SCHWING CONCRETE PUMP MANUALS

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SCHWING CONCRETE PUMP MANUALS

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Home TOC Print OPERATION MANUAL ORIGINAL INSTRUCTIONS FOR CONCRETE LINE PUMPS All SP “Rock Valve” Models Part Number 30100750 Line Pump Division 5900 Centerville Rd White Bear, MN 55127 1-888-SCHWING (724-9464) www.schwing.com Home TOC Print 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 Version 3.0.8 Revision date 05/14 Home TOC Print ORIGINAL OPERATING INSTRUCTIONS FOR ALL SP ÒROCK VALVE ” MODELS swg99a001.eps Part Number 30100750 Version 3.0.8 Copyright © 2014, Schwing All rights reserved Home TOC Print Table of Contents Introduction Manufacturer’s Statement Safety alert symbol and signal word explanation How to reach us How to order parts Model Number: Serial Number: ID Tag Location 10 ID Tag 11 If your ID tag is missing 11 Specifications Unit Specifications 14 Hydraulic Pressure Specifications 16 Concrete Pump bar (PSI) 16 Noise emission levels Decibels 16 Safety How to Order Additional Safety Manuals 18 Product Overview First Commissioning 22 Installation of your new unit 22 Machine Description 23 Emergency Stop switches 23 Concrete pump hydraulic pumps 24 Concrete Pump Circuit 24 SP Circuit Diagram 28 Phase A 28 Phase B 30 Phase C 32 Phase D 34 SP 2000 Circuit Diagram 36 Phase A 36 Phase B 38 Phase C 40 Phase D 42 Phase E 44 Phase F 46 Phase G 48 Phase H 50 Phase I 52 Phase J 54 Phase K 56 Component Locations 58 Hopper Area 63 iv Operation Manual - All SP Rock Valve models revDate Home TOC Print Table of Contents Safety Devices Emergency Stop Switches Automatic Shut-off Circuit Agitator Safety Valves (Pressure relief valves) Safety Guards Fuses Warning Labels 66 66 66 66 66 66 67 Operation Preparation Arrive to work on time, with a clear head Have the right machine for the job Have the equipment that you will need for the job Have the right personal protective equipment for the job Check the equipment before leaving the yard Towing the unit Licensing Backing up Changing lanes Loading the unit for shipment Unit Setup Selecting the proper set up location on the job site Laying out the pipeline Setting the Stabilizers Operating the Pump Basic Troubleshooting Before the first truck backs up to your hopper Lubricate your pipeline To control the speed of the unit Pump the job Time Constraints To disable the entire unit in an emergency Delays Keep the waterbox full Use of the vibrator Blockages Clean-out Disposing of excess concrete Clean the hopper Clean the rock valve and material cylinders Be careful with acid Clean the waterbox Preparation for travel Special Pumping Situations Rod side to piston side pumping (SP 2000) Quick Clean-out Cold weather pumping Preheating the hydraulic oil Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame files:AllSPRockvalveTOC.fm Operation Manual - All SP Rock Valve models 70 70 70 70 72 73 74 74 74 74 74 75 75 75 76 76 77 78 81 83 84 85 86 86 86 86 87 87 88 88 92 93 94 95 95 95 96 96 97 v Home TOC Print Table of Contents Maintenance Filtration 100 General Information 100 Specific Information 100 Hydraulic Oils 102 General Information 102 Specific information 102 Pressure, Hoses and Fittings 102 General Information 102 Specific Information 103 General Maintenance Tips 104 Torque Specifications 104 Adjusting relief valves 104 Removal of safety devices 104 Preventative Maintenance 105 Daily Maintenance 105 Weekly Maintenance 106 Monthly maintenance 107 Quarterly Maintenance 109 Semiannual maintenance 110 Annual maintenance 114 Scheduled maintenance checklist 115 Unscheduled maintenance 116 Inspecting hydraulic hoses 116 Changing rams 116 Preparation for long term storage 116 Restarting unit after long term storage 116 Tier IV engine Regeneration Control Logic 121 Regeneration Monitoring and Warning Levels 122 Appendix Hydraulic Oil Viscosity Chart 126 Torque Specifications for Metric Bolts 127 Recommended Emergency Hose Kit 128 Fitting Wrench Sizes 129 Straight Fittings 129 Banjo Fittings 129 Maintenance checklist 130 Output charts 131 Using the chart 132 Nomograph 137 Using a Nomograph 137 Weld On Ends / Coupling Comparison 145 MInimum Pipe Wall Thickness 146 Glossary of Terms 147 Additional Reading Material 152 List of Lubricants and Nitrogen 153 vi Operation Manual - All SP Rock Valve models revDate Home TOC Print Table of Contents End of Life Protocol 156 Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame files:AllSPRockvalveTOC.fm Operation Manual - All SP Rock Valve models vii Home TOC Print Table of Contents viii Operation Manual - All SP Rock Valve models revDate Home TOC Print Introduction swg99a001.eps INTRODUCTION Manufacturer’s Statement Model Number: Serial Number: ID Tag Location 10 ID Tag 11 Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:All SP Rock Valve models:Frame files:Intro.fm Operation Manual - All SP Rock Valve Models Home TOC Print Introduction Introduction This operation manual contains unit specifications, product overview information, the safety manual, operation information, and maintenance information for your concrete pump unit 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: Manufacturer’s Statement WARNING Danger 000099.eps Improper setup / operation creates hazards Do not operate this machine without training Understand the warnings in safety manuals and on decals Technical modifications that are made to units will be documented in each new edition of the operation manual 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 Warning Caution • • • • 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 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 Operation Manual - All SP Rock Valve Models revDate Home Print Fittings Book Hose 25 Material Description End End Degree Part # Hydraulic hose 25bar DN 25 x 4600 STR STR 98324080 Hydraulic hose 25bar DN 25 x 4800 STR 90° 98324048 Hydraulic hose 25bar DN 25 x 5200 STR STR 98359798 HOSE DN 25 X X 550 Hydraulic hose 25bar DN 25 x 5800 10011159 STR STR Hydraulic hose 350bar DN 25/4SH x 6000 Hydraulic hose 380bar DN 25/4SH x 12000 Hydraulic hose 88bar DN 25/1SC a=3.7m 98318584 10025195 STR STR 10214502 98383996 97 Home Print Home Print Fittings Book Hose 31 Material Description End End Degree Part # Hydraulic hose 45 bar DN 31/3TEx 750 STR 180° 98388283 Hydraulic hose 350bar DN 31/4SHx 1350 STR 90° 98392205 Hydraulic hose 350bar DN 31/4SHx 1500 STR 90° 98389993 99 Home Print Home Print Fittings Book Hose 32 Material Description End End Degree Part # HOSE HIGH PRESSURE DN 32 MM X 36' LG 30326096 HOSE HIGH PRESSURE DN 32 X 44' LG 30323982 HOSE HIGH PRESSURE DN 32 MM X 48' LG 30326097 Hydraulic hose 125bar DN 32/2ST x 1100 STR 90° 10160808 HOSE DN 32 X X 200 Hydraulic hose 350bar DN 32/4SHx 2200 10021822 90° STR 113° HOSE DN 32 X X 300 Hydraulic hose 350bar DN 32/4SHx 340 98393511 10027619 STR STR 98393340 HOSE DN 32 X X 400 10025092 Hydraulic hose 350 bar DN 32/4SHx   400 STR STR 98390345 Hydraulic hose 350bar DN 32/4SH x 400 STR STR 10000191 Hydraulic hose 350bars DN 32/4SH x 425 90° STR 10310017 Hydraulic hose 350bar DN 32/4SH x 450 STR STR 10200946 Hydraulic hose 350bar DN 32/4SH x 450 STR STR 98316690 Hydraulic hose 350bar DN 32/4SH x 500 STR STR 10000194 Hydraulic hose 350bar DN 32/4SH x 500 90° STR 98351546 Hydraulic hose 350bars DN 32/4SH x 550 90° 90° Hydraulic hose 125bar DN 32/2ST x 550 STR 45° 10160807 Hydraulic hose 325bar DN 32/4SH x 550 STR 45° 10197722 Hydraulic hose 325bar DN 32/4SH x 550 STR 90° 10197724 Hydraulic hose 325bar DN 32/4SH x 550 0° 90° 98344488 Hydraulic hose 350bar DN 32/4SH x 550 STR STR 10000195 Hydraulic hose 325bar DN 32/4SH x 600 STR 45° 10198913 Hydraulic hose 350bar DN 32/4SH x 600 STR STR 98355063 0° Hydraulic hose 350bars DN 32/4SH x 600 10306495 98325396 Hydraulic hose 350bar DN 32/4SH x 620 STR STR 98382857 Hydraulic hose 350bars DN 32/4SH x 620 90° 90° Hydraulic hose 325bar DN 32/4SH x 650 STR 45° 10196638 Hydraulic hose 350bar DN 32/4SH x 650 STR STR 10000197 Hydraulic hose 350bar DN 32/4SH x 660 STR STR 98328517 Hydraulic hose 350bar DN 32/4SH x 660 STR STR 98390345 0° 10306494 101 Home Print Fittings Book Hose 32 Material Description End End Degree Hydraulic hose DN 32/4 X 670 - 350 BAR Part # 30380089 Hydraulic hose 325bar DN 32/4SH x 700 STR 45° 10211137 Hydraulic hose 350bar DN 32/4SH x 700 STR STR 10000202 Hydraulic hose 350bars DN 32/4SH x 700 STR 90° Hydraulic hose 325bar DN 32/4SH x 750 STR 45° 10186988 Hydraulic hose 350bar DN 32/4SH x 750 STR STR 10000207 Hydraulic hose 350bars DN 32/4SH x 750 90° STR 98316551 Hydraulic hose 350bars DN 32/4SH x 760 90° 90° Hydraulic hose 350bar DN 32/4SH x 780 STR STR Hydraulic hose 125bar DN 32/2SN x 800 90° 90° Hydraulic hose 350bar DN 32/4SH x 800 STR STR Hydraulic hose 350bars DN 32/4SH x 800 STR 90° 90° 0° 10306496 10306456 10001128 90° 10215814 10000213 90° Hydraulic hose 350bars DN 32/4SH x 800 10306498 98325398 Hydraulic hose DN 32/4SH x 800 - MSHA + STR STR 98377763 Hydraulic hose 350bars DN 32/4SH x 820 STR 45° 98318100 Hydraulic hose 350bar DN 32/4SH x 850 STR STR 98383683 Hydraulic hose 350bar DN 32/4SH x 850 STR 90° 10215809 Hydraulic hose 350bar DN 32/4SH x 850 STR STR 98383683 Hydraulic hose 350bar DN 32/4SH x 870 STR STR 10001131 Hydraulic hose 350bars DN 32/4SH x 880 STR 90° Hydraulic hose 125bar DN 32/2SN x 900 STR 90° 10210576 Hydraulic hose 125bar DN 32/2ST x 900 STR STR 10176003 Hydraulic hose 350bar DN 32/4SH x 900 STR STR 10000217 Hydraulic hose 350bar DN 32/4SH x 900 STR 90° 10205293 Hydraulic hose 350bar DN 32/4SH x 900 45° STR 10205301 Hydraulic hose 350bar LOBA DN 32/4SH-FLH- x 900 STR STR 10036732 Hydraulic hose DN 32/4SH x 900 - MSHA + STR STR 98377764 Hydraulic hose 350bar DN 32/4SH x 920 STR 90° 10215810 Hydraulic hose 350bar DN 32/4SH x 950 STR STR 10000220 Hydraulic hose 350bar DN 32/4SH x 950 STR 90° 10215811 Hydraulic hose 350bar DN 32/4SH x 950 90° 90° 102 90° 0° 10309768 10215812 Home Print Fittings Book Hose 32 Material Description End End Degree Part # Hydraulic hose 350bars DN 32/4SH x 980 STR 90° 90° 10309769 Hydraulic hose 350bars DN 32/4SH x 990 90° 90° 210° 98316550 Hydraulic hose 350bars DN 32/4SH x 990 STR 45° 98318101 Hydraulic hose 125bar DN 32/2SN x 1000 90° STR 10205323 Hydraulic hose 155bar DN 32/2ST x 1000 STR STR 10143969 Hydraulic hose 325bar DN 32/4SH x 1000 STR 45° 10201897 Hydraulic hose 350bar DN 32/4SH x 1000 STR STR 10000226 Hydraulic hose DN 32/4SH x 1000 - MSHA + STR STR 98383467 Hydraulic hose 325bar DN 32/4SH x 1050 STR 45° 98344031 Hydraulic hose 125bar DN 32/2ST x 1100 STR STR 10165866 Hydraulic hose 325bar DN 32/4SH x 1100 STR 45° 10184096 Hydraulic hose 350bar DN 32/4SH x 1100 STR STR 10000230 Hydraulic hose 350bar DN 32/4SH x 1120 STR 90° 10215813 Hydraulic hose 350bar DN 32/4SH x 1150 STR STR 98382290 Hydraulic hose 350bar DN 32/4SHx 1150 90° STR 98292965 Hydraulic hose 125bar DN 32/2ST x 1200 STR STR 10168193 Hydraulic hose 325bar DN 32/4SH x 1200 STR 45° 10183219 Hydraulic hose DN 32/4SH x 1200 - MSHA + STR STR 98387499 Hydraulic hose 350bar DN 32/4SH x 1200 STR STR 10000231 Hydraulic hose 350bar DN 32/4SHx 1200 90° STR 98392963 Hydraulic hose 350bar DN 32/4SH x 1250 STR 45° 98321262 Hydraulic hose 350bar DN 32/4SH x 1250 STR STR 98339506 Hydraulic hose 350bars DN 32/4SH x 1250 STR 90° 10306460 Hydraulic hose 325bar DN 32/4SH x 1300 STR 45° 10184097 Hydraulic hose 325bar DN 32/4SH x 1300 45° 45° Hydraulic hose 350bar DN 32/4SH x 1300 STR STR 10195313 Hydraulic hose 350bar DN 32/4SH x 1300 STR 90° 10205294 Hydraulic hose 350bar DN 32/4SH x 1300 STR STR 98364461 Hydraulic hose DN 32/4SH x 1300 - MSHA + STR STR 98383468 Hydraulic hose 350bar DN 32/4SH x 1350 STR STR 10000232 Hydraulic hose 125bar DN 32/2ST x 1400 STR 90° 10165867 0° 10215853 103 Home Print Fittings Book Hose 32 Material Description End End Degree Part # Hydraulic hose 350bar DN 32/4SH x 1400 90° 90° 10207843 Hydraulic hose 350bar DN 32/4SH x 1400 STR STR 98350899 Hydraulic hose 350bars DN 32/4SH x 1400 90° 90° 10306547 Hydraulic hose 325bar DN 32/4SH x 1450 STR 45° 10195312 Hydraulic hose 325bar DN 32/4SH x 1450 STR 45° 10213684 Hydraulic hose 350bar DN 32/4SH x 1450 STR STR 10000233 Hydraulic hose 350bar DN 32/4SH x 1450 STR 90° 98347356 Hydraulic hose 350bar DN 32/4SH x 1500 STR STR 10000234 Hydraulic hose 350bar DN 32/4SH x 1500 STR 90° 98347357 Hydraulic hose DN 32/4 X 1500 - DEMO 30328404 Hydraulic hose 350bar DN 32/4SH x 1550 STR STR 98378861 Hydraulic hose 350bar DN 32/4SH x 1560 STR 45° 98384978 Hydraulic hose 350bar DN 32/4SH x 1600 STR STR 10000236 Hydraulic hose 350bar LOBA DN 32/4SH-FLH- x 1600 STR STR 10037388 Hydraulic hose 350bars DN 32/4SH x 1600 STR 90° 10307951 Hydraulic hose 325bar DN 32/4SH x 1650 STR 45° 10209377 Hydraulic hose 350bar DN 32/4SH x 1650 STR STR 98378854 Hydraulic hose 325bar DN 32/4SH x 1700 STR 45° 10215838 Hydraulic hose 350bar DN 32/4SH x 1700 STR STR 98339457 Hydraulic hose 350bar DN 32/4SH x 1700 STR 90° 98343036 Hydraulic hose 350bar DN 32/4SH x 1750 STR STR 10308433 Hydraulic hose 350bar DN 32/4SH x 1750 STR STR 98324632 Hydraulic hose 350bar DN 32/4SH x 1800 STR STR 10154054 Hydraulic hose 350bar DN 32/4SH x 1800 STR 90° 98347355 Hydraulic hose 350bars DN 32/4SH x 1850 90° STR 98318255 Hydraulic hose 350bar DN 32/4SH x 1950 STR 90° 98343037 Hydraulic hose 350bar DN 32/4SH x 2000 STR STR 10077214 Hydraulic hose 350bar DN 32/4SH x 2060 STR 45° 98382819 Hydraulic hose 325bar DN 32/4SH x 2100 STR STR 10302761 Hydraulic hose 350bar DN 32/4SH x 2150 STR STR 98324633 Hydraulic hose 350bars DN 32/4SH x 2150 STR 90° 10306461 104 Home Print Fittings Book Hose 32 Material Description Hydraulic hose 350bar DN 32/4SH x 2200 End STR End Degree STR Hose DN 32 x x 2300 Part # 98326264 10306090 Hydraulic hose 350bar DN 32/4SH x 2300 STR STR 10306985 Hydraulic hose 350bar DN 32/4SH x 2400 90° STR 98330009 Hydraulic hose 350bars DN 32/4SH x 2400 STR STR 98318186 Hydraulic hose 325bar DN 32/4SH x 2500 STR STR 98345459 Hydraulic hose 350bar DN 32/4SH x 2600 STR STR 98326263 Hydraulic hose 350bar DN 32/4SH x 2700 STR STR 98382374 Hydraulic hose 350bar DN 32/4SH x 2800 STR STR 98380872 HOSE DN 32 X X 3000 Hydraulic hose 350bar DN 32/4SH x 3000 10127165 STR STR HOSE DN 32 X X 3500 10151306 10127166 Hydraulic hose 125bar DN 32/2ST x 4000 STR STR 10169630 Hydraulic hose 350bar DN 32/4SH x 4000 STR STR 98349932 Hydraulic hose 350bar DN 32/4SH x12000 STR STR 10214499 105 Home Print Print Home Fittings Book Torque Wrench Settings for Coated Fittings Wrench Head Hose to fitting Fitting to Fitting Fitting to Block Banjo Size Nm / Ft Lbs Nm / Ft Lbs Nm / Ft Lbs Nm / Ft Lbs - - L = 35 / 26 S = 55 / 41 75 / 55 L = 90 / 66 S = 115 / 85 - 17mm 20 / 15 50 / 37 19mm - - 22mm 40 / 30 60 / 44 27mm - - 30mm 70 / 52 120 / 89 36mm 100 / 74 190 / 140 46mm 160 / 118 260 / 192 - 50mm 210 / 155 400 / 295 450 / 332 55mm - - 540 / 398 60mm 300 / 221 440 / 325 - 80 / 59 150 / 111 - Bulkhead Fitting Installation Unscrew the nut Apply Red Loctite 371 as described below Insert the bulkhead lead-in into the hole Manually screw on the lock nut You can install the lock nut with a suitable torque wrench and the assembling torque applying to the respective union system (see table) Install fitting into the pipe joint and properly torque Apply Red Loctite 271on front surfaces Apply only a very small amount of adhesive (one drop) on thread Fitting torque for bulkhead glands [Nm] Size Series [Nm] / [Ft lbs] Size Series [Nm] / [Ft lbs] 25 / 18 35 / 26 40 / 30 55 / 41 10 50 / 37 10 70 / 52 12 70 / 52 12 85 / 63 90 / 66 14 15 18 L 110 / 81 S 115 / 85 16 120 / 89 22 210 / 155 20 200 / 148 28 310 / 229 25 340 / 251 35 500 / 369 30 480 / 354 42 600 / 443 38 850 / 627 Print Home Fittings Book Wrench and Coupling for Fittings Table 1:Straight Fittings Fitting/Tube Size 8mm 12mm 16mm 20mm 25mm 38mm Capnut Coupling Body 17mm 19mm 27mm 32mm 41mm 55mm 17mm 22mm 30mm 36mm 46mm 60mm American Cap Nut 11/16” 7/8” - 3/16” - 7/16” - 13/16” - 3/8” American Coupling Body 11/16” 3/4” - 1/16” - 1/4” - 5/8” - 3/16” Table 2:Banjo Fittings Fitting/Tube Size 8mm 12R-1/4mm 12R-1/4mm 16mm 20mm 25mm 38mm Capnut 17mm 22mm 22mm 30mm 36mm 46mm 60mm Coupling End Cap American American Coupling End Cap Body Cap Nut Body 17mm 19mm 11/16” 11/16” 3/4” 19mm 19mm 7/8” 3/4” 3/4” 27mm 22mm 7/8” - 1/16” 7/8” 32mm 27mm - 3/16” - 1/4” 1-1/16” 41mm 32mm - 7/16” - 5/8” 1-1/4” 55mm 41mm - 13/16” 2” 1-5/8” -55mm - 3/8” -2-3/16” Table 3: Fitting Size / Hose Size Fitting/Tube Size Hose Size 8mm 10mm 12mm 16mm 20mm 22mm 25mm 30mm 38mm 8 13 16 16 20 25 32 Home Print Fittings Book Fitting Assembly Instruction NS Style Profile - Dull Green Colored NOTE! The profile ring fittings are coated with a clear sliding agent which reduces friction and avoids the need to additionally oil the fittings components In order to ensure positive assembly, fittings should always be pre-assembled using a spare mating fitting After pre-assembly, discharge the spare fitting In case of repair, direct assembly in the pre-assembly adapter is also possible Direct Assembly Saw off the tube at right angles and debur it Do not use a tube cutter, but a sawing machine, if possible Lightly debur tube ends at inside and outside 699001.ai Place the nut and profile ring on the tube as shown 699002.ai Press tube into fitting body up to tube abutment tighten nut by hand 699003.ai Print Home Fittings Book Tighten nut until ferrule grips tube which is felt by a noticeable increase in torque Controlled Final Assembly Using MEG-R3 Tube OD Assembly Torque Pre-Assy Force 1) [mm] Min tube wall thickness [mm] [Nm] / [ft lb] (30º) [kN] 10 12 15 18 22 28 35 42 6x1 8x1 10x1 12x1.5 15x1.5 18x1.5 22x2 28x2 35x3 42x3 25 / 18 40 / 30 50 / 37 70 / 52 90 / 66 115 / 85 210 / 155 310 / 229 500 / 369 600 / 443 17 22 30 40 44 46 77 77 100 125 6x2 8x1.5 10x1.5 12x1.5 14x2 16x1.5 20x2 25x2.5 30x3 38x4 35 / 26 55 / 41 70 / 52 85 / 63 110 / 81 120 / 89 200 / 148 340 / 251 480 / 354 850 / 627 23 40 37 40 46 46 77 95 120 145 Series 10 12 14 16 20 25 30 38 L S Final assembly by turn Important: Hold fitting body firmly by means of a spanner Application of deviating numbers of tightening turns reduces the nominal pressure rating and the life of the fitting which causes leakages or displacement of the tube 699005.ai Check penetration of cutting edge A visible ring of material should fill the space in front of the profile ring end face Profile ring may turn tube but should not be capable of axial displacement 699003.ai Home STANDARD NEW PRODUCT WARRANTY Schwing America, Inc (“Schwing”) warrants its new equipment against defects in material and workmanship under normal use and service, provided such equipment shall not have been subject to misuse, negligence or accident, for a period of twelve months from the date of purchase, or 2000 hours of use, whichever shall occur first Schwing warrants new spare parts against defects in material and workmanship for a period of six months from the date of purchase This warranty shall not apply to any equipment or spare parts which shall have been loaded or operated beyond their rated capacity as specified by Schwing Damage resulting from improper installations, alterations or neglect of recommended maintenance will be considered as misuse and not as a defect Certain parts of the equipment, such as, but not limited to, the pumping cylinders, pumping rams, concrete pump systems, mixer drums and chutes, are subject to normal wear Normal wear is not covered under this warranty Your Schwing equipment is designed to operate with only Schwing OEM products Use of nonSchwing OEM products voids any warranties provided by Schwing Buyer’s SOLE AND EXCLUSIVE REMEDY for breach of this warranty shall be replacement or repair, free of charge, of such part or parts as are determined to be defective, or repayment of the purchase price paid by Buyer, whichever such remedy Schwing shall select To make a claim under this warranty, Buyer must, within ninety (90) days of discovery of the defect in material or workmanship, give written notice of the defect to Schwing and, if requested by Schwing, promptly deliver the equipment to Schwing, FOB Schwing warehouse On boom units, structural components such as weldments provided by Schwing are warranted against defects in materials and workmanship for a period of ten years from the date of purchase, provided structural inspections have been conducted and necessary repairs have been made in accordance with the American National Standard, ASME 830.27, Material Placement Systems, and such inspections and repairs have been properly documented If such inspections have not been conducted and necessary repairs made, this warranty is void Buyer’s SOLE AND EXCLUSIVE REMEDY for breach of this warranty shall be repair or replacement of any components found to be defective, whichever such remedy Schwing should select, but Buyer shall be responsible for the cost of any replaced components at Schwing’s current published list prices and for the labor charged by a Schwing authorized servicer to repair or replace the components, based upon a fraction, the numerator of which is the number of years since the date of purchase of the equipment, and the denominator of which is ten (10) SCHWING SHALL HAVE NO LIABILITY TO THE BUYER OF SUCH EQUIPMENT OR SPARE PARTS OR OTHER PERSON FOR INCIDENTAL DAMAGES, SPECIAL DAMAGES, CONSEQUENTIAL DAMAGES OR OTHER DAMAGES OF ANY KIND OR NATURE WHATSOEVER, WHETHER ARISING OUT OF BREACH OF WARRANTY OR OTHER BREACH OF CONTRACT, NEGLIGENCE, STRICT LIABILITY OR OTHER TORT, OR OTHERWISE, EVEN IF SCHWING SHALL HAVE BEEN ADVISED OF THE POSSIBILITY OR LIKELIHOOD OF SUCH POTENTIAL LOSS OR DAMAGE For purposes hereof, the term “consequential damages” shall include lost profits, penalties, delay damages, liquidated damages or other damages and liabilities which the Buyer shall be obligated to pay or which the Buyer may incur based upon, related to or arising out of its contracts with its customers or other third parties In no event shall Schwing be liable for any amount of damages in excess of the amounts paid by the Buyer for goods or services as to which a breach of warranty or contract has been determined to exist The parties expressly agree that the price for goods and the services was determined in consideration of the limitation on damages set forth herein and such limitation has been specifically bargained for and constitutes an agreed allocation of risk which shall survive the determination of any court of competent jurisdiction that any remedy herein fails of its essential purpose Schwing reserves the right to make changes and improvements in its product without incurring any obligation to install any such changes or improvements in its products previously manufactured Schwing makes no warranty of components or accessory equipment purchased by Schwing from third parties, such as, but not limited to, truck chassis, engines, transmissions, gear cases, tires, wheels and tools, the same being subject to the warranties of their respective manufacturers Except as provided herein, and in Schwing’s General Terms and Conditions of Sale, which are incorporated herein by reference, SCHWING MAKES NO OTHER REPRESENTATIONS OR WARRANTIES, EXPRESS OR IMPLIED, WITH RESPECT TO NEW EQUIPMENT OR SPARE PARTS, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED 4968873v3 11/201 SCHWING AMERICA, INC ... 250:Users:Danny:Desktop:Operation manuals: line pumps:All SP Rock Valve models:Frame Operation Manual - All SP Rock Valve Models 23 Home TOC Print Overview Concrete pump hydraulic pumps Concrete Pump Circuit The hydraulic pumps... while you are near the concrete pump so that you can identify the components that are discussed The Schwing trailer-mounted concrete pump is mounted on a trailer chassis The pump is hydraulically... psi) CONCRETE PUMP KIT Strokes/minute (max.) Max Output Power Power (Current Electric Motor) Power (hyd pumps) Output (hyd pumps) Req’d Speed (hyd pumps) Pressure (max hyd.) Theoretical Concrete

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  • 98330783_Small Rock Valve

    • Small Rock Valve

      • Safety Instruction

        • 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 circui...

        • 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...

        • 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.

      • Rock Valve Parts Identification and Clearance Specifications

      • Small Rock Valve Lubrication Points

      • Lengthening the Service Life of the Spectacle Plate and Cutting Ring

        • 1. Move the Rock Valve to the left and right end position once a week after thorough cleaning, and check the condition of both the Cutting Ring and the Housing Lining.

      • 2. Turn the Cutting Ring 90 degrees when there is a clearance greater than 1.5mm-2.0mm (.0590”-.0590”) between the Cutting Ring and the Housing Lining. The Cutting Ring typically wears at the 3 and 9 o’clock position. Turning the Cutting Ring 9...

      • 3. Check the distance between the Cutting Ring and the Rock after each turn of the Cutting Ring. If it exceeds 8mm (.315”), the pretension of the Pressure Spring is not enough to correctly press the worn cutting ring up against the Spectacle Plate....

      • Rebuilding the Rock Valve

        • 1. Remove the Locking Bolt from the Tension Nut.

        • 2. Loosen the Tension Nut.

        • 3. Remove the Tension Nut.

        • 4. Remove the Setting Disc

        • 5. Install the alignment rods

        • 6. Slide the rear housing cover back slightly.

        • 7. Center Rock Valve using a pry bar, so the lever is straight up.

        • 8. Remove the Locking Bolt for the Cylinder Pin on the Slewing Yoke

        • 9. Using a drift punch, drive pin out of the hole.

        • 10. Pull yoke up and out of the slew lever. Move out of the way and tie up.

        • 11. Remove 12mm bolt and lever disk from Rock shaft

        • 12. Remove slew lever.

        • 13. Using a lifting device, slide Rock Valve out of bushing and place on a work surface.

        • 14. Remove Kidney Seal and Pressure Spring. Clean both ends of the Rock Valve, removing all concrete debris.

        • 15. Remove the Seal Cover from the Rock Slewing Shaft and remove the O-ring.

        • 16. Remove the O-ring from the groove of the Rock shaft bushing on the Rear Cover Housing.

        • 17. Clean the O-ring groove removing all concrete debris, paying special attention to the grease journals are clean.

        • 18. Using the correct size bushing driver, drive the old Rock shaft bushing out of the front cover of the Rock housing.

        • 19. Using the correct size bushing driver, drive the old Rock Shaft Bushing out of the Rear Cover Housing.

        • 20. Remove the two bolts attaching the Spectacle Plate to the Front Cover.

        • 21. Carefully remove the Spectacle Plate from the Rock Housing.

        • 22. Remove the four, 20 mm bolts from the outlect delivery pipe.

        • 23. Remove the four bolts from the rear cover that attach the Kidney Plate to the rear cover.

        • 24. Remove the Kidney Plate.

        • 25. Reassemble the Rock Valve assembly in the reverse order that it was disassembled. Slide the cover back in place.

        • 26. Adjust the Tension Nut, which is tightened only hand tight. If the Locking Bolt shown can be installed in the Setting Disc freely, then do so. If the hole in the Tension Nut does not align with the thread hole in the Setting Disc, loosen the Tens...

      • Mounting a New Pressure Spring

        • Determining Wear on the Kidney Seal & Housing Lining - Outlet Side

        • Replacement of Cutting ring and Kidney seal

          • 1. Remove the Locking Bolt from the Tension Nut.

        • 2. Loosen the Tension Nut.

        • 3. Remove the Tension Nut.

        • 4. Remove the Setting Disc.

        • 5. Install the Alignment Rods

        • 6. Slide the rear housing cover back slightly.

        • 7. Remove the Kidney Seal for inspection, and replace it if necessary. See the previous section of this manual entitled Determining Wear on the Kidney Seal and Housing Lining--Outlet Side for reference.

        • 8. Loosen the bolt that holds the slew lever on the Rock shaft, but do not remove

        • 9. Slide the Rock Valve back about 1.5 inches, and carefully remove the cutting ring.

        • 10. Make sure that all parts are thoroughly cleaned, and reassemble in reverse order. Slide the Rock cover back into place, and secure it with bolts.

        • 11. Adjust the Tension Nut, which is tightened only hand tight. If the Locking Bolt shown can be installed in the Setting Disc freely, then do so. If the hole in the Tension Nut does not align with the thread hole in the Setting Disc, loosen the Tens...

      • Slewing Yoke Timing

    • Blank Page

  • 500_750_CAT_Hydrel

    • 1.0 Sub Assembly

    • Axle Assembly

    • Axle Placement

    • Chassis Assembly (1 of 2)

    • Chassis Assembly (2 of 2)

    • CAT C4 4T 80 HP Engine Assembly (1 of 3)

    • CAT C4 4T 80 HP Engine Assembly (2 of 3)

    • CAT C4 4T 80 HP Engine Assembly (3 of 3)

    • Air Intake Extensions

    • Fuel Separator / Baffle Installation

    • Heat Shield Installation

    • 1015-80/50 Pump kit Assembly

      • 10040856 - Differential Cylinder Assembly

    • Differential Cylinder Plumbing

      • 10192655 - MPS Valve

    • 1015 (6”) - Ram with Connector & Adapter

    • Long Rock - Housing Assembly

    • Long Rock Valve Assembly

    • Long Rock - Slewing Cylinders/Agitator

      • 30390238 - Slewing Cylinder Assembly

    • Long Rock Valve Greaser Assembly

    • Hydraulic Tank Assembly (1 of 2)

    • Hydraulic Tank Assembly (2 of 2)

      • 98350314 - Hydraulic Oil Cooler Assembly

    • Controller Assembly (1 of 2)

    • Controller Assembly (2 of 2)

      • 10192654 - Control Block Assembly

        • 10188446 - Control Unit S1-S2

          • 98352331 / 98352332 - Solenoid Valve DS3-S2

            • 10183940 - NG 25 Poppet Valve Insert

      • 2.0 Main Assembly

    • Pumpkit Installation

    • Hydraulic Controller - Tube Rack

    • Tube Rack Hydraulic Hoses (1 of 2)

    • Tube Rack Hydraulic Hoses (2 of 2)

    • Hopper Assembly

    • Engine Installation

    • Fuel Tank Installation

    • Fuel Lines Installation - SP500

    • Fuel Lines Installation - SP750

    • Hydraulic Pump Connections

    • Hydraulic Tank / Accumulator Installation

      • 10304502 - E-Stop Assembly

    • Hydraulic Tank Connections

    • Hydraulic Cooler Installation

    • MPS Valve Plumbing

    • Emergency Stop Manifold Plumbing

    • 10201988 / 10201989 Emergency Stop Manifold

    • Operator Controls Installation

      • 98347086 - Control Panel Assembly

      • 3.0 Final Assembly

    • Shroud Installation

    • Exhaust Installation

    • Exhaust Installation with Catalytic Convertor

    • 98365128-Assy. Exhaust Muffler System CAT C4.4

    • Miscellaneous

      • 4.0 Schematics

        • 98378929 - Hydraulic Schematic

          • 98380853 - Electrical Schematic

      • 5.0 Shipping

    • Spare Parts and Accesories

    • 98347141 - Cable Remote

    • 98392576 Decal Kit (1 of 4)

    • 98392576 Decal Kit (2 of 4)

    • 98392576 Decal Kit (3 of 4)

    • 98392576 Decal Kit (4 of 4)

      • 6.0 Options

    • 98347792 - Radio Remote Kit

    • Radio Remote Installation

    • Hydraulic Outrigger Assembly (1 of 3)

    • Hydraulic Outrigger Assembly (2 of 3)

    • Hydraulic Outrigger Assembly (3 of 3)

    • Dual Axle Assembly

    • Dual Axle Fenders

    • Dual Axle Fenders - w/Lifting Frame

    • Dual Axle Fenders - Accumulator Installation

    • Vibrator Assembly

    • Water Pump Assembly

    • 98348884 - Water Pump Unit

    • Water Pump Installation (1 of 2)

    • Water Pump Installation (2 of 2)

    • Water Pump Installation w/Agitator

    • Auxiliary Valve Installation

    • Auxiliary Circuit Gear Pump Assembly

    • Auxiliary Circuit Installation

    • Dual Stroke Counter Installation

    • Auto Greaser Pump/Feeder Block Install

    • Auto Greaser Feeder Valve Plumbing

    • Electric Throttle

    • Lifting Frame

    • Reflector Locations

      • Appendix A

    • Hayes Coupling Installation

      • Appendix B

    • Hydraulic Fittings Tightening Procedure

    • Axle Assembly

    • Axle Placement

    • Chassis Assembly (1 of 2)

    • Chassis Assembly (2 of 2)

    • CAT C4 4T 80 HP Engine Assembly (1 of 3)

    • CAT C4 4T 80 HP Engine Assembly (2 of 3)

    • CAT C4 4T 80 HP Engine Assembly (3 of 3)

    • Air Intake Extensions

    • Fuel Separator / Baffle Installation

    • Heat Shield Installation

    • 1015-80/50 Pump kit Assembly

      • 10040856 - Differential Cylinder Assembly

    • Differential Cylinder Plumbing

      • 10192655 - MPS Valve

    • 1015 (6”) - Ram with Connector & Adapter

    • Long Rock - Housing Assembly

    • Long Rock Valve Assembly

    • Long Rock - Slewing Cylinders/Agitator

      • 30390238 - Slewing Cylinder Assembly

    • Long Rock Valve Greaser Assembly

    • Hydraulic Tank Assembly (1 of 2)

    • Hydraulic Tank Assembly (2 of 2)

      • 98350314 - Hydraulic Oil Cooler Assembly

    • Controller Assembly (1 of 2)

    • Controller Assembly (2 of 2)

      • 10192654 - Control Block Assembly

      • 10188446 - Control Unit S1-S2

      • 98352331 / 98352332 - Solenoid Valve DS3-S2

      • 10183940 - NG 25 Poppet Valve Insert

    • Shroud Installation

    • Exhaust Installation

    • Exhaust Installation with Catalytic Convertor

    • 98365128-Assy. Exhaust Muffler System CAT C4.4

    • Miscellaneous

    • 98378929 - Hydraulic Schematic

      • 98380853 - Electrical Schematic

    • Spare Parts and Accesories

    • 98347141 - Cable Remote

    • 98392576 Decal Kit (1 of 4)

    • 98392576 Decal Kit (2 of 4)

    • 98392576 Decal Kit (3 of 4)

    • 98392576 Decal Kit (4 of 4)

    • 98347792 - Radio Remote Kit

    • Radio Remote Installation

    • Hydraulic Outrigger Assembly (1 of 3)

    • Hydraulic Outrigger Assembly (2 of 3)

    • Hydraulic Outrigger Assembly (3 of 3)

    • Dual Axle Assembly

    • Dual Axle Fenders

    • Dual Axle Fenders - w/Lifting Frame

    • Dual Axle Fenders - Accumulator Installation

    • Vibrator Assembly

    • Water Pump Assembly

    • 98348884 - Water Pump Unit

    • Water Pump Installation (1 of 2)

    • Water Pump Installation (2 of 2)

    • Water Pump Installation w/Agitator

    • Auxiliary Valve Installation

    • Auxiliary Circuit Gear Pump Assembly

    • Auxiliary Circuit Installation

    • Dual Stroke Counter Installation

    • Auto Greaser Pump/Feeder Block Install

    • Auto Greaser Feeder Valve Plumbing

    • Electric Throttle

    • Lifting Frame

    • Reflector Locations

    • Hayes Coupling Installation

    • Hydraulic Fittings Tightening Procedure

  • Fittings_Book_2015

    • Cap Nut

    • Ferrule

    • EGESD

    • ELSD

    • ETSD

    • EWSD

    • GAS

    • GES

    • GFS

    • GS

    • GSS

    • MAS

    • RED

    • RSWS

    • S

    • SNV

    • TS

    • VS

    • VSD

    • WFS

    • WS

    • WSS

    • Hose 6

    • Hose 8

    • Hose 10

    • Hose 12

    • Hose 16

    • Hose 20

    • Hose 25

    • Hose 31

    • Hose 32

      • Torque Wrench Settings for Coated Fittings

      • Bulkhead Fitting Installation

      • Wrench and Coupling for Fittings

      • Fitting Assembly Instruction NS Style Profile - Dull Green Colored

  • SchwingProductWarranty

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