SCHWING TrainingManual

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(1)SERVICE TRAINING. TRAINING MANUAL. Copyright All rights reserved. The information and drawings contained herein must not be duplicated, used improperly, or communicated to third parties without the consent of Schwing America Inc. All Information is subject to revision 5900 Centerville Road White Bear, MN 55127 TEL 651-429-0999 FAX 651-429-2112 www.schwing.com.

(2) SCHWING SERVICE DEPARTMENT (651) 429-0999 OR. 1-888-292-0262 OR. FAX (651) 429-2112 8:00 A.M. TO 5:00 P.M. (Central Time) (MONDAY THROUGH FRIDAY). SCHWING PARTS DEPARTMENT 1-800-328-9635 OR. FAX (651) 429-2112 6:00 A.M. - 9:00 P.M. (Central Time) (MONDAY THROUGH FRIDAY). 24 Hour Service Hotline 1-888-292-0262 (MONDAY THROUGH SATURDAY). Branches Florida............................................................. 1-813-985-8311 Northern California........................................ 1-925-371-8595 Southern California ....................................... 1-562-493-1012 Georgia ........................................................... 1-678-560-9801 Texas .............................................................. 1-972-245-5166.

(3) SERVICE TRAINING. Table of Contents. Typical Twin Circuit ........................ 1. Typical Boom Circuit .................... 16. PTO Switch/Air Valve ..................................................1 PTO ...............................................................................2 Continuous Duty Solenoid ............................................2 CPC/CPCII Controller ..................................................3 Hydraulic Pumps ...........................................................3 Fixed Displacement ......................................................4 Variable Displacement ..................................................4 Main Control Block “Brain” .........................................4 Concrete Pump Forward/Reverse Valve .......................5 Main Control Block - S1/S2 Spool ...............................5 Main Relief Valve .........................................................6 Differential Cylinders ...................................................6 Material Cylinders ........................................................7 Differential Cylinder - Bottomed Out ...........................7 MPS Valve ....................................................................8 S3/Accumulator Control Block .....................................8 Accumulator Theory .....................................................9 Rock Valve Slewing Cylinder ......................................9 Soft Switch Relief Valve ............................................10 Main Control Block - S2 Spool ..................................10 Differential Cylinder - Beginning of stroke ................11 MPS ............................................................................11 Differential Cylinder - Bottomed Out .........................12 MPS ............................................................................12 S3/Accumulator Control Block ...................................13 Rock Valve Slewing Cylinder ....................................13 Soft Switch Relief Valve ............................................14 Main Control Block - S2 Spool ..................................14 Differential Cylinders .................................................15. Boom Pump ................................................................16 E-Stop Manifold .........................................................17 Poppet Valve Theory ..................................................17 E-Stop - Override .......................................................18 Boom Handvalve - No functions activated ................18 Boom Handvalve - Outrigger enabled ........................19 Outrigger Handvalve ..................................................19 Boom Handvalve - Boom Function Activated ...........20 Pulsar Coil Theory ......................................................20 Boom Holding Valves ................................................21 Manual Controls and Overrides ..................................21. Training Manual.

(4) Table of Contents. SERVICE TRAINING. Service Manual.

(5) SERVICE TRAINING. Typical Twin Circuit Main Control Block Main Relief/Soft Switch. MPS Valve. Differential Cylinders S3/Accumulator Valve Rock Valve Slewing Cylinder. Accumulator Pump Boom Pump. Rock Valve. PTO Material Cylinders. Hydraulic Pumps. PTO Switch/Air Valve Air Pressure Switch. Air Pressure Switch (Energized) To:PTO. • Switch pushed “in”, air supply blocked by spool. • Switch pulled “out” , opening is created allowing air pressure to energize the air pressure switch. • A passage way is created allowing air pressure to be sent to the PTO.. Air blocked by spool PULL TO APPLY. PARKING BRAKE PUSH TO RELEASE. QUARTZ 00000.1. 1 HOURS. From:Truck Air Supply. PTO switch Must be pulled. Training Manual. Power to fuse. 1.

(6) SERVICE TRAINING. PTO • Air is routed to the small cylinder mounted in the distribution gear case (PTO). • When the cylinder is pushed “in” the PTO is in the pumping position. • When the cylinder is pushed “out” the PTO is in the travel position. Air Supply Block. To:12v Controller. PTO.eps. Fork. All hydraulic pumps for the concrete pump, placing boom, agitator, etc. are mounted on a distribution gearcase. When you are driving the truck, the power of the truck engine is transmitted through the truck transmission, through a propeller shaft, through the bottom of the distribution gearcase, through another propeller shaft, and into the rear end(s) of the truck. When you are operating the unit, the distribution gearcase interrupts the power to the rear ends, and transmits it to internal gears that turn the hydraulic pumps. Changing between travel and pumping modes is accomplished by means of an air switch in the truck cab.. Continuous Duty Solenoid • Electric signal from Air Switch enters Continuous Duty Solenoid. CPC/CPC II Style (Not used on Vector units). • The signal energizes the magnetic coil in the Continuous Duty Solenoid • The energized magnetic coil, pulls the plunger “down” To: Controller. • A connection is established between the 12 volt power supply and CPC Controller. Plunger. Magnetic Coil. From: 12v Power Supply. Cont_Solenoid.eps. 2. Training Manual.

(7) SERVICE TRAINING. CPC/CPCII Controller The CPC/CPC II provides a proportional signal to each of the boom functions and the concrete pump output. It also controls all on/off functions on the unit. The CPC/CPC II receives power via the PTO switch through the Continuos duty solenoid and into the “Power” connector.. CPC/CPC II POWER REAR CTR UMB CTR RADIO CTR ID LINK ALARM E-STOP. WHEN WELDING ANYWHERE ON UNIT POWER CABLE MUST BE DISCONNECTED. L1357-01. Vector Controller. “Power” Connector. The Vector control system is a completely digital control system, which means that the function movements are converted to numbers (0’s and 1’s). The numbers are sent to the controller where they are analyzed, converted back to analog (voltage or current), and sent to the valves and indication devices.. Vector. 1. OK. 2. OFF. x1000 3 0 PTO 1500 rpm 62˚C. Menu: [ENTER]=ON. HOME. +. HELP. START. CLEAR. -. ENTER. QUIT. X12 Connector (Behind). Hydraulic Pumps Typical Gearbox To: Main Control Block. To: Boom Control Block. Pumpkit Pumps. s .ep ps um licP u dra To: Hy. The hydraulic pumps for the concrete pump circuit are bent axis, variable displacement piston pumps. They are horsepower controlled, which means that as pressure rises towards maximum, the flow can decrease, so the power consumption remains constant. We use this type of pump so the truck engine will not bog down under hard pumping conditions. The pumps also accept external signals for control of the output. At Schwing, we route signals to the pump from the hydraulic stroke limiter. The net effect of these devices is to tell the pump to put out less oil per revolution, as required by the pump operator.. To: S3 Accumulator Agitator To: Oil Cooler. Training Manual. 3.

(8) SERVICE TRAINING. Fixed Displacement Puts out a set amount of oil, that can only be changed by increasing/decreasing the RPMs. Fixed Dispalcement Bent Axis. Variable Displacement Variable or Positive displacement pumps deliver to the system, a variable amount of oil according to the angle for the rotary group or swash plate.. min. max. min. Variable Displacement Bent Axis. max. Variable Displacement Swash Plate PumpCutaways.eps. Main Control Block “Brain” • Oil from hydraulic pumps enter the “P1” and “P2” ports of the Main Control Block. • S1 spool is in the neutral position From: Pumps. • Hydraulic oil will flow through the Main Control Block and go back to the hydraulic tank.. To: Tank. To: Tank. S1 Spool. From: Pump From: Pump S2 Spool. HiFlowBrain.eps. S1 - Neutral Position, pathway block. 4. Training Manual.

(9) SERVICE TRAINING. Concrete Pump Forward/Reverse Valve. A. B. To: Main Control Block/MPS Valve “P2” Vent T. Blocked pathway (Neutral). A B. From: Pump. • In the “forward” position, a passage way is created between the pressure port and the “A” port, through grooves in the spool.. P. • Oil is sent to the “XP” port of the Main Hydraulic Control Block and the “XB” port of the MPS valve.. To: Main Control Block (XP port) and MPS Valve (XB port) A. The Concrete Pump Forward/Reversing valve is a simple control device, containing a 3 position, 6 way spool attached to a handle. The valve receives hydraulic oil from the Accumulator pump. • In the neutral position, the passage way for the hydraulic oil is blocked and will return to tank.. B. • This valve also plugs the vent line, which allows pressure to build in the system. Passageway created (Forward position). Main Control Block - S1/S2 Spool • With hydraulic pressure on the “XP” side of the spool and no pressure on the “XR” side, the S1 spool will move into the “Forward” position.. S1 - Forward Position, pathway to S2 spool created. • Passage way created for the hydraulic oil from the Main Hydraulic Pumps to move past the S1 spool and unto the S2 spool. • Passage way created for the hydraulic oil moving past the S2 spool and unto the Differential Cylinder.. S1 Spool. “XP”. “XR”. From: CP Forward/Reverse Valve From: Pump. S2 Spool. From: Pump. HiFlowBrain_S1.eps. Pathway to Differential cylinder To: Differential Cylinder. Training Manual. 5.

(10) SERVICE TRAINING. Main Relief Valve The main relief valve protects the hydraulic circuit, by relieving pressure before it reaches 350 bar or greater. • Pressure exceeds 350 bar and presses against the 350 bar main relief valve plunger.. 80 bar 350 bar. • The 350 bar relief valve spring will collapse, creating a passage way for the oil to bleed to tank. This creates a pressure drop in the poppet spring chamber. Less than relief pressure. Over relief pressure. • Pressure is greater on the piston side of the poppet than the spring side. This will collapse the poppet spring allowing the poppet to open. • With the poppet opened, a passage way is created, allowing oil to escape to tank until 350 bar pressure or lower is achieved.. Poppet opens. Excess oil drained to tank. Differential Cylinders. Loop Oil. To:MPS ZK2 To:MPS ZK1 High pressure oil. The term differential cylinder means that each hydraulic cylinder that pushes the concrete has an area difference (referred to as an “area differential”) between the two sides of the piston. This area differential exists because the rod extends only from one side of the piston. This is in contrast to the rock valve slewing cylinder, for example, which has a rod extending from both ends of the piston and therefore has the same area on both sides of the piston (it is a nondifferential cylinder). • Hydraulic oil from the Main Control Block flows to the rod side of the left hand differential cylinder. • The pressure from the hydraulic oil extends the rod of the left hand differential cylinder.. From: Pumps To:MPS ZS1 To:MPS ZS2 From: Pumps. 6. DiffCylinders.eps. • Loop oil on the piston side of the left hand differential cylinder crosses over to piston side of the right hand differential cylinder, causing that rod to retract.. Training Manual.

(11) SERVICE TRAINING. Material Cylinders The material cylinders contain rubber rams that are connected to the differential cylinder rods. One side will push the concrete through the Rock valve while the opposite side will suck concrete from the hopper. Concrete “pushed” through Rock Valve. Concrete “sucked in” from hopper. MatCylinders.e. Differential Cylinder - Bottomed Out • Left-hand differential cylinder bottoms out. • Signal lines connected to the “ZK1”,“ZK2”, “ZS1” and “ZS2” ports of the MPS valve.. To:MPS ZK2 To:MPS ZK1. From: Pumps To:MPS ZS1 To:MPS ZS2 From: Pumps. DiffCylinders_Bottom.ep. Training Manual. 7.

(12) SERVICE TRAINING. MPS Valve. X3. To: Soft Switch Reversing Valve To: S3 Spool. A. B. XB. XA. ZS1. ZS2. ZK1. ZK2. The MPS system consists of three small directional control valves. The main pressure that is supplied to these directional control valve is supplied by the accumulator. • A high pressure signal line from the Differential Cylinder enters the MPS valve through the “ZK2” port. • This moves the NG 6 directional valve over creating a passage way for the Accumulator oil to flow through MPS valve and out the “A” and “X3” port. From: Differential Cyl.. From: Differential Cylinder. T. SP. Passage way created To:S3 Spool From: Accumulator Pump. From: Differential Cyl. From: Accumulator Pump. S3/Accumulator Control Block • Hydraulic oil from the MPS valve “A” port enters the “XA” port of the S3/Accumulator Control Block. To: Rock valve slewing cylinder and S2 spool. • The S3 spool moves to the “left”.. From: MPS valve "B" port. • A passage way is created for accumulator oil to travel to the Rock valve Slewing Cylinder and S2 spool in the Main Control Block.. From: MPS valve "A" port To: Rock valve slewing cylinder To: S2 spool Manual Bleed. S3_Block02.eps From: Accumulator Pump From: Accumulator Pump. 8. Training Manual.

(13) SERVICE TRAINING. Accumulator Theory. Without Nitrogen Charge. With nitrogen charged to pressure P1. Influx of hydraulic oil for storage. The accumulator can be considered an energy storage device for hydraulics, similar to the function of a battery in an electrical circuit. The accumulator stores the oil flow of a small hydraulic pump until it is time to shift the Rock Valve. When needed all of the oil that as been stored in the accumulator is quickly released. This has the following benefits: • Lower power requirements for switching the RockValve (less horsepower taken from the engine). • Simpler switching to begin the next stroke (the differential cylinders get the signal to change direction as soon as the S3 spool moves, regardless if the Rock Valve has moved or not).. Fluid charged to maximum working pressure P3. Discharge of hydraulic oil. Fluid discharged down to minimum working pressure P2 AccumulatorTheory.eps. Rock Valve Slewing Cylinder From: S3/Accumulator Control Block. From: S3/Accumulator Control Block. The rock valve slewing cylinder is a nondifferential cylinder (see Differential Cylinder). The switching grooves are used in single-circuit machines, but not in twin-circuit machines. • A working line from the “A” port of the S3/ Accumulator Control Block enters the rear of the Rock Valve Slewing cylinder • This pushes the rod over, thus “switching” the rock valve.. RockSlewingCylinder.eps. Training Manual. 9.

(14) SERVICE TRAINING. Soft Switch Relief Valve Signal from MPS Valve X3. X3. 80 bar. 80 bar. 350 bar. 350 bar. When the Rock Valve is shifting, a signal line enters the “X3” port of the Main Control Block • The Soft Switch Reversing Valve is opened, creating a passageway to the 80 bar relief valve. • Pressure exceeds 80 bar and presses against the 80 bar Soft Switch relief valve plunger. • The 80 bar relief valve spring will collapse, creating a passage way for the oil to bleed to tank. This creates a pressure drop in the poppet spring chamber.. X3. X3. 80 bar. 80 bar. 350 bar. 350 bar. • Pressure is greater on the piston side of the poppet than the spring side. This will collapse the poppet spring allowing the poppet to open. • With the poppet opened, a passage way is created, allowing oil to escape to tank until 80 bar pressure or lower is achieved.. Path open to tank. Main Control Block - S2 Spool • Signal line from the MPS valve enters the “XB” port of the Main Control Block • S2 spool moves to the ‘right” • A passage way is created for oil to travel to the Differential Cylinder. From: CP Forward/Reverse Valve S1 Spool. From: Pump. From: Pump S2 Spool. “XB”. “XA”. From: Accumulator Control Block. HiFlowBrain_S2.eps. Pathway to Differential cylinder. 10. Training Manual. To: Differential Cylinder.

(15) SERVICE TRAINING. Differential Cylinder - Beginning of stroke Loop Oil. • Hydraulic oil from the Main Control Block flows to the rod side of the right-hand differential cylinder. • The pressure from the hydraulic oil extends the rod of the right-hand differential cylinder.. pressure oil. To:MPS ZK2. • Loop oil on the piston side of the right-hand differential cylinder crosses over to piston side of the left hand differential cylinder, causing that rod to retract.. To:MPS ZK1. From Pumps To:MPS ZS1 To:MPS ZS2 DiffCylinders_NewStroke.eps. From Pumps. MPS. X3. • A high pressure signal line from the Differential Cylinder is sent to the “ZK1” port of the MPS valve.. B. • Pressure is greater on the “ZK1” side of the NG 6 spool than the “ZK2” side.. Signal lost. A. • The NG 6 spool will move to the “right” closing the passage way for high pressure accumulator oil.. XB. XA. ZS1. ZS2. ZK1. ZK2. SP. From: Differential Cyl.. T. Passage way closed. From: Differential Cyl. From: Accumulator Pump. From: Accumulator Pump. Training Manual. 11.

(16) SERVICE TRAINING. Differential Cylinder - Bottomed Out • The Differential cylinder has reached the bottom of the last stroke. • High pressure signal line are sent to the “ZK1”, “ZK2”, “ZS1” and “ZS2” ports of the MPS valve.. To:MPS ZK2 To:MPS ZK1. From Pumps To:MPS ZS1 To:MPS ZS2 DiffCylinders_03.eps. From Pumps. MPS X3. To: Soft Switch Reversing Valve B. A. To: S3 Spool. XB. XA. ZS1. ZS2. • A high pressure signal line from the Differential Cylinder enters the MPS valve through the “ZS2” port. • This moves the NG 6 directional valve over creating a passage way for the Accumulator oil to flow through MPS valve and out the “B” port and unto the S3 spool. • Accumulator oil also travels out the “X3” port and unto the Soft Switch Reversing Valve.. From: Differential Cylinder To:Soft Switch Reversing Valve To:S3 Spool. ZK2. ZK1. From:Differential Cylinder. SP. T. Passage way created. From: Accumulator Pump. From:Differential Cylinder. From: Accumulator Pump. 12. Training Manual.

(17) SERVICE TRAINING. S3/Accumulator Control Block To: Rock valve slewing cylinder and Main Control Block From: MPS valve "A" port. • Hydraulic oil from the MPS valve “B” port enters the “XB” port of the S3/Accumulator Control Block. • The S3 spool moves to the “left”.. A. • A passage way is created for accumulator oil to travel to the Rock valve Slewing Cylinder and S2 spool in the Main Control Block.. B. S3_Block.eps. To: Rock valve slewing cylinder Manual Bleed. To: S2 spool From: MPS valve "A" port. From: Accumulator Pump. From: Accumulator Pump. Rock Valve Slewing Cylinder • A working line from the “B” port of the S3/ Accumulator Control Block enters the front of the Rock Valve Slewing cylinder. From: S3/Accumulator Control Block. • This pushes the rod over, thus “switching” the rock valve. From: S3/Accumulator Control Block. Training Manual. 13.

(18) SERVICE TRAINING. Soft Switch Relief Valve Signal from MPS Valve X3. X3. 80 bar. 80 bar. 350 bar. 350 bar. When the Rock Valve is shifting, a signal line enters the “X3” port of the Main Control Block • The Soft Switch Reversing Valve is opened, creating a passageway to the 80 bar relief valve. • Pressure exceeds 80 bar and presses against the 80 bar Soft Switch relief valve plunger. • The 80 bar relief valve spring will collapse, creating a passage way for the oil to bleed to tank. This creates a pressure drop in the poppet spring chamber.. X3. X3. 80 bar. 80 bar. 350 bar. 350 bar. • Pressure is greater on the piston side of the poppet than the spring side. This will collapse the poppet spring allowing the poppet to open. • With the poppet opened, a passage way is created, allowing oil to escape to tank until 80 bar pressure or lower is achieved.. Path open to tank. Main Control Block - S2 Spool • Signal line from the MPS valve enters the “XA” port of the Main Control Block • S2 spool moves to the “left” • A passage way is created for oil to travel to the Differential Cylinder.. S1 Spool. From: CP Forward/Reverse Valve From: Pump. From: Pump. S2 Spool. To: Differential Cylinder. HiFlowBrain_S2.eps. From: Accumulator Control Block. 14. Training Manual.

(19) SERVICE TRAINING. Differential Cylinders • Hydraulic oil from the Main Control Block flows to the rod side of the left hand differential cylinder. • The pressure from the hydraulic oil extends the rod of the left hand differential cylinder. • Loop oil on the piston side of the left hand differential cylinder crosses over to piston side of the right hand differential cylinder, causing that rod to retract.. From Pumps. From Pumps. DiffCylinders_04.eps. Training Manual. 15.

(20) SERVICE TRAINING. Typical Boom Circuit Boom Cylinder. To:Outrigger Function Outrigger Handvalve. Boom Pump. 1 PM. P1. P4. T. T. M. P3 P2. Boom Handvalve Estop Manifold. Boom Pump To: Boom Control Block. To: Main Control Block. The hydraulic pump for the placing boom is a variable displacement, bent axis, axial piston pump. It feeds all of the following components: • the hydraulic cylinders on the boom sections • the hydraulic cylinders on the outriggers • the hydraulic motor for the boom slewing gear. Boom Pump. • the hydraulic motor for the water pump • the hydraulic motor of the compressor (optional equipment). dra Hy. s .ep 02 s_ mp u P ulic. To: S3 Accumulator. To: Agitator To: Oil Cooler. Training Manual. 16.

(21) SERVICE TRAINING. E-Stop Manifold • Hydraulic oil from the boom pump enters the E-stop Manifold from the “P1” port.. P2 T. T P4. P3. Equal Pressure Poppet Closed. P1. Energized Solenoid. • If the solenoid is not energized, a passage way will be created for the signal line to go to tank.. Signal Line from P1 port. • This will create a pressure drop on the spring side of the poppet valve.. P2 T. T P3. • With the solenoid energized, a signal line from the “P1” port enters the spring side of the poppet valve. This will equalize the pressure on both sides of the poppet. The pressure plus spring tension will hold the poppet closed.. Greater Pressure Poppet Opened. P4 P1. De-energized Solenoid. • Pressure from the P1 port will overtake the spring tension, allowing the poppet to open. • A passage way is created for the oil from the “P1” port to escape to tank.. Passage way to tank. Poppet Valve Theory 1. Pressure “A” = “B”. 2. Pressure “A”. Pressure “A”. Pressure “B” + Spring. 3. Pressure “A” > “B”. Pressure “A” > “B”. Pressure “B” + Spring. 4. 1. Pressure “A” and “B” are equal. With ‘B” pressure, plus the spring, Pressure “A” is not great enough to open the poppet. 2. If pressure “A” is greater than pressure “B” plus the spring tension, pressure “A” will collapse the spring, lower the poppet. 3. With the poppet lowered, a path for excess pressure is created and flows back to tank. 4. When pressure ‘B” is greater or equal to pressure “A” the spring will expand, closing the pathway to tank.. Pressure “A” = “B”. Housing. Pressure “A” Poppet Pathway to Tank (open). Pressure “B” + Spring. Pathway to Tank (closed). Spring. Pressure “B” + Spring. Training Manual. 17.

(22) SERVICE TRAINING. E-Stop - Override Concrete pump, agitator, accumulator dump valve. Override buttons MP. S. Boom/outrigger circuit dump valve. T MP. S. P3. P2. Agitator system plumbing. P4. P1. Concrete pump system plumbing. • Turn the bypass key switch to “Bypass” position. If control is not restored, there probably a hydraulic problem; Proceed to the next step. • To manually bypass each system, the inlet plumbing to the nonworking system must be plumbed out of the manifold. • With the engine stopped, disconnect the plumbing for the nonworking system at the appropriate fitting. Boom/outrigger system plumbing. Accumulator system plumbing. BY-PASS NORM. BY-PASS. by-pass2.eps. Boom Handvalve - No functions activated • Oil enters the Boom Handvalve from the “P” port.. Blocked passage way. C2. C1. Apitech_Side_03.eps. From: Pump. From: Boom Pump. 18. Training Manual.

(23) SERVICE TRAINING. Boom Handvalve - Outrigger enabled • Outrigger push button is depressed • Pulsar coil is activated • Spool moves, creating a passage way for the oil to exit out of the “C2” port and unto the outrigger hand valve.. To: Outrigger Handvalve To: Outrigger Handvalve. Apitech_Side_02.eps. Solenoid Energized Passage open. From: Boom Pump. Outrigger Handvalve. A. B. The Outrigger hand valve is a simple control device, containing four - 3 position, 6 way spools attached to handles. The valve receives hydraulic oil from the Boom Handvalve. • In the neutral position, the passage way for the hydraulic oil is blocked • In the “extend” position, a passage way is created between the pressure port and the “A” port of the Outrigger hand valve.. To: Outrigger Function. A. • This will send oil to whatever outrigger function has been activated. Example “Outrigger Extend”.. B. Training Manual. 19.

(24) SERVICE TRAINING. Boom Handvalve - Boom Function Activated • Either the pulsar coil or handle are activated • A passage way is created for the oil to be sent to whatever boom function has been activated.. Blocked passage way. To: Boom Function From: Pump. Passage open. Apitech_Side_01.eps. From: Boom Pump. Pulsar Coil Theory Coil Control Oil to Spool. Control Disk. As the control disk pulses “on” and “off”, pretension oil is allowed to flow from the pressure passage to the tank passage. Since the top orifice is larger than the bottom orifice, eventually more oil will be in the tank passage than can leave through the 0.024 orifice. At this point, pressure will build in the main spool control port and move the main spool. The longer the “on” time, the greater the pressure in the control port, and the further the main spool is moved, causing the boom to go faster.. 0.040 Orifice Pilot Pressure. 20. Training Manual.

(25) SERVICE TRAINING. Boom Holding Valves Passage way for rod side oil (to tank). Passage way for piston side oil. Two hydraulically unlockable check valves (H.E.R. valves, or holding valves) on each boom cylinder prevent the boom from coming down unintentionally. LINE B LINE A. From:Boom Handvalve. Passage way closed. Oil trapped, cylinder held in place. LINE B LINE A. Manual Controls and Overrides 000419.eps. 1. 2. 3. 4. 5. 6. 7. 10 11. AGITATOR. CONCRETE PUMP. Boom 1. Boom 2. Boom 3. Boom 4. Boom 1 Telescope. Slewing Boom / Outrigger. Water / Compressor. 10189517. DANGER Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).. 1. 3. 4. WARNING Do not operate this machine without training. Understand the warnings in safety manuals and on decals.. 2. WARNING Clear area before activating outriggers. REAR EXTEND. REAR JACKING. FRONT JACKING. FRONT EXTEND. 8 12. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.. E-stop Boom #1 Control Handle Boom #2 Control Handle Boom #3 Control Handle Boom #4 Control Handle Boom Telescope Handle Boom Slewing Control Handle Water Pump/Air Compressor Handle Water Pump System Change-Over Valve Concrete Pump Handle Agitator Handle Two Position Boom/Outrigger Handle.. 9. Training Manual. 21.

(26) SERVICE TRAINING. 22. Training Manual.

(27) SERVICE TRAINING The Schwing Group ............................................................ 1 Schwing America, Inc. ................................................. 1. Hydraulic Training General Principles ............................................................... 3 Mechanical Versus Hydraulic ............................................. 7 Transfer of Energy .............................................................. 7 Hydraulic Jack ..................................................................... 8 Linear & Rotary Actuators .................................................. 8 Basic Hydraulic Components .............................................. 9 Check Valve Comparison ................................................. 10 Shuttle Valve ..................................................................... 11 Throttle Check Valve ........................................................ 12 Switching Valves .............................................................. 13 Hydraulic Pumps ............................................................... 14 Placing boom hydraulic pumps .................................. 14 Concrete pump hydraulic pumps ............................... 14 Fixed Displacement Pump ................................................ 15 Rexroth A2F20 ........................................................... 15 Variable Displacement Pump ............................................ 15 Rexroth A7VO ........................................................... 15 Variable Displacement Axial Piston Pump ....................... 16 RexrothA10VO .......................................................... 16 RexrothA11VO .......................................................... 16 Rexroth A11VO Adjustments .................................... 17 Transfer Cases ................................................................... 18 Relief Valves ..................................................................... 19 Safety Relief Valves .......................................................... 20 Pressure Relief Valve Type DB ................................. 20 Pressure Relief Valves Type DBW ............................ 20 Hydraulic Symbols ............................................................ 21 Hydraulic Symbols (Cont.) ............................................... 22 Hydraulic Symbols (Cont.) ............................................... 23 Hydraulic Symbols (Cont.) ............................................... 24 Hydraulic Symbols (Cont.) ............................................... 25 Hydraulic Symbols (Cont.) ............................................... 26 Hydraulic Symbols (Cont.) ............................................... 27 Formulas ............................................................................ 28. Pumpkits 800 Gate Valve .................................................................. 30 801 Gate Valve .................................................................. 31 801 Pumpkit Schematic ............................................. 32 Concrete Pump Control Block ................................... 33 Stroke Limiter ............................................................ 34. Table of Contents. 494 Block ....................................................................34 Hydraulically Unlockable CheckValve ......................35 Gate Valve ..................................................................35 900-1200 Single Circuit .....................................................37 900-1200 Single Circuit Schematic ............................38 Concrete Pump Control Block ....................................39 Stroke Limiter .............................................................40 494 Block ....................................................................40 Switching Valve .........................................................41 A7VO .........................................................................41 Rock Valve .................................................................42 Phase A .......................................................................44 Phase B .......................................................................45 Phase C .......................................................................46 Phase D .......................................................................47 Phase E .......................................................................48 Phase F ........................................................................49 Phase G .......................................................................50 Phase H .......................................................................51 Phase I ........................................................................52 Phase J ........................................................................53 Phase K .......................................................................54 Troubleshooting .................................................................55 High-Flow Single Circuit 2020/2023 ................................61 High-Flow Single Circuit Schematic ..........................62 Concrete Pump Control Block ....................................63 Switching Manifold ....................................................64 Stroke Limiter with Fast Switch/Dampner .................64 Phase A .......................................................................66 Phase B .......................................................................68 Phase C .......................................................................70 Phase D .......................................................................72 Twin Circuits .....................................................................74 1200 Twin Circuit with Switching Valves ........................75 Twin Circuit Schematic w/Soft Switch ......................76 Concrete Pump Control Block ....................................77 S3 Control Block ........................................................77 Soft Switch .................................................................78 Accumulator Unloader Valve .....................................78 Accumulator Control Block/Dump Valve ..................79 Phase A .......................................................................80 Phase B .......................................................................82 Phase C .......................................................................84 Phase D .......................................................................86 1200 Twin Circuit with MPS .............................................89 Twin Circuit with MPS/Soft Switch ...........................90 Concrete Pump Control Block ....................................91 S3 Control Block ........................................................91 MPS ............................................................................92 Accumulator Control Block/Dump Valve ..................93 Soft Switch .................................................................94 Phase A .......................................................................96. Training Manual.

(28) Table of Contents Phase B .......................................................................98 Phase C .....................................................................100 Phase D .....................................................................102 Twin Circuit with Variable displacement accumulator pump Schematic 104 Model Number Nomenclature .........................................105 Hi-Flow Pumpkits (2023-2525) ......................................106 Hi-Flow Pumpkits (2525H) .............................................107 Hi-Flow Pumpkits Schematic ...................................108 Concrete Pump Control Block .................................109 Main Relief/Soft Switch Block ................................110 MPS ..........................................................................111 S3 Control Block - Machined ...................................112 S3 Control Block - Cast ...........................................113 2023 Circuit diagram ................................................114 Phase A .....................................................................114 Phase B .....................................................................116 Phase C .....................................................................118 Phase D .....................................................................120. Booms Black & White .................................................................123 Electric/Air/Oil .........................................................123 Electric/Oil/Oil .........................................................123 Proportional .....................................................................125 Boom Holding Valves .....................................................126 28X B&W Boom .............................................................127 Load Sense Hydraulic Circuits ........................................131 Overview ..................................................................131 Components ..............................................................132 Basic Principles - Simple Circuit .............................133 Basic Principles - Orifice .........................................134 Basic Principles - Without Relief Valve ..................135 Basic Principles - With Relief Valve .......................136 Basic Principles - Delta-P ........................................137 Basic Principles - Delta-P ........................................138 Basic Principles - Pressure Cut-Off .........................139 Basic Principles - Shuttle Valves .............................140 Basic Principles - Pressure Regulator ......................141 A7 Variable Displacement Hydraulic Pump Training ....142 All Functions in Neutral ...........................................142 Cylinder Extend Function Initiated ..........................144 Hydraulic Cylinder Extending .................................146 Hydraulic Cylinder Fully Extended Pump ...............148 Fixed Displacement Pump Training ................................150 All Function in Neutral ............................................150 Boom Function Activated ........................................151 Cylinder Pressurized at the End of Stroke ...............152 Output Charts ...................................................................153 Using the Chart ................................................................154. Using a Nomograph ........................................................ 159 General information ................................................. 159 The quadrants ........................................................... 161 Minimum Pipe Wall Thickness ....................................... 167 Preventative Maintenance ............................................... 168 Scheduled Maintenance ........................................... 168 Filtration .......................................................................... 170 General information ................................................. 170 Specific information ................................................. 170 Changing hydraulic oil filters .................................. 170 Changing high pressure water filter ......................... 171 Hydraulic Oils ................................................................. 171 General information ................................................. 171 Specific information ................................................. 172 When to change your hydraulic oil .......................... 172. Electrical Introduction ..................................................................... 173 What is Electricity? ......................................................... 173 Amperage ........................................................................ 176 Voltage ............................................................................ 177 Resistance ........................................................................ 177 Basic Circuits .................................................................. 179 Schematics ...................................................................... 181 Circuit Types ................................................................... 181 Ohm’s Law ...................................................................... 183 Series Circuit Laws ......................................................... 185 Parallel Circuit Laws ....................................................... 186 Series – Parallel Circuits ................................................. 188 Circuit Faults ................................................................... 189 Using Test Equipment ..................................................... 190 The Troubleshooting Process ................................... 195 Electrical Symbols .......................................................... 196 Electrical Symbols .......................................................... 197 Electrical Symbols .......................................................... 198 Controller Systems .......................................................... 199 Analog ...................................................................... 199 Digi-Prop (Microwave) ............................................ 199 Comfort Control ....................................................... 199 C32 ........................................................................... 200 CPC .......................................................................... 200 CPC II ...................................................................... 200 Vector - Current Production ..................................... 201 28X Truck and Pumpkit Circuit ...................................... 203 28X Boom Circuit ........................................................... 204. Training Manual.

(29) SERVICE TRAINING. Misc Procedures Material Cylinder Alignment .......................................... 205 Pumping on piston side ................................................... 207 (Available on some units only) ................................ 207 Shimming the Differential Cylinders .............................. 208 Determining the proper shimm size ......................... 208 Dimension A ............................................................ 208 Dimension B ............................................................ 208 Formula .................................................................... 209 Apitech Control Chamber Air Bleed Procedure ............. 210 Hydraulic Pump Adjustments ......................................... 213 Main System Pumps A11VO ................................... 213 Setting the Flow Rate ............................................... 213 Horsepower Setting .................................................. 214 Q-min Output Flow .................................................. 214 Check all hydraulic pressures. ................................. 215 Setting pressures on Hi-flo -6 pumpkits .................. 215 Pressure setting procedure: ...................................... 216 Setting the soft switch relief pressure ...................... 217 Accumulator Bypass Retrofit .......................................... 219 Service Bulletin 1001-03 ......................................... 219 Trouble Shooting Kit ...................................................... 220. Training Manual. Table of Contents.

(30) Table of Contents. Training Manual.

(31) SERVICE TRAINING. The Schwing Group. Schwing America, Inc.. Schwing America, Inc. is a wholly owned subsidiary of the Schwing GmbH located in Herne, Germany. Schwing was founded in Germany in 1934, it has always been a family owned company and is currently managed by Gerhard Schwing. The Schwing Group has grown steadily since its inception over sixty years. The company is known for its innovation and worldwide operations. The Groups primary products are concrete pumps, ready mix trucks and batch plants. Pumping and boom technologies are applied to other products as opportunities arise. Currently the Schwing Group has factories located around the world at: • Schwing GmbH, Herne, Germany • Schwing GmbH, Memmingen, Germany • Schwing America, Inc., White Bear, USA • Schwing GmbH, St. Stefan, Austria • Schwing SIWA, Sao Paulo, Brazil • Schwing Shanghai, China • Schwing India The Schwing group also has numerous sales and service locations around the world.. SAI was started in 1974, located in a small office on Pierce Butler Road. At this time SAI was primarily a sales, service and parts facility, with the assembly and some manufacturing subbed out to Telelect. This arrangement continued until October 1978. Telelect suffered a prolonged strike, which really hurt SAI. It was at this time that the Schwing company purchased the property here at 5900 Centerville Road. This facility was previously a distribution center for Arctic Cat snowmobiles, and consisted of 114,000 sq. ft., which included a couple pole barns on 16 acres of land. In 1983, we added 20,000 sq. ft. of production space and then in 1986 we added 28,000 sq. ft. to this space introducing our paint facility and testing facility. Then in 1989, an additional 29 acres of land was purchased to the North, and our 20,000 sq. ft. weld shop was constructed. We also worked over one of the pole barns for our fab facility and trailer assembly plant. These additions have proven to be a major break through to make us a complete manufacturing facility. In 1993 we started on our 28,000 sq. ft. office facility. In 1995 we completed construction of a 62,000 sq. ft. state of the art Weld Shop. In addition, in 1996 we added the 15,000 sq. ft.. Training Manual. 1.

(32) SERVICE TRAINING. machining center, which is home of the new Forrest Line machining Center. For the year 2000, Schwing America, Inc. has added a 75,000 sq. ft paint booth. This state-of-the-art behemoth is the largest building in the surrounding communities. Dubbed the “Super Booth” by industry insiders. This is the largest facility for painting concrete pumps in the world. The six-story structure combines with retractable roof panels to accommodate unfolded booms. Painters will use catwalks to cover. every surface with high quality acrylic urethane in an endless array of colors and paint schemes. Climate controlled conditions assure proper curing and drying time. A new solvent recovery system keeps the Super Booth environmentally friendly. Today Schwing America has over 326,000 square feet of manufacturing space and employs over 400 people.. E N. S W. 2. Training Manual.

(33) SERVICE TRAINING. Hydraulic Training General Principles 1. Hydraulic pressure always takes path of least resistance.. 2. Hydraulic pressure is created equal in all directions (Pascal's Law). Pascal's Law 2 A 10 pound force applied to a stopper with a surface area of one square inch....... 1 The bottle is filled with a liquid, which is not compressible. 3 Results in 10 pounds of force on every square inch (pressure) of the container wall. 4 If the bottom has an area of 20 square inches and each square inch is pushed on by 10 pounds of force, the entire bottom recieves a 200 pound push.. 3. Liquids (oil) are relatively incompressible.. OIL. AIR. 1000 lbs of Force. 1000 lbs of Force. Training Manual. OIL. AIR. 3.

(34) SERVICE TRAINING. 4. When hydraulic pressure and flow is not converted into work it is converted into heat.. Open relief (Heat). 5. When oil is heated it will expand (5% or more). Atmospheric pressure forces water past seals. Vacuum formed as hydraulic oil cools Seals. Hydraulic Cylinder. Water Box. 6. When oil is heated the viscosity of it changes.. 6 bar 4. Training Manual.

(35) SERVICE TRAINING. 7. GPM (Gallons Per Minute) only determine the speed at which the actuator (motor or cylinder) operates.. 0 GPM. 10 GPM. 8. P.S.I. (Pounds Per Square Inch) determine only the amount of force exerted upon the load by the actuator. 10,000 LBS LOAD. 10 gallon maximum capacity cylinder. 10 inch of area on cylinder piston. 1000 PSI. Training Manual. 5.

(36) SERVICE TRAINING. 9. The resistance created in a hydraulic circuit, whether by the amount of the load on the actuator and/or the pressure drop in a circuit, is what determines how much work is required.. U.S. F = FORCE (in pounds) (lb). F=PxA. F P. A. P = F/A A = F/P. P = PRESSURE (in pounds per square inch) (P.S.I.) A = AREA (in square inches) (in2). METRIC F = FORCE (in kilograms) (Kg) P = PRESSURE (in kilograms per square centimeter) (Kg/cm2) A = AREA (in square centimeters) (cm2). GENERAL POWER =. QxP CONSTANT. Q = FLOW RATE (unit of volume per time period) P = PRESSURE (unit of force per unit of area). U.S. HP = HORSEPOWER HP =. GPM x PSI 1714. GPM = GALLONS PER MINUTE PSI = POUNDS PER SQUARE INCH 1714 = KNOWN CONSTANT. METRIC KW = KILOWATTS KW =. LPM x BAR 600. LPM = LITERS PER MINUTE BAR = METRIC UNIT OF PRESSURE 600 = KNOWN CONSTANT. 6. Training Manual.

(37) SERVICE TRAINING. Mechanical Versus Hydraulic. 1. An input force of 10 lb.(44.48 N) on a one square inch 2 (6.45 cm ) piston.... COMPARISON OF MECHANICAL FORCES VERSUS HYDRAULIC FORCES 2. will balance 100 lb (444.82 N) here.... 1. Ten pounds (44.48 N) here.... 3. This pressure will support a 100 lb. (444.82 N) weight if this is a 10 sq. in. (64.52 cm2 ) piston.. 100 lb. (444.82 N). 10 lb. (44.48 N) 1 sq. in. (6.45 cm2 ). 10 sq. in. (64.51 cm2 ). 2. develops a pressure of 10 pounds per square inch(psi) (.69 bar) (68.94 kilopascals) throughout the container. 100 lb. (444.82 N) 10 lb. (44.48 N). INPUT 4. this arm.. 3. if this arm is 10 times as long as.... 4. The forces are proportional to the piston areas.. OUTPUT. 100 lb. (444.82 N) 10 lb. (44.48 N) = 10 sq. in (64.52 cm2) 1 sq. in (6.45 cm2). A. SIMPLE MECHANICAL LEVER. B. SIMPLE HYDRAULIC PRESS. Transfer of Energy ENERGY CAN NEITHER BE CREATED NOR DESTROYED 1. Moving the small piston 10 in. 0.25 m) displaces 10 cu. in. (163.87 cm3) of liquid. (1 sq. in. x 10 in. =10 cu. in.) (6.45 cm2 x 25.40 cm = 163.87 cm3). 2. 10 cu. in. (163.8 cm3) of liquid will move the larger piston only 1 in. (2.54 cm) (10 sq. in. x 1 in. = 10 cu. in.) (64.52 cm x 2.54 cm = 163.87 cm ). 100 lb. (444.82 N). 10 lb. (44.48 N) 1 sq. in. (6.45 cm2). 10 sq. in. (64.51 cm2) 1 in (0.02 m) 10 in (0.25 m). 4. The energy transfer here also is 100 in. lb. (11.30 Nm) (1 in. x 100 lb. = 100 in. lb.) (.02 m x 444.82 N = 11.30 Nm). 3. The energy transfer here equals 10 lb. x 10 in. (44.48 N x 0.25 m) or 100 in. lb. (11.30 Nm). Training Manual. 7.

(38) SERVICE TRAINING. Hydraulic Jack. HYDRAULIC ROD. 8". PISTON. Linear & Rotary Actuators LINEAR ACTUATOR. 1.The pump pushes the hydraulic liquid into lines.. ROTARY ACTUATOR. 2. Lines carry the liquid to actuators which are pushed to cause a mechanical output to move a load.. 4. Rotary actuators or motors give the system rotating output. They can be connected to pulleys, gears,rack-and-pinions, conveyors, etc.. MOTOR. PUMP LOAD. PUMP. PISTON & ROD TO RESERVOIR. 3. Some actuators operate in a straight line (linear actuators). They are called cylinders or rams. They are used to lift weight, exert force, clamp, etc.. 8. Training Manual. ROTARY DRIVE SHAFT.

(39) SERVICE TRAINING. Basic Hydraulic Components. Check Valve. Throttle Valve. Throttle Check Valve. Switching Valve. Training Manual. 9.

(40) SERVICE TRAINING. Check Valve Comparison. In-Line Check Valve. Cartridge Check Valve. Right Angle Check Valves. 10. CHECK VALVE COMPLETE P/N 30333030. CHECK VALVE COMPLETE P/N 30333031. CARTRIDGE W/SEALS P/N 30333032. CARTRIDGE W/SEALS P/N 30333033. SEAL KIT ONLY P/N 30333034. SEAL KIT ONLY P/N 30333035. TORQUE SPECIFICATION 55 ft/lbs.. TORQUE SPECIFICATION 200 ft/lbs.. Training Manual.

(41) SERVICE TRAINING. Shuttle Valve. B. A shuttle valve is used where the higher of the two pressures must be selected, while blocking the lower pressure input.. A. C B. A. C. The valve has two inlet, ports “A” and “C”, and one output port “B”. When either port A or C is pressurized, a ball automatically seals the other inlet and allows the higher pressure fluid to flow to port “B”.. B. B. A. C. Greater pressure from "A" port. A. C Greater pressure from "C" port 39000145.ai. Training Manual. 11.

(42) SERVICE TRAINING. Throttle Check Valve Flow control valve Model MK is pressure, temperature and viscosity dependent throttle/check valves, used to restrict flow. It consists of adjustment sleeve (1) and inner housing (2).. 5. 4. 3. 1. 6. 2. Model MK (Throttle/Check Valve) This valve is capable of flow control in one direction while allowing reverse free flow in the opposite. Fluid passes spring (6), through radial drilling and throttling area (4). Throttling is achieved similarly to the MG valve. In the reverse direction, pressure acts on the area of check valve (5). When pressure exceeds spring force (6), the poppet opens, allowing reverse free flow through the valve. Fluid also passes through the throttle area (4), thereby flushing contamination from the valve.. Throttle Check Valve Model MK. Caution! Do not adjust the valve while under pressure. 5. 12. 4. 6. 5. Training Manual. 4. 6.

(43) SERVICE TRAINING. Switching Valves. POPPET END PORT. The switching valves have a logic function in that they sense multiple pressures simultaneously and will route oil from the poppet end port to the output port only when the pressure from the poppet end port exceeds the pressure at the spring end port by more than 2:1 in most situations. BODY SEAT. O-RING AND BACK-UP RINGS. POPPET HOUSING. SIDE POR (PLUGGED. SIDE PORT POPPET. BODY. O-RING AND BACK-UP RING. SPRING. SIDE PORT. SPRING GUIDE. SPRING END POR T SPRING END PORT. SPRING GUIDE SPRING POPPET POPPET END PORT. Pressure equal on both sid es. POPPET HOUSING. High Pressure pushes poppet backallowing oil to flow through th e side port, sending a signalto S3. Training Manual. Pressure greater onthe Spring End Port forcingthe poppet to close. 13.

(44) SERVICE TRAINING. Hydraulic Pumps. Concrete pump hydraulic pumps. Placing boom hydraulic pumps Load sensing proportional The hydraulic pump for the placing boom is a variable displacement, bent axis, axial piston pump, with load sensing control. It can feed all of the following components: • the hydraulic cylinders on the boom sections • the hydraulic cylinders on the outriggers • the hydraulic motor for the boom slewing gear • the hydraulic motor for the water pump • the hydraulic motor of the compressor (optional equipment). The hydraulic pumps for the concrete pump circuit are bent axis, variable displacement piston pumps. They are horsepower controlled, which means that as pressure rises, the flow decreases, so the power consumption remains constant. We use this type of pump so the truck engine will not bog down under hard pumping conditions. The pumps also accept external signals for control of the output. At Schwing, we route signals to the pump from the hydraulic stroke limiter and the dampener (with single circuit), or the accumulator (with twin circuit). The net effect of these devices is to tell the pump to put out less oil per revolution, as required by the pump operator.. The directional control valves for all of the above circuits are incorporated into control blocks and equipped with hand levers. In addition, the control block for the boom functions have electric over oil piloting for operation via remote control. PumpKit Pumps PumpKit Pumps. Proportional Boom Pump. Boom Pump Accumulator Pump. Oil Cooler Pump. Agitator Pump. Stiebel 4194. Proportional Boom Pump. Stiebel 4400 PumpKit Pumps. PumpKit Pumps. Proportional Boom Pump. Accumulator Pump. Oil Cooler Pump. Accumulator Pump Agitator Pump Oil Cooler Pump. Agitator Pump. Stiebel 4194. InLine Drive (other options are available). 14. Training Manual.

(45) SERVICE TRAINING. Fixed Displacement Pump. Variable Displacement Pump. Rexroth A2F20. Rexroth A7VO. Fixed displacement pumps discharge a set volume of fluid regardless of the system requirements. This volume can be changed only by changing the drive speed of the pump. If the system requires less fluid than the pump is discharging, the balance of the flow must find an alternate pah which is usually over a relief valve and back to the reservoir.. Variable pump with axial tapered piston rotary group of bent axis design, for open circuit hydraulic drives. This pump is suitable for mobile applications. Comprehensive programming of control devices is available. The robust taper roller drive shaft bearings are designed to give long service life. Output flow is proportional to drive speed and pump displacement is steplessly variable between maximum and zero. Horse Power Control (other locations possible) Q min. Q max. Q max. 25ß -. 0ß. Q min. Horsepower Adjustment Screw (other locations possible). Training Manual. 15.

(46) SERVICE TRAINING. Variable Displacement Axial Piston Pump RexrothA10VO Variable displacement axial piston A10VO of swash plate design is designed for hydrostatic transmissions in open loop circuits. Flow is proportional to the drive speed and the displacement. By adjusting the position of the swash plate it is possible to smoothly vary the flow.. RexrothA11VO The A11VO is a variable displacement pump of axial piston swash plate design for use in open circuit hydrostatic drives. Designed principally for use in mobile applications. A wide variety of controls are available. Setting of the constant power control is possible via external adjustments, even when the unit is operating. The pump is available with a through drive to accept a gear pump or a second axial piston pump up to the same size (100% through drive). Output flow is proportional to drive speed and pump displacement and is steplessly variable between maximum and zero.. Q min. Pressure Cut-off Screw Q max. 16. Training Manual.

(47) SERVICE TRAINING. Rexroth A11VO Adjustments Pressure Cut-Off. Pressure Cut-Off. Delta P. Q min. Q min. Load Sense Port. Q max Q max. A11VO Boom Pump. A11VO Accumulator Pump. Horsepower Control *Stroke Regulation. *Stroke Regulation **Pressure Cut-Off. Pressure Cut-Off. Horsepower Control. Style #1 ***Pressure Cut-Off Q min Horsepower Control. Q min *Stroke Regulation. Style #2 * The beginning of stroke regulation has been increased from 5-7 bar to 8-10 bar on pumps with the following serial numbers:. **. Pressure Cut-Off / Style #1 Turn Clock-wise to increase the pressure Turn Counter-Clock-wise to decrease the pressure. ***. Pressure Cut-Off / Style #2 Turn Counter-Clock-wise to increase the pressure Turn Clock-wise to decrease the pressure. A11VO 130 - 21034174, dated 08/22/05 A11VO 190 - 21006318, dated 08/01/05 Pumps with serial numbers below these should also have beginning of stroke regulation pressure set to 8-10 bar.. A11VO 190/130 Main Pumps. Training Manual. 17.

(48) SERVICE TRAINING. Transfer Cases Hydraulic pumps for the concrete pump, placing boom, agitator, etc., are usually mounted on a distribution gearcase. When you are driving the truck, the power of the truck engine is transmitted through the truck transmission, through a propeller shaft, through the bottom of the distribution gearcase, through another propeller shaft, and into the rear end(s) of the truck.. When you are operating the unit, the distribution gearcase interrupts the power to the rear ends, and transmits it to internal gears that turn the hydraulic pumps. Changing between travel and pumping modes is accomplished by means of an air switch in the truck cab.. 4194. 4195. 4400. 18. Training Manual.

(49) SERVICE TRAINING. Relief Valves This is a direct acting non adjustable relief valve. When the oil has enough pressure to over take the spring the relief poppet will start to move out of the way and allow the excess pressure to be relieved to tank. This style pressure relief is not adjustable except by changing the internal spring.The maximum system pressure that this style can be used for is limited because the spring must directly act upon system pressure and thus higher pressures would require a larger spring. When this direct acting design relieves it causes pulsations in the system.. Pressure. This is a pilot operated adjustable relief valve. The relief poppet has a small orifice in it that allows the hydraulic pressure to also be applied on the back side of the poppet. This internal chamber is hydraulically locked and it will hold the main poppet closed as long as it has equal pressure on the front side and the back side. There is also a much smaller pilot poppet, that is operator adjustable. This smaller poppet, with a smaller area, can have a smaller spring controlling it. Once this pilot poppet opens we lose our hydraulic lock, the pressure is reduced on the back side and thus the main poppet can relieve the excess pressure to tank. With this design we are able to control large volumes of oil at high pressures with minimal sized springs.. Pressure. Tank. Tank. This is a direct acting adjustable relief valve. When the oil has enough pressure to over take the spring the relief poppet will start to move out of the way and allow the excess pressure to be relieved to tank. This style is adjustable though a external control which varies the spring tension on the relief poppet.The maximum system pressure that this style can be used for is limited because the spring must directly act upon system pressure and thus higher pressures would require a larger spring.. Pressure. Tank. Pressure Pressure. Tank. Tank. Training Manual. 19.

(50) SERVICE TRAINING. Safety Relief Valves. Pressure Relief Valves Type DBW. Pressure control valve type DB/DBW are pilot operated pressure relief valves. They are used to limit (DB) or unload by means of solenoids (DBW) pressure in a system. Pressure relief valves (DB) consist mainly of a pilot valve with pressure setting element and main valve with main spool insert.. In principle, the function of this valve is the same as that of valve type DB. Unloading at the main spool is achieved by means of actuating the built-on directional control valve.. Pressure Relief Valve Type DB Pressure in line A affects the main spool (1). At the same time there is pressure via control passage (4) and (5) through orifice (2), (3) and (15) to the spring loaded side of the main spool (1) and pilot poppet (6). If system pressure exceeds the value set at the spring (8), pilot poppet (6) opens. The oil on the spring loaded side of the main spool (1) now flows through orifice (3), control passage (5) and poppet (6), and into spring chamber (9). From here it flows internally - type DB.-30/.through passage (10), or externally-type DB.-20/.Y.by means of control port (11) to tank. Orifices (2), (3) and (15) cause a pressure drop at the main spool (1), and the connection from line A to line B opens. The oil now flows from line A to line B, while the set operating pressure in maintained. The valve can be unloaded or switched to a different pressure (second pressure rating) by means of port “X” (13).. VENT LINE. 20. Training Manual.

(51) SERVICE TRAINING. Hydraulic Symbols SHOWING DIN (DEUTSCHE INDUSTRIAL NORM) SYMBOLS USED ON SCHWING SCHEMATICS NO ATTEMPT HAS BEEN MADE TO SHOW EVERY POSSIBLE COMBINATION.. LINE, WORKING P = R 1/2" T = R 1/2" SP = R 3/4" G = R 3/8" AC = R 11/2" Y = R 3/8". Nitrogen pressure set at 55 bar (800 PSI) G. 1.9 mm. LINE, JOINING ("T" FITTING). S3 0.8 mm hole drilled through spool. 190 bar. SP. LINE, PASSING 138 bar Y. This line MUST return to tank by itself. P. NG 10. 10. T. Filter. Agitator. LINE TO RESERVOIR (TANK). 2.0 mm. A. LINE, PILOT or SIGNAL. B. 300 bar. BP 750 & 1000 TC. S1. (with twin cylinder switching and Hartman control valves). X. P 0-25 bar. 2.0 mm. 599010 1-95 RE Y(T) A. 125 b bar. LINE, PLUGGED P. RESTRICTION, FIXED (orifice, nozzle) 0.7 mm. 100 bar. LINE, WORKING. LINE, PILOT or SIGNAL. Y. G. 12. Filter. R. A11VO. LINE, PASSING. LINE TO RESERVOIR (TANK) (ABOVE FLUID LEVEL) (BELOW FLUID LEVEL). CONNECTOR LINE, PLUGGED LINE, JOINING ("T" FITTING). RESTRICTION, FIXED (orifice, nozzle). Training Manual. 1.3. 1.3 OR. 21.

(52) SERVICE TRAINING. Hydraulic Symbols (Cont.). RESTRICTION, VARIABLE (throttle valve or adjustable orifice). PUMP, SINGLE FIXED DISPLACEMENT. MANUAL SHUT-OFF VALVE. PUMP, SINGLE VARIABLE DISPLACEMENT. (MANITROL VALVE). X1 X2. M. A A1. PRIME MOVER, ELECTRIC MOTOR PUMP, SINGLE VARIABLE DISPLACEMENT, SHOWING HORSEPOWER CONTROL CIRCUITS.. D PRIME MOVER, INTERNAL COMBUSTION ENGINE (Diesel shown..."G" if gas.). MOTOR, ROTARY, FIXED DISPLACEMENT. MOTOR, ROTARY, FIXED DISPLACEMENT BI - DIRECTIONAL. 22. Training Manual. S.

(53) SERVICE TRAINING. Hydraulic Symbols (Cont.). CYLINDER, SINGLE ACTING. PRESSURE GAUGE. CYLINDER, DIFFERENTIAL ROD. TEMPERATURE GAUGE. ACCUMULATOR, GAS CHARGED. CYLINDER, DOUBLE END ROD. ACCUMULATOR, SPRING LOADED. FILTER OR STRAINER. CYLINDER, DOUBLE END ROD WITH GROOVES IN PISTON ROD FOR SWITCHING FUNCTION (ROCK VALVE SHIFTING CYLINDER). FILTER WITH INTEGRAL BYPASS CHECKVALVE. Training Manual. 6 bar. 23.

(54) SERVICE TRAINING. Hydraulic Symbols (Cont.) OIL COOLER WITH ELECTRIC FAN MOTOR. M. HYDRAULICALLY UNLOCKABLE CHECK VALVE. (CLOSED). OIL COOLER WITH HYDRAULIC FAN MOTOR. HYDRAULICALLY UNLOCKABLE CHECK VALVE WITH INTEGRAL RELIEF VALVE.. (OPEN). 320 BAR. (H.E.R. BOOM HOLDING VALVE). BASIC VALVE ENVELOPE PRESSURE SWITCH NORMALLY CLOSED NORMALLY OPEN. PRESSURE RELIEF VALVE (SAFETY VALVE OR SAFETY CARTRIDGE). CHECK VALVE (BASIC). CHECK VALVE, FIXED FORCE. 280 bar. A 2.0. (SPRING FORCE INDICATED). PRESSURE RELIEF VALVE WITH EXTERNAL DRAIN. 300 bar. (SHOWN WITH A NORMALLY OPEN SOLENOID VALVE... MANY OTHER POSSIBILITIES ARE AVAILABLE).. ADJUSTABLE CHECK VALVE (PRETENSION OR PRELOAD VALVE) (Desired spring force indicated). 6 BAR. 300 bar. PRESSURE RELIEF VALVE WITH EXTERNAL DRAIN. 24. Training Manual. F NR.

(55) SERVICE TRAINING. Hydraulic Symbols (Cont.) A. P 0-55 bar. Y(T) A. PRESSURE REDUCING VALVE. ACCUMULATOR UNLOADING VALVE. MANUAL (STROKE LIMITER) OR DAMPNER. P. Y. T. P T. 70 bar. B. 300 bar. 0-50 bar. A. PRESSURE REDUCING VALVE (ELECTRIC STROKE LIMITER). P. P. T. T. ACCUMULATOR DUMP VALVE (ELECTRIC). A 55 bar T P T P MY. Pressure reducing valve. MG G Y. A Electric stroke limiter. 1.5. THROTTLE CHECK VALVE. FIXED (size shown). ADJUSTABLE. SLEW BRAKE VALVE. P. P A. CARTRIDGE VALVE (SWITCHING VALVE). OLD WAY. NEW WAY. SHUTTLE VALVE. SHOWN 2 DIFFERENT WAYS. P. P. Training Manual. A. 25.

(56) SERVICE TRAINING. Hydraulic Symbols (Cont.). X1 X2. A A1. S. B. COMPONENT ENCLOSURE BRAKE VALVE (BERINGER) (USED ON #1 SECTION DOWN FUNCTION). X. A. BALL COCK (SHUT OFF VALVE, QUARTER TURN VALVE) B. BRAKE VALVE (COUNTERBALANCE VALVE) (USED ON ALL SECTIONS KVM 52 & 55) B R. X. Z. A. Y. BRAKE VALVE (SAUER) (USED ON #1 SECTION DOWN FUNCTION). Z. VENTED RESERVOIR (TANK). R. 26. Training Manual. X. A.

(57) SERVICE TRAINING. Hydraulic Symbols (Cont.) DIRECTIONAL CONTROL VALVES. DIRECTIONAL VALVE: METHODS OF OPERATION. BASIC VALVE SYMBOL MULTIPLE FLOW PATHS PILOT PRESSURE. DIRECTIONAL VALVE. OR. 2 POSITION, 3 WAY. SOLENOID. DIRECTIONAL VALVE 2 POSITION, 4 WAY. SPRING. DIRECTIONAL VALVE 3 POSITION, 4 WAY, CLOSED CENTER. MANUAL (HANDLE OR PUSHBUTTON). DIRECTIONAL VALVE 3 POSITION, 4 WAY, OPEN CENTER. DETENT. DIRECTIONAL VALVE 3 POSITION, 4 WAY CLOSED PRESSURE CENTER. HAND LEVER. DIRECTIONAL VALVE 3 POSITION, 4 WAY, TANDEM CENTER (REQUIRES A HOLLOW SPOOL). EXAMPLES OF COMBINATIONS OF METHODS. 3 POSITION, 6 WAY, CLOSED CENTER (10631). SOLENOID OPERATED, SPRING RETURN. DIRECTIONAL VALVE, 3 POSITION, 6 WAY, CLOSED PRESSURE CENTER, ORIFICED A & B PORTS IN CENTER (10632F). HAND LEVER OPERATED WITH DETENT. DIRECTIONAL VALVE, 3 POSITION, 5 WAY, LOAD SENSING, CLOSED PRESSURE CENTER, INFINITE POSITIONING. HAND LEVER OR SOLENOID OPERATED, SPRING CENTERED. DIRECTIONAL VALVE. (PROPORTIONAL). SOLENOID CONTROLLED, PILOT PRESSURE OPERATED, SPRING CENTERED, WITH HAND LEVER. DIRECTIONAL VALVE, 3 POSITION, 5 WAY, LOAD SENSING, CLOSED CENTER, INFINITE POSITIONING (PROPORTIONAL). X. P. PRESSURE REGULATOR (REGULATES DELTA P) USED ON LOAD SENSING SYSTEMS. OR. A. T. Training Manual. 27.

(58) SERVICE TRAINING. Formulas Piston Side. Rod Side. R2. R2. = 3.14 R = 1/2 of Diameter 5. = 3.14 R = 1/2 of Diameter 2.5. 10,000 Pounds. 3.14(2.5 x 2.5) = 19.625 3.14 x 6.25 = 19.625. 3.14(1.25 x 1.25) = 4.90625 3.14 x 1.5625 = 4.90625. Piston - Rod = Rod Side Area. Area of piston = 19.625. 19.625 - 4.90625 = 14.719. 19.625 10,000 Pounds. 10,000 = 509.55 19.625. 10,000 = 679.39 14.719. To move this load it will take about 510 psi. To move this load it will take about 680 psi. POWER =. 5100 1714. 28. 14.719 10,000 Pounds. 10 GPM x 510 1714 (A Constant). POWER =. 6800 1714. = 2.975 HP. Training Manual. 10 GPM x 680 1714 (A Constant) = 3.967 HP.

(59) SERVICE TRAINING. Pumpkits Single Circuit Pumpkits. Twin Circuit Pumpkits. 800. 1200 w/Switching Valves. 801. 1200 w/MPS. 900/1200. 2023 Hi-Flow. Hi-Flow. 2525 Hi-Flow PumpkitCompare.eps. Training Manual. 29.

(60) SERVICE TRAINING. 800 Gate Valve. 30. Training Manual.

(61) SERVICE TRAINING. 801 Gate Valve. Training Manual. 31.

(62) SERVICE TRAINING. 801 Pumpkit Schematic 5. Pipe Gate. Hopper Gate. 9B 9A. 6. 4. 3. 7 300 bar. 8. 10A. 10B D. 12A. 12B. 11A. 11C 11B. 2 6 bar. 2 1. 39000156.eps. 1. Hydraulic oil reservoir. 7. Directional control valve S-2. 2. Main hydraulic pumps. 8. Locking Valve. 3. Main pressure relief valve. 9A–9B. Needle valves. 4. Directional control valve S-1 (forward/reverse). 10A–10B. Hydraulically Unlockable Check valves. 5. Gate Valve. 11A–11C. Check valves. 6. Directional control valve S-3. 12A–12B. Differential Cylinders. 32. Training Manual.

(63) SERVICE TRAINING. Concrete Pump Control Block. T P1. 9B 9A. T. 9B. 6. S3. S1. 4. 1.5 mm hole drilled through spool. S2. 300 bar. B. 7. A. 3 8. 9A. 3. 8. S-1. S-2 7. S-3 6 39000155.eps. Training Manual. 33.

(64) SERVICE TRAINING. Stroke Limiter. 1. P 2. A 4. T. P. 3. 0-50 BAR. 4 1. 3 2. T. A 39000158.eps. 494 Block A 5. B. 3. agitator motor. 6. P 1 2. Agitator pressure*. H2O pump motor. 6. 3. A B. 2. H2O pressure*. 5 1. 4. 2. 1. 4. 39000157.eps. CA B. 34. Training Manual.

(65) SERVICE TRAINING. Hydraulically Unlockable CheckValve. C B. B. A C. B. 2 1. A 1. C. 0.7 mm. 2. 39000160.eps. Gate Valve B. A. B. 1. D 1. A. C 2. D 2. C Training Manual. 39000163.eps. 35.

(66) SERVICE TRAINING. 36. Training Manual.

(67) SERVICE TRAINING. 900-1200 Single Circuit. Single Circuit. Training Manual. 37.

(68) SERVICE TRAINING. 900-1200 Single Circuit Schematic. 900 Pumpkit - eps. 5. 1. 10A. 11. 10B. 6. 7. 3. 4 10D. 10C. D. 10E. 9A 8A. 2. 8B. 2. 12. 9B. 10F 1. 1. Hydraulic oil reservoir. 8A–8B. Differential hydraulic cylinders. 2. Main hydraulic pumps. 9A–9B. Switching valves. 3. Main pressure relief valve. 10A–10F. Check valves. 4. Directional control valve S-1 (forward/reverse). 11. Ball cock (Shutoff valve). 5. Rock valve slewing cylinder. 12. Hydraulic oil filter with bypass valve (return filter. 6. Directional control valve S-3 7. Directional control valve S-2. 38. Training Manual.

(69) SERVICE TRAINING. Concrete Pump Control Block. P1 X. S3 1.5 mm hole drilled through spool. 6. S1. P. 10B. P2. T. 4. 300 bar. S2. B. 3. R. X. 7. A 10A. Port size limits flow. 3. 4. S-1. 7. S-2. S-3 6. 39000147.eps. Training Manual. 39.

(70) SERVICE TRAINING. Stroke Limiter. 1. P 2. A 4. T. P. 3. 0-50 BAR. 4 1. 3 2. T. A 39000158.eps. 494 Block A 5. B. 3. agitator motor. 6. P 1 2. Agitator pressure*. H2O pump motor. 6. 3. A B. 2. H2O pressure*. 5 1. 4. 2. 1. 4. 39000157.eps. CA B. 40. Training Manual.

(71) SERVICE TRAINING. Switching Valve C C B. B 2. 1. A. 2 1. 39000161.eps. A. A7VO. 1. A. 2. Q min. 1 2 B. Q max. A. X1. B. X1 X2. X2. 1. A. A A1. 1. A1. D 2. 2 To Boom Circuit. S. S. Training Manual. 39000162.eps. 41.

(72) SERVICE TRAINING. Rock Valve 1. A 2. B. C. D. A 1. C D. 2. E. F GH. B F H. G E 39000164.eps. 42. Training Manual.

(73) SERVICE TRAINING. Training Manual. 43.

(74) SERVICE TRAINING. Phase A. oil of the left hand differential is directed back to tank via valves S2 and S1 and through the filter (7). Oil directed through the S3 has the rock valve shift cylinder held in the retracted (right) position so that concrete from the left hand material cylinder is being pushed into the delivery pipe line. Concrete from the hopper is being sucked into the right hand material cylinder.. First working stroke. With S1 valve (1) in the forward position, and the S2 valve (2) in the left position oil flows to the right hand differential acting on the rod side. Oil from the piston side of the right hand differential oil is passed to the piston side of the left hand differential and the rod side. KEY. 4. High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest). 12. 18. 13. 3 S3. 1.5 mm hole drilled through spool. S1 300 bar. 1 10. 2 S2 14. 15. 20 D. 5 6. 44. 16. 8. 7. M. 17. Training Manual. 6 bar.

(75) SERVICE TRAINING. Phase B. (1), filter (7) and back to the hydraulic tank.. End of first working stroke. * NOTE: If the left hand differential has not fully extended at this point due to not enough loop oil, high pressure oil will continue to flow through check valve (17) on the right hand differential until the left hand differential is fully extended.. The differential cylinders have reached the end of their stroke position*. Switching valve (5) is sending a high pressure signal to the left hand end cap of S3 valve (3). Oil from the right hand end cap of the S3 valve (3) is relieved via check valve (15), the S2 valve (2), S1 valve. KEY. 4. High Pressure Rocking Oil Low Pressure Zero Pressure (Tank, or oil at rest). 12. 18. 13. 3 S3. 1.5 mm hole drilled through spool. S1 300 bar. 1 10. 2 S2 14. 15. 20 D. 5 6. 16. 8. 7. M. 17. Training Manual. 6 bar. 45.

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