schwing trainingmanual

TRAINING MANUAL

5900 Centerville Road White Bear, MN 55127 TEL 651-429-0999 FAX 651-429-2112 www.schwing.com

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

SERVICE TRAINING

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............................................................. 1-813-985-8311Northern California........................................ 1-925-371-8595Southern California ....................................... 1-562-493-1012Georgia ........................................................... 1-678-560-9801Texas .............................................................. 1-972-245-5166

Training Manual

Table of Contents

SERVICE TRAINING

Typical Twin Circuit ........................ 1

PTO Switch/Air Valve ..................................................1PTO ...............................................................................2Continuous Duty Solenoid ............................................2CPC/CPCII Controller ..................................................3Hydraulic Pumps ...........................................................3Fixed Displacement ......................................................4Variable Displacement ..................................................4Main Control Block Brain .........................................4Concrete Pump Forward/Reverse Valve .......................5Main Control Block - S1/S2 Spool ...............................5Main Relief Valve .........................................................6Differential Cylinders ...................................................6Material Cylinders ........................................................7Differential Cylinder - Bottomed Out ...........................7MPS Valve ....................................................................8S3/Accumulator Control Block .....................................8Accumulator Theory .....................................................9Rock Valve Slewing Cylinder ......................................9Soft Switch Relief Valve ............................................10Main Control Block - S2 Spool ..................................10Differential Cylinder - Beginning of stroke ................11MPS ............................................................................11Differential Cylinder - Bottomed Out .........................12MPS ............................................................................12S3/Accumulator Control Block ...................................13Rock Valve Slewing Cylinder ....................................13Soft Switch Relief Valve ............................................14Main Control Block - S2 Spool ..................................14Differential Cylinders .................................................15

Typical Boom Circuit .................... 16

Boom Pump ................................................................16E-Stop Manifold .........................................................17Poppet Valve Theory ..................................................17E-Stop - Override .......................................................18Boom Handvalve - No functions activated ................18Boom Handvalve - Outrigger enabled ........................19Outrigger Handvalve ..................................................19Boom Handvalve - Boom Function Activated ...........20Pulsar Coil Theory ......................................................20Boom Holding Valves ................................................21Manual Controls and Overrides ..................................21

Service Manual

Table of Contents

SERVICE TRAINING

SERVICE TRAINING

Training Manual 1

Typical Twin Circuit

PTO

Hydraulic Pumps

Accumulator Pump

Boom Pump

Differential Cylinders

Main Control Block

Main Relief/Soft Switch

MPS Valve

S3/Accumulator Valve

Rock ValveSlewing Cylinder

Rock Valve

Material Cylinders

To:PTO

From:Truck Air Supply

Air Pressure Switch

Air blocked by spool

Air Pressure Switch(Energized)

PTO Switch/Air Valve

Switch pushed in, air supply blocked by spool.

Switch pulled out , opening is created allowing air pressure to energize the air pres-sure switch.

A passage way is created allowing air pres-sure to be sent to the PTO.

PULLTO APPLY

PARKINGBRAKEPUSH TORELEASE

QUARTZ00000.11 HOURS

Must be pulled

PTO switchPower to fuse

SERVICE TRAINING

Training Manual2

Air Supply Block

ForkPTO.eps

To:12v Controller

CPC/CPC II Style(Not used on Vector units)

Cont_Solenoid.eps

Magnetic Coil

Plunger

From: 12v Power Supply

To: Controller

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.

All hydraulic pumps for the concrete pump, plac-ing boom, agitator, etc. are mounted on a distri-bution gearcase. When you are driving the truck, the power of the truck engine is transmitted through the truck transmission, through a propel-ler 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 distributiongearcase 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 Con-tinuous Duty Solenoid

The signal energizes the magnetic coil in the Continuous Duty Solenoid

The energized magnetic coil, pulls the plunger down

A connection is established between the 12 volt power supply and CPC Controller

SERVICE TRAINING

Training Manual 3

POWER

REAR CTR

UMB CTR

RADIO CTR

ID

LINK

ALARM

E-STOP

WHEN WELDING ANYWHERE ON UNITPOWER CABLE MUST BE DISCONNECTED

L1357-01

HOME HELP

CLEAR ENTER

OFF

QUIT

+

-

START

OK1

0

2

3PTO

Menu: [ENTER]=ON

1500 rpm 62C

x1000

CPC/CPC II

Vector

X12 Connector(Behind)

Power Connector

Typical Gearbox

To: Main Control Block

Pumpkit Pumps

To: Boom Control Block

To: S3 Accumulator

To: Agitator

To: Oil Cooler

Hydra

ulicPu

mps.e

ps

CPC/CPCII Controller

The CPC/CPC II provides a proportional signal toeach of the boom functions and the concrete pumpoutput. 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.

Vector Controller

The Vector control system is a completely digi-tal control system, which means that the function movements are converted to numbers (0s and 1s). The numbers are sent to the controller where they are analyzed, converted back to ana-log (voltage or current), and sent to the valves and indication devices.

Hydraulic Pumps

The hydraulic pumps for the concrete pump cir-cuit 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.

SERVICE TRAINING

Training Manual4

Variable DisplacementBent Axis

Fixed DispalcementBent Axis

Variable DisplacementSwash Plate

PumpCutaways.eps

min

min

max

max

S1 Spool

S2 Spool

From: Pumps

S1 - Neutral Position, pathway block

HiFlowBrain.eps

To: TankTo: Tank

Fixed Displacement

Puts out a set amount of oil, that can only be changed by increasing/decreasing the RPMs.

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.

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 Hydraulic oil will flow through the Main

Control Block and go back to the hydraulic tank.

From: Pump

From: Pump

SERVICE TRAINING

Training Manual 5

From: Pump

P2 Vent

To: Main Control Block/MPS Valve

To: Main Control Block (XP port)and MPS Valve (XB port)

Passageway created (Forward position)

Blocked pathway (Neutral) AB

P

T

A B

A B

XP XR

S1 Spool

S2 Spool

S1 - Forward Position,pathway to S2 spool created

Pathway to Differential cylinder

HiFlowBrain_S1.eps

Concrete Pump Forward/Reverse Valve

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.

In the forward position, a passage way is created between the pressure port and the A port, through grooves in the spool.

Oil is sent to the XP port of the Main Hydraulic Control Block and the XB port of the MPS valve.

This valve also plugs the vent line, which allows pressure to build in the system

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.

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 Dif-ferential Cylinder.

From: Pump

To: Differential Cylinder

From: CP Forward/Reverse Valve

From: Pump

SERVICE TRAINING

Training Manual6

Less than relief pressure Over relief pressure

Poppet opens Excess oil drained to tank

80 bar

350 bar

To:MPS ZK2

To:MPS ZK1

To:MPS ZS1To:MPS ZS2

From: Pumps

From: Pumps

DiffCylinders.eps

Loop Oil

High pressure oil

Main Relief Valve

The main relief valve protects the hydraulic cir-cuit, by relieving pressure before it reaches 350 bar or greater.

Pressure exceeds 350 bar and presses against the 350 bar main relief valve plunger.

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 pop-pet spring chamber.

Pressure is greater on the piston side of the poppet than the spring side. This will col-lapse 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.


The term differential cylinder means that each hydraulic cylinder that pushes the concrete has an area difference (referred to as an area differ-ential) 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 con-trast to the rockvalve slewing cylinder, for example, which has a rodextending from both ends of the piston and there-fore 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 differen-tial 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.

SERVICE TRAINING

Training Manual 7

MatCylinders.e

Concrete pushed through Rock Valve

Concrete sucked in from hopper

From: Pumps

From: Pumps

To:MPS ZK2

To:MPS ZK1

DiffCylinders_Bottom.ep


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.

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.

SERVICE TRAINING

Training Manual8

ZK2

ZS2

XA

B

ZK1

SP T

ZS1

XB

A

X3

To:S3 Spool

From:Differential

Cylinder

Passage way created

To: Soft SwitchReversing Valve

From: Accumulator Pump


From: MPS valve "B" port

To: Rock valve slewing cylinderand S2 spool

S3_Block02.eps

MPS Valve

The MPS system consists of three small direc-tional control valves. The main pressure that is supplied to these directional control valve is sup-plied by the accumulator.

A high pressure signal line from the Differ-ential 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.

To:S3 Spool


From: Differential Cyl.


S3/Accumulator Control Block

Hydraulic oil from the MPS valve A port enters the XA port of the S3/Accumulator Control Block.

The S3 spool moves to the left. 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


SERVICE TRAINING

Training Manual 9

Without NitrogenCharge

With nitrogen chargedto pressure P1

Influx of hydraulic oilfor storage

Fluid charged tomaximum working

pressure P3

Discharge ofhydraulic oil

Fluid dischargeddown to minimum

working pressure P2

AccumulatorTheory.eps

RockSlewingCylinder.eps

From: S3/Accumulator Control Block


Accumulator Theory

The accumulator can be considered an energy storage device for hydraulics, similar to the func-tion of a battery in an electrical circuit. The accu-mulator 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).

Rock Valve Slewing Cylinder

The rock valve slewing cylinder is a nondifferen-tial 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.

SERVICE TRAINING

Training Manual10

80 bar

350 bar

Path open to tank

Signal from MPS Valve

X3 X3

X3

80 bar

350 bar

80 bar

350 bar

80 bar

350 bar

X3

S1 Spool

S2 Spool

XB XA

Pathway to Differential cylinder

HiFlowBrain_S2.eps

Soft Switch Relief Valve

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.




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: Pump

From: AccumulatorControl Block



From: Pump

SERVICE TRAINING

Training Manual 11

From Pumps

From Pumps

To:MPS ZK2

To:MPS ZK1


DiffCylinders_NewStroke.eps

Loop Oil

pressure oil

ZK2

ZS2

XA

B

ZK1

SP T

ZS1

XB

A

X3


Passage way closed

Signal lost

Differential Cylinder - Beginning of stroke

Hydraulic oil from the Main Control Block flows to the rod side of the right-hand differ-ential cylinder.

The pressure from the hydraulic oil extends the rod of the right-hand differential cylin-der.

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.

MPS

A high pressure signal line from the Differ-ential Cylinder is sent to the ZK1 port of the MPS valve.

Pressure is greater on the ZK1 side of the NG 6 spool than the ZK2 side.

The NG 6 spool will move to the right closing the passage way for high pressure accumulator oil.




SERVICE TRAINING

Training Manual12

From Pumps

From Pumps

To:MPS ZK2

To:MPS ZK1


DiffCylinders_03.eps

ZK2

ZS2

XA

B

ZK1

SP T

ZS1

XB

A

X3

To: Soft SwitchReversing Valve

To: S3 Spool

From:Differential Cylinder


Passage way created

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.

MPS

A high pressure signal line from the Differ-ential 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.



To:S3 SpoolTo:Soft Switch Reversing Valve


SERVICE TRAINING

Training Manual 13


To: Rock valve slewing cylinderand Main Control Block


S3_Block.eps

A B


From: S3/AccumulatorControl Block

S3/Accumulator Control Block

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 passage way is created for accumulator oil

to travel to the Rock valve Slewing Cylinder and S2 spool in the Main Control Block.


To: Rock valve slewing cylinder

To: S2 spool


Manual Bleed

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

This pushes the rod over, thus switching the rock valve.

SERVICE TRAINING

Training Manual14

80 bar

350 bar

Path open to tank

Signal from MPS Valve

X3 X3

X3

80 bar

350 bar

80 bar

350 bar

80 bar

350 bar

X3

HiFlowBrain_S2.eps

S1 Spool

S2 Spool

Soft Switch Relief Valve

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.




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.

From: Pump

From: AccumulatorControl Block



From: Pump

SERVICE TRAINING

Training Manual 15

From Pumps

From Pumps

DiffCylinders_04.eps


Hydraulic oil from the Main Control Block flows to the rod side of the left hand differen-tial 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.

SERVICE TRAINING

Training Manual 16

Typical Boom Circuit

TT

MP1

M

P1

P4

P2

P3

Boom Pump

Boom Handvalve

Estop Manifold

To:Outrigger Function

Outrigger Handvalve

Boom Cylinder

To: Main Control BlockTo: Boom Control Block

To: AgitatorHy

draulic

Pump

s_02.e

ps

Boom Pump

To: S3 Accumulator

To: Oil Cooler

Boom Pump

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 the hydraulic motor for the water pump the hydraulic motor of the compressor

(optional equipment)

SERVICE TRAINING

Training Manual 17

Energized Solenoid

De-energized Solenoid

Equal PressurePoppet Closed

Greater PressurePoppet Opened

Signal Line from P1 port

Passage way to tank

P1P4

P2

P3

T T

P1P4

P2

P3

T T

Pressure A

Pressure A = B

Pressure B + Spring

Pressure A

Pressure A = B

Pressure B + Spring

Pressure A

Pressure A > B

Pressure A > B

Pressure B + Spring

Pressure B + Spring

Pathway to Tank(open)

Pathway to Tank(closed)

1 2

3 4

E-Stop Manifold Hydraulic oil from the boom pump enters the

E-stop Manifold from the P1 port. With the solenoid energized, a signal line

from the P1 port enters the spring side of the poppet valve. This will equalize the pres-sure on both sides of the poppet. The pres-sure plus spring tension will hold the poppet closed.

If the solenoid is not energized, a passage way will be created for the signal line to go to tank.

This will create a pressure drop on the spring side of the poppet valve.

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.

Poppet Valve Theory1. 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.

Housing

Poppet

Spring

SERVICE TRAINING

Training Manual18

MPS

MPS

T

P3

P2 P4 P1

Boom/outriggercircuit dumpvalve

Boom/outriggersystem plumbingAccumulator

system plumbing

Agitatorsystem plumbing

Concrete pumpsystem plumbing

Concrete pump,agitator, accumulatordump valve

Overridebuttons

C1C2

Apitech_Side_03.eps

From: Pump

Blocked passage way

E-Stop - Override 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

BY-PASSNORM. BY-PASS

by-pass2.eps

Boom Handvalve - No functions acti-vated

Oil enters the Boom Handvalve from the P port.

From: Boom Pump

SERVICE TRAINING

Training Manual 19

Apitech_Side_02.eps

To: Outrigger Handvalve

Passage openSolenoid Energized

To: Outrigger Function

A B

A B

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.

From: Boom Pump

To: Outrigger Handvalve

Outrigger HandvalveThe 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.

This will send oil to whatever outrigger func-tion has been activated. Example Outrigger Extend.

SERVICE TRAINING

Training Manual20

Apitech_Side_01.eps

From: Pump

Blocked passage way

Passage open

Coil

Control Disk0.040 Orifice

Pilot Pressure

Control Oil to Spool

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.

From: Boom Pump

To: Boom Function

Pulsar Coil TheoryAs the control disk pulses on and off, pre-tensionoil 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.

SERVICE TRAINING

Training Manual 21

Passage way for piston side oil

Passage way closed. Oil trapped, cylinder held in place

From:Boom Handvalve

Passage way for rod side oil (to tank)

LINE B

LINE A

LINE B

LINE A

13

2

4

WARNINGClear area before activating outriggers

REAR EXTEND REAR JACKING FRONT JACKING FRONT EXTEND

DANGERElectrocution hazard.Stay back from high voltage wires at least 17 feet (5 meters).

WARNINGDo not operate this machine without training. Understandthe warnings in safety manuals and on decals.

AGITATOR CONCRETE PUMP

Boom 1 Boom 2 Boom 3 Boom 4 Boom 1 Telescope SlewingBoom / Outrigger Water / Compressor

10189517

1

10 11

2 3 4 5 6 7

128

9

000419.eps

Boom Holding ValvesTwo hydraulically unlockable check valves (H.E.R. valves, or holding valves) on each boom cylinder prevent the boom from coming down unintentionally

Manual Controls and Overrides1. E-stop

2. Boom #1 Control Handle




6. Boom Telescope Handle

7. Boom Slewing Control Handle

8. Water Pump/Air Compressor Handle

9. Water Pump System Change-Over Valve

10. Concrete Pump Handle

11. Agitator Handle

12. Two Position Boom/Outrigger Handle.

SERVICE TRAINING

Training Manual22

Training Manual

SERVICE TRAINING

Table of Contents

The Schwing Group ............................................................ 1Schwing America, Inc. ................................................. 1

Hydraulic Training

General Principles ............................................................... 3Mechanical Versus Hydraulic ............................................. 7Transfer of Energy .............................................................. 7Hydraulic Jack ..................................................................... 8Linear & Rotary Actuators .................................................. 8Basic Hydraulic Components .............................................. 9Check Valve Comparison ................................................. 10Shuttle Valve ..................................................................... 11Throttle Check Valve ........................................................ 12Switching Valves .............................................................. 13Hydraulic Pumps ............................................................... 14

Placing boom hydraulic pumps .................................. 14Concrete pump hydraulic pumps ............................... 14

Fixed Displacement Pump ................................................ 15Rexroth A2F20 ........................................................... 15

Variable Displacement Pump ............................................ 15Rexroth A7VO ........................................................... 15

Variable Displacement Axial Piston Pump ....................... 16RexrothA10VO .......................................................... 16RexrothA11VO .......................................................... 16Rexroth A11VO Adjustments .................................... 17

Transfer Cases ................................................................... 18Relief Valves ..................................................................... 19Safety Relief Valves .......................................................... 20

Pressure Relief Valve Type DB ................................. 20Pressure Relief Valves Type DBW ............................ 20

Hydraulic Symbols ............................................................ 21Hydraulic Symbols (Cont.) ............................................... 22Hydraulic Symbols (Cont.) ............................................... 23Hydraulic Symbols (Cont.) ............................................... 24Hydraulic Symbols (Cont.) ............................................... 25Hydraulic Symbols (Cont.) ............................................... 26Hydraulic Symbols (Cont.) ............................................... 27Formulas ............................................................................ 28

Pumpkits

800 Gate Valve .................................................................. 30801 Gate Valve .................................................................. 31

801 Pumpkit Schematic ............................................. 32Concrete Pump Control Block ................................... 33Stroke Limiter ............................................................ 34

494 Block ....................................................................34Hydraulically Unlockable CheckValve ......................35Gate Valve ..................................................................35

900-1200 Single Circuit .....................................................37900-1200 Single Circuit Schematic ............................38Concrete Pump Control Block ....................................39Stroke Limiter .............................................................40494 Block ....................................................................40Switching Valve .........................................................41A7VO .........................................................................41Rock Valve .................................................................42Phase A .......................................................................44Phase B .......................................................................45Phase C .......................................................................46Phase D .......................................................................47Phase E .......................................................................48Phase F ........................................................................49Phase G .......................................................................50Phase H .......................................................................51Phase I ........................................................................52Phase J ........................................................................53Phase K .......................................................................54

Troubleshooting .................................................................55High-Flow Single Circuit 2020/2023 ................................61

High-Flow Single Circuit Schematic ..........................62Concrete Pump Control Block ....................................63Switching Manifold ....................................................64Stroke Limiter with Fast Switch/Dampner .................64Phase A .......................................................................66Phase B .......................................................................68Phase C .......................................................................70Phase D .......................................................................72

Twin Circuits .....................................................................741200 Twin Circuit with Switching Valves ........................75

Twin Circuit Schematic w/Soft Switch ......................76Concrete Pump Control Block ....................................77S3 Control Block ........................................................77Soft Switch .................................................................78Accumulator Unloader Valve .....................................78Accumulator Control Block/Dump Valve ..................79Phase A .......................................................................80Phase B .......................................................................82Phase C .......................................................................84Phase D .......................................................................86

1200 Twin Circuit with MPS .............................................89Twin Circuit with MPS/Soft Switch ...........................90Concrete Pump Control Block ....................................91S3 Control Block ........................................................91MPS ............................................................................92Accumulator Control Block/Dump Valve ..................93Soft Switch .................................................................94Phase A .......................................................................96

Training Manual

Table of Contents

Phase B .......................................................................98Phase C .....................................................................100Phase D .....................................................................102Twin Circuit with Variable displacementaccumulator pump Schematic 104

Model Number Nomenclature .........................................105Hi-Flow Pumpkits (2023-2525) ......................................106Hi-Flow Pumpkits (2525H) .............................................107

Hi-Flow Pumpkits Schematic ...................................108Concrete Pump Control Block .................................109Main Relief/Soft Switch Block ................................110MPS ..........................................................................111S3 Control Block - Machined ...................................112S3 Control Block - Cast ...........................................1132023 Circuit diagram ................................................114Phase A .....................................................................114Phase B .....................................................................116Phase C .....................................................................118Phase D .....................................................................120

Booms

Black & White .................................................................123Electric/Air/Oil .........................................................123Electric/Oil/Oil .........................................................123

Proportional .....................................................................125Boom Holding Valves .....................................................12628X B&W Boom .............................................................127Load Sense Hydraulic Circuits ........................................131

Overview ..................................................................131Components ..............................................................132Basic Principles - Simple Circuit .............................133Basic Principles - Orifice .........................................134Basic Principles - Without Relief Valve ..................135Basic Principles - With Relief Valve .......................136Basic Principles - Delta-P ........................................137Basic Principles - Delta-P ........................................138Basic Principles - Pressure Cut-Off .........................139Basic Principles - Shuttle Valves .............................140Basic Principles - Pressure Regulator ......................141

A7 Variable Displacement Hydraulic Pump Training ....142All Functions in Neutral ...........................................142Cylinder Extend Function Initiated ..........................144Hydraulic Cylinder Extending .................................146Hydraulic Cylinder Fully Extended Pump ...............148

Fixed Displacement Pump Training ................................150All Function in Neutral ............................................150Boom Function Activated ........................................151Cylinder Pressurized at the End of Stroke ...............152

Output Charts ...................................................................153Using the Chart ................................................................154

Using a Nomograph ........................................................ 159General information ................................................. 159The quadrants ........................................................... 161

Minimum Pipe Wall Thickness ....................................... 167Preventative Maintenance ............................................... 168

Scheduled Maintenance ........................................... 168Filtration .......................................................................... 170

General information ................................................. 170Specific information ................................................. 170Changing hydraulic oil filters .................................. 170Changing high pressure water filter ......................... 171

Hydraulic Oils ................................................................. 171General information ................................................. 171Specific information ................................................. 172When to change your hydraulic oil .......................... 172

Electrical

Introduction ..................................................................... 173What is Electricity? ......................................................... 173Amperage ........................................................................ 176Voltage ............................................................................ 177Resistance ........................................................................ 177Basic Circuits .................................................................. 179Schematics ...................................................................... 181Circuit Types ................................................................... 181Ohms Law ...................................................................... 183Series Circuit Laws ......................................................... 185Parallel Circuit Laws ....................................................... 186Series Parallel Circuits ................................................. 188Circuit Faults ................................................................... 189Using Test Equipment ..................................................... 190

The Troubleshooting Process ................................... 195Electrical Symbols .......................................................... 196Electrical Symbols .......................................................... 197Electrical Symbols .......................................................... 198Controller Systems .......................................................... 199

Analog ...................................................................... 199Digi-Prop (Microwave) ............................................ 199Comfort Control ....................................................... 199C32 ........................................................................... 200CPC .......................................................................... 200CPC II ...................................................................... 200Vector - Current Production ..................................... 201

28X Truck and Pumpkit Circuit ...................................... 20328X Boom Circuit ........................................................... 204

Training Manual

SERVICE TRAINING

Table of Contents

Misc Procedures

Material Cylinder Alignment .......................................... 205Pumping on piston side ................................................... 207

(Available on some units only) ................................ 207Shimming the Differential Cylinders .............................. 208

Determining the proper shimm size ......................... 208Dimension A ............................................................ 208Dimension B ............................................................ 208Formula .................................................................... 209

Apitech Control Chamber Air Bleed Procedure ............. 210Hydraulic Pump Adjustments ......................................... 213

Main System Pumps A11VO ................................... 213Setting the Flow Rate ............................................... 213Horsepower Setting .................................................. 214Q-min Output Flow .................................................. 214Check all hydraulic pressures. ................................. 215Setting pressures on Hi-flo -6 pumpkits .................. 215Pressure setting procedure: ...................................... 216Setting the soft switch relief pressure ...................... 217

Accumulator Bypass Retrofit .......................................... 219Service Bulletin 1001-03 ......................................... 219

Trouble Shooting Kit ...................................................... 220

Training Manual

Table of Contents

Training Manual 1

SERVICE TRAINING

The Schwing Group

Schwing America, Inc. is a wholly owned subsidiary ofthe Schwing GmbH located in Herne, Germany.Schwing was founded in Germany in 1934, it hasalways been a family owned company and is currentlymanaged by Gerhard Schwing.The Schwing Group has grown steadily since itsinception over sixty years. The company is known forits innovation and worldwide operations. The Groupsprimary products are concrete pumps, ready mix trucksand batch plants. Pumping and boom technologies areapplied to other products as opportunities arise.Currently the Schwing Group has factories locatedaround 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 IndiaThe Schwing group also has numerous sales andservice locations around the world.

Schwing America, Inc.

SAI was started in 1974, located in a small office onPierce Butler Road. At this time SAI was primarily asales, service and parts facility, with the assembly andsome manufacturing subbed out to Telelect. Thisarrangement continued until October 1978. Telelectsuffered a prolonged strike, which really hurt SAI. Itwas at this time that the Schwing company purchasedthe property here at 5900 Centerville Road. Thisfacility was previously a distribution center for ArcticCat 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 spaceand then in 1986 we added 28,000 sq. ft. to this spaceintroducing our paint facility and testing facility.Then in 1989, an additional 29 acres of land waspurchased to the North, and our 20,000 sq. ft. weldshop was constructed. We also worked over one of thepole barns for our fab facility and trailer assemblyplant. These additions have proven to be a major breakthrough 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.

2 Training Manual

SERVICE TRAINING

machining center, which is home of the new ForrestLine machining Center.For the year 2000, Schwing America, Inc. has added a75,000 sq. ft paint booth. This state-of-the-artbehemoth is the largest building in the surroundingcommunities. Dubbed the Super Booth by industryinsiders. This is the largest facility for paintingconcrete pumps in the world. The six-story structurecombines with retractable roof panels to accommodateunfolded booms. Painters will use catwalks to cover

every surface with high quality acrylic urethane in anendless array of colors and paint schemes. Climatecontrolled conditions assure proper curing and dryingtime. A new solvent recovery system keeps the SuperBooth environmentally friendly.

Today Schwing America has over 326,000 square feetof manufacturing space and employs over 400 people.

E

W

SN

Training Manual 3

SERVICE TRAINING

Hydraulic Training

General Principles

1. Hydraulic pressure always takes path of leastresistance.

2. Hydraulic pressure is created equal in all directions (Pascal's Law).

3. Liquids (oil) are relatively incompressible.

12

3

4

The bottle is filled with a liquid, which is not compressible

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.

A 10 pound force applied to a stopper with a surface area of one square inch......

Results in 10 pounds of force on every square inch (pressure) of the container wall

Pascal's Law

1000 lbs of Force

1000 lbs of Force

OIL

AIR

OIL

AIR

4 Training Manual

SERVICE TRAINING

4. When hydraulic pressure and flow is not converted into work it is converted into heat.

5. When oil is heated it will expand (5% or more).

6. When oil is heated the viscosity of it changes.

Open relief (Heat)

Vacuum formed ashydraulic oil cools

Atmospheric pressureforces water past seals

Seals

Hydraulic Cylinder

Water Box

6 bar

Training Manual 5

SERVICE TRAINING

7. GPM (Gallons Per Minute) only determine the speed at which the actuator (motor or cylinder) operates.

8. P.S.I. (Pounds Per Square Inch) determine only the amount of force exerted upon the load by the actua-tor.

0 GPM 10 GPM

1000 PSI

10 gallon maximumcapacity cylinder

10,000 LBSLOAD

10 inch of area oncylinder piston

6 Training Manual

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 deter-mines how much work is required.

F

P A

F = FORCE (in pounds) (lb)

P = PRESSURE(in pounds per square inch) (P.S.I.)

A = AREA (in square inches) (in2)F = P x A

P = F/A

A = F/PF = FORCE (in kilograms) (Kg)

P = PRESSURE(in kilograms per square centimeter) (Kg/cm2)A = AREA (in square centimeters) (cm2)

U.S.

METRIC

Q = FLOW RATE(unit of volume per time period)P = PRESSURE(unit of force per unit of area)

GENERAL

POWER =CONSTANT

Q x P

HP = HORSEPOWER

GPM = GALLONS PER MINUTE

PSI = POUNDS PER SQUARE INCH

U.S.

1714 = KNOWN CONSTANT

HP =1714

GPM x PSI

KW = KILOWATTS

LPM = LITERS PER MINUTE

BAR = METRIC UNIT OF PRESSURE

METRIC

600 = KNOWN CONSTANT

KW =600

LPM x BAR

Training Manual 7

SERVICE TRAINING

Mechanical Versus Hydraulic

Transfer of Energy

10 lb.(44.48 N)

100 lb.(444.82 N)

1. Ten pounds (44.48 N) here...

3. if this arm is 10 timesas long as...

4. this arm.

2. will balance 100 lb(444.82 N) here...

A. SIMPLE MECHANICAL LEVER

COMPARISON OF MECHANICAL FORCESVERSUS HYDRAULIC FORCES

10 lb.(44.48 N)

100 lb.(444.82 N)

1. An input force of10 lb.(44.48 N) on aone square inch(6.45 cm ) piston...

2. develops a pressure of10 pounds per square inch(psi)(.69 bar) (68.94 kilopascals)throughout the container.

3. This pressure willsupport a 100 lb.(444.82 N) weight ifthis is a 10 sq. in.(64.52 cm ) piston.2

INPUT OUTPUT4. The forces are proportionalto the piston areas.

10 lb. (44.48 N)1 sq. in (6.45 cm2)=

100 lb. (444.82 N)10 sq. in (64.52 cm2)

B. SIMPLE HYDRAULIC PRESS

2

10 sq. in.(64.51 cm2 )

1 sq. in.(6.45 cm )2

10 lb.(44.48 N)

100 lb.(444.82 N)

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)

10 in(0.25 m)

1 in(0.02 m)

10 cu. in. (163.8 cm3) of liquidwill move the larger piston only1 in. (2.54 cm)(10 sq. in. x 1 in. = 10 cu. in.)(64.52 cm x 2.54 cm = 163.87 cm )

2.

3. The energy transfer here equals10 lb. x 10 in. (44.48 N x 0.25 m)or 100 in. lb. (11.30 Nm)

4. The energy transfer here also is100 in. lb. (11.30 Nm)(1 in. x 100 lb. = 100 in. lb.)(.02 m x 444.82 N = 11.30 Nm)

10 sq. in.(64.51 cm2)

1 sq. in.(6.45 cm2)

ENERGY CAN NEITHER BE CREATED NOR DESTROYED

8 Training Manual

SERVICE TRAINING

Hydraulic Jack

Linear & Rotary Actuators

PISTON

HYDRAULICROD

8"

PUMP

PUMP

MOTOR

ROTARYDRIVE SHAFT

LOAD

1.The pump pushes thehydraulic liquid into lines.

2. Lines carry the liquid toactuators which are pushedto cause a mechanical outputto move a load.

3. Some actuators operate ina straight line (linear actuators).They are called cylinders or rams.They are used to lift weight, exertforce, clamp, etc.

PISTON & ROD

TO RESERVOIR

ROTARY ACTUATORLINEAR ACTUATOR4. Rotary actuators or motors give the system rotating output.They can be connected to pulleys,gears,rack-and-pinions, conveyors, etc.

Training Manual 9

SERVICE TRAINING

Basic Hydraulic Components

Check Valve

Throttle Valve

Throttle Check Valve

Switching Valve

10 Training Manual

SERVICE TRAINING

Check Valve Comparison

In-Line Check Valve

Cartridge Check Valve

Right Angle Check ValvesCHECK VALVE

COMPLETEP/N 30333030

CHECK VALVECOMPLETE

P/N 30333031

CARTRIDGEW/SEALS

P/N 30333032

SEAL KIT ONLYP/N 30333034

TORQUESPECIFICATION

55 ft/lbs.

CARTRIDGEW/SEALS

P/N 30333033

SEAL KIT ONLYP/N 30333035

TORQUESPECIFICATION

200 ft/lbs.

Training Manual 11

SERVICE TRAINING

Shuttle Valve

A shuttle valve is used where the higher of the twopressures must be selected, while blocking the lowerpressure input.

The valve has two inlet, ports A and C, and oneoutput port B. When either port A or C ispressurized, a ball automatically seals the other inletand allows the higher pressure fluid to flow to port B.

B

CA

A C

B

A C

B

Greater pressure from "A" port Greater pressure from "C" port

A C

B

39000145.ai

12 Training Manual

SERVICE TRAINING

Throttle Check Valve

Flow control valve Model MK is pressure, temperatureand viscosity dependent throttle/check valves, used torestrict flow. It consists of adjustment sleeve (1) andinner housing (2).

Model MK (Throttle/Check Valve)This valve is capable of flow control in one directionwhile allowing reverse free flow in the opposite. Fluidpasses spring (6), through radial drilling and throttlingarea (4). Throttling is achieved similarly to the MGvalve. In the reverse direction, pressure acts on the areaof check valve (5). When pressure exceeds spring force(6), the poppet opens, allowing reverse free flowthrough the valve. Fluid also passes through the throttlearea (4), thereby flushing contamination from thevalve.

Caution! Do not adjust the valve while under pressure

Throttle Check Valve Model MK

5 4 3 1 6 2

5 4 6 5 4 6

Training Manual 13

SERVICE TRAINING

Switching Valves

The switching valves have a logic function in that theysense multiple pressures simultaneously and will routeoil from the poppet end port to the output port

onlywhen the pressure from the poppet end port exceeds thepressure at the spring end port by more than 2:1 inmost situations

SPRING END PORT

SIDE PORT

POPPET END PORT

POPPET

BODY

POPPETHOUSING

SPRINGGUIDE

SPRING

SPRING END PORT

SIDE PORT

POPPET END PORT

SIDE POR(PLUGGED

O-RINGAND

BACK-UPRINGS

POPPET

BODY

POPPETHOUSING

SEAT

O-RINGAND

BACK-UPRING

SPRING

SPRINGGUIDE

Pressure equal on both sides High Pressure pushes poppet back allowingoil to flow through the side port, sending a

signal to S3

Pressure greater on the Spring End Portforcing the poppet to close

14 Training Manual

SERVICE TRAINING

Hydraulic Pumps

Placing boom hydraulic pumps

Load sensing proportional

The hydraulic pump for the placing boom is a variabledisplacement, bent axis, axial piston pump, with loadsensing control. It can feed all of the followingcomponents: 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 directional control valves for all of the abovecircuits are incorporated into control blocks andequipped with hand levers. In addition, the controlblock for the boom functions have electric over oilpiloting for operation via remote control.

Concrete pump hydraulic pumps

The hydraulic pumps for the concrete pump circuit arebent axis, variable displacement piston pumps. Theyare horsepower controlled, which means that aspressure rises, the flow decreases, so the powerconsumption remains constant. We use this type ofpump so the truck engine will not bog down under hardpumping conditions. The pumps also accept externalsignals for control of the output. At Schwing, we routesignals to the pump from the hydraulic stroke limiterand the dampener (with single circuit), or theaccumulator (with twin circuit). The net effect of thesedevices is to tell the pump to put out less oil perrevolution, as required by the pump operator.

PumpKit Pumps

PumpKit Pumps

PumpKit Pumps

Boom Pump

Proportional Boom Pump

Proportional Boom Pump

Stiebel 4194

(other options are available)

Stiebel 4400

InLine Drive

Agitator Pump

Agitator Pump

Oil Cooler Pump

Oil Cooler Pump

Accumulator Pump

Accumulator Pump

PumpKit PumpsProportional Boom Pump

Agitator Pump

Stiebel 4194Oil Cooler Pump

AccumulatorPump

Training Manual 15

SERVICE TRAINING

Fixed Displacement Pump

Rexroth A2F20

Fixed displacement pumps discharge a set volume offluid regardless of the system requirements. Thisvolume can be changed only by changing the drivespeed of the pump. If the system requires less fluid thanthe pump is discharging, the balance of the flow mustfind an alternate pah which is usually over a relief valveand back to the reservoir.

Variable Displacement Pump

Rexroth A7VO

Variable pump with axial tapered piston rotary groupof bent axis design, for open circuit hydraulic drives.This pump is suitable for mobile applications.Comprehensive programming of control devices isavailable. The robust taper roller drive shaft bearingsare designed to give long service life. Output flow isproportional to drive speed and pump displacement issteplessly variable between maximum and zero.

25

- 0

Q min

Q max

Q min

Horse Power Control(other locations possible)

Q max

Horsepower Adjustment Screw(other locations possible)

16 Training Manual

SERVICE TRAINING

Variable Displacement Axial Piston Pump

RexrothA10VO

Variable displacement axial piston A10VO of swashplate design is designed for hydrostatic transmissionsin open loop circuits. Flow is proportional to the drivespeed and the displacement. By adjusting the positionof the swash plate it is possible to smoothly vary theflow.

RexrothA11VO

The A11VO is a variable displacement pump of axialpiston swash plate design for use in open circuithydrostatic drives.Designed principally for use in mobile applications. Awide variety of controls are available. Setting of theconstant power control is possible via externaladjustments, even when the unit is operating. Thepump is available with a through drive to accept a gearpump or a second axial piston pump up to the samesize (100% through drive).Output flow is proportional to drive speed and pumpdisplacement and is steplessly variable betweenmaximum and zero.

Pressure Cut-off Screw

Q min

Q max

Training Manual 17

SERVICE TRAINING

Rexroth A11VO Adjustments

Q min

Q max

Pressure Cut-Off **Pressure Cut-Off

***Pressure Cut-Off

*Stroke Regulation

*Stroke Regulation

*StrokeRegulation

Q min

Q min

HorsepowerControl

HorsepowerControl

Horsepower Control

A11VO 190/130 Main Pumps

Style #1

Style #2

Pressure Cut-OffPressure Cut-Off

Q min

Q max

Load Sense Port

Delta P

A11VO Boom PumpA11VO Accumulator Pump

The beginning of stroke regulation has been increased from 5-7 bar to 8-10 bar on pumps with the following serial numbers:

A11VO 130 - 21034174, dated 08/22/05A11VO 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.

Pressure Cut-Off / Style #1Turn Clock-wise to increase the pressureTurn Counter-Clock-wise to decrease the pressure

Pressure Cut-Off / Style #2Turn Counter-Clock-wise to increase the pressureTurn Clock-wise to decrease the pressure

* **

***

18 Training Manual

SERVICE TRAINING

Transfer Cases

Hydraulic pumps for the concrete pump, placing boom,agitator, etc., are usually mounted on a distributiongearcase. When you are driving the truck, the power ofthe truck engine is transmitted through the trucktransmission, through a propeller shaft, through thebottom of the distribution gearcase, through anotherpropeller shaft, and into the rear end(s) of the truck.

When you are operating the unit, the distributiongearcase interrupts the power to the rear ends, andtransmits it to internal gears that turn the hydraulicpumps. Changing between travel and pumping modesis accomplished by means of an air switch in the truckcab.

4194 4195

4400

Training Manual 19

SERVICE TRAINING

Relief Valves

This is a

direct acting non adjustable relief valve.

When the oil has enough pressure to over take thespring the relief poppet will start to move out of theway and allow the excess pressure to be relieved totank. This style pressure relief is not adjustable exceptby changing the internal spring.The maximum systempressure that this style can be used for is limitedbecause the spring must directly act upon systempressure and thus higher pressures would require alarger spring. When this direct acting design relieves itcauses pulsations in the system.

This is a

direct acting adjustable relief valve

. Whenthe oil has enough pressure to over take the spring therelief poppet will start to move out of the way andallow the excess pressure to be relieved to tank. Thisstyle is adjustable though a external control whichvaries the spring tension on the relief poppet.Themaximum system pressure that this style can be usedfor is limited because the spring must directly act uponsystem pressure and thus higher pressures wouldrequire a larger spring.

This is a

pilot operated adjustable relief valve.

Therelief poppet has a small orifice in it that allows thehydraulic pressure to also be applied on the back sideof the poppet. This internal chamber is hydraulicallylocked and it will hold the main poppet closed as longas it has equal pressure on the front side and the backside. There is also a much smaller pilot poppet, that isoperator adjustable. This smaller poppet, with a smallerarea, can have a smaller spring controlling it. Once thispilot poppet opens we lose our hydraulic lock, thepressure is reduced on the back side and thus the mainpoppet can relieve the excess pressure to tank. Withthis design we are able to control large volumes of oilat high pressures with minimal sized springs.

Tank

Pressure

Tank

Pressure

Tank

Pressure

Tank

Pressure

Tank

Pressure

20 Training Manual

SERVICE TRAINING

Safety Relief Valves

Pressure control valve type DB/DBW are pilotoperated pressure relief valves. They are used to limit(DB) or unload by means of solenoids (DBW) pressurein a system. Pressure relief valves (DB) consist mainlyof a pilot valve with pressure setting element and mainvalve with main spool insert.

Pressure Relief Valve Type DB

Pressure in line A affects the main spool (1). At thesame time there is pressure via control passage (4) and(5) through orifice (2), (3) and (15) to the spring loadedside of the main spool (1) and pilot poppet (6). Ifsystem 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) andpoppet (6), and into spring chamber (9). From here itflows 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 pressuredrop at the main spool (1), and the connection fromline A to line B opens. The oil now flows from line A toline B, while the set operating pressure in maintained.

The valve can be unloaded or switched to a differentpressure (second pressure rating) by means of port X(13).

Pressure Relief Valves Type DBW

In principle, the function of this valve is the same asthat of valve type DB. Unloading at the main spool isachieved by means of actuating the built-on directionalcontrol valve.

VENTLINE

Training Manual 21

SERVICE TRAINING

Hydraulic Symbols

SHOWING DIN (DEUTSCHE INDUSTRIAL NORM) SYMBOLS USED ON SCHWING SCHEMATICSNO ATTEMPT HAS BEEN MADE TO SHOW EVERY POSSIBLE COMBINATION.

LINE, WORKING

LINE, PILOT or SIGNAL

CONNECTOR

LINE, JOINING("T" FITTING)

LINE, PASSING

LINE TO RESERVOIR (TANK)

(ABOVE FLUID LEVEL)

LINE, PLUGGED

RESTRICTION, FIXED(orifice, nozzle) OR

1.3 1.3

(BELOW FLUID LEVEL)

G

SP

T

Y

P

Nitrogen pressure set at 55 bar(800 PSI)

190bar 138 bar

0.8 mmhole drilled

throughspool

S1

S3

NG10

BP 750 & 1000 TC(with twin cylinder switching and

Hartman control valves)

1-95 RE

10 Filter

A

P

Y(T)

0-25 bar

G

300bar

X

BA

RP

125 bar

Agitator

12 Filter

599010

2.0mm

2.0 mm

SP = R 3/4"G = R 3/8"

Y = R 3/8"

P = R 1/2"

This line MUSTreturn to tank byitself.

1.9 mm

T = R 1/2"

AC = R 11/2"

Y

A11VO

100bar

0.7 mm

P

bar

T

2.0 mm

LINE, WORKING

LINE, PILOT or SIGNAL

LINE, JOINING("T" FITTING)

RESTRICTION, FIXED(orifice, nozzle)

LINE TO RESERVOIR (TANK)

LINE, PLUGGED

LINE, PASSING

X

125 b

22 Training Manual

SERVICE TRAINING

Hydraulic Symbols (Cont.)

RESTRICTION, VARIABLE(throttle valve or adjustable orifice)

MANUAL SHUT-OFF VALVE(MANITROL VALVE)

M

PRIME MOVER,ELECTRIC MOTOR

D

PRIME MOVER,INTERNAL COMBUSTION ENGINE(Diesel shown..."G" if gas.)

PUMP, SINGLEFIXED DISPLACEMENT

PUMP, SINGLEVARIABLE DISPLACEMENT

X1X2

A1

S

A

PUMP, SINGLEVARIABLE DISPLACEMENT,SHOWING HORSEPOWERCONTROL CIRCUITS.

MOTOR, ROTARY,FIXED DISPLACEMENT

MOTOR, ROTARY,FIXED DISPLACEMENTBI - DIRECTIONAL

Training Manual 23

SERVICE TRAINING


CYLINDER, SINGLE ACTING

CYLINDER,DIFFERENTIAL ROD

CYLINDER, DOUBLEEND ROD

CYLINDER, DOUBLE END ROD WITH GROOVES INPISTON ROD FOR SWITCHING FUNCTION(ROCK VALVE SHIFTING CYLINDER)

PRESSURE GAUGE

TEMPERATURE GAUGE

ACCUMULATOR,GAS CHARGED

FILTER OR STRAINER

ACCUMULATOR,SPRING LOADED

FILTER WITH INTEGRALBYPASS CHECKVALVE

6 bar

24 Training Manual

SERVICE TRAINING


CHECK VALVE (BASIC)

HYDRAULICALLY UNLOCKABLECHECK VALVE.

(CLOSED) (OPEN)

OIL COOLER WITHELECTRIC FAN MOTOR

OIL COOLER WITHHYDRAULIC FAN MOTOR

M

PRESSURE SWITCH

A 2.0CHECK VALVE, FIXED FORCE(SPRING FORCE INDICATED)

6 BARADJUSTABLE CHECK VALVE(PRETENSION OR PRELOAD VALVE)(Desired spring force indicated)

PRESSURE RELIEF VALVE(SAFETY VALVE ORSAFETY CARTRIDGE)

HYDRAULICALLY UNLOCKABLECHECK VALVE WITH INTEGRALRELIEF VALVE.(H.E.R. BOOM HOLDING VALVE)

320 BAR

BASIC VALVE ENVELOPE

NORMALLY CLOSED

NORMALLY OPEN

280 bar

PRESSURE RELIEF VALVEWITH EXTERNAL DRAIN(SHOWN WITH A NORMALLYOPEN SOLENOID VALVE...MANY OTHER POSSIBILITIESARE AVAILABLE).

300 bar

PRESSURE RELIEF VALVEWITH EXTERNAL DRAIN

300 bar F N R

Training Manual 25

SERVICE TRAINING


A

P

Y(T)

0-55 bar

PRESSURE REDUCING VALVEMANUAL (STROKE LIMITER) ORDAMPNER

1.5

THROTTLECHECK VALVE ADJUSTABLE

CARTRIDGE VALVE(SWITCHING VALVE)SHOWN 2 DIFFERENT WAYS

NEW WAYOLD WAY

FIXED (size shown)

A

B

T

P

0-50bar

70 bar

PRESSURE REDUCING VALVE(ELECTRIC STROKE LIMITER)

P

A

Y TACCUMULATORUNLOADING VALVE

ACCUMULATOR DUMP VALVE(ELECTRIC)

SLEW BRAKEVALVE

A

A

P

P

P

P

SHUTTLE VALVE

300bar

T

P

MY

T

P

MG

YG

T

P

A

T

P

A

Electricstroke limiter

Pressurereducing valve

55 bar

26 Training Manual

SERVICE TRAINING


X A

B

BRAKE VALVE(COUNTERBALANCE VALVE)(USED ON ALL SECTIONS KVM 52 & 55)

BALL COCK(SHUT OFF VALVE,QUARTER TURN VALVE)

BRAKE VALVE(BERINGER)(USED ON #1 SECTIONDOWN FUNCTION)

B

AX

COMPONENT ENCLOSURE

VENTED RESERVOIR(TANK)

X1X2

A1

S

A

BRAKE VALVE (SAUER)(USED ON #1 SECTIONDOWN FUNCTION)

A

B

YX

R

R

Z

Z

Training Manual 27

SERVICE TRAINING


BASIC VALVE SYMBOLMULTIPLE FLOW PATHS

DIRECTIONAL CONTROL VALVES

DIRECTIONAL VALVE2 POSITION, 3 WAY

DIRECTIONAL VALVE2 POSITION, 4 WAY

DIRECTIONAL VALVE3 POSITION, 4 WAY, CLOSED CENTER

DIRECTIONAL VALVE3 POSITION, 4 WAY, OPEN CENTER

DIRECTIONAL VALVE3 POSITION, 4 WAYCLOSED PRESSURE CENTER

DIRECTIONAL VALVE3 POSITION, 4 WAY, TANDEM CENTER(REQUIRES A HOLLOW SPOOL)

DIRECTIONAL VALVE3 POSITION, 6 WAY, CLOSED CENTER (10631)

DIRECTIONAL VALVE, 3 POSITION,6 WAY, CLOSED PRESSURE CENTER,ORIFICED A & B PORTS IN CENTER (10632F)

DIRECTIONAL VALVE: METHODS OF OPERATION

DIRECTIONAL VALVE, 3 POSITION,5 WAY, LOAD SENSING, CLOSED PRESSURE CENTER,INFINITE POSITIONING(PROPORTIONAL)

DIRECTIONAL VALVE, 3 POSITION,5 WAY, LOAD SENSING, CLOSED CENTER,INFINITE POSITIONING(PROPORTIONAL)

PILOT PRESSURE OR

SOLENOID

SPRING

MANUAL(HANDLE OR PUSHBUTTON)

DETENT

HAND LEVER

EXAMPLES OF COMBINATIONS OF METHODS

SOLENOID OPERATED,SPRING RETURN

HAND LEVER OPERATEDWITH DETENT

HAND LEVER ORSOLENOID OPERATED,SPRING CENTERED

SOLENOID CONTROLLED,PILOT PRESSURE OPERATED,SPRING CENTERED,WITH HAND LEVER

OR

A

X

P

T

PRESSURE REGULATOR(REGULATES DELTA P)USED ON LOAD SENSING SYSTEMS

28 Training Manual

SERVICE TRAINING

Formulas

R2

R = 1/2 of Diameter

3.14 x 6.25 = 19.6253.14(2.5 x 2.5) = 19.625

Area of piston = 19.625

= 509.55

To move this load it will takeabout 510 psi

19.62510,000

= 3.14

R2

R = 1/2 of Diameter

3.14(1.25 x 1.25) = 4.90625

3.14 x 1.5625 = 4.90625

Piston - Rod = Rod Side Area

19.625 - 4.90625 = 14.719

= 3.14

10,000Pounds

5 2.5

10,000Pounds

19.625

14.719

= 679.39

To move this load it will takeabout 680 psi

14.71910,000

POWER =1714 (A Constant)

10 GPM x 510

= 2.975 HP17145100

POWER =1714 (A Constant)

10 GPM x 680

= 3.967 HP17146800

Piston Side Rod Side

10,000Pounds

Training Manual 29

SERVICE TRAINING

Pumpkits

Single Circuit Pumpkits Twin Circuit Pumpkits

800

801

900/1200

1200 w/Switching Valves

1200 w/MPS

2023 Hi-Flow

Hi-Flow

PumpkitCompare.eps

2525 Hi-Flow

30 Training Manual

SERVICE TRAINING

800 Gate Valve

Training Manual 31

SERVICE TRAINING

801 Gate Valve

32 Training Manual

SERVICE TRAINING

801 Pumpkit Schematic

1. Hydraulic oil reservoir

2. Main hydraulic pumps

3. Main pressure relief valve

4. Directional control valve S-1 (forward/reverse)

5. Gate Valve

6. Directional control valve S-3


8. Locking Valve

9A9B. Needle valves

10A10B. Hydraulically Unlockable Check valves

11A11C. Check valves

12A12B. Differential Cylinders

300bar

6 bar

D

Pipe Gate

Hopper Gate

39000156.eps1

22

34

5

69A9B

10A

11A

12A 12B

11B

11C

10B

7

8

Training Manual 33

SERVICE TRAINING

Concrete Pump Control Block

S1

S2

1.5 mmhole drilled

through spool

S3

300bar

39000155.eps

S-1

S-2

S-3

4

6

9A

9B

9B

3

3

8

8

7

7

6

TT P1

B A

9A

34 Training Manual

SERVICE TRAINING

Stroke Limiter

494 Block

P

P

0-50BAR

A

A

T

T

39000158.eps

1

1

4

2

3

4

2

3

1

4

5

6

1

4

5

2

3

2

3

6

12

H2Opressure*

Agitatorpressure*

P

A

B

A

B

BC A

H2O pumpmotor

agitatormotor

39000157.eps

Training Manual 35

SERVICE TRAINING

Hydraulically Unlockable CheckValve

Gate Valve

A

B

AB

B

C

C

C

1

1

2

20.7mm

39000160.eps

1

1

2

2

A

A B

B

C

C

D

D

39000163.eps

36 Training Manual

SERVICE TRAINING

Training Manual 37

SERVICE TRAINING

900-1200 Single Circuit

Single Circuit

38 Training Manual

SERVICE TRAINING

900-1200 Single Circuit Schematic

1. Hydraulic oil reservoir

2. Main hydraulic pumps

3. Main pressure relief valve

4. Directional control valve S-1 (forward/reverse)

5. Rock valve slewing cylinder



8A8B. Differential hydraulic cylinders

9A9B. Switching valves

10A10F. Check valves

11. Ball cock (Shutoff valve)

12. Hydraulic oil filter with bypass valve (return filter

1

D

22

34

5

6

7

8A 8B

9B

9A

10C10D

10B 11

12

10A

1

10E

10F

900 Pumpkit - eps

Training Manual 39

SERVICE TRAINING

Concrete Pump Control Block

S-1

S-2

S-3

S2

1.5 mmhole drilled

through spool

S3

S1

300 bar

Port sizelimits flow

39000147.eps

4

4

6

6

3

3

7

7

XR

XPT

P2P1

B A

10A

10B

40 Training Manual

SERVICE TRAINING

Stroke Limiter

494 Block

P

P

0-50BAR

A

A

T

T

39000158.eps

1

1

4

2

3

4

2

3

1

4

5

6

1

4

5

2

3

2

3

6

12

H2Opressure*

Agitatorpressure*

P

A

B

A

B

BC A

H2O pumpmotor

agitatormotor

39000157.eps

Training Manual 41

SERVICE TRAINING

Switching Valve

A7VO

1

1

2

A

A

B B

CC

39000161.eps

2

Q min

Q max

1

122

A

A

B

B

39000162.eps

X1

X2

A1

S S

A1

X1

X2

A A

ToBoomCircuit

D

1 1

2 2

42 Training Manual

SERVICE TRAINING

Rock Valve

A B C

BCD

E

D

F G

F

E

H

GH

39000164.eps

A

1

1

2

2

Training Manual 43

SERVICE TRAINING

44 Training Manual

SERVICE TRAINING

Phase A

First working stroke

With S1 valve (1) in the forward position, and the S2valve (2) in the left position oil flows to the right handdifferential acting on the rod side. Oil from the pistonside of the right hand differential oil is passed to thepiston side of the left hand differential and the rod side

oil of the left hand differential is directed back to tankvia valves S2 and S1 and through the filter (7). Oildirected through the S3 has the rock valve shiftcylinder held in the retracted (right) position so thatconcrete from the left hand material cylinder is beingpushed into the delivery pipe line. Concrete from thehopper is being sucked into the right hand materialcylinder.

KEYHigh Pressure

Rocking Oil

Low Pressure

Zero Pressure(Tank, or oil at rest)

M

D

S3

1.5 mmhole drilled

through spool

S2

S1

300bar

6 bar

1

4

57

8

10

12 13

1415

16

17

18

20

6

2

3

Training Manual 45

SERVICE TRAINING

Phase B

End of first working stroke

The differential cylinders have reached the end of theirstroke position*. Switching valve (5) is sending a highpressure signal to the left hand end cap of S3 valve (3).Oil from the right hand end cap of the S3 valve (3) isrelieved via check valve (15), the S2 valve (2), S1 valve

(1), filter (7) and back to the hydraulic tank.* NOTE: If the left hand differential has not fullyextended at this point due to not enough loop oil, highpressure oil will continue to flow through check valve(17) on the right hand differential until the left handdifferential is fully extended.

KEYHigh Pressure

Rocking Oil

Low Pressure


M

D

S3

1.5 mmhole drilled

through spool

S2

S1

300bar

6 bar

1

4

57

8

10

12 13

1415

16

17

18

20

6

2

3

46 Training Manual

SERVICE TRAINING

Phase C

Rock valve cylinder getting oil to extend

High pressure oil from switching valve (5) has nowshifted the S3 valve (3) fully to the right hand position.At this point the pressure oil to the rock valve shift

cylinder (4) is changed and the right hand side of thecylinder is getting oil so that the cylinder will extend.Oil from the left hand side of the rock valve shiftcylinder is routed to tank via valves (3, 1) and filter (7).

KEYHigh Pressure

Rocking Oil

Low Pressure


M

D

S3

1.5 mmhole drilled

through spool

S2

S1

300bar

6 bar

1

4

57

8

10

12 13

1415

16

17

18

20

6

2

3

Training Manual 47

SERVICE TRAINING

Phase D

S2 valve getting signal to shift

The rock valve shift cylinder (4) has now fullyextended. At this point a signal is sent to the left handend cap of the S2 valve (2) from a signal port on the

rock valve shift cylinder (4). As the S2 valve (2) shiftsto the right oil from the right hand end cap of the S2valve (2) is routed to the hydraulic tank via check valve(13), valves (3, 1) and the filter (7).

KEYHigh Pressure

Rocking Oil

Low Pressure


M

D

S3

1.5 mmhole drilled

through spool

S2

S1

300bar

6 bar

1

4

57

8

10

12 13

1415

16

17

18

20

6

2

3

48 Training Manual

SERVICE TRAINING

Phase E

Left hand differential getting oil to move

With the S2 valve (2) fully shifted and held in the righthand position, pressure oil is routed through the S1valve (1) and the S2 valve (2) to the rod side of the left

hand differential cylinder. Please note that while theleft hand differential cylinder is starting to retract,check valve (17) must close otherwise the right handdifferential cylinder will not extend.

KEYHigh Pressure

Rocking Oil

Low Pressure


M

D

S3

1.5 mmhole drilled

through spool

S2

S1

300bar

6 bar

Note: Check Valve Must Close

1

4

57

8

10

12 13

1415

16

17

18

20

6

2

3

Training Manual 49

SERVICE TRAINING

Phase F

Middle of the second working stroke (diagram 6)

Pressure oil is being routed through the S1 valve (1)and S2 valve (2) to the rod side of the left handdifferential cylinder causing it to retract. Oil from thepiston side of the left hand differential cylinder ispassed to the piston side of the right hand differential

via the loop hose. The oil on the rod side of the righthand differential is going through valves (2 and 1),filter (7) and back to the tank. Oil directed through theS3 valve has the rock valve shift cylinder held in theextended position so that concrete from the right handmaterial cylinder is being pushed into the delivery pipeline and concrete from the hopper is being sucked intothe left hand material cylinder.

KEYHigh Pressure

Rocking Oil

Low Pressure


M

D

S3

1.5 mmhole drilled

through spool

S2

S1

300bar

6 bar

1

4

57

8

10

12 13

1415

16

17

18

20

6

2

3

50 Training Manual

SERVICE TRAINING

Phase G

End of second working stroke (diagram 7)

The left hand differential cylinder has now fullyretracted*. Switching valve (6) is sending a highpressure signal to the right hand end cap of the S3valve (3). Oil from the left hand end cap of the S3 valve

(3) is relieved via check valve (14), the S2 valve (2), S1valve (1), filter (7) and back to the hydraulic tank.* NOTE: If the left hand differential cylinder has notfully retracted at this point because of to much loop oil,high pressure oil will continue to flow through checkvalve (16) and back to the hydraulic tank until the lefthand differential cylinder is fully retracted.

KEYHigh Pressure

Rocking Oil

Low Pressure


M

D

S3

1.5 mmhole drilled

through spool

S2

S1

300bar

6 bar

1

4

57

8

10

12 13

1415

16

17

18

20

6

2

3

Training Manual 51

SERVICE TRAINING

Phase H

Rock valve cylinder getting oil to retract

High pressure oil from the switching valve (6) has notshifted the S3 valve (3) fully to the left hand position.At this point the pressure oil to the rock valve shiftcylinder (4) is changed and the left hand side of the

cylinder is getting oil so that the cylinder will retract.Oil from the right hand side of the rock valve shiftcylinder (4) is being routed to tank via valves (3, 1) andfilter (7).

KEYHigh Pressure

Rocking Oil

Low Pressure


M

D

S3

1.5 mmhole drilled

through spool

S2

S1

300bar

6 bar

1

4

57

8

10

12 13

1415

16

17

18

20

6

2

3

52 Training Manual

SERVICE TRAINING

Phase I

S2 valve getting signal to shift

The rock valve shift cylinder (4) has now fullyretracted. At this point a signal is sent to the right handend cap of the S2 valve (2) from a signal port on the on

the rock valve shift cylinder (4). As the S2 valve (2)shifts to the left oil from the right hand end cap of theS2 valve (2) is routed to the hydraulic tank via checkvalve (12), valves (3, 1) and filter (7).

KEYHigh Pressure

Rocking Oil

Low Pressure


M

D

S3

1.5 mmhole drilled

through spool

S2

S1

300bar

6 bar

1

4

57

8

10

12 13

1415

16

17

18

20

6

2

3

Training Manual 53

SERVICE TRAINING

Phase J

Right hand differential getting oil to move

With the S2 valve (2) fully shifted and held in the leftposition, pressure oil is routed through the S1 valve (1)and the S2 valve (2) to the rod side of the right hand

differential cylinder. Please note that check valve (16)must close otherwise the right hand differentialcylinder will not retract.

KEYHigh Pressure

Rocking Oil

Low Pressure


M

D

S3

1.5 mmhole drilled

through spool

S2

S1

300bar

6 bar

1

4

57

8

10

12 13

1415

16

17

18

20

6

2

3

54 Training Manual

SERVICE TRAINING

Phase K

First working stroke

Refer to diagram 1 for explanation of first workingstroke.

KEYHigh Pressure

Rocking Oil

Low Pressure


M

D

S3

1.5 mmhole drilled

through spool

S2

S1

300bar

6 bar

1

4

57

8

10

12 13

1415

16

17

18

20

6

2

3

Training Manual 55

SERVICE TRAINING

T

schwing trainingmanual

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