Schwing ROCK Setup guide

SERVICE REPAIR INSTRUCTIONS FOR
THE "ROCK" VALVE
DOCUMENT #799000 5900 Centerville Road
St.Paul, MN 55127
Tel [phone]
Fax [phone]
www.schwing.com
REV. 10/23/07

d

TABLE OF CONTENTS
Safety Instruction .....................................................................................................................................1
Rock Valve Parts Identification - “M” Rock ...........................................................................................2
Rock Valve Parts Identification - “E” Rock ............................................................................................3
Rock Valve Parts Identification - “B” Rock ............................................................................................4
Rock Valve Lubrication Points ................................................................................................................5
Rotating The Cutting Ring .......................................................................................................................6
Replacing the Cutting Ring ......................................................................................................................8
Pressure Spring ......................................................................................................................................10
Tension Nut ............................................................................................................................................10
Determining Wear on Kidney Seal and Kidney Plate ...........................................................................11
Replacing the Kidney Seal .....................................................................................................................12
Spectacle Plate .......................................................................................................................................16
Replacement of Spectacle Plate .............................................................................................................17
Replacement of Outlet Housing Lining (Kidney Plate) Plate ................................................................19
Replacement of Outlet Insert (Cover Lining) ........................................................................................21
Rock Valve Body ...................................................................................................................................22
Pivot Shaft ..............................................................................................................................................23
Pivot Shaft Bushing ...............................................................................................................................26
Setting Pivot Angles ..............................................................................................................................29
Replacement of Pivot Shaft Bushings ....................................................................................................30
Additional Mounting Instructions for E-Rock Assembly ......................................................................33
Rock Slewing Cylinder ..........................................................................................................................36
Rock Valve with Insert - Conversion .....................................................................................................38

TABLE OF CONTENTS

Service Manual
SERVICE TRAINING
Rock Valve
1
Rock Valve
Safety Instruction
When performing maintenance on Schwing Equipment, the safety regulations must be followed. The observation
of these regulations is the responsibility of the maintenance personnel. The following are some supplementary
recommendations.
1. WARNING! Read and understand the operation manual of the machine before attempting any repairs. If in
doubt, call the manufacturer. Incorrectly done repairs endanger operational safety of the machine.
2. WARNING! Burning hazard! Never work on a hydraulic system with hot oil.
3. WARNING! Falling hazard! If you cannot work at ground level, you must use a suitable work platform.
4. WARNING! If maintenance work requires that you use a crane, hoist, fork truck, etc., you must read and
understand the safety regulations for that equipment.
5. WARNING! If working the machine requires that it be operated, and you are not qualified as an operator, you
must get someone who is qualified to assist you.
6. WARNING! If you will be working in a hidden area inside the machine, protect yourself by taking the key
from the ignition and putting a “DO NOT OPERATE” sign on the controls. In the case of electrically driven
units, disconnect the main circuit breaker and lock it in the disconnected position.
7. WARNING! Never activate the system hydraulics without checking if another workman is in a hidden
position. Always yell “CLEAR”, and allow time for response, before starting the prime mover.
8. WARNING! Never use gasoline or diesel fuel as a cleaning solvent. This is critical to remember when
cleaning hydraulic oil reservoirs, because gas and diesel fuels are highly explosive, and gasoline or diesel fuel
traces left in the oil may ignite when compressed.
9. WARNING! Always use the correct tools for the job. Tools should be kept clean, and in good condition.
10. If you see a co-worker engaging in an unsafe practice, explain the dangers. Safety is always in the hands of
those on the job.
11. WARNING! Never work on a pressurized hydraulic system. Stop the prime mover and relieve the accumulator
circuit (if so equipped) before you open the hydraulic system.
WARNING
READ FIRST!

Service Manual
SERVICE TRAINING
Rock Valve
2
Rock Valve Parts Identification - “M” Rock
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Service Manual
SERVICE TRAINING
Rock Valve
3
Rock Valve Parts Identification - “E” Rock
Pivot Lever
Cover Bolt
Cover
Slewing Lever
Bearing Bushing
Bearing Bushing
Sealing
Cover
Cover
Pivot Bushing
Wearing
Plate
Plate
Wearing
Insert
(Left Hand)
Wearing
Insert
(Right Hand)
Pivot Bushing
"E" Rock Valve
Housing
Cutting
Ring
"E" Rock Valve
Kidney Seal
Setting Disc
Tension Nut
Bearing
Bushing
Pivot
Shaft
Keeper
Bolt
End Cover
Bolt
End Cover
Pressure
Spring
Support
Ring
Outlet Side Housing Lining
(Kidney Plate)
"E" Rock
Extension
Spectacle
Plate

Service Manual
SERVICE TRAINING
Rock Valve
4
Rock Valve Parts Identification - “B” Rock
Pivot Lever
Cover Bolt
Cover
Slewing Lever
Bearing Bushing
Bearing Bushing
Sealing
Cover
Cover
Pivot Bushing
Wearing
Plate
Plate
Wearing
Insert
(Left Hand)
Wearing
Insert
(Right Hand)
Pivot Bushing
"B" Rock Valve
Housing
Cutting
Ring
"B" Rock Valve
Kidney Seal
Setting Disc
Tension Nut
Bearing
Bushing
Pivot Shaft
Keeper
Bolt
End Cover Bolt
End Cover
Pressure
Spring
Outlet Side
Housing Lining
(Kidney Plate)
Spectacle
Plate

SERVICE TRAINING
Service Manual 5
Rock Valve
zerks.epsL
Grease Zerk #1,2,3,4
Grease Zerk #5
Grease Zerk #6
Grease Zerk #7
Grease Zerk #8
Rock Valve Lubrication
Points
If your unit is not equipped with an auto-lube,
grease your agitator bearings. There is one zerk
on each side of the hopper. Grease every 200 or
300 yards, as the pour allows.
Grease your agitator bearings. There is one zerk
on each side of the hopper. Re-grease every two
or three hundred yards, as the pour allows.
NOTE! You don’t grease agitator bearings like
you grease most other bearings. That is, if you
normally pump in grease until you see it squirt-
ing out somewhere, you will ruin your agitator
seals. When you grease the agitator bearings,
watch the rubber grease cones that are located
inside the hopper. You want the cones to bulge
out slightly because they are full of grease, but
you don’t want to have the grease come out
around the shaft, because where the grease
comes out concrete will be able to go in. Once
concrete makes it inside of the grease cone, you
will quickly wear out the bearings. When re-
greasing after the hopper is full of concrete and
you can no longer see the cones, just give the
zerks a couple of squirts. This is one of the few
times when it is better to under grease than to
over grease.
Grease the rock valve lubrication points before
the pour begins. Once you start pumping, grease
them every couple of hours. There are six zerks
to grease for the rock valve, plus the two for the
agitator.
If your unit is equipped with an auto-lube, greas-
ing is accomplished automatically. The grease
timers in the cab must be adjusted to assure
proper grease flow from each feeder. Check with
SAI’s Service Department for timer adjustment
instructions. The timers are usually mounted on
the top of the doghouse between the seats.

SERVICE TRAINING
Service Manual
6
Rock Valve
M
E
M
B
E
R
A
M
E
R
I
C
A
N
C
O
N
C
R
E
T
E
P
U
M
P
I
N
G
A
S
S
O
C
I
A
T
I
O
N
Stayclear.
Contactwill result in
deathorseriousinjuryif
theunitbecomes
electrically charged.
Thismachine is
remotecontrolledand
may startatany time.
Stop enginebefore
servicingunit.
Keephandsout
ofhopper and
valveassembly.
Seeoperation
manual if access
is required.
Tapered bend
Cover bolts
Spacer
Keeper Bolt
Tension Nut w/Wrench flats
Wedge
6 inch clamp
Rotate the Cutting Ring 90˚ clockwise
Rotating The Cutting Ring
1. First, shut off the truck engine and put the
key in your pocket.
2. Remove the 6-inch clamp between the
tapered bend and the 6-inch elbow.
3. Remove the wedge from the tapered bend,
and pull the tapered bend away from the 6-
inch clamp.
4. Loosen the tension nut as explained previ-
ously.
5. Loosen the seven cover bolts two or three
full turns, but do not remove the bolts.
6. Push forward on the end of the rock valve
slewing cylinder. Because it has a single
pivot point, it will push the rock valve back-
wards toward the loosened cover. If you meet
resistance, do not force it. After you have
removed the hopper grate, you can gently
pry the rock valve backward from inside the
hopper.
7. Remove the hopper grate.
8. From inside the hopper, tap the cutting ring
forward, toward the spectacle plate. The ring
should pop loose. If it doesn’t, loosen the
cover bolts a little more, then gently pry the
rock valve rearward a little more until it
does. Rotate the ring 90 ° clockwise. (It
doesn’t really matter which way you rotate,
but to keep from forgetting which way you
went last time, Schwing recommends going
clockwise each time.)
9. Be sure that the ring is centered in the rock
valve. Tighten the cover bolts slightly, if
needed, to be sure that the ring isn’t cocked
one way or the other.
WARNING
Never rotate the cutting ring without
disabling the unit’s hydraulic system.
Amputation hazard!

SERVICE TRAINING
Service Manual 7
Rock Valve
M
E
M
B
E
R
A
M
E
R
I
C
A
N
C
O
N
C
R
E
T
E
P
U
M
P
I
N
G
A
S
S
O
C
I
A
T
I
O
N
Stayclear.
Contactwill result in
deathorseriousinjuryif
theunitbecomes
electrically charged.
Thismachine is
remotecontrolledand
may startatanytime.
Stop enginebefore
servicingunit.
Keephandsout
ofhopper and
valveassembly.
Seeoperation
manual if access
is required.
Tapered bend
Cover bolts
Spacer
Keeper Bolt
Tension Nut w/Wrench flats
Wedge
6 inch clamp
10. Be sure there is no debris between the back
cover and the rock valve housing. If there is,
clean it out. Tighten the cover bolts just
enough to bring the back plate up against the
rock housing. Then tighten each bolt equally,
using a torque wrench. Alternate which bolts
you tighten, as you would when tightening a
wheel on a car. The torque specification for
these bolts (M24 x 60, 8.8 hardness) is 485
ft./lb. Replace the bolts once per year.
11. Position the hopper grate over the hopper.
Bolt it into place.
12. Tighten the tension nut. Tighten the keeper
bolt.
13. Push the tapered bend closed and install the
wedge. Remember to install the hairpin.
14. Install the 6-inch clamps and the hairpin.

SERVICE TRAINING
Service Manual
8
Rock Valve
Replacing the Cutting Ring
1. Loosen the bolt on the Pivot Lever a few
turns with a 30 mm wrench.
2. Remove the Housing End Cover Bolts with a
36 mm. wrench.

SERVICE TRAINING
Service Manual 9
Rock Valve
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 
 
 
3. Pry the End Cover away from the housing as
far as the Pivot Lever will allow.
4. Remove the Cutting Ring, and replace it with
the new part.
5. When reassembling, make sure that the Cut-
ting Ring fits correctly and that the Pressure
Spring is in full contact with the face of the
Cutting Ring. Reassembly is opposite to the
procedure above.

SERVICE TRAINING
Service Manual
10
Rock Valve
Inlet Housing Lining
Cutting Ring
Cutting Ring
A
Rock Valve
Rock Valve
Pressure Spring
Pressure Spring
Tension Nut
Keeper Bolt
Pressure Spring
If the Pressure Spring has to be replaced, dis-
mantle the old spring and clean the vacant area
thoroughly to clear it of cement dust, etc. If dust
and residue are ignored, the new spring cannot
be installed correctly, and the flow of concrete
can pull it out of the groove. Furthermore, the
high pretension leads to premature wear of the
Cutting Ring and Housing Lining.
NOTE: Slightly grease the new Pressure
Spring when installing it. The same applies to
the Kidney Seal. Do not use too much grease,
because grease accumulating in the spring
chamber operates as a spacer, and the conse-
quently increased spring pretension can lead
to the same damages as described above.
Tension Nut
Do not use the Tension Nut to adjust the position
of the Cutting Ring. Excessive wear of the Inlet
Housing Lining, Cutting Ring, Pressure Spring,
and Kidney Seal would result.
The Tension Nut adjusts the Kidney Seal area of
the Rock Valve ONLY. To check or adjust,
remove the Keeper Bolt will line up with a
threaded hole in the Setting Disc. If you are
between two holes, loosen the Tension Nut so it
lines up with the previous hole. Do not use a
wrench to tighten. The flat sides of the Tension
Nut are to loosen the nut only. Please call the
Schwing Service Department if you have any
questions.

SERVICE TRAINING
Service Manual 11
Rock Valve
(2) - Pressure Relief Grooves
(1) - Lip
Spring compressed
(Installed)
Spring uncompressed
d
mm
M
Figure 1
Figure 3
Aggregate Particle
Figure 2
DeterminingWear on Kidney
Seal and Kidney Plate
Replace the kidney seal if any of the following
conditions exist:
• The seal is swollen due to use of aggressive
or harsh cleaning agents. (See Service bulle-
tin G-113-84, dated July 18, 1984)
• A considerable formation of cracks are
found in the areas marked by arrows. (fig. 1)
This problem is very rare.
• Lip (Item 1, fig. 1) is completely worn to the
point that the pressure relief grooves (Items
2, fig. 1) are no longer recognizable.
• The distance indicated by “M” of the Kidney
Seal (when force is relieved) does not exceed
30mm (1 3/16”).
Replace the Housing Lining-Oulet Side (Kidney
Plate) only if scores deeper than 2.5mm are
found, in the area that contacts the Kidney Seal.
You can measure this by placing a steel ruler
across the kidney Plate in several places, and
using a depth gauge to determine the gap.
NOTE: Outside of the area that contacts the
Kidney Seal, you may detect scores that are
due to aggregate particles stuck between the
Rock Valve and the Kidney Plate. (See fig. 2
and fig. 3) These scores will not affect the
operation of thr Rock Valve.
Under no circumstances should you allow the
Kidney Seal to be run with a dry hopper. This
will destroy the Kidney Seal, and is the primary
cause of premature wear encountered at the out-
let side of the Rock Valve.
If you will be repairing the Rock, or trouble-
shooting a problem, always fill the hopper with
water to the top of the Rock Valve before switch-
ing.

SERVICE TRAINING
Service Manual
12
Rock Valve
 
 
Replacing the Kidney Seal
Kidney Seal
1. Remove the Keeper Bolt from the Tension
Nut using a 24 mm wrench.
2. Remove the Tension Nut using a 60 mm.
wrench.

SERVICE TRAINING
Service Manual 13
Rock Valve
 
Guide Rod
End Plate
3. Remove the Setting Disc from the Rock
pivot shaft.
4. Remove the bolts from the End Cover and
insert the two Guide/Support Rods into the
upper holes using a 36 mm. wrench.

SERVICE TRAINING
Service Manual
14
Rock Valve
Kidney Seal
 
5. Slide the End Cover along the inserted
Guide/Support Rods.
6. Remove the Kidney Seal with a screw driver
or similar tool.
7. Clean the Kidney Seal groove of the Rock
Valve thoroughly.
8. Replace the Kidney Seal while making sure
that the flat surface is toward the End Cover.
9. Push the End Cover back into place and
replace the bolts. Clean away any debris that
would prevent the cover from sitting flat.
10. Replace the Setting Disc onto the square por-
tion of the Rock Pivot Shaft.

SERVICE TRAINING
Service Manual 15
Rock Valve
1.5 to 2.0mm
Kidney Plate
Rock
 
11. Replace the Tension Nut onto the Rock Pivot
Shaft, and tighten it by hand. In this position,
the clearance between the Rock Valve and
the housing should be 1.5 to 2.0 mm.
NOTE: If either the Spectacle Plate or the
Cutting Ring are not replaced at the same
time as the Kidney Seal, the clearance will be
greater and can be adjusted by further tight-
ening of the Tension Nut to the next Setting
Disc hole only.
12. Replace the Keeper Bolt.
13. IMPORTANT! At no time should the Rock
Valve be operated without first lubricating
the outlet wear plate. Usually, spraying the
plate with water or oil prior to start-up will
be adequate. Moving the kidney seal against
a dry plate will cause excessive wear to the
seal and will lead to premature failure. If
switching the Rock Valve is necessary for
shop work (adjusting, inspecting, etc.), you
must take the necessary precautions and
ensure that the plate and seal are properly
lubricated.

SERVICE TRAINING
Service Manual
16
Rock Valve
Friction
Friction
Friction and
stone crushing
Friction and
stone crushing
Housing Lining
Cutting Ring
max 1.5mm
0.590"
max 1.5mm
0.590"
Cutting Ring
Housing Lining
Spectacle Plate
Lengthening the Service Life
The amount of wear on the Housing Lining and
the Cutting Ring will vary, and it will affect the
length of time they can safely be used. The
condition of each part depends on outside
influences that affect them daily, including
varying concrete mixes and changing weather
conditions. The Cutting Ring and Housing
Lining cannot be expected to wear equally and
will need to be replaced accordingly.
NOTE: The grooves in the Base Plate (Specta-
cle Plate) resulting from basic operation are
irrelevant as long as the hard facing is in good
working condition.
To assist in achieving uniform wear and, thus,
considerably longer service lives, we
recommend:
1. Moving the Rock Valve to the left and right
end positions once a week--after thorough
cleaning--and checking the condition of the
cutting ring & housing lining.
2. Turning the Cutting Ring 90 degrees if there
is a visible space between the Cutting Ring
and the Housing Lining that is greater than
1.0-1.5 mm. (.0393”-.0590”). Check for this
gap at several points along the circumfer-
ence. Instructions for cutting ring can be
found on page 6 of this document.