Schwing SP 305 User manual

Operation Manual for
Model SP 305
Operation Manual
Version 5.0.1
Part Number 30362000
Copyright © 2011, Schwing America, Inc.
All rights reserved
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Table of Contents
Operation Manual - SP 305ii
revDate
INTRODUCTION
Manufacturer’s Statement........................................................................... 6
Safety alert symbol and signal word explanation ................................. 6
How to reach us .................................................................................... 7
How to order parts ................................................................................ 7
Model Number............................................................................................ 7
Serial Number ............................................................................................. 7
Orientation ............................................................................................ 7
Model Number Nomenclature .................................................................... 8
SP 305 ................................................................................................... 8
ID Tags ....................................................................................................... 8
Main ID tag........................................................................................... 9
If your ID tag is missing ....................................................................... 9
SPECIFICATIONS
SP 305 ....................................................................................................... 12
Functional Description of the Main Control Block .................................. 13
SAFETY
How to Order Additional Safety Manuals ................................................ 16
Warning Labels (Decals) .......................................................................... 19
OPERATION
Preparing for the Job................................................................................. 22
Towing the unit................................................................................... 22
Setting Up ................................................................................................. 23
Arrival at the job ................................................................................. 23
Laying pipe ......................................................................................... 23
Starting the engine .............................................................................. 24
Controlling the pump .......................................................................... 25
The control panel ................................................................................ 25
The remote control box....................................................................... 27
Note about the electric system ............................................................ 27
The volume control knob.................................................................... 27
Throttle control ................................................................................... 27
The pressure gauge ............................................................................. 27
Starting the Pour ....................................................................................... 27
Concrete mixes ................................................................................... 27
Preparing for concrete......................................................................... 27
Ready the pump .................................................................................. 28
Mix your slurry ................................................................................... 28
Beginning to pump.............................................................................. 28
Cleanout .................................................................................................... 31
Clean the delivery system ................................................................... 31
Clean the pump ................................................................................... 32
Special Pumping Situations ...................................................................... 34
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Operation Manual - iii
Plugs.................................................................................................... 34
Cold weather pumping........................................................................ 35
Hot weather pumping.......................................................................... 36
Emergency procedures........................................................................ 36
Other Things You Need to Know ....................................................... 37
MAINTENANCE
Filtration.................................................................................................... 40
General information............................................................................ 40
Specific information............................................................................ 40
To change the element ........................................................................ 41
Hydraulic Oils........................................................................................... 41
General information............................................................................ 41
Specific information............................................................................ 42
When to change your hydraulic oil..................................................... 42
Pressure, Hoses and Fittings ..................................................................... 42
General Information............................................................................ 42
Specific Information ........................................................................... 43
General Maintenance Tips ........................................................................ 44
Torque specifications.......................................................................... 44
Adjusting relief valves ........................................................................ 44
Removal of safety devices .................................................................. 44
Preventative Maintenance......................................................................... 45
Daily maintenance .............................................................................. 45
Monthly maintenance.......................................................................... 47
Semiannual maintenance (every 6 months) ........................................ 48
Annual maintenance............................................................................ 49
Scheduled maintenance checklist ....................................................... 57
Unscheduled Maintenance........................................................................ 58
Wear parts ........................................................................................... 58
Changing rams .................................................................................... 58
APPENDIX
Hydraulic Oil Viscosity Chart .................................................................. 62
Torque Specifications for SAE Bolts........................................................ 63
Recommended Emergency Hose Kit ........................................................ 64
Fitting Wrench Sizes................................................................................. 64
Maintenance Checklist.............................................................................. 66
Weld-on Ends / Coupling Comparison..................................................... 67
Output Charts............................................................................................ 68
Using the chart .................................................................................... 68
Using a Nomograph .................................................................................. 74
General information............................................................................ 74
The quadrants...................................................................................... 76
Minimum Pipe Wall Thickness ................................................................ 82
Pictograms................................................................................................. 83
Decal Location Guide ............................................................................... 84
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Table of Contents
Operation Manual - SP 305iv
revDate
Glossary of Terms..................................................................................... 86
Additional Reading Material .............................................................. 90
List of Lubricants and Nitrogen................................................................ 91
Hydraulic Schematic—Concrete Pump SP305 - Schematic..................... 95
Electrical Schematic SP305 - 2004 Electric ............................................. 96
Electric Schematic CE/Tier III SP305 ...................................................... 97
Nomograph SP 305................................................................................... 98
Output Chart available upon request ........................................................ 99
INDEX
Alphabetical Index.................................................................................. 102
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SP 305 OPERATION MANUAL
Introduction 5
INTRODUCTION
Manufacturer’s Statement........................................................................ 6
Model Number ......................................................................................... 7
Serial Number.......................................................................................... 7
Model Number Nomenclature.................................................................. 8
ID Tags..................................................................................................... 8
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Introduction
Operation Manual - SP 305
6
8/4/11
INTRODUCTION
This operation manual contains unit specifications,
product overview information, the Safety Manual ,
operation information, and maintenance information
for your concrete pump unit.
Manufacturer’s Statement
The information contained in the operation manual is
absolutely necessary for the safety, proper setup,
operation, maintenance, and servicing of your concrete
pump. By learning this information and practicing it
every day, you can expect that your concrete pump unit
will give you efficient and reliable service year after
year.
For your own benefit and safety, read the information in
this manual, and follow the instructions to the letter.
Before you operate your concrete pump for the first
time, you should read the operating instructions several
times through. We recommend that you keep a copy
with the concrete pump for quick reference while on
the job site. The general knowledge must be in place
before you arrive on the job site. Any and all persons
who operate a concrete pump must be familiar with the
operating instructions. Even a temporary operator (for
example, if the normal operator is ill or on vacation)
must be familiar with the operation instructions. It
stands to reason that a person who has not operated a
particular concrete pump before will not know how to
safely operate that concrete pump. The machine is built
to the latest technology and safety regulations, but it
may still be dangerous to people and property if it is
operated, maintained, repaired, or used incorrectly.
The illustrations contained in this manual are intended
to clarify text passages. They may look slightly
different from your unit, but this has only been allowed
if it does not fundamentally change the factual
information.
Technical modifications that are made to units will be
documented in each new edition of the operation
manual.
Safety alert symbol and signal word
explanation
The triangle with the exclamation point inside is used
to alert you to an important safety point and is called a
safety alert symbol . One of the following signal words
will appear after the safety alert symbol:
• If the safety alert symbol is followed by the signal
word DANGER , it indicates a hazardous situation
which, if not avoided, WILL lead to death or
serious injury.
• If the safety alert symbol is followed by the signal
word WARNING , it indicates a potentially
hazardous situation which, if not avoided, COULD
result in death or serious injury.
• If the safety alert symbol is followed by the signal
word CAUTION , it indicates a potentially
hazardous situation which, if not avoided, MAY
result in minor to moderate injury.
• The signal word CAUTION used without the
safety alert symbol means the point addresses a
hazard which COULD cause damage to
equipment or property.
Warnings have been placed in the text where needed.
Additional information used with the signal words is
printed in decal format, as shown below, to explain the
specific hazard. Occasionally bold text is used in
addition to the decal for emphasis.
All persons working near the concrete pump unit must
be able to recognize hazardous situations. They must
know how to avoid these situations and how to react
quickly and appropriately whenever hazardous
situations arise.
Heed the warnings shown on the decals!
WARNING
Improper setup / operation creates
hazards. Do not operate this machine
without training. Understand the
warnings in safety manuals and on
decals.
000099.eps
Danger
Warning
Caution
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Operation Manuall - SP 305 7
How to reach us
If you encounter a circumstance that is not covered by
this manual, Schwing America’s Service Department
will be more than happy to assist you with all of your
parts and service needs. Call us at either of these #’s:
• Minnesota (main office) (651) 429 - 0999
• Call Center 1- 888-Schwing (724-9464)
How to order parts
To place an order for spare parts, you can order on line
at schwingparts.com , or you can call our toll free parts
line from anywhere in the continental United States,
except Minnesota. Parts department hours are Monday
through Friday, 6:00 AM to 6:00 PM (central time).
Orders will also be accepted via fax, 24 hours/day.
• Spare Parts 1- 888-Schwing (724-9464)
• Spare Parts (fax) (651) 429 - 2112
Whenever you call the factory for spare parts or
service, always have the model number handy. You can
find the model and serial number on the ID tag that is
mounted to the subframe of the unit (Figure 2).
For future reference, the model number and serial
number of your machine has been placed in the spaces
provided below
Orientation
Throughout this manual, we will refer to locations on
the unit as driver side and passenger side . We use these
terms instead of right or left to avoid confusion
regarding which way you must be facing to have a left
or right orientation (Figure 1).
;;;;;;;;;;
;;;;;;;;;;
DANGER
Hazard and consequence will be shown
in this space.
000054.eps
WARNING
Hazard and consequence will be shown
in this space.
000057.eps
Hazard and consequence will be shown
in this space.
000036.eps
CAUTION
Model Number
Serial Number
Driver Side
Passenger Side
psds.eps
Figure 1
Driver Side / Passenger Side
orientation
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Introduction
Operation Manual - SP 305
8
8/4/11
Model Number Nomenclature
The complete model number of Schwing America’s
concrete pumps is designated by codes like the
following:
SP 305
The code is broken down as follows:
The “P”, as the illustration shows, stands for pumpkit.
The 305, in this example, designates 30 yards per hour
and the 5 inch diameter of the material cylinders.
Other pumpkits are available for this machine style,
and using any of them would change the model number
of the unit. For example, if you ordered this unit with a
204 pumpkit, the model number of the same unit would
become:
P 305
The pumpkit has its own complete model number
which will tell you about the differential cylinder bore
diameter, rod diameter, and stroke length, as well as the
material cylinder diameter. You will find this used on
the output charts and nomographs for specific
machines. For example:
The bore diameter of the differential cylinders in this
example is 2.5 inches, while the rod diameter is 1.75
inches. The stroke length of the differential cylinders is
30 inches, and the diameter of the material cylinders is
5 inches.
ID Tags
There is an identification tag on the unit, called the
main ID tag . The main ID tag is attached on the
passenger side of the subframe (Figure 2).
Schwing
Pumpkit
Pumpkit yards per hour
Diameter of material c
y
linder (5 inches)
305nomen.eps
530PS
2.5 / 1.75 x 30 : 5
Diff. cyl. bore dia. (in inches)
Diff. cyl. rod dia. (in inches)
Diff. cyl. stroke length (in inches)
Material cyl. diameter (in inches)
305pknomen.eps
ID tag
SN stamping
mavIDtag.eps
Figure 2
Main ID tag and stamped serial number locations
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Operation Manuall - SP 305 9
NOTE!
The information represented on the tag is
for illustration only. Check the tag on your
unit to obtain the specific numbers which
apply to your unit.
Main ID tag
The main ID tag contains model information, the serial
number, the year of manufacture, the weight of the
unit, the strokes per minute and material pressure, and
the hydraulic systems. The unit serial number is
stamped into the subframe immediately above or below
the ID tag (Figure 3).
If your ID tag is missing
If the tag has been removed from the unit and you must
have some information about it, read the main serial
number that is stamped into the steel subframe. The
serial number is located at the base of the tongue on the
right-hand side, as shown in Figure 2. When you find
the number, call Schwing America’s Service
Department for the information. The unit files are
arranged by this serial number, and we can find out
anything about the unit from the file that corresponds
to this number. New ID tags are available once we have
the unit serial number.
SUBSIDIARY OF
GmbH.
Herne / Germany
Phone: [phone]
www.schwing.de
AMERICA INC.
5900 Centerville Rd
White Bear, MN 55127
Phone: [phone]
www.schwing.com
MODEL
WEIGHT
Max. hyd.
pressure:
System
1
System
2
System
3
System
4
System
5
MAX.
YEAR
MATERIAL
PRESSURE
30301733F
SERIAL NO.
STROKESPER MINUTE
LBS.
Thisproduct iscovered by one or more U.S. patents- see patent decal
SP 305 171530001 2009
625
2500 n/an/an/an/a
403350
mavmainID.eps
1 7 1 5 3 0 0 0 1
Figure 3
Main ID Tag (for reference only)
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Introduction
Operation Manual - SP 305
10
8/4/11
NOTES
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SP 305 OPERATION MANUAL
Specifications
SPECIFICATIONS
SP 305................................................................................................... 12
Functional Description of the Main Control Block.................................. 13
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Specifications
Operation Manual - SP 305
12
4/30/12
SPECIFICATIONS
Note! All specifications are subject to change without notice.
** Max RPM of the hydraulic pumps is calculated while the pump is under a full load. Depending on the unit it is acceptable for
the max RPM to vary slightly from the published estimate.
Model
SP 305
Pump Kit
2.5/1.75 x 30:5
Orientation
Piston Side
Strokes/minute (max.)
40
Material Output (max.)
30 yd
3
/hr (23 m
3
/hr)
Material Pressure (max.)
625 PSI (43 bar)
Power (Diesel Engine)
CAT C2.2NA (Tier 4 interim)
50 HP (37 Kw)
Power (Electric Motor)
40 HP (30 Kw)
Power (hyd. pumps)
30 Kw
Output (hyd. pumps)
27 GPM (102 lpm)
Speed (hyd. pumps) (diesel)
2700 RPM**
(elect. motor)
1800 RPM
Pressure (max. hyd.)
2500 PSI (172 bar)
Max. horizontal distance
800 feet (244 m)
Max. vertical distance
200 feet (61 m)
Max. aggregate size
1” (25 mm)
Minimum Slump
0”
Material Cylinder Diameter
5” (125 mm)
Stoke Length
30” (762 mm)
Differential Cyl. Diameter
2.5 (63.5 mm)
Concrete Valve Type
S
Hopper Height
42” (1065 mm)
Fuel Tank Capacity
15 gal. (58 l)
Gross Weight
3400 lb. (1525 Kg)
Length
149” (3785 mm)
Width
64” (1625 mm)
Height
66” (1675 mm)
Remote Cable Length
100 ft. (30.5 m)
Electric Motor (optional)*
*Contact Schwing America for specs
*
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Operation Manual - SP 305
Functional Description of the
Main Control Block
When the spool of the NG06 solenoid valve is in the
neutral position (no electrical signal to the solenoids of
the NG06), the S-port of the load sensing pump is
vented to tank so that the pump is in “stand-by” mode.
When the NG06 solenoid valve is switched to an
activated position (forward or reverse), the S-port of
the load sensing pump is closed, the pump will create a
pressure, and at 3.5 bar the S1 spool starts to open the
internal connections to the S2 spools. At 5 bar the S1
spool is totally switched over into the activated
position, so the pump kit starts to work. (The 5 bar
pressure is always necessary to hold the S1 spool in the
activated position, just like the NG 20 control block).
The signal of the shifting cylinder pilots the S2 spool
and the signal of the switching valve pilots the S3
spool.
The needle valve cartridge DVE 16 of the manifold at
the pump regulates the flow of the pump, and the direct
acting SUN pressure relief cartridge limits the max.
pressure if the regulator of the pump fails. (The SUN
pressure relief cartridge is good for a flow of 200 l/
min.)
The small accumulator damps the pressure spikes.
To stop pumping, the NG06 solenoid valve has to be
deactivated; the spring centers the NG06 spool in the
neutral position. The S1 pilot system, the S-port of the
load sensing pump, and the accumulator are vented to
tank, the S1 spool switches into the neutral position,
and the pump kit stops working. The nozzle in the P-
line restricts the flow so that the accumulator is vented
softly. During “stand-by” mode, the pump creates the
stand-by pressure, so there is a flow through the nozzle
back to tank. If the stand-by pressure of the pump is
adjusted to 15 bar (218 PSI), there would be a flow
through the 1.5mm orifice of 4.3 l/min. In this
operating status we would create a lost energy of 0.1
KW.
Even a bigger orifice (quicker reaction) should not
cause a heat problem.
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Specifications
Operation Manual - SP 305
14 8/4/11
NOTES
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SP 305 OPERATION MANUAL
Safety
SAFETY
How to Order Additional Safety Manuals............................................... 16
Warning Labels (Decals)........................................................................ 19
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Safety
Operation Manual - SP 305
16 8/4/11
SAFETY
The information contained in this section of the
operation manual is absolutely necessary for the safe
setup, operation, maintenance, and servicing of your
concrete pump and placing boom.
The Safety Manual is a separate document from the
rest of this manual. Because it is a separate document,
the page numbering and formatting will be different
than the rest of your manual. This was done to allow
the Safety Manual to be inserted in many different
publications while appearing exactly the same in all
places. The Safety Manual has its own alphabetical
index, which is found at the end of the Safety Manual.
How to Order Additional Safety
Manuals
To place an order for additional Safety Manuals (or any
other manual), you can call our toll free parts line from
anywhere in the continental United States except
Minnesota, where you must use the main Schwing
office number. Schwing Spare Parts Department hours
are Monday through Friday, 6:00 AM - 9:00 PM
(Central Time). Orders will also be accepted via fax, 24
hours/day.
We will ship one set of each of the following manuals
free of charge for each unit that is listed with its serial
number and current location:
Safety Manual, English: 30327535
Safety Manual, Spanish: 30381024
Co-worker Safety Rules, laminated, English: 30381022
Co-worker Safety Rules, laminated, Spanish:
30381027
Co-worker Safety Rules, paper, English: 30381023
Co-worker Safety Rules, paper, Spanish: 30381028
Small line Safety Manual, English: 30381680
Small line Safety Manual, Spanish: 30381841
Schwing phone numbers
Spare Parts (Small line)(800) 237 - 8960
Spare Parts(800) 328 - 9635
Spare Parts (fax)(651) 429 - 2112
Spare Parts (toll free fax)(877) 554 - 5119
In Minnesota,
or outside of continental U.S.(651) 429 - 0999
NOTE!
To order manuals, copy the order form
shown on page 18, and Fax it to Schwing at
one of the above numbers, or mail it to:
Schwing Spare Parts Department
5900 Centerville Rd
St. Paul, MN, 55127
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Safety
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Operation Manual - SP 305
October 27, 2008
safemanbulletinletter.fm
Safety/Service Bulletin 1023-08
Subject: Release of Safety Manual version 6.x.1
Dear Schwing Customer,
The Safety Manual has been updated to version 6.0.1 and has several changes most of which
pertain to the more common incidents currently being reported in the concrete pumping industry
(hose whipping, tip overs and electrocution). One notable pagination change occurred. The
pipewall thickness chart, which has always appeared on page 73 of the Safety Manual, has been
pushed back to page 75. In the past, releases such as this would include the complete paperback
manual and a non-laminated version of the updated Co-worker Safety Rules. In an effort to “Go
Green” we have decided to ship a CD containing six PDF files: Version 6.0.1 of Safety Manual
(English & Spanish); version 6.0.1 of the Co-worker Safety Manual (English & Spanish); and
version 6.0.1 of the Line Pump Safety Manual (English & Spanish). This package, as in the past,
also includes an order form for hard copies of any of those documents. Just fill out the attached
form(s) and fax it to us at the number listed. We will ship one of each manual ordered free of
charge for each unit that is listed with its serial number (including line pump units if you want that
manual) and current location. Additional manuals are available at a nominal fee. The Co-worker
Safety Rules are available as laminated books intended to be kept on the pump for easy reference.
Please instruct your operators to make the co-worker information available to the placing crew
and laborers and to read the information to the workers if they believe the workers would not
understand the printed text. If you are planning any safety training for your customers, the Co-
worker Safety Rules booklet is also available in a non-laminated version at a fraction of the cost. If
you choose to order the un-laminated version, the part numbers are 30381023 for English and
30381028 for Spanish. You could also print them yourself from the file on the enclosed disc. Of
course, the non-laminated version is not intended to be kept on the pump. It is our objective to get
a copy of each of these publications into the hands of every operator and the workers around the
pump. Please help us make the Safety Manual effective for jobsite safety by obtaining a copy for
each of your operators and encourage them to read and understand the rules. Older versions of the
manual should be discarded when the new version is in hand.
Thank you in advance for your consideration in this matter.
Best Regards,
Danny L. Mace
Manager, Product Safety Department
Schwing America, Inc.
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Safety
Operation Manual - SP 305
18 8/4/11
1
page 2 of 2 safemanbulletinletter.fm
Safety Manual v 6.0.1 Order Form
Fax # (651) 429 - 8261
(publications dept.)
Please complete this form and mail to:
Or send via fax to:
5900 Centerville Road
White Bear, Mn. 55127
Telephone [phone]
Attention: Publications
Feel free to copy or otherwise reproduce this form if more copies are needed.
Company:
Street Address:
City, State, Zip:
Attention: Phone ( )
We cannot ship manuals to a P.O. box
Safety Manual, Bound, English v 6.0.1 .................................................................................. Part #30327535
Safety Manual, Bound, Spanish v 6.1.1 .................................................................................. Part #30381024
Co-worker, Bound & Laminated, English v 6.0.1 .................................................................... Part #30352799
Co-worker, Bound & Laminated, Spanish v 6.1.1 .................................................................. Part #30381027
Line Pump, Bound, English v 6.0.1 ......................................................................................... Part #30381680
Line Pump, Bound, Spanish v 6.1.1 ....................................................................................... Part #30381841
Model number:
Serial number:
Model number:
Serial number:
Model number:
Serial number:
Model number:
Serial number:
Model number:
Serial number:
internal250:servicebulletins:601order form.ai
Manual part number:____________________
Manual part number:____________________
Manual part number:____________________
Manual part number:____________________
Manual part number:____________________
Manual part number:____________________
Manual part number:____________________
Manual part number:____________________
Manual part number:____________________
Manual part number:____________________
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Operation Manual - SP 305
Warning Labels (Decals)
Each machine is equipped with a set of warning labels
specific to the model, boom style and installed options.
Safety decals MUST be replaced if they are damaged,
faded, missing, or unreadable for any reason.
Ultraviolet radiation, rain, steam cleaning, and other
factors cause these labels to fade in time. Sets include
outrigger load labels, but they do not include metal
plates, which can be ordered separately. For installation
locations, see the decal location guide insert found in
the Appendix section of this manual. To get
replacement labels, identify which label(s) you need
from the diagrams and lists, get the serial number of
the unit from the serial number plate, and call the
Schwing America Call Center at 888- Schwing (724-
9464). The person taking the order will make a note of
the serial number of the unit for our files and send you
the labels you need. You may order complete sets or
single labels. If the serial number plate is missing or
unreadable, the number is stamped into the subframe
just below the normal location of the serial number
plate.
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Safety
Operation Manual - SP 305
20 8/4/11
NOTES
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