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Schwing Rock Valve User manual

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Line Pump Division
5900 Centerville Rd
White Bear, MN. 55127
1-888-SCHWING (724-9464)
www.schwing.com
OPERATION MANUAL
FOR CONCRETE LINE PUMPS
All SP “Rock Valve” Models
Part Number 30100750
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Revision date
01/10
Version
2.0.1
OPERATION MANUAL FOR
ALL SP ÒROCK VALVE ”MODELS
Part Number 30100750
Version 2.0.1
Copyright © 2010, Schwing
All rightsreserved
swg99a001.eps
Table of Contents
Operation Manual - Line pumpsiv
revDate
Introduction
Manufacturer’s Statement......................................................................... 10
Safety alert symbol and signal word explanation ............................... 10
How to reach us .................................................................................. 11
How to order parts .............................................................................. 11
Model Number:......................................................................................... 11
Serial Number:.......................................................................................... 11
ID Tag Location........................................................................................ 12
ID Tag ....................................................................................................... 13
If your ID tag is missing ..................................................................... 13
Specifications
Concrete Pump Specifications .................................................................. 16
Hydraulic Pressure Specifications ............................................................ 19
Safety
How to Order Additional Safety Manuals ................................................ 22
Product Overview
First Commissioning................................................................................. 26
Installation of your new unit............................................................... 26
Machine Description................................................................................. 27
Emergency Stop switches ................................................................... 27
Concrete pump hydraulic pumps ........................................................ 28
Concrete Pump Circuit........................................................................ 28
BPA Circuit Diagrams .............................................................................. 32
Phase A ............................................................................................... 32
Phase B ..................................................................................................... 34
Phase C ..................................................................................................... 36
Phase D ..................................................................................................... 38
Phase E...................................................................................................... 40
WP Circuit Diagram ................................................................................. 42
Phase A ............................................................................................... 42
Phase B ..................................................................................................... 44
Phase C ..................................................................................................... 46
Phase D ..................................................................................................... 48
BPA 2000 Circuit Diagram....................................................................... 50
Phase A ............................................................................................... 50
Phase B ..................................................................................................... 52
Phase C ..................................................................................................... 54
Phase D ..................................................................................................... 56
Phase E...................................................................................................... 58
Phase F...................................................................................................... 60
Phase G ..................................................................................................... 62
Phase H ..................................................................................................... 64
Table of Contents
Line pumps
Startup 250:Users:Danny:Desktop:Operation manuals:small line:All SP Rock Valve models:Frame
files:AllSPRockvalveTOC2
Operation Manual - v
Phase I....................................................................................................... 66
Phase J....................................................................................................... 68
Phase K ..................................................................................................... 70
Component Locations ............................................................................... 72
Right Side Components ...................................................................... 72
Towing End......................................................................................... 76
Left Side.............................................................................................. 79
Hopper Area........................................................................................ 87
Safety Devices .......................................................................................... 90
Emergency Stop Switches................................................................... 90
Automatic Shut-off Circuit Agitator................................................... 90
Safety Valves (Pressure relief valves) ................................................ 90
Safety Guards...................................................................................... 90
Fuses ................................................................................................... 90
Warning Labels................................................................................... 91
Operation
Preparation ................................................................................................ 98
Arrive to work on time, with a clear head. ......................................... 98
Have the right machine for the job. .................................................... 98
Have the equipment that you will need for the job............................. 98
Have the right personal protective equipment for the job................. 100
Check the equipment before leaving the yard................................... 101
Towing the unit....................................................................................... 102
Licensing........................................................................................... 102
Backing up. ....................................................................................... 102
Changing lanes.................................................................................. 102
Loading the unit for shipment........................................................... 102
Unit Set-Up ............................................................................................. 103
Selecting the proper set up location on the job site. ......................... 103
Laying out the pipeline ..................................................................... 103
Setting the Stabilizers ....................................................................... 103
Operating the Pump ................................................................................ 104
Basic Troubleshooting ...................................................................... 104
Before the first truck backs up to your hopper ................................. 104
Lubricate your pipeline..................................................................... 108
To control the speed of the unit ........................................................ 110
Pump the job ..................................................................................... 111
Time Constraints............................................................................... 112
To disable the entire unit in an emergency ....................................... 113
Delays ............................................................................................... 113
Keep the waterbox full...................................................................... 113
Use of the vibrator ............................................................................ 113
Blockages.......................................................................................... 114
Clean-out........................................................................................... 114
Clean the hopper ............................................................................... 115
Table of Contents
Operation Manual - Line pumpsvi
revDate
Clean the rock valve and material cylinders..................................... 119
Be careful with acid .......................................................................... 120
Clean the waterbox ........................................................................... 121
Preparation for travel ........................................................................ 122
Special Pumping Situations .................................................................... 122
Rod side to piston side pumping (BPA 2000) .................................. 122
Quick Clean-out................................................................................ 123
Cold weather pumping...................................................................... 123
Preheating the hydraulic oil .............................................................. 124
Maintenance
Filtration.................................................................................................. 126
General Information.......................................................................... 126
Specific Information ......................................................................... 126
Hydraulic Oils......................................................................................... 128
General Information.......................................................................... 128
Specific Information ......................................................................... 128
Pressure, Hoses and Fittings ................................................................... 128
General Information.......................................................................... 128
Specific Information ......................................................................... 129
General Maintenance Tips ...................................................................... 130
Torque Specifications ....................................................................... 130
Adjusting relief valves. ..................................................................... 130
Removal of safety devices. ............................................................... 130
Preventative Maintenance....................................................................... 131
Daily Maintenance............................................................................ 131
Weekly Maintenance ........................................................................ 132
Monthly maintenance ....................................................................... 133
Quarterly Maintenance ..................................................................... 136
Semiannual maintenance .................................................................. 136
Annual maintenance ......................................................................... 140
Scheduled maintenance checklist ........................................................... 141
Unscheduled maintenance ...................................................................... 142
Changing rams .................................................................................. 142
Appendix
Hydraulic Oil Viscosity Chart ................................................................ 150
Torque Specifications for Metric Bolts .................................................. 151
Recommended Emergency Hose Kit...................................................... 152
Fitting Wrench Sizes............................................................................... 153
Straight Fittings................................................................................. 153
Banjo Fittings.................................................................................... 153
Maintenance checklist............................................................................. 154
Output charts........................................................................................... 155
Using the chart. ................................................................................. 156
Nomograph ............................................................................................. 161
Table of Contents
Line pumps
Startup 250:Users:Danny:Desktop:Operation manuals:small line:All SP Rock Valve models:Frame
files:AllSPRockvalveTOC2
Operation Manual - vii
Using a Nomograph .......................................................................... 161
Weld On Ends / Coupling Comparison .................................................. 169
MInimum Pipe Wall Thickness .............................................................. 170
Decal Location Guides............................................................................ 171
BPA 450 and 500 units ..................................................................... 171
BPA 450 and 500 units (continued).................................................. 172
WP 750 and 1000 units..................................................................... 173
WP 750 and 1000 units (continued).................................................. 174
BPA 2000 units................................................................................. 175
BPA 2000 units (continued).............................................................. 176
Glossary of Terms................................................................................... 178
Additional Reading Material................................................................... 183
List of Lubricants and Nitrogen.............................................................. 184
Hydraulic Schematics ............................................................................. 188
HBV 160/260.......................................................................................... 188
Hydraulic Schematics - continued - BPA 450 ........................................ 189
Hydraulic Schematics - continued - BPA 500 ........................................ 190
Hydraulic Schematics - continued - BPA 2000 ...................................... 191
Electric Schematics................................................................................. 192
BPA 450/500........................................................................................... 192
WP FWD/REV w/FWD VIBRATOR .................................................... 193
Electric Schematics BPA 2000 ............................................................... 194
Electric Schematics WPT 50/70/95 ........................................................ 195
Electric Schematics WPT 50/70/95 - continued ..................................... 196
Electric Schematic SP 1000X ................................................................. 197
Electric Schematics SP 1000 X - continued (ECM wiring diagram)...... 198
Nomographs............................................................................................ 199
SP 450 ..................................................................................................... 199
Nomographs - continued - SP 500.......................................................... 200
Nomographs - continued - SP 750 - 15................................................... 201
Nomographs - continued - SP 750 -18.................................................... 202
Nomographs - continued - SP 1000 - 18................................................. 203
Nomographs - continued - WPT 95........................................................ 204
Nomographs - continued - BPA 2000..................................................... 205
Output Charts.......................................................................................... 206
SP 450 ..................................................................................................... 206
Output Charts SP 500.............................................................................. 207
Output Charts SP 750 -15 ....................................................................... 208
Output Charts SP 750 -18 ....................................................................... 209
Output Charts SP 1000............................................................................ 210
Output Charts SP 1000............................................................................ 212
Output Charts SP 1000XHP.................................................................... 213
Table of Contents
Operation Manual - Line pumpsviii
revDate
Introduction
Line pumps
Startup 250:Users:Danny:Desktop:Operation manuals:small line:All SP Rock Valve
models:Frame files:Intro.fm
Operation Manual - 9
INTRODUCTION
Manufacturer’sStatement....................................................................... 10
ID Tag Location ........................................................................................ 12
ID Tag....................................................................................................... 13
swg99a001.eps
Introduction
Operation Manual - Line pumps10
revDate
Introduction
This operation manual contains unit specifications,
product overview information, the safety manual,
operation information, and maintenance information
for your concrete pump unit.
Manufacturer’sStatement
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.
WARNING
Improper setup / operation creates
hazards. Do not operate thismachine
without training. Understand the
warningsin safety manualsand on
decals.
000099.eps
Danger
Warning
Caution