjustment screw in (clockwise) one full turn
and tighten the jam nut. Restart the truck engine.
10. Adjust the engine RPM to maximum specification.
Concrete pump
(See decal in truck cab)
hif
shutoff valve lob
rn
.e
ps 11. Pressure out the system by activating the concrete
pump forward switch on the rear panel. Using the
Figure 56 rear panel controls will allow you to read the
Concrete pump and Soft switch concrete pump main system pressure gauge, near
shutoff valves the e-stop manifold, from a safe distance.
NOTE!
1. Be sure that the waterbox covers and guards are in
Because you turned out the pressure relief
place any time you will be working in the area cartridge in step 7, the system pressure
around the main control block. should read low at this time. If it does not
2. Wear safety glasses when working around a and the gauge spikes to 320 bar or more,
concrete pump. disengage the pump immediately. Turn the
relief cartridge out (counterclockwise)
NOTE! more. For safety, it is important to adjust
It is vital that each adjustment screw be the pressure up from below the specified
properly identified prior to making any target pressure rather than down from a
adjustment. All screw adjustments for the pressure which exceeds the target. Continue
system relief must be made with the this procedure until the main system
pumpkit in the neutral position and pressure gauge reads lower than the
adjustments for pressure cutoff must be specified target.
made with the engine shut off. 12. To increase the pressure put the pump in the
3. Start the truck engine, and put the PTO in gear just neutral position and adjust the relief cartridge by
as you would to pump a job. turning it in (clockwise). When increasing the
pressure, the adjustments should be made in
quarter turn increments. If you make adjustments
to increase the pressure but the pressure does not
revDate
272 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
come up, you are probably reading the pressure 18. When you have achieved the same pressure on the
cutoff of the pumps, if so proceed to the next step M1 port gauges, you can begin to adjust the
otherwise skip to step 15.Turn the relief cartridge pressure cutoff screws in or out simultaneously
adjustment screw back out (counterclockwise) until you achieve the desired pressure setting of
until you can no longer see a pressure drop and 350 bar (again, confirm the pressure specification
tighten the jam nut. with the hydraulic schematic).
13. Stop the truck engine, put the key in your pocket. After pressure cutoff is set, return the pump to neutral,
14. Go to the pressure cutoff screw on both hydraulic bring engine RPM to idle, open the soft switch quarter
pumps (Figure 57) and back off the jam nut with a turn valve, and either proceed to other pressure settings
13mm wrench. Turn the adjustment screws in with or take the transmission and PTO out of gear and shut
a 4mm allen wrench one or two more turns, restart off the truck.
the engine and check the pressure again. Repeat
this procedure until the main system relief can be
set to the target pressure.
15. When the proper main relief pressure is achieved,
1 STROKE REGULATION 2 PRESSURE CUT OFF
pressure cutoff can be set. Shut off the engine, put 3 HORSE POWER 4 Q-MIN
the key in your pocket and install 0-600 bar gauges 2
2
with whip hoses to the M1 gauge ports on the 1
3
1 3
bottom of the two hydraulic pumps (Figure 57). 4
4
You must be able to read both gauges
simultaneously to ensure that one pump is not
M1 GAUGE PORT
more dominant than the other. (BOTTOM OF EACH PUMP)
130ajst.eps
NOTE!
The gauges in the M1 ports will read Figure 57
considerably less than the cutoff pressure of A11VO adjustment screws for Hi-flo 6
the pump. On a -6 (190/130 pump units 190/130
combination) the 190 will usually read 85 to
90 bar while the 130 reads about 110 bar.
They could read the same however, at
approximately 110 bar, but the 190 must
never read higher than the 130. The actual
cutoff pressure will be read on the concrete
pump main system pressure gauge near the
e-stop manifold.
16. Activate concrete pump forward to pressure out the
pump and read the pressure on the two gauges in
the M1 ports.
17. Always stop the truck engine and put the key in
your pocket before making any adjustment on the
hydraulic pump. If the cutoff on one pump is set
higher than the other, that pump will be more
dominant. The pressure gauge in the M1 port of the
dominant pump will however, read lower than the
other. To equalize the two pumps you must either
adjust the cutoff screw in (clockwise) to increase
the pressure of the pump showing the higher
reading or adjust the cutoff screw of the dominant
pump showing the lower reading out
(counterclockwise) to reduce the pressure. These
adjustments must be made until the two gauges in
the M1 ports are reading approximately the same.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 273
HOME PRINT
Pressure Settings
Closed Open
soft switch
relief valve
openclsd.eps
Main relief valve
5/32" Allen head
9/16" jam nut
Figure 58
Soft switch components
Setting the soft switch relief pressure Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure This unit is equipped with a load-sensing, proportional
58, right) that you closed in the previous procedure. boom hydraulic system. In a black-and-white system,
The rest of the unit should still be set up as if you were the hydraulic pump puts out an unchanging amount of
going to check the main relief valve pressure (concrete oil, and speed control is done by restricting the oil to
pump shutoff valve still closed). certain functions with orifices. In a load-sensing
When you put the pump in forward now, the main system, the pump puts out more or less oil to respond
concrete pump pressure gauge should read the pressure to the needs of the system. Generally, the pump puts
shown on the schematic for soft switch. If adjustment out enough oil to maintain 20 bar higher pressure at the
is needed, loosen the soft switch relief valve jam nut pump than the cylinders actually require. This 20 bar is
(Figure 58, right) with a 9/16 open end wrench, and use called delta P (P). Additionally, we set the hydraulic
a 5/32 allen wrench to adjust the pressure. Turn the pump so that it always puts out a small amount of oil,
adjustment screw in (clockwise) to raise the pressure or even if no oil is needed for the system. This oil is used
out (counter clockwise) to lower the pressure. When to ensure that you have control when you need it. The
you attain the required pressure, tighten the jam nut setting to maintain this minimum amount of oil is
while holding the allen wrench to keep the pressure called Q-min (pronounced cue min). To set the boom
from rising. Be sure to open the concrete pump shutoff or outrigger hydraulic pressures on a load-sensing
valve on the side of the brain (Figure 58, left) when system, begin by setting P and Q-min.
you are finished. The unit will not stroke with this
valve closed.
revDate
274 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
0-600 bar
gauge port
ps
0.e
60
top
es
pretension
only Boom pressure
33-35 bar relief cartridge
0-600 bar
gauge port
45bmcnbl.epsL
Figure 59
(Left) The 060 bar gauge port is located at the top of the boom control block, and the 0-600
bar port is at the bottom. (Right) A 0600 bar gauge port is located on the E-stop manifold.
Setting delta P pressure bar. After achieving proper P, tighten the jam nut
Do not adjust P or Q-min if your boom is running as and bring the engine RPM up. If the pressure
you like it. The pressure setting procedure uses a gauge continues to read 20 bar, you are reading the
standard starting point and must be fine tuned from that true P pressure and may move on to setting the Q-
point. The pressure was fine tuned at the factory and min. If the pressure rises with the RPM, however,
should not be adjusted unless absolutely necessary. you may be reading the Q-min pressure instead of
true P. If that happens, stop the engine, put the
1. Start by turning off the engine and putting the key key in your pocket, and place a Do Not Operate
in your pocket; then place a Do Not Operate sign sign on the windshield of the truck before
on the windshield of the truck. proceeding.
2. Install a 0-100 bar gauge in the high pressure test
port at the bottom of the boom control block
(Figure 16).
pressreg.eps
Regulator pressure
NOTE! adjustment
Do not activate any boom/outrigger
T
functions or release any e-stops with a low Adjustment for P pressure
pressure gauge attached to a high pressure
port. Delta-P
Pressure Settings
Q-min
Delta-P Pressure cut-off
adjustment screw
hifloreg.eps
Figure 61
Location of Q-min screw on the A7VO (left) and all adjustment screws of the A11VO (right)
Regulator pressure
If pressure cannot be set correctly, there is a problem adjustment
either with the orifices in the base of the regulator or
with the regulator itself. Contact the Schwing Service T
Adjustment for P pressure
Department to determine how to continue.
If the boom does not run smoothly at 17 bar, you
must fine tune the adjustment. Remove the gauge, and Figure 62
turn the P adjustment screw until the boom is Boom pressure regulator for units
responsive and smooth. After adjusting, the gauge with A7VO pumps
(reinstalled) must read between 14-25 bar. The
electronics in the control system can also affect how
the boom operates, so if P adjustment does not seem
to help, reset to 17 bar and check the electrical settings.
Once electrical settings are verified, you could again
try to refine the boom action with the P adjustment.
NOTE!
The pressure regulator (Figure 62) is
usually mounted on the inside of the
subframe, near the cab end of the
differential cylinders.
revDate
276 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting Q-min 4. Identify the main boom pressure relief cartridge on
Check Q-min when the engine is at maximum specified the boom control block (Figure 64) and loosen the
RPM. You must not adjust Q-min with the drive jam nut. Then unscrew the adjustment two full
shafts turning! Each time the Q-min screw must be turns.
adjusted, the engine must be stopped or, at least, the 5. Take engine RPM to full throttle and activate boom
transmission must be taken out of gear so that the retract for any boom section except #1.
drivelines stop turning. 6. Now adjust pressure, which is read at the main
1. If you unscrewed the Q-min screw as part of the P boom gauge port, to the setting found on the
adjustment, begin by returning the screw to its schematic by turning the boom pressure relief
original position. cartridge in, or clockwise, using no more than 1/4
2. All boom functions must be in neutral, and all turn increments.
emergency stop buttons should be up (not 7. When desired pressure is achieved, lock down the
engaged). Clear away all personnel, start the truck jam nut.
engine, engage the pumps and bring engine RPM
to max. Read the pressure at the 0600 bar main
boom gauge port (Figure 63) with a 0-100 bar
gauge. Pressure should be at 30 bar. If no
adjustment is needed, be sure the jam nut on the 0-600 bar
Q-min screw is tight; then continue to set the rest gauge port
of the boom and outrigger pressures. If adjustment ps
0.e
60
is needed, continue to the next step. es
top
Pressure Settings
Setting outrigger pressure
mainrlf.eps
After the boom circuit is properly set, you can set the
outrigger pressure. Find the relief cartridge
located on the front of the passenger side outrigger
control valve (Figure 48).
#1 down side
relief cartridge
revDate
278 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
CONCRETE PUMP
FORWARD/REVERSE
AGITATOR
Relief valve
Gauge port
Figure 66
Agitator component location
NOTE!
Do not jam the paddles to force the oil over
relief by stopping the movement of the Cap Nuts
agitator.
3. Increase the throttle to any speed above idle.
Activate the agitator valve handle in either forward
or reverse, and read the gauge. If it does not read
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 279
HOME PRINT
Pressure Settings
the specified pressure, adjustment is required. Turn January 1, 2000, it will have an emergency stop
the entire valve body (Figure 50) in to increase manifold similar to the illustration shown in the bottom
pressure or out to decrease pressure. of Figure 52, which no longer has a redundant relief
4. When the pressure is set, deactivate the agitator by cartridge, and you must skip steps 3. and 7. in the
placing the manual control handle in the neutral following procedure.
position. To check or adjust the hydraulic pressure in the
5. Remove the whip gauge. accumulator circuit:
6. Reopen the shutoff valve or remove the dead plugs 1. Stop the truck, put the key in your pocket, and
and reconnect the capped hydraulic line. place a Do Not Operate sign on the windshield.
2. Loosen the jam nut on the pressure regulator of the
Setting accumulator circuit pressure accumulator hydraulic pump (Figure 51). Turn the
screw in two-and-one-half turns. This will raise the
regulator pressure above 300 bar.
3. Loosen the jam nut (Figure 52) on the accumulator
redundant relief cartridge located on the
emergency stop manifold. Turn the screw in two
000289a.eps
turns. This will raise the relief setting above 300
bar.
Accumulator pump
pressure regulator accurlf2.eps
Accumulator redunant
relief cartridge
Figure 69
Accumulator pump pressure regulator for Figure 70
A7VO (above) and for A11VO (below) Accumulator redundant relief cartridge
(above) is only present on early production
Boom Pump models. New e-stop (below) has no redundant
relief cartridge.
Accumulator Pump
Pressure Regulator
@@@@@@@@
;;;;;;;;
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
45acumpr.epsL
@@@@@@@@
;;;;;;;;
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
;;;;;;;;
@@@@@@@@
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
;;;;;;;;
@@@@@@@@
QQQQQQQQ
;;;;;;;;
@@@@@@@@
QQQQQQQQ
8. After the truck engine is stopped, go back to the
accumulator circuit hydraulic pump pressure
Figure 71 regulator (Figure 51), and turn the screw back out
Accumulator circuit pressure gauge two-and-one-half turns. This restores it to its
original setting.
acumrlf.epsL
9. Clear all personnel from the drive line area, start
the truck, and bring the engine RPM up to
maximum.
10. Read the pressure on the accumulator gauge. It
should read the proper accumulator system
pressure.
11. If adjustment is needed, you must stop the truck
engine, or a least stop the drive lines from turning,
each and every time you approach the accumulator
circuit hydraulic pump. Turn the screw in to
increase the pressure or out to decrease pressure.
Lock the jam nut when the pressure is correct.
NOTE!
The accumulator circuit hydraulic pump
pressure regulator is referred to as the
pressure cut-off.
Figure 72
Accumulator manifold pressure
relief cartridge
6. Locate the accumulator manifold pressure relief
cartridge (Figure 54). Loosen the jam nut, and turn
the screw clockwise to increase the pressure or
counterclockwise to decrease the pressure. Tighten
the jam nut when the pressure reaches the value
required.
7. You will need an assistant for this step. With the
engine still running, one person must go to the
redundant relief valve on the emergency stop
manifold (Figure 52) and back out the adjustment
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 281
HOME PRINT
Pressure Settings
revDate
282 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 42M - Proportional pocket, remove the check plug from the check port. The
oil should be at the level of the bottom of the hole in
(Apitech) Single Circuit the case. If oil is needed, add it by removing the
Check the fluid level of the distribution gearcase breather and pouring the oil through the top of the fill
(Figure 10). Be sure the truck is on reasonably level port. This gearcase uses 90W gear lube.
ground. With the truck engine off and the key in your
Drain port
Figure 10
Fill, check, and drain ports
of Stiebel 4194 gearcase
Check the mounting hardware of the subframe, the oil 1. Place a 4-by-4 in front of the agitator paddle.
and water tanks, the delivery pipeline, the pumpkit, the 2. Turn on the agitator. The agitator will not be able
differential cylinders, the material cylinders, and the to turn, and the oil will be forced over the relief
driveline hardware. Check for bolt tightness, cracks, valve.
and other abnormalities.
At an idle (about 600 RPM), you are converting about
4.5 horsepower to heat, which is a good-sized heater.
Check hydraulic pressures
Shut off the concrete pump when the oil shows 40C
Check all hydraulic pressures. Changes in pressures on the temperature gauge of the operators panel.
can indicate trouble in one or more components.
Pressure settings must be made with the oil at normal Setting concrete pump pressure (single-
operating temperature (4060C). The specifications circuit units)
for all circuits are shown on the hydraulic schematics
in the appendix of this manual. Schwing single-circuit pumpkits are designed to be
operated at a maximum pressure of 300 bar (4350 PSI).
Preheat the hydraulic oil The pressure in the system is controlled by the main
relief valve on the forward end (toward the truck cab)
Pressure settings must be made with the oil at normal of the main control block (Figure 11).
operating temperatures (40 60C). Because the
system is load-sensing, the boom circuit cannot be used
to heat the hydraulic oil. The agitator circuit must be
used instead. To preheat the hydraulic oil using the
agitator circuit, follow these instructions:
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 283
HOME PRINT
Pressure Settings
Jam nut
gray valve.eps L
Figure 11
Concrete pump circuit main relief valve
Shutoff valve
quarter turn.eps
Figure 12
Concrete pump shutoff valve
5. Put the main operators panel remote / local will retract. Oil will be forced over the main relief
switch into the local position. valve. This procedure is called high-pressuring the
6. Using the switch on the main operators panel, rev concrete pump.
the truck engine up to full RPM.
7. Put the operators panel forward / neutral /
reverse switch into the forward position. The
unit will stroke only once; then the rock cylinder
revDate
284 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Groove at 90 to ports
Closed
Figure 13
Open/closed orientation of concrete pump shutoff valve
8. Read the pressure on the gauge. It should read 300 12. Put the concrete pump into the forward position
bar. Return the pump to neutral whether it needs again. The machine will not stroke this time, but it
adjustment or not. If no adjustment is needed, skip will high-pressure again. Read the pressure on the
to step (n). gauge. If more adjustment is needed, return the
9. Using a 13-mm spanner wrench, loosen the jam pump to neutral, then repeat steps (i) through (l)
nut on the relief valve adjusting screw (Figure 11). until the pressure is correct.
Note! If you cannot adjust the pressure up to
10. Turn the knob on the relief valve to adjust the
specification, you have a problem. In this case,
pressure. Screw the handle in to raise pressure, and
unscrew the adjustment handle several turns so that
out to lower pressure.
your pressure is not too high when you find the
11. Retighten the jam nut. Tightening the nut tends to problem. Contact Schwing Americas Service
raise the pressure setting. If the rise in pressure Department for advice on how to continue.
becomes a problem, hold the knob while tightening
13. Return the pump to the neutral position.
the jam nut.
14. Open the concrete pump shutoff valve (Figure 14).
Shutoff valve
quarter turn.eps
Figure 14
Concrete pump shutoff valve
15. Return the RPM of the truck to idle, take the truck, or go on to other pressure settings.
transmission and PTO out of gear, and shut off the
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 285
HOME PRINT
Pressure Settings
Setting boom circuit pressures oil, and speed is controlled by restricting the oil to
Note! Whenever you set pressures for any circuit on certain functions with orifices. In a load-sensing
any unit, the hydraulic oil should be at normal system, the pump puts out more or less oil to respond
operating temperature (4060C). Instructions on to the needs of the system. Generally, the pump puts
preheating the hydraulic oil for this procedure are in out enough oil to maintain 20 bar higher pressure at the
section on page 6-97. Read all of the instructions pump than what the cylinders actually require. This 20
before beginning any pressure settings. You will need bar is called delta P (P). Additionally, we set the
an assistant for parts of the procedure. You and any hydraulic pump so that it always puts out a small
assistants should wear eye protection when setting amount of oil, even if no oil is needed for the system.
pressures. This oil ensures that you have control when you need
it. The setting to maintain this minimum amount of oil
Load-sensing boom hydraulic controls is called Q-min (pronounced cue min). To set the
boom or outrigger hydraulic pressures on a load-
This unit is equipped with a load-sensing, proportional sensing system, begin by setting Q-min and P (Figure
boom hydraulic system. In a black-and-white system, 15).
the hydraulic pump puts out an unchanging amount of
42 Location Page 1
Component Locations
Figure 16Boom control handvalves
Figure 17Q-min adjustment screw
Figure 18P regulator
Figure 20E-stop manifold
Figure 15
Locations of components used to check boom pressures
Setting P
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. To check or set P, follow these steps:
1. Stop the truck engine and place a Do Not
Operate sign on the windshield of the truck.
2. Install a 040 bar gauge in the pressure check port
of the boom handvalve. Take care not to accidently
install the gauge in the pretension check port
(Figure 16).
revDate
286 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
42 apitech back.epsL
Adjustment screw
(15 bar pretension)
Pretension check
port (040)
Figure 16
Boom control handvalve (Apitech)
3. To be sure that the pump is only putting out the oil
needed to maintain P, we need to change the
setting of the Q-min screw. Q-min is adjusted by a
screw on the boom hydraulic pump (Figure 17).
Q-min
adjustment screw
Q-minscrew.eps
Q-max
Figure 17
Location of the Q-min adjustment screws
CAUTION
Do not operate any functions while setting P.
4. Unscrew the Q-min screw three full turns. Check Make sure that all emergency stop switches are in
that all personnel are clear of the truck, then restart the up (not engaged) position. Pressure can be read
the engine, engage the pumps, and leave the engine on the 040 bar gauge that you installed. Pressure
at an idle. If you activate any boom or outrigger should read 20 bar. If no adjustment is needed,
functions, you will damage the 040 bar gauge.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 287
HOME PRINT
Pressure Settings
simply reset the Q-min screw as described in 5. Delta P is adjusted by the P adjustment screw on
paragraph . If adjustment is needed, continue to the boom pump (Figure 18). Loosen the jam nut,
step (5). and adjust the screw inward to increase pressure, or
outward to decrease pressure until it is set at 20 bar
1.
deltaPvlv.eps
pressreg.eps
Regulator pressure
adjustment
T
Adjustment for P pressure
Figure 18
P regulator valve
6. If pressure cannot be set correctly, contact the each time before making the adjustment. When
Schwing Service Department to determine how to pressure is correct, tighten the jam nut on the
continue. adjustment screw before continuing with the other
procedures.
Setting Q-min
You must check Q-min pressure when the engine is at Setting boom pressure
the maximum specified RPM, but you must adjust it Now that P and Q-min are set, you can check or set
with the engine stopped. the main boom pressures. There are three pressure
1. If you unscrewed the Q-min screw as the first step settings:
of P adjustment, begin by returning the screw to
its original position (see Figure 17).
2. Remove the 040 bar gauge from the pressure
check port, and install the 0600 bar gauge in its
place.
3. Clear all personnel away from the drive lines, start
the truck engine, engage the pumps, and bring
engine RPM to max. All boom functions must be
in neutral, and all emergency stop buttons should
be up (not engaged). Read the pressure on the 0
600 bar gauge. Pressure should be at 4045 bar. If
no adjustment is needed, stop the drivelines, be
sure the jam nut on the Q-min screw is tight, then
continue to paragraph to check the rest of the
boom and outrigger pressures. If adjustment is
needed, continue to step (4).
4. Turn the Q-min screw in to raise the pressure (see
Figure 17). Turn it out to lower the pressure. Be
sure that you stop the drive shafts from turning
revDate
288 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
1. Pressure regulator (the high-pressure adjustment
screw on the P regulator valve), set at 290 bar
(Figure 18)
deltaPvlv.eps
pressreg.eps
Regulator pressure
adjustment
T
Adjustment for P pressure
Figure 19
P regulator valve
P3
P2
P4
P1
M
TT
1
MP
Figure 20
Emergency stop manifold,
and boom redundant relief
Pressure Settings
3. Boom control block relief, set at 350 bar.
42 apitech relief.eps
350 bar
relief
30 bar relief
Figure 21
Apitech boom control block relief
To check the setting of the valve with the highest NOTE! Although the pressure specification for the
pressure, you must first raise the pressure of the lower Apitech relief valve is 350 bar, you may continue
two: to use the relief valve as long as the cartridge
1. Loosen the jam nut of the high-pressure adjustment maintains at least 330 bar. If you must replace the
screw of the P regulator (see Figure 18). Turn the valve, proceed to step (4) before using the machine
screw in two-and-a-half turns. This will raise the again, and redo this entire procedure when you
pressure on the regulator above 350 bar. have installed the new valve. If pressure on the
Apitech relief valve is below 290 bar, you should
2. Loosen the jam nut of the adjustment screw of the
not use the machine until the valve is replaced.
redundant relief valve in the emergency stop
manifold (see Figure 20). Turn the screw in one- 4. Screw out the redundant relief valve adjustment
and-a-half turns. This will raise the pressure on the screw (see Figure 20) one-and-a-half turns.
relief valve to above 350 bar. Pressure out any boom cylinder except #1 down,
and read the gauge. Pressure should read 320 bar.
3. Pressure out any boom cylinder except #1 down by
If does not, turn the screw in to raise pressure, or
pushing or pulling the control handle. To pressure
out to lower pressure until it is at 320 bar. If the
out a cylinder, retract a fully retracted cylinder or
location of this valve causes you to be near the
extend a fully extended cylinder. The oil is forced
drivelines, be sure to stop them from turning before
over the relief valve.
accessing the valve.
The telltale hiss of an open relief valve should be
coming from the Apitech control block relief valve 5. You will need a helper for this step. While
now. If it isnt, raise the setting of the other pressuring out any boom cylinder except #1 down,
pressure devices until the hiss originates at the have your helper adjust the high-pressure screw of
Apitech control block relief valve. Read the the P regulator out (lowering the pressure) until
pressure on the gauge. It should read 350 bar. If the gauge reads 290 bar (see Figure 18). Release
pressure is correct, proceed to step (4). the pressurized function and lock the jam nut. The
boom pressures are now set. If you did not get the
revDate
290 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
readings specified after following the instructions, 2. Stop the truck engine. Plug the 040 bar gauge into
contact Schwings Service Department for advice the pretension gauge port of the Apitech handvalve
on how to continue. (Figure 22).
3. Start the truck engine, but leave it at an idle. Read
Setting pretension the pressure on the gauge. If it reads 15 bar 1 bar,
To check or set pretension follow these steps: the pressure is set correctly. If the pressure is not
1. Remember that the oil must be at normal operating set correctly, continue to point (4.)
temperature (4060C). See point for
information about preheating the oil.
CAUTION
Truck engine must be at idle when pretension is set.
Adjustment screw
Gauge port
Apitech pretnscrw.eps
Figure 22
Pretension adjustment
screw and gauge port
Pressure Settings
revDate
292 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 42M - Proportional pocket, remove the check plug from the check port. The
oil should be at the level of the bottom of the hole in
(Apitech) Twin Circuit the case. If oil is needed, add it by removing the
Check the fluid level of the distribution gearcase breather and pouring in the oil through the top. This
(Figure 23). Be sure the truck is on reasonably level gearcase uses 90W gear lube.
ground. With the truck engine off and the key in your
Drain port
Figure 23
Fill, check, and drain ports of Stiebel 4194 gear
Check the mounting hardware of the subframe, the oil 2. Turn on the agitator. The agitator will not be able
and water tanks, the delivery pipeline, the pumpkit, the to turn, and the oil will be forced over the relief
differential cylinders, the material cylinders, and the valve.
driveline hardware. Check for bolt tightness, cracks, 3. At an idle (about 600 RPM), you are converting
and other abnormalities. about 4.5 horsepower to heat, which is a pretty
good-sized heater. Shut off the concrete pump
Check hydraulic pressures when the oil shows 40C on the temperature gauge
Check all hydraulic pressures. The specifications for of the operators panel.
each circuit are shown on the hydraulic schematics in
the appendix of this manual. Changes in pressures can Setting concrete pump pressure (High-
indicate trouble in one or more components. flow pumpkits)
Schwing units with high-flow pumpkits are designed to
Preheat the hydraulic oil be operated at a maximum pressure of 320 bar (4640
Pressure settings must be made with the oil at normal PSI). The pressure in the system is limited by the relief
operating temperatures (40 60C). Because the valve located on the forward end (toward the truck cab)
system is load-sensing, the boom circuit cannot be used of the main control block (Figure 24). In addition, the
to heat the hydraulic oil. The agitator circuit must be hydraulic pumps have a pressure cutoff function, set at
used instead. To preheat the hydraulic oil using the 350 bar.
agitator circuit, follow these instructions: To check or set concrete pump circuit pressures, follow
1. Place a 4-by-4 in front of the agitator paddle. these steps:
1. Wear safety glasses when setting pressures.
Pressure Settings
2. Be sure that the waterbox covers and guards are 9. Loosen the jam nut on the relief valve adjusting
installed on the waterbox. Schwing does not screw (Figure 24).
recommend using the remote control box when 10. Insert a hex key (allen) wrench into the screw, and
setting the main relief pressure. turn the screw to adjust the pressure. Turn the
3. Start the truck engine, and put the PTO and screw in to raise pressure, out to lower pressure.
transmission into gear, just as you would to pump a 11. Retighten the jam nut. (Tightening the nut tends to
job. raise the pressure. If the rise in pressure becomes a
4. Locate and close the concrete pump shutoff valve problem, hold the hex key wrench while tightening
(quarter-turn valve), and the soft switch shutoff the jam nut.)
valve (quarter-turn valve) (Figures 25 and 26). 12. High-pressure the concrete pump again. Read the
5. Put the operators panel remote / local switch pressure on the gauge. If more adjustment is
into the local position. needed, return the concrete pump switch to
6. Using the switch on the operators panel, rev the neutral, then repeat steps (i) through (l) until the
truck engine up to full RPM. pressure is correct.
7. Put the operators panel forward / neutral /
Note! If you cannot adjust the pressure up to
reverse switch into the forward position. The
specification, you have a problem. In this case,
unit will stroke only once, then the rock cylinder
unscrew the adjustment knob several turns so that
will retract. The oil leaving the hydraulic pumps
your pressure is not too high when you find the
will be forced over the main relief valve. This
problem. Contact Schwing Americas Service
procedure is called high-pressuring the concrete
Department at (612) 429-0999 for advice on how
pump.
to continue.
8. Read the pressure on the gauge, as shown. It
13. If you will not be setting the soft switch pressure,
should read 320 bar. Return the pump control to
open the shutoff valves. The unit will not stroke
neutral, whether it needs adjustment or not. If no
with closed shutoff valves.
adjustment is needed, skip to step (13).
Gauge port
revDate
294 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Soft switch
shutoff valve
Main Pressure
Gauge port
Concrete pump
hif
shutoff valve lob
rn
.e
ps
Figure 25
Locations of the concrete pump and soft switch shutoff valves
grooves.eps
openclsd.eps
Groove at 90 to ports
- closed
Figure 26
Open/closed orientation of the concrete pump shutoff
valve (left) and the soft switch shutoff valve (right)
Setting the soft switch circuit relief concrete pump shutoff valve on the side of the
pressure brain (shown in Figure 25) when you are finished.
The unit will not stroke with this valve closed.
To check or adjust the soft switch pressure setting,
proceed as follows:
1. Open the soft switch shutoff valve. The rest of the
unit should still be set up as if you were going to
check concrete pump pressure (Figure 27).
2. High-pressure the concrete pump. The pressure
gauge should read 80 bar (1160 PSI) instead of 320
bar. If adjustment is needed, loosen the jam nut of
the relief valve cartridge. Using the hex key
wrench, adjust the pressure up or down as needed,
and lock into place with the jam nut. Recheck.
Hold the screw with the hex key wrench, if
necessary, to prevent the screw from turning while
tightening the jam nut. Be sure to open up the
Pressure Settings
Soft switch
shutoff valve Open
Main Pressure
Gauge port
sftopen.eps
Soft switch
relief valve
Concrete pump
hif
shutoff valve lob
rn Figure 27
.e
ps
Soft switch circuit components
revDate
296 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
42 Location Page 1
Component Locations
Figure 16Boom control handvalves
Figure 17Q-min adjustment screw
Figure 18P regulator
Figure 20E-stop manifold
Figure 28
Locations of components used to check boom pressures
Adjustment screw
(15 bar pretension)
Pretension check
port (040)
Figure 29
Boom control handvalve (Apitech)
Pressure Settings
3. To be sure that the pump is only putting out the oil
needed to maintain P, we need to change the
setting of the Q-min screw. Q-min is adjusted by a
screw on the boom hydraulic pump (Figure 30).
Q-min
adjustment screw
Q-minscrew.eps
Q-max
Figure 30
Locations of the Q-min adjustment screws
CAUTION
Do not operate any functions while setting 20 bar P.
4. Unscrew the Q-min screw three full turns. Check simply reset the Q-min screw as described in
that all personnel are clear of the truck, then restart paragraph . If adjustment is needed, continue to
the engine, engage the pumps, and leave the engine step (5).
at an idle. If you activate any boom or outrigger 5. Delta P is adjusted by the P adjustment screw on
functions, you will damage the 040 bar gauge. the P regulator (Figure 31). Loosen the jam nut,
Make sure that all emergency stop switches are in and adjust the screw inward to increase pressure, or
the up (not engaged) position. Pressure can be read outward to decrease pressure until it is set at 20 bar
on the 040 bar gauge that you installed. Pressure 1.
should read 20 bar. If no adjustment is needed,
deltaPvlv.eps
pressreg.eps
Regulator pressure
adjustment
T
Adjustment for P pressure
Figure 31
Delta P regulator valve
Regulator pressure
adjustment
T
Adjustment for P pressure
Figure 45
P regulator valve
TT
1
MP
Figure 32
Emergency stop manifold, and
boom redundant relief valve
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 299
HOME PRINT
Pressure Settings
3. Boom control block relief, set at 350 bar.
42 apitech relief.eps
350 bar
relief
30 bar relief
Figure 33
Apitech boom control block relief valve
revDate
300 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
the pressurized function and lock the jam nut. The 1. Stop the truck engine. Plug the 040 bar gauge into
boom pressures are now set. If you did not get the the pretension check port of the Apitech handvalve
readings specified after following the instructions, (Figure 33).
contact Schwings Service Department for advice 2. Start the truck engine, but leave it at an idle. Read
on how to continue. the pressure on the gauge. If it reads 15 bar 1 bar,
the pressure is set correctly. If the pressure is not
Setting 15 bar pretension set correctly, continue to point (4.)
To check or set pretension follow these steps:
CAUTION
Truck engine must be at idle when pretension is set.
Apitech pretnscrw.eps
Figure 34
Pretension adjustment
screw and check port
Pressure Settings
revDate
302 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 42M - Proportional pocket, remove the check plug from the check port. The
oil should be at the level of the bottom of the hole in
(Rexroth) the case. If oil is needed, add it by removing the
Check the fluid level of the distribution gearcase breather and pouring the oil through the top of the fill
(Figure 35). Be sure the truck is on reasonably level port. This gearcase uses 90W gear lube.
ground. With the truck engine off and the key in your
Drain port
Figure 35
Check, drain, and fill ports of Stiebel 4194 gearcase
Check the mounting hardware of the subframe, the number 30303432 (tube). Contact the Schwing
oil and water tanks, the delivery pipeline, the America Service Department for installation
pumpkit, the differential cylinders, the material instructions.
cylinders, and the driveline hardware. Check for 2. Turn on the agitator. The agitator will not be able
bolt tightness, cracks, and other abnormalities. to turn, and the oil will be forced over the relief
valve.
Check hydraulic pressures
At an idle (about 600 RPM), about 4.5 horsepower is
Check all hydraulic pressures. Changes in pressures being converted to heat. Shut off the concrete pump
can indicate trouble in one or more components. The when the oil temperature gauge on the operators panel
specifications for all circuits are shown on the shows 40C.
hydraulic schematics in the appendix of this manual.
Setting concrete pump pressure (single-
Preheat the hydraulic oil circuit units)
Pressure settings must be made with the oil at normal Schwing single-circuit pumpkits are designed to be
operating temperature (40 60C). The agitator circuit operated at a maximum pressure of 300 bar (4350 PSI).
must be used to heat the hydraulic oil. To preheat the The pressure in the system is controlled by the main
hydraulic oil using the agitator circuit, follow these relief valve on the forward end (toward the truck cab)
instructions: of the main control block (Figure 36).
1. Locate the agitator shutoff valve and close it.
Pressure Settings
Jam nut
gray valve.eps L
Figure 36
Concrete pump circuit main relief valve
3. Start the truck engine, and put the PTO and
To check or set the main relief pressure:
Shutoff valve
quarter turn.eps
Figure 37
Concrete pump shutoff valve
revDate
304 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
forward position. The unit will stroke only once;
then the rock cylinder will retract. Oil will be
forced over the main relief valve.
Groove at 90 to ports
Closed
Figure 38
Open/closed orientation of concrete pump shutoff valve
8. Read the pressure on the gauge. It should read 300 12. Put the concrete pump into the forward position
bar. Return the pump to neutral, whether it needs again. The machine will not stroke this time, but it
adjustment or not. If no adjustment is needed, skip will high-pressure again. Read the pressure on the
to step (14). gauge. If more adjustment is needed, return the
9. Using a 13-mm spanner wrench, loosen the jam pump to neutral, then repeat steps (9) through
nut on the relief valve adjusting screw (see Figure (11) until the pressure is correct.
13).
IMPORTANT! If you cannot adjust the pressure
10. Turn the knob on the relief valve to adjust the
up to specification, you have a problem. In this
pressure. Screw the handle in to raise pressure, and
case, unscrew the adjustment handle several turns
out to lower pressure.
so that your pressure is not too high when you find
11. Retighten the jam nut. Tightening the nut tends to the problem. Contact Schwing Americas Service
raise the pressure setting. If the rise in pressure Department for advice on how to continue.
becomes a problem, hold the knob while tightening
13. Return the pump to the neutral position.
the jam nut.
14. Open the concrete pump shutoff valve (Figure 39).
Shutoff valve
quarter turn.eps
Figure 39
Concrete pump shutoff valve
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 305
HOME PRINT
Pressure Settings
15. Return the RPM of the truck to idle, take the Load-sensing boom hydraulic controls
transmission and PTO out of gear, and shut off the This unit is equipped with a load-sensing, proportional
truck, or go on to other pressure settings. boom hydraulic system. In a black-and-white system,
the hydraulic pump puts out an unchanging amount of
Setting boom circuit pressures oil, and speed control is done by restricting the oil to
NOTE! Any time you set pressures for any circuit on certain functions with orifices. In a load-sensing
any unit, the hydraulic oil should be at normal system, the pump puts out more or less oil to respond
operating temperature (4060 C). Instructions on to the needs of the system. Generally, the pump puts
heating the hydraulic oil for this procedure are found out enough oil to maintain 20 bar higher pressure at the
on page 6-97. Read all of the instructions before pump than what the cylinders actually require. This 20
beginning any pressure settings. You will need an bar is called delta P (P). Additionally, we set the
assistant for parts of the procedure. You and any hydraulic pump so that it always puts out a small
assistants should wear eye protection when setting amount of oil, even if no oil is needed for the system.
pressures. This oil is used to ensure that you have control when
you need it. The setting to maintain this minimum
amount of oil is called Q-min (pronounced cue min).
To set the boom or outrigger hydraulic pressures on a
load-sensing system, begin by setting Q-min and P
(Figure 42).
42 Location Page 1
Component Locations
Figure 16Boom control handvalves
Figure 18Q-min adjustment screw
Figure 43P regulator (original locationinside frame; current locationoutside frame)
Figure 45Normally open bypass valve
Figure 40
Locations of components used to check boom pressures
Setting P 1. Stop the truck engine, put the key in your pocket,
You must not adjust Q-min with the drive shafts and place a Do Not Operate sign on the
turning! Each time the Q-min screw must be adjusted, windshield of the truck.
the engine must be stopped, or at least the transmission 2. Install a 0-600 bar gauge and a 0-40 bar gauge in
must be taken out of gear so that the drivelines stop the boom control hand valve (Figure 41).
turning.
To check or set P, follow these steps:
revDate
306 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
WARNING
Do not operate at DANGER WARNING
pressures exceeding Electrocution hazard. Do not operate this
the rating of the Stay back from high machine without
voltage wires at least training. Understand
entire material the warnings in safety
delivery system. 17 feet (5 meters).
manuals and on decals.
0-40
42 rexman.epsL
0-600
Figure 41
Boom control handvalve (Rexroth)
3. To be sure that the pump is putting out only enough the boom hydraulic pump (Figure 42).
oil to maintain P, we need to change the setting of
the Q-min screw. Q-min is adjusted by a screw on
Q-min
adjustment screw
Q max
Figure 42
Location of Q-min screw
CAUTION
Do not operate any functions when setting P.
Pressure Settings
Unscrew the Q-min screw three full turns. Check 20 bar. If no adjustment is needed, simply reset the
that all personnel are clear of the truck, then restart Q-min screw. If adjustment is needed, continue
the engine, engage the pumps, and leave the engine with step (5).
at an idle. If you activate any boom or outrigger 4. Delta P is adjusted on the P adjustment screw of
functions, you will damage the 040 bar gauge. the P regulator (Figure 43). There are two
Make sure that all emergency stop switches are in adjustment screws on the P regulator. The smaller
the up (not engaged) position. Pressure can be read screw is used to adjust P. Loosen the jam nut, and
on either the main boom gauge (0600 bar) or the adjust the screw inward to increase pressure, or
pretension (040 bar) gauge. Pressure should read outward to decrease pressure, until it is set at 20
bar (1).
High-pressure
adjustment screw
P
T
Figure 43
Delta P regulator.
5. If pressure cannot be set correctly, contact the Setting Q-min
Schwing Service Department to determine how to You must check Q-min pressure when the engine is at
continue. the maximum specified RPM, but you must adjust it
with the engine stopped.
1. If you unscrewed the Q-min screw as the first step
of P adjustment, begin by returning the screw to
its original position (Figure 44).
Q-min
adjustment screw
Q-minscrew.eps
Q-max
Figure 44
Q-min screw
2. Clear all personnel away from the drivelines, start no adjustment is needed, stop the drivelines, be
the truck engine, engage the pumps and bring sure the jam nut on the Q-min screw is tight, then
engine RPM to max. All boom functions must be continue to Setting boom pressure to set the rest
in neutral, and all emergency stop buttons should of the boom and outrigger pressures. If adjustment
be up (not engaged). Read the pressure on the 0 is needed, continue to step 3.
600 bar gauge. Pressure should be at 4045 bar. If
revDate
308 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
3. Turn the Q-min screw in to raise the pressure. Turn High-pressure adjustment screw of the P regula-
it out to lower the pressure. Be sure that you stop tor (the large adjustment screw on the P regula-
the drive shafts from turning each time before tor), set at 290 bar (see Figure 43).
making the adjustment. When pressure is correct, Normally open bypass valve (the valve that opens
tighten the jam nut on the adjustment screw before when an E-stop switch is activated), set at 320 bar
continuing with the other procedures. (see Figure 45).
Handvalve relief (located in the boom control
Setting boom pressure
block), set at 330 bar (Figure 46).
Now that P and Q-min are set, you can check or To check or adjust the high pressure settings on the
adjust the boom circuit high pressure settings. boom circuit, follow these steps:
1. Loosen the jam nut of the large adjustment screw
NOTE! These instructions apply to units built of the P regulator. (see Figure 43). Turn the screw
before January, 1997. in two full turns. This will raise the pressure on the
regulator above 330 bar.
There are three pressure settings on the boom circuit:
WARNING
If the P regulator is located inside the frame, stop the drivelines
from turning before making adjustments.
2. Loosen the jam nut on the normally open bypass adjusting screw in one full turn. This will raise the
valve adjustment screw (see Figure 45). Turn the pressure of this valve above 330 bar.
Jam nut
Adjustment
screw
3
age
Protective
nP
atio
Loc
cover
42
Figure 45
Normally open bypass valve
3. Pressure out any boom cylinder except #1 down, tings of the other pressure devices until the hiss
by pushing or pulling the control handle. To pres- originates at the boom control block relief valve.
sure out a cylinder, retract a fully retracted cylinder Read the pressure on the gauge. It should read 330
or extend a fully extended cylinder. The oil is bar. If no adjustment is needed, skip to step (4). If
forced over the relief valve. The telltale hiss of an adjustment is needed, proceed to step (4).
open relief valve should be coming from the con-
trol block relief valve now. If it isnt, raise the set-
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 309
HOME PRINT
Pressure Settings
4. Adjust the pressure by turning the adjustment pressure. When pressure is correct, lock the jam
screw on the boom handvalve relief valve (Figure nut, and continue to step (4).
46). Screw in to raise pressure, or out to lower
5. You will need a helper for this step. Pressure out the A-frame when the boom is being folded into the
any boom cylinder except #1 down, as described in transport position. To prevent this, there is a secondary
(3) above. Read the gauge while your helper turns relief valve that regulates only the pressure on the #1
the adjustment screw of the normally open bypass retract function (Figure 47).
valve out (lowering the pressure). Continue adjust-
ing until the pressure reads 320 bar. Lock the jam
nut before proceeding.
6. While pressuring out any boom cylinder except #1
down, have your helper turn the high-pressure
adjustment screw of the pressure regulator out
(lowering the pressure) until the gauge reads 290
bar. Lock the jam nut. The boom pressures are now
set. If you did not get the readings specified after
following the instructions, contact Schwings Ser-
vice Department for advice on how to continue.
Figure 47
Down side relief valve
1. Set up the unit as if to pump a job. Put down the 7. Stop the truck engine. Remove the gauges from the
outriggers, avoiding overhead wires and other boom control block. The job is now complete.
obstructions.
2. Bottom out the #1 cylinders completely. No posi- Setting outrigger pressure
tion can allow the boom to do this without hitting After the boom circuit is properly set, you can set the
something unless the boom is unfolded. Unfold outrigger pressure. Find the relief valve on the back
side of the passenger side outrigger control bank relief
sections #2, #3, and #4 away from section #1. valve (Figure 48).
3. Slew the boom to a position that will allow section
#1 to come all the way down without hitting any-
thing, then bring section #1 down.
4. When the #1 cylinders have completely bottomed
out, the oil coming from the pump will have
nowhere to go except over the relief valve. Read
the gauge; it should say 100 bar. (Although pres-
sure is specified as 80 bar, the gauge will read 100
bar because of the 20 bar P that we set earlier.) If
no adjustment is needed, skip to step (6). If adjust-
ment is needed, proceed to step (5).
5. Loosen the jam nut on the down side relief car-
tridge. Adjust the pressure by turning the screw in
to increase pressure, or out to decrease pressure.
When the gauge reads 100 bar, retighten the jam
nut.
6. Fold up the boom, stow the outriggers, and refasten
the tie-down strap, or move on to other mainte-
nance procedures.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 311
HOME PRINT
Pressure Settings
280 Bar
280 Bar
relief valve
relief valve
Lower Lower
Higher PS
ou
trig Higher 6p
lc
cn ou
trb tri
lk- g
42 cn
.ep trb
s
lk
-4
2.
ep
s
Outrigger
enable button
EXTEND REAR EXTEND FRONT FOLD REAR FOLD FRONT FOOT REAR FOOT FRONT
42 p.s. outrigger.epsL
Figure 49
Passenger side outrigger enable button (current production)
2. Pressure out an outrigger jacking cylinder. Pressure into the valve. While holding the handle, have your
out by retracting a retracted cylinder. The oil from helper read the pressure gauge installed on the
the pump will be forced over the relief valve. You boom control block.
cannot use an extension cylinder, because these
have secondary, nonadjustable relief functions built
revDate
312 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
3. The pressure should read 280 bar. Adjust by turn- Set agitator pressure
ing the body of the valve in or out. When 280 bar is The agitator circuit has a maximum pressure of 200 bar
reached, let go of the handle. (2900 PSI), which is limited by the relief valve in the
4. On original units, restore the outrigger/boom selec- agitator handvalve (Figure 50).
tor valve to the boom position. On units in current 1. There is a gauge port for checking or setting agita-
production, release the pushbutton. tor pressure. Plug the 0600 bar whip gauge into
the port.
AGITATOR
FORWARD REVERSE
Gauge port
behind here
Relief valve
42 E Stop & PS Agit Lever.eps
Figure 50
Agitator relief valve
2. With the engine shut off and the key in your number 30308553. Schwing recommends that you
pocket, remove one of the hoses from the agitator purchase this kit. It will pay for itself many times
motor and plug the hose and the open fitting with over.
approved hydraulic dead plugs. Do not substitute Be sure that one of the locking plugs and cap nuts
other plugs. If you have no hydraulic dead plugs, are tightened on the straight fitting, and that the
contact the Schwing America Spare Parts Depart- dead plugs are securely tightened to the hose and
ment and order them before continuing with this the open motor fitting.
procedure. You will need:
3. Restart the engine, engage the pumps, and bring
the throttle anywhere above idle. Activate the agi-
Qty. 2 VS-16S locking plugs, part number tator valve handle in either forward or reverse.
10016803 Read the gauge. If adjustment is needed, turn the
Qty. 1 GS-16S straight fitting, part number entire valve body in to increase pressure, or out to
10008088 decrease pressure.
Qty. 2 16S cap nuts, part number 10001743 4. When the pressure is set, stop the engine and
or remove the key. Remove the dead plugs and store
Qty. 1 size 16 shutoff valve, part number 10004680 in a clean area or in a plastic bag or another con-
tainer to keep dirt out of the fittings. Reattach the
Qty. 1 size 16 tube, part number 30303432.
hose to the agitator motor fitting and tighten
If you install the shutoff valve, you can leave it
securely. (Torque is correct if you make one com-
installed for future use.
plete revolution after initial resistance increases.)
All of these fittings and many more useful
items are included in the troubleshooting kit, part
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 313
HOME PRINT
Pressure Settings
5. Remove the whip gauge. Restart the engine, if nec- b. Loosen the jam nut on the accumulator unloading
essary. valve. Turn the accumulator unloading valve
adjustment screw in two-and-a-half turns. This will
Set accumulator circuit hydraulic oil raise the pressure above 300 bar (Figure 86).
pressure (units with accumulator
unloading valves)
5.3-7 You will need an assistant for parts of this pro-
cedure. To check or adjust the hydraulic pres-
sure in the accumulator circuit, follow these
steps:
a. Stop the truck, put the key in your pocket, and
place a Do Not Operate sign on the windshield.
Jam nut
Accumulator unloading
valve adjustment screw
s
.ep
Figure 51 un
lvlv
revDate
314 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
s
ep
rl.
an
cm
Accumulator relief valve
ac
P1 P4 P2
P3
MP
S
MP
S
Figure 52
Accumulator redundant relief valve
d. Clear all personnel away from the drive lines, start adjustment is needed, skip to (g). If additional
the truck engine, engage the pumps, and bring pressure adjustment is needed, continue to (f).
engine RPM to maximum. f. Locate the accumulator manifold pressure relief
e. Read the pressure on the accumulator circuit gauge valve (Figure 53). Loosen the jam nut, and turn the
located just between the hopper and the A-frame. screw in to increase pressure, or out to decrease
Pressure should read 300 bar (4350 PSI). If no pressure. Tighten the jam nut when pressure is at
300 bar.
acc
ma
nrlf
.ep
s
Figure 53
Accumulator manifold pressure relief
g. You will need an assistant for this step. With the redundant relief valve on the emergency stop mani-
engine still running, one person must go to the fold and back out the adjustment screw. The other
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 315
HOME PRINT
Pressure Settings
person should stand by the pressure gauge to let
him know when pressure reads 260 bar (3770 PSI).
h. After the truck engine is stopped, go back to the
accumulator circuit hydraulic pump pressure regu-
lator and the turn the screw back out two-and-one-
half turns. This restores it to its original setting.
i. Read the pressure on the accumulator gauge. It
should read 200 bar (2900 PSI).
j. If adjustment is needed, you must stop the truck
engine, or at least stop the drivelines from turning
each and every time you approach the accumulator
circuit hydraulic pump. Turn the screw in to
increase pressure, or out to decrease pressure. Lock
the jam nut when the pressure is correct.
revDate
316 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
S 45/47SX
Figure 54
Oil check plug for spline flange cavity Oil check plug
(4400 gearcase) flange.eps
Pressure Settings
a 13mm wrench. Using a 4mm allen wrench, turn
Soft switch the adjustment screw in (clockwise) one full turn
shutoff valve and tighten the jam nut. Restart the truck engine.
Main Pressure 10. Adjust the engine RPM to maximum specification.
Gauge port (See decal in truck cab)
11. Pressure out the system by activating the concrete
pump forward switch on the rear panel. Using the
rear panel controls will allow you to read the
Concrete pump
concrete pump main system pressure gauge, near
shutoff valve hif
lob
rn
.e
the e-stop manifold, from a safe distance.
ps
revDate
318 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Note: The gauges in the M1 ports will read After pressure cutoff is set, return the pump to neutral,
considerably less than the cutoff pressure of the pump. bring engine RPM to idle, open the soft switch quarter
On a -6 (190/130 pump combination) the 190 will turn valve, and either proceed to other pressure settings
usually read 85 to 90 bar while the 130 reads about 110 or take the transmission and PTO out of gear and shut
bar. They could read the same however, at off the truck.
approximately 110 bar, but the 190 must never read
higher than the 130. The actual cutoff pressure will be 2 PRESSURE CUT OFF
1 STROKE REGULATION
read on the concrete pump main system pressure gauge
3 HORSE POWER 4 Q-MIN
near the e-stop manifold.
16. Activate concrete pump forward to pressure out the 2 2
1
pump and read the pressure on the two gauges in 1 3
3
the M1 ports. 4
4
17. Always stop the truck engine and put the key in
your pocket before making any adjustment on the
hydraulic pump. If the cutoff on one pump is set M1 GAUGE PORT
higher than the other, that pump will be more (BOTTOM OF EACH PUMP)
dominant. The pressure gauge in the M1 port of the 130ajst.eps
Pressure Settings
Concrete pump
shutoff valve hif
lob
rn
.e
ps
Figure 58
Soft switch components
Setting the soft switch relief pressure Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure 58 This unit is equipped with a load-sensing, proportional
right) that you closed in the previous procedure. The boom hydraulic system. In a black-and-white system,
rest of the unit should still be set up as if you were the hydraulic pump puts out an unchanging amount of
going to check the main relief valve pressure (concrete oil, and speed control is done by restricting the oil to
pump shutoff valve still closed). certain functions with orifices. In a load-sensing
When you put the pump in forward now, the main system, the pump puts out more or less oil to respond
concrete pump pressure gauge should read the pressure to the needs of the system. Generally, the pump puts
shown on the schematic for soft switch. If adjustment out enough oil to maintain 20 bar higher pressure at the
is needed, loosen soft switch relief valve jam nut pump than the cylinders actually require. This 20 bar is
(Figure 58 right) with a 9/16 open end wrench, and use called delta P (P). Additionally, we set the hydraulic
a 5/32 allen wrench to adjust the pressure. Turn the pump so that it always puts out a small amount of oil,
adjustment screw in (clockwise) to raise the pressure or even if no oil is needed for the system. This oil is used
out (counter clockwise), to lower the pressure. When to ensure that you have control when you need it. The
you attain the required pressure, tighten the jam nut setting to maintain this minimum amount of oil is
while holding the allen wrench to keep the pressure called Q-min (pronounced cue min). To set the boom
from rising. Be sure to open the concrete pump shutoff or outrigger hydraulic pressures on a load-sensing
valve on the side of the brain (Figure 58 left) when you system, begin by setting P and Q-min.
are finished. The unit will not stroke with this valve Note: The illustration in Figure 59 shows a gauge port
closed. in the center of the main control block. Your main con-
crete pump pressure gauge should be plumbed to that
Setting boom circuit pressures port.
Note! Any time you set pressures for any circuit on any
unit, the hydraulic oil should be at normal operating WARNING
temperature (4060 C). Instructions on heating the
hydraulic oil are found in the first step of this Entanglement hazard. Stop drive shafts
checking hydraulic pressures segment. before adjusting Delta P on A11VO pump.
W020.eps
revDate
320 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
0-600 bar
gauge port
ps
0.e
60
top
es
pretension
only
Boom pressure
33-35 bar
relief cartridge
0-600 bar
gauge port
45bmcnbl.epsL
Figure 59
(Left) The 060 bar gauge port is located at the top of the boom control block, and the 0-600
bar port is at the bottom. (Right) A 0600 bar gauge port is located on the E-stop manifold.
Setting delta P pressure 5. If adjustment is required, loosen the jam nut, and
Note! Do not adjust P or Q-min if your boom is adjust the screw inward to increase pressure or
running as you like it. The pressure setting procedure outward to decrease pressure until it is set at 20
uses a standard starting point and must be fine tuned bar. After achieving proper P, tighten the jam nut
from that point. The pressure was fine tuned at the and bring the engine RPM up. If the pressure
factory and should not be adjusted unless absolutely gauge continues to read 20 bar, you are reading the
necessary. true P pressure and may move on to setting the Q-
min. If the pressure rises with the RPM however,
1. Start by turning off the engine and putting the key you may be reading the Q-min pressure instead of
in your pocket; then place a Do Not Operate sign true P. If that happens, stop the engine, put the
on the windshield of the truck. key in your pocket, and place a Do Not Operate
2. Install a 0-100 bar gauge in the high pressure test sign on the windshield of the truck before
port at the bottom of the boom control block proceeding .
Pressure Settings
Q-min
Delta-p Pressure Cut-off
adjustment screw
hifloreg.eps
Figure 61
Location of Q-min screw on the A7VO (left) and all adjustment screws of the A11VO (right)
Regulator pressure
If pressure cannot be set correctly, there is a problem adjustment
either with the orifices in the base of the regulator or
with the regulator itself. Contact the Schwing Service T
revDate
322 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting Q-min 5. Identify the main boom pressure relief cartridge on
Check Q-min when the engine is at maximum specified the boom control block (Figure 64) and loosen the
RPM. You must not adjust Q-min with the drive jam nut. Then unscrew the adjustment two full
shafts turning! Each time the Q-min screw must be turns.
adjusted, the engine must be stopped, or at least the 6. Take engine RPM to full throttle and activate boom
transmission must be taken out of gear so that the retract for any boom section except #1.
drivelines stop turning. 7. Now adjust pressure, which is read at the main
1. If you unscrewed the Q-min screw as part of the P boom gauge port, to the setting found on the
adjustment, begin by returning the screw to its schematic by turning the boom pressure relief
original position. cartridge in, or clockwise, using no more than 1/4
2. All boom functions must be in neutral, and all turn increments.
emergency stop buttons should be up (not 8. When desired pressure is achieved, lock down the
engaged). Clear away all personnel, start the truck jam nut.
engine, engage the pumps and bring engine RPM
to max. Read the pressure at the 0600 bar main
boom gauge port (Figure 63) with a 0-100 bar
gauge. Pressure should be at 4045 bar. If no
adjustment is needed, be sure the jam nut on the 0-600 bar
Q-min screw is tight, then continue to set the rest gauge port
of the boom and outrigger pressures. If adjustment ps
0.e
60
is needed, continue to the next step. es
top
Pressure Settings
Setting outrigger pressure
mainrlf.eps
After the boom circuit is properly set, you can set the
outrigger pressure. Find the relief cartridge
located on the front of the passenger side outrigger
control valve (Figure 48).
#1 down side
relief cartridge
Figure 65
Outrigger valve bank relief cartridge
and gauge port
revDate
324 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
CONCRETE PUMP
FORWARD/REVERSE
AGITATOR
Relief valve
Gauge port
Figure 66
Agitator component location
Pressure Settings
3. Increase the throttle to any speed above idle. redundant relief cartridge in the emergency stop
Activate the agitator valve handle in either forward manifold(Figure 52 top). If your pump was built after
or reverse, and read the gauge. If it does not read January 1, 2000. It will have an emergency stop
the specified pressure, adjustment is required. Turn manifold similar to the illustration shown in the bottom
the entire valve body (Figure 66) in to increase of Figure 52 which no longer has a redundant relief
pressure or out to decrease pressure. cartridge and you must skip steps 3. and 7. in the
4. When the pressure is set, deactivate the agitator by following procedure.
placing the manual control handle in the neutral To check or adjust the hydraulic pressure in the
position. accumulator circuit:
5. Remove the whip gauge. 1. Stop the truck, put the key in your pocket, and
place a Do Not Operate sign on the windshield.
6. Reopen the shutoff valve or remove the dead plugs
and reconnect the capped hydraulic line. 2. Loosen the jam nut on the pressure regulator of the
accumulator hydraulic pump (Figure 69). Turn the
Set accumulator circuit pressure screw in two-and-one-half turns. This will raise the
regulator pressure above 300 bar.
3. Loosen the jam nut (Figure 70) on the accumulator
redundant relief cartridge located on the
emergency stop manifold. Turn the screw in two
turns. This will raise the relief setting above 300
bar.
45Accreg.eps
accurlf2.eps
Figure 69
Accumulator pump pressure regulator for Figure 70
A7VO (above) and for A11VO (below) Accumulator redundant relief cartridge
(above) is only present on early production
Boom Pump models. New e-stop (below) has no redundant
Accumulator Pump relief cartridge.
Standby
Pressure Screw
Accumulator Pump
Pressure Regulator accumpmp.eps
hgacugc.psd
You will need an assistant for parts of this procedure. 4. Clear all personnel away from the drive lines, start
There are three relief settings for the accumulator the truck engine, engage the pumps, and bring the
circuit if your unit is equipped with an accumulator, engine RPM to maximum.
revDate
326 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
5. Read the pressure on the accumulator circuit counter clockwise to decrease the pressure.
pressure gauge (Figure 71). The pressure should Tighten the jam nut when the pressure reaches the
read the value shown on the hydraulic schematic. If value required.
no adjustment is needed, skip to step number 7. If 7. You will need an assistant for this step. With the
additional pressure adjustment is needed, continue engine still running, one person must go to the
with step number 6. redundant relief valve on the emergency stop
@@@@@@@@
;;;;;;;;
QQQQQQQQ
manifold (Figure 70) and back out the adjustment
@@@@@@@@
;;;;;;;;
QQQQQQQQ
45acumpr.epsL
@@@@@@@@
;;;;;;;;
QQQQQQQQ
gauge to let him know when the pressure reads the
value shown on the schematic for accumulator
@@@@@@@@
;;;;;;;;
QQQQQQQQ
;;;;;;;;
@@@@@@@@
redundant relief.
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
;;;;;;;;
@@@@@@@@
QQQQQQQQ
;;;;;;;;
@@@@@@@@
Figure 71
QQQQQQQQ
Accumulator circuit pressure gauge
acumrlf.epsL
Pressure Settings
revDate
328 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
S 45SX Hi-Flow - 6
Breather
Breather filter grbx-5-6.eps
filler spout
Oil check plug
Figure 73
Check fluid level of distribution gearcase Stiebel
box 4194 (left) or 4400 (right)
Figure 74
Oil check plug for spline flange cavity Oil check plug
(4400 gearcase) flange.eps
Setting Pressures Pressure settings must be made with the oil at normal
operating temperatures (40 60 C). In the past we
The following pages provide the proper techniques for could pressure out a function in the boom or outrigger
checking and setting hydraulic pressures of each system to create heat, but load sensing systems no
system included on your unit. longer allow maximum oil flow to be forced over relief.
Because of this the agitator circuit must be used to heat
Check all hydraulic pressures. the hydraulic oil.
Changes in pressures can indicate trouble in one or To preheat the hydraulic oil:
more components. The specifications for each circuit
1. Locate the agitator shutoff valve (Figure 55) and
are shown on the hydraulic schematics found in the
close it. NOTE! If your unit does not have a
Appendix of this manual. The hydraulic schematics are
shutoff valve, order one from the Schwing Spare
the only documents in this manual that have been
Parts Department using part number 10004680
updated specifically for your unit, by the serial number,
(valve), and number 30303432 (tube). Contact the
so in each of the following procedures you will be told
Service Department for installation instructions.
to refer to the schematic for the pressure required.
Preheat the hydraulic oil
Pressure Settings
2. Activate the agitator. With the valve closed the 1. Be sure that the waterbox covers and guards are in
agitator will not be able to turn and the oil will be place any time you will be working in the area
forced over the relief valve. At an idle (about 600 around the main control block.
RPM), 4.5 horsepower is being converted to heat. 2. Wear safety glasses when working around a
concrete pump.
agitoff2.eps
Note! It is vital that each adjustment screw be properly
identified prior to making any adjustment. All screw
adjustments for the system relief must be made with
the pumpkit in the neutral position and adjustments for
pressure cutoff must be made with the engine shut off.
3. Start the truck engine, and put the PTO in gear just
as you would to pump a job.
4. If you have not already closed the soft switch
Figure 75 Agitator shutoff valve shutoff valve and the concrete pump shutoff valve
3. When the oil temperature gauge shows 50C, open (Figure 56) do so at this time.
the shutoff valve. 5. At the rear panel, select local control with the
local/remote switch and turn the electric stroke
Setting the main relief pressure and limiter knob clockwise to maximum strokes per
pressure cutoff on Hi-flo -6 pumpkits minute.
a. To set the pressure of the main relief valve on 6. The main system control block pressure must be
Hi-flo pumpkits, you must first disable the soft set first to properly set the pressure cutoff on both
switch circuit. Simply locate the ball cock for pumps. Begin by backing off the jam nut of the
the soft switch circuit (Figure 76) and close it main relief cartridge (Figure 78) with a 9/16 inch
by rotating the handle 90 degrees. wrench.
b. The quarter turn shutoff valve for the concrete 7. Using a 5/32 inch allen wrench, turn the
pump (Figure 76) will also need to be closed adjustment screw out (counterclockwise) until you
during this procedure. can feel no spring tension on the adjustment screw.
Note: Main system adjustments are preset at the 8. Now, turn the screw back in (clockwise) two or
factory. The following procedure begins with three full turns to give you a proper starting point
adjustment of the main relief cartridge and pressure and tighten the jam nut.
cutoff. If proper pressures can not be obtained through 9. Stop the truck engine and put the key in your
these steps, contact the Schwing Service Department pocket. Adjust the pressure cutoff screw (Figure
for specific instructions on the adjustment of flow, 57) on each pump, by backing off the jam nut with
horsepower, beginning of stroke regulation and Q-min. a 13mm wrench. Using a 4mm allen wrench, turn
Pressure setting procedure: the adjustment screw in (clockwise) one full turn
and tighten the jam nut. Restart the truck engine.
Soft switch 10. Adjust the engine RPM to maximum specification.
shutoff valve
(See decal in truck cab)
Main Pressure 11. Pressure out the system by activating the concrete
Gauge port
pump forward switch on the rear panel. Using the
rear panel controls will allow you to read the
concrete pump main system pressure gauge, near
the e-stop manifold, from a safe distance.
Concrete pump Note: Because you turned out the pressure relief
shutoff valve hif
lob
rn.
ep
s cartridge in step 7, the system pressure should read low
Figure 76 at this time. If it does not and the gauge spikes to 320
Concrete pump, Soft switch shutoff valves bar or more, disengage the pump immediately. Turn the
relief cartridge out (counterclockwise) more. For
safety, it is important to adjust the pressure up from
revDate
330 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
below the specified target pressure rather than down other. To equalize the two pumps you must either
from a pressure which exceeds the target. Continue this adjust the cutoff screw in (clockwise) to increase
procedure until the main system pressure gauge reads the pressure of the pump showing the higher
lower than the specified target. reading or adjust the cutoff screw of the dominant
12. To increase the pressure put the pump in the pump showing the lower reading out
neutral position and adjust the relief cartridge by (counterclockwise) to reduce the pressure. These
turning it in (clockwise). When increasing the adjustments must be made until the two gauges in
pressure, the adjustments should be made in the M1 ports are reading approximately the same.
quarter turn increments. If you make adjustments 18. When you have achieved the same pressure on the
to increase the pressure but the pressure does not M1 port gauges, you can begin to adjust the
come up, you are probably reading the pressure pressure cutoff screws in or out simultaneously
cutoff of the pumps, if so proceed to the next step until you achieve the desired pressure setting of
otherwise skip to step 15.Turn the relief cartridge 350 bar (again, confirm the pressure specification
adjustment screw back out (counterclockwise) with the hydraulic schematic).
until you can no longer see a pressure drop and After pressure cutoff is set, return the pump to neutral,
tighten the jam nut. bring engine RPM to idle, open the soft switch quarter
13. Stop the truck engine, put the key in your pocket. turn valve, and either proceed to other pressure settings
14. Go to the pressure cutoff screw on both hydraulic or take the transmission and PTO out of gear and shut
pumps (Figure 77) and back off the jam nut with a off the truck.
13mm wrench. Turn the adjustment screws in with
a 4mm allen wrench one or two more turns, restart
the engine and check the pressure again. Repeat
this procedure until the main system relief can be
set to the target pressure.
15. When the proper main relief pressure is achieved,
pressure cutoff can be set. Shut off the engine, put
the key in your pocket and install 0-600 bar gauges
with whip hoses to the M1 gauge ports on the
bottom of the two hydraulic pumps (Figure 77).
You must be able to read both gauges
-6adjust.eps
simultaneously to ensure that one pump is not
more dominant than the other.
Note: The gauges in the M1 ports will read
considerably less than the cutoff pressure of the pump.
On a -6 (190/130 pump combination) the 190 will Figure 77
usually read 85 to 90 bar while the 130 reads about 110 A11VO adjustment screws for Hi-flo 6
bar. They could read the same however, at units 190/130
approximately 110 bar, but the 190 must never read
higher than the 130. The actual cutoff pressure will be
read on the concrete pump main system pressure gauge
near the e-stop manifold.
16. Activate concrete pump forward to pressure out the
pump and read the pressure on the two gauges in
the M1 ports.
17. Always stop the truck engine and put the key in
your pocket before making any adjustment on the
hydraulic pump. If the cutoff on one pump is set
higher than the other, that pump will be more
dominant. The pressure gauge in the M1 port of the
dominant pump will however, read lower than the
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 331
HOME PRINT
Pressure Settings
opencls.eps
pumpkit will be rotated 9/16" jam nut
180 degrees from the
illustration shown
5/32" Allen head
ga
ug
pr
t.e
ps
9/16" jam nut
Figure 78
Location of soft switch shutoff and relief cartridges
Setting the soft switch relief pressure Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure 78 This unit is equipped with a load-sensing, proportional
right) that you closed in the previous procedure. The boom hydraulic system. In a black-and-white system,
rest of the unit should still be set up as if you were the hydraulic pump puts out an unchanging amount of
going to check the main relief valve pressure (concrete oil, and speed control is done by restricting the oil to
pump shutoff valve still closed). certain functions with orifices. In a load-sensing
When you put the pump in forward now, the main system, the pump puts out more or less oil to respond
concrete pump pressure gauge should read the pressure to the needs of the system. Generally, the pump puts
shown on the schematic for soft switch. If adjustment out enough oil to maintain 20 bar higher pressure at the
is needed, loosen Soft switch relief valve jam nut pump than the cylinders actually require. This 20 bar is
(Figure 78 right) with a 9/16 open end wrench, and use called delta P (P). Additionally, we set the hydraulic
a 5/32 allen wrench to adjust the pressure. Turn the pump so that it always puts out a small amount of oil,
adjustment screw in (clockwise), to raise the pressure even if no oil is needed for the system. This oil is used
or out (counter clockwise), to lower the pressure. When to ensure that you have control when you need it. The
you attain the require pressure, tighten the jam nut setting to maintain this minimum amount of oil is
while holding the allen wrench, to keep the pressure called Q-min (pronounced cue min). To set the boom
from rising. Be sure to open the concrete pump shutoff or outrigger hydraulic pressures on a load-sensing
valve on the side of the brain (Figure 78 left) when you system, begin by setting P and Q-min.
are finished. The unit will not stroke with this valve Note: The illustration in Figure 78 shows a gauge port
closed. in the center of the main control block. Your main
concrete pump pressure gauge should be plumbed to
Setting boom circuit pressures that port
Note! Any time you set pressures for any circuit on any
unit, the hydraulic oil should be at normal operating
temperature (4060 C). Instructions on heating the
hydraulic oil are found in the first step of this
checking hydraulic pressures segment.
Read all of the instructions before beginning any pres-
sure settings. You will need an assistant for parts of the
procedure. You and any assistants should wear eye pro-
tection when setting pressures.
revDate
332 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 52M (pre-1998) As mentioned earlier before we check or adjusts
settings of the pressure limit valve or the two relief
valves, we must make sure the Delta-P and Q-
Pressure Settings for KVM 52 Proportional
minimum settings are correct.
Load Sensing
NOTE!
NOTE:All pressure settings must be done
when the hydraulic oil is at 50 to 70 degrees
Celsius.
Please read all instructions before attempting to check
or set pressures.
There is a pressure limit valve and two different relief
valves in the KVM 52 boom circuit. Before checking
or setting these 3 valves, you should make sure that the
Delta-P setting on the pressure regulator and the Q
minimum setting on the hydraulic pump are properly
set. In order to help you better understand this, we will
describe the functions of each valve and the hydraulic
pump before attempting to set or check pressures.
Refer to Illustration 3 on Page- E2 for the location of
each item as it is mounted on the unit.
Figure 1 of this page, is called the pressure regulator.
Adjusting screw (item 4) is the pressure limit function
of the pressure regulator. Adjusting screw (item 3) is
the Delta-P function of the regulator. The Delta-P
function senses pressure on both sides of the boom
control blocks, and adjusts the output flow of the
hydraulic pumps.
Figure 2 of this page is the "normally open" relief
valve. (Normally open denotes that unless the coil is
energized, the relief valve will not develop any
pressure). This is the valve that opens and vents your
boom circuit to tank when you hit the red emergency
shut off button on your remote control box or
operations panel.
Figure 3 of this page shows one of the two boom
control blocks. (Item 5) is pointing to the primary
relief valve located on the control block. It's function
is to protect the block from any pressure spikes that
might be in the system.
Figure 4 of this page is the boom circuit hydraulic
pump. This style of hydraulic pump has a variable
output depending on the requirements of the boom,
which is controlled by the pressure regulator described
in Figure 1 (above).
Figure 5 of this page is the pre-control block. (Item 6)
designates the gauge port. (Item 7) designates the 34
Bar pressure reducing valve. (Item 8) designates the
50 Bar pretension relief valve.
Pressure Settings
Component Location Guide- KVM 52
KVM 52M
Illustration 3
item item 5
4
item 3 a6 b6
A6
T
FIGURE 1 a5 b5
A5 B5
item 2 a4
b4
24V A4 B4
FIGURE 2 FIGURE 3
item item
1 8
STOP for Q min
L
P
item
6
item
7
FIGURE 4 FIGURE 5
Pressure Settings
Pressure Regulator Cutaway KVM 52
Pressure
Regulator
P
Regulator
X
A T
P 0.8 mm
NOTE:
NO ORIFICE
USED ON KVM 52
revDate
336 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Pressure Settings for Regulator and Releif Setting Pretension Pressure(Refer to
Valves KVM 52 Figure 5)
Now that we know our delta-P and Q-minimum are set a. To set the pretension pressure, install a 0-250
correct we can check and reset the pressure limit and Bar gauge and connection hose on the gauge
two relief valves. The correct pressure settings are as port (item 6). Loosen the locknut on the
follows: pressure reducing valve (item 7), and turn the
adjusting screw inward approximately two
1) PRESSURE REGULATOR (Figure turns. This will raise the valves pressure
1, item 4)320 Bar higher than 50 Bar.
b. While holding a function pressured out, adjust
2) CONTROL BLOCK RELIEF (Figure the pretension relief valve (item 8), until the
3, item 5)350 Bar gauge reads 50 Bar.
c. Remove 0-250 Bar gauge, and install a 0-40
3) NORMALLY OPEN BYPASS VALVE
Bar gauge. With all boom functions in neutral
(Figure 2, item 2)360 Bar and engine at full rpms (this provides Q-Min),
In order to reset the valve with the highest pressure, we adjust the pressure reducing valve (item 7),
must first raise the pressure of the other two valves. until the gauge reads 34 Bar.
a. To set the pressure regulator (Figure 1), loosen (CAUTION!!! - do not activate any boom
the lock nut (Item 4), and turn the adjusting functions during this operation or damage
screw inward approximately two turns. This to the 0-40 Bar gauge will result).
will raise the pressure of this valve higher than
360 bar.
b. To set the control block (Figure 3), loosen the
lock nut (item 5), and turn the adjusting screw
inward approximately one turn. This will raise
the relief pressure higher than 360 Bar.
c. Pressure out any boom section. The pressure
can now be read on the 0-600 Bar gauge that is
near the control blocks. The gauge should read
360 Bar. If not, adjust the normally open
bypass valve, (Figure 2, item 2). After you
have this relief set to 360 Bar, you can lock the
locknut and move on to the control block
relief. (Be careful not break off the electrical
connections or over-torque the locknuts on this
valve.
d. While you continue to hold a function
pressured out you can adjust the control block
relief valve (Figure 3, item 5), until the
pressure gauge now reads 350 Bar. After this
pressure is set and the locknut is locked,
proceed to the pressure regulator.
e. While still holding a function pressured out
you can now adjust the pressure regulator (Fig.
1, Item 4), until the pressure gauge reads 320
Bar. When this pressure has been set and the
locknut is locked, you are finished setting the
main circuit pressures on the boom.
Pressure Settings
Control Block 1 for KVM 52 Boom 3, Boom 4, & Slewing
a3 b3
A3 B3 BOOM #3
BOOM DOWN TIME
SPEED ADJUSTMENT a2 b2
A2 B2 BOOM #4
a1
b1
A1 B1 SLEWING
BOOM UP TIME
SPEED ADJUSTMENT
A1-A3 B1-B3
T
a1-a3 b1-b3
P
revDate
338 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Control Block 2 for KVM 52 Boom 1, Boom 2, & Outriggers
a6 b6
A6
OUTRIGGER
a5 b5
A5 B5 BOOM #1
a4
b4
BOOM DOWN TIME
A4 B4 BOOM #2
SPEED ADJUSTMENT
BOOM UP TIME
SPEED ADJUSTMENT
A4-A6 B4-B6
T
a4-a6 b4-b6
P
Pressure Settings
Pre-Control Block 1-A for KVM 52
PRETENSION RELIEF
O-ring
50 Bar
Filter
O-ring
Orifice
NOT USED
24V
L
PV (PST)
24V
PRESSURE
REDUCING
NOTE: 34 Bar
GAUGE PORT FOR CHECKING THESE PRESSURES
IS ON THE PRE-CONTROL BLOCK 2-A.
revDate
340 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Pre-Control block 1-B for KVM 52
TOP VIEW
b3 b2 b1
PV
BOTTOM VIEW
REXROTH a1 a2 a3
M10-100S
a1 a2 a3
INPUT INPUT INPUT
342
PRINT
Pressure Settings
PV
(PST)
50
Service Manual
BAR
34
BAR
P L b1 b1 a1 a1 b2 b2 a2 a2 b3 b3 a3 a3
revDate
HOME
PRINT
Service Manual
24V 24V 24V 24V 24V 24V 24V
PV PV
SERVICE TRAINING
(PST) (PST)
b4 a4 b5 a5 b6
L REXROTH L
Quick
M10-1006
Gauge
Port
b4 a4 b5 a5 b6
INPUT INPUT INPUT INPUT INPUT
Pressure Settings
343
HOME
344
PRINT
Pressure Settings
PV (PST) PV (PST)
GAUGE PORT
L X L
Service Manual
b4 b4 a4 a4 b5 b5 a5 a5 b6 b6
revDate
HOME PRINT
SERVICE TRAINING
Pressure Settings
Electric Bypass Valve for KVM 52
A A
360 Bar
PRESSURE ADJUSTMENT
15 FT.LBS.
LOCK NUT
7.5 FT.LBS.
CARTRIDGE(COMPLETE)
37 FT.LBS.
Y X
A A A
SAI ITEM#
(Cartridge Only)
B 10055188
Pressure Settings
revDate
346 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
S 52 SX 2. Activate the agitator. With the valve closed, the
agitator will not be able to turn and the oil will be
forced over the relief valve. At an idle (about 600
Setting Pressures RPM), 4.5 horsepower is being converted to heat.
The following pages provide the proper techniques for 3. When the oil temperature gauge shows 50C, open
checking and setting hydraulic pressures of each the shutoff valve.
system included on your unit. Agitator quarter turn
000174.eps
Pressure Settings
Setting pressures on Hi-flo -6 pumpkits shutoff valve and the concrete pump shutoff valve
To set the pressure of the main relief valve on (Figure 56), do so at this time.
Hi-flo pumpkits, you must first disable the soft 5. At the Vector controller, select local control with
switch circuit. Simply locate the ball cock the local/remote switch, and activate the electric
shutoff for the soft switch circuit (Figure 56), stroke limiter switch to maximum strokes per
and close it by rotating the handle 90 degrees. minute.
The quarter turn shutoff valve for the concrete 6. The main system control block pressure must be
pump (Figure 56) will also need to be closed set first to properly set the pressure cutoff on both
during this procedure. pumps. Begin by backing off the jam nut of the
NOTE! main relief cartridge (Figure 58) with a 9/16 inch
wrench.
Main system adjustments are preset at the
factory. The following procedure begins 7. Using a 5/32 inch allen key, turn the adjustment
with adjustment of the main relief cartridge screw out (counterclockwise) until you can feel no
and pressure cutoff. If proper pressures can spring tension on the adjustment screw.
not be obtained through these steps, contact
the Schwing Service Department for specific 8. Now, turn the screw back in (clockwise) two or
instructions on the adjustment of flow, three full turns to give you a proper starting point,
horsepower, beginning of stroke regulation and tighten the jam nut.
and Q-min.
9. Stop the truck engine, and put the key in your
Pressure setting procedure: pocket. Adjust the pressure cutoff screw (Figure
57) on each pump by backing off the jam nut with
Soft switch a 13mm wrench. Using a 4mm allen key, turn the
shutoff valve adjustment screw in (clockwise) one full turn, and
tighten the jam nut. Restart the truck engine.
Main Pressure
Gauge port 10. Adjust the engine RPM to maximum specification.
(See decal in truck cab)
11. Pressure out the system by activating the concrete
pump forward switch on the rear panel. Using the
rear panel controls will allow you to read the
Concrete pump
shutoff valve 00
02
concrete pump main system pressure gauge, near
74
.e
ps
the e-stop manifold, from a safe distance.
Figure 80 NOTE!
Concrete pump and Soft switch shutoff Because you turned out the pressure relief
cartridge in step 7, the system pressure
1. Be sure that the waterbox covers and guards are in should read low at this time. If it does not,
place any time you will be working in the area and the gauge spikes to 320 bar or more,
disengage the pump immediately. Turn the
around the main control block. relief cartridge out (counterclockwise)
2. Wear safety glasses when working around a more. For safety, it is important to adjust
concrete pump. the pressure up from below the specified
target pressure rather than down from a
NOTE! pressure which exceeds the target. Continue
It is vital that each adjustment screw be this procedure until the main system pres-
properly identified prior to making any sure gauge reads lower than the specified
adjustment. All screw adjustments for the target.
system relief must be made with the pump- 12. To increase the pressure put the pump in the
kit in the neutral position, and adjustments neutral position, and adjust the relief cartridge by
for pressure cutoff must be made with the turning it in (clockwise). When increasing the
engine shut off.
pressure, the adjustments should be made in
3. Start the truck engine, and put the PTO in gear just
quarter turn increments. If you make adjustments
as you would to pump a job.
to increase the pressure but the pressure does not
4. If you have not already closed the soft switch come up, you are probably reading the pressure
revDate
348 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
cutoff of the pumps. If so, proceed to the next step; 16. Activate concrete pump forward to pressure out the
otherwise skip to step 15. Turn the relief cartridge pump, and read the pressure on the two gauges in
adjustment screw back out (counterclockwise) the M1 ports.
until you can no longer see a pressure drop, and 17. Always stop the truck engine and put the key in
tighten the jam nut. your pocket before making any adjustment on the
13. Stop the truck engine and put the key in your hydraulic pump. If the cutoff on one pump is set
pocket. higher than the other, that pump will be more
14. Go to the pressure cutoff screw on both hydraulic dominant. The pressure gauge in the M1 port of the
pumps (Figure 57), and back off the jam nut with a dominant pump will, however, read lower than the
13mm wrench. Turn the adjustment screws in with other. To equalize the two pumps, you must either
a 4mm allen key one or two more turns, restart the adjust the cutoff screw in (clockwise) to increase
engine, and check the pressure again. Repeat this the pressure of the pump showing the higher
procedure until the main system relief can be set to reading or adjust the cutoff screw of the dominant
the target pressure. pump showing the lower reading out
(counterclockwise) to reduce the pressure. These
15. When the proper main relief pressure is achieved,
adjustments must be made until the two gauges in
pressure cutoff can be set. Shut off the engine, put
the M1 ports are reading approximately the same.
the key in your pocket, and install 0-600 bar
gauges with whip hoses to the M1 gauge ports 18. When you have achieved the same pressure on the
on the bottom of the two hydraulic pumps (Figure M1 port gauges, you can begin to adjust the
57). You must be able to read both gauges pressure cutoff screws in or out simultaneously
simultaneously to ensure that one pump is not until you achieve the desired pressure setting of
more dominant than the other. 350 bar (again, confirm the pressure specification
with the hydraulic schematic).
NOTE!
19. After pressure cutoff is set, return the pump to
The gauges in the M1 ports will read consid-
erably less than the cutoff pressure of the neutral, bring engine RPM to idle, open the soft
pump. On a -6 (190/130 pump combina- switch quarter turn valve, and either proceed to
tion), the 190 will usually read 85 to 90 bar, other pressure settings or take the transmission and
while the 130 reads about 110 bar. They PTO out of gear and shut off the truck.
could read the same, however, at approxi-
mately 110 bar, but the 190 must never read
higher than the 130. The actual cutoff pres-
sure will be read on the concrete pump main
system pressure gauge near the e-stop mani-
fold.
000277.eps
2
2
3
1 1
3
4 4
Figure 81
A11VO adjustment screws M1 GAUGE PORT
for Hi-flo 6 units 190/130 (BOTTOM OF EACH PUMP)
Pressure Settings
Soft switch
shutoff valve Closed Open
000276.eps
9/16" jam nut
Figure 82
Soft switch components
Setting the soft switch relief pressure Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure This unit is equipped with a load-sensing, proportional
58, right) that you closed in the previous procedure. boom hydraulic system. In a black-and-white system,
The rest of the unit should still be set up as if you were the hydraulic pump puts out an unchanging amount of
going to check the main relief valve pressure (concrete oil, and speed control is done by restricting the oil to
pump shutoff valve still closed). certain functions with orifices. In a load-sensing
When you put the pump in forward now, the main system, the pump puts out more or less oil to respond
concrete pump pressure gauge should read the pressure to the needs of the system. Generally, the pump puts
shown on the schematic for soft switch. If adjustment out enough oil to maintain 20 bar higher pressure at the
is needed, loosen soft switch relief valve jam nut pump than the cylinders actually require. This 20 bar is
(Figure 58 right) with a 9/16 open end wrench, and use called delta P (P). Additionally, we set the hydraulic
a 5/32 allen key to adjust the pressure. Turn the pump so that it always puts out a small amount of oil,
adjustment screw in (clockwise) to raise the pressure or even if no oil is needed for the system. This oil is used
out (counterclockwise) to lower the pressure. When to ensure that you have control when you need it. The
you attain the required pressure, tighten the jam nut setting to maintain this minimum amount of oil is
while holding the allen key to keep the pressure from called Q-min (pronounced cue min). To set the boom
rising. Be sure to open the concrete pump shutoff valve or outrigger hydraulic pressures on a load-sensing
on the side of the brain (Figure 58, left) when you are system, begin by setting P and Q-min.
finished. The unit will not stroke with this valve closed. Note: The illustration in Figure 58 shows a gauge port
in the center of the main control block. Your main
Setting boom circuit pressures concrete pump pressure gauge should be plumbed to
Read all of the instructions before beginning any that port.
pressure settings. You will need an assistant for parts of
the procedure. You and any assistants should wear eye
protection when setting pressures.
WARNING
NOTE!
Any time you set pressures for any circuit
on any unit, the hydraulic oil should be at Entanglement hazard. Stop drive shafts
000004.eps
normal operating temperature (4060 C). before adjusting Delta P on A11VO pump.
Instructions on heating the hydraulic oil are
found in the first step of this checking
hydraulic pressures segment.
revDate
350 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
gauge ports
for Delta P
Figure 83
Gauge ports for setting Delta P
delta/p.eps
Pressure Settings
If pressure cannot be set correctly, there is a problem NOTE!
with the regulator itself. Contact the Schwing Service If you dont have a 0-100 bar gauge, you can
Department to determine how to continue. order one from Schwing Spare Parts
Department at (800) 328-9635, part #
If the boom does not run smoothly at 20 bar, you must 10004659.
fine tune the adjustment. Remove the gauge, and turn
the P adjustment screw until the boom is responsive
and smooth. After adjusting, the difference between the
gauges (reinstalled) must read between 14-25 bar. The
electronics in the control system can also affect how
the boom operates, so if P adjustment does not seem Boom pressure
relief cartridge
to help, reset to 20 bar and check the electrical settings.
When the electrical settings are verified, you could
again try to refine the boom action with the P
adjustment.
ps
lf.e
ssr
pre
0-600 bar
WARNING gauge port
Figure 85
0-600 bar gauge port
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.
1. All boom functions must be in neutral, and all Delta-p Pressure Cut-off
emergency stop buttons should be up (not
engaged). Clear away all personnel, start the truck
engine, engage the pumps, and bring engine RPM
to max. Read the pressure at the 0600 bar main
boom gauge port (Figure 124) with a 0-100 bar
gauge. Pressure should be at 4045 bar. If no
adjustment is needed, be sure the jam nut on the
Q-min screw is tight, then continue to set the rest
of the boom and outrigger pressures. If adjustment
is needed, continue to the next step. 000282.eps
2. Turn the Q-min screw (Figure 125) in to raise the Q-min Q-max (Bottom Of Pump)
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 Figure 86
is correct, tighten the jam nut on the adjustment Location of Q-min screw
screw before continuing with the other procedures;
then, recheck P to make sure that it hasnt
changed during the Q-min adjustment.
revDate
352 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting boom pressures
Now that P and Q-min are set, you can remove the 0-
100 bar pressure gauge and proceed to check and
adjust the main boom pressures.
Boom pressure
relief cartridge
Figure 89 000257.eps
Approved dead
plugs Cap Nuts
ps
lf.e
ssr
pre
Pressure Settings
Setting pressure cut-off
Delta-p Pressure Cut-off
10. Return to the pressure cut-off screw (Figure 131).
Back off the jam nut, and turn the screw counter
clockwise until you achieve the pressure shown on
the schematic, then lock the jam nut.
dwnsdrlf.eps
Figure 93
Piston side relief
NOTE!
Figure 91
HWslew.eps If you are unable to achieve 230 bar by
Boom slewing adjusting the relief valve in Figure 64, call
Boom Slewing
relief valves relief valves the Schwing Service Department and ask if
the unit has a redundant relief valve.
revDate
354 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting outrigger pressure Setting the agitator pressure
The agitator circuit has a maximum pressure shown on
WARNING the hydraulic schematic, which is limited by the relief
cartridge (Figure 50) in the agitator hand valve. The
Tipping hazard. Never set outrigger relief cartridge is located on the back side of the
pressures with the boom unfolded. agitator manual control handle (Figure 50). The
Pressure setting procedure requires cartridge is adjustable with just a 19mm open end
retraction of an outrigger jacking wrench.
000359.eps
cylinder. 1. Plug the 0600 bar whip gauge into the gauge port
(Figure 50) for checking or setting agitator pres-
After the boom circuit is properly set, you can set the sure.
outrigger pressure. Find the relief cartridge 2. Locate the agitator shutoff valve (Figure 67), and
located on the front of the passenger side outrigger close it. If your unit does not have a shutoff valve,
control valve (Figure 48). order one from the Schwing Spare Parts Depart-
1. Attach 0-600 bar whip gauge to the gauge port ment using part numbers 10004680 (valve) and
below the outrigger valve bank. 30303432 (tube). Contact the Service Department
2. Push the outrigger enable button. for installation instructions. If you cant wait for a
shutoff valve, you will need to remove one of the
3. Activate an outrigger jacking cylinder to retract.
hoses from the agitator motor and plug the hose
By retracting a fully retracted cylinder, the oil
and open fitting with approved hydraulic dead
coming from the pump has nowhere to go but over
plugs (Figure 68).
the relief valve. You cannot use an extension or
slewing cylinder because they have secondary NOTE!
relief functions (nonadjustable) built into the valve. Do not jam the paddles to force the oil over
While holding the handle to retract, read the relief by stopping the movement of the
pressure gauge. agitator.
4. The pressure should read the bar value shown on 3. Increase the throttle to any speed above idle. Acti-
the hydraulic schematic. Adjust by loosening the vate the agitator valve handle in either forward or
jam nut and turning the cartridge (Figure 48) in or reverse, and read the gauge. If it does not read the
out. When the proper pressure is achieved, let go of specified pressure, adjustment is required. Turn the
the handle, and release the outrigger enable button. entire relief valve cartridge (Figure 50) in to
increase pressure or out to decrease pressure.
4. When the pressure is set, deactivate the agitator by
placing the manual control handle in the neutral
position.
5. Remove the whip gauge.
6. Reopen the shutoff valve or remove the dead plugs,
Outrigger valve and reconnect the capped hydraulic line.
Agitator Relief Valve Turn body of valve
relief cartridge Gauge port Higher
to adjust.
Lower
ps
2.e
itrlf
ag
otrigrlf.eps
Figure 95
Figure 94 Agitator relief cartridge located on
Outrigger valve bank relief cartridge back side hand valve
Pressure Settings
000174.eps
Agitator quarter turn
shutoff valve (open position)
Motor
Figure 96
Agitator shutoff valve
000289.eps
Accumulator pump
Figure 97 pressure regulator
000257.eps
Approved hydraulic
dead plugs
Cap Nuts
Figure 98
Accumulator pump pressure regulator for
A7VO (above) and for A11VO on a unit
Setting accumulator circuit pressure with a stiebel gearcase (below)
To check or adjust the hydraulic pressure in the
accumulator circuit:
1. Stop the truck, put the key in your pocket, and
Boom Pump
place a Do Not Operate sign on the windshield.
Accumulator Pump
2. Loosen the jam nut on the pressure regulator of the
accumulator hydraulic pump (Figure 51). Turn the
screw in two-and-one-half turns. This will raise the
regulator pressure above 300 bar.
Accumulator Pump
Pressure Regulator
Standby 000446.eps
revDate
356 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
000449.eps
Manual bleed
Boom pressure valve
relief cartridge
ps
lf.e
ssr
pre
Figure 99
New e-stop has no redundant Figure 101
relief cartridge. Accumulator manifold pressure
relief cartridge
Figure 100
Accumulator circuit pressure gauge
Pressure Settings
WARNING
Entanglement hazard. Stop drive shafts
before adjusting the accumulator pump
000075.eps
pressure regulator.
revDate
358 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 52M replaced in a different configuration the grooves in
the handle may no longer indicate the proper open/
Preheat the hydraulic oil. Pressure settings must be closed orientation of the valve. The grooves in the
made with the oil at normal operating temperatures shaft give the only true indication of the valves
(50 to 60 C). In the past we could pressure out a position.
function in the boom or outrigger system to create heat, Note! If your unit is an early production model,
but today, load sensing systems no longer allow and does not have an agitator shutoff valve, order
maximum oil flow to be forced over relief. Because of one from the Schwing Spare Parts Department,
this, the agitator circuit must be used to heat the using part number 10004680 (valve) and number
hydraulic oil. 30303432 (tube). Contact the Service Department
To heat the oil to operating temperature: for installation instructions.
1. Locate the agitator shutoff valve (Figure 102) and 2. Activate the agitator. With the valve closed, the
close it. The quarter turn shutoff valve has a agitator will not be able to turn and the oil will be
grooved line (Figure 102) on the shaft or pivot forced over the relief valve. At an idle (about 600
point of the handle as well as on the handle itself, RPM) you will be converting 4.5 horsepower to
which will indicate the open or closed heat.
configuration of the valve. If the handle is removed 3. When the oil temperature gauge shows 50 C, open
from the agitator shutoff valve (Figure 102) or the the shutoff valve.
concrete pump shutoff valve (Figure 103) and
agitoff.eps
Figure 102
Agitator shutoff valve (left) and Open/closed orientation of shutoff valve (right)
Pressure Settings
Soft switch
shutoff valve
Main Pressure
Gauge port
Figure 103
Concrete pump and Soft switch shutoff
valves
Concrete pump
hif
shutoff valve low
br
n.
ep
s
Note: Main system adjustments are preset at the 8. Now, turn the screw back in (clockwise) two or
factory. The following procedure begins with three full turns to give you a proper starting point
adjustment of the main relief cartridge and pressure and tighten the jam nut.
cutoff. If proper pressures can not be obtained through 9. Stop the truck engine, put the key in your pocket
these steps, contact the Schwing Service Department and adjust the pressure cutoff screw (Figure 104)
for specific instructions on the adjustment of flow, on each pump, by backing off the jam nut with a
horsepower, beginning of stroke regulation and Q-min. 13mm wrench. Using a 4mm allen wrench, turn the
Pressure setting procedure: adjustment screw in (clockwise) one full turn and
1. Be sure that the waterbox covers and guards are in tighten the jam nut. Restart the truck engine.
place any time you will be working in the area 10. Adjust the engine RPM to maximum specification.
around the main control block. (See decal in truck cab)
2. Wear safety glasses when working around a 11. Pressure out the system by activating the concrete
concrete pump. pump forward switch on the rear panel. Using the
Note! It is vital that each adjustment screw be properly rear panel controls will allow you to read the
identified prior to making any adjustment. All screw concrete pump main system pressure gauge, near
adjustments for the system relief must be made with the e-stop manifold, from a safe distance.
the pumpkit in the neutral position and adjustments for Note: Because you turned out the pressure relief
pressure cutoff must be made with the engine shut off. cartridge in step 7, the system pressure should read low
3. Start the truck engine, and put the PTO in gear just at this time. If it does not and the gauge spikes to 320
as you would to pump a job. bar or more, disengage the pump immediately. Turn the
4. If you have not already closed the soft switch relief cartridge out (counterclockwise) more. For
shutoff valve and the concrete pump shutoff valve safety, it is important to adjust the pressure up from
(Figure 103) do so at this time. below the specified target pressure rather than down
from a pressure which exceeds the target. Continue this
5. At the rear panel, select local control with the
procedure until the main system pressure gauge reads
local/remote switch and turn the electric stroke
lower than the specified target.
limiter knob clockwise to maximum strokes per
minute. 12. To increase the pressure put the pump in the
6. The main system control block pressure must be neutral position and adjust the relief cartridge by
set first to properly set the pressure cutoff on both turning it in (clockwise). When increasing the
pumps. Begin by backing off the jam nut of the pressure, the adjustments should be made in
main relief cartridge (Figure 104) with a 9/16 inch quarter turn increments. If you make adjustments
wrench. to increase the pressure but the pressure does not
7. Using a 5/32 inch allen wrench, turn the come up, you are probably reading the pressure
adjustment screw out (counterclockwise) until you cutoff of the pumps, if so proceed to the next step
can feel no spring tension on the adjustment screw. otherwise skip to step 15.Turn the relief cartridge
revDate
360 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
adjustment screw back out (counterclockwise) 16. Activate concrete pump forward to pressure out the
until you can no longer see a pressure drop and pump and read the pressure on the two gauges in
tighten the jam nut. the M1 ports.
13. Stop the truck engine, put the key in your pocket. 17. Always stop the truck engine and put the key in
14. Go to the pressure cutoff screw on both hydraulic your pocket before making any adjustment on the
pumps and back off the jam nut with a 13mm hydraulic pump. If the cutoff on one pump is set
wrench. Turn the adjustment screws in with a 4mm higher than the other, that pump will be more
allen wrench one or two more turns, restart the dominant. The pressure gauge in the M1 port of the
engine and check the pressure again. Repeat this dominant pump will however, read lower than the
procedure until the main system relief can be set to other. To equalize the two pumps you must either
the target pressure. adjust the cutoff screw in (clockwise) to increase
the pressure of the pump showing the higher
15. When the proper main relief pressure is achieved,
reading or adjust the cutoff screw of the dominant
pressure cutoff can be set. Shut off the engine, put
pump showing the lower reading out
the key in your pocket and install 0-600 bar gauges
(counterclockwise) to reduce the pressure. These
with whip hoses to the M1 gauge ports on the
adjustments must be made until the two gauges in
bottom of the two hydraulic pumps (Figure 105).
the M1 ports are reading approximately the same.
You must be able to read both gauges
simultaneously to ensure that one pump is not 18. When you have achieved the same pressure on the
more dominant than the other. M1 port gauges, you can begin to adjust the
pressure cutoff screws in or out simultaneously
Note: The gauges in the M1 ports will read
until you achieve the desired pressure setting of
considerably less than the cutoff pressure of the pump.
350 bar (again, confirm the pressure specification
On a -6 (190/130 pump combination) the 190 will
with the hydraulic schematic).
usually read 85 to 90 bar while the 130 reads about 110
bar. They could read the same however, at After pressure cutoff is set, return the pump to neutral,
approximately 110 bar, but the 190 must never read bring engine RPM to idle, open the soft switch quarter
higher than the 130. The actual cutoff pressure will be turn valve, and either proceed to other pressure settings
read on the concrete pump main system pressure gauge or take the transmission and PTO out of gear and shut
near the e-stop manifold. off the truck.
Figure 104
Location of soft switch shutoff and relief cartridges
Pressure Settings
130-6.eps
2
2
3
1 1
3
4 4
M1 GAUGE PORT
(BOTTOM OF EACH PUMP)
Figure 105
A11VO adjustment screws for Hi-flo 6 units 190/130
NOTE: The main control block (brain) of a 2525 Set boom circuit pressures
pumpkit will be rotated 180 degrees from the NOTE! Any time you set pressures for any circuit on
illustration shown in Figure 57. any unit, the hydraulic oil should be at normal
operating temperature (50 to 60 C). Instructions on
Setting the soft switch circuit relief heating the hydraulic oil for this procedure are found in
pressure step on page 6-359.
a. If you havent already done so, open the soft
Please read all of the instructions before beginning any
switch quarter turn valve (Figure 104). The rest
pressure settings. You will need an assistant for parts of
of the unit should still be set up as though you
the following procedure. You and any assistants should
were going to check the main relief valve
wear eye protection when setting pressures.
pressure (concrete pump shutoff valve still
closed). Current production model 52 meter pumps are
b. When you put the pump in forward now, the equipped with a load sensing, proportional boom
pressure gauge should read the pressure shown hydraulic system. If the system were black and white,
on the schematic for soft switch. If adjustment the hydraulic pump would put out an unchanging
is needed, loosen the jam nut of the soft switch amount of oil and speed control is done by restricting
relief cartridge (Figure 57) with a 9/16 inch the oil to certain functions with orifices. With a load
open end wrench, and use a 5/32 inch allen sensing system, the pumps put out more or less oil to
wrench to adjust the pressure. Turn the respond to the needs of the system. Generally, the
adjustment screw in (clockwise) to raise the pump always puts out enough oil to maintain 20 bar
pressure or out (counter clockwise) to lower higher pressure at the pump than the boom cylinders
the pressure. When you attain the required actually require. This 20 bar is called delta P. You may
pressure, tighten the jam nut while holding the see it referred to by a symbol ( P). Additionally, we
allen wrench, to keep the pressure from rising. set the hydraulic pump so that it always puts out a
Be sure to open the concrete pump quarter turn small amount of oil, even if none is needed for the
valve on the side of the brain (Figure 57) when system. This oil is used to ensure that you have control
you are finished. The unit will not stroke with when you need it. The setting to maintain this
this valve closed. minimum amount of oil is called Q-min (pronounced
revDate
362 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
cue min). To set the boom or outrigger hydraulic
CAUTION! When checking Delta P, it is important to
pressures on a load sensing system, begin by checking note that you will be installing a low pressure gauge into
P and Q-min.t a high pressure port. Any activation of a boom function
or activation of an e-stop, while this gauge is attached
Checking and Setting P pressure will destroy your gauge. On Comfort control units,
Note! Do not adjust delta P or Q-min if your boom is always center the boom speed switch on the remote box
running as you like it. The pressure setting procedure to prevent accidental activation of a joy stick.
uses a standard starting point and must be fine tuned 1. Install a 0-100 bar whip gauge in the high pressure
from that point. The pressure was fine tuned at the test port (Figure 106) located on the inside of the
factory, and should not be adjusted unless absolutely right boom control block as you face the three
necessary. valve blocks.
rtblock2.eps
Figure 106
The high pressure gauge
port is located between the
blocks on the inside edge of
the right boom control
High pressure
gauge port
2. With the engine at idle, turn the adjustable relief turns. Remember exactly how much you move this
cartridge (Figure 107) on the boom pilot control cartridge because it will need to be returned to the
valve, out (counter clockwise) approximately three original position.
adjustable relief
cartridge
P
L
52pilot.eps
preset pressure
reducing valve
gauge port
Figure 107
Location of adjustable relief cartridge on the boom pilot control valve
3. With the engine running and the relief cartridge showing Delta P. The pressure could be anywhere
backed out, the gauge (Figure 16) should be from 16-25 bar.
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 363
HOME PRINT
Pressure Settings
4. Increase the throttle RPM and the pressure should and adjusting the screw (3mm allen wrench)
remain the same. If the pressure fluctuates with clockwise to increase pressure or counter
engine RPM you are probably still reading Q-min, clockwise to decrease it.
and the adjustable relief cartridge (Figure 108) will 7. The delta P adjustment screw on the A11VO boom
need to be turned out more. pump also shown in Figure 43 below, requires a
5. If no further adjustment is needed, return the pilot 13mm open end wrench and a 4mm allen wrench.
valve relief cartridge to its original position. If 8. If no further adjustment is needed, return the pilot
adjustment is required, proceed to the next step. valve relief cartridge to its original position, and
6. Delta P is adjusted on the bottom (smaller) screw proceed to Q-min.
of the pressure regulator shown in Figure 108 9. If pressure cannot be correctly set, there is a
below, if your unit has an A7VO boom pump, by problem, contact Schwing Service Department to
loosening the jam nut (10mm open end wrench), determine how to continue.
Delta-p
pressreg.eps
Regulator pressure
adjustment
T
Adjustment for P pressure
smdeltap.eps
Figure 108
Location of the delta P adjustment screw for a unit with A7VO pump
(left) and A11VO pump (right)
Set Q-min
WARNING
Stop the engine before adjusting
the Q-min screw or Delta P on A11.
Driveline entanglement hazard!
Check Q-min with the engine at maximum specified 2. All boom functions must be in neutral, and all
RPM. Each time the Q-min screw must be adjusted, the emergency stop buttons should be up (not
engine must be stopped, or at least the transmission engaged). Clear away all personnel, start the truck
must be taken out of gear so that the drivelines stop engine, engage the pumps and bring engine RPM
turning. to maximum specification.
1. Before proceeding, remove the 0-100 bar whip 3. Read the pressure. If the pressure reads less than
gauge from the high pressure gauge port (Figure 100 bar, remove the high pressure gauge and
16) and install a 0-400 or 0-600 bar gauge to the reinstall the 0-100 bar gauge. Pressure should be at
same port, to make certain that the higher pressure 50-55 bar. If adjustment is needed, continue to
wont destroy your 0-100 bar gauge. point 4.
4. Stop the engine and turn the Q-min screw (Figure
109) in (clockwise) to raise the pressure, or out
(counter-clockwise) to lower the pressure. Be sure
that you stop the drive shafts from turning each
revDate
364 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
time before making the adjustment. When pressure Note! If you dont have a 0-100 bar gauge you can
is correct, tighten the jam nut on the adjustment order one from Schwing Spare Parts Department at
screw before continuing with the other procedures. (800) 328-9635, part #10004659.
hifloreg.eps
Checking boom pressures 3. Read the gauge. It should be showing the lowest
After the Delta P and Q-min are set, remove the 0-100 relief pressure setting of the boom circuit (pressure
bar gauge and proceed to check and adjust, if regulator or cutoff) + or - 5 bar (See schematic). If
necessary, the main boom pressures. it does not, a minor adjustment can be made by
going to the pressure regulator (large screw) for
1. To check the boom pressure, install a 0-600 bar units with A7VO pumps or after stopping the
gauge in the boom circuit high pressure gauge port engine, the pressure cutoff screw for units with
(Called out but not visible in Figure 110). A11VO pumps, backing off the jam nut and
2. With the engine at full RPM and the boom folded, turning the adjustment screw to achieve the desired
activate boom #2, #3, or #4 to the in position, pressure. If the pressure can not be reached, return
which will pressure out the function. A function the screw to the original setting and proceed to
must be pressured out each time you want to check Setting boom circuit pressures.
the pressure.
Down side dynamic
gauge port
Figure 110
Main boom circuit high pressure gauge port
(not visible on illustration)
lftblock.eps
Pressure Settings
Setting main boom circuit pressures 2. Since the gauge will always show you the lowest of
1. Review the hydraulic schematic and identify the the three settings, it is necessary to raise the two
three different pressure settings involved in this lowest pressures enough to allow us to see the
circuit. 1) Boom block main relief, 2) e-stop highest one, which will be the main relief at the
manifold relief, and boom block (Figure 111).
3) pressure regulator.
Down side dynamic
gauge port
Figure 111
Main relief adjustment screw and gauge ports
lftblock.eps
Regulator pressure
adjustment
T
Adjustment for P pressure
hifloreg.eps
Figure 112
Pressure regulator adjustment (A7VO left) and Pressure cutoff screw (A11VO right)
4. Loosen the jam nut on the boom circuit relief If the pressure reading is still lower than the maximum
cartridge located on the e-stop manifold (Figure shown on the schematic, loosen the jam nut on the
113) using a 9/16 wrench and turn the adjustment control block main relief (Figure 111) adjustment
screw using a 5/32 allen wrench in until you can screw and turn the adjusting screw in. This will raise
see the maximum pressure of the boom block main the pressure of the main relief valve until the desired
relief showing on the gauge while pressuring out a pressure is achieved. Tighten the jam nut to secure the
boom function. adjustment screw.
revDate
366 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
;;;;
@@
@@
@@;;
;; @@;;
@@;@
@@;;
;; @@
@@
;; @@
;; @@
;;
@@
;; @@
;;
52estp1.eps
@@;;
;; @@;;
@@;;
@@;;
@@
;;
@@;;
;; @@
@@
;; @@
;; @@
@@;;
;; @@;;
@@;;
@@;;
@@
;;
@@;;
;; @@
@@
;; @@
;; @@
@@
;; @@
;; @@
;; @@
;; @@
;;
@@
;;
QQ
@@
;;
QQ
@@
;;
QQ
@@
;;
QQ
@@
;;
Q;@
Figure 113
Boom circuit relief cartridge on e-stop @@
;;
QQ @@
;;
QQ
QQ
@@
;; @@
;;
QQ
@@
;; @
;
Q
@@
;;
QQ
@@
;;
QQ @@
;;
QQ @@
;;
QQ
@@
;;
Q;@
manifold
@@
;;
QQ
@@
;; @@
;;
QQ
@@
;; @@
;;
QQ
@@
;; @@
;;
QQ
@@
;; @@
;;
@
;
Q
@@;;
;;
QQ
@@
;; @@;;
;;
QQ
@@
@@
;;
QQ
@@
@@
;;
QQ
@@
;; @@
;; @
;
Q
;@
@@
;;
QQ
@@
;; @@
;;
QQ
@@
;; @@;;
;;
QQ
@@
;; @@;;
;;
QQ
@@
@@
;;
Q;@ ;@ @
;
@@
;;
QQ
@@
;; @@
;;
QQ
@@
;; @@
;;
QQ
@@
;; @@
;;
QQ
@@
;; @@
@
;
Q
@@relief
;;
QQ
@@
;;
@@;;
;;
QQ
Boom
@@
;;
@@
;;
QQ
@@
@@;;
;;
QQ
circuit
@@
;; @@
;;
@
;
Q
;@
@@
;;
QQ
@@
;;
QQ
@@
;;
QQ
@@
;;
QQ
@@
@
;
@@
;; @@
;; @@
;; @@
;; Q;@Q;@ ;@;@
@@
;;
cartridge
@@;;
;;
QQ
@@
;; @@;;
;;
QQ
@@
@@;;
;;
QQ
@@
@@;;
;;
QQ
@@
@@
5. Now return to the boom circuit relief cartridge Checking pretension pressure
(Figure 113) and turn the adjustment screw back This procedure is to check the pretension pressure only.
out (counter-clockwise) until the second highest The pressure you will be reading is from the factory
pressure on the boom circuit schematic is achieved, preset pressure reducing valve (Figure 114) which can
and tighten the jam nut to secure the adjustment not be adjusted.
screw.
1. Install a 0-60 bar whip gauge on the gauge port of
6. Finally, return to the pressure regulator or pressure the precontrol block (Figure 114) and bring the
cutoff (Figure 112) and turn the adjustment screw engine RPM to full throttle. The gauge should read
out until the lowest pressure on the schematic is 33-35 bar. If the pressure reading is different than
achieved, and lock the jam nut. that, contact the Schwing Service Department for
instructions on how to proceed.
adjustable relief
cartridge
P
L
lrgpilot.eps
preset pressure
reducing valve
gauge port
Figure 114
Showing the precontrol valve gauge port and adjustment points
Pressure Settings
Set the outrigger pressure use an extension cylinder because they have
To set the outrigger pressure. Find the relief cartridge secondary relief functions (non-adjustable) built
(Figure 115) located on the passenger side outrigger into the valve. While holding the push-button and
control valve. activating either handle number 4 or 5 Figure 48, to
retract position, read the pressure on the gauge.
1. Attach 0-600 bar whip gauge to gauge port shown
in Figure 48. 4. Check the schematic to see what the pressure
should read. Adjust by loosening the jam nut with a
2. Push the outrigger button. 9/16 open end wrench and turning the cartridge
3. Activate an outrigger jacking cylinder to retract. with a 5/32 allen wrench. When the desired
By attempting to retract a cylinder which is already pressure is reached, let go of the handle and the
retracted the oil coming from the pump has no push-button.
where to go but over the relief valve. You cannot 5. Remove the whip gauge when the job is complete.
PScntrl#.eps
1 2 3 4
EXTEND FOLD - REAR FOLD - FRONT FOOT
Relief cartridge
Gauge port
Gauge port
1 2 3 4 5 otrgrlf2.eps
Figure 115
Passenger side outrigger valve bank for units built after mid 1999 (left) and prior
to mid 1999 (right)
revDate
368 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Set the agitator pressure 1. Plug the 0 - 600 bar whip gauge into the gauge port
The agitator circuit has a maximum pressure, shown on which is located on the front of the agitator hand
the schematic, which is limited by the relief cartridge valve (not shown in this illustration).
(Figure 116) in the agitator hand valve. The cartridge is
adjustable with a 19mm socket or wrench.
Relief cartridge
Figure 116
Location of the agitator
relief cartridge
agitrlf.eps
2. Locate the agitator shutoff valve (Figure 117) and qty 1 GS-16S straight fitting, part number
close it. If your unit does not have a shutoff valve, 10008088
order one from the Schwing Spare Parts qty 2 16S capnuts, part number 10001743.
Department using part number 10004680 (valve),
All of these fittings and many, many more extremely
and number 30303432 (tube). Contact the Service
useful items are included in the trouble shooting kit,
Department for installation instructions. If you
part number 30308553.
cant wait for a shutoff valve, you will need to shut
off the engine and place the key in your pocket as 3. Be sure that one of the locking plugs and capnuts
you remove one of the hoses from the agitator are tightened on the straight fitting, and that the
motor and plug the hose and open fitting with dead plugs are securely tightened to the hose and
approved hydraulic dead plugs (Figure 117). the open motor fitting.
qty 2 VS-16S locking plugs, part number 4. Be sure that all personnel are clear, and restart the
10016803 engine.
WARNING
Do not jam agitator paddles to force
oil over relief. Entanglement hazard!
Pressure Settings
agitoff.eps
capplug.eps
Figure 117
Agitator shutoff valve and approved hydraulic dead plugs
revDate
370 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 55M could pressure out a function in the boom or outrigger
system to create heat, but today, load sensing systems
no longer allow maximum oil flow to be forced over
Check all hydraulic pressures
relief. Because of this, the agitator circuit must be used
Changes in pressure can indicate trouble in one or to heat the hydraulic oil.
more components and will serve as early warning indi- To heat the oil to operating temperature:
cators if you check them on a regular basis. The speci- 1. Locate the agitator shutoff valve (Figure 102), and
fications for each circuit are shown on the hydraulic close it. The quarter turn shutoff valve has a
schematics found in the Appendix section of this man- grooved line (Figure 102) on the shaft or pivot
ual. The hydraulic schematics are the only documents point of the handle as well as on the handle itself,
in this manual that have been updated specifically for which will indicate the open or closed configura-
your unit, by the serial number, so in each of the fol- tion of the valve. If the handle is removed from the
lowing procedures you will be told to refer to the sche- agitator shutoff valve (Figure 102) or the concrete
matic for the pressure required. pump shutoff valve (Figure 56) and replaced in a
If you wish to order a CD ROM which explains the different configuration, the grooves in the handle
pressure setting procedure for a specific model (All may no longer indicate the proper open/closed ori-
pumpkits), call SAI Spare Parts Department at (800) entation of the valve. The grooves in the shaft give
328 - 9635 and request the CD using the following part the only true indication of the valves position.
numbers: NOTE:
61/58 meter. . . . . . . . . . . . . . . . . . . . . . . 30365860 If your unit is an early production model and does
52 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30354732 not have an agitator shutoff valve, order one from
the Schwing Spare Parts Department, using part
45/47 meter. . . . . . . . . . . . . . . . . . . . . . . 30356770
number 10004680 (valve) and number 30303432
42 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30355485 (tube). Contact the Service Department for instal-
39 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30365861 lation instructions.
34 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30356772 2. Activate the agitator. With the valve closed, the
32 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30355486 agitator will not be able to turn and the oil will be
31 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30365862 forced over the relief valve. At an idle (about 600
RPM) you will be converting 4.5 horsepower to
Preheat the hydraulic oil heat.
Pressure settings must be made with the oil at normal 3. When the oil temperature gauge shows 50 C, open
operating temperatures (50 to 60 C). In the past we the shutoff valve.
Motor Open
Mounting screw and washer
removed for illustration
Figure 46
Agitator shutoff valve (left) and Open/closed orientation of shutoff valve (right)
Pressure Settings
Soft switch
shutoff valve
Main Pressure
Gauge port
Figure 47
Concrete pump and Soft switch shutoff
valves
Concrete pump
hif
shutoff valve low
br
n.
ep
s
Setting relief pressure and pressure cutoff 6. If you have not already closed the soft switch shut-
on Hi-flo -6 pumpkits off valve and the concrete pump shutoff valve (Fig-
ure 56), do so at this time.
1. To set the pressure of the main relief valve on Hi-
flo pumpkits, you must first disable the soft switch 7. At the rear panel, select local control with the
circuit. Simply locate the ball cock for the soft local/remote switch, and turn the electric stroke
switch circuit (Figure 56), and close it by rotating limiter knob clockwise to maximum strokes per
the handle 90 degrees. minute.
2. The quarter turn shutoff valve for the concrete 8. The main system control block pressure must be
pump (Figure 56) will also need to be closed dur- set first to properly set the pressure cutoff on both
ing this procedure. pumps. Begin by backing off the jam nut of the
main relief cartridge (Figure 104) with a 9/16 inch
Note: Main system adjustments are preset at the fac-
wrench.
tory. The following procedure begins with adjustment
of the main relief cartridge and pressure cutoff. If 9. Using a 5/32 inch allen wrench, turn the adjust-
proper pressures cannot be obtained through these ment screw out (counterclockwise) until you can
steps, contact the Schwing Service Department for spe- feel no spring tension on the adjustment screw.
cific instructions on the adjustment of flow, horse- 10. Now, turn the screw back in (clockwise) two or
power, beginning of stroke regulation, and Q-min. three full turns to give you a proper starting point,
Pressure setting procedure: and tighten the jam nut.
3. Be sure that the waterbox covers and guards are in 11. Stop the truck engine, put the key in your pocket,
place any time you will be working in the area and adjust the pressure cutoff screw (Figure 57) on
around the main control block. each pump, by backing off the jam nut with a
4. Wear safety glasses when working around a con- 13mm wrench. Using a 4mm allen wrench, turn the
crete pump. Note! It is vital that each adjustment adjustment screw in (clockwise) one full turn, and
screw be properly identified prior to making any tighten the jam nut. Restart the truck engine.
adjustment. All screw adjustments for the system 12. Adjust the engine RPM to maximum specification.
relief must be made with the pumpkit in the neutral (See decal in truck cab)
position, and adjustments for pressure cutoff must 13. Pressure out the system by activating the concrete
be made with the engine shut off. pump forward switch on the rear panel. Using the
5. Start the truck engine, and put the PTO in gear just rear panel controls will allow you to read the con-
as you would to pump a job. crete pump main system pressure gauge, near the
e-stop manifold, from a safe distance.
revDate
372 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
NOTE: 16. Activate the concrete pump forward to pressure out
Because you turned out the pressure relief cartridge in the pump and read the pressure on the two gauges
step 7, the system pressure should read low at this time. in the M1 ports.
If it does not and the gauge spikes to 320 bar or more, 17. Always stop the truck engine, and put the key in
disengage the pump immediately. Turn the relief car- your pocket before making any adjustment on the
tridge out (counterclockwise) more. For safety, it is hydraulic pump. If the cutoff on one pump is set
important to adjust the pressure up from below the higher than the other, that pump will be more dom-
specified target pressure rather than down from a pres- inant. The pressure gauge in the M1 port of the
sure which exceeds the target. Continue this procedure dominant pump will, however, read lower than the
until the main system pressure gauge reads lower than other. To equalize the two pumps, you must either
the specified target. adjust the cutoff screw in (clockwise) to increase
14. To increase the pressure, put the pump in the neu- the pressure of the pump showing the higher read-
tral position and adjust the relief cartridge by turn- ing, or adjust the cutoff screw of the dominant
ing it in (clockwise). When increasing the pressure, pump showing the lower reading out (counter-
the adjustments should be made in quarter turn clockwise) to reduce the pressure. These adjust-
increments. If you make adjustments to increase ments must be made until the two gauges in the M1
the pressure but the pressure does not come up, you ports are reading approximately the same.
are probably reading the pressure cutoff of the 18. When you have achieved the same pressure on the
pumps. If so, proceed to the next step; otherwise M1 port gauges, you can begin to adjust the pres-
skip to step 15. sure cutoff screws in or out simultaneously until
Turn the relief cartridge adjustment screw back out you achieve the desired pressure setting of 350 bar
(counterclockwise) until you can no longer see a (again, confirm the pressure specification with the
pressure drop, and tighten the jam nut. hydraulic schematic).
Stop the truck engine, and put the key in your After pressure cutoff is set, return the pump to neutral,
pocket. bring engine RPM to idle, open the soft switch quarter
Go to the pressure cutoff screw on both hydraulic turn valve, and either proceed to other pressure settings
pumps, and back off the jam nut with a 13mm or take the transmission and PTO out of gear; then shut
wrench. Turn the adjustment screws in with a 4mm off the truck.
allen wrench one or two more turns, restart the
engine, and check the pressure again. Repeat this
procedure until the main system relief can be set to
the target pressure.
15. When the proper main relief pressure is achieved,
pressure cutoff can be set. Shut off the engine, put
the key in your pocket, and install 0-600 bar
gauges with whip hoses to the M1 gauge ports on
the bottom of the two hydraulic pumps (Figure 57).
You must be able to read both gauges simulta-
neously to ensure that one pump is not more domi-
nant than the other.
NOTE:
The gauges in the M1 ports will read considerably less
than the cutoff pressure of the pump. On a -6 (190/130
pump combination) the 190 will usually read 85 to 90
bar while the 130 reads about 110 bar. They could read
the same at approximately 110 bar, but the 190 must
never read higher than the 130. The actual cutoff pres-
sure will be read on the concrete pump main system
pressure gauge near the e-stop manifold.
Pressure Settings
openclsd.eps
9/16" jam nut
Figure 48
Location of soft switch shutoff and relief cartridges
130-6.eps
2
2
3
1 1
3
4 4
M1 GAUGE PORT
(BOTTOM OF EACH PUMP)
Figure 49
A11VO adjustment screws for Hi-flo 6 units 190/130
revDate
374 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting the soft switch circuit relief on a load sensing system, begin by checking P and
pressure Q-min.
1. If you havent already done so, open the soft Checking and setting P pressure
switch quarter turn valve (Figure 57). The rest of
the unit should still be set up as though you were NOTE: Do not adjust delta P or Q-min if your boom is
going to check the main relief valve pressure (con- running as you like it. The pressure setting procedure
crete pump shutoff valve still closed). uses a standard starting point and must be fine tuned
2. When you put the pump in forward now, the pres- from that point. The pressure was fine tuned at the fac-
sure gauge should read the pressure shown on the tory and should not be adjusted unless absolutely nec-
schematic for soft switch. If adjustment is needed, essary.
loosen the jam nut of the soft switch relief cartridge
(Figure 57) with a 9/16 inch open end wrench, and rtblock2.eps
Pressure Settings
3. With the engine running and the relief cartridge
backed out, the gauge (Figure 16) should be show-
WARNING ing delta P. The pressure could be anywhere from
16-25 bar.
Entanglement hazard. Stop drive shafts 4. Increase the throttle RPM, and the pressure should
before adjusting Delta P on A11VO pump.
W020.eps
remain the same. If the pressure fluctuates with
engine RPM, you are probably still reading Q-min,
1. Install a 0-100 bar whip gauge in the high pressure and the adjustable relief cartridge (Figure 107) will
test port (Figure 16), located on the inside of the need to be turned out more.
right boom control block as you face the three
5. If no further adjustment is needed, return the pilot
valve blocks.
valve relief cartridge to its original position. If
2. With the engine at idle, turn the adjustable relief adjustment is required, proceed to the next step.
cartridge (Figure 107) on the boom pilot control
6. Delta P is adjusted on the bottom (smaller) screw
valve out (counter clockwise) approximately three
of the pressure regulator shown in Figure 43 below,
turns. Remember exactly how much you move this
if your unit has an A7VO boom pump you can do
cartridge, because it will need to be returned to the
so by loosening the jam nut (10mm open end
original position.
wrench) and adjusting the screw (3mm allen
wrench) clockwise to increase pressure or counter
adjustable relief clockwise to decrease it.
cartridge
7. The delta P adjustment screw on the A11VO boom
pump, also shown in Figure 43 below, requires a
L
P
13mm open end wrench and a 4mm allen wrench.
8. If no further adjustment is needed, return the pilot
valve relief cartridge to its original position, and
52pilot.eps
Figure 51
Location of adjustable relief cartridge
on the boom pilot control valve
Delta-p
pressreg.eps
Regulator pressure
adjustment
T
Adjustment for P pressure
smdeltap.eps
Figure 52
Location of the delta P adjustment screw for a unit with A7VO pump
(left) and A11VO pump (right)
revDate
376 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting Q-min
hifloreg.eps
Pressure Settings
Figure 54
Main relief cartridge
Main relief adjustment screw and
gauge ports. (High pressure gauge
port not visible on illustration) lftblock.eps
Setting main boom circuit pressures 3. Loosen the jam nut on the large screw of the pres-
sure regulator or the pressure cutoff screw (Figure
1. Review the hydraulic schematic, and identify the
45), depending which one your unit has, and turn
three different pressure settings involved in this cir-
the adjustment screw clockwise, all the way in.
cuit. 1) boom block main relief, 2) e-stop manifold
relief, and 3) pressure regulator.
2. Since the gauge will always show you the lowest of WARNING
the three settings, it is necessary to raise the two
lowest pressures enough to allow us to see the Entanglement hazard. Stop drive shafts
highest one, which will be the main relief at the before adjusting Pressure cut-off on
W021.eps
boom block (Figure 111). A11VO pump.
Regulator pressure
adjustment
T
Adjustment for P pressure
hifloreg.eps
Figure 55
Pressure regulator adjustment (A7VO left) and Pressure cutoff screw (A11VO right)
revDate
378 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Boom circuit
relief cartridge
s
ep
trl.
crc
bm
Figure 56
Boom circuit relief cartridge
on e-stop manifold
4. Loosen the jam nut on the boom circuit relief car- 7. Finally, return to the pressure regulator or pressure
tridge located on the e-stop manifold (Figure 113) cutoff (Figure 45), and turn the adjustment screw
using a 9/16 wrench, and turn the adjustment screw out until the lowest pressure on the schematic is
in using a 5/32 allen wrench until you can see the achieved. Lock the jam nut.
maximum pressure of the boom block main relief
showing on the gauge while pressuring out a boom Checking pretension pressure
function.
This procedure is to check the pretension pressure only.
5. If the pressure reading is still lower than the maxi- The pressure you will be reading is from the factory
mum shown on the schematic, loosen the jam nut preset pressure reducing valve (Figure 114), which can
on the control block main relief adjustment screw, not be adjusted.
(Figure 111) and turn the adjusting screw in. This
1. Install a 0-60 bar whip gauge on the gauge port of
will raise the pressure of the main relief valve until
the precontrol block (Figure 114), and bring the
the desired pressure is achieved. Tighten the jam
engine RPM to full throttle.
nut to secure the adjustment screw.
2. The gauge should read 33-35 bar. If the pressure
6. Now return to the boom circuit relief cartridge
reading is different than that, contact the Schwing
(Figure 113), and turn the adjustment screw back
Service Department for instructions on how to pro-
out (counter-clockwise) until the second highest
ceed.
pressure on the boom circuit schematic is achieved.
Tighten the jam nut to secure the adjustment screw.
adjustable relief
cartridge
P
L
lrgpilot.eps
preset pressure
reducing valve
Figure 57
The precontrol valve gauge gauge port
port and adjustment points
Pressure Settings
Setting the outrigger pressure use an extension cylinder because they have sec-
ondary relief functions (non-adjustable) built into
To set the outrigger pressure, find the relief cartridge
the valve. While holding the push-button and acti-
(Figure 48) located on the passenger side outrigger
vating handle number 4 (Figure 48) to retract posi-
control valve.
tion, read the pressure on the gauge.
1. Attach a 0-600 bar whip gauge to the gauge port
4. Check the schematic to see what the pressure
shown in Figure 48.
should read. Adjust by loosening the jam nut with a
2. Push the outrigger button. 9/16 open end wrench and turning the cartridge
3. Activate an outrigger jacking cylinder to retract. with a 5/32 allen wrench. When the desired pres-
By attempting to retract a cylinder which is already sure is reached, let go of the handle and the push-
retracted, the oil coming from the pump has no button.
where to go but over the relief valve. You cannot 5. Remove the whip gauge when the job is complete.
PScntrl#.eps
1. Front extend
Relief cartridge
2. Rear fold
3. Front fold
4. Foot (jacking) 1 2 3 4
Gauge port
Figure 58
Passenger side outrigger valve bank
revDate
380 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Lower
Figure 59 2.e
ps
itrlf
Location of the agitator relief ag
Set the agitator pressure motor and plug the hose and open fitting with
approved hydraulic dead plugs (Figure 117).
The agitator circuit has a maximum pressure, shown on
the schematic, which is limited by the relief cartridge Qty 2 VS-16S locking plugs, part number
(Figure 50) in the agitator hand valve. The cartridge is 10016803
adjustable with a 19mm socket or wrench. Qty 1 GS-16S straight fitting, part number
10008088
1. Plug the 0 - 600 bar whip gauge into the gauge
port, which is located on the top of the agitator Qty 2 16S capnuts, part number 10001743
hand valve. 3. All of these fittings and many, many more
2. Locate the agitator shutoff valve (Figure 117), and extremely useful items are included in the trouble
close it. If your unit does not have a shutoff valve, shooting kit, part number 30308553.
order one from the Schwing Spare Parts Depart- 4. Be sure that one of the locking plugs and capnuts
ment using part number 10004680 (valve) and are tightened on the straight fitting, and that the
number 30303432 (tube). Contact the Service dead plugs are securely tightened to the hose and
Department for installation instructions. If you the open motor fitting.
cant wait for a shutoff valve, you will need to shut 5. Be sure that all personnel are clear, and restart the
off the engine and place the key in your pocket as engine.
you remove one of the hoses from the agitator
agitoff2.eps
Agitator quarter turn Plugs Straight Fitting
shutoff valve (open position)
capplug.eps
Figure 60
Agitator shutoff valve and approved hydraulic dead plugs
6. Increase the engine RPM to full throttle, activate and read the gauge. If it does not read the specified
the agitator hand valve in either forward or reverse, pressure, turn the body of the relief valve using a
Media:Service_ Service Manual Set:2008:SERVICE_MANUAL:PressureSettings.fm
Service Manual 381
HOME PRINT
Pressure Settings
19mm socket or wrench. The cartridge should be
turned in (clockwise) to increase pressure or out
(counterclockwise) to decrease pressure.
7. After the pressure is set, deactivate the agitator sys-
tem by placing the manual control handle in the
neutral position. 45Accreg.eps
Accumulator redunant
relief cartridge
Figure 62
Accumulator redundant relief
cartridge
revDate
382 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
4. Clear all personnel away from the drive lines, start
the truck engine, engage the pumps, and bring the acumrlf.epsL
@@@@@@@@
;;;;;;;;
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
@@@@@@@@
;;;;;;;;
QQQQQQQQ
;;;;;;;;
@@@@@@@@
QQQQQQQQ
;;;;;;;;
@@@@@@@@
Figure 63
QQQQQQQQ
Accumulator circuit pressure gauge Figure 64
Accumulator manifold pressure
6. Locate the accumulator manifold pressure relief relief cartridge
cartridge (Figure 64). Loosen the jam nut, and turn
the screw clockwise to increase the pressure or 8. After the truck engine is stopped, go back to the
counter clockwise to decrease the pressure. accumulator circuit hydraulic pump pressure regu-
Tighten the jam nut when the pressure reaches the lator (Figure 61), and turn the screw back out two-
value required. and-one-half turns. This restores it to its original
7. You will need an assistant for this step. With the setting.
engine still running, one person must go to the 9. Clear all personnel from the drive line area, start
redundant relief valve on the emergency stop mani- the truck, and bring the engine RPM up to maxi-
fold (Figure 62) and back out the adjustment screw mum.
while the other person stands by the pressure gauge 10. Read the pressure on the accumulator gauge. It
to let him know when the pressure reads the value should read the proper accumulator system pres-
shown on the schematic for accumulator redundant sure.
relief. 11. If adjustment is needed, you must stop the truck
engine, or a least stop the drive lines from turning,
each and every time you approach the accumulator
WARNING circuit hydraulic pump. Turn the screw in to
increase the pressure or out to decrease pressure.
Entanglement hazard. Stop drive shafts Lock the jam nut when the pressure is correct.
before adjusting the accumulator pump
pressure regulator. NOTE: The accumulator circuit hydraulic pump pres-
W010.eps
Pressure Settings
revDate
384 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
S 58/61SX RPM), 4.5 horsepower is being converted to heat.
3. When the oil temperature gauge shows 50C, open
The following pages provide the proper techniques for
the shutoff valve.
checking and setting hydraulic pressures of each
system included on your unit. Agitator quarter turn
000174.eps
Pressure Settings
2. Wear safety glasses when working around a more. For safety, it is important to adjust
concrete pump. the pressure up from below the specified
target pressure rather than down from a
NOTE! pressure which exceeds the target. Continue
It is vital that each adjustment screw be this procedure until the main system pres-
properly identified prior to making any sure gauge reads lower than the specified
adjustment. All screw adjustments for the target.
system relief must be made with the pump- 12. To increase the pressure put the pump in the
kit in the neutral position, and adjustments neutral position, and adjust the relief cartridge by
for pressure cutoff must be made with the turning it in (clockwise). When increasing the
engine shut off.
pressure, the adjustments should be made in
3. Start the truck engine, and put the PTO in gear just
quarter turn increments. If you make adjustments
as you would to pump a job.
to increase the pressure but the pressure does not
4. If you have not already closed the soft switch come up, you are probably reading the pressure
shutoff valve and the concrete pump shutoff valve cutoff of the pumps. If so, proceed to the next step;
(Figure 56), do so at this time. otherwise skip to step 15. Turn the relief cartridge
5. At the Vector controller, select local control with adjustment screw back out (counterclockwise)
the local/remote switch, and activate the electric until you can no longer see a pressure drop, and
stroke limiter switch to maximum strokes per tighten the jam nut.
minute. 13. Stop the truck engine and put the key in your
6. The main system control block pressure must be pocket.
set first to properly set the pressure cutoff on both 14. Go to the pressure cutoff screw on both hydraulic
pumps. Begin by backing off the jam nut of the pumps (Figure 57), and back off the jam nut with a
main relief cartridge (Figure 58) with a 9/16 inch 13mm wrench. Turn the adjustment screws in with
wrench. a 4mm allen key one or two more turns, restart the
7. Using a 5/32 inch allen key, turn the adjustment engine, and check the pressure again. Repeat this
screw out (counterclockwise) until you can feel no procedure until the main system relief can be set to
spring tension on the adjustment screw. the target pressure.
8. Now, turn the screw back in (clockwise) two or 15. When the proper main relief pressure is achieved,
three full turns to give you a proper starting point, pressure cutoff can be set. Shut off the engine, put
and tighten the jam nut. the key in your pocket, and install 0-600 bar
9. Stop the truck engine, and put the key in your gauges with whip hoses to the M1 gauge ports
pocket. Adjust the pressure cutoff screw (Figure on the bottom of the two hydraulic pumps (Figure
57) on each pump by backing off the jam nut with 57). You must be able to read both gauges
a 13mm wrench. Using a 4mm allen key, turn the simultaneously to ensure that one pump is not
adjustment screw in (clockwise) one full turn, and more dominant than the other.
tighten the jam nut. Restart the truck engine. NOTE!
10. Adjust the engine RPM to maximum specification. The gauges in the M1 ports will read consid-
(See decal in truck cab) erably less than the cutoff pressure of the
pump. On a -6 (190/130 pump combina-
11. Pressure out the system by activating the concrete tion), the 190 will usually read 85 to 90 bar,
pump forward switch on the rear panel. Using the while the 130 reads about 110 bar. They
rear panel controls will allow you to read the could read the same, however, at approxi-
concrete pump main system pressure gauge, near mately 110 bar, but the 190 must never read
the e-stop manifold, from a safe distance. higher than the 130. The actual cutoff pres-
sure will be read on the concrete pump main
NOTE! system pressure gauge near the e-stop mani-
Because you turned out the pressure relief fold.
cartridge in step 7, the system pressure 16. Activate concrete pump forward to pressure out the
should read low at this time. If it does not, pump, and read the pressure on the two gauges in
and the gauge spikes to 320 bar or more, the M1 ports.
disengage the pump immediately. Turn the
relief cartridge out (counterclockwise) 17. Always stop the truck engine and put the key in
revDate
386 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
your pocket before making any adjustment on the 18. When you have achieved the same pressure on the
hydraulic pump. If the cutoff on one pump is set M1 port gauges, you can begin to adjust the
higher than the other, that pump will be more pressure cutoff screws in or out simultaneously
dominant. The pressure gauge in the M1 port of the until you achieve the desired pressure setting of
dominant pump will, however, read lower than the 350 bar (again, confirm the pressure specification
other. To equalize the two pumps, you must either with the hydraulic schematic).
adjust the cutoff screw in (clockwise) to increase After pressure cutoff is set, return the pump to neutral,
the pressure of the pump showing the higher bring engine RPM to idle, open the soft switch quarter
reading or adjust the cutoff screw of the dominant turn valve, and either proceed to other pressure settings
pump showing the lower reading out or take the transmission and PTO out of gear and shut
(counterclockwise) to reduce the pressure. These off the truck.
adjustments must be made until the two gauges in
the M1 ports are reading approximately the same.
000277.eps
2
2
3
1 1
3
4 4
Figure 120
A11VO adjustment screws M1 GAUGE PORT
for Hi-flo 6 units 190/130 (BOTTOM OF EACH PUMP)
Pressure Settings
Soft switch
shutoff valve Closed Open
soft switch
Main Pressure
relief cartridge
Gauge port Main relief cartridge
000276.eps
9/16" jam nut
Figure 121
Soft switch components
Setting the soft switch relief pressure Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure This unit is equipped with a load-sensing, proportional
58, right) that you closed in the previous procedure. boom hydraulic system. In a black-and-white system,
The rest of the unit should still be set up as if you were the hydraulic pump puts out an unchanging amount of
going to check the main relief valve pressure (concrete oil, and speed control is done by restricting the oil to
pump shutoff valve still closed). certain functions with orifices. In a load-sensing
When you put the pump in forward now, the main system, the pump puts out more or less oil to respond
concrete pump pressure gauge should read the pressure to the needs of the system. Generally, the pump puts
shown on the schematic for soft switch. If adjustment out enough oil to maintain 20 bar higher pressure at the
is needed, loosen soft switch relief valve jam nut pump than the cylinders actually require. This 20 bar is
(Figure 58 right) with a 9/16 open end wrench, and use called delta P (P). Additionally, we set the hydraulic
a 5/32 allen key to adjust the pressure. Turn the pump so that it always puts out a small amount of oil,
adjustment screw in (clockwise) to raise the pressure or even if no oil is needed for the system. This oil is used
out (counterclockwise) to lower the pressure. When to ensure that you have control when you need it. The
you attain the required pressure, tighten the jam nut setting to maintain this minimum amount of oil is
while holding the allen key to keep the pressure from called Q-min (pronounced cue min). To set the boom
rising. Be sure to open the concrete pump shutoff valve or outrigger hydraulic pressures on a load-sensing
on the side of the brain (Figure 58, left) when you are system, begin by setting P and Q-min.
finished. The unit will not stroke with this valve closed. Note: The illustration in Figure 58 shows a gauge port
in the center of the main control block. Your main
Setting boom circuit pressures concrete pump pressure gauge should be plumbed to
Read all of the instructions before beginning any that port.
pressure settings. You will need an assistant for parts of
the procedure. You and any assistants should wear eye
protection when setting pressures.
NOTE! WARNING
Any time you set pressures for any circuit
on any unit, the hydraulic oil should be at Entanglement hazard. Stop drive shafts
normal operating temperature (4060 C).
before adjusting Delta P on A11VO pump.
000004.eps
revDate
388 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
gauge ports
for Delta P
Figure 122
Gauge ports for setting Delta P
delta/p.eps
Pressure Settings
If pressure cannot be set correctly, there is a problem NOTE!
with the regulator itself. Contact the Schwing Service If you dont have a 0-100 bar gauge, you can
Department to determine how to continue. order one from Schwing Spare Parts
Department at (800) 328-9635, part #
If the boom does not run smoothly at 20 bar, you must 10004659.
fine tune the adjustment. Remove the gauge, and turn
the P adjustment screw until the boom is responsive
and smooth. After adjusting, the difference between the
gauges (reinstalled) must read between 14-25 bar. The
electronics in the control system can also affect how
the boom operates, so if P adjustment does not seem
Boom pressure
to help, reset to 20 bar and check the electrical settings.
relief cartridge
When the electrical settings are verified, you could
again try to refine the boom action with the P
adjustment.
ps
lf.e
ssr
pre
WARNING
0-600 bar
Wear safety glasses any time you check gauge port
or set pressures. Oil expulsion hazard!
000438.eps
Figure 124
0-600 bar gauge port
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. Delta-p Pressure Cut-off
1. All boom functions must be in neutral, and all
emergency stop buttons should be up (not
engaged). Clear away all personnel, start the truck
engine, engage the pumps, and bring engine RPM
to max. Read the pressure at the 0600 bar main
boom gauge port (Figure 124) with a 0-100 bar
gauge. Pressure should be at 4045 bar. If no
adjustment is needed, be sure the jam nut on the
Q-min screw is tight, then continue to set the rest
of the boom and outrigger pressures. If adjustment
000282.eps
is needed, continue to the next step.
Q-min Q-max (Bottom Of Pump)
2. Turn the Q-min screw (Figure 125) in to raise the
pressure. Turn it out to lower the pressure. Be sure
that you stop the drive shafts from turning each Figure 125
time before making the adjustment. When pressure Location of Q-min screw
is correct, tighten the jam nut on the adjustment
screw before continuing with the other procedures;
then, recheck P to make sure that it hasnt
changed during the Q-min adjustment.
revDate
390 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting boom pressures
Now that P and Q-min are set, you can remove the 0-
100 bar pressure gauge and proceed to check and
adjust the main boom pressures.
Boom pressure
relief cartridge
Figure 128 000257.eps
Approved dead
plugs
ssr
lf.e
ps Cap Nuts
pre
Pressure Settings
Setting pressure cut-off
10. Return to the pressure cut-off screw (Figure 131). Delta-p Pressure Cut-off
Back off the jam nut, and turn the screw counter
clockwise until you achieve the pressure shown on
the schematic, then lock the jam nut.
dwnsdrlf.eps
Figure 132
Piston side relief
NOTE!
Figure 130 HWslew.eps
If you are unable to achieve 230 bar by
Boom slewing adjusting the relief valve in Figure 64, call
Boom Slewing the Schwing Service Department and ask if
relief valves relief valves
the unit has a redundant relief valve.
revDate
392 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting outrigger pressure Setting the agitator pressure
The agitator circuit has a maximum pressure shown on
WARNING the hydraulic schematic, which is limited by the relief
cartridge (Figure 50) in the agitator hand valve. The
Tipping hazard. Never set outrigger relief cartridge is located on the back side of the
pressures with the boom unfolded. agitator manual control handle (Figure 50). The
Pressure setting procedure requires cartridge is adjustable with just a 19mm open end
retraction of an outrigger jacking wrench.
000359.eps
cylinder. 1. Plug the 0600 bar whip gauge into the gauge port
(Figure 50) for checking or setting agitator pres-
After the boom circuit is properly set, you can set the sure.
outrigger pressure. Find the relief cartridge 2. Locate the agitator shutoff valve (Figure 67), and
located on the front of the passenger side outrigger close it. If your unit does not have a shutoff valve,
control valve (Figure 48). order one from the Schwing Spare Parts Depart-
1. Attach 0-600 bar whip gauge to the gauge port ment using part numbers 10004680 (valve) and
below the outrigger valve bank. 30303432 (tube). Contact the Service Department
2. Push the outrigger enable button. for installation instructions. If you cant wait for a
shutoff valve, you will need to remove one of the
3. Activate an outrigger jacking cylinder to retract.
hoses from the agitator motor and plug the hose
By retracting a fully retracted cylinder, the oil
and open fitting with approved hydraulic dead
coming from the pump has nowhere to go but over
plugs (Figure 68).
the relief valve. You cannot use an extension or
slewing cylinder because they have secondary NOTE!
relief functions (nonadjustable) built into the valve. Do not jam the paddles to force the oil over
While holding the handle to retract, read the relief by stopping the movement of the
pressure gauge. agitator.
4. The pressure should read the bar value shown on 3. Increase the throttle to any speed above idle. Acti-
the hydraulic schematic. Adjust by loosening the vate the agitator valve handle in either forward or
jam nut and turning the cartridge (Figure 48) in or reverse, and read the gauge. If it does not read the
out. When the proper pressure is achieved, let go of specified pressure, adjustment is required. Turn the
the handle, and release the outrigger enable button. entire relief valve cartridge (Figure 50) in to
increase pressure or out to decrease pressure.
4. When the pressure is set, deactivate the agitator by
placing the manual control handle in the neutral
position.
5. Remove the whip gauge.
6. Reopen the shutoff valve or remove the dead plugs,
and reconnect the capped hydraulic line.
Outrigger valve Agitator Relief Valve
relief cartridge
otrigrlf.eps
Pressure Settings
000174.eps
Agitator quarter turn
shutoff valve (open position)
Motor
Figure 135
Agitator shutoff valve
000289.eps
Figure 136
Approved hydraulic
dead plugs 000257.eps
Figure 137
Cap Nuts Accumulator pump pressure regulator for
A7VO (above) and for A11VO on a unit
Setting accumulator circuit pressure with a stiebel gearcase (below)
To check or adjust the hydraulic pressure in the
accumulator circuit: Boom Pump
Accumulator Pump
1. Stop the truck, put the key in your pocket, and
place a Do Not Operate sign on the windshield.
2. Loosen the jam nut on the pressure regulator of the
accumulator hydraulic pump (Figure 51). Turn the
screw in two-and-one-half turns. This will raise the
regulator pressure above 300 bar.
Accumulator Pump
Pressure Regulator
Standby 000446.eps
revDate
394 Service Manual
HOME PRINT
SERVICE TRAINING
Pressure Settings
000449.eps
Manual bleed
valve
Boom pressure
relief cartridge
ps
lf.e
ssr
pre
Pressure relief
0-600 bar cartridge
gauge port
3. Clear all personnel away from the drive lines, start 5. Locate the accumulator manifold pressure relief
the truck engine, engage the pumps, and bring the cartridge (Figure 54). Loosen the jam nut, and turn
engine RPM to maximum. the screw clockwise to increase the pressure or
4. Read the pressure on the accumulator circuit pres- counterclockwise to decrease the pressure. Tighten
sure gauge (Figure 53). The pressure should read the jam nut when the pressure reaches the value
the value shown on the hydraulic schematic. If no required.
adjustment is needed, skip to step number 7. If
additional pressure adjustment is needed, continue
with step number 5.
000292.eps
Figure 139
Accumulator circuit pressure gauge
Pressure Settings
WARNING
Entanglement hazard. Stop drive shafts
before adjusting the accumulator pump
000075.eps
pressure regulator.
revDate
396 Service Manual
HOME PRINT
SERVICE TRAINING
Electrical
Electrical Information
Boom Control Systems and the Advantages of Each
Manual Controls
Manual Black and White (On-Off) System:
Totally, completely reliable.
Electrical malfunctions are impossible.
Cable Remote Controls
Remote Controlled Black and White System:
Operator can go to the location with the best possible view of the boom and job.
Allows mobility to move around the unit.
Analog Proportional Remote Control System:
Infinitely variable speed control.
No need to use the feathering technique of speed control.
Start and stop the boom with smooth acceleration and deceleration.
Hydraulic stroke limiter can be adjusted from the remote box.
Digital Proportional Remote Control System:
Less susceptible to external noise interference (from radio transmitters, for example).
Cable requires only 6 wires, instead of 25. One for power, one for ground, two for the emergency stop cir-
cuit, and two for data transfer.
More precise adjustment of boom speed than previous systems.
Troubleshooting a non-working system can be done in minutes via a hand held test device.
Increased safety because of numeric operating principles. (Cannot go out of adjustment).
A digital system can be updated or expanded by E-prom replacement or reprogramming. (Analog sys-
tems are not possible to improve without hardware replacement).
The proportional valve amplifiers are self diagnosing via L.E.D.s.
The boom can go slower before shut-off than with an analog system.
Digital system has built in ramp functions, which makes it impossible to accidentally go to full speed by
bumping a joystick.
Comfort Proportional Remote Control System
Has the Schwing information system
1. Pumped volume determination by means of stroke counter and pumped volume calculation.
2. Extensive operational data acquisition and display.
3. Safely stored malfunction list of last 100 malfuction messages.
4. Manual operation of lubricating cycles.
5. Status display of all signals of the electronic control.
6. Password-protected parameter setting for the central lubricating system
7. Password-protected parameter setting for the proportional boom fuctions.
Has the Schwing diagnostic system.
1. The diagnosis system monitors the control unit, the machine and partly also the vehicle for mal-
functions or inadmissible states of operation.
2. The system recognizes e.g. parting of cables or short-circuits in electric lines of solenoids, Fault
sensors, contaminated oil filters or critical hydraulic oil or diesel engine temperatures and displays
different operating conditions.
3. The system is to assist the concrete pump operator in his work on site and to inform him about the
possible causes of malfunctions when they occur.
A
MANUAL - BLACK
AND WHITE
TO
BOOM
lts
B
vo
12
REMOTE CONTROL Switches +
s
BLACK AND WHITE +12 volt Relay Box
TO
BOOM
1000 mA
to
C
0
20
ANALOG Potentiometers
lt s
PROPORTIONAL 6 to 9 vo Proportional
Amplifiers TO
BOOM
0 1 1 0100 1 1 0 1 1 0 0 1 0
0 1 0 10 0 1 0
011 0
D
0 101 1
0 01
DIGITAL
PROPORTIONAL
A/D Converters
Radio
0 10
1000 mA
to
D
0
20
The proportional system can be broken down into 3 major components. They are as follows:
A. The Joystick with the Potentiometer.
B. The Proportional amplifier
C. The Solenoid valves.
BOOM FUNCTION
7.5 VOLTS
UP DOWN
+ 1.5 VOLTS
MICROSWITCH -
1 3
V V
15 VOLTS
1 3
2
MICROSWITCH
7.5 VOLTS
15 VOLTS 0 VOLTS
RELAY
28
26
24
22
PRESSURE AT PORT "A" IN BAR
20
18
A T
16
14
12
10
8
P
6
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
CURRENT IN AMPS
TRANSMITTER
MICRO-
SWITCH
RADIO
SIGNAL
CONNECTING CABLE
RELAY
RECEIVER
BRIDGE FOR
RADIO REMOTE
12 21 22 24
PROPORTIONAL CARD
PILOT VALVES
BOOM BOOM
UP DOWN
ADAPTER CARD
FOR TEST METER
(PART# BEFORE 1992 10074136
AFTER 1992 10023317)
EMPTY
SLOT
9 1 2 3 5
CARD 9
LED 4
LED 5
CARD 1, 2, 3
MIN
MAX
LED Function
LED 1
Channel 1 1 Illuminates when the corresponding function has
MIN been activated.
MAX
2 Illuminates when the corresponding function has
LED 2 been activated.
LED 6
CARD 1, 2, 3
BOOM FUNCTION
UP DOWN
MICROSWITCH
LED 1
Channel 1
MIN
MAX
LED 2
MIN
MAX
LED 3
Channel 2
MIN
MAX
LED 4
LED 5
LED 6
1 3
2
1000
MAXIMUM CURRENT OUTPUT (mA)
900
800
MAX
700
600
500
MIN
400
300
200
100
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
MIN MAX
PRETENSION PRESSURE (Bar)
The optimum adjustment makes full use of the joysticks range of travel. Other adjustments
result in poor response and on/off switching of valves, which in turn causes jerky motion of the
bomm and possible structure damage.
MIN
0 5 0
MIN
MAX MAX
36 36 36 36
1 3 1 3
2 2
PN
2 4 6 8 10 12 14 16 18 20 22
327524
9 SLOT 1 2 3 4 5
MIN
MAX
Slew Boom 2 Boom 4
7.5v
Output
15v Main Boom 3 volume
DOWN DOWN CABLE
18v
24v
ES
Output
Main Boom 3 volume
UP UP RADIO
FU
FUSE 1 FUSE 1 FUSE 1
+ + - - 20 18 16 14 12 10 8 6 4 2
Truck batteries
GND
IGN.
24v 12v
+ 12V - + 12V -
Ignition
switch
(on)
PTO (on)
switch
12V 12V
ACTUATED ACTUATED
Truck batteries
GND
IGN.
24v 12v A C
30A 30A + 12V - + 12V -
+ 12V - + 12V -
B D
Ignition
switch
(on)
PTO (on)
switch
12V 12V
ACTUATED ACTUATED
1. Determine which battery doesnt have any accessary power leads. This will be the battery used
to create the 24V power.
2. Disconnect the truck cables from that battery (BE CERTAIN THERE ISNT ANY OTHER WIRES
CONNECTED TO THE 24V BATTERY OR SEVERE DAMAGE COULD RESULT TO OTHER
CIRCUITS ON THE UNIT).
3. Connect jumper from Battery "A" (+ positive) to Battery "B" (- negative) and then connect Battery
"B" (+ positive) to the 24V wire disconnected from the Duvacs 24V post.
4. It may be required to swap Battery "B" with Battery "D" if operated in this mode for an extended
period of time because the battery used to create 24V isnt being charged.
ANALOG 1000 mA
PROPORTIONAL
o
0t
20
Potentiometers
15 volts Proportional
Amplifiers
6 to 9 v olts TO
BOOM
DIGITAL 1000 mA
o
PROPORTIONAL
0t
20
Figure 1
ana/digi compare.eps
Digital systems have definite advantages over the analog proportional system found on older machines. Because
everything is translated into numbers, there can be no mis-adjustments. Instead of adjusting a trim pot to fine tune
the response, you simply enter in the parameters that you want, and the processor takes care of the rest. In addition,
the zeros and ones (referred to as bits) travel to the processor in groups (referred to as bytes). Each bit in the
byte tells the processor something about the condition of the machine. If you could translate one of the bytes into
plain English, it would look something like this:
I am a Schwing with an ID number of 7. Emergency stop is not activated. Concrete pump is activated in forward.
Boom #3 retract joystick is activated to 48% travel. Boom #2 extend joystick is activated to 85% travel.
10101110011000010100100011000100101010010100010 11010001
Identifier
NG NF MC2 MC1
ST 1
UF K1 TEL ST 2
UE1 K2 REL
UCC1 PROP
UE2 TEL
UCC2 TST 3
NOT1 TST 2
K1 TST 1
Figure 2
M.A.T.
The M.A.T. is a hand held programmer that can be plugged into the digital controller. It consists of an 8 digit
alphanumeric display and a 4 button keypad. Its used to access information and program the system. This is
important because you cant troubleshoot a digital system with a test light. However, the advantage of a digital
system is that in most cases the processor already knows what is wrong by the time you notice a problem. See
Figure 3.
*scv
P
C
M.A.T.
Figure 3
+ .A12 + A11 + .A10 + .A9 + .A8 + .A7 + .A6 + .A5 + .A4 + .A3
REC 2 SCV HC2L-1 HC2L-1 HC2L-1 HC2L-1 HC2L-1 HC2L-1 DG8-1 DG8-1
M.A.T.
CONNECTOR
DG 8
SCV 9 HC 2
(slave card
(master card) (slave card
Figure 4
1 2 3 4 5 6 7 8
+ .A12 + A11 + .A10 + .A9 + .A8 + .A7 + .A6 + .A5 + .A4 + .A3
REC 2 SCV HC2L-1 HC2L-1 HC2L-1 HC2L-1 HC2L-1 HC2L-1 DG8-1 DG8-1
1
2
3
M.A.T.
CONNECTOR
DIGITAL INPUTS
4
+
5
MIN RES.
6
7
MOTOR
8
Figure 5
RS 485 BUS
Figure 6
Software
*scv
CUSTOMER MENU Version 2.4X
To cable
remote &
back
panel
C cards
?AUSL 2H
1S3 900
2H1 200
2H2 300
Max. current (mA.)
Min. stop current (mA.)
Figure 7 (PG-1)
MAT Operation
The MAT (Manual Adjustment Terminal) is the setting and diagnostic unit for the digital proportional control
system.When plugged into the 9 pin front panel connector it goes through an initializing phase, then *SCV 9 or
? SCV 9 appears in the 8-digit, alphanumeric display.
There are 4 keys on the M.A.T. which allow you to scroll through the menu structure in order to set system parameters to there
required values, observe the non-adjustable entries, or perform well aimed signal tracing while troubleshooting.
The symbols on the keys stand for the following:
P = Program = Up
C = Clear = Down
To cable
remote &
back
panel
*SCV 9 ?PAR ?AUSL ?AUSL 1H 1H1 200 Min. stop current (mA.)
Boom up
1H2 300 Min. start current (mA.) Section 1
1H3 900 Max. current (mA.)
1H2 300 M
1H3 900 M
1S2 300 M
Figure 9 1S3 900 M
Menu RP1 25
RP2 50
(White) RP3 75
?INS ?V24 OK 0
CE 0
FE 0
PE 0
OE 0
VE 0
?TELEGR. W0 0000
W1 0000
W2 0000
W3 0000
W4 0000
W5 0000
Service CRC 00
CERR
NA_F OFF
NA_C OFF
STOER 0
(PG-2) PERR
Figure 12
Note: Some of the definitions listed are common to both menu structures, while others are specific to the 2.4 menu.
After selecting the *SCV 9 controller, you can scroll the individual main menu items with the and keys.
After selecting the ?PAR main menu, you can scroll the individual submenus with the and keys.
XY1 200 =Here, the jump-out or minimum stop current can be set within the
range from 50 to 1100 mA.
Default 200 mA.
XY2 300=Here, the jump-in or minimum start current can be set within the range
from 50 to 1100mA.
Default 300 mA.
XY3 900 = Here, the maximum current can be set within the range from 50 to
1100 mA.
Default 900 mA.
?MAST_X = Setting the current values for boom slewing X, where: X = L (left) or R (eight).
The individual parameters are:
MX1 200 = Here, the jump-out or minimum stop current can be set within the
range from 50 to 1100 mA.
Default 200 mA.
MX2 300 = Here, the jump-in or minimum start current can be set within the
range from 50 to 1100 mA.
Default 300 mA.
MX3 900 = Here, the jump-in or minimum start current can be set within the
range from 50 to 1100 mA.
Default 900 mA.
F.MENGE = Setting the stroke limiter current values
The individual parameters are:
FM1 200 = Here, the jump-out or minimum stop current can be set within the
range from 50 to 1100 mA.
Default 200 mA.
FM2 300 = Here, the jump-out or minimum stop current can be set within the
range from 50 to 1100 mA.
RP1 25 = Here, the speed step 1 ramp value can be set within the range from 0 to 99%.
Default: 25.
RP2 50 = Here, the speed step 2 ramp value can be set within the range from 0 to 99%.
Default: 50.
RP2 75 = Here, the speed step 3 ramp value can be set within the range from 0 to 99%.
Default: 75.
?SELECT
Submenu Functions and Parameters (In Service Menu Only!)
?SELECT = Submenu for locking or unlocking prop channels (In service menu only!).
The individual parameters are:
MX ON= Parameter, by means of which the prop output for boom slewing X
(X = L/R) can be activated or deactivated.
FM ON= Parameter, by means of which the prop output for the stroke limiter
can be activated or deactivated.
?BDI_A= Input Date from BDI_A (Rear Panel) Display submenu display or selection.
?BDI_F= Input Date from BDI_F (Cable or Radio Remote Control) Display submenu
display or selection.
UMSO/F= Entry indicating how the system recognized the outrigger input
instruction.
DWLO/F= Entry indicating how the system recognized the limit switch slewing
left input instruction.
DWRO/F= Entry indicating how the system recognized the limit switch slewing
right input instruction.
BPVO/F= Entry indicating how the system recognized the concrete pump
forward input instruction from site control.
BRPO/F= Entry indicating how the system recognized the concrete pump
reverseinput instruction from site control.
WMNrO/F= Entry indicating how the system recognized the water level
minimuminput instruction.
RWKO/F = Entry indicating how the system recognized the agitator ON input
instruction.
(Input active for AGRs = 1 function.)
REPO/F= Entry indicating how the system recognized the Maintenance ON input
instruction.
(Input active for MTNs = ON function.
DIGf = Digital inputs from BDI_A (Remote Control) submenu display or selection.
The individual displays are:
RP3fO/F= Entry indicating how the system recognized the ramp 3 input
instruction.
For the FBP type, this entry is substituted by:
AUTfO/F= Entry indicating how the system recognized the automatic
input instruction.
RWVfO/F= Entry indicating how the system recognized the agitator forward
input instruction.
After selecting the ?SOUT_1 main menu, you can scroll the individual entries with the and keys.
In the ?SOUT_1 main menu, the first group of the digital outputs as to be given out by the system is represented. The fol-
lowing individual entries can be found:
MOF O/F = Entry indicating whether the system wants to give out the motor OFF
output instruction.
MON O/F = Entry indicating whether the system wants to give out the motor ON
output instruction.
MDN O/F = Entry indicating whether the system wants to give out the rms - output
instruction.
MUP O/F = Entry indicating whether the system wants to give out the rms + output
instruction.
HP1 O/F = Entry indicating whether the system wants to give out the horn 1
(communication) output instruction.
HP2 O/F = Entry indicating whether the system wants to give out the horn 2
(slewing mechanism end position) output instruction.
ASW O/F = Entry indicating whether the system wants to give out the spotlight output
instruction.
RTE O/F = Entry indicating whether the system wants to give out the vibrator
output instruction.
After selecting the ?SOUT_2 main menu, you can scroll the individual entries with the and keys.
In the ?SOUT_2 main menu, the second group of the digital outputs as to be given out by the system is represented. The
following individual entries can be found:
In the ?POUT_1 main menu, the first group of the proportional outputs as to be given out by the system is represented. The
following individual entries can be found:
A1H XXX = Entry indicating what current the system wants to drive through the boom
1 up valve.
A1S XXX = Entry indicating what current the system wants to drive through the boom
1 down valve.
A2H XXX = Entry indicating what current the system wants to drive through the boom
2 up valve.
A2S XXX = Entry indicating what current the system wants to drive through the boom
2 down valve.
A3H XXX = Entry indicating what current the system wants to drive through the boom
3 up valve.
A3S XXX = Entry indicating what current the system wants to drive through the boom
3 down valve.
A4H XXX = Entry indicating what current the system wants to drive through the boom
4 up valve.
A4S XXX = Entry indicating what current the system wants to drive through the boom
4 down valve.
After selecting the ?POUT_2 main menu, you can scroll the individual entries with the and keys.
In the ?POUT_2 main menu, the second group of the proportional outputs as to be given out by the system is represented.
The following individual entries can be found:
MR XXX = Entry indicating what current the system wants to drive through the
slewing right valve.
ML XXX = Entry indicating what current the system wants to drive through the
slewing left valve.
FM XXX = Entry indicating what current the system wants to drive through the
stroke limiter valve.
After selecting the ?DIAG main menu, you can scroll the individual submenus and entries with the and keys.
In the ?DIAG main menu, a few entries can be found for easier diagnosing. The following individual entries can be found:
WAS O/F = This entry indicates whether the control system is under restart protection
for the time being, i.e. no output signal is given unless all instruction
sources of the newly selected mode (LOCAL or REMOTE) are at their
neutral positions.
NAH O/F = Entry indicating whether the control system is in LOCAL mode.
FERN O/F = Entry indicating whether the control system is in REMOTE mode.
REPB O/F = Entry indicating whether the control system is in maintenance mode.
(On-site control active!)
MAST O/F = Entry indicating whether the control system wants to five out the
boom active output instruction.
DWL O/F = Entry indicating how the system recognized the limit switch slewing left
input instruction.
DWR O/F = Entry indicating how the system recognized the limit switch slewing
right input instruction.
LDK O/F = Entry indicating how the system recognized the alternator (D+) input
instruction.
WMH O/F = Entry indicating how the system recognized the water level minimum
input instruction.
In the ?SYSTEM main menu, some system information and setting aids can be found. This menu should only be used by
especially trained personnel as system data can be changed here that may result in system failure when entered in the wrong
way!!! The following individual entries can be found:
SCV_S = This entry indicates which hardware (which card) and which software
(program) can be found.
V2.4x = This entry indicates what software version is found. (See Explanation of Different Software Versions).
TYPXXX = This entry indicates what type of unit the card is currently programmed to.
hh : mm : ss = This entry indicates the time of operation since the last reset or restart.
USAGE XX = This entry indicates the current usage of the bus system in percent (0...99).
!RESET = By selecting this item, a so-called warm start can be initiated, i.e. the system
is brought to the same condition as after turning on the supply voltage.
! N E W = Selecting this item brings all parameters in the system to factory-set default.
In the ?GERAET main menu, all unit-specific settings are concentrated. The following
individual entries can be found:
REP OFF = This serves to select the concrete pump on-site control mode.
If on-site control is to be activated by a release switch, this parameter must be programmed ON.
Default: OFG
RWK 0 = This switches off the optional agitator (0), and activates it for simple functioning forward only / 1), or for
extended functioning (forward and reverse / 2).
Default: 0
FHYS 2.0 = This serves to set the hysteresis compensation factory within the range from 1.0 to 10.0.
Default 2.0
IVOR 50 = This serves to set the driver current within the range from 0 to 200mA.
Default: 50 mA
V2.4 Menus
The V2.4x software version has two different levels of access, the customer menu and the service menu. The customer menu
has the parameter settings for the current that is used for driving the hydraulic valves. These settings are changeable from the
customer menu in the ?PAR portion of the main menu. The customer menu also allows you to view non-changeable entries
such as inputs to and outputs from the SCV card. The customer menu only allows you access to the SCV card.
The service menu allows you to access some extra troubleshooting entries in the SCV card along with all HCL and DG cards.
Along with this, you can also view the BDI_A (rear operators panel card and the BDI_F (cable remote) card.
On the following pages containing the 2.4 menu structure, the service menu entries are all the entries in the shaded boxes. All
the entries in the unshaded boxes can be accessed from the customer or the service menu. To access the service menu, do the
following:
1. From the SCV entry in the controller column, you press the P button. This will bring
up the ?PAR entry in the main menu column.
2. Press the arrow key down until the ?SYSTEM entry is displayed on the mat.
3. Press P to display SCV_S.
4. Press the P key one, then the C key once, and finally the arrow up key once.
The display should now read NR500.
5. Press the P key and a dotted line will appear under the NR500.
6. Press the arrow up key until the display reads NR530.
7. Press the P key and a dashed line will appear under the NR530. You now have access
to all entries in the customer and service entries.
Every time the unit is reset, either by shutting off the power and turning it back on, or my using the reset function in the mat,
you will automatically be in the customer menu and must re-enter the code to access the service menu.
On the following pages there is one menu structure for the 2.2x and 2.3x version and one menu structure for the
2.4x version.
The BDI cards or the cards used for the rear panel and remote control box can also have various versions. The
versions are either 1.xx or 2.xx. In the 1.xx version the cards were specific to their location, ie., the BDIA card was
used for the rear panel and the BDIF card was used for the remote box. The 2.xx version is called BDI S and it can
be programmed to be used in the rear panel or remote box. The versions are interchangeable, however the 1.xx
version cannot be used in systems with remote agitator controls as used in the 52m.
The HCL and DG cards have different versions and they are interchangeable and compatible with all SCV card
version
Software
MENU STRUCTURE Version 2.4X
To cable
remote &
back
panel
*SCV 9 ?PAR ?AUSL ?AUSL 1H 1H1 200 Min. stop current (mA.)
Boom up
1H2 300 Min. start current (mA.) Section 1
1H3 900 Max. current (mA.)
RP1 25
RP2 50
RP3 75
?TELEGR. W0 0000
W1 0000
W2 0000
W3 0000
W4 0000
W5 0000
CRC 00
?SELECT A1Hs ON
A1Ss ON
A2Hs ON Lock/Unlock
A2Ss ON Proportional
A3Hs ON Outputs
A3Ss ON
A4Hs ON
A4Ss ON
MLs ON
MRs ON
FMs ON
?DIN ?BDI-A
?DIGa Spotlight
ASWa O/F
Horn
HUPa O/F
RTHa O/F Vibrator Manual
Vibrator Automatic
RTAa O/F
Compressor
KPRa O/F
Water Pump
WPEa O/F
Concrete Pump Forward
BPVa O/F
Concrete Pump Reverse
BPRa O/F
Engine Start
MONa O/F
Engine Stop
MOFa O/F
RPM Up
MUPa O/F
RPM Down
MDNa O/F
Local (on)/Remote (off)
FSTa O/F
RE1a O/F Spare
MM O/F Slewing
DSL O/F Push button Left
Version 2.4X
Version 2.4X
REPs ON
RWKs 2 Agitator For/Rev mode
FHYs 2.0 Refer to balancing valve currents
IVOR 50 Refer to balancing valve currents
Version 2.4X
?DIGITAL
ASW O/F Spotlight
HUP O/F Horn
RTH O/F Vibrator manual
?DIGITAL
ASW O/F Spotlight
HUP O/F Horn
RTH O/F Vibrator manual
?SYS
USP XX Percentage bus employment
TAS XX Task posed by bus communication
BDI A Card type/hardware
?DIGITAL ?MSTS
M1 O/F Boom 1 microswitch
?ANALOG
A1p XX Boom 1 potentiometer (-99 to 99%)
Continued
?PARM1
1PN HHHH Calibration (do not change)
1PX HHHH Calibration (do not change)
1NN HHHH Calibration (do not change)
1NX HHHH Calibration (do not change)
2PN HHHH Calibration (do not change)
2PX HHHH Calibration (do not change)
2NN HHHH Calibration (do not change)
2NX HHHH Calibration (do not change)
4PN HHHH Calibration (do not change)
4PX HHHH Calibration (do not change)
4NN HHHH Calibration (do not change)
4NX HHHH Calibration (do not change)
?PARM2
MPN HHHH Calibration (do not change)
MPX HHHH Calibration (do not change)
MNN HHHH Calibration (do not change)
MNX HHHH Calibration (do not change)
FPN HHHH Calibration (do not change)
FPX HHHH Calibration (do not change)
FNN HHHH Calibration (do not change)
FNX HHHH Calibration (do not change)
MI1 HHHH Calibration (do not change)
MI2 HHHH Calibration (do not change)
MI4 HHHH Calibration (do not change)
MIM HHHH Calibration (do not change)
MF1 HHHH Calibration (do not change)
?BDI1 11
?ANALOG
%A1 XX Boom 1 potentiometer (-99% - 99%)
?HEXIN
A1 HHH Boom 1 (Hexidecimal code)
?DIGITAL
SWH HHHH All function hexadecimal code
M1 O/F Boom 1 microswitch
?CALIB ?PARMS
1PN HHHH Calibration (dont change)
1PX HHHH Calibration (dont change)
1NN HHHH Calibration (dont change)
1NX HHHH Calibration (dont change)
BDI 11
?SYS
USP XX Percentage bus usage
PV 3.0 ----------------
TN 0.06 ----------------
!NEW ENA ----------------
!NEW Return to factory setting
?DG8 X
Software Version
MENU STRUCTURE 2.2X & 2.3X
USP XX -------------
TASK XX -------------
SCV_S Hardware Version
V2.21 Software Version
HH:MM:SS Time since last reset
? NEW P Return to the factory setting
USAGE XX --------------
TASK XX -------------
PV 3.0 --------------
TN 0.06 --------------
!NEW ENA --------------
TASK XX ----------------
BDI_F Hardware Version
1000
MAXIMUM CURRENT OUTPUT
900
800
MAX
700
600
500
MIN
400
300
200
100
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
MIN MAX
PRETENSION PRESSURE (BAR)
MAX MIN
MICROSWITCH
CLOSED
Figure 13
1000
MAXIMUM CURRENT OUTPUT
900
800
MAX
700
600
500
MIN
400
300
200
MIN, START
100
SETTING
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
MIN MAX
PRETENSION PRESSURE (BAR)
MAX MIN
"DEAD" AREA
MICROSWITCH
CLOSED
Figure 14
The maximum current setting controls the amount of driver current available. When properly adjusted, the
hydraulic valve should just contact the mechanical stop as the joystick reaches the 100% position. See Figure 15.
1000
800
MAX
700
600
500
MIN
400
300
200
100
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
MIN MAX
PRETENSION PRESSURE (BAR)
MAX MIN
MICROSWITCH
CLOSED
Figure 15
Hysteresis
Because of the inertia generated by the weight of the boom, the system responds differently when increasing the
driver current (accelerating the boom) than it does to decreasing driver current (slowing the boom). This difference
in response is referred to as hysteresis. To provide smooth transitions when controlling boom speed, a hysteresis
compensation factor is programmed into the system. This setting is located in the FHYS 2.0 submenu, but the
value should not be changed.
Diagnostic Signal
Part of the systems self diagnostic ability is a result of a 50 mA driver current programmed into the system. This
diagnostic current is applied to both values on axis at the same time. This small amount of current is not enough to
run the boom; however, it does allow the system to detect an open circuit such as a broken wire or faulty solenoid.
HYSTERESIS COMPENSATION:
DRIVER CURRENT:
Figure 16
Troubleshooting
LEDs
+ .A12 + A11 + .A10 + .A9 + .A8 + .A7 + .A6 + .A5 + .A4 + .A3
REC 2 SCV HC2L-1 HC2L-1 HC2L-1 HC2L-1 HC2L-1 HC2L-1 DG8-1 DG8-1
M.A.T.
CONNECTOR
Figure 17
If a problem exists, the first step is to check the status of the LEDs on the digital controller. Use the charts to
interpret the messages communicated by the LEDs, then follow the appropriate troubleshooting (T.S.) procedure
on the following page.
Troubleshooting
Message Meaning
procedure
NOTE: The rear panel board will light for approximately 1 second on system activation or restart.
Note: The troubleshooting procedures listed below pertain to the electrical system. Make sure that there are no
problems with the hydraulic system before performing any of these procedures.
Troubleshooting procedure 2
If none of the control functions are working and the SCV9 card is steady green, but the other cards are off, it
indicates a communication error between SCV9 and one or more of the slave cards.
To locate the problem, connect the M.A.T. and scroll to the INS main menu. Then scroll to the C-E-R-R display
which is the entry for communication errors. The number in the display indicates the position to the right of the
SCV 9 card where the first error occurred. To determine if the problem is on the card, swap it into another position
of the same card type and reset the system. If the error follows to the new position, the board is defective. If the
error is still in the same position, call Schwing Service for assistance.
Troubleshooting procedure 3
If the card that controls the problem function is flashing, along with the SCV9 card, there is a hardware fault
somewhere between the output of the digital processor and the hydraulic valve. To determine if the problem is the
solenoid or the wiring, swap the solenoid caps. If the problem is unchanged, replace the solenoid. If the problem
follows the solenoid caps, the problem is in the wiring. If this is the case, you should consult the electrical
schematics to track the faulty wire.
Troubleshooting procedure 4
If the SCV9 is the only card flashing, it means the problem is intermittent, possibly a bad connection. It continues
to flash because it stores fault information in its memory until the system is reset.
Because of the sensitivity of the system the SCV light may blink for various reasons, if resetting the system does
not clear the problem refer to troubleshooting procedure 3.
Resetting the system can be accomplished either by turning the power off and on, or by using the M.A.T.
POWER
Figure 19
SCHWING 20 K28
NG NF MC2 MC1
ST 1
UF K1 TEL ST 2
UE1 K2 REL
UCC1 PROP
UE2 TEL
UCC2 TST 3
NOT1 TST 2
K1 TST 1
T 2 T 1
RADIO CONTROL
FCC ID. DA87G6 FW
SCHWING AMERICA .
GERMANY
SERIAL NR 003 143
FREQ. 456.962S
(mHZ) 457.762S
Radio Receiver
Figure 20
Operation
With the Local/Remote switch located on the rear operators panel in the local mode:
1. Connect the Funk plug or cable remote to the remote receptacle (one or the other must be connected to operate a digital
machine). See Figure 21.
2. Properly set the machine, as described in the operators manual, then turn the mode switch back to the remote position.
FUNK
Figure
3. Make sure all the function switches on the remote control transmitter are in the neutral position.
4. Turn the remote control power supply on. (the LED on the right should start flashing)
5. Turn the power switch located on the transmitter to the on position. (the E-stop LED should flash faster) See Figure 22.
Figure 22
Emergency Stop
Pushing the emergency stop button stops the main functions of the machine.
NG HF MC2 MC1
ST 1
UF K1 TEL ST 2
UE1 K2 REL
UCC1 PROP
UE2 TEL
UCC2 TST 3
NOT1 TST 2
NOT2 TST 1
T2 T1
REMEDIAL
LED DISPLAY MESSAGE
ACTION
UF, UE1, UCC1, UE2, Switch in, check power
None lit Machine power failure
UCC2 supply
REMEDIAL
LED DISPLAY MESSAGE
ACTION
Switch on transmitter,
Transmitter scan, no radio
choose better transmitter
K1, K2 Alternately flashing contact
location, check antenna
Message format error
See MC1
REMEDIAL
LED DISPLAY MESSAGE
ACTION
Transmitter off, no radio Switch on transmitter,
contact choose better transmitter
TEL Irregular flashing
Transmitter defective, RF location, check antenna
section defective Call Schwing Service
REMEDIAL
LED DISPLAY MESSAGE
ACTION
Failure in MC1 or in periph-
ST1 On ery module, e.g. REL, NG, Call after Schwing Service
PROP
Failure in MC2, no
ST2 On Call after Schwing Service
exchange of data
REMEDIAL
LED DISPLAY MESSAGE
ACTION
Vehicle power supply volt-
PROP On Check vehicle power supply
age <20V resp.>28V
REMEDIAL
TST TST TST
MESSAGE ACTION
3 2 1
No empty message after switch-on emergency Set control element to 0 position
shut-off activated Unlock E stop
HF interference3 Call Schwing Service
The SCHWING info & diagnosis system for truck-mounted concrete pumps is located in the rear panel unit at the
rear step-ladder of the machine and is operated with the display and the 6 function buttons below.
-Pumped volume determination by means of stroke counter and pumped volume calculation
(cf. 1.2.3)
-Extensive operational data acquisition and display (cf. 1.2.4)
-Safely stored malfunction list of the last 100 malfunction messages (cf. 1.2.5)
-Manual operation of lubricating cycles (cf. 1.2.6)
-Status display of all signals of the electric control (cf. 1.2.7 & 3.0)
-Password-protected efficiency adjustment for the pumped volume determination of the concrete pump (cf. 2.0)
-Password-protected parameter setting for the central lubricating system (cf. 2.0)
-Password-protected parameter setting for the proportional boom functions (cf. 2.0)
The diagnosis system monitors the control unit, the machine and partly also the vehicle for malfunctions or
inadmissible states of operation.
The system recognizes e.g. parting of cables or short-circuits in electric lines of solenoids, Fault sensors,
contaminated oil filters or critical hydraulic oil or diesel engine temperatures and displays different operating
conditions.
The system is to assist the concrete pump operator in his work on site and to inform him about the possible causes
of malfunctions when they occur.
The malfunction messages are displayed as continuous text in the form of an easily understandable plain language
message with additional fault code. The manual contains a detailed description of the faults for each fault code (cf
4.0)
In case of recognized malfunctions, the diagnosis system distinguishes between minor faults and severe faults.
Minor faults do not require immediate elimination of the fault cause and the machine can be used - possibly with
some restrictions - until the job is finished
A severe fault bears the risk that the machine or the vehicle may be severely damaged. An immediate elimination of
the fault cause is therefore necessary.
If the integrated diagnosis system recognizes a malfunction or an inadmissible state of operation of the machine, a
horn sounds intermittently and a fault message appears on the display of the rear panel unit.
Moreover, the last 100 recognized malfunctions are stored safely in a malfunction list together with date and time.
They can be recalled at any time.
In the event of severe faults, the horn signal cannot be cancelled with the buttons on the remote control box.
The operator can therefore recognize severe faults by the fact that the horn signal continues to sound although the
[Hupe / quitt] button on the remote control box or the cable control box has been actuated.
Since severe faults cause considerable damage of the machine, the concrete pump operator must inform himself at
the display of the diagnosis system on the machine about the fault occurred. In the event of severe faults, the horn
signal can be cancelled and the fault message be deleted only with the [QUITT] button below the diagnosis display.
Fault messages are also definitely cancelled when the electric control system is switched off.
The operator himself is responsible for the elimination of indicated faults in order to prevent the machine from
being damaged.
If the message of a fault that has not been eliminated is being cancelled, there is no new fault indication.
A persistant fault will however be recognized and reported again by the diagnosis system after the machine has
been de-activated with the EMERGENCY SHUT-OFF button on the machine or on the remote control box.
SCHWING is not responsible for damage caused by non-eliminated faults of the machine !
The operation of the diagnosis system on all menu levels is explained on the following pages.
The message displayed is shown in a frame. The menu functions and the selection of special functions is described
by the key symbols in brackets and the pertaining explanantions.
When the diagnosis system recognizes a malfunction of the machine or the electrical system, the actual
message on the display is overwritten with the actual fault message.
PUMPED ON JOB (S) [ START ] Start new pump volume determination &
1723.5 cbm
delete old value (cf. 2.2)
[ CLEAR ] Back to main menu
HYD OIL TEMP Display of actual oil temperature in hydraulic oil reservoir
062 C
[] [ CLEAR ] Back to main menu
TOTAL VOL. PUMPED Display of stored total pumped quantity of concrete pump
1491258 cbm
[] [] [ CLEAR ] Back to main menu
STROKES PER MIN Display of actual number of strokes of concrete pump in strokes/
21.4 S/min
min
[] [ CLEAR ] Back to main menu
MACHINE-CONTROL [ ENTER ] Call up I/O display for machine control module (cf.
/ ENTER / CLEAR
3.1)
[] [ CLEAR ] Back to main menu
CP-CONTROL [ ENTER ] Call up I/O display for concrete pump control mod-
/ / ENTER / CLEAR
ule (cf. 3.2)
[] [] [ CLEAR ] Back to main menu
BOOM-CONTROL [ ENTER ] Call up I/O display for boom control module (cf.
/ / ENTER / CLEAR
3.3)
[] [] [ CLEAR ] Back to main menu
REAR PANEL [ ENTER ] Call up I/O display for rear panel module (cf. 3.4)
/ / ENTER / CLEAR
[] [] [ CLEAR ] Back to main menu
EXTENSION I/O [ ENTER ] Call up I/O display for extension module
/ ENTER / CLEAR
(cf. 3.5)
[] [ CLEAR ] Back to main menu
This sub-menu can be used to adjust the so-called "SCROLLING rate" (running speed) of fault message texts in the
display.
For easier checking during adjustment, the "SCROLL-speed" text always moves through the first line of the display
at the actually set speed.
Depressing [ ENTER ] activates the adjusting mode for the scrolling rate.
The activation of the adjusting mode is indicated by a flashing scrolling rate (300 ms) in the display.
By depressing the [ ] [ ] keys, the scrolling-speed rate can be changed by 50 ms at a time. Depressing [ ENTER
] stores the set value and quits the adjusting mode.
Unintentional or unauthorized access to the adjustment of set values (parameters) for the pumped volume
determination of the concrete pump for the central lubrication and the prop current characteristics of the boom
functions is protected by a password.
After selecting "PARAMETER" in the main menu, the password must be entered first.
Explanation :
The password can be entered with the [ ] [ ] keys. If one of the keys is kept depressed, the password display
starts incrementing slowly. After abt. 5 seconds, the display starts incrementing faster and after further 5 seconds,
the speed increases once again.
After pressing [ ENTER ] and after the correct password has been selected, the display shows "Password OK" and
jumps to the parameter selection menu.
In the event of a wrong password, the display shows "Password wrong" and the diagnosis system goes back to the
standard display.
LUBRIC. PARAM [ ENTER ] Call up parameter menu for central lubrication (cf.
/ / ENTER / CLEAR
2.3)
[] [ CLEAR ] Back to PASSWORD entry
PROP-CUR SLEW [ ENTER ] Select parameter setting for BOOM SLEW function
/ / ENTER / CLEAR
[] [ CLEAR ] Back to PASSWORD entry
PROP-CUR BOOM 1 [ ENTER ] Select parameter setting for boom function BOOM
/ / ENTER / CLEAR
1
[] [] [ CLEAR ] Back to PASSWORD entry
PROP-CUR BOOM 2 [ ENTER ] Select parameter setting for boom function BOOM
/ / ENTER / CLEAR
2
[] [] [ CLEAR ] Back to PASSWORD entry
PROP-CUR BOOM 3 [ ENTER ] Select parameter setting for boom function BOOM
/ / ENTER / CLEAR
3
[] [] [ CLEAR ] Back to PASSWORD entry
PROP-CUR BOOM 4 [ ENTER ] Select parameter setting for boom function BOOM
/ / ENTER / CLEAR
4
[] [] [ CLEAR ] Back to PASSWORD entry
PROP-CUR BOOM 5 [ ENTER ] Select parameter setting for boom function BOOM
/ / ENTER / CLEAR
5
[] [ CLEAR ] Back to PASSWORD entry
2.2 Setting the concrete pump efficiency for pumped volume determination
The volumetric efficiency of the pumped volume calculation (efficiency CP) of the concrete pump can be set in this
parameter menu.
The setting acts on the pumped volume counter (PUMPED VOLUME) and on the total pumped quantity of the
concrete pump (TOTAL VOL. PUMPED).
The pumping volume of the concrete pump is determined by counting the pump strokes and by calculating the
delivery rate by means of the pumped volume of the pumping cylinder and the CP EFFICIENCY:
EFFICIENCY CP should therefore be an average value for the pump efficiency of the concrete pump depending on
the most often pumped concrete qualities.
[ ENTER ] activates the setting mode for the "Concrete pump efficiency" parameter.
The activation of the adjusting mode is indicated by a flashing percentage for the pumped quantity efficiency in the
display.
The efficiency concrete pump value can then be changed in steps of 1% by pressing the [ ] [ ] keys.
Depressing [ ENTER ] stores the set value and quits the adjusting mode.
If "0" lubricating cycles have been preset, the corresponding lubricating circuit is shut off.
LUBRIC. CYCLE [ ENTER ] Activate parameter setting for placing boom greas-
BOOM 09
ing circuit
[] [ CLEAR ] Back to parameter selection menu
The adjusting ranges of the prop current values are limited as follows :
- Current value for "I min" within 250 mA to 1000 mA.
(The set value must be less than the value for "I max")
- Current value for "I max" within 500 mA to 1500 mA.
(The set value must be greater than the value for "I min")
The following examples illustrate changes of the proportional values for the BOOM SLEWING MECHANISM for
valves of the PROP type and for BOOM SECTION 1 for valves of the PULSAR type.
BOOM SLEW RIGHT Display of actual value for proportional current boom slew
I act 510 mA
right !
BOOM SLEW RIGHT [ ENTER ] Activate parameter adjustment for MIN current of
I min 340 mA
boom slew right function
BOOM SLEW RIGHT [ ENTER ] Activate parameter adjustment for MAX current of
I max 850 mA
boom slew right function
BOOM SLEW LEFT Display of actual value for proportional current boom slew left
I act 470 mA
BOOM SLEW LEFT [ ENTER ] Activate parameter adjustment for MIN current of
I min 340 mA
boom slew left function
BOOM SLEW LEFT [ ENTER ] Activate parameter adjustment for MAX current of
I max 850 mA
boom slew left function
BOOM 1 EXTEND Display of actual value for the actual PWM boom 1 extend
PWM act 43 %
value
BOOM 1 RETRACT Display of actual value for the actual PWM boom 1 retract
PWM act 49 %
value
The status display of all inputs & outputs shows the real state of the respective input or output!
( = high = +24 V / = Low = 0 V )
The arrow keys [ ] [ ] are used to move between the status displays !
[ CLEAR ] returns to the module selection of the I/O displays !
INP MACHINE-C1
12345678
OUTP MACHINE-C1
12345678
INP MACHINE-C2
12345678
OUTP MACHINE-C2
12345678
INP CP-CONTROL
12345678
OUTP CP-CONTROL
12
INP BOOM-C1
123456
INP BOOM-C2
123456
BOOM-SLEW LEFT
[]
BOOM 1 RETRACT
[]
BOOM 2 RETRACT
[]
BOOM 3 RETRACT
[]
BOOM 4 RETRACT
[]
BOOM 5 RETRACT
Signal Module / Assembly Connector / Pin
Output "boom-slew right" solenoid Boom control (-A161) -X161 / 21
Output "boom-slew left" solenoid Boom control 1 (-A161) -X161 / 12
Output "boom 1 extend" solenoid Boom control 1 (-A161) -X161 / 03
Output "boom 1 retract" solenoid Boom control 1 (-A161) -X161 / 13
Output "boom 2 extend" solenoid Boom control 1 (-A161) -X161 / 04
Output "boom 2 retract" solenoid Boom control 1 (-A161) -X161 / 09
Output "boom 3 extend" solenoid Boom control 2 (-A181) -X181 / 21
Output "boom 3 retract" solenoid Boom control 2 (-A181) -X181 / 12
Output "boom 4 extend" solenoid Boom control 2 (-A181) -X181 / 03
Output "boom 4 retract" solenoid Boom control 2 (-A181) -X181 / 13
Output "boom 5 extend" solenoid Boom control 2 (-A181) -X181 / 04
Output "boom 5 retract" solenoid Boom control 2 (-A181) -X181 / 09
INP EXTENSION
12345678
OUTP EXTENSION
12345678
Each fault message has its own fault code permitting to obtain further information about a special fault from this
list.
This fault code consists of the machine section identification, a number and the fault category !
The "Disconnected" fault is reported when the cable from this output to the relay / solenoid is broken.
This fault can only be detected when the output is not activated !
The cause of this fault is either a broken cable or a disconnected solenoid connector !
The "Overload" fault is reported when an inadmissibly high current has been detected for this output.
This fault can only be detected when the output is activated!
The cause of this fault is either a short-circuit in the electric cable to the relay / solenoid or a defect of the solenoid
coil (charred) !
This applies to all following faults reported as "Disconnected" or "Overload" faults !!!
System faults are reported when the module in question does not work perfectly. All modules are regularly checked
by the central module !
In the event of a system fault, the electric control of the truck-mounted concrete pump should be switched off once
for ca. 5 secs. with the key-operated switch in the driver's cab.
M05L Truck Cab Protection Switch 1 Boom 2 < 20 Degree Fault (cab protection)
Source: Input 3 / INP BOOM-C2statistical function: (5 x 5 sec.!)
Indicated when limit switch monitor detects that the redundant limit switches "boom 2 < 20 degrees" 1 &
2 are in different signal states.
M06L Truck Cab Protection Switch 2 Boom 2 < 20 Degree Fault (cab protection)
Source: Input 4 / INP BOOM-C2statistical function: (5 x 5 sec.!)
Indicated when limit switch monitor detects that the redundant limit switches "boom 2 < 20 degrees" 1 &
2 are in different signal states.
M07L Truck Cab Protection Switch 1 Boom 1 < 50 Degree Fault (cab protection)
Source: Input 1 / INP BOOM-C2statistical function: (5 x 5 sec.!)
Indicated when limit switch monitor detects that the redundant limit switches "boom 1 < 50 degrees" 1 &
2 are in different signal states.
M08L Truck Cab protection Switch 2 Boom 1 < 50 Degree Fault (cab protection)
Source: Input 2 / INP BOOM-C2statistical function: (5 x 5 sec.!)
Indicated when limit switch monitor detects that the redundant limit switches "boom 1 < 50 degrees" 1 &
2 are in different signal states.
M09L Truck Cab Protection Switch 1 Boom 1 > 180 Degree Fault (cab protection)
Source: Input 5 / INP BOOM-C2statistical function : (5 x 5 sec.!)
Indicated when limit switch monitor detects that the redundant limit switches "boom 1 > 180 degrees" 1
& 2 are in different signal states.
M10L Truck Cab Protection Switch 2 Boom 1 > 180 Degree Fault (cab protection)
Source: Input 6 / INP BOOM-C2statistical function: (5 x 5 sec.!)
Indicated when limit switch monitor detects that the redundant limit switches "boom 1 > 180 degrees" 1
& 2 are in different signal states.
M11L Truck Cab Protection Switch 1 Boom Slewing Fault (cab protection)
Source: Input 5 / INP BOOM-C1statistical function: (5 x 5 sec.!)
Indicated when limit switch monitor detects that the redundant limit switches "cab protection boom slew-
ing" 1 & 2 are in different signal states.
M12L Truck Cab Protection Switch 2 Boom Slewing Fault (cab protection)
Source: Input 6 / INP BOOM-C1statistical function: (5 x 5 sec.!)
Indicated when limit switch monitor detects that the redundant limit switches "cab protection boom slew-
ing" 1 & 2 are in different signal states.
Boom control
Boom-slewing right / left (prop. or switched output !)depends on :
- Emergency-stop not actuated !
- Restart protection after emergency-stop or change of Local / Remote mode of operation !
- Slewing gear limit switch 1 or 2 on slewing ring not actuated !
- Boom limiting (cab protection at KVM 52 & S 45 SX) not active !
- REMOTE mode selected and RAM CHANGE mode not activated !
- Slewing function on remote-control box activated, [HARE/SNAIL] switch not in "0" position !
Cleaning systems
Water pump ON (switched output !) depends on:
- Emergency-stop not actuated !
- Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation !
- Correct mode of operation LOCAL / REMOTE selected !
- Water tank level switch indicates sufficient amounts of water in tank !
(dry running protection for water pump !)
- Water pump activated on remote-control box or at rear panel !
[ENTER]
[] [] ------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------
[] []
14.02.95 / 10:17 Display of previous fault
(Code) fault text message !
[] [] [] [] etc !
------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------
BOOM-CONTROL
//ENTER/CLEAR
[] [] [] []
REAR PANEL
//ENTER/CLEAR
[] []
EXTENSION I/O
//ENTER/CLEAR
------------------------------------------------------------------------------------------------------------------------
[] [] ------------------------------------------------------------------------------------------------------------------------
[] [] ------------------------------------------------------------------------------------------------------------------------
LUBRIC. PARAM
//Enter/Clear
[] []
PROP-CUR SLEW
//Enter/Clear
[] []
PROP-CUR BOOM 1
//Enter/Clear
[] []
PROP-CUR BOOM 2
//Enter/Clear
[] []
PROP-CUR BOOM 3
//Enter/Clear
[] []
PROP-CUR BOOM 4
//Enter/Clear
[] []
PROP-CUR BOOM 5
//Enter/Clear
------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------
[] []
------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------
Parameter adjustment menu for EFFICIENCY concrete pump / Central lubrication / Prop cur-
rent values
[] [] ------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------
The parameter adjustment menu for prop current values of the current control (Rexroth valves) please turn over
------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------
[] [] ------------------------------------------------------------------------------------------------------------------------
[] [] ------------------------------------------------------------------------------------------------------------------------
[] [] ------------------------------------------------------------------------------------------------------------------------
The parameter adjustment menu for prop-current values PWM-controlled (Apitech valves) please turnover
PROP-CUR SLEW [ENTER] SLEW RIGHT Online-display of effective
//ENTER/CLEAR [CLEAR] PWM act 33 % current value of valve
[] []
------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------
[] [] ------------------------------------------------------------------------------------------------------------------------
[] [] ------------------------------------------------------------------------------------------------------------------------
[] [] ------------------------------------------------------------------------------------------------------------------------
Service Manual
2
1
OK OFF
0 x1000 3
PTO 1500 rpm 62C
Menu: [ENTER]=ON
PART 1: OPERATION
PART 2: TEACH MODE
PART 3: EASy MODE (SHORT INSTRUCTIONS)
5900 Centerville Road
White Bear, Mn. 55127
Tel. (651) 429-0999
Fax (651) 429-3464
www.schwing.com
Service Manual
START SCREEN:
Control status
Oil cooler "On"
PTO Speed OK System is running
Hydraulic oil temperature
Start
Start up control unit
Control switches not
1 2
OK Off?
in neutral position
Emergency stop
STOP!
activated
Entry expected
0 x1000 3
Modes of operation
PTO 1350 rpm 62C
Remote mode
Menu: [ENTER]=ON
Local mode
StartScreen.eps
Service Manual
PART 1
OPERATION
The present instructions are intended to serve as a 'memory aid'. They do not refer to any
particular type of machine and do not relieve the user of familiarizing himself with the operating
manual of the machine in question.
CONTENTS
Commissioning .......................................................................................514
Selecting local control .............................................................................515
Selecting remote control .........................................................................516
Ram change mode:.................................................................................517
Emergency stop buttons .........................................................................518
Override of the E-stop manifold ..............................................................518
Options box .............................................................................................519
Control and monitoring components .......................................................520
Menu control ...........................................................................................521
Local control............................................................................................522
Remote control........................................................................................523
Menu overview - Main menu ...................................................................524
Menu overview - submenus ....................................................................528
Menu operation - Example: .....................................................................529
Diagnostic system/Fault handling .........................................................530
Acknowledging faults ..............................................................................532
Fault definition.........................................................................................532
Summary of messages ...........................................................................540
Heat the oil first .......................................................................................552
Service Manual
remotecontrol.eps
1 2
Start OFF
0 x1000 3
NA 1760 U/min 52C
Menu: [ENTER]=ON
1 2
Start
0 x1000 3
PTO 1760 rpm 52C
Menu: [ENTER]=ON
vectornormal.eps
Figure 1
Vector start screen
Service Manual
1 2
OK
0 x1000 3 2
PTO 1500 rpm 62C
Menu: [ENTER]=ON
Figure 3
Vector display window
This symbol is displayed in section #2 of Figure 3 Start up the system by activating the I switch on the
when local control is selected. front panel of the controller (Figure 1).
localcontrol.eps
Iswitch.eps
OK
STOP!
estop.eps
Start
Istart.eps
Service Manual
2
1
OK
1
30356 534 C
0 x1000 3 2 2
3
4
5 6
displayID.eps
7
3
8
2
9
1
0 10
Figure 4
Display screen for remote control
Service Manual
Ram change mode: The ram change position disables both local (rear
panel) and remote control, brings the engine to idle,
reduces the stroke limiter to minimum output, and
gives complete concrete pump control to the concrete
pump fwd/rev switch located at the ram change station
vectorramchange.eps
(Figure 6). See the Maintenance section of the
This symbol is displayed in section 2 of operation manual for ram change instructions.
the screen (Figure 4).
0 x1000 3
PTO 1500 rpm 62C
Menu: [ENTER]=ON
Istart.eps
CLEAR - ENTER QUIT
panelID.eps
switch
Start up the controller with the I switch
in (Figure 5). Figure 5
Iswitch.eps
Vector control panel
32ramchange.eps
Figure 6
Ram change station
Service Manual
E_Stopbutton.eps
Figure 7
E-stop button by-pass2.eps
When and E-stop is pushed, all hydraulic functions of If the problem is actually a bad solenoid, the pilot
the machine will stop. Do not use the emergency stop signal to the dump valve can be overridden by having
for an on/off switch. It is for emergencies only. one person push and hold the override handle on the E-
In normal operating conditions, always stop the stop manifold while the other person activates the
machine functions with the controls provided for that manual controls for the nonworking system.
purpose.
WARNING 0 x1000 3
PTO 1500 rpm 62C
Menu: [ENTER]=ON
bypasskeyswitch.eps
for clean out
Figure 8
Use override only for emergency fold-up Bypass key switch location
and cleaning.
Emergency stop buttons do not function
when the bypass mode is used.
If there is a malfunction in the E-stop circuit and the
dump valves (in the E-stop manifold) open, oil will be
routed from the hydraulic pump directly back to the
tank. The dump valves also open when any emergency
stop button is pushed.
If the dump valves open and the machine cannot be
repaired immediately, the power supply to the dump
valves can be reactivated by using the bypass switch
(Figure 8).
By activating the bypass key switch to the bypass
position, you send power to the solenoid of the
normally open dump valve. If the solenoid is functional
the dump valve will close and you should be able to
fold up the boom and outriggers with the manual
controls.
Service Manual
Options box The bottom of the two switches (Figure 11) is used to
control the function of the optional concrete shut-off
valve.
The three position switch allows the operator to control
the function of the valve in three different modes:
Position number 1 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 boom. 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 12 to the down position which is the
concrete shut-off icon and the valve will open.
The switch is located to the left of the E-stop
button on the remote box.
optionsbox.eps Concrete shut-off valve
disable switch
Figure 9
Electrical options box for Vector units
shutoffswtch.eps
Night light switch
1
3035653 4 C
2
3
3036 2348
5 6
4
7
3
8
2
9
1
0 10
switchlocation.eps
valveicon.eps
Figure 10 Figure 12
Switch to activate the Switch on the remote box (left)
night light kit shut-off valve icon (right)
The switch shown in Figure 10 is used to activate the
Position number 2 closes the valve full time.
optional night light kit.
NOTE!
Concrete shut-off valve switch Do not activate the concrete pump in this
mode with full air pressure on the valve.
Damage could occur!
Position number three supplies power to the
concrete shut-off valve full time and disables
the valve. This position can be used instead of
the disable switch shown in Figure 12, to allow
Figure 11 the boom to drain prior to inserting a cleanout
Concrete shut-off ball, or any time the concrete needs to be
valve switch removed from the boom by gravity.
Service Manual
Control and monitoring components On start-up the following data is displayed on screen
(Figure 14):
Controller cabinet (Figure 13)
1. PTO speed
6 2. Hydraulic oil temperature
1 3. Oil cooler ON
4. Control status
5 5. Selected mode of operation
6. Concrete pump delivery rate
2
1
OK OFF
0 x1000 3
PTO 1500 rpm 62C
7. Menu options
Menu: [ENTER]=ON
NOTE!
2 4 After pressing arrow down key on the menu
HOME + HELP START
control panel, further operational data will
CLEAR - ENTER QUIT
3 be displayed:
- Concrete pump hydraulic oil
panelID.eps
pressure -
Figure 13
- Hydraulic oil level indication menuarrowdwn.eps
Component locations on the (optional equipment)
controller cabinet
- Engine load factor (optional
1. Display window equipment.)
2. Key: menu control Control status indications
3. Operating mode selector Section 4 (Figure 14) of the screen displays the
Local mode following conditions:
Remote mode
Ram change mode OK Control system is running
4. Momentary contact I switch (Start switch)
5. Key switch: E-stop bypass
6. Connector: radio or remote control System ready for start up.
Display window (Figure 14) Start
Istart.eps
information
Service Manual
HOME + -
and or
HOME + HELP START home.eps down.eps
home.eps
Service Manual
Local control
HP
RPM engine
(-) = down Compressor
(+) = up
Concrete pump
forwards (pumping)
Ball injection system
Service Manual
Remote control
1
30356534 C
2
3
48
303623
5 6
4
7
3
8
2
9
1
0 10
RPM engine
(-) = down Water pump
(+) = up
Agitator in:
Vehicle engine ( ) = forward
( ) = reverse
(0) = off (stopping)
(I) = on (starting)
Concrete pump
forwards (pumping)
Control on
Diagnostic horn signal confirm
Concrete pump
(shut-off)
reverse (suction)
LED:
Concrete pump delivery rate charge condition of transmitter battery
(-) = decrease
(+) = increase LED:
tansmitter state of operation:
continuously on = transmitter ready
Vibrator in automatic mode(on)
flashing = transmitting control
signals
Service Manual
0 0
Function: h Function: h
Boom C Agitator C
33 0
Function: h Function: h
Concrete Pump C Vibrator C
Switch/Command 0 Manufacturer/Type
Water Tank OK OK KFZ.-TYP OK
Valve Output 0 Truck Serial Number
KFZ.-NR
0
Function: h
Water Pump C Truck Data C
O Hotline 1-888-292-0262
Function: h
Compressor C Machine Data C
Pumped Volume?
Service Manual
Status-Screen?
2
1
OK Malfunction List
Start
! n/a !!
0 x1000 3
PTO 1500 rpm
Malfunct.List? Malfunct.List! C
Oper. Data! C
Oper. Data! C
Boom 0.00 h
Slewing 0.00 h
Outrigger 0.00 h
Oper. Data! C
I/O-Readout?
Service Manual
Oper.Data?
2
1
OK
Dig. Input?
0 x1000 3
NA 1350 U/min
I/O-Readout?
2
1
OK Pumped Volume shown in:
Current: cbm OK
------------------------
0 x1000 3 Change? [ENTER]
NA 1350 U/min Select Language [ ] [ ]
Store? [ENTER]
Display cbm/cby?
Displ cbm/cby!
Service Manual
I/O-Readout?
2
1
OK
0 x1000 3
NA 1350 U/min DI11 F31 Pwr Supply Dig Out 1 PO41 Slew right 0 mA
2
DI12 F32 Pwr Supply PropOut 1
1
OK PO42 Slew left 0 mA
Dig. Input? DI13 F20 Pwr Supply Dig Out 1 PO43 Boom A extend 0 mA
DI14 F18 Pwr Supply Inputs 1 PO44 Boom A retract 0 mA
0 x1000 3
DI15 Dump Valve Boom 1 PO45 Boom B extend 0 mA
DI16 Dump Valve CP 1 NA 1350 U/min PO46 Boom B retract 0 mA
DI17 Dump Valve MPS 1 PO47 Boom C extend 0 mA
DI18 E-STOP Chain 1 Prop. Output? PO48 Boom C retract 0 mA
AI11 87 mV
2
1
OK AI12
AI13
5100
9810
mV
mV
AI14 9790 mV
0 x1000 3 AI15 4330 mV
NA 1350 U/min AI16 9800 mV
AI17 06.8 mV
Analog Input? AI18 06.4 mV
Service Manual
Status Screen? Pumped Volume? Fault list? Oper. data? I/O readout? Parameters?
Service Manual
ACTION: RESULT:
Service Manual
The integrated diagnostic system informs the The following message origins are available
operator about certain operating states, displays (1st column):
faults, and indicates the possible causes.
B = Boom (placing boom control)
The corresponding messages are displayed on
the screen of the control unit 1 (Fig. 1). D = Diesel engine (truck diesel engine)
0 = Optional
(Optional control functions)
MESSAGE
P = Pump (concrete pump)
CODE
R = Remote (remote control system)
CODE S = System
Example: 8
1
P01M
P............: Pump (concrete pump) 7
6
01.......: Number of message 1 2
OK OFF
0 x1000 3
Menu: [ENTER]=ON
5
2 4
HOME + HELP START
Fig. 1
Service Manual
Display language
Texts can be displayed in three languages; Text messages, as well as international symbols,
English, German, and Spanish. may include additional information for service
personnel.
The language of text displays can be selected in
the "Parameter?" menu under "Language
Example 1: Text display
MMI?".
If "International" is selected, the messages are Disconnected / Overload
displayed without text by means of symbols. Solenoid Slewing Right
- PO41 !
The Summary of Messages section of this book
contains a complete list of the text messages
together with the international symbols. Example 2: International display
The messages are sorted by their code in alpa-
betical order.
PO41
Example 1: Text display
K = Relay
Message: F = Fuse
Code: P01M
Important:
Since the international display makes multiple
use of the various symbols, it is absolutely
essential to consult Summary of Messages
for a clear identification of the message.
Service Manual
Acknowledging messages
NOTE!
Messages are not faults! They
are announced only visually on
CLEAR
the display and can be
clear.eps acknowledged with the
CLEAR key.
Acknowledging faults
Low level faults are announced visually on the screen
and acoustically by an intermittent tone from the
controller and the warning horn. These faults can be
acknowledged via remote control or directly on the
control cabinet.
High level faults are also announced visually on
display and acoustically by an intermittent tone from
the controller and the warning horn. They can only be
acknowledged on the control cabinet
NOTE!
In both cases the acoustic signal can be shut
off via remote control.
Fault definition
Low level fault
In the event of a low level fault, the job can still be
finished even if only with certain restrictions.
Service Manual
Silent diagnostic
the op ra or ca s l c w
e t n r a faul is sig all d i
ee t hethe t n e n
Change? [ENTER]
Select y/n [ ][ ]
Store? [ENTER]
Silent Diagn? E C
d
Silent iagnostic: Yes
Silent diagnostic: No
Service Manual
The way faults are acknowledged depends on the 2. Mode of operation : LOCAL
se lected mode of operation (LOCAL or REMOTE)
and on the severity of the fault: Silent diagnostic : Yes or No
2
1
OK OFF
0 x1000 3
PTO 1500 rpm 62C
Menu: [ENTER]=ON
Fig. 1
QUIT key
Service Manual
Silent diagnostic : No
Minor fault
48
303623
5 6
7
3
8
2
9
1
0 01
62C
Service Manual
Minor fault
48
303623
7
3
8
2
control cabinet (F ig. 2) once.
9
1
0 10
QUIT switch
T he buzzer stops sounding. Fig. 1
T he message continues to be
displayed and can be read without
hurry.
0 x1000 3
PTO 1500 rpm 62C
acknowledged.
HOME + HELP START
Service Manual
Silent diagnostic : No
Severe fault
hurry. 3
48
303623
5 6
4
7
- Depress the "QUIT" key on the
8
2
9
1
0 10
2
1
OK
ATTENTION: 0 x1000 3
OFF
Menu: [ENTER]=ON
Service Manual
possible.
2
3
48
303 623
5
7
3
8
2
9
1
0 10
The message is deleted from = PTO RPM (all digits are numbers)
Service Manual
Service Manual
Summary of messages
B = Boom
Limitation
Slewing Gear
B01M Activated !
BOOM Limitation
Activated !
B02M
Disconnected / Overload
E-Stop Solenoid BOOM !
B04L
Disconnected / Overload
Solenoid Slewing Right
PO41 - PO41 !
B05L
Disconnected / Overload
Solenoid Slewing Left
PO42 - PO42 !
B06L
Disconnected / Overload
Solenoid BOOM A extend
PO43 - PO43 !
B07L
Disconnected / Overload
Solenoid BOOM A retract
PO44 - PO44 !
B08L
Disconnected / Overload
Solenoid BOOM B extend
PO45 - PO45 !
B09L
Service Manual
Disconnected / Overload
Solenoid BOOM B retract
PO46 - PO46 !
B10L
Disconnected / Overload
Solenoid BOOM C extend
PO47 - PO47 !
B11L
Disconnected / Overload
Solenoid BOOM C retract
PO48 - PO48 !
B12L
Disconnected / Overload
Solenoid BOOM D extend
PO51 - PO51 !
B13L
Disconnected / Overload
Solenoid BOOM D retract
PO52 - PO52 !
B14L
Disconnected / Overload
Solenoid BOOM E extend
PO53 - PO53 !
B15L
Disconnected / Overload
Solenoid BOOM E retract
PO54 - PO54 !
B16L
! Machine Safety Stop !
D = Diesel Engine
Service Manual
Service Manual
M = Machine
Ball Injector
Activated !
M01M
End-Hose Shut-Off
Activated !
M02M
Temperature Transmitter
Hydraulic Oil Fault !
M03L
Hydraulic Oil Filter
BOOM Contaminated !
Please Exchange Filter!
M04L
Hydraulic Oil Filter
CP Contaminated !
Please Exchange Filter!
M05L
Low Level
Hydraulic Oil
Reservoir !
M06L
High Temperature
Air Compressor !
M07L
Service Manual
Level Transmitter
Hydraulic Reservoir
Fault !
M08L
Transmitter
Oil Pressure Service
Fault !
M09L
Transmitter
Cleaning Ball Detection
Fault !
M10L
Disconnected PowerOutput
DO13 Oil Cooler - DO13 !
M11L
Overload / Fuse
PowerOutput
DO13 Oil Cooler - DO13 !
M12L
Disconnected PowerOutput
DO12 Vibrator - DO12 !
M13L
Overload / Fuse
PowerOutput
DO12 Vibrator - DO12 !
M14L
Disconnected PowerOutput
DO16 Horn Boom C - DO16 !
M15L
Overload / Fuse
PowerOutput
DO16 Horn Boom C - DO16 !
M16L
Disconnected PowerOutput
DO17 Horn Slew - DO17 !
M17L
Overload / Fuse
PowerOutput
DO17 Horn Slew - DO17 !
M18L
Disconnected Solenoid
Ball-Injector
DO38 - DO38 !
M19L
Service Manual
Overload Solenoid
Ball-Injector
DO38 - DO38 !
M20L
Disconnected Solenoid
DO26 Water Pump - DO26 !
M21L
Overload Solenoid
DO26 Water Pump - DO26 !
M22L
Kabelbruch Schaltventil
Kompressor - DO28 !
DO28
M23L
Disconnected Solenoid
DO28 Air-Compressor - DO28 !
M24L
Disconnected Solenoid
Agitator
DO21 Forward - DO21 !
M25L
Overload Solenoid
Agitator
DO21 Forward - DO21 !
M26L
Disconnected Solenoid
Agitator
DO22 Reverse - DO22 !
M27L
Overload Solenoid
Agitator
DO22 Reverse - DO22 !
M28L
Disconnected Solenoid
Hydraulic On Outriggers
DO25 - DO25 !
M29L
Overload Solenoid
Hydraulic On Outriggers
DO25 - DO25 !
M30L
Disconnected Solenoid
High Pressure
DO27 Water Pump - DO27 !
M31L
Service Manual
Overload Solenoid
High Pressure
DO27 Water Pump - DO27 !
M32L
Disconnected Solenoid
End-Hose Shut-Off
DO37 - DO37 !
M33L
Overload Solenoid
End-Hose Shut-Off
DO37 - DO37 !
M34L
Disconnected / Overload
Solenoid Hydraulic On
PO56 Outrigger - PO56 !
M35L
! Machine Safety Stop !
Hydraulic Oil
Temperature Exceeded !
M36H
O = Optional
Disconnected PowerOutput
Central Lubrication
DO15 CP active / Pump - DO15!
O01L
Overload PowerOutput
Central Lubrication
DO15 CP active / Pump - DO15!
O02L
Disconnected Output
Central Lubrication
DO35 BOOM active - DO35 !
O03L
Overload Output
Central Lubrication
DO35 BOOM active - DO35 !
O04L
Disconnected LED-Output
DO36 BOOM above rest - DO36 !
O05L
Overload LED-Output
DO36 BOOM above rest - DO36 !
O06L
Service Manual
P = Pump
Pressure Limiter
Concrete Pump
Activated !
P01M
Stroke Rate Limitation
Concrete Pump
Activated !
P02M
Disconnected / Overload
E-Stop Solenoid CP !
P08L
Disconnected / Overload
E-Stop Solenoid MPS !
P09L
Disconnected Solenoid
Concrete Pump
DO23 Forward - DO23 !
P10L
Overload Solenoid
Concrete Pump
DO23 Forward - DO23 !
P11L
Service Manual
Disconnected Solenoid
Concrete Pump
DO24 Reverse - DO24 !
P12L
Overload Solenoid
Concrete Pump
DO24 Reverse - DO24 !
P13L
Disconnected / Overload
Solenoid Stroke Limiter
PO55 - PO55 !
P14L
R = Remote
R01M Emergency-Stop On
Radio Control Box
Activated !
R02M Low Battery In Radio
Control Box !
R03M CAN-FST /
Transmission With
Remote Control Fault !
R04M No Radio Control
Transmission !
Service Manual
S = System
Disconnected
Rear Panel !
S01M
Power Supply
MAIN-Board
Fault !
S02L
Power Supply
MMI-Board
Fault !
S03L
CAN-Communication to MMI
or MMI-Board Fault !
S04L
Relay Contact
K 13
K 13 Override / Fault !
S05L
Fuse F 18 Fault !
F 18
S06L
Service Manual
Fuse F 20 Fault !
F 20
S07L
Fuse F 16 Fault !
F 16
S08L
Fuse F 31 Fault !
F 31
S09L
Fuse F 32 Fault !
F 32
S10L
MF1 : Power Supply
Diagnosis E-Stop Board
MF1 DI15 - DI18 Fault !
S11L
MF2 : Power Supply
Truck Interface etc.
MF2 DI21 - DI27 Fault !
S12L
MF3 : Power Supply
DI28,DI38,DI46,DI48
MF3 Fault !
S13L
MF4 : Power Supply
DI31-DI37,DI43,DI44
MF4 Fault !
S14L
MF5 : Power Supply
DI36,DI37,DI45
MF5 Fault !
S15L
MF6 : Power Supply
DI41,DI42,DI47,AI21,AI22
MF6 Fault !
S16L
MF7 : Power Supply
RAM-Change Station
MF7 DI51-DI54 Fault !
S17L
MF8 : Power Supply
DI55 - DI58
MF8 Fault !
S18L
Service Manual
Service Manual
PART 2
TEACH MODE
NOTE! Restore original factory settings
Setting the parameters in Teach Mode When setting parameters you will need to take your
should only be done by persons with a remote control with you and go to the main controller.
complete understanding of the vector
control system. If your boom parameters have been changed and you
would like to have them revert to where they were
Teach mode offers the user the opportunity to teach the
originally, you can perform a simple procedure to
main controller how he or she would prefer to have the
restore the original factory settings.
boom respond to the remote control joystick
movements by setting parameters for minimum and 1. Open the front cover and without activating the I
maximum response times of each boom movement. switch, insert the Teach Key into the connector
MIN being the amount of signal it takes to start boom shown in Figure 17.
movement and MAX is the signal required to make the 2. The display window on the front cover should now
boom manual control handle travel all the way to the be showing you the screen shown in Figure 16.
mechanical stop. Setting these parameters requires
setting up the unit and unfolding the boom. Be certain
Restore parameters
that the boom has room to move safely during this
procedure.
to factory setting Start
NOTE! no yes
When the unit is in teach mode, the concrete [CLEAR] [ENTER]
pump and agitator are disabled to prevent
the operator from accidentally trying to
pump while the teach mode key is installed.
Teach Mode E C
vectorrestore.eps
Figure 16
WARNING Vector display window for restoring
to factory settings
Improper setup causes job site accidents:
Look for power lines before unfolding 3. Push the ENTER button to select yes. The
W024.eps
Service Manual
1
303565 34 C
2
3
48
303 623
5 6
4
7
3
8
2
connectorlocation.eps
9
1
0 10
Service Manual
5. After activating the I switch, the display window 7. Start by holding down the I switch on the remote
will show you the screen in Figure 20. This chart box while you activate the right hand joystick
shows you RPM, Oil temperature, a picture of a forward to the extend positon.
boom cylinder, and six different boom options. The
far left column is where the boom slewing
adjustment will show, while columns A through E
represent each boom section A=1, B=2, C=3, D=4,
and E=5 if you have a five section boom.
activate"I".eps
1760 rpm 52 C
OK Figure 22
Activate I switch and hold
A B C D E
Teach NOTE!
mode! Boom movement is not proportional in
Teach mode so the joystick can be moved
all the way to extend or half way, it doesnt
Teach Mode matter as long as the boom function is
teachfunctionscreen.eps
activated.
Figure 20 8. When the joystick is activated and the I switch is
Teach mode parameter screen still being held down, the display will show a bar
graph like the one shown in Figure 23, at which
6. You are now ready to teach the controller what time the I switch can be released. The joystick
parameters you prefer. Well use boom #1 extend however, must remain activated or the screen will
as an example. Before you activate the function to revert to the one shown in Figure 20 and you will
be adjusted, you must decide which parameter you need to start over at the previous step. The
want to adjust (MIN or MAX). The selection is percentage shown on the graph indicates the
made with the Rabbit/Off/Snail switch. Choose amount of signal to this particular function (45%).
Rabbit for MAX or Snail for MIN. So to set the #1
boom extend MIN, you must first place the switch
to the Snail position (Figure 21). Engine speed (RPM) Oil temperature
1760 rpm 52 C
OK
snailspeed.eps
Figure 21
A
15
45 %
50
Teach
mode!
Choose Snail speed to set MIN
45
Teach Mode
minparameterscreen.eps
Figure 23
#1 boom extend MIN screen
Service Manual
9. If the boom is not moving you should increase the 11. If you felt that the boom took off too fast when
percentage to this function by activating the joystick was activated and the percentage needs to
throttle switch to the + position. Each time you be decreased, tap the throttle switch Figure 24 to
tap the switch the duty cycle percentage will the - position until the boom responds as you like
increase by 1%. 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 as you did for extend, and after storing
vectorthrtlpicto.eps
Teach Mode
10. When the boom just begins to move, you have minretractstored.eps
attained the required MIN signal and you will be Retract MIN
required to push up on the horn switch Figure 22 to stored
store the number. If you release the joystick before
Figure 26
beeping the horn, the percentage will revert to
Boom #1 retract MIN stored
where it was when you began. After you store the
information for #1 boom extend MIN the screen
will display a single mark in the A column as 13. You now have the option of continuing on to set the
shown in Figure 25. MIN on the other boom sections or moving the
rabbit/snail switch to the rabbit position (Figure
27) and set the MAX for boom #1 as follows.
1760 rpm 52 C
OK
A B C D E
Teach rabbitspeed.eps
mode!
Figure 27
Rabbit speed
Teach Mode NOTE!
extendstored.eps
Service Manual
1760 rpm 52 C
OK
A
60
80 %
95
Teach
mode!
80
Teach Mode
maxparameterscreen.eps
s
Figure 29
V.ep
vlvR
MAX parameter screen
xbm
42s
Service Manual
Teach Mode
Extend MAX
stored
maxextendstored.eps
no yes
?
Figure 30 [CLEAR] [ENTER]
Boom #1 MAX extend stored
17. Now activate the I switch again and move the Teach Mode E C
right hand joystick to the retract position. Follow Storenew.eps
Service Manual
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 to prevent losing your stored
information. The restart takes only seconds
and when completed the display will again
show the screen below (Figure 34).
1 2
Start
0 x1000 3
PTO 1760 rpm 52C
Menu: [ENTER]=ON
vectornormal.eps
Figure 34
Vector normal operation screen
REVISED
1/25/94
CROSS REFERENCE CHART FOR S.A.I. CABLE REMOTE CONTROL SYSTEMS GRP
REMOTE CONTROL FUNCTIONS * PIN ASSIGNMENTS FOR CONNECTORS USED ON S.A.I. REMOTE BOXES, PRIMARY CABLES AND EXTENSION REELS
HARTING WEILAND BURNDY HARTING AMPHENOL INTERCON 16 POLE HARTING 15 POLE INTERCON 12 POLE
PROPORTIONAL UNITS BLACK & WHITE UNITS w/throttle without
42 POLE 24 POLE 23 POLE 25 POLE 19 POLE BPLs S.P.B.s S.P.B.s BPLs
up & down throttle
Service Manual
POT. VOLTAGE + 15V UN-ASSIGNED 31 11 S
POT. VOLTAGE + 0V UN-ASSIGNED 42 12 T
ELEC. STROKE LIMITER CONCRETE PUMP POWER 7 21 X 14 C-4 C-2 12 9
MAIN POWER 24 VOLTS MAIN POWER 12 VOLTS 36 22 Z B-5 N 11 11 C-1 C-1 11 11
SERVICE TRAINING
S0063.eps
* Per this chart, designations of the boom slewing speed functions for KVM 32XL and KVM 32XL with Flyaway Boom are NOT applicable. Refer to the repective electrical print for wiring information.
559
Remote Control Cable/Radio
HOME PRINT
SERVICE TRAINING
Remote Control Cable/Radio
Transmitter:
7. Brief Description
The new generation of SCHWING RADIO
Operating Frequency : in the 70 cm band REMOTE CONTROLS are an advanced develop-
(27.55 inches) ment of the systems first introduced in 1983.
Radio remote controls can be retrofitted or fitted at
RF output power : 4 mW the factory.
Receiver
The receiver is mounted in the drivers cabin and is
powered by the truck voltage. The hydraulic com-
ponent (pilot control) is connected by cable to the
machine control panel via the socket provided.
1 1 5 2
8 12 13 8
12 13 4
3
11
4
14 6 4 11
10 9 10 14
9
3 2 4
1
6
5
4
7 9 8
5
9. Commissioning
Preparations
3 2
1. Switch all controls on the machine and on the 1
transmitter to 0 or OFF.
2. Switch truck engine off when warm and with PTO
switched on.
NOTE: After a remote start, the engine should
run smoothly immediately. The remote control can 4
give no cold start assistance. 5
3. Disconnect remote control cable from control
panel and replace with cable: receiver - control 6. Unlock EMERGENCY OFF button of transmitter
panel. by turning to the right.
4. Check whether power supply cable, antenna cable,
and connecting cable are connected to the receiver. 2
5. Check whether antennas for transmitter and
receiver are mounted. If not, install. 1
8
Ready for operation 12 13
3
1. Switch on ignition.
2. Insert charged battery into the transmitter and spare 11
battery into charger. 4
14
NOTE! Make sure that the charger is inserted with 10
the correct polarity 9
3. Set selector switch on machine control panel to
remote control.
WARNING
Do not operate at
pressures exceeding
the rating of the
7. Set selection switch to ON. This causes the
entire material
delivery system.
1 following:
1 a) The power supply of the transmitter is
4 5 switched on. The red LED lights up for a short
time and extinguishes if the battery volt-
15 20
DO
IN
NO
10 U/minx100 25
RED
T OPERATE
ZONE
40 60 5 30
80
20 100
!
6 O I O I
7 9 indicates that a radio telegram is being
M
ERGENC
O I O I HAND AUTOMATIK
transmitted.
E
1 5 2
12 13 8
9 10 14 6 4 11
Please observe the following instructions for safe, Breaks in the work
uninterrupted operation: In order to prevent unauthorized operation of the
Capacity of the transmitter battery machine, the operator should not set down the
The capacity of each battery is dependent upon: transmitter once it has been switched on.
the age of the battery,
the charge level, and
the ambient temperature. 2
3 2
1 4
5
4
5. **The LED extinguishes.
5 6. Switch the truck engine off and remove the
ignition key.
7. Lock the transmitter in the drivers cabin and
secure the machine against unauthorized use.
Putting out of Operation
1. Set all controls on the transmitter to 0 or OFF Changeover to Cable Remote Control
position. 1. Put out of operation as described above.
2. Set the selector switch to OFF. 2. Remove the connecting cable: between receiver
and control panel from machine control panel.
3. Connect standard remote control cable to the
2 machine control panel.
4. Perform commissioning as normal for cable
1 remote control.
8
12 13
3
11
4
14
10
9
Changing the transmitter battery NOTE: Check that the cover is correctly mounted.
If mounted upside down, there is a visible gap
1. Switch off the transmitter and press the
through which humidity can penetrate into the bat-
EMERGENCY OFF button.
tery compartment.
2. Undo the locking screws by rotating through 90
degrees.
Charging the transmitter battery
The battery in the charger is exchanged in the
same way as described above, but:
CAUTION! The charger is not equipped with an
automatic polarity switch-over circuit. If the LED
lights up RED, IMMEDIATELY remove the bat-
tery and change over the contact position (turn the
battery around). The LED will indicate GREEN if
the polarity is correct.
NOTE! The time it takes to charge a battery com-
pletely is approximately 14 hours or less, if the
battery is exchanged in good time.
Radio Control FW 20
Table of Contents
1. TABLE OF CONENTS
2. SHORT OPERATING INSTRUCTIONS
3. FOREWORD
4. DESIGNATED USE, WARRANTY
5. SAFETY REGULATIONS AND ACCIDENT
PREVENTION REGULATIONS
6. CERTIFICATE OF APPROVAL
7. SHORT DESCRIPTION
8. TECHINCAL DATA, RATING PLATES
9. MONITORING-, WARNING-, AND CONTROL
ELEMENTS
10. PRE-OPERATING INSTRUCTIONS
11. OPERATION
12. EMERGENCY SHUT-OFF
13. INTERRUPTIONS OF WORK, END OF
OPERATION
14. REPLACING OF BATTERY
15. MALFUNCTIONS
16. MAINTENANCE, REPLACING OF FUSES
17. REPAIR
2 3 4 5 6
8. Technical Data:
Transmitter
General
Operating temperature range: . . . . . . . . . . . . . . . . . . . . . . . . . . : -10 to +50 C
Type of protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : IP 65
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 280 x 140 x 135
Transmitter-rechargeable battery set . . . . . . . . . . . . . . . . . . . . . : 9.6 V / 1000 mAh
Battery replacement at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : < 9.0 V
Automatic transmitter shut-off at . . . . . . . . . . . . . . . . . . . . . . . . : < 8.7 V
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 3 kg
Transmitter
Frequency range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 430 to 470 MHz, 2 RF channels, switch-selected
Transmitter output power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 5 mW
Transmitting range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : > 100 m
Digital System
CMOS microcontroller
PCM data transmission
Transmission time of radio commands
-pulse control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 110 msec
-proportional control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 155 msec
Operating time with fully charged battery. . . . . . . . . . . . . . . . . . : approximately 12 hours
Receiver
Frequency range : 430 to 470 MHz, automatic transmitting frequency
scan
Sensitivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 1 uV
Digital System
CMOS microcontroller
PCM data telegramme decoding
Frequency: ______________________________
TRANSMITTER (fig. 1)
2 3 4 5 6
1- EMERGENCY SHUT-OFF button
2- Bi-coloured LED
4-Battery compartment
fig. 2
fig. 1
1-Cover lock
fig. 2
RECEIVER (fig. 3)
fig. 3
LEDs
NG = power supply
UE 1 = controller 1 supply
UE 2 = controller 2 supply
K1 = RF-channel 1 selected
K2 = RF-channel 1 selected
MC 1 = controller 1
ST 1 = controller 1 failure
ST 2 = controller 2 failure
NG all LEDs on
alternating in 1-second-intervals
HF K1 + K2
(transmitter-scanning)
MC 2 MC 2 flickering irregularly
flickering irregularly
TEL
MC1 on
TST 2
all others off
2 3 4 5 6
2 3 4 5 6
1
An energy-saving feature prevents the transmitter
battery from deep discharge. The energy-saving feature
is reset after activation of any switch.
Choose your location in such a way that the concrete
placing site and the receiver antenna can be clearly
seen from a distance of not more than 50 meters. If all control elements of the transmitter are in their
0-position, the transmitter power supply is cut off
after 30 minutes.
Battery Capacity
The capacity of the battery depends on
The operations required to control the machine with the the age of the battery
radio transmitter are the same as with the cable control the charge condition
unit. the ambient temperature
Flashing of LED 3 indicates that active messages are Under normal conditions, the operating time of a new
being transmitted. and fully charged battery is approximately 12 hours.
In case of wrong polarity, the transmitter cannot be put It is recommended to interrupt the power-supply of the
into operation. battery charger if longer operating breaks are to be
Put on compartment lid. expected (e.g. weekends).
Turn locking screws clockwise by 90 degrees, and To do so, withdraw cable from socket 3.
engage under slight pressure without further turning. Replace the battery as described on the front
side.
Take care that the lid fits correctly. Turning the lid 180
degrees during fitting leaves a visible air gap. In this The polarity is correct if LED 2 displays green, and it is
position, moisture can penetrate into the battery wrong if it displays red.
compartment.
If the LED shows a red light, remove the bat-
Recharging of Battery
tery immediately and change polarity by turning
The battery charger is permanently connected to the the battery.
power-supply.
Charging of the battery is completed after 14 hours
max.
The ready-for-operation state is indicated by LED 1. The battery cannot be overcharged. If the battery is full,
2 3 4 5 6
2 3 4 5 6
Trouble Shooting
Never attempt repairs beyond those recommended in
For function checking and fault detection, the
the troubleshooting section.
transmitter and the receiver are both equipped with
LEDs.
SCHWING assumes no responsibility for inappropriate
repairs.
In case of proper function, only the green LEDs may be
lit. Red LEDs indicate fault.
[TROUBLESHOOTING TABLE (needs to be made)]
For troubleshooting, use the fault detection tables on
Troubleshooting: Receiver LEDs
the following pages and state the last fault message
recorded if you contact us for help. Troubleshooting Table: Transmitter LED s
+
STOP
LED LED LED DESCRIPTION ACTION
Battery empty, battery wrongly
Charge Battery; Turn Power On
inserted, power OFF
Valid empty messages, energy-
Begin machine control
saving timer ON
Valid control commands Control O.K.
Low battery voltage, approx. 30 Replace battery
minutes operating time left
Transmittter shut-off due to low
Replace battery
battery voltage
EMERGENCY SHUT-OFF See receiver
EMERGENCY SHUT-OFF test Push EMERGENCY SHUT-OFF
request button
Unlock EMERGENCY SHUT-
X EMERGENCY SHUT-OFF O.K.
OFF
Not all control elements in 0 -
Control elements in 0 -
position before the transmitter was position, restart.
switched on.
Only if check is carried out by
Fault detection mode quailified personnel
Module failure Call after-sale service
MESSAGE/POSSIBLE
LED DISPLAY REMEDIAL ACTION
CAUSE OF TROUBLE
Transmitter scan, no radio Switch on transmitter, choose
alternately contact better transmitter location, check
K1, K2
flashing antenna
Message format error see MC1
MESSAGE/POSSIBLE
LED DISPLAY REMEDIAL ACTION
CAUSE OF TROUBLE
Transmitter off, no radio
not flashing Switch on transmitter, choose
contact
at message better transmitter location, check
TEL
transmission antenna
Transmitter defective, RF
rate Call after-sales service
section defective
MESSAGE/POSSIBLE CAUSE
TST3 TST2 TST1 OF TROUBLE REMEDIAL ACTION
No empty message after switch-on Set control element to 0 -pos.
EMERGENCY SHUT-OFF act. Unlock EMERGENCY SHUT-OFF
Contact jamming Call Service Department
Format error in pulse-coded
Call Service Department
message
Format error in proportional
Call Service Department
message
Another transmitter with same
frequency nearby, message affected Call Service Department
by address error
Message affected by mode error;
Call Service Department
encoder switch in wrong position
Message affected by cyclic
Call Service Department
redundancy check error
EMERGENCY SHUT-OFF Rectify fault, unlock EMERGENCY
message SHUT-OFF
Use only miniature fuses 5 x 20 mm, 3.15 A. Open lid of mounting rack with special key.
Swing back lid of mounting rack and replace
fuse.
Fuses can be replaced as follows:
Close mounting rack and put on cover.
Switch off the unit.
Open lock 1 and swing back cover.
17. Repair
REMOVAL OF RECEIVER
For repairs or for regular checks, the receiver must be
removed from the vehicle and sent to the factory for Push EMERGENCY SHUT-OFF button.
repair complete with the transmitter. Open cover, as described in section 16
Withdraw the (blue) multipole connector from
the circuit board.
For repairs outside Germany, please address to your
Pull off the antenna cable.
local agent.
Loosen the four fastening screws at the front
side.
Take care that the equipment is packed shock-proof.
(IS) ITA
SPECIAL INDUSTRIAL RADIO SERVICE INDUSTRIAL
TELECOMMUNICATIONS ASSOCIATION
ATTN. FREQUENCY COORDINATION DEPARTMENT
1110 NORTH GLEBE ROAD, SUITE 500
ARLINGTON, VA 22201
703-528-5115
(IB) NABER NATIONAL ASSOCIATION OF BUSINESS AND EDUCATIONAL
RADIO, INC.
ATTN. FREQUENCY COORDINATION DEPARTMENT
1501 DUKE STREET, SUITE 200
ALEXANDRIA, VA 22314
800-759-0300
703-739-0300
(LM) ATA AMERICAN TRUCKING ASSOCIATION, INC.
ATTN. GUS GYLLENHOFF
2200 MILL ROAD
ALEXANDRIA, VA 22314
703-838-1730
(IP) PFCC PETROLEUM FREQUENCY COORDINATING COMMITTEE
ATTN. MARIE HAWKINS
1110 NORTH GLEBE ROAD, SUITE 500
ARLINGTON, VA 22201
703-528-5115
Radio Control FW 24
Table of Contents
1. Safety Instructions
2. Scope of Application
3. Start-up
4. Operation
5. Charging the Battery
6. Maintenance
7. Operation
8. Fault Indicators
Safety Instructions
SAFETY INSTRUCTIONS
Scope of Application
SCOPE OF APPLICATION
1 2 3
The present operating instructions are
applicable to FW 24 radio remote-control FW24-ID.eps
Stop POWER
FW24rmbx.eps
"COMFORT-Control" type. 6 5
The operator panels of the radio
transmitters are the same (with the
exception of switch 6, Fig.1) for both control Fig.1
systems. For detailed description please
refer to chapter 3.
MANUFACTURER
Start-Up
START-UP
Remote-control system 1 2 3
FW24-ID.eps
FW24rmbx.eps
6 5
both devices have the same serial number
and frequency.
- Insert charged battery pack into the The red light-emitting diode (LED 3) now
transmitter housing and lock the battery starts flashing at a slow rate.
case.
Stop
2. Make sure all switches are in their basic
(or neural) position before switching on the
transmitter (Fig. 1)
Fig. 1 shows only those control and 4. Perform the emergency shut-off test:
monitoring elements as a are typical of
radio remote-control unit. -Depress the emergency shut-off test,
All other elements correspond to those of -The red LED 3 now flashes at a fast rate.
the standard cable remote-control.
- Release the emergency shut-off button
Refer to the machine operating instructions. (unlock).
Unlock the EMERGENCY SHUT-OFF
button. Without unlocking, starting of the
system is inhibited for reasons of safety.
The red diode (LED 3) goes out and the In the center position ("0") of this switch all
green one (LED 2) is lit up. functions of the boom are deactivated.
The transmitter is now ready for operation Moving the joysticks causes the red diode
and the commands given with the control (LED 3) to light up to indicate that boom
elements are executed by the concrete operation is disabled.
pump.
The switch must be set to the "Snail" or
Note: "Hare" symbol.
The "COMFORT-Control" system does not "Snail" = slow is the preferred speed for
provide an enabling function for switch 6. normal working operation and
Switch 6 is needed for a fault- "Hare" = fast is the speed used for setting
acknowledging function labeled "quitt" up of the placing boom.
[acknowledge].
Depending on the type of control, the After switching over to another channel, the
selection of either "Snail" or "Hare" has a transmitter must be re-activated as
different effect: described on page 3.1 (EMERGENCY
Control digital proportional SHUT-OFF test etc.).
reduced slewing- 0-50% speed for
gear speed all boom func- The receiver will be switched over
tions automatically to the new transmission
channel.
Note:
HF2
Operation
OPERATION
.
SHUT-OFF buttons on the machine have
.
ig
og
C
Pr
Fr
M
been unlocked, all functions of the concrete
pump can be operated with the remote-
control unit (see the machine operating
2
1
2
T
T
C
O
M
M
N
N
instructions.) 4 5 6 7 11
n
de
tt
n
po
Indicator lamps on receiver
tla
de
r
En
Ve
La
8 9 10
Figs. 1 and 2 show the layout of the
receiver front panels:
Fig. 1 = "MULTI-Control" + -
Fig. 2 = "COMFORT-Control"
2
1
2
T
T
C
O
M
M
N
N
signals from the correctly activated
transmitter are being received. 4 5 6 7 11
n
de
tt
n
po
tla
de
r
En
Ve
La
They are lit up if no valid radio data 8 9 10
telegrams are being received or when the
emergency shut-off button on the
transmitter has been depressed.
+ -
In this case, the receiver in in the
EMERGENCY SHUT-OFF state, i.e.
deactivated.
Fig.2
The green light-emitting diodes 4 and 6 "Multi-Control" only
("MC 1 + 2") indicate by fast flashing that
valid radio data telegrams are being In this system, the green LED 1 ("MC 3")
recieved. and the green LED 2
("Freigabe/Enable") are lit up in addition.
When the red LED 1 (battery) of the To maintain the full charging capacity of the
transmitter starts to blink during normal battery over a long time, it should be
operation, the battery is almost empty. completely discharged once a week before
Stop recharging.
.
og
ei
C
Pr
Fr
M
2
T
T
C
O
M
M
N
n
po
tla
de
r
En
Ve
La
2
1
2
T
T
C
O
M
M
N
n
po
tla
de
r
En
Ve
La
insert correctly.
Note: On compact units, LED 8 is not available. In + -
these units, the green LED 9 ("Laden/Charge") does
not light up when the battery is inserted with wrong
polarity. Fig.2
Maintenance
MAINTENANCE
= ON = OFF = FLASHING
1. TRANSMITTER
START-UP/OPERATION
MALFUNCTIONS
2. RECEIVER
Mounting the Receiver where. The mounting bracket may be bolted to the
vehicle frame, but do not allow the antenna whip
Antenna: to contact metal parts! After mounting, insert the
The receiver antenna assembly (Figure 1) consists connector end of the cable into the mating receiver
of a mounting bracket with attached coaxial cable connector and secure the cable with tie-wraps if
and a removable whip antenna. For most close required to prevent damage.
range applications (< 300') the location of the
antenna is not too critical since the receiver is sen- Figure 1. Receiver Antenna Assembly
sitive enough to pick up the signal almost any-
(FLAHSING)
Battery low.
3. COMMUNICATION LED
(FLASHING)
Function turned on.
4. E-STOP LED
(FLASHING)
E-Stop still active due to power up
sequence or function On.
Remote Radio Controller have the numbers 1 & 8 printed above it. The
second row SW2 will have 9 & 16 printed above
DIP SWITCH SETTINGS it. In order for the radio to operate, the switches
must be set the same as the decal. EXAMPLE: if
Each T45 transmitter is supplied with a unique ID the punched hole in the decal for SW1-1 is a 1
code (Figure 4). This code is marked on the label (Figure 7), then the corresponding dip switch must
located on the handle mounting plate, along with be set to ON. If the punched hole in the decal for
the radio serial number. The receiver must be set SW1-1 is a 0, then the corresponding dip switch
to match this code. To match the settings, the must be set to OFF. After all switches are set, re-
power to the receiver must be off. power the receiver.
WARNING
Do not operatre this
machine without
training. Understand
the warnings in safety
manuals and on decals.
ASSY-326-08
SERIAL NUMBER 70136 ISSUE 2
ID CODE 1 1
SW 1: SW 2:
L1393-01 0 0
0 = Off
ID
1 8
1 = On
SW1
1 2 3 4 5 6 7 8
9 16
SW2
SW3 1 2 3 4 5 6 7 8
Set all switches
to 00001000
1 2 3 4 5 6 7 8
1 8
MODE
+
STOP
LED LED LED DESCRIPTION ACTION
Battery Dead; Power Off Charge Battery; Turn Power
On
E-Stop Test Press E-STOP button
2. Physical Mounting
The receiver should be mounted with the connec-
tors down and in a location that allows the enclo-
sure door to be opened conveniently for access to
the inside.
3. Considerations for
Electrowelding
The high currents and voltages employed by elec-
trowelding can damage the electronics in the Com-
fort Concrete Pump Remote Control System. If
electrowelding must be performed after the Con-
trol System has been installed, observe the follow-
ing precautions to reduce the risk of damage:
Unplug the connectors to the receiver and
The enclosure is sealed and has a NEMA-4 rating. cable units.
When installing, ensure that nothing is done to Do not strike an arc close to the enclosure.
compromise the watertightness of the enclosure.
When performing maintenance, it may be neces-
sary to gain access to the inside of the enclosure;
take care to close the door securely when you are
done.
TPCB-1527-01
Function Burndy Conn. Pin
Conn.
Receiver Power (24V Bat.) C J7-6
Receiver Ground D J7-5
E-Stop Contact 1A E J7-4
E-Stop Contact 1B F J7-2
E-Stop Contact 2A G J7-3
E-Stop Contact 2B H J7-1
Hydraulic Enable Valve Output (drives
J J6-3
power out when boom function on)
CAN-Bus High K J6-1
CAN-Bus Low L J6-2
Internal
Function Sine Conn. Pin
Connection
Cable Unit Ground A TPCB-1605-01 J1-4
Cable Unit Power (24V Bat.) B TPCB-1605-01 J1-2
E-Stop Contact 1A C Contact Block 1
E-Stop Contact 2A D Contact Block 2
Hydraulic Enable Valve Output (drives
E PCB-I24-MC DB15-4
power out when boom function on)
CAN-Bus High G PCB-I24-MC DB15-6
CAN-Bus Low H PCB-I24-MC DB15-7
E-Stop Contact 1B J Contact Block 1
E-Stop Contact 2B K Contact Block 2
6. Fuses
There is one replaceable fuse on the receiver
TPCB-1527-01 circuit board. It is an American
automotive cartridge (ATO) style fuse; F2 should
be 5A (brown color code). It provides power to
the E-Stop relays. The other fuses used are self-
resetting. They need the input power removed in
order to reset after a fault is corrected. The
Hydraulic Enable Output Supply has no internal
protection in either the receiver or the cable unit.
7. Operations section).
This section describes how the Comfort Concrete
Pump Remote Control System operates. It details 6. BOOM ENABLE
the operation of the lights and special consider- -on =boom function on - hydraulic enable out-
ations. put active
-off=boom functions off - hydraulic enable
7.1 Receiver output off
The receiver is operational when power is applied.
The receiver is designed to be a plug in replace- 7. E-STOP
ment of the German unit. The Hydraulic Enable -on=Receiver in E-Stop mode, E-Stop contacts
Output is capable of supplying 1 Amp. and is open.
short-circuit protected. It has a one-second hold -off=Receiver in operating mode, E-Stop con-
over after all boom functions are released. tacts closed.
-flashing (with RECEIVER MICRO STATUS
on) = restart blocking
7.1.1 Receiver Lights - General Function -other=error condition - see next section
The receiver lights are defined according to the
list below. 7.1.2 Receiver Lights - Error Conditions
The receiver lights also indicate error condi-
1. POWER-on=normal tions as defined according to the list below.
-off=no power, input power fuse blown or power
supply fault on TPCB-1527-01. 1. RECEIVER MICRO STATUS flashing con-
tinuously on first time power up of micro.
2. RECEIVER MICRO STATUS (only will occur if new micro. installed).
-on=normal Cause: CONFIG register programmed.
-off=micro. on TPCB-1527-01 failed Resolution: Cycle power to continue.
-other =error condition - see next section
2. RECEIVER MICRO STATUS flashing once
3. COM LINK -on=radio communications link per second on power up
with transmitter Cause: Software initialization failed.
-off=no link with transmitter Resolution: Cycle power. If not cleared, CPU
or EPROM circuitry is faulty.
4. SIGNAL STRENGTH 3. RECEIVER MICRO STATUS and E-STOP
-on or mostly on =good link with transmitter flashing continuously together.
-mostly off =poor link with transmitter Cause: E-Stop Drive circuitry fault detected.
-off= no data from transmitter Resolution: If COM LINK is on, HopLink
module is faulty. Otherwise, cycle power. It if
5. CAN-BUS MICRO STATUS recurs, TPCB-1527-01 board is faulty.
-blinking continuously=normal when receiv-
ing data 4. RECEIVER MICRO STATUS blinks off
-blink every 2 seconds=no CANBUS link to three times with a 2-second interval.
Comfort but receiver Cause: HopLink failure detected.
interface OK Resolution: Check ribbon cable to HopLink.
-off=normal when E-Stop is on. When E-Stop Check that HopLink ON light is on. Check
is off or blinking: CANBUS micro. failed or power to HopLink. If ON light off and power
interface failed (check error conditions in next is good, then HopLink is faulty. In all other
7.2 Transmitter
7.2.1 Transmitter Lights
The transmitter lights are similar to all the other
transmitter products supplied to SAI. The following Troubleshooting Table: Transmitter LED s
chart details their operation.
+
STOP
LED LED LED DESCRIPTION ACTION
Charge Battery; Turn Power
Battery Dead; Power Off On
E-Stop Test Press E-STOP button
X E-Stop Test Part Two Release E-STOP Button
N/A X E-Stop Failed Set all functions off
Not all functions off on E-Stop
N/A OK, continue as required
release
N/A Valid Data, all functions OK, continue as required
N/A Valid Data, 1 + functions on E-STOP Button Pressed
N/A Emergency Stop Replace/Recharge Battery
Boom Function on when Boom Cycle Power - if not
N/A
disabled remedied, call service
Cycle Power - if not
Low Battery
NORMAL NORMAL remedied, call service
Cycle Power - if not
X Module failure: Joystick remedied, call service
Cycle Power - if not
X Module failure: Radio remedied, call service
Cycle Power - if not
Module failure: Micro remedied, call service
7.3 Cable Unit tions since the Comfort System does not supply E-
Stop status information to the cable unit. The fol-
7.3.1 Cable Unit Lights
lowing chart details the operation of the lights.
The cable unit lights are unique. That is, they do
not act the same as other cable units supplied to
SAI. The STOP light is used only for error condi- Troubleshooting Table: Transmitter LED s
+
STOP
LED LED LED DESCRIPTION ACTION
No Power Connect Cable, check fuse
Valid Data, all function off OK, continue as required
Valid Data, 1 + functions on OK, continue as required
Boom Function on with Boom Enable Boom to activate
Disabled Boom Function.
Function on after E-Stop release Reset all function to neutral
Cycle Power - if not
Internal Interface Failure remedied internal wiring or
board faulty
Check cable/truck wiring -
CAN-Bus Interface Failure otherwise - internal I24-MC
board or wiring faulty*
Cycle Power-if not
remedied joystick faulty
Joystick Failure
(LED on faulty joystick ON
when powered)
The Boom (2) Ramp speed is fixed at 1.0-second 8.2 Receiver TPCB-1527-01 Board
ramp up to 100% and 0.25-second ramp down The TPCB-1527-01 board is used in the receiver to
from 100%. provide the interface between the I24-MC board
and the HopLink module. The MAIN BYPASS
8. Troubleshooting Information jumper (JPI) must have a shorting block on pins 2
to 3 (position nearest the edge of the board) in
This section includes information on the circuit
order for the E-stop Relays to work. The on-board
boards in the receiver and cable units, including a
LEDs are defined as follows:
description of on-board LEDs.
CR3 (MICRO PWR) = 5V Power to micropro-
8.1 I24-MC Board cessor.
The I24-MC board is used in both the receiver and CR4 = Relay Drive Power through 5A fuse -
the cable units to provide the CAN-Bus interface F2.
and the Hydraulic Enable Output to the Comfort D6 (Top Red LED) = HopLink E-Stop Relay
Control System. The on-board LEDs are defined Drive OFF.
as follows: D4 (Bottom Red LED) = TPCB-1527-01 E-
LED 1 = CAN-BUS MICRO STATUS Stop Relay Drive OFF.
LED 2 = BOOM ENABLE
LED 3 = CAN-Bus Link Failure
LED 4 = Internal Error (Hydraulic Enable Out-
put shorted to supply)
LED 5 = Internal Diagnostic Mode
Conversion Charts
METRIC TO AMERICAN AND VICE-VERSA
Abbreviation TO CONVERT MULTIPLY BY TO OBTAIN Abbreviation
A atmospheres 1.0132739 bars b
A atmospheres 1.0333 kilograms/sq. centimeter kgs./cm2
A atmospheres 14.7 pounds/sq. inch PSI
b bars 0.9869 atmospheres A
b bars 1 deka newtons daN
b bars 0.98069 kilograms/sq. centimeter kgs/cm2
b bars 14.5 pounds/sq. inch PSI
btu british thermal units 778.16 foot-pounds ft-lbs
btu/min british thermal units/min. .000393 horsepower hp
btu/min british thermal units/min. 0.01757 kilowatts kw
cm centimeters .03281 feet ft
cm centimeters 0.3937 inches in
cm centimeters 10. millimeters mm
cm centimeters 0.01 meters m
cc or cm3 cubic centimeters 0.001 liters l
cc or cm3 cubic centimeters 0.000001 cubic meters m3
cc or cm3 cubic centimeters 0.00003531 cubic feet ft3
cc or cm3 cubic centimeters 0.061 cubic inches in3
ft3 cubic feet 28,320. cubic centimeters cc or cm3
ft3 cubic feet 1,728. cubic inches in3
ft3 cubic feet 0.03704 cubic yards yd3
ft3 cubic feet 7.48052 gallons (U.S. liquid) G
in3 cubic inches 16.39 cubic centimeters cc or cm3
in3 cubic inches 0.0005787 cubic feet ft3
in3 cubic inches 0.00002143 cubic yards yd3
in3 cubic inches 0.004329 gallons (U.S. liquid) G
in3 cubic inches 0.01639 liters l
m3 cubic meters 1,000,000. cubic centimeters cc or cm3
m3 cubic meters 35.31 cubic feet ft3
m3 cubic meters 1.308 cubic yards yd3
m3 cubic meters 1,000. liters l
m3 cubic meters 264.2 gallons (U.S. liquid) G
m3/hr cubic meters/hour 1.308 cubic yards/hour yd3/hr
yd3 cubic yards 764,600 cubic centimeters cc or cm3
yd3 cubic yards 27. cubic feet ft3
yd3 cubic yards 46,656. cubic inches in3
yd3 cubic yards 764.526 liters l
yd3 cubic yards 202. gallons (U.S. liquid) G
3
yd /hr cubic yards/hour 0.764526 cubic meters/hour m3/hr
daN dekanewtons 1. bars b
daN dekanewtons 14.50377 pounds/sq. inch PSI
ft feet 30.48 centimeters cm
ft feet 0.0003048 kilometers km
ft feet 0.3048 meters m
ft feet 304.8 millimeters mm
ft-lb foot-pounds 0.001286 british thermal units btu
ft-lb foot-pounds 0.1383 kilogram.-meters kg-m
ft-lb foot-pounds 1.356 newton-meters Nm
Metric Conversion01.eps
Metric_Conversion03.eps
INCHES INCHES
FRACTIONS DECIMALS
mm FRACTIONS DECIMALS
mm
0.00004 0.0010 0.13780 03.5000
0.00039 0.0100 9/64 0.14063 03.5719
0.00079 0.0200 0.15000 03.8100
0.00100 0.0250 5/32 0.15625 03.9688
0.00118 0.0300 0.15748 04.0000
0.00157 0.0400 11/64 0.17188 04.3656
0.00197 0.0500 0.17500 04.4450
0.00200 0.0510 0.17717 04.5000
0.00236 0.0600 3/16 0.18750 04.7625
0.00276 0.0700 0.19685 05.0000
0.00300 0.0762 0.20000 05.0800
0.00315 0.0800 13/64 0.20313 05.1594
0.00354 0.0900 0.21654 05.5000
0.00394 0.1000 7/32 0.21875 05.5562
0.00400 0.1016 0.22500 05.7150
0.00500 0.1270 15/64 0.23438 05.9531
0.00600 0.1524 0.23622 06.0000
0.00700 0.1778 1/4 0.25000 06.3500
0.00787 0.2000 0.25591 06.5000
0.00800 0.2032 17/64 0.26563 06.7469
0.00900 0.2286 0.27500 06.9850
0.00984 0.2500 0.27559 07.0000
0.01000 0.2540 9/32 0.28125 07.1438
0.01181 0.3000 0.29528 07.5000
1/64 0.01563 0.3969 19/64 0.29688 07.5406
0.01575 0.4000 0.30000 07.6200
0.01969 0.5000 5/16 0.31250 07.9375
0.02000 0.5080 0.31496 08.0000
0.02362 0.6000 21/64 0.32813 08.3344
0.02500 0.6350 0.33465 08.5000
0.02756 0.7000 11/32 0.34375 08.7312
0.02950 0.7500 0.35000 08.8900
0.03000 0.7620 0.35433 09.0000
1/32 0.03125 0.7938 23/64 0.35938 09.1281
0.03150 0.8000 0.37402 09.5000
0.03543 0.9000 3/8 0.37500 09.5250
0.03937 1.0000 25/64 0.39063 09.9219
0.04000 1.0160 0.39370 10.0000
3/64 0.04687 1.1910 0.40000 10.1600
0.04724 1.2000 13/32 0.40625 10.3188
0.05000 1.2700 0.41339 10.5000
0.05512 1.4000 27/64 0.42188 10.7156
0.05906 1.5000 0.43307 11.0000
0.06000 1.5240 7/16 0.43750 11.1125
1/16 0.06250 1.5875 0.45000 11.4300
0.06299 1.6000 0.45276 11.5000
0.06693 1.7000 29/64 0.45313 11.5094
0.07000 1.7780 15/32 0.46875 11.9062
0.07087 1.8000 0.47244 12.0000
0.07500 1.9050 31/64 0.48438 12.3031
5/64 0.07813 1.9844 0.49213 12.5000
0.07874 2.0000 1/2 0.50000 12.7000
0.08000 2.0320 0.51181 13.0000
0.08661 2.2000 33/64 0.51563 13.0969
0.09000 2.2860 17/32 0.53125 13.4938
0.09055 2.3000 0.53150 13.5000
3/32 0.09375 2.3812 35/64 0.54688 13.8906
0.09843 2.5000 0.55000 13.9700
0.10000 2.5400 0.55118 14.0000
0.10236 2.6000 9/16 0.56250 14.2875
7/64 0.10937 2.7781 0.57087 14.5000
0.11811 3.0000 37/64 0.57813 14.6844
1/8 0.12500 3.1750 0.59055 15.0000
Conversion_Formulas01.eps
INCHES INCHES
FRACTIONS DECIMALS
mm FRACTIONS DECIMALS
mm
19/32 0.59375 15.0812 1.57480 040.00
0.60000 15.2400 1.65354 042.00
39/64 0.60938 15.4781 1 3/4 1.75000 044.45
0.61024 15.5000 1.77170 045.00
5/8 0.62500 15.8750 1.88976 048.00
0.62992 16.0000 1.96850 050.00
41/64 0.64063 16.2719 2 2.00000 050.80
0.64961 16.5000 2.04724 052.00
0.65000 16.5100 2.16540 055.00
21/32 0.65625 16.6688 2.20472 056.00
0.66929 17.0000 2 1/4 2.25000 057.15
43/64 0.67188 17.0656 2.36220 060.00
11/16 0.68750 17.4625 2 1/2 2.50000 063.50
0.68898 17.5000 2.51968 064.00
0.70000 17.7800 2 3/4 2.75000 069.85
45/64 0.70313 17.8594 2.83464 072.00
0.70866 18.0000 2.95280 075.00
23/32 0.71875 18.2562 3 3.00000 076.20
0.72835 18.5000 3.14960 080.00
47/64 0.73438 18.6531 3 1/2 3.50000 088.90
0.74803 19.0000 3.54330 090.00
3/4 0.75000 19.0500 3.93700 100.00
49/64 0.76563 19.4469 4 4.00000 101.60
0.76772 19.5000 4.33070 110.00
25/32 0.78125 19.8438 4 1/2 4.50000 114.30
0.78740 20.0000 4.72440 120.00
51/64 0.79688 20.2406 5 5.00000 127.00
0.80000 20.3200 5.51180 140.00
0.80709 20.5000 5.90550 150.00
13/16 0.81250 20.6375 6 6.00000 152.40
0.82677 21.0000 6.29920 160.00
53/64 0.82813 21.0344 7.08660 180.00
27/32 0.84375 21.4312 7.87400 200.00
0.84646 21.5000 8 8.00000 203.20
0.85000 21.5900 8.66140 220.00
55/64 0.85938 21.8281 9.44880 240.00
0.86614 22.0000 9.84250 250.00
7/8 0.87500 22.2250 10 10.00000 254.00
0.88583 22.6219 10.23620 260.00
57/64 0.89063 22.8600 11.02360 280.00
0.90000 23.0000 11.81100 300.00
0.90551 23.0188 12 12.00000 304.80
29/32 0.90625 23.0188 12.59840 320.00
59/64 0.92188 23.4156 13.38580 340.00
0.92520 23.5000 13.77950 350.00
15/16 0.93750 23.8125 14.17320 360.00
0.94488 24.0000 14.96060 380.00
0.95000 24.1300 15.74800 400.00
61/64 0.95313 24.2094 16 16.00000 406.40
0.96457 24.5000 17.71650 450.00
31/32 0.96875 24.6062 19.68500 500.00
0.98425 25.0000 20 20.00000 508.00
63/64 0.98438 25.0031 23.62200 600.00
1 1.00000 25.4000 24 24.00000 609.60
1.06299 27.0000 36 36.00000 914.40
1.10240 28.0000 39.37000 1000.00
1.18110 30.0000 48 48.00000 1219.20
1 1/4 1.25000 31.7500 60 60.00000 1524.00
1.29921 33.0000 72 72.00000 1828.80
1.37800 35.0000 78.74000 2000.00
1.41732 36.0000 96 96.00000 2438.40
1 1/2 1.50000 38.1000 118.11000 3000.00
1.53543 39.0000 196.85000 5000.00
Conversion_Formulas02.eps
*The diagram below relates 3 formulas regarding force, pressure, and area:
U.S.
F = FORCE (in pounds) (lb)
P = PRESSURE (in pounds per square inch) (P.S.I.)
F F=PxA
A = AREA (in square inches) (in2)
P = F/A
P A METRIC
A = F/P
F = FORCE (in kilograms) (Kg)
P = PRESSURE (in kilograms per square centimeter) (Kg/cm2)
A = AREA (in square centimeters) (cm2)
GENERAL
QxP Q = FLOW RATE (unit of volume per time period)
POWER =
CONSTANT P = PRESSURE (unit of force per unit of area)
U.S.
HP = HORSEPOWER
GPM x PSI
HP = GPM = GALLONS PER MINUTE
1714
PSI = POUNDS PER SQUARE INCH
1714 = KNOWN CONSTANT
METRIC
KW = KILOWATTS
LPM x BAR LPM = LITERS PER MINUTE
KW =
600
BAR = METRIC UNIT OF PRESSURE
600 = KNOWN CONSTANT
The above state only the power drawn by the system, and make no allowance for the efficiency of the components.
To determine the power needed to drive a specific system, the answer to the formula must be divided by the efficiency factor.
QxP
REQUIRED POWER = E = EFFICIENCY FACTOR
CONSTANT
E
The rule of thumb for figuring efficiencies is: E = 0.7 for internal combustion engines, or E = 0.85 for electric motors.
It would be the same in Metric as in U.S. calculations.
FluidPowerFormulas01.eps
T=
P x CONSTANT GENERAL
RPM T = TORQUE
T x RPM P = POWER
P=
CONSTANT RPM = REVOLUTIONS PER MINUTE
P x CONSTANT
RPM =
T
HP x 5252 U.S.
T=
RPM T = TORQUE (in foot-pounds) (ft-lb)
T x RPM HP = HORSEPOWER
HP =
5252 5252 = K NOWN CONSTANT
HP x 5252
RPM =
T
KW x 9543 METRIC
T=
RPM T = TORQUE (in newton-meters) (Nm)
T x RPM KW = KILOWATTS
KW =
9543 9543 = K NOWN CONSTANT
KW x 9543
RPM =
T
T=
DxP D = DISPLACEMENT (in cubic inches per revolution) (in3/rev.)
24 P = PRESSURE (in pounds per square inch) (PSI)
= Pi (3.1415927)
FluidPowerFormulas02.eps
Torque Specifications has a dial scale. If no dial scale is present, the bolts
must be torqued to within 6% of the requirement. For
The following charts show the tightening torques example, a bolt to be torqued to a 200-lb requirement
specified for the bolts used on Schwing equipment. The must be within the range of 208192 ft-lb for a dial
charts are to be followed unless a different torque scale torque wrench. Schwing equipment uses two
specification is indicated for a particular procedure. different types of bolts, one black/yellow chromated
A torque wrench must be calibrated to within 1% of its finish and one Dacromet finish.
indicated value throughout its range. Bolts must be
torqued to within 4% of the requirement if the wrench
I. APPLICABLE TO:
A. 500 Geomet fasteners, nuts, and washers
B. Black or yellow-chromate fasteners, nuts, and washers (using Cu or MOS2 mounting paste)
Designation
8.8 10.9 12.9 8.8 10.9 12.9
Thread
Thread
Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb
M 14 X 2 100 74 140 103 170 125 M 16 X 1.5 160 118 235 173 280 206
M 16 X 2 150 111 225 166 260 192 M 18 X 1.5 240 177 345 254 400 295
M 18 X 2.5 220 162 310 228 365 269 M 20 X 1.5 335 247 475 350 560 413
M 20 X 2.5 300 221 440 324 510 376 M 22 X 1.5 460 339 650 479 750 553
M 22 X 2.5 420 310 590 435 700 516 M 24 X 2 560 413 810 597 940 693
M 24 X 3 530 391 750 553 880 649 M 27 X 2 820 604 1170 862 1390 1025
M 27 X 3 780 575 1120 826 1300 958 M 30 X 2 1170 862 1660 1224 1930 1423
* The tightening torque corresponds to the axial force in the fastener where the
limit of elasticity of the latter is utilized 90% by tension and torsion
assuming a friction coefficient of m = 0.1.
REFERENCES:
1. DIN 912, 931, 933, 934, 6914, and 6915
2. VDI 2230
Designation
8.8 10.9 12.9 8.8 10.9 12.9
Thread
Thread
Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb
M 14 X 2 120 88 180 133 210 155 M 16 X 1.5 200 147 295 217 350 258
M 16 X 2 185 136 275 203 325 240 M 18 X 1.5 300 221 435 321 510 376
M 18 X 2.5 270 199 385 284 450 332 M 20 X 1.5 425 313 610 450 710 523
M 20 X 2.5 380 280 550 405 640 472 M 22 X 1.5 580 428 825 608 940 693
M 22 X 2.5 520 383 740 545 870 641 M 24 X 2 720 531 1030 759 1210 892
M 24 X 3 650 479 940 693 1095 807 M 27 X 2 1030 759 1480 1091 1750 1290
M 27 X 3 990 730 1390 1025 1620 1194 M 30 X 2 1480 1091 2110 1555 2470 1821
* The tightening torque corresponds to the axial force in the fastener where the
limit of elasticity of the latter is utilized 90% by tension and torsion
assuming a friction coefficient of m = 0.14.
REFERENCES:
1. DIN 912, 931, 933, 934, 6914, and 6915
3. VDI 2230
Torque - Ft-Lbs
Size (Newton-meters)
Part
Unit (Course Grade DIN
Number Black or Yel- Dacrometer
Threads)
low Cromate Geomet
Bolt 10207022 M20 x 140 10.9 931 405 (550 Nm) 326 (440 Nm)
S 17
Washer 10141124 M20
Bolt 10030718 M24 x 130 10.9 931 694 (940 Nm) 553 (750 Nm)
S 31 XT
Washer 10141125 M24
KVM 32XL Bolt 10072024 M20 X 2.5 X 110 10.9 6914 405 (550 Nm) 326 (440 Nm)
and
KVM 36L Washer 10001509 M21
Bolt 10030718 M24 x 130 10.9 931 694 (940 Nm) 553 (750 Nm)
KVM 34X
Washer 10141125 M24
Bolt 10120666 M20 X 2.5 X 140 12.9 6914 472 (640 Nm) 376 (510 Nm)
KVM 36X
Washer 10001509 M21
Bolt 10009258 M20 X 2 X 150 12.9 960 472 (640 Nm) 376 (510 Nm)
Bolt 10120666 M20 X 2.5 X 140 12.9 960 472 (640 Nm) 376 (510 Nm)
KVM 39
Washer 10001509 M21
Bolt 10117168 M24 X 150 10.9 931 694 (940 Nm) 553 (750 Nm)
S 42 SX
Washer 10141124 M24
Bolt 10012926 M22 X 2.5 X 180 10.9 931 546 (740 Nm) 440 (592 Nm)
S 45 SX Bolt 10117168 M24 X 150 10.9 931 694 (940 Nm) 553 (750 Nm)
S 47 SX Washer 10141125 M24
Bolt 10044746 M24 X 3 X 140 10.9 6914 694 (940 Nm) 553 (750 Nm)
KVM 52
KVM 55 Washer 10001504 M25
Bolt 10188613 M24 X 3 X160 10.9 6914 694 (940 Nm) 553 (750 Nm)
S 52 SX
Washer 10188948 M25
S 58 SX Bolt 10188613 M24 X 3 X160 10.9 6914 694 (940 Nm) 553 (750 Nm)
S 61 SX Washer 10188948 M25
Torque
Cyl. Part
Unit Piston Cylinder End
No. Number
Nm Ft-Lb Nm Ft-Lb
#1 10004728 128 94 313 231
#3 10004747 36 27 128 94
Torque
Cyl. Part Piston Cylinder End
Unit
No. Number
Nm Ft-Lb Nm Ft-Lb
#4 10158050 - - - -
Torque
Cyl. Part Piston Cylinder End
Unit
No. Number
Nm Ft-Lb Nm Ft-Lb
#4 10049570 -- -- -- --
#1 10185967 -- -- -- --
S 58SX #2 10185968 1150 850
and
S 61SX #3 10185969 -- -- -- --
#4 10185970 -- -- -- --
WP Number Codes
EXPLANATION OF NOMENCLATURE
WP 1000 XE
WP 750 - 15XE
WP 750 - 18XE
In practical usage, it would be common to refer to these units as a 1000, 750-15, and a 750-18.
The pumpkit has its own complete model number. You will nd this used on the output char ts and nomographs for
speci c machines . An example:
S0014.eps
KVM 23-4 H 225 5715 134 3404 236 5994 22,050 98 15,250 68
KVM 24-4 H 235 5969 142 3607 268 6807 27,000 120 20,500 91
KVM 25 225 5715 134 3404 244 6198 23,200 103 14,300 64
KVM 26-4 235 5969 142 3607 268 6807 29,000 129 23,500 105
KVM 28 245 6223 180 4572 271 6883 27,560 123 17,420 78
KVM 28 X 235 5969 142 3607 268 6807 28,500 127 22,800 101
S 28 X 235 5969 142 3607 259 6579 40,464 180 38,216 170
KVM 31 244 6198 244 6198 248 6299 24,255 108 28,665 128
S 31 EZ (HT) 245 6223 202 5131 293 7442 39,700 177 30,900 137
KVM 32 278 7061 192 4877 271 6883 30,430 135 22,930 102
KVM 32 XL 234 5944 204 5182 294 7468 32,600 145 27,000 120
KVM 34 X 245 6223 225 5715 283 7188 39,500 176 31,500 140
KVM 36 274 6960 294 7468 282 7163 32,630 145 36,380 162
KVM 36 X 292 7417 232 5893 353 8966 37,800 168 33,300 148
KVM 39 X 307 7798 252 6401 359 9119 42,000 187 35,200 157
S 41 SX 312 7925 252 6401 352 8941 42,000 187 35,200 157
KVM 42 HW 354 8992 354 8992 363 9220 49,600 221 52,900 235
KVM 42 LW 335 8509 331 8407 333 8458 43,400 193 45,400 202
S 42 SX 327 8306 327 8306 348 8839 50,700 226 52,900 235
S 45/47 SX 327 8306 327 8306 348 8839 58,500 260 56,200 250
KVM 52/55 374 9500 374 9500 410 10414 60,000 267 60,000 267
S 52 SX 350 8890 411 10439 424 10770 75,308 335 78,680 350
S 58/61 SX 350 8890 493 12522 453 11506 78,680 350 83,176 370
Notes: S0016.eps
1. All dimensions and weights are approximate;
2. Two axle Mack truck listed.
(C0)
Issue: 01/31/05
(C4) 5 (C1)
8 6
(B1)
(B0) 2
1 D 7
04/13/05
(B4) (C3) (D4)
(C2)
3 (D1)
(B2) 10
C 11
(B3) (D2)
B
(A0) (A3)
HP
A
(A2)
Upper
Subject: Maximum Pin-Bushing-Bore Clearances
Lower 5115-1.eps
Service Manual
HP NA A NA B NA 1 2 3 3.1 C 4 5 6 7 7.1 D 8 9 10 11 11.1 E 12
KVM LWR UPR A0 A1 A2 A2.1 A3 A4 B0 B1 B2 B2.1 B3 B4 C0 C1 C2 C2.1 C3 C4 D0 D1 D2 D2.1 D3 D4
SAIE STANDARD
23M .099 .150 .098 ----- .041 ----- .041 ----- .047 .041 .041 ----- .041 .041 .035 .030 .030 ----- .030 .030 ----- ----- ----- ----- ----- -----
28M .108 .138 .098 ----- .047 ----- .047 ----- .044 .047 .047 ----- .047 .047 .035 .030 .035 ----- .035 .030 ----- ----- ----- ----- ----- -----
Mehl
31M .108 .158 .114 ----- .041 ----- .041 ----- .044 .047 .047 ----- .047 .047 .067 .035 .035 ----- .035 .035 ----- ----- ----- ----- ----- -----
32M .108 .158 .114 ----- .054 ----- .054 ----- .044 .041 .044 ----- .044 .044 .067 .035 .041 ----- .041 .041 .035 .030 .035 ----- .035 .035
32XL Rollix Rollix .045 ----- .044 ----- .044 ----- .044 .041 .044 ----- .044 .044 .045 .035 .041 ----- .041 .041 .035 .030 .035 ----- .035 .035
36M Rollix Rollix .114 ----- .047 ----- .047 ----- .054 .049 .054 ----- .054 .049 .067 .041 .047 ----- .047 .041 .035 .030 .030 ----- .030 .030
NOTES:
1. REFERENCE SAIE 5114 FOR SLEWING BEARING INSPECTION.
2. ALL MEASUREMENTS ARE IN INCHES AND REPRESENT MAXIMUM ALLOWABLE CLEARANCES.
3. FOR SPLIT BOOM AND DETACH TOWER CONNECTIONS, ALLOWED BOOM PIN CLEARANCE IS 0.050 MAXIMUM
Page: 1 of 10
4. CONTACT THE SAI SERVICE DEPARTMENT AT (651) 429-0999 IF YOU HAVE QUESTIONS
Standard: 5115
655
Formulas, Conversions & Specifications
HOME
656
PRINT
Issue: 01/31/05
(C0)
(C4) 5 (C1)
8 6
(B1)
04/13/05
(B0) 2
A
(A2)
Upper
Subject: Maximum Pin-Bushing-Bore Clearances
Lower 5115-2.eps
Service Manual
BEARING CLEARANCES
SAIE STANDARD
Mehl
26-4 .108 .138 .060 ----- .044 ----- .044 ----- .041 .041 .041 .047 .041 .047 .045 .035 .035 .041 .035 .041 .027 .027 .024 .032 .024 .032
28X .108 .138 .060 ----- .044 ----- .044 ----- .041 .041 .032 .047 .032 .047 .027 .027 .024 .032 .024 .032 ----- ----- ----- ----- ----- -----
34X Rollix Rollix .045 ----- .049 ----- .049 ----- .049 .047 .047 .049 .047 .049 .045 .038 .038 .047 .038 .047 .032 .032 .032 .032 .032 .032
36LW Rollix Rollix .045 ----- .044 ----- .044 ----- .044 .044 .047 .049 .047 .049 .045 .041 .032 .047 .032 .047 .027 .027 .024 .032 .024 .032
36X Rollix Rollix .045 ----- .044 ----- .044 ----- .044 .047 .047 .049 .047 .049 .038 .038 .032 .047 .032 .047 .024 .024 .024 .032 .024 .032
39X Rollix Rollix .114 ----- .044 ----- .044 ----- .044 .044 .047 .049 .047 .049 .041 .041 .032 .047 .032 .047 .030 .027 .027 .035 .027 .035
NOTES:
Page: 2 of 10
Issue: 01/31/05
(C0)
(C4) 5
8 (C1)
6
(B1)
04/13/05
(B0) 2 D
5115-3.eps
Service Manual
SAIE STANDARD
Mehl
HP NA A NA B NA 1 2 3 3.1 C 4 5 6 7 7.1 D 8 9 10 11 11.1 E 12
KVM A0 A1 A2 A2.1 A3 A4 B0 B1 B2 B2.1 B3 B4 C0 C1 C2 C2.1 C3 C4 D0 D1 D2 D2.1 D3 D4
42M .114 ----- .044 ----- .044 ----- .054 ----- ----- ----- ----- ----- .073 .047 .047 ----- .047 .047 .035 .035 .035 .035 .035 .035
42LW .114 ----- .044 ----- .044 ----- .054 .044 .049 .047 .049 .049 .073 .047 .047 ----- .047 .047 .035 .035 .035 ----- .035 .035
42HW .114 ----- .044 ----- .044 ----- .054 .054 .054 .059 .054 .059 .073 .047 .047 ----- .047 .047 .035 .035 .035 ----- .035 .035
NOTES:
1. REFERENCE SAIE 5114 FOR SLEWING BEARING INSPECTION.
2. ALL MEASUREMENTS ARE IN INCHES AND REPRESENT MAXIMUM ALLOWABLE CLEARANCES.
Page: 3 of 10
3. CONTACT THE SAI SERVICE DEPARTMENT AT (651) 429-0999 IF YOU HAVE QUESTIONS.
Standard: 5115
657
Formulas, Conversions & Specifications
HOME
658
(C0)
PRINT
5
(C4) (C1)
8 6
Issue: 01/31/05
7.1
(C2.1) E
7 (D3) (D4)
(C2) 12
D (D0)
04/13/05
(B1) (C3) 9
(A4)
13
A (A0)
Subject: Maximum Pin-Bushing-Bore Clearances
(A2) HP
15
(A2.1)
Service Manual
14
(A1) 5115-4.eps
SAIE STANDARD
Mehl
45SX .045 .051 .051 .075 .051 .075 .054 .054 .049 .051 .049 .051 .044 .044 .047 .054 .047 .054 .045 .032 .027 .035 .027 .035
47SX .045 .051 .051 .075 .051 .075 .054 .054 .049 .051 .049 .051 .044 .044 .047 .054 .047 .054 .045 .032 .027 .035 .027 .035
52M .045 .079 .071 .075 .071 .079 .059 .059 .059 .059 .059 .071 .054 .054 .054 .055 .054 .055 .045 .035 .035 .035 .035 .035
52EX .045 .079 .071 .075 .071 .079 .059 .059 .059 .059 .059 .071 .054 .054 .054 .055 .054 .055 .045 .035 .035 .035 .035 .035
55M .045 .079 .071 .075 .071 .079 .059 .059 .059 .059 .059 .071 .054 .054 .054 .055 .054 .055 .045 .035 .035 .035 .035 .035
58SX .045 .055 .055 .075 .055 .079 .051 .051 .059 .071 .059 .071 .054 .044 .044 .049 .044 .049 .045 .035 .032 .044 .032 .044
61SX .045 .055 .055 .075 .055 .079 .051 .051 .059 .071 .059 .071 .054 .044 .044 .049 .044 .049 .045 .035 .032 .044 .032 .044
Page: 4 of 10
NOTES:
Standard: 5115
Issue: 01/31/05
(C0)
(C4) 5 (C1)
8 6
(B1)
04/13/05
(B0) 2
Lower 5115-5.eps
Service Manual
SAIE STANDARD
Mehl
SERVICE TRAINING
23-4H .108 .138 .060 ----- .047 ----- .047 ----- .044 .041 .041 ----- .041 .041 .035 .030 .047 .030 .047 .041 .065 .030 .035 .030 .035 .035
24-4H .108 .138 .060 ----- .044 ----- .044 ----- .044 .041 .041 ----- .041 .041 .035 .030 .047 .030 .047 .041 .065 .030 .035 .030 .035 .035
NOTES:
1. REFERENCE SAIE 5114 FOR SLEWING BEARING INSPECTION.
2. ALL MEASUREMENTS ARE IN INCHES AND REPRESENT MAXIMUM ALLOWABLE CLEARANCES.
3. CONTACT THE SAI SERVICE DEPARTMENT AT (651) 429-0999 IF YOU HAVE QUESTIONS.
4. ALL DIMENSIONS ARE IN INCHES.
Page: 5 of 10
Standard: 5115
659
Formulas, Conversions & Specifications
HOME
660
PRINT
Issue: 01/31/05
(C0)
(C4) 5 (C1)
8
6
(B1)
04/13/05
(B0) 2
3
(B2)
C
(B3)
B
(A3)
(A0)
Formulas, Conversions & Specifications
HP
A
(A2)
Upper
Subject: Maximum Pin-Bushing-Bore Clearances
Lower 5115-6.eps
Service Manual
SAIE STANDARD
Mehl
SERVICE TRAINING
(D2) (D2.1)
Issue: 01/31/05
11 11.1
10
(D1)
(D3) 9
04/13/05
(C2) E 12 (D0)
3.1 3
(B2.1) (B2)
B
(A3)
Subject: Maximum Pin-Bushing-Bore Clearances
(A0)
HP
Service Manual
A
(A2)
SAIE STANDARD
5115-7.eps
Mehl
HP NA A NA B NA 1 2 3 3.1 C 4 5 6 7 7.1 D 8 9 10 11 11.1 E 12
KVM A0 A1 A2 A2.1 A3 A4 B0 B1 B2 B2.1 B3 B4 C0 C1 C2 C2.1 C3 C4 D0 D1 D2 D2.1 D3 D4
31-5HT .045 ----- .049 ----- .049 ----- .041 .035 .032 .047 .032 .047 .035 .035 .035 .041 .035 .041 .027 .027 .027 .030 .027 .030
NOTES:
Page: 7 of 10
661
Formulas, Conversions & Specifications
HOME PRINT
SERVICE TRAINING
Formulas, Conversions & Specifications
Standard: 5115
SAIE STANDARD Page: 8 of 10
Subject: Maximum Pin-Bushing-Bore Clearances
NOTE:
1. CLEARANCE OF SOLID PINS AND HOLLOW PINS TO BORE WITH KEEPER
CAN NOT EXCEED THE FOLLOWING.
2. CLEARANCE BETWEEN INDIVIDUAL PINS AND BUSHINGS ARE PER CHARTS
FROM PREVIOUS PAGES.
PER CHART
BOOM
HYDRAULIC CYLINDER
or GUIDE LEVER
BOOM
PER CHART
GUIDE LEVER
OR BOOM
BOOM
PER CHART
Standard: 5115
SAIE STANDARD Page: 9 of 10
Subject: Maximum Pin-Bushing-Bore Clearances
HOLLOW PINS
MAIN COLUMN
OR TURRET
TURRET
BOOM #2
Standard: 5115
SAIE STANDARD Page: 10 of 10
Subject: Maximum Pin-Bushing-Bore Clearances
GUIDE LEVER
PER CHART
GUIDE LINK
HYDR. CYLINDER
Nozzle Chart
KVM 17 58/52 30/22 (90) 37/25 *(180) N/A N/A 35 N/A N/A N/A
KVM 23 52/72 60/74 (180) 43/46 N/A N/A 23 N/A N/A N/A
KVM 23-4H 54/65 43/40 (90) 27/30 *(90) 26/34 *(90) N/A 27 9/14 N/A N/A
KVM 24-4 50/59 36/35 (90) 26/36 *(90) 24/33 *(90) N/A 29 9/14 N/A N/A
24-4 Prop. (Apitech) 53/60 48/43 (90) 27/33 *(90) 22/31 *(90) N/A 35 14/27 N/A N/A
KVM 26-4 54/65 43/40 (90) 27/36 *(90) 26/34 *(90) N/A 27 9/14 N/A N/A
26-4 Prop. (Apitech) 50/64 45/43 (90) 53/68 45/61 N/A 33 12/20 N/A N/A
KVM 26 Meter 55/70 69/77 (180) 45/60 N/A N/A 27 9/14 N/A N/A
KVM 28 65/62 62/67 (180) 40/48 N/A N/A 28 N/A N/A N/A
KVM 28X 65/58 43/42 (90) 41/51 N/A N/A 28 13/22 N/A N/A
KVM 28X (Apitech) 53/60 74/78 (180) 44/46 N/A N/A 34 13/22 N/A N/A
S 28-4 H 50/50 35/35 (90) 50/50 25/25 N/A 40 13/26 N/A N/A
KVM 31 81/79 75/85 (180) 47/51 N/A N/A 28 N/A N/A N/A
#1 Boom Telescopic
S 31 HT 70/70 33/33 (90) 43/43 23/23 N/A 43 12/23 8/12 In / Out 40/50
KVM 32 94/90 63/54 (90) 75/70 40/46 N/A 30 7/12 7/12 8/14
KVM 32XL Black &
76/73 63/54 (90) 75/70 40/46 N/A 43 13/21 8/10 N/A
White or Proportional
KVM 34X Standard 63/63 46/46 (90) 62/62 31/31 N/A 35 12/23 8/12 N/A
Outrigger System
KVM 34X Regenerative 63/63 46/46 (90) 62/62 31/31 N/A 35 12/13 6/6 N/A
Outrigger System
KVM 36 with 3 SPD. 65/92 50/61 (90) 70/105 31/75 N/A 6/6 6/6 22/15
KVM 36 Prop. 73/75 48/47 (90) 55/63 39/44 N/A 45 8/10 8/10 17/25
36X Prop.(Rexroth) 80/78 49/47 (90) 59/63 47/52 N/A 49 8/10 8/10 N/A
36X Prop.(Apitech) 80/95 49/47 (90) 59/65 47/52 N/A 60 8/10 8/10 N/A
S 36 RZ 70/70 50/50 (90) 70/70 20/20 N/A 50 10/10 10/10 N/A
KVM 39 X 80/80 60/60 (90) 75/75 50/50 N/A 60 15/12 7/6 N/A
S 41 SX 80/80 60/60 (90) 80/80 50/50 N/A 60 10/10 7/8 N/A
KVM 42 75/80 68/70 (90) 76/79 51/53 N/A 70 11/19 11/19 17/30
KVM 42 with 2 SPD. 75/80 68/70 (90) 76/79 51/53 N/A 10/18 10/18 16/28
42 Prop. (Rexroth) 76/80 52/61 (90) 71/76 60/61 N/A 60 10/18 10/18 16/28
42 Prop. (Apitech) 80/90 60/60 (90) 80/83 55/64 N/A 65 10/18 10/18 16/28
S 45/47 SX 90/95 70/70 (90) 90/90 60/60 N/A 70 12/12 N/A 8/7
Front Slewing Rear Slewing
KVM 52 76/90 60/67 (90) 66/76 81/75 N/A 82 17/26
23/37 6/10
Rear Slewing
S 52 SX 105/105 90/90 (90) 65/65 40/40 20/20 85 25/25 N/A
17/17
Front Slewing Rear Slewing
KVM 55 110/110 90/90 (90) 120/120 70/70 N/A 95 17/26
23/37 6/10
Rear Slewing
S 58 SX 120/120 95/95 (90) 120/120 65/65 N/A 90 25/25 N/A
17/17
Rear Slewing
S 61 SX 130/130 105/105 (90) 135/135 70/70 N/A 100 25/25 N/A
17/17
FUNCTION
DumpValve/E-Stop 320 320 250 250 320 350
Boom Regulator 290 290 290 290
Handvalve Relief 300 310 280 350 350 280 290 330 290 350 280 260 280
Downside Relief 140 140 140 140 140 140 140 140 140 140 140 140 170
OUTRIGGER 280 320 200 280 280 300 290 280 280 280 280 260 280
PRETENSION 6 (air) 5.5 5.5 15 15 5.5 5.5 15 5-7 15 5-7 5.5 5-7
Pretension Relief 30 30 30 30 30
Piston Side Relief
Boom Circuit Nozzle Sizes are in mm / "T" after size denotes a Throttle Check
FUNCTION
Sec. 1 Piston Side 1.9T 1.9T 2.0T 1.9T 1.9T 1.8T 1.1 1.9T 1.5T 1.1
Sec. 1 Rod Side 1.5 1.5 1.7 1.5 1.7 1.4 0.8 1.5 1.3 0.9
Sec. 2 Piston Side 1.7 1.7 1.7 1.1 1.7 1.4 1.0 1.0 1.3 1.1
Sec. 2 Rod Side 1.3 1.3 1.3 1.5 1.3 1.1 1.2 1.3 1.0 0.9
Sec. 3 Piston Side 1.4 1.4 1.3 0.8 1.3 1.1 1.1 1.2 1.0 0.9
Sec. 3 Rod Side 1.1 1.1 1.0 1.1 1.0 0.9 1.5 1.7 0.7 0.5
Sec. 4 Piston Side 1.1 1.1 1.2
Sec. 4 Rod Side 0.8 0.8 1.0
Tower Slewing 1.3 1.2 1.3 1.3 1.2 1.3 1.0 0.7
S0020.eps
FUNCTION
DumpValve/E-Stop 350 360 330 320 320 330 330 330 300 330 350
Boom Regulator 310 320 310 290 310 300 310 310 300 310
Handvalve Relief 360 350 350 330 330 350 340 330 280 350 350
Downside Relief 80 80 140 80 80 140 140
OUTRIGGER 350 150 300 280 280 280 280 160 200 280 280
PRETENSION 20 35 35 25 25 15 25 25 5.5 15 15
Pretension Relief 50 40 34 34 30 40 40 30 30
Piston Side Relief 230
Boom Circuit Nozzle Sizes are in mm / "T" after size denotes a Throttle Check
FUNCTION
Sec. 1 Piston Side 1.4T
Sec. 1 Rod Side 1.4T
Sec. 2 Piston Side 1.8T
Sec. 2 Rod Side 1.3
Sec. 3 Piston Side 1.3T
Sec. 3 Rod Side 1.2
Sec. 4 Piston Side 0.9T
Sec. 4 Rod Side 0.8
Tower Slewing
S0131.eps
When doing the boom inspections on slew bearing units, the drive spur gear and the turret slewing bear-
ing gear must be inspected for wear and/or galling, tipping, and gear lash as outlined. The drive gear must
all be inspected by axial and radial movement.
Warning!
Allow yourself enough room to move the
boom without causing danger to yourself
or others. Set up the outriggers for sup-
port, the same as you would for any job,
use carpenters level or the units bubble
level to set the base both longitudinally
and laterally level.
Standard: 5114
SAIE STANDARD Page: 2 of 9
Subject: Slewing Bearing & Drive Gear Inspection
Standard: 5114
SAIE STANDARD Page: 3 of 9
Subject: Slewing Bearing & Drive Gear Inspection
Neutral Position
5-10
Dial indicator will move fast when
Set dial indicator at zero indicator slows down to slow
movement.
Take reading approximately 5-10
then divide dial indicator reading by
2 and compare to maximum tipping
clearances listed below.
Pressure #1 out
2 to 3 Maximum
Standard: 5114
SAIE STANDARD Page: 4 of 9
Subject: Slewing Bearing & Drive Gear Inspection
2. Then using a protractor, position the #1 boom over top dead center toward the cab at 10
4. The position the #1 boom over top dead center toward the hopper at 10 at this position the reading on
dial indicator is divided by 2 and compare to maximum tipping clearance chart below.
Neutral Position
10 10
KVM 36X .074 +.010 = .084 KVM 42HW .025 +.010 = .035
Standard: 5114
SAIE STANDARD Page: 5 of 9
Subject: Slewing Bearing & Drive Gear Inspection
Note: If the markings are not visible, rotate the boom 360 in small increments and measure the clear-
ance (gap) until the minimum and maximum clearances have been located. Mark the minimum clear-
ance gear points on the slewing bearing teeth with an H stamp.
Total Gap
Standard: 5114
SAIE STANDARD Page: 6 of 9
Subject: Slewing Bearing & Drive Gear Inspection
Standard: 5114
SAIE STANDARD Page: 7 of 9
Subject: Slewing Bearing & Drive Gear Inspection
Shroud Bolts
Standard: 5114
SAIE STANDARD Page: 8 of 9
Subject: Slewing Bearing & Drive Gear Inspection
3. Lower the drive gear enough to rotate it at least one bolt hole
position, which will amount to approximately .017 gear lash
depending on the location of eccentricity and amount of tol-
erance desired.
Note: Once the drive gear has been rotated, the supply tubes Lower hoist
on the 42M will not fit becuase of their alignment features.
Replace the three tubes with three hydraulic hoses, Schwing
part#10050169 (944-070-308-100). The 36M may not need
any replacement hoses, unless the tower weldment interfers
with the tubing while rotating the gear housing. In this case,
use one hydraulic hose, Schwing part #10050168 (994-070-
308-080).
Standard: 5114
SAIE STANDARD Page: 9 of 9
Subject: Slewing Bearing & Drive Gear Inspection
Warning!
Shroud
To prevent any danger to yourself or oth-
ers and to protect the gears from damage
from any foreign objects or debris, Bolts connecting the
replace the protective shrouding for both two shroud halves
Drive Gear
the slewing gear and drive gear. Shroud
Shroud Bolts
S0038.eps S0179.eps
S0039.eps
Specifications:
Maximum Flow (G.P.M.).........................................200
Flow Ranges-High Scale:
U.S.G.P.M .......................................................... 25-200
t/min. ................................................................ 100-750
Flow Ranges-Low Scale:
U.S.G.P.M .............................................................. 5-40
t/min ................................................................... 20-150
Dimensions:
Length ............................................ 15 7/8" (403.47mm)
Width.............................................. 13 1/4" (336.55mm)
Height............................................... 6 3/4" (171.45mm)
Material Cylinder Alignment machine requires, measure the O.D. of your differential
rod and the I.D. of the material cylinders installed. To
Tool order one of those tools, find the proper tool from the
Schwing America offers a tool which aligns the following chart, and contact our Spare Parts
material cylinders after rotation or replacement has Department.
been completed. To determine whick tool your
Rod Diameter
Ordering Chart
Rod Cylinder Item
Diameter Diameter Number Pumpkit Model Number
Piston Installation Tools for completely installed. Attempting to install the piston
without this tool can cause damage to the piston rings.
Differential Cylinders
Because the differential cylinders are designed with a To obtain any of these tools, find the proper sized tool
counter bore, it is extremely difficult to install the for your application from the chart below, and contact
differential piston while compressing the piston rings our Spare Parts Department to place your order.
at the same time. These piston intalling tools have a
taper at the mouth of tool to help compress the piston
rings and keep them compressed untill the piston is
Ordering Chart
Piston Item
Diameter Number Description
S0045.eps
Gland Packing Installation Tools pushed into the mouth of the guide bushing and then
pushed completely into position by using the packing
for Differential Cylinders tool as a slide-hammer.
Important! Reference SAIE 5221 regarding proper To do this, first * lightly lubricate the inside radius of
shimming, in "Rock Valve" section in this Service the packing tool to avoid scratching the rod surface.
Manual. Then gently slide the packing tool along the rod
The gland packing tools are designed to aid in surface, drawing away from the seal and then back to
installing the gland packing seal kit (chevrons) into the the seal; again and again tapping it a little further in
guide bushing of the diff cylinder. The packing tool with each slide until the packing section is completely
has a "V" groove machined into one end to fit the shape home.
of the individual seals of the packing set. The guide NOTE: do not attempt to insert all seal sections at the
tool is beveled on one end forcing the hard edge of the same time. Rather, remove both tools from the rod and
seal section to compress thus providing easy check the seal section you just installed to be sure it did
installation into the bushing. not catch on the mouth of the guide bushing and roll
To properly use these tools together, first * lightly inside-out. If seal appears correctly installed, repeat
lubricate the inside radius of the guide tool and also the this exact procedure with the remaining seal sections,
rod surface. Then insert the guide tool onto the rod * but do not reapply any more lubricant.
with beveled edge facing outward. Now take one * To avoid trapping air or lubricant between the
section of the packing set and slide it onto the piston packing sections, we recommend using a silicone spray
rod all the way to the beveled edge of the guide tool. lubricant, if oil is used, be careful not to over-lubricate
Slide the packing tool onto the rod, with "V" groove any surfaces or seal sections.
inward mating the "V" groove with the curvature of the
seal section. Using a rubber mallet, softly strike the flat
end of the packing tool to start the seal section into the To obtain any of these tools, find the proper sized tool
guide tool. for your application from the following chart, and
contact our Spare Parts Department to place your order.
With this seal section inside the guide tool, check to
be sure the guide tool is resting flush with the guide
bushing of the diff cylinder. Now the section can be
S0054.eps
S0056.eps
S0055.eps
Tool, Installation, 95 mm Rock Shaft Bushing
Piston Seal Form Tool Schwing Part#..........................................10013417
Schwing Part#..........................................30313745
Schwing Part# (150mm)..........................30356741
100
50 1
50
150
100 0 20
0 00
50 25
0 00
30
00
0 35 20
00 0
25
0
S0163.eps
S0164.eps
O-Ring - 48 X 55
O-Ring O-Ring O-Ring 10004053
12 X 5 22 X 2.5 34 X 2.5
10000205 10061728 10077601 O-Ring - 56.74 X 3.53
Accumulator Charging Kit 10118767
Drawer 1
Toggle Switch ON/OFF/ON Toggle Switch ON/ON Corrosion Inhibitor Press Out Tool - Harting
1TL 1-8 2TL 1-3 30346014 10083751
30315771 30341455
S0052.eps Drawer 2
Adjusting Device Technition Support Cabinet
Schwing Part# .........................................30321192 Schwing Part#..........................................30366963
Electrical Tools and connectors. The kit includes an ejection tool for
removing and inserting the contacts into the
Accessories connectors. The kit also includes a crimping pliers
Schwing America Inc. is offering an Electrical Service with interchangeable jaw inserts that adapt to both
Kit for the repair of electrical connections in cables and styles of connector contacts. All the following pieces
connectors. This kit enables a wide range of repairs to of this kit are contained in a painted metal box with a
Schwing electrical equipment. The kit includes crimp plastic divider tray and may be ordered separately or as
style pin and bushing contacts for the BURNDY brand a complete kit.
electrical connectors as well as the HARTING brand
Spanner Socket Tools for Boom life of the boom pin nuts by preventing the need to
hammer the nuts on and off with a drift. To order these
Pins tools, find the sizes for your machine from the chart
The spanner socket tools are designed to remove and below, and contact the Schwing America Spare Parts
install the round, notched nuts which thread onto Department with the corresponding part number:
certain boom pins. These handy sockets prolong the
Ordering Chart
Boom Item
Pin Nut Number Tool Description
S0059.eps
9 _
8 6 +
7 5 3
4 2
1
O
S0062.eps
Kent-Moore
Heavy Duty Division
29784 Little Mack
Roseville, MI 48066-2298
1-800-328-6657
MPSI
Micro Processor System, Inc.
6405 Nineteen Mile Road
Sterling Heights, MI 48314
1-810-731-6410