Service Manual PDF

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SERVICE MANUAL CONCRETE PUMPS
Sections
Safety Manual
Maintenance, Lubrication & Schedules
Rock Valve & Gate Valve
Pumpkits
Hydraulic Pumps
Hydraulic Parts
Pressure Settings
Hydraulic Pump Adjustments
Electrical
Radio Remotes
Formulas, Conversions & Specifications
Special Tools
Fittings Book
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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
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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
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SERVICE TRAINING
Table of Contents
Table of Contents Product Data .........................................................................23

Features .................................................................................23
Uses ......................................................................................23
Maintenance of Hydraulic Cylinders ........................................24
Table of Contents Lubrication Specs for Schwing Placing Booms .......................26
Boom Inspections ........................................................................27
Maintenance
Maintenance Chart ...................................................................... 1
Rock Valve
Operators Check list for Weekly Maintenance (Ex.) ............... 3 Safety Instruction .......................................................................29
Size Comparison of Particles ...................................................... 4 Rock Valve Parts Identification - “M” Rock ...........................30
Filtration Ratings ......................................................................... 5 Rock Valve Parts Identification - “E” Rock ............................31
Nominal Rating ...................................................................... 5 Rock Valve Parts Identification - “B” Rock ............................32
Absolute Rating ..................................................................... 5 Rock Valve Lubrication Points .................................................33
Filtration Ratio(bn) ................................................................ 5 Rotating The Cutting Ring ........................................................34
Filter Facts ............................................................................. 5
Replacing the Cutting Ring .......................................................35
Fluid Contamination and Control .............................................. 6
Tension Nut/Pressure Spring .....................................................37
Primary sources of contamination ......................................... 6
Control Methods .................................................................... 6 Pressure Spring ...........................................................................37
Handling, Storing & Dispensing Lubricating fluids ................. 7 Determining Wear on Kidney Seal and Kidney Plate .............38
Hydraulic Oils .............................................................................. 8 Replacing the Kidney Seal .........................................................39
General information ............................................................... 8 Kidney Seal ...........................................................................39
Specific information .............................................................. 8 Spectacle Plate .............................................................................43
Hydraulic Oils ........................................................................ 9 Lengthening the Service Life of the Housing
When to change your hydraulic oil ........................................ 9 Lining-Inlet Side ...................................................................43
Hydraulic Oil Viscosity Chart .................................................. 10 Replacement of Spectacle Plate .................................................45
Lubrication Prefix Codes .......................................................... 11 Replacement of Outlet Housing Lining (Kidney Plate) Plate .46
Standard codes used ............................................................. 11 Replacement of Outlet Insert (Cover Lining) ..........................47
Hydraulic oil codes .............................................................. 11 Rock Valve Body .........................................................................48
“Industrial” gear lubricant codes ......................................... 11
Pivot Shaft ...................................................................................49
Lubrication Recomendations .................................................... 12
Pivot Shaft Bushing ....................................................................51
Motor Vehicle Gearbox Oil ................................................. 12
Compressor Oil .................................................................... 13 Setting Pivot Angles ....................................................................54
Filling Capacities ........................................................................ 14 Replacement of Pivot Shaft Bushings .......................................55
Hydraulic Reservoirs ........................................................... 14
Transmissions ...................................................................... 15
Gear Boxes ........................................................................... 16
E-Rock
Spicer Transmisions .................................................................. 17 Additional Mounting Instructions for E-Rock Assembly .......57
Lubrication Specs ................................................................ 17 Rock-Extension pre assembly: .....................................57
Recommended Lubricants ................................................... 17 Mounting of E-Rock-Valve and Cover ........................58
Oil Changes .......................................................................... 17 Placing the Counter-Nut at the lever side: ....................59
Over-Filling ......................................................................... 17 Rock Slewing Cylinder ...............................................................60
ZF Transmissions ....................................................................... 18 Welding Procedures-SAIE 5312 ................................................61
Lubrication Specs ................................................................ 18 Rock Valve with Insert - Conversion ........................................62
Steyr Gear Boxes ........................................................................ 19
Lubrication Specs ................................................................ 19
Transfer Case Gear Oil Capacities are as Follows: ............. 19 Small Rock Valve - Repair
Stiebel Gear Boxes ..................................................................... 20 Safety ............................................................................................63
Lubrication Specs ................................................................ 20 Parts Identification .....................................................................64
FABCO Gear Boxes ................................................................... 21 Lubrication Points ......................................................................65
Lubrication Specs ................................................................ 21 Lengthening the Service Life of the Spectacle Plate and
ZF Torque Converters ............................................................... 22 Cutting Ring ................................................................................66
Lubrication Specs ................................................................ 22
Rebuilding of Rock Valve ..........................................................68
WSK Torque Converters ..................................................... 22
Hydraulic Pump Spline Lubrication ........................................ 23
Service Manual
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SERVICE TRAINING
Table of Contents
Determining Wear on the Kidney Seal Housing Hydraulic Parts
Lining - Outside ......................................................................... 78
Boom Handvalves .....................................................................116
Replacement of Cutting Ring and Kidney Seal ....................... 79 “SP” Series directional valves ............................................124
Adjustment of the Slewing Cylinder and Installation Adjustable Ofifice ...............................................................125
of the Slewing Yoke .................................................................... 83 Flow Limiter .......................................................................125
Slewing Yoke Timing .......................................................... 83 42 - Rexroth - Hand valve Shuttles ....................................128
Rock Slewing Cylinder .............................................................. 84 Preload block for Rexroth Hand valve ...............................129
Apitech Cut-Away ..............................................................144
Boom Holding Valves ...............................................................145
Pumpkits Load Holding Valve/Brake Valve ......................................149
Specifications .............................................................................. 85 BRAKE VALVES ..............................................................150
2023-4 .................................................................................. 85 Sauer Brake Valve ......................................................150
2023-5 .................................................................................. 85 Beringer Brake Valve .................................................151
2023H-6 ............................................................................... 85 Slewing Brake Valves ...............................................................152
2525H-5 ............................................................................... 85 Boom Slewing Brake Valve - Rexroth Spec Sheet ....152
2525H-6 ............................................................................... 85 Boom Regulator ........................................................................158
Change rams ............................................................................... 86 Counter Balance Valve .............................................................159
Changing the material cylinders .............................................. 90 Control Blocks ...........................................................................160
Material Cylinder Alignment ................................................... 90 S3/Accumulator Valve ..............................................................164
Pumping on piston side .............................................................. 92 Machined Block ..........................................................164
Sealing Gland Replacement ...................................................... 93 Stroke Limiters .........................................................................168
Shimming the Differential Cylinders ....................................... 94 Outrigger Handvalves ..............................................................180
Determining the proper shimm size ..................................... 94 E-Stop Manifolds ......................................................................192
Dimension A ........................................................................ 94
Dimension B ........................................................................ 94
Formula ................................................................................ 95 Pressure Settings
General ......................................................................................209
Stroke Limiter Adjustment .................................................209
Hydraulic Pumps Check the accumulator Pre-Charge ....................................210
Hydraulic Pump Drive .............................................................. 97
Placing boom hydraulic pumps ................................................ 97
Concrete pump hydraulic pumps ............................................. 97
Hydraulic Pump Adjustments
Hydraulic Pump Locations ....................................................... 98 Main System Pumps A11VO ...................................................215
Fixed Displacement Pump A2FO ............................................. 99 Setting the Flow Rate .........................................................215
Horsepower Setting ............................................................216
Rexroth/Hydromatik Model A7V Series 2 ............................ 100
Setting Stroke Limitation ....................................................216
Constant Pressure Control DR ........................................... 101
Q-min Output Flow ............................................................216
Constant Horsepower Control LV ..................................... 101
Check all hydraulic pressures. ............................................217
Commencement of control: 50 bar min. ............................ 101
Setting pressures on Hi-flo -6 pumpkits .............................217
Auxiliary Equipment: Stroke Limiter ................................ 102
Pressure setting procedure: .................................................218
Rexroth/Hydromatik Model A7V Series 6 ............................ 103 Setting the soft switch relief pressure .................................219
LR Constant Power Control ............................................... 104
BPL 500 .....................................................................................221
LRH Constant Power Control With Hydraulic
Stroke Limiter .................................................................... 104 BPL 2000 ...................................................................................227
Variation: Hydraulic Stroke Limiter (H...) ........................ 105 BPL 4000 ...................................................................................231
H1/H5 (Negative Control Function): Vg max to Vg min .. 105 KVM 17M ..................................................................................243
DR Constant Pressure Control ........................................... 105 Setting concrete pump pressure ..........................................244
Rexroth/Hydromatik Model A10VO ..................................... 107 Setting the soft switch circuit relief pressure ......................246
Rexroth/Hydromatik Model A11VO ..................................... 109 Setting accumulator E-Stop manifold pressure
(original production) ...........................................................246
Linde Hydraulik BPR 105 ....................................................... 112
Setting the accumulator unloading valve
Constant Power Regulator (LR) ........................................ 113
(original production) ...........................................................247
Power Regulator With Hydraulic Stroke Limiter (LRH) .. 113
Setting accumulator E-Stop manifold pressure
Voac Variable Displacement Axial Piston Pump .................. 114 (current production) ............................................................247
Setting the accumulator unloading valve
(current production) ............................................................248
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SERVICE TRAINING
Table of Contents
Setting the boom E-Stop manifold pressure ...................... 248 Setting the outrigger
Setting the boom/outrigger pressure .................................. 249 pressures (7 place boom valve systems) .............................292
Setting the outrigger pressure ............................................ 249 Setting 15 bar pretension ....................................................294
Setting the boom pressures ................................................ 250 To set the agitator circuit pressure: .....................................294
Set boom section #1 down pressure ................................... 251 32 XL Twin Circuit ...................................................................297
Setting water pump pressure .............................................. 252 Units up to 450 l/m .....................................................297
Setting the agitator pressure ............................................... 253 Check hydraulic pressures ..................................................297
KVM 28X .................................................................................. 255 Preheat the hydraulic oil .............................................297
Check hydraulic pressure ................................................... 255 Check the concrete pump pressure
Set the concrete pump main relief valve (single- circuit). . 257 (900-1200 - MPS pumpkits) ...............................................297
Setting the soft switch circuit relief pressure ..................... 259 Setting the soft switch circuit relief pressure ......................299
Set accumulator circuit hydraulic oil pressure (units with a Setting the boom pressures .................................................299
pressure- compensated pump) 260 Load-sensing boom pressures .............................................301
Setting the outrigger pressure ............................................ 262 Preheat the oil .............................................................301
Check or set ∆P .................................................................. 264 About proportional boom systems ..............................301
Check or set Q-min ............................................................ 265 Setting DP ...........................................................................302
Set boom pressures (load sensing proportional booms) .... 265 Setting Q-min .....................................................................304
Set the down side relief valve pressure .............................. 267 Setting boom pressures ...............................................304
Set 15 bar pretension .......................................................... 268 Setting the 140 bar down side relief valve pressure ...........306
Set water pump pressure .................................................... 269 Setting the outrigger
Set the agitator pressure ..................................................... 269 pressures (7 place boom valve system) ..............................306
31 EZ ......................................................................................... 271 Setting the water pump hyd. pressure .................................308
Check all hydraulic pressures ............................................ 271 To set the agitator circuit pressure: .....................................308
Preheat the hydraulic oil .................................................... 271 32 XL Hi-Flow B&W ................................................................311
Check the concrete pump pressure -4 pumpkits ................ 272 Units up to 450 l/m .............................................................311
To check or set the concrete pump pressure Check hydraulic pressures ..................................................311
adjustments, follow these steps: ................................. 272 Preheat the hydraulic oil .............................................311
Setting the main relief valve .............................................. 272 Location of pressure setting/checking devices ...........312
Setting the soft switch circuit relief pressure ..................... 274 Check the concrete pump pressure
To check or adjust the soft switch pressure setting, (2020, 2023, 2525 pumpkits) ..............................................313
proceed as follows: .................................................... 274 Setting the main relief valve ...............................................314
Setting pressures on load-sensing booms .......................... 274 Setting the soft switch circuit relief pressure ......................315
Preheat the oil .................................................................... 274 Setting the boom pressures .................................................315
About proportional boom systems ..................................... 274 Setting the 140 bar down side relief valve pressure ...........318
Setting DP .......................................................................... 275 Setting the outrigger pressures
Setting Q-min ..................................................................... 277 (7 place boom valve systems) .............................................319
Setting boom pressures ...................................................... 277 To set the agitator circuit pressure: .....................................321
There are several devices on the boom circuit 32 XL High Flow Proportional ................................................323
which control boom pressure (Figure 226): ............... 277 Units up to 450 l/m .............................................................323
Raise the pressure of the lowest circuit ............................. 278 Check hydraulic pressures ..................................................323
Setting the outrigger pressures ........................................... 278 Check the concrete pump pressure
To set the 280 bar relief valve for the (2020, 2023, 2525 pumpkits) ..............................................323
outrigger circuit: ........................................................ 278 Setting the main relief valve ...............................................324
Setting 15 bar pretension ................................................... 280 Setting the soft switch circuit relief pressure ......................326
To check or set pretension, follow these steps: ................. 280 Load-sensing boom pressures .............................................326
Setting the agitator circuit pressure ................................... 281 Preheat the oil .............................................................327
Setting accumulator circuit pressure .................................. 282 About proportional boom systems ..............................327
32XL Single Circuit ................................................................. 285 Setting DP ...........................................................................327
Check hydraulic pressures ................................................. 285 Setting Q-min .....................................................................329
Preheat the hydraulic oil .................................................... 285 Setting boom pressures .......................................................329
Check the concrete pump pressure (900 or 1200) ............. 285 Setting the 140 bar down side relief valve pressure ...........331
Setting boom pressures ...................................................... 286 Setting the outrigger pressures ...........................................331
Preheat the oil ............................................................ 286 Setting the water pump hyd. pressure .................................333
About proportional boom systems ............................. 287 Setting 15 bar pretension ....................................................333
Setting DP .......................................................................... 287 To set the agitator circuit pressure: .....................................334
Setting Q-min ..................................................................... 288 32 XL Hi-Flow Prop, A11VO ..................................................337
Setting boom pressures ...................................................... 289 Units above 450 l/m (-5 and -6 units) .................................337
Setting the 140 bar down side relief valve pressure .......... 290 Check hydraulic pressures ..................................................337
Service Manual
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SERVICE TRAINING
Table of Contents
Preheat the hydraulic oil .................................................... 337 Set accumulator circuit hydraulic oil pressure
Check the concrete pump pressure (units with a pressure- compensated pump) .......................382
(2020, 2023, 2525 pumpkits) ............................................. 337 Setting the outrigger pressure .............................................383
Setting the main relief valve .............................................. 339 Check or set ∆P ...................................................................386
Setting the soft switch circuit relief pressure ..................... 340 Set boom pressures (load sensing proportional booms) .....387
Setting boom pressures ...................................................... 340 Set water pump pressure .....................................................389
Preheat the oil ............................................................ 341 Set the agitator pressure ......................................................389
About proportional boom systems ............................. 341 KVM 39X ...................................................................................391
Setting DP .......................................................................... 341 Check hydraulic pressures ..................................................391
Setting Q-min ..................................................................... 343 Set the soft switch circuit relief pressure ............................394
Setting boom pressures ...................................................... 343 Set accumulator circuit hydraulic oil pressure
Setting the 140 bar down side relief valve pressure .......... 345 (units with a pressure- compensated pump) .......................395
Setting the outrigger pressures Set the outrigger pressure ...................................................396
(7 place boom valve systems) ............................................ 346 Check or set ∆P ...................................................................399
Setting 15 bar pretension ........................................... 348 Check or set Q-min .............................................................399
To set the agitator circuit pressure: .................................... 348 Set boom pressures (load sensing proportional booms) .....400
KVM 34X .................................................................................. 351 Set 15 bar pretension ..........................................................402
Check hydraulic pressures ................................................. 351 Set water pump pressure .....................................................402
Preheat the hydraulic oil .................................................... 351 Set the agitator pressure ......................................................402
Check the concrete pump pressure KVM 42SX ................................................................................405
(2020, 2023, 2525 pumpkits) ............................................. 351 Setting Pressures .......................................................................405
Setting the main relief valve .............................................. 352 Check all hydraulic pressures .............................................405
Setting the soft switch circuit relief pressure ..................... 354 Preheat the hydraulic oil .............................................405
Load-sensing boom pressures ............................................ 355 Setting pressures on Hi-flo -6 pumpkits .............................406
Preheat the oil .................................................................... 355 Setting the soft switch relief pressure .................................408
About proportional boom systems ............................. 355 Setting boom circuit pressures ............................................408
Setting DP .......................................................................... 355 Load-sensing boom hydraulic controls ...............................408
Setting Q-min ..................................................................... 357 Setting delta P pressure .......................................................409
Setting boom pressures ...................................................... 357 Setting Q-min .....................................................................411
Setting the 140 bar down side relief valve pressure .......... 358 Setting boom pressures .......................................................411
Setting the outrigger pressures ........................................... 358 Setting outrigger pressure ...................................................412
Setting the water pump hydraulic pressure ........................ 360 Setting the agitator pressure ...............................................413
Setting 15 bar pretension ................................................... 361 Setting accumulator circuit pressure ...................................414
Setting the agitator circuit pressure ................................... 361
KVM 42M - Proportional (Apitech) Single Circuit ...............417
Setting accumulator circuit pressure .................................. 363
Check hydraulic pressures ..................................................417
KVM 36X-42M (pre-1998) ...................................................... 365 Preheat the hydraulic oil .....................................................417
Pressure Settings for KVM 36X Proportional Setting concrete pump pressure (single-circuit units) ........417
Load Sensing ...................................................................... 365 Setting boom circuit pressures ............................................420
Component Location Guide KVM 36 X Load-sensing boom hydraulic controls ...............................420
W/Rexroth Handvalves ...................................................... 366 Setting DP ...........................................................................420
Pressure Settings for KVM 36X Proportional Setting Q-min .....................................................................422
Load Sensing ...................................................................... 367 Setting boom pressure ........................................................422
Pressure Regulator Cutaway .............................................. 368 Setting pretension ...............................................................425
Pressure Settings for Regulator and Releif Valves ............ 369
KVM 42M - Proportional (Apitech) Twin Circuit ................427
KVM 36 LW & 36 X W/Rexroth Boom Handvalve ......... 370
Pressure Settings for KVM 42
Preheat the hydraulic oil .....................................................427
(B&W Load sensing and Proportional Load Sensing ........ 371
Setting concrete pump pressure (High-flow pumpkits) ......427
Component Location Guide KVM 42
Setting the soft switch circuit relief pressure ......................429
W/Rexroth Handvalves ...................................................... 372
reheat the oil to check pressures .........................................430
Pressure Settings for KVM 42LW
Load-sensing boom hydraulic controls ...............................430
Proportional Load Sensing ................................................. 373
Setting DP ...........................................................................431
Pressure Regulator Cutaway .............................................. 374
Setting Q-min .....................................................................433
Pressure Settings for Regulator and Relief Valves
Setting boom pressure ........................................................433
KVM 42 ............................................................................. 375
Setting 15 bar pretension ....................................................435
KVM 42 LW, W/Rexroth BoomHandvalve ...................... 376
KVM 42M - Proportional (Rexroth) .......................................437
KKVM 36X ............................................................................... 377
Check hydraulic pressure ................................................... 377
Preheat the hydraulic oil .....................................................437
Set the soft switch circuit relief pressure ........................... 381
Setting concrete pump pressure (single-circuit units) ........437
Service Manual
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SERVICE TRAINING
Table of Contents
Setting boom circuit pressures ........................................... 440 Setting main boom circuit pressures ...................................490
Load-sensing boom hydraulic controls .............................. 440 Checking pretension pressure .............................................491
Setting DP .......................................................................... 441 Set the outrigger pressure ...................................................492
Setting Q-min ..................................................................... 443 Set the agitator pressure ......................................................493
Setting boom pressure ........................................................ 444 KVM 55M ..................................................................................495
Set the #1 down side pressure ............................................ 445 Check all hydraulic pressures .............................................495
Setting outrigger pressure .................................................. 446 Preheat the hydraulic oil .....................................................495
Set accumulator circuit hydraulic oil pressure Setting relief pressure and pressure cutoff on
(units with accumulator unloading valves) ........................ 449 Hi-flo -6 pumpkits ..............................................................496
KVM 45/47SX .......................................................................... 453 Setting the soft switch circuit relief pressure ......................498
Setting Pressures ...................................................................... 453 Setting boom circuit pressures ............................................499
Check all hydraulic pressures. ........................................... 453 Checking and setting DP pressure ......................................499
Setting pressures on Hi-flo -6 pumpkits ............................ 453 Setting Q-min .....................................................................501
Setting the soft switch relief pressure ................................ 456 Checking boom pressures ...................................................501
Setting boom circuit pressures ........................................... 456 Setting main boom circuit pressures ...................................502
Load-sensing boom hydraulic controls .............................. 456 Checking pretension pressure .............................................503
Setting delta P pressure ...................................................... 457 Setting the outrigger pressure .............................................504
Setting Q-min ..................................................................... 459 Set the agitator pressure ......................................................505
Setting boom pressures ...................................................... 459 Set accumulator circuit pressure .........................................506
Setting outrigger pressure .................................................. 460 S 58/61SX ...................................................................................509
Set the agitator pressure ..................................................... 461 Check all hydraulic pressures .............................................509
Set accumulator circuit pressure ........................................ 462 Preheat the hydraulic oil .............................................509
KVM 45SX Hi-Flow - 6 ........................................................... 465 Setting pressures on Hi-flo -6 pumpkits .............................509
Setting Pressures ...................................................................... 465 Pressure setting procedure: .........................................509
Check all hydraulic pressures. ........................................... 465 Setting the soft switch relief pressure .................................512
Setting the main relief pressure and pressure Setting boom circuit pressures ............................................512
cutoff on Hi-flo -6 pumpkits .............................................. 466 Load-sensing boom hydraulic controls ...............................512
Setting the soft switch relief pressure ................................ 468 Setting Delta P pressure ......................................................513
Setting boom circuit pressures ........................................... 468 Setting Q-min .....................................................................514
Load-sensing boom hydraulic controls .............................. 468 Setting boom pressures .......................................................515
Setting main pressure ..................................................515
KVM 52M (pre-1998) .............................................................. 469
Setting boom pressure (redundant) relief ...................515
Pressure Settings for KVM 52 Proportional Load
Setting pressure cut-off ...............................................516
Sensing ............................................................................... 469
Setting slewing pressure .............................................516
Component Location Guide- KVM 52 .............................. 470
Setting outrigger pressure ..................................................517
Pressure Settings for KVM 52 Proportional Load
Setting the agitator pressure ...............................................517
Sensing ............................................................................... 470
Setting accumulator circuit pressure ...................................518
Pressure Regulator Cutaway KVM 52 ............................... 472
Pressure Settings for Regulator and Releif Valves
KVM 52 ............................................................................. 473 Electrical Information
Setting Pretension Pressure(Refer to Figure 5) .................. 473
Control Block 1 for KVM 52 Boom 3, Boom 4, & Boom Control Systems and the Advantages of Each ............521
Slewing .............................................................................. 474 Boom Control Systems .............................................................523
Control Block 2 for KVM 52 Boom 1, Boom 2, & Introduction to Proportional Controls ...................................524
Outriggers .......................................................................... 474 The Joystick with Potentiometer ........................................524
Pre-Control Block 1-A for KVM 52 ................................. 476 The Proportional Amplifier ................................................525
Pre-Control block 1-B for KVM 52 .................................. 477 The Solenoid Valves ...........................................................525
Pre-Control Block 1-C for KVM 52 ................................. 478 The Proportional Amplifier in Use with the Radio ...............526
Pre-Control Block 2-A for KVM 52 ................................. 479
Motherboard for Proportional Units ......................................527
Pre-Control Block 2-B for KVM 52 ................................. 480
Electric Bypass Valve for KVM 52 ................................... 481 Power Supply - Slot 9 ...............................................................528
KVM 52M ................................................................................. 483 Proportional Amplifier - Slot 1,2,3 ..........................................529
Setting relief pressure and pressure cutoff on Calibration of Proportional Amplifier Cards ........................530
Hi-flo -6 pumpkits ............................................................. 483 Linear Signal Diagram .............................................................531
Setting the soft switch circuit relief pressure ..................... 486 Decal of Proportional Motherboard .......................................532
Set boom circuit pressures ................................................. 486 Wiring Diagram - DUVAC II 12V / 24V Transformer .........533
Checking and Setting DP pressure ..................................... 487
Wiring Diagram - DUVAC II 12V / 24V Transformer .........534
Set Q-min ........................................................................... 488
Checking boom pressures .................................................. 489 Digital Proportional - Overview (1 of 5) .................................535
Service Manual
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Table of Contents
Overview ............................................................................ 535 1.2.8 SCROLLING" sub-menu ..................................598
M.A.T. ................................................................................ 536 2.0 Concrete pump efficiency parameter setting
Processor Unit .................................................................... 537 / Central lubrication / Prop characteristics ..........................599
Card Functions ................................................................... 538 2.1 Password entry and parameter selection menu .....599
Control System Arrangement ............................................ 539 2.2 Setting the concrete pump efficiency for
Digital Proportional - Programming ...................................... 540 pumped volume determination ...................................600
Programming ..................................................................... 540 2.3 Adjusting the central lubrication ..................................601
MAT Operation .................................................................. 540 2.4 Adjusting the proportional parameters for boom
Menu Structure .................................................................. 541 functions .............................................................................602
Moving Through The Menu Survey .................................. 542 Proportional characteristics adjustment for the
Access The Service Menu .................................................. 543 BOOM SLEW function with PROP valve types : ..............603
Identifying the Entries and Parameters .............................. 544 Proportional characteristics adjustment for the
“SCV” Card Main Menus .................................................. 544 BOOM 1 function with PULSAR valve types : .................604
“?PAR” Main Menu ........................................................... 544 3.0 I/O status display - signals & references ......................605
Submenus Functions and Parameters ................................ 545 3.1 Machine control ....................................................605
“?SELECT ” Submenu Functions and Parameters 3.2 Concrete pump control .........................................607
(In Service Menu Only!) .................................................... 546 3.3 Boom control ........................................................608
“?V24” Submenu Functions and Parameters ..................... 547 3.4 Rear panel .............................................................610
“?DIN” Main Menu ........................................................... 547 3.5 Extension module .................................................611
“?RACK” Submenu Functions and Parameters ................ 548 4.0 Fault messages and fault causes ...................................612
“?BDI A” Submenu Functions and Parameters ................ 549 4.1Introduction ...........................................................612
“?BDI F” Submenu Functions and Parameters ................. 550 4.2 Control diagnosis electronic modules..........................
“?SOUT" Main Menu ........................................................ 551 (fault code S !) ............................................................613
“?POUT” Main Menu ........................................................ 552 4.3 Remote-control system diagnosis (fault code F!) .614
“?DIAG” Main Menu ........................................................ 553 4.5 Engine/PTO Diagnosis (fault code D!) ................617
“?SYSTEM” Main Menu .................................................. 553 4.6 Concrete pump diagnosis (fault code B!) .............618
“?GERAET” Main Menu (In Service Menu Only!) .......... 554 4.7 Boom control diagnosis (fault code M!) ...............619
V2.4 Menus ........................................................................ 554 4.8 Central lubrication/extension diagnosis
Software Versions .............................................................. 555 (fault code Z/E!) .........................................................621
Digital Proportional - Balancing Valve Currents ................. 577 5.0 Output signal interdependence list ...............................622
Hysteresis ........................................................................... 579 Part 1 Operation .......................................................................638
Diagnostic Signal ............................................................... 579 Commissioning ...................................................................638
Setting Valve Currents ....................................................... 579 Selecting local control ........................................................639
Digital Proportional - Troubleshooting ................................. 581 Selecting remote control .....................................................640
Troubleshooting procedure 1 ............................................. 583 Ram change mode: .............................................................641
Troubleshooting procedure 2 ............................................. 583 Emergency stop buttons ......................................................642
Troubleshooting procedure 3 ............................................. 583 Override of the E-stop manifold .........................................642
Troubleshooting procedure 4 ............................................. 583 Bypass mode ...............................................................642
Troubleshooting The Radio ............................................... 584 Options box .........................................................................643
Operation ........................................................................... 585 Night light switch .......................................................643
Emergency Stop ................................................................. 586 Concrete shut-off valve switch ...................................643
Automatic Shut down ........................................................ 586 Control and monitoring components ..................................644
Trouble-shooting ................................................................ 587 Controller cabinet (Figure 13) ....................................644
Troubleshooting tables ....................................................... 588 Display window (Figure 14) .......................................644
Control status indications ...........................................644
Operating mode display ..............................................644
Comfort Control Manual Menu control .......................................................................645
Basic functions of the keys (Figure 15) ......................645
1.0 Working with the info & diagnosis system ................. 592
Fast selection/abbreviated function keys (shortcuts): .645
1.1 Introduction into the info & diagnosis system ..... 592
Local control .......................................................................646
1.2 Menu structure info & diagnosis system
Remote control ...................................................................647
/ Operation data display ..................................................... 594
Menu overview - Main menu .............................................648
1.2.1 Standard display & malfunction messages ....... 594
Menu overview - Main menu (continued) ..........................649
1.2.2 Main menu ........................................................ 595
Menu overview - submenus ................................................652
1.2.3 "PUMP VPUME" sub-menu ............................. 596
Menu operation - Example: ................................................653
1.2.4 "OPERATION DATA" sub-menu .................... 596
Diagnostic system/”Fault handling” ...................................654
1.2.5 "MALFUNCTION LIST" sub-menu ................ 597
Display language ........................................................655
1.2.6 "LUBRICATION-UNIT" sub-menu ................ 597
Acknowledging messages ...........................................656
1.2.7 "I/O DISPLAY" sub-menu ............................... 597
Service Manual
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SERVICE TRAINING
Table of Contents
Acknowledging faults ........................................................ 656 13. Maintenance Works and Checks .......................................699
Fault definition ................................................................... 656 Changing the transmitter battery ........................................699
Low level fault ........................................................... 656 Charging the transmitter battery .........................................699
High level faults ......................................................... 656
Silent diagnostic ......................................................... 657
Reporting and acknowledging of faults ..................... 658 Radio Control FW 20
Acknowledging of several faults ............................... 663 Table of Contents ......................................................................701
Switching off the control system ............................... 663
2. Short Operating Instructions ..............................................702
Summary of messages ....................................................... 664
Preparations ........................................................................702
Heat the oil first ................................................................. 676
Ready-for-Operation State ..................................................702
Restore original factory settings ................................ 676
Emergency Shut-Off ...........................................................702
Setting parameters ...................................................... 677
Automatic Shut-Off ............................................................702
Interruptions of Work .........................................................702
Radio Remotes 3. Foreward ...............................................................................703
4. Designated Use ......................................................................703
Cross Reference Wiring Chart ............................................... 683
Non Designated Use ..................................................................703
Extract from Terms of Warranty ...........................................704
Radio Control FW 18 5. Safety Rules and Accident Prevention Regulations ...........705
Table of Contents ..................................................................... 685 7. Short Description ..................................................................706
1. Safety and Accident Prevention Regulations .................... 685 8. Technical Data: .....................................................................707
Safety Regulations - Concrete Pumps with Transmitter ..........................................................................707
placing booms .................................................................... 686 Receiver ..............................................................................708
Traveling ............................................................................ 686 9. Monitoring-, Warning-, and Control Elements .................709
Jacking ............................................................................... 686 10. Pre-Operational Instructions .............................................712
Concrete Pump ................................................................... 686
11. Operation .............................................................................716
Placing Boom ..................................................................... 686
Battery Capacity .................................................................716
Pipelines ............................................................................. 687
Disturbances .......................................................................717
Remote Controls ................................................................ 687
Frequency Change ..............................................................717
Electrical Connections on the site-Hydraulic
Power Packs, etc. ............................................................... 687 12. Emergency Shut-Off ...........................................................717
2. Short Instructions ................................................................ 688 13. Interruptions of Work/End of Operation .........................718
Preparing the Commissioning ............................................ 688 14. Replacing the Battery .........................................................719
Making Ready for Operation ............................................. 688 Recharging of Battery .........................................................719
Operating Mode ................................................................. 688 15. Malfunctions ........................................................................720
Reasons for Automatic Switch-off .................................... 688 Message Interference ..........................................................721
3. Preface ................................................................................... 688 Trouble Shooting ......................................................................722
4. Extract from the Terms of Warranty ................................ 689 Troubleshooting: Receiver LEDs .......................................722
5. Model Plates ......................................................................... 690 Troubleshooting Controller (MC1) ....................................724
Troubleshooting Table: Transmitter LED’s ......................724
6. Technical Data ...................................................................... 690
16. Maintenance ........................................................................726
7. Brief Description .................................................................. 690
Replacing of Fuses ..............................................................726
Transmitter ......................................................................... 690
Receiver ............................................................................. 691 17. Repair ..................................................................................727
8. Control and Monitoring Equipment .................................. 692
Radio Remote .................................................................... 692 Radio Control FW 24
Receiver ............................................................................. 693
9. Commissioning ..................................................................... 694 Safety Instructions ....................................................................730
Preparations ....................................................................... 694 Scope of Application .................................................................731
Ready for operation ........................................................... 694 Start-Up .....................................................................................732
10. Operating the Radio Remote Control .............................. 695 Operation ...................................................................................735
Transmitter mode ............................................................... 695 Charging the Battery ................................................................736
Transmitter range ............................................................... 696 Maintenance ..............................................................................737
Putting out of Operation .................................................... 697
Operation Fault Indicators ......................................................738
Changeover to Cable Remote Control ............................... 697
12. Safety Facilities .................................................................. 698
Fuses .................................................................................. 698 C32/CPC Radio Remote
Service Manual
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SERVICE TRAINING
Table of Contents
Spread Spectrum Technology ................................................. 741 Piston Installation Tools for Differential Cylinders ..............804
Mounting the Receiver Antenna: ........................................... 742 Gland Packing Installation Tools for Differential Cylinders 805
Transmitter Operation ............................................................ 743 Seal Replacement Tools ............................................................806
Remote Radio Controller ........................................................ 746 Piston Seal Guide Tool .......................................................806
Piston Seal Form Tool ........................................................806
Bushing Installation Tool .........................................................806
Omnex Radio Control System Rock Shaft Bushing Installation Tool ................................806
1. Introduction .......................................................................... 751 Accumulator Charging Kit ......................................................807
2. Physical Mounting ............................................................... 752 Adjustment Meters for Analog Proportional Cards .............807
3. Considerations for Electrowelding ..................................... 752 Analog Adjustment Meter ..................................................807
4. Receiver Connector Assignments ....................................... 753 Technition Support Kit ............................................................807
5. Cable Unit Connector Assignments ................................... 754 Electrical Tools and Accessories ..............................................808
6. Fuses ...................................................................................... 754 Spanner Socket Tools for Boom Pins ......................................809
7. Operations ............................................................................ 755 Truck Engine Tools ..................................................................810
7.1 Receiver ....................................................................... 755 Pro-Link 9000 .....................................................................810
7.1.1 Receiver Lights - General Function .................. 755 Micellaneous Tools ...................................................................810
7.1.2 Receiver Lights - Error Conditions ................... 755 Whip Hose and Fittings ......................................................810
7.1.3 Operator Adjustments: ...................................... 756 Rock Valve Cover Alignment ............................................810
7.2 Transmitter ................................................................... 757
7.2.1 Transmitter Lights ............................................. 757
7.2.2 Operator Controls: ............................................ 758
7.3 Cable Unit .................................................................... 758
7.3.1 Cable Unit Lights .............................................. 758
7.3.2 Operator Controls: ............................................ 759
8. Troubleshooting Information ............................................. 759
8.1 I24-MC Board .............................................................. 759
8.2 Receiver TPCB-1527-01 Board ................................... 759
Conversion Charts
Fluid Power Formulas ............................................................. 766
Torque Specifications .............................................................. 768
Torque Specification: Slewing Roller Bearing Bolts ............ 772
WP Number Codes .................................................................. 776
BP Model Number Codes ........................................................ 777
Outrigger Spreads and Loads ................................................. 778
Boom Pin Clearances ............................................................... 779
Nozzle Chart ............................................................................. 788
Boom Times/Without Weights ................................................ 789
Boom Pressures & Nozzle Chart Size .................................... 791
Boom Pressures & Nozzle Chart Size .................................... 792
Rotek Bearing Clearance Instructions - SAIE - 5114 ........... 793
Special Tools
Hydraulic Trouble Shooting Kits ........................................... 801
Schroeder Filter Cart .............................................................. 801
Features: ..................................................................... 801
Flow Meters and Accesories .................................................... 802
Flow Meter Y223 Model HT200 ............................... 802
Specifications: ............................................................ 802
Accessories: ............................................................... 802
Material Cylinder Alignment Tool ......................................... 803
Service Manual
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SERVICE TRAINING
Maintenance, Lubrication Schedules, etc.
Maintenance
Maintenance Chart
Table 1. Scheduled Maintenance
Semi-annually
As Indicated
Quarterly
Annually
Monthly
Weekly
Daily
Task
Change main hydraulic oil filter √
Change high pressure oil filter √
Change water system inline filter √
Check truck fluid levels √
Bleed moisture from air tank √
Check tires √
Check hydraulic oil √
Bleed moisture from hydraulic tank √
Check differential cylinder rod packings √
Inspect bolts on Rock Valve and rams √
Grease Rock Valve and agitator bearings √
Grease Rollix bearing and hollow pin √
Check optional auto greaser reservoir √
Fill optional auto greaser reservoir √
Inspect for damage and leaks √
Check if maintenance is due √
Grease boom zerks √
Check pipe wall thickness √
Check oil in optional air compressor √
Check Rock Valve tension nut √
Service Manual 1
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SERVICE TRAINING
Table 1. Scheduled Maintenance (Continued)
Semi-annually
As Indicated
Quarterly
Annually
Monthly
Weekly
Daily
Task
Inspect cutting ring/rotate if needed √
Lubricate mechanical moving parts √
Check tapered bend wedge bolt √
Check boom slewing gearcase oil level √
Clean slewing gearcase breather cap √
Check function of mech. boom brake √
Clean and repack the Rollix gear √
Inspect the turret bolts for tightness √
Check fluid in distribution gearcase √
Check unit mounting hardware √
Check hydraulic pressures √
Clean hydraulic oil cooler fins √
Check drive pinion mounting screw √
Change oil in optional compressor √
Change hydraulic oil for temp. reasons √

a √
Check the accumulator pre-charge a
Change oil in distribution gearcase √
Change oil in boom slewing gearcase √
Test dirty filter lamp circuit √
Change hydraulic oil for age reasons √
Clean optional compressor √
Change corrosion inhibitors √
Periodic - structural inspection √

a. break-in period
2 Service Manual
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SERVICE TRAINING
Operators Check list for Weekly

Maintenance (Ex.)
Operator’s Check List for Unit # Week Ending

1 = Once per Week
2 = Twice per Week
MON TUE WED THU FRI SAT SUN
E = Everyday
( E ) Truck Engine Oil
( E ) Hydraulic Oil Level - TANKS
( E ) Water Box Level & TANKS
( E ) Flush Grease Lines
( E ) Hoses & Pipes
( E ) Clamps & Rubbers
( E ) All Tools & SAFETY Gear
( E ) Grease Agitator Bearings
( 2 ) Agitator Gearbox Oil Level-90W
( 2 ) Transfer Case Oil Level
( 2 ) Transmission Oil Level
( 2 ) Hyd. Pump Gear Oil Level
( 1 ) Bleed Air from A3V Hyd. Pump
( 1 ) Bleed Water from Air/Oil Tanks
( 1 ) Check Pipeline Structural Pts.
( 1 ) Check Oil Filter Light
Daily Yards Pumped (1 st Job)
Daily Yards Pumped (2 nd Job)
S0021.eps
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SERVICE TRAINING
Size Comparison of Particles
SCREEN SIZES
U.S. SIEVE NUMBER OPENING (micro-meters) OPENING (inches)
50 297 0.0117
60 238 0.009
70 210 0.0083
100 149 0.0059
140 105 0.0041
200 74 0.0029
270 53 0.0021
325 44 0.0017
PAPER 10 0.00039
PAPER 5 0.00019
SIZES OF FAMILIAR OBJECTS

SUBSTANCE MICRO-METERS INCHES
Grain of Table Salt 100 0.004
Human Hair 70 0.0027
Lower Limit of Visibility 40 0.00158
White Blood Cell 25 0.001
Talcum Powder 10 0.0004
Red Blood Cell 8 0.0003
Bacteria (average) 2 0.00008
149 mm
(100 Mesh)
SIZES IN MICRO-METERS
(Magnification 500x) 74 mm
(200 Mesh)
44 mm
(325 Mesh)
25 mm
10 mm
5 mm
2 mm
S0022.eps
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SERVICE TRAINING
Filtration Ratings Filter Facts

• Fine Filters have ∆P
Nominal Rating • Fine filters have long life
An arbitrary micrometer value indicated by the filter • Harmful particles cannot be seen
manufacturer. Due to lack of reproducibility, this rating • 1 micron nominal filters pass 10 micron particles
is deprecated. • Fine filters remove silt, not additives
• Metal mesh breathers allow airborne ingression
Absolute Rating • New oil can be very dirty
The diameter of the largest hard spherical particle that
will pass through a filter under specified test
BETA RATINGS
conditions. This is an indication of the largest opening
in the filter element. Particles in this range (and smaller) should {
pass through the filter.
Filtration Ratio(βn)
The ratio of the number of particles greater than a
given size (n) in the influent fluid to the number of
particles greater than the same size (n) in the effluent
fluid.
Particles in this range (and larger) should
be removed by the filter.
β X = 200
{
example: β12 = 200.
This means that for every 200 particles of
HOW BETA WORKS 12 microns or larger that hit the
media, 1 will make it through.
IN OUT β= IN
OUT
PARTICLES > 5 m UPSTREAM DOWNSTREAM
FILTER IN OUT β5 FLOW
FILTER A 10,000 5000 2 β X = 75

example: β12 = 75.
FILTER B 10,000 100 100 This means that for every 75 particles of
12 microns or larger that hit the
FILTER C 10,000 1 10,000
media, 1 will make it through.
S0023.eps (225 particles shown entering, 3 coming out)
Figure 2
Figure 2: The filtration ratio or Beta is calculated by
dividing the number of particles entering the filter by
the number of particles exiting the filter. β5 represents
the filtration ratio at 5 micrometers or the ratio of UPSTREAM DOWNSTREAM
upstream to the downstream particles larger than 5
micrometers. FLOW S0024.eps
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SERVICE TRAINING
Fluid Contamination and Control Methods

• Built in
Control
a. Clean all components before installation
The sources of contamination in hydraulic and b. Use only straight thread fittings or flange fit-
lubricating systems are divided into three general tings
categories. The degree of importance of each source
c. Flush new systems with high efficiency filters
depends on: system design, operating environment, and
maintenance practices • Ingressed
a. Use reservoir breather filters that are as fine as
Primary sources of contamination the system filters
• Bulit-In Contamination (dirt, shavings, slag, and b. Use high quality seals in all system compo-
etc. that may be present during assembly). nents
c. Always keep maintenance environment clean
• Ingressed Contamination (is an environmental d. Pre-filter the new oil prior to dispensing to tank
type which happens during routine servicing or • Internally Generated
from lack of maintenance). a. Always use fine "silt control" filters
b. Use specified lubricants for components
• Internally Generated Contamination (occurs c. Eliminate water from the system to reduce rust
from the rubbing and grinding of all moving parts d.
inside each and every component of the system).
S0025.eps
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SERVICE TRAINING
Handling, Storing & Dispensing and snow. The proper storing position of an oil drum
is: drum should be laid on it’s side with the bungs
Lubricating fluids approximately horizontal and at the lowest point. In
To obtain optimum performance from oil, proper this position, water and moisture cannot collect in the
handling, storing and dispensing is required. These chime and because the bungs are below the level of the
steps are necessary to preserve the integrity of the drum’s contents, the incidence of water being drawn
product. It is uneconomic to buy a high quality into the drum from normal breathing is greatly
lubricant and then permit degradation through reduced. For maximum protection, drums should be
contamination. stood on end with bungs down on a well-drained
surface. In circumstances when all the aforementioned
Unless simple precautions are observed, contamination
storing methods are impractical, drum covers should be
of lubricants can occur during storage; or during
used. Covers are available in both metal and plastic.
transfer of oil from the original container to the
Drums with a bung on the side should be stored either
dispensing equipment; or during dispensing of oils to
on their end, or on their side with the bung facing
the equipment to be lubricated. Pumps, oil cans,
down. Regardless of the position, drums should
measures, funnels and other dispensing equipment
always be placed on blocks or racks several inches
must be kept clean at all times and covered when not in
from the ground to avoid contact with moisture or
use.
standing water.
Storing oil drums, fill carts, or other containers outside
When drums must be stored outside with the bung end
of climate controlled areas is a poor practice. Water
upward, they should be blocked up in a manner that
and moisture may get into the drum around the bungs
will keep the drum teetered to provide sufficient
and contaminate or destroy the drum’s contents. A
draining of water. The drum should be rotated on the
drum standing on end with the bungs facing up can
blocks so that any water collecting on the top of the
collect rain water or condensation inside the chime.
drum surface does not come in contact with or
This water can gradually be drawn in around the bungs
submerge the bung openings.
by the breathing of the drum as the ambient
temperature rises and falls. This can occur even with Before opening a drum that has been stored outside, the
bungs drawn tight and the tamper-proof seals in place. bung and chime areas should be cleaned thoroughly to
In addition, the dirt and rust that can accumulate inside eliminate the hazard of collected rust, scale and dirt
the chime and around the bungs may contaminate the from falling into the drum.
drum’s contents when the drum is opened for use. Always use the oldest oil first. The probability of
As a general rule, lubricants in drums smaller than 16 oxidation, contamination and attack by heat and cold,
gallon capacity should never be stored outside. increase with age. If the oil quality is suspect due to
However if drums must be stored outside, a temporary long periods of storage, have the oil analyzed before
shelter or lean-to, and/or a waterproof tarpaulin is using it.
highly recommended for protecting the drum from rain
SUN
standing
RAIN
water
chime bungs
COOL air space WARM powerful COOLING

air space
reduced suction
created
Contaminating
Clean oil in sealed Oil and air in drum water is drawn into
drum as delivered expand from heat drum through the
and then stored exposure forcing bungs when oil
outside standing air out through top water and air cools and
on end contracts
S0026.eps
Service Manual 7
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SERVICE TRAINING
Hydraulic Oils gets. The lower the ISO VG number the thinner the oil
and the lower the pour point of the oil. On the other
General information relates to all hydraulic oils. hand, the thinner the oil, the lower the temperature will
Specific information contains hydraulic oil have to be before it breaks down the lubricating film
recommendations for Schwing concrete pumps. that protects your components. See the hydraulic oil
chart on page 9 of this manual for help in selecting the
General information proper oil for your requirements.
Hydraulic oils are rated for viscosity, heat dissipation, The quality of the oil needed for use in a Schwing
foaming characteristics, pour point, antiwear additives, concrete pump is rated in the DIN system. The ratings
anticorrosive additives, lubricating qualities, have to do with the chemical additive package that is
compressibility, temperature range, temperature introduced into the oil. Both the DIN rating HLP and
stability, and other functions. Although many different HV qualities are approved for use in our concrete
brands of oil meet these specifications, they may use pumps.
different chemical additive packages to achieve the end
result. For this reason, you should not mix two Specific information
different brands of oil. The additive package from one All concrete pumps leave the Schwing factory filled
brand may be incompatible with the additive package with Texaco Rando HD 46 hydraulic oil, which has an
from the other, rendering both packages useless. ISO viscosity rating of VG 46. Rando HDZ 46, an
Recently a few manufacturers have introduced extended-viscosity oil designed for use under severe
biodegradable hydraulic oils onto the market. These conditions, is available on request. If you want your
oils are based on vegetable extracts instead of mineral new concrete pump filled with a different brand or
extracts. They are considered safer for the environment different viscosity oil, you should specify it when
in the event of a spill, although the additive packages ordering.
are not inert. One brand, Mobil EAL 224-H, has been Many other brands of oil have been approved for use in
accepted for use in Schwing pumps, and other brands Schwing concrete pumps, including:
are under consideration and testing. These oils must
not be mixed with mineral-based hydraulic oils, even in • Mobil DTE
very small amounts. If you will be pumping a job in an • Shell Tellus oil
environmentally sensitive location and want to use this • BP Energol
type of hydraulic oil, please contact the Schwing
• Aral Vitam
Service Department at (651) 429-0999 for instructions
on making the change from mineral oil. • Esso Nuto
Viscosity of hydraulic oil is similar in concept to the • Esso Univis
different weights of motor oil. For example, in the • Total Azolla
winter you may run 5W-30 in your car, while in the
• Wintershall Wiolan
summer you run 10W-40. The same is true for
hydraulic systems. If you live in a climate where the The order of the brands listed is not significant. Any oil
weather is changing from extremely hot conditions to that meets the quality and viscosity standards described
extremely cold conditions, you should consider above can be used.
changing the weight of the hydraulic oil that you use
by the season. The International Standards
Organization (ISO) has developed a method of grading
hydraulic oils for viscosity. For summer in northern
North America, we recommend ISO VG 46 weight oil,
while in the winter we recommend ISO VG 32 or even
VG 22, depending on how cold it gets in your area. For
southern North America and Central America, we
recommend ISO VG 46 for the winter and ISO VG 68
or VG 100 for the summer, depending on how hot it
8 Service Manual
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SERVICE TRAINING
Hydraulic Oils When to change your hydraulic oil
VG 32 = Winter application conditions in Central Change your hydraulic oil at least once a year. If you
Europe. use good filters, and change them when they are dirty,
VG 46 = Summer application conditions in Central the oil will be clean even after a year. The chemical
Europe. additive packages that give the oil its properties will
break down with time, however and no amount of
VG 68 = Excessive heat indoors application or in the
filtration will bring them back.
Tropics.
ISO viscosity / DIN quality VG 32 / HLP VG 46 / HLP VG 68 / HLP

ARAL - VITAM GF 32 GF 46 GF 68
BP - ENERGOL HLP 32 HLP 46 HLP 68
ESSO - NUTO H 32 H 46 H 68
MOBIL - DTE 24 25 26
SHELL - TELLUS OIL 32 46 68
TOTAL - AZOLLA ZS 32 ZS 46 ZS 68
TEXACO - RANDO OIL HD* A-32 B-46 C-68
WINTERSHALL - WIOLAN HS 32 HS 46 HS 68
* Factory Fill oil at Schwing America Inc.
Service Manual 9
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SERVICE TRAINING
Hydraulic Oil Viscosity Chart • The minimum permissible viscosity represents the
warmest temperature at which the oil will still be
The illustration below shows the relationship between thick enough to provide lubrication and sealing.
the oil temperature and its viscosity. As you can see, Anything warmer, and the components will have
the oil gets thicker when the temperature is low and metal-to-metal contact (thermal breakdown).
thinner as the temperature rises. • The optimum operating viscosity is the range of oil
• The cold start limit represents the coldest thickness at which the oil works best (thin enough
temperature at which the oil is thin enough to flow to flow easily yet thick enough to protect the
into the hydraulic pumps. Anything colder, and system components).
the pumps would not be able to suck in the oil An example of how to read a chart for VG-46 oil is
(cavitation). given in the chart below. The chart shows the cold start
limit as –8°C (18°F) and the minimum permissible
viscosity as 90°C (194°F). The optimum range is 50°–
76°C.
Temperature of Hydraulic Oil

(°C)
Cold Start Limit
(very thick oil)
Water freezes
Water boils
VG
VG 2
VG 2
VG 6
VG 8
2
3
4
6
10
0
Optimum
Operating
Viscosity
temp chart.eps
Minimum permissible
viscosity
(°C)
(°F)
°C = degrees Celsius
°F = degrees Fahrenheit S0027.eps
10 Service Manual
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Lubrication Prefix Codes “Industrial” gear lubricant codes

CLP An "industrial" gear lubricant oil with
Standard codes used additives to improve corrosion protection,
API American Petroleum Institute aging stability, and protection against wear in
areas with many types of friction, and to
BI Main Association of the German increase gear stability under load. Meets
Construction Industry. As an alternative to DIN 51517.
the recommended lubricants and operating
agents, the standard lubricants with this Vehicle gear box oil codes
prefix may be substituted. GO 90 BI standard lubricant, a gear box oil that
DIN Deutche Industrie Norm (German Industry meets API-GL 5.
Norm) MIL-L-2105B Motor vehicle gear lubricant oil for
ISO International Standardization Organization hypoid bevel gear lubrication under
highest demands in gears and axles.
MIL-L American Military Standard for Lubricants Roughly corresponds to API-GL 5.
SAE Society of Automotive Engineers Compressor oil codes
VG Viscosity in millimeters 3/s @ 10° F (40° C) VDL Mineral oil for air compressors with additives
to improve corrosion protection and aging
Hydraulic oil codes stability. Coke residue after aging is no more
API-CD Engine oil for heavily loaded diesel engines than 3%. Meets DIN 51532.
with or without superchargers. Grease codes
EO BI standard lubricant, a quality engine oil. KP 2 K Grease for high pressure load; in working
HLP Hydraulic oils with additives to improve temperature range from -20° C to 140° C;
corrosion protection, aging stability, and worked penetration from 265 to 295; and
protection against wear in areas with many minor or no changes due to presence of water.
types of friction. Meets DIN 51524. MPG-A BI standard lubricant, a grease in accordance
Temperature Range: 0° F up to 180° F. to KP 2 N. Meeting more requirements than
HV Hydraulic oils with low viscosity- KP 2 K and K 2 K.
temperature dependance, otherwise like If hydraulic oil of another manufacturer is to be used,
HLP. Meets DIN 51524. Temperature or oil of a different type; e.g. HP instead of HLP, a
Range: -30° F (-34° C) up to 180° F (82° C). complete oil change is necessary.
VG 32 Oil viscosity for winter application Mixing different viscosities of oil of the same
conditions in Northern USA or Central manufacturer is permissible in some cases. Consult the
Europe. oil manufacturer to be sure, and take into account that
VG 46 Oil viscosity for summer application the new viscosity is dependent on the ratio of the
conditions in Northern USA or Central mixture.
Europe. All hydraulic oil should be filtered from the storage
VG 68 Oil viscosity for extremely high temperatures container to the concrete pump hydraulic system. This
such as in the tropics, or within very hot filtering must be performed with a filter rated at 10
enclosed rooms. micron.
VG 220 Corresponds approximately to SAE 90 for For additional information on oil and specific
Industrial Gear Lubrication. viscosities, refer to Service Bulletin G112/84 and 103/
97.
Service Manual 11
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SERVICE TRAINING
Lubrication Recomendations
Industrial Gear Lubricant Oil
ISO viscosity / DIN quality VG 220 / CLP

ARAL DEGOL BG 220, DEGOL BMB 220
BP ENERGOL GR-XP 220
ESSO SPARTAN - EP 220
MOBIL MOBILGEAR 630
SHELL OMALA OIL 220
TEXACO MEROPA 220
WINTERSHALL WIOLAN - IT 220
BI -
Motor Vehicle Gearbox Oil
ISO viscosity / MIL-L quality 90 (85w-90) / 2105 B

ARAL GEARBOX OIL HYP
BP ENERGEAR HYPO 90, HYPOGEAR 90
ESSO GEAR OIL GX-D, GEAR OIL GX
MOBIL MOBILUBE HD
SHELL SPIRAX HD, SPIRAX MB
TEXACO GEARTEX EP-C
WINTERSHALL WIOLAN HYPOID GEARBOX OIL 90

BI GO 90
The gear lubricant oils Industrial and Motor Vehicle are Under extreme conditions, please inquire as to
suitable for continuous ambient temperatures of suitability. The viscosity class ISO-VG 220 roughly
approximately -10° C to approximately +40° C. corresponds to SAE 90.
12 Service Manual
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Compressor Oil
VG 100 = AMBIENT TEMPERATURE 0° C to +10° C
VG 150 = AMBIENT TEMPERATURE ABOVE +10° C
ISO viscosity / DIN quality VG 100 / VDL VG 150 / VDL

ARAL MOTANOL - HE 100 MOTANOL - HE 150
BP ENERGOL - RC 100 ENERGOL - RC 150
MOBIL RARUS 427 RARUS 429
SHELL CORENA - H 100 CORENA - H 150
TEXACO COMP. OIL - EP 100 COMP. OIL - EP 150
WINTERSHALL WIOLAN - CD 100 WIOLAN - CD 150
Operating the compressor below 0° C may only be For an explanation of the various lubricant prefix codes
done according to manufacturer’s specifications. for determining suitable lubricant substitutes, refer to
page 11 of this section in this Service Manual.
Service Manual 13
HOME PRINT
SERVICE TRAINING
Filling Capacities
Hydraulic Reservoirs
Model System 1 & 2 System 3

BPL 500 66 gallons
BPA 750 37 gallons
BPA 750-18/1000 75 gallons
BPL 750/1000 66 gallons
BPA 2000 100 gallons
BPL 2000 120 gallons
BP 3000/3001 126 gallons
BP 4000 126 gallons
BPL 4000
BP 5000 126 gallons
BP 8000 126 gallons
KVM 17M 102 gallons
KVM 23M
KVM 23-4H 102 gallons 26.5 gallons
KVM 24-4 102 gallons 26.5 gallons
KVM 25
KVM 26M
KVM 26-4
KVM 28M 102 gallons 26.5 gallons
KVM 28 XL 125 gallons
KVM 31 EZ 127 gallons
KVM 32M 132 gallons
KVM 32 XL 127 gallons
KVM 34 X 127 gallons
KVM 36M 147 gallons
KVM 36XL 127 gallons
KVM 39XL 127 gallons
KVM S 39/41 SX 110 gallons
14 Service Manual
HOME PRINT
SERVICE TRAINING
Model System 1 & 2 System 3

KVM 42M 147 gallons
KVM S 42 SX 169 gallons
KVM 45/47 SX 169 gallons
KVM 52/55 M 206 gallons
KVM 58/61 SX 153 gallons
SPB Power Pack 30 gallons
Slew Drives
Schwing Model Model Part Number Liters

KVM 32 XL ZHP 10072000 2.25 liters
KVM 36M ZHP 3.19 10150116 3.0 liters
KVM 34X/36X ZHP 3.19 10117070 3.0 liters

KVM 39X ZHP 3.20 10174652 5.0 liters
KVM 42M ZHP 3.20 10150115 4.5 liters
DVM 42M ZHP 3.21L 10013890 5.0 liters
KVM 45/47 SX ZHP 3.20 10174104 4.0 liters
KVM 52 M ZHP 3.25 10154423 3.7 liters
KVM 58/61 SX ZHP 3.25 10188099 9 liters
Transmissions
Model Number Quarts/Liters

‘ZF Model WSK 400 21.5 quarts
ZF Model 4-S-150 GPA 20 quarts
ZF Model 16-S-190 A 20 quarts
Service Manual 15
HOME PRINT
SERVICE TRAINING
Gear Boxes
Model Number Quarts/Liters

STEYR Model VG2000 9 quarts
STEYR VG2000 w/cooler 10 quarts
STIEBEL Model 4190 NA
STIEBEL Model 4193 4.5 Liters
FABCO Transfer Case NA
16 Service Manual
HOME PRINT
SERVICE TRAINING
Spicer Transmisions of over-the-road service, but not exceeding 4000 miles.

In off-highway use, the oil change should be made
after 24 elapsed hours, but not exceeding 100 elapsed
Lubrication Specs
hours of service.
To ensure proper lubrication and operating
There are many factors that influence the following oil
temperatures in these units, it is important that the
change periods and we have not specified a definite
proper lubricants be used and that correct oil levels be
mileage interval.
maintained.
In general, it is suggested that a drain and flush period
Recommended Lubricants be scheduled every 20,000 miles for normal over-the-
road service. Off-highway service usually requires an
The following lubricants are recommended for use in
oil change every 30 days. The oil level in the
all SPICER Unit Power Transmissions, Auxiliary
transmission should be checked every 2000 miles (on-
Transmissions, and Transfer Cases.
highway), or every 24 hours (off-highway). The
1. Above 0° F, use SAE 50, 40, or 30 heavy duty correct oil level in all SPICER transmissions is
engine oil, API service classification MS, DG, DM, established by the filler plug opening.
or DS.
TO REFILL: Remove all dirt around the filler plug
2. Below 0° F, use SAE 30 heavy duty engine oil, before unscrewing plug; then refill with new oil of a
API service classification MS, DG, DM, or DS. grade recommended for the present season and
DO NOT USE EXTREME PRESSURE prevailing service. Fill to the bottom of the level-
ADDITIVES - such as found in multi-purpose or rear testing plug positioned on the side of the transmission.
axle type lubricants. These additives are not required
in SPICER transmissions, and may in some cases Over-Filling
create transmission problems. Multi-purpose oils as a Do not over-fill the transmission. Over-filling usually
group have; relatively poor oxidation stability, a high results in oil breakdown due to excessive heat and
rate of sludge formation, and a greater tendency to aeration from the churning action of the gears.
react on or corrode the steel or bronze parts within the Breakdown of the oil will result in heavy varnish and
unit. sludge deposits that plug up oil ports and build up on
splines and bearings. Also, overflow from overfilling
Oil Changes of oil usually escapes onto clutch or parking brake
SPICER recommends an initial oil change and flush area, causing additional trouble.
after the transmission is placed in actual service. This
oil change can be made any time following 1000 miles
TRANSMISSION CAPACITY MODEL (PINTS) TRANSMISSION CAPACITY MODEL (PINTS)
UNIT POWER TRANSMISSIONS UNIT POWER TRANSMISSIONS (cont)
3152, 3153 10 8251, 8255, 8753, 8755 24

5652 13 1062, 1262, 1263, 1010 28
5662 17 *1211 10
5752, 5753 15 Auxiliary Unit 10
5852, 5853 15 *1020 28
6352, 6354 17 Auxiliary Unit 10
6452, 6453, 6454, 6455, 6456 17 8440, 8445, 8842, 8844 16
6852, 6853, 6854, 6855 17 * These transmissions have separate oil suppliers. Each pod must be selected and filled separately.
7016, 7216 (4x4) 28 AUXILIARY TRANSMISSIONS
7352 18
7452, 7453 18 5831 4
8012, 8212, 8512 (4x3) 36 6041 8
8016, 8216, 8516, 8716 (4x4), P8516, P8716 36 7041 11
8041, 8045, 8542, 8544 16 7231 8
8051, 8055, 8553, 8555 24 8031, 8035 12
8052, 8054, 8552, 8554 24 8431, 8345, P8341, P8345 12
8241, 8245, 8742, 8744 16 9341 18
9441 12
S0028.eps
Service Manual 17
HOME PRINT
SERVICE TRAINING
ZF Transmissions oil. (Please ask the oil supplier to certify fulfillment of

these conditions).
Lubrication Specs In torrid zones, oil grades SAE 85 W/90 or SAE 90
• ZF-Synchromesh gearboxes can be used if the grades 80 W, 80 W/85 W or 80 W/90
are not available.
• ZF-Constant mesh gearboxes W/splitter group &
range change gearboxes If these gear oils cannot be obtained, engine oils SAE-
• ZF-Gearboxes with disc-clutch operated NMV 30 or SAE-40 in accordance with specification API-
CC, CD, SE, SF, or MIL-L-2104 C, MIL-L-2104 D,
• ZF-Transfer gearboxes
MIL-L-46152 A & B should be used as a substitute. In
The oil grades listed on the following page are in this case, intervals between oil changes are to be
accordance with specification MIL-L-2105 and API reduced by half. NOTE! Multi-grade engine oils ARE
classification GL-4. Gear oils of viscosity group SAE NOT approved.
80 W, must be used.
THE SELECTOR TRANSMISSION MUST BE
These oils are partly available in viscosity grades SAE FILLED WITH OIL WHICH CONFORMS TO THE
80 W/85 and SAE 80 W/90. These multi-grade gear FOLLOWING LUBRICANT LIST: TE-ML 02 (API
oils can be used instead of SAE 80 W, under the GL-4, SAE 80W) UNIT CAPACITY =
condition that in addition to the EP additives, (the type APPROXIMATELY 20 QUARTS
and concentration of which are specified by ZF), any
other dissolved components (VI-Improver, Pour point
depressant) DO NOT exceed 2% (weight) of the basic
TE-ML 10
APPROVED LUBRICANTS
TRANSMISSION FOR SERVICE FILL
16 S 151 +WSK 4 S 120 GP +WSK Engine oils
16 S 160 (A) +WSK 4 S 150 GP (A) +WSK - API CD / CE / CF / SF / SG
16 S 190 (A) +WSK S 6-65 +WSK - MIL-L-2104C / -D / -E
16 S 220 (A) +WSK S 6-90 +WSK - MIL-L-46152C / -D / -E
16 S 221 +WSK 9 S 75 +WSK -SAE 20W-20
16 S 251 +WSK 9 S 109 +WSK
16 S 150 +WSK
3 DS 18 +WSK 244 Engine oils

- API CD / CE / CF / SF / SG
- MIL-L-2104C / -D / -E
- MIL-L-46152C / -D / -E
- SAE 10W for ambient temperatures above-10ßC, (14ßF)
- SAE 30 for ambient temperatures above-10ßC, (14ßF)
Add Add
Dip Stick
Oil Level
Indicator Plug
Drain Drain
Drain Drain
16 S 190 A 4 S-150 GPA S0029.eps
18 Service Manual
HOME PRINT
SERVICE TRAINING
Steyr Gear Boxes Remove the proper level checking plug (either #3
or #5), if no oil comes from the port, start to
dispense new oil into the filling port until oil starts
Lubrication Specs
to over-flow out the checking port, then replace all
1. Steyr specifies 85-140 weight gear oil and strongly plugs and tighten.
advises a change of gear oil on all their transfer
5. With this method, proper oil filling is achieved
cases every 3300 hours or once per year.
without over-filling.
2. Whenever leakage of gear oil is discovered,
preventative measures must be taken. Transfer Case Gear Oil Capacities are as
3. Operating the transfer case with too low an oil Follows:
level WILL result in severe damage to the unit. • Model VG2000 w/o cooler ...........2.25gal/8.5 liters
4. IMPORTANT! A proper oil level check can only • Model VG2000 w/cooler ..............2.50gal/9.5 liters
be done by dispensing new oil into the filling port
at position #1 of figure 5; be sure that vehicle is on
level surface before removing any port plugs.
Breather
Oil Filler Plug
Oil Drain Plugs
Oil Level Plug

Oil Drain Plugs
(only for models with oil cooler)
S0031.eps
Service Manual 19
HOME PRINT
SERVICE TRAINING
Stiebel Gear Boxes 5. Subsequent oil changes should occur every 2000
operating hours or at least, every 12 months.
Lubrication Specs 6. The oil type and quality approved by Stiebel is
determined by the following index. In situations
1. Reducers are supplied without oil. For filling
when an oil from this index cannot be acquired, use
capacity, please see data on the gear plate.
EP SAE 90 with viscosity 220 cST at 40° C.
2. Refilling is only necessary in case of oil leakage
7. Special conditions and applications will require
due to defective seals or defective gear case
special lubricants. Consult the gear manufacturer
gaskets. Such defects should be repaired
for special recommendations.
immediately.
• GEAR OIL SAE 90 (or as we call it: 90W) IS A
3. First change of oil should be after 200 operating
SINGLE RANGE OIL.
hours.
• GEAR OIL SAE 85-90 IS A MULTIGRADE OIL.
4. Drain the old oil immediately after the stopping of
• EITHER OF THESE OILS MAY BE USED
reducer operation, while oil is still warm. Prior to
refilling the gear case, dispense some new oil into
the top of case to flush remaining old oil out.
ARAL Aral Degol BG 220, or Aral Degol BMB 220, or Aral Getriebeol EP 90
BP BP Energol GR-XP 220, or BP Getriebeoel EP SAE 90, or BP Gear Oil 90 EP
COLYPSOL UK-ECUBSOL OL 8050, or UK-ECUBSOL OL DB 90
CHEVRON Universal Gear Lubricant E SAE 85W-90, or Non-Leaded Gear Compound 220
ESSO SPARTAN EP 220, or ESSO GETRIEBEOEL GP-D 90, or ESSO GEAR OIL GP 90
MOBIL Mobilgear 630, or Mobil SHC 630, or Mobilube GX 85W-90-A
SHELL Shell Spirax EP 90, or Shell Omala Ol 220
TEXACO Meropa 220, or Geartex EP-D SAE 85W/90, or Geartex EP-A SAE 85W/90
20 Service Manual
HOME PRINT
SERVICE TRAINING
FABCO Gear Boxes

Lubrication Specs
Lubricating Oil for Fabco TC-143 Transfer Case

LUBRICATION OIL CHANGE
The transfer case lubricant should be changed on all
RECOMMENDED LUBRICANTS new transfer cases after the first 3,000 to 5,000 miles
(on-highway), or the first 40 hours (off-highway):
On Highway Vehicles thereafter, oil changes should be done at the following
intervals:
1. Heavy-Duty Engine Oil:
Temperature Grade On Highway Service...........10,000-15,000 miles
Above + 10 F SAE 50 Off-Highway Service (Logging, dirt moving, mining,
Below + 10 F SAE 30 and associated operations)..500-750 hr.
Be sure to specify heavy-duty type MIL-L-2104B
specifications. The recommended oil change and inspection periods
are based on the average use and operating
2. Mineral Gear Oil: conditions that the unit may encounter. It is suggested
that the individual owner make a periodic lab analysis
Temperature Grade
of the lubricant to determine contamination based on
Above + 10 F SAE 90 the unit’s specific operating conditions. With this data,
Below + 10 F SAE 80 the oil change and inspection periods can be better
Must be inhibited against corrosion, oxidation, and determined.
foam.
DRAINING THE OIL
3. MIL-L-2105B E.P. Oil, except sulfer-chlorine-lead
type: Draining is best accomplished after the vehicle has
Temperature Grade been operated briefly, allowing the oil to become warm
Above + 10 F SAE 90 and flow more freely. Remove both drain and fill plugs.
Below + 10 F SAE 80 Allow the housing to empty completely. Before the unit
is refilled, it should be thoroughly flushed with clean
Extreme pressure oils under some conditions might flushing oil or kerosene.
form carbon deposits on gears, shafts, and bearings,
which will result in transfer case malfunctions and If the unit is equipped with an oil pump, the lube oil
premature failure. It is suggested that if these filter should be replaced whenever the oil is changed.
conditions exsist, and E.P. oil is being used, a change The element is of the spin-on type. A film of clean oil
should be made to mineral gear oil or heavy-duty should be applied to the rubber gasket of the new
engine oil as recommended. element before installing. Do not overtighten.
Off Highway & Mining Equipment

REFILLING THE OIL
1. Heavy-Duty Engine Oil:
If the transfer case has been removed from the vehicle
Temperature Grade for service, it is best to refill the oil after the unit has
Above + 10 F SAE 50 been reinstalled into the vehicle.
Below + 10 F SAE 30
Be sure to specify heavy-duty type MIL-L-2104B Clean and replace the drain plug and fill the transfer
specifications. case with the appropriate oil with the vehicle on level
ground. Fill the transfer case to the level of the fill plug.
2. Special Recommendation: For extreme cold On transfer cases equipped with a proprtional
weather where temperature is consistently below 0ßF, differential, it may take some time for the oil to flow into
use SAE 20W heavy-duty engine oil meeting MIL-L- the main housing; therefore, it is necessary to fill the
2104B specifications unit to the level of the fill plug, wait a few minutes, and
top off the oil level. It may be necessary to do this
several times. The plug should be installed only after
the oil level has stabilized.
S0035.ai
Service Manual 21
HOME PRINT
SERVICE TRAINING
ZF Torque Converters WSK Torque Converters

Independent oil circuit in convertor and clutch unit and
Lubrication Specs selector transmission systems.
HE TORQUE CONVERTOR and CLUTCH SYSTEM The ATF (Automatic Transmission Fluid) oil grades on
MUST BE filled with the SPECIFIED ENGINE OILS the following list may be used with all the WSK
or with AUTOMATIC TRANSMISSION FLUIDS Transmissions.
which conform to the following lubricant list; TE-ML NOTE! When using Dexron II products, particular
14. UNIT CAPACITY= APPROXIMATELY 21.5 care must be taken to ensure that the trade name and
QUARTS. the "D" number on the oil barrel correspond.
If ATF is not available, SAE 10W mono-grade engine
ADD oils conforming to the following specifications may
also be used: MIL-L-2104 C, or MIL-L-2104 D, or
MIL-L-46152 A, or
MIL-L-46152 B, or API-CC, CD, SC, SD, SE, or
OIL LEVEL
INDICATOR SF.
PLUG NOTE! When engine oils are used in place of ATF,
there may be a loss in shifting comfort because the
DRAIN
DRAIN shifting elements and friction are adapted to ATF.
S0032.eps A range of suitable engine oils are also included in the
following list.
TE-ML 09
APPROVED LUBRICANTS
VERSION FOR SERVICE FILL
Hydraulic power-assisted steering systems Automatic Transmission Fluid (ATF)

Hydrostatic steering systems - Dexron¤ - IID / -IIE / -III
In-line boosters - Mercon¤ -M
Oil pumps
Intermediate drives
TE-ML 14
APPROVED LUBRICANTS RECOMMENDED
VERSION ALTERNATIVES
FOR SERVICE FILL
Automatic Transmission Fluid (ATF) Engine oils

Ecomat 1. Base oil: mineral - API CD / CE / CF / SF / SG
1.1 - Dexron - IID - MIL-L-2104C / -D / -E
- MIL-L46152C / -D / -E
- Mercon - M -SAE 10W
1.2 - Dexron - III
- Mercon - M The shift elements and friction linings
are designed for use with ATFs. Using
engine oils may result in reduced shift
2. Base oil semi-synthetic/hydrocracked comfort.
- Dexron - IID
- Mercon - M
3. Base oil synthetic

3.1 - Dexron - IID / -IIE
- Mercon - M
(Not approved for transmissions with ratio 5.6-0.83/ 1.0)
3.2 - Dexron -III

- Mercon -M
22 Service Manual
HOME PRINT
SERVICE TRAINING
Hydraulic Pump Spline Product Data

Lubrication Optimoly Paste White T - white paste for clean
assembly work, prevents fretting corrosion (false
It is highley recommended prior to the installation of brinelling). Tight fitting components may be
any model/manufaturer of hydraulic pump(s) that the disassembled without any difficulties even after many
drive spline be lubricated with a special pre-assembly years of operation.
grease--Optimoly Paste White T. Following this
Optimoly Paste White T - is excellently suited for all
procedure will add extended life to the spline and
assembly work and for base thin-film lubrication in all
related parts.
engineering areas.
Optimoly Paste White T is available in cartridge (p/n
Optimoly Paste White T - is also available as a spray.
30346107) or aerosol (p/n 30346108) from, and can
also be used in other pre-assembly work.
Typical Hydraulic Pump Spline

S0036.eps
Features Uses
• inhibits fretting corrosion and false brinelling • Assembly paste with universal application range
• clean handling due to its clean handling and long-term separating
• facilitates assembly and disassembly and lubrication effect. Superior to lack assembly
lubricants in performance test for a variety of
• good separating effect for all types of contact
applications.
• resistant to cold and hot water
• Prevents fretting corrosion on bearing seals, spline
• excellent rust protection even in salt water shafts, torque loaded connections.
• white, almost colorless in thin layer
• easy application (spray-without CFC)
• temperature application range: -30˚C/-22˚F to
+250˚C/+482F
• USDA-H2 approval
Service Manual 23
HOME PRINT
SERVICE TRAINING
Maintenance of Hydraulic then piston sealing and/or holding valve on the

piston side have internal leakage.
Cylinders 1. Remove the hose connections at the hold-
ing valve on the piston side.
2. If no oil runs out of the hose connections at
the holding valve, then that means the pis-
WARNING ton seal is leaking, allowing oil to by-pass
READ FIRST! S0101.ai

from the piston side of the cylinder to the
rod side of the cylinder.
3. If oil runs out of the hose connected to the
holding valve, then the holding valve on
Warning! Danger of crushing! Before removing any the piston side is defective.
holding valve, the boom MUST be completely
supported so that removal of the valve will not cause
the boom to fall. If an extended boom is unsupported 2. To check the rod side holding valve: Set the
when a holding valve is removed, oil will escape under boom section to be checked in the retracted
high pressure, and can cause serious injury. position, but do not completely retract. Make a
Warning! Before removing any holding valve, hoses, mark on the piston side rod (with a felt tip pen) and
tubes or fittings, the engine or motor MUST be shut observe if there is any movement indicating
off; the key removed; and a "DO NOT OPERATE" tag leakage.
attached to the door of the truck or in case of an electric a. If there is no movement of the cylinder rod,
motor as the unit’s prime mover, the electrical panel then piston sealing and holding valve are free
MUST be "locked out" and "tagged out", preventing from internal leakage.
any accidental power up. b. If there is movement of the cylinder rod,
then piston sealing and/or holding valve on the
rod side have internal leakage.
1. To check the piston side holding valves: Set the
1. Remove the hose connecting at the holding
boom into a horizontal position, but do not
valve on the piston side.
completely extend the boom cylinder. Make a
mark on the piston rod (with a felt pen) and 2. If no oil runs out of the hose connections at
observe if there is any movement indicating the holding valve, then that means the pis-
leakage. ton seal is leaking, allowing oil to by-pass
from the rod side of the cylinder to the pis-
a. If there is no movement of the cylinder rod,
ton side of the cylinder.
then piston sealing and holding valve are free
from internal leakage. 3. If oil runs out of the hose connections at
the holding valve, then the holding valve
b. If there is movement of the cylinder rod,
on the rod side is defective.
Holding valves mounted on a hydraulic cylinder (H.E.R. Valves)
24 Service Manual
HOME PRINT
SERVICE TRAINING
3. Check Outrigger Cylinder for: b. Check the lever position with the respective
a. Any missing or damaged parts, then check for cylinder movements. Test is to be carried out
leakage of shut-off valves or cylinder seals. while you have an operating oil temperature of
b. With no load applied to the outrigger cylinder, approximately 30˚ to 50˚ (86˚ to 122˚ F.)
close the shut-off valve and remove the 5. Check the #1 boom down relief - Refer to Service
hydraulic line between this valve, and the out- Bulletin G-103-89 for checking this function.
rigger cylinder. Engage control valve for the 6. Check boom slewing cylinders for:
outrigger cylinder to level position, “front” to a. Exterior damage of cylinders tubes and mount-
extend the outrigger cylinder. If the valve is ing flanges.
leaking, oil will run out of the shut-off valve.
b. Leakage and correct movement.
c. Slew the extended boom over the outrigger
7. Check the hydraulic tank for:
cylinder which is to be checked. Close the
shut-off valve and remove the hydraulic line a. Proper oil level and leakage
between this valve and the boom control block. b. Contamination and oil purity. (if necessary,
Mark the cylinder rod (with a felt tip pen) and take an oil sample for evaluation).
observe. If the cylinder retracts and no oil runs 8. Check boom operation speed (too fast / too slow),
out of the shut-off valve, then the piston seal- with unstressed boom as per Boom Time Chart.
ing is leaking. 9. Check remote control motions with all switch
4. Check the control block for: functions and operation symbols.
a. Any missing parts (knobs, symbol of switching 10. Check remote control safety switch (emergency
levers, etc.), damaged or leaking parts, and stop button) for proper operation.
cleanliness.
S0099.eps
Service Manual 25
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SERVICE TRAINING
Lubrication Specs for Schwing equivalent with the below listed minimum
characteristics:
Placing Booms • Base Type....................................................Lithium
• Maintenance of the collar bearing, step bearing on • NLG1 No. ..............................................................2
the shorter booms and rollix bearing for the slew- • cSt @ 40˚ C (104˚ F) ........320 summer, 150 winter
ing gear of longer booms should be lubricated
• Molybdenum disulfide.......................3% minimum
daily.
• ASTM dropping point (degrees F..... 350 degrees F
• The boom should be rotated while grease is applied
minimum
to achieve adequate lubrication.
• The outriggers and boom should be greased
monthly. 2. All other bearings must be greased with a lithium
The grease recommendations are as follows: grease such as Mobil Grease HP, CM-S, or an
equivalent.
1. The bronze tower or column bushings must be
greased with a moly additive which has a minimum In order to ensure that the grease is uniformly
of 3% molybdenum disulfide. distributed on the bearing surface, you must lubricate
while slowly rotating the boom.
Greases such as Lubriplate Mo-Lith No. 2, Texaco
Molytex EP2, Mobil Grease CM-P may be used or an
Greasing zerks.eps L
32XLZerks above stack.eps L
S102.eps
26 Service Manual
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SERVICE TRAINING
Boom Inspections This schedule must be a planned schedule based on the

age of the unit.
Inspections of the boom, outriggers, subframe, tower,
It is the concrete pump owner who is responsible for
and guide levers are recommended by Schwing
completing scheduled inspections, either by himself or
America Inc. according to the following schedule:
whomever he authorizes to do so. Upon request
however, Schwing America will provide a qualified
Years of Service Inspection Interval service person to aid pump owners in doing boom
First 4 years every 12 months inspections. To request a service person to do your
4 to 8 years every 6 months inspections, or to request guidebooks and inspection
8 years or more 12 months or 500 working hours forms for doing your own inspections, make a copy of
the “Inspection Request Form” printed on the reverse
side of this page, complete the form and mail to
Schwing America Inc. Attn.: Service Dept. Manager.
S0162.eps
Service Manual 27
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SERVICE TRAINING
BOOM INSPECTION REQUEST FORM
TODAY S DATE: / /
COMPANY:
STREET ADDRESS:
CITY: STATE: ZIP:
CONTACT: PHONE: ( )
LIST ALL MACHINES REQUIRING INSPECTION(S)/REPAIR(S) BELOW:
MODEL SERIAL NO. LOCATION
PLEASE FILL OUT AND FAX OR MAIL THIS FORM TO:
SERVICE DEPARTMENT
SCHWING AMERICA INC.
5900 CENTERVILLE ROAD
WHITE BEAR, MN 55127
FAX: 651/429-2112
SAISVC 018REV05/03/00
28 Service Manual
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SERVICE TRAINING
Rock Valve
Rock Valve
Safety Instruction
When performing maintenance on Schwing Equipment, the safety regulations must be followed. The observation
of these regulations is the responsibility of the maintenance personnel. The following are some supplementary
recommendations.
WARNING
READ FIRST!
1. WARNING! Read and understand the operation manual of the machine before attempting any repairs. If in
doubt, call the manufacturer. Incorrectly done repairs endanger operational safety of the machine.
2. WARNING! Burning hazard! Never work on a hydraulic system with hot oil.
3. WARNING! Falling hazard! If you cannot work at ground level, you must use a suitable work platform.
4. WARNING! If maintenance work requires that you use a crane, hoist, fork truck, etc., you must read and
understand the safety regulations for that equipment.
5. WARNING! If working the machine requires that it be operated, and you are not qualified as an operator, you
must get someone who is qualified to assist you.
6. WARNING! If you will be working in a hidden area inside the machine, protect yourself by taking the key
from the ignition and putting a “DO NOT OPERATE” sign on the controls. In the case of electrically driven
units, disconnect the main circuit breaker and lock it in the disconnected position.
7. WARNING! Never activate the system hydraulics without checking if another workman is in a hidden
position. Always yell “CLEAR”, and allow time for response, before starting the prime mover.
8. WARNING! Never use gasoline or diesel fuel as a cleaning solvent. This is critical to remember when
cleaning hydraulic oil reservoirs, because gas and diesel fuels are highly explosive, and gasoline or diesel fuel
traces left in the oil may ignite when compressed.
9. WARNING! Always use the correct tools for the job. Tools should be kept clean, and in good condition.
10. If you see a co-worker engaging in an unsafe practice, explain the dangers. Safety is always in the hands of
those on the job.
11. WARNING! Never work on a pressurized hydraulic system. Stop the prime mover and relieve the accumulator
circuit (if so equipped) before you open the hydraulic system.
Service Manual 29
HOME PRINT
SERVICE TRAINING
Rock Valve
Rock Valve Parts Identification - “M” Rock
!

#
!
$

%

& "
'

"

$

%

&! "
'
$

(
"
!

&
'

30 Service Manual
HOME PRINT
SERVICE TRAINING
Rock Valve
Rock Valve Parts Identification - “E” Rock

Pivot Lever
Cover Bolt Cover
Bearing Bushing
Cover Bearing Bushing
Sealing
Slewing Lever Cover
Pivot Bushing
Wearing
Insert
(Right Hand)
"E" Rock Valve

Housing
Pivot Bushing Wearing
Insert
(Left Hand)
Plate
Wearing
Plate
Spectacle
Plate
Cutting
Ring
Outlet Side Housing Lining
Pivot (Kidney Plate)
Shaft End Cover
"E" Rock End Cover
Extension Bolt
Pressure
Spring
Bearing
Support Bushing
Ring
Setting Disc
"E" Rock Valve Keeper
Tension Nut Bolt
Kidney Seal
Service Manual 31
HOME PRINT
SERVICE TRAINING
Rock Valve
Rock Valve Parts Identification - “B” Rock
Cover
Pivot Lever
Cover Bolt Bearing Bushing
Bearing Bushing
Cover Sealing
Cover
Slewing Lever
Pivot Bushing
Wearing
Insert
(Right Hand)
"B" Rock Valve

Housing
Pivot Bushing Wearing
Insert
(Left Hand)
Spectacle Plate
Plate Wearing
Plate
Outlet Side
Housing Lining
Pivot Shaft (Kidney Plate)
End Cover
End Cover Bolt
Bearing
Cutting Bushing
Ring
Pressure
Spring
"B" Rock Valve

Setting Disc
Keeper
Kidney Seal Tension Nut Bolt
32 Service Manual
HOME PRINT
SERVICE TRAINING
Rock Valve
Rock Valve Lubrication Points

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

Grease Zerk #8
Locations of the six Rock Valve greasing points (1-5,7) and the two
agitator grease points (6,8)
Service Manual 33
HOME PRINT
SERVICE TRAINING
Rock Valve
Rotating The Cutting Ring

45 rock valve assembly.eps L
Setting Disc
Keeper bolt
Tension nut
Wrench flats
Wedge
Tapered bend
6-inch clamp
Cover bolts
WARNING
Never rotate the cutting ring without
disabling the unit’s hydraulic system.
Amputation hazard!
1. First, shut off the truck engine and put the key in your pocket.
2. Remove the 6-inch clamp between the tapered bend and the 6-inch elbow.
3. Remove the wedge from the tapered bend, and pull the tapered bend away from the 6-inch clamp.
4. Loosen the tension nut as explained previously.
5. Loosen the seven cover bolts two or three full turns, but do not remove the bolts.
6. Push forward on the end of the rock valve slewing cylinder. Because it has a single pivot point, it will push the
rock valve backwards toward the loosened cover. If you meet resistance, do not force it. After you have
removed the hopper grate, you can gently pry the rock valve backward from inside the hopper.
7. Remove the hopper grate.
8. From inside the hopper, tap the cutting ring forward, toward the spectacle plate. The ring should pop loose. If it
doesn’t, loosen the cover bolts a little more, then gently pry the rock valve rearward a little more until it does.
Rotate the ring 90° clockwise. (It doesn’t really matter which way you rotate, but to keep from forgetting which
way you went last time, Schwing recommends going clockwise each time.)
9. Be sure that the ring is centered in the rock valve. Tighten the cover bolts slightly, if needed, to be sure that the
ring isn’t cocked one way or the other.
10. Be sure there is no debris between the back cover and the rock valve housing. If there is, clean it out. Tighten
the cover bolts just enough to bring the back plate up against the rock housing. Then tighten each bolt equally,
using a torque wrench. Alternate which bolts you tighten, as you would when tightening a wheel on a car. The
torque specification for these bolts (M24 x 60, 8.8 hardness) is 485 ft./lb. Replace the bolts once per year.
11. Position the hopper grate over the hopper. Bolt it into place.
12. Tighten the tension nut. Tighten the keeper bolt.
13. Push the tapered bend closed and install the wedge. Remember to install the hairpin.
14. Install the 6-inch clamps and the hairpin.
34 Service Manual
HOME PRINT
SERVICE TRAINING
Rock Valve
Replacing the Cutting Ring

1. Loosen the bolt on the Pivot Lever a few turns with a 30 mm. wrench.
2. Remove the Housing End Cover Bolts with a 36 mm. wrench.
Service Manual 35
HOME PRINT
SERVICE TRAINING
Rock Valve
3. Pry the End Cover away from the housing as far as the Pivot Lever will allow.

NOTE!
Remove the Cutting Ring, and replace it with the new part.

NOTE!
When reassembling, make sure that the Cutting Ring fits correctly and that the Pressure Spring is in
full contact with the face of the Cutting Ring. Reassembly is opposite to the procedure above.
36 Service Manual
HOME PRINT
SERVICE TRAINING
Rock Valve
Tension Nut/Pressure Spring

Do not use the Tension Nut to adjust the position of the Cutting Ring. Excessive wear of the Inlet Housing Lining,
Cutting Ring, Pressure Spring, and Kidney Seal would result.
The Tension Nut adjusts the Kidney Seal area of the Rock Valve ONLY. To check or adjust, remove the Keeper Bolt
will line up with a threaded hole in the Setting Disc. If you are between two holes, loosen the Tension Nut so it
lines up with the previous hole. Do not use a wrench to tighten. The flat sides of the Tension Nut are to loosen the
nut only. Please call the Schwing Service Department if you have any questions.
Adjustment Screw
Pressure Spring
If the Pressure Spring has to be replaced, dismantle the old spring and clean the vacant area thoroughly to clear it of
cement dust, etc. If dust and residue are ignored, the new spring cannot be installed correctly, and the flow of
concrete can pull it out of the groove. Furthermore, the high pretension leads to premature wear of the Cutting Ring
and Housing Lining.
Inlet Housing Lining
Cutting Ring
Rock Valve
Pressure Spring A
NOTE!
Slightly grease the new Pressure Spring when installing it. The same applies to the Kidney Seal. Do
not use too much grease, because grease accumulating in the spring chamber operates as a spacer,
and the consequently increased spring pretension can lead to the same damages as described above.
Service Manual 37
HOME PRINT
SERVICE TRAINING
Rock Valve
Determining Wear on Kidney Seal and Kidney Plate

Replace the kidney seal if any of the following conditions exist:
2 2
Spring installed
d 1
mm
Figure 1
• The seal is swollen due to use of aggressive or harsh cleaning agents. (See Service bulletin G-113-84, dated
July 18, 1984)
• A considerable formation of cracks are found in the areas marked by arrows. (fig. 1) This problem is very rare.
• Lip (Item 1, fig. 1) is completely worn to the point that the pressure relief grooves (Items 2, fig. 1) are no longer
recognizable.
• The distance indicated by “M” of the Kidney Seal (when force is relieved) does not exceed 30mm (1 3/16”).
Replace the Housing Lining-Oulet Side (Kidney Plate) only if scores deeper than 2.5mm are found, in the area that
contacts the Kidney Seal, that are deeper than 2.5mm. You can measure this by placing a steel ruler across the
kidney Plate in several places, and using a depth gauge to determine the gap.
NOTE!
Outside of the area that contacts the Kidney Seal, you may detect scores that are due to aggregate
particles stuck between the Rock Valve and the Kidney Plate. (See fig. 2 and fig. 3) THESE SCORES
DO NOT MATTER IN THE LEAST!

We would like to draw your attention to the fact that under no circumstances should you allow the Kidney Seal to
be run with a dry hopper. This will destroy the Kidney Seal, and is the primary cause of premature wear
encountered at the outlet side of the Rock Valve.
If you will be repairing the Rock, or troubleshooting a problem, always fill the hopper with water to the top of the
Rock Valve before switching.
38 Service Manual
HOME PRINT
SERVICE TRAINING
Rock Valve
Replacing the Kidney Seal

Kidney Seal
1. Remove the Keeper Bolt from the Tension Nut using a 24 mm. wrench.
Keeper Bolt
2. Remove the Tension Nut using a 60 mm. wrench.

Service Manual 39
HOME PRINT
SERVICE TRAINING
Rock Valve
3. Remove the Setting Disc from the Rock pivot shaft.

4. Remove the bolts from the End Cover and insert the two Guide/Support Rods into the upper holes using a 36
mm. wrench.

5. Slide the End Cover along the inserted Guide/Support Rods.
40 Service Manual
HOME PRINT
SERVICE TRAINING
Rock Valve
6. Remove the Kidney Seal with a screw driver or similar tool.

7. Clean the Kidney Seal groove of the Rock Valve thoroughly.

8. Replace the Kidney Seal while making sure that the flat surface is toward the End Cover.
9. Push the End Cover back into place and replace the bolts. Clean away any debris that would prevent the cover
from sitting flat.
10. Replace the Setting Disc onto the square portion of the Rock Pivot Shaft.

Service Manual 41
HOME PRINT
SERVICE TRAINING
Rock Valve
11. Replace the Tension Nut onto the Rock Pivot Shaft, and tighten it by hand. In this position, the clearance
between the Rock Valve and the housing should be 1.5 to 2.0 mm.
Rock 1.5 to 2.0mm
Kidney Plate
NOTE!
If either the Spectacle Plate or the Cutting Ring are not replaced at the same time as the Kidney
Seal, the clearance will be greater and can be adjusted by further tightening of the Tension Nut to
the next Setting Disc hole only.
12. Replace the Keeper Bolt.
Keeper Bolt
13. IMPORTANT! At no time should the Rock Valve be operated without first lubricating the outlet wear plate.
Usually, spraying the plate with water or oil prior to start-up will be adequate. Moving the kidney seal against a
dry plate will cause excessive wear to the seal and will lead to premature failure. If switching the Rock Valve is
necessary for shop work (adjusting, inspecting, etc.), you must take the necessary precautions and ensure that
the plate and seal are properly lubricated.
42 Service Manual
HOME PRINT
SERVICE TRAINING
Rock Valve
Spectacle Plate
Lengthening the Service Life of the Housing Lining-Inlet Side
The amount of wear on the Housing Lining and the Cutting Ring will vary, and it will affect the length of time they
can safely be used. The condition of each part depends on outside influences that affect them daily, including
varying concrete mixes and changing weather conditions. The Cutting Ring and Housing Lining cannot be
expected to wear equally and will need to be replaced accordingly.
NOTE!
The grooves in the Base Plate (Spectacle Plate) resulting from basic operation are irrelevant as long
as the hard facing is in good working condition.
To assist in achieving uniform wear and, thus, considerably longer service lives, we recommend:
1. moving the Rock Valve to the left and right end positions once a week--after thorough cleaning--and checking
the condition of the cutting ring & housing lining.
Friction and Friction

stone crushing
Friction and
stone crushing
Friction
Figure 1
2. turning the Cutting Ring 90 degrees if there is a visible space between the Cutting Ring and the Housing Lining
that is greater than 1.0-1.5 mm. (.0393”-.0590”). Check for this gap at several points along the circumference.
Instructions for cutting ring can be found on page 4 of this document.

Service Manual 43
HOME PRINT
SERVICE TRAINING
Rock Valve
3. checking the distance between the Cutting Ring and the Rock Valve after each turn of the Cutting Ring. If it
exceeds 8 mm. (.31”), the pretension of the Pressure Spring is not enough to correctly press the Cutting Ring to
the inlet side of the Housing Lining, and the Cutting Ring should be changed.
Cutting Ring
Rock Valve
Pressure Spring A
Figure 1
44 Service Manual
HOME PRINT
SERVICE TRAINING
Rock Valve
Replacement of Spectacle Plate

Check the plate for wear, and if replacement is necessary, follow these steps:
1. Loosen the bolt on the Pivot Lever a few turns with a 30 mm. wrench.
2. Remove the Housing End Cover Bolts with a 36 mm. wrench.

3. Pry the End Cover away from the Housing Cover as far as the Pivot Lever will allow.
4. Using a 14 mm. allen wrench, remove the socket head bolts that secure the plate.
5. Pry the Spectacle Plate (Base Plate) away from the pumping cylinders.
Remove
spectacle plate
NOTE!
In some old models, the transition pieces may come out with the Spectacle Plate. If this becomes a
problem, see Service Bulletin G-104/89 for assistance.
6. Thoroughly clean the area where the plate is to be mounted, install the new Spectacle Plate, and secure it.
Reassembly requires following the above steps in reverse order.
Service Manual 45
HOME PRINT
SERVICE TRAINING
Rock Valve
Replacement of Outlet Housing Lining (Kidney Plate) Plate

Check the plate for wear, and if replacement is necessary, follow these steps:
1. Remove the Keeper Bolt from the tension nut using a 24 mm. wrench.
2. Remove the Tension Nut using a 60 mm. wrench.
3. Remove the Setting Disc from the Rock Pivot Shaft.
4. Remove the bolts from the End Cover and insert the two Guide/Support rods into the upper holes using a 36
mm wrench.
5. Slide the end cover along the inserted Guide Rods.
6. To replace the lining, remove both Securing Bolts in the End Cover using a 24 mm wrench.

1. Free the lining from the End Cover, and remove it. It is heavy...get help if needed
Lining
2. Thoroughly clean the entire area that the Outlet Housing Lining touches.
3. Fit a new O-ring into the replacement lining, and reassemble by following steps 1-7 in reverse order.
O-Ring
46 Service Manual
HOME PRINT
SERVICE TRAINING
Rock Valve
Replacement of Outlet Insert (Cover Lining)

(TO BE REPLACED AT THE SAME TIME AS THE KIDNEY SEAL AND/OR OUTLET HOUSING LINING)
1. Remove the Tapered-Bend (Reducing Elbow) from the Pipe Bend (Connection Piece).

2. Remove the Outlet Housing Lining (End Cover Lining) as described in the Outlet Housing Lining
Replacement section.
3. Remove the Pipe Bend from the End Cover.
4. Press out the Cover Lining.

5. Grease the outer surface of the Cover Lining before reinstalling it into the End Cover.
6. Clean all of the contacted areas, replace the O-ring, replace the Pipe Bend, and reassemble by following the
above directions in reverse order.
O-Ring
Service Manual 47
HOME PRINT
SERVICE TRAINING
Rock Valve
Rock Valve Body

NOTE!
Because this is a major procedure, we recommend close inspection of the Spectacle Plate (Base
Plate), Outlet Housing Lining (End Cover Lining), and all other parts that require periodic replace-
ment, so you can replace all necessary parts at the same time.
1. Remove the agitator motor along with the hydraulic lines that are connected to it.
2. Remove any and all electric wires from the hopper. Mark the wires to aid in reassembly.
3. Completely remove the hopper.
4. Remove the End Cover as explained in the Kidney Seal or Outlet Housing Lining replacement section.
5. Remove the bolts from the Rock Valve while making sure to support it from underneath.
Bolts
6. Remove the Rock Valve body.

7. Install new rubber seals.
IMPORTANT: Be sure that the Pressure Spring is properly inserted into the housing (most easily done by hand).
The thick rubber goes on the inside towards the concrete.
8. Check the condition of the Rock Pivot Shaft Bushings, as well as the condition of the parts mentioned in the
note above, to see if anything else needs to be replaced while you’ve got the unit disassembled.
9. Reassemble the Rock Valve in reverse order.
Thin rubber layer

Reinforced layer
Thick rubber layer
Pressure Spring
48 Service Manual
HOME PRINT
SERVICE TRAINING
Rock Valve
Pivot Shaft
1. Remove the Rock Valve as described in the previous section.
2. Remove the Pivot Level Bolt and Cover Plate.
3. Remove the Pivot Cylinder Pin Retainer Bolt and Keeper Bar.
4. Remove the Pivot Cylinder Pin from the slewing lever.

Service Manual 49
HOME PRINT
SERVICE TRAINING
Rock Valve
5. Move the Pivot Lever away from the Cylinder Rod, and remove it from the shaft.
6. Remove the Pivot Shaft from the Bearing Housings.
7. Examine and, if necessary, replace the bearing bushings as described later.
NOTE!
The pivot shaft seals should always be replaced when replacing the Pivot Shaft.
8. Install the Pivot Shaft with the alignment marking on the top.
9. Assemble the Pivot Lever onto the Pivot Shaft, making sure the markings are in alignment.
Alignment
Markings
IMPORTANT: If the markings are not correctly aligned, the Cutting Ring will not cover the ports in the Spectacle
Plate.
50 Service Manual
HOME PRINT
SERVICE TRAINING
Rock Valve
Pivot Shaft Bushing

1. Remove the Pivot Shaft as described in the Pivot Shaft replacement section of this manual.
2. To replace the bushings, remove the Seal Cover and Bolts.
Bushing
Seal Cover
Bushing
Seal Cover
3. Remove the bushings from the housing.

4. Clean the housing bores.
NOTE!
To replace the bushings, use the installation tool.

5. Fit the rear bushing (pivot lever side) first with a 46 mm wrench.
Service Manual 51
HOME PRINT
SERVICE TRAINING
Rock Valve
6. Insert the bushing so that it is flush with the end of the bushing housing.

7. Now replace the front bushing (Spectacle Plate Side) with the installation tool, tightening the nut from the
opposite end.
NOTE!
When the bushing is correctly installed, it will protrude 5 mm from the housing on the Spectacle
Plate side.

52 Service Manual
HOME PRINT
SERVICE TRAINING
Rock Valve
8. Install a new O-ring into the Seal Cover, and secure the Seal Cover onto the 5 mm of protruding bushing.
O-Ring
9. Remove the Bushing from the End Cover using a hydraulic press or similar tool.
10. Thoroughly clean the Bushing housing bore.
11. Install the new Bushing using the installation tool, and ensure that it is fully in place.
12. Install a new O-ring into the seat.

13. Install the Pivot Shaft as described in the Pivot Shaft replacement section of this manual.
14. Finally, inject grease through the grease zerks provided.
Service Manual 53
HOME PRINT
SERVICE TRAINING
Rock Valve
Setting Pivot Angles

After any repairs or dismantling, the pivot angles must be checked and reset, if necessary.
1. The distance between the Pivot Pin and the Cylinder Body must be approximately 185 mm(7 9/32”) with the
cylinder fully retracted.
185 mm
2. To adjust the correct setting, loosen the Piston Rod Locknut and adjust as required.

NOTE!
After approximately setting the Piston Rod, check that the Rock Valve travels across the Spectacle
Plate, and ensure that the Cutting Ring is centered over each port. When stopped in the end position
equally on both sides.
3. To check the setting, fully unscrew the pressure reducing valve and close the ball cock.Then, move the pivot
cylinder to the end of its stroke.
4. In this position, check that the ports are completely covered by the cutting ring by looking through the pipe
bend (connection piece). If they are not, make adjustments using the Piston Rod.
5. After the setting is checked, tighten the locknut onto the Piston Rod.
54 Service Manual
HOME PRINT
SERVICE TRAINING
Rock Valve
Replacement of Pivot Shaft Bushings

When changing the pivot on a Rock Valve Slewing Cylinder, please be sure that you install new bushings in the
pivot eyelets. These bushings are not automatically shipped with a pivot, so please order them with the pivot if you
don’t have them in stock. The part number for this bushing is: 10006726.
Bushings
Pivot
Also, when you change the pivot, we recommend that you change the Pivot Bushings, if your unit has the thin,
teflon coated bushings. The part number on these thin bushings is: 10016324. If your unit has the thick, steel
bushing, you need not change it out. To tell if your unit has a thin or thick bushing, you must remove the rock
cylinder from the rock housing. The thick bushing is one piece, about 1/4” thick. The thin bushings are in two
pieces. If you don’t want to pull your slewing cylinder just to find out, we would recommend ordering the thin
bushings. If you don’t need them, return them to us for credit.
Pivot Bushings
Pivot Bushing
If any “clearance” is detected in the bushing of the Rock Slewing Pivot, the bushing should be checked
immediately in order to prevent further damage.
Bushings
Pivot
To check the bushing bore, drive out the thin, Teflon Coated Bushings or the Single Style Bushing.
Service Manual 55
HOME PRINT
SERVICE TRAINING
Rock Valve
Pivot Bushings
Pivot Bushing
If the thin, teflon coated bushings are used, they can be replaced with new ones providing that the bore diameter is
80mm to a maximum of 80.20mm. A diameter over 80.20mm must be re-worked on a boring machine and bored to
90mm and the new style solid steel bushing* pressed in.

If the single slotted bushing* is used, the bore diameter is 90mm to a maximum of 90.20mm. A diameter of over
90.20mm can be repaired by the use of a repair kit (Part no. 10063611).

NOTE!
The single slotted bushing is no longer available, but it has been replaced with a solid steel bushing
with the same part number.
56 Service Manual
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SERVICE TRAINING
Rock Valve
E-Rock
Additional Mounting Instructions for E-Rock Assembly
The E-rock is generally assembled by the same procedure as any other standard M-Rock. Only the Rock-Extension
and a Counter Nut have been added. The Back-up ring will act as an axial bearing if the Counter-NUt is in place
and has been directly adjusted.
Rock-Extension pre assembly:

1. Place the pivot shaft onto the rock and push it against the “stop” before tightening the screws.
2. Push the Rock-Extension supplied with O-rings over the pivot shaft and into the Rock.
3. Extension and Rock are held together by two screws.
4. Protection-Ring is placed inside the Extension and spot welded at four places around the circumference.
Pivot Shaft Screw
Rock Extension
Pivot Shaft
Rock Extension
O-Rings Screw
Rock
Service Manual 57
HOME PRINT
SERVICE TRAINING
Rock Valve
Mounting of E-Rock-Valve and Cover

The pre assembled E-Rock-Valve (supplied with kidney seal and cutting ring assembly) is pushed into the Housing
till the cutting rings hit the wear insert (spectacle plate). The end-cover will then compress the E-Rock-Valve
assembly and the swivel shaft will be ready to be fixed by the Adjusting nut and Locking-Ring by the following
procedure:
1. Place the Locking-Ring onto the square section at the shaft end.
2. Screw on the Adjusting-Nut till it hits the Locking-Ring and make up HAND TIGHT.
3. Turn the Adjusting-Nut clockwise only till the next possible hole of the Locking-Ring is reached to place the
Locking Screw for securing the Adjustment-Nut.
Locking Ring
Swivel Shaft
Adjusting Nut
Locking Screw
58 Service Manual
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SERVICE TRAINING
Rock Valve
Placing the Counter-Nut at the lever side:

Only the E-Rock Valve requires an additional Counter-Nut to compensate for internal thrust forces when the
system is in operation. The Counter-Nut can only be adjusted after the swivel drive is completely assembled. The
Counter-Nut has a pitch of 2 mm.
1. Place the Ring and Lever supplied with the O-rings onto the Swivel Shaft. The parts are in the right position if
the marked points (at the face) are matching.
2. Insert Ring into the Lever and watch out for the O-ring.
3. Screw on the Counter-Nut till it hits the Ring and make it hand tight.
4. Screw back the Counter-Nut by 1/4 turn and measure the gap. (approx. 0.5mm).
5. Secure the Counter-Nut by it’s 3 worm screws.
6. Place the Cover over the Counter-Nut and secure with Bolt. Don’t forget the O-Ring.
Bolt
Cover
Worm Screws O-Ring
Swivel Shaft Insert Ring
Counter Nut
Lever
Service Manual 59
HOME PRINT
SERVICE TRAINING
Rock Valve
Rock Slewing Cylinder
21
1
17
2 18
15 19
14 20
13 16
34
22
23
8
7 9 24
6 10 3 22
11 12
5 34 11 4
12 10
4 9
3 8
25
26
27 34
28
29 34
31 13
14
34
30
32
33
32
34
Pos Qty. Description Part No.

1 1 SCREW DIN 908 R 3/8", 5.8.................................................................................................. 10001767
2 1 SEALING RING DIN 7603 A 17 X 21 CU............................................................................... 10003956
3 8 NUT DIN 6915 M 20, 10......................................................................................................... 10001232
4 8 DISC DIN 6916 M 21 C.45 ..................................................................................................... 10001509
5 1 PIPE PROTECTION............................................................................................................... 10017554
6 1 O-RING 56 X 4 ....................................................................................................................... 10000749
7 1 CYLINDER HEAD .................................................................................................................. 10017555
8 2 BALL STEEL .......................................................................................................................... 10006002
9 2 SPRING BOLT EV 105-0199 ................................................................................................. 10017561
10 2 SPRING PRESSURE............................................................................................................. 10013054
11 2 SEALING RING DIN 7603 A 21 X 26 CU............................................................................... 10004056
12 2 VALVE PLUG EV 105-006C .................................................................................................. 10017562
13 2 O-RING 72 X 4 ....................................................................................................................... 10000933
14 2 BACK-RING PTFE 80/73.6 X 1.5........................................................................................... 10016238
15 1 CYLINDER PIPE .................................................................................................................... 10017557
16 1 SLEWING PIVOT ................................................................................................................... 10118218
17 2 BUSHING MB 3530................................................................................................................ 10006726
18 2 BOLT ...................................................................................................................................... 10058467
19 2 GREASE NIPPLE DIN 71412 CM 10 X 1, 5.8 ....................................................................... 10007884
20 2 SCREW DIN 933 M 10 X 20, 8.8 ........................................................................................... 10001855
21 1 CYLINDER BEARING ............................................................................................................ 10058466
22 2 RING SAFETY 68 X 2.5 DIN 472........................................................................................... 10016233
23 1 ROD EYE ............................................................................................................................... 10017560
24 1 BEARING ARTUCULATED GE 45 DO-2 RS......................................................................... 10019455
25 1 NUT HEX DIN 934 M 42 X 3 8 ............................................................................................... 10017021
26 1 SCRAPER 45 X 44 X 7 P 6-45............................................................................................... 10006804
27 1 RING TENSION ..................................................................................................................... 10017559
28 1 ROD SEALING R 32510055 45 X 60 X 11 ............................................................................ 10016236
29 1 CYLINDER HEAD .................................................................................................................. 10094649
30 1 PISTON ROD ......................................................................................................................... 10017556
31 4 ANCHOR SCREW 20 X 570 M20 X 40 10.9.......................................................................... 10016797
32 2 GUIDE BAND 9287 - 076.519................................................................................................ 10016234
33 1 PISTON SEALING OMK - 5 - 80............................................................................................ 10016235
34 1 SEAL KIT FOR SLEWING CYLINDER .................................................................................. 10064756
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Rock Valve
Welding Procedures-SAIE 5312

No. : SAIE - 5312
SAIE STANDARD Date : 12-10-92 Rev :
Subject: By : TA
WELDING PROCEDURES - ROCK VALVE HOUSING
Sheet : 1 of 1
For general welding on the rock valve housing, Schwing Germany recommends a
UTPO68HH DIN 1736, S-NiCr 19 Nb, material number 2.4648. An equivalent American
electrode must have the following physical and chemical properties:
Alloy by % Weight Permissible Additives

Ni - at least 67 C - 0.1%
Cr - 18.0 to 22.0 S - 0.015%
Mn - 2.0 to 6.0 Co - 0.1%
Nb - 1.5 to 3.0 Si - 1.0%
Cu - 0.5%
Ti - 0.5%
Fe - 4.0%
Mo - 2.0%
other elements total - 0.5%
Melting range - approx. 1400 C (2550 F).

Nb is Niobium and it can be replaced by Ta (Tantalum)
Preheat the electrodes for 2 to 3 hours at 250 to 300 C (480 to 570 F)
The electrode must be high Ni and Cr content and high elongation. For
example, Huntington INCONEL #82 wire, (AWS-ERNICRS) and Huntington
INCO weld A, for 1/8" (Schwing Part#30352281) or 3/32"(Schwing
Part#30352282) electrode AWS-ENICRFE2 or equivalent.
The parts to be welded must be very clean. Preheat the area to be welded to 250 to 300 C
(480 to 570 F). Incline the electrode slightly and weld with short arcing. To prevent final
crater cracks, fill up the crater as well as possible and lift-off the arcing at the side. To
prevent cracking, we recommend placement of the casting into a preheated oven and letting
it cool from 600 F to room temperature over 12 hours. If an oven is not available in your city,
you can try to let the weld cool slowly under an asbestos blanket, an aluminum cover, or
sand.
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Rock Valve
Rock Valve with Insert - Conversion

Procedure for converting older Rock Valves to accept removable pressure spring insert.
1. Weld per SAIE 5125 using E7108 and preheat to 200˚F complete 360˚ of weld circle.
2. Addition of the insert requires a depth of 2.047. So if the Rock Valve has the standard depth 1.732 then it must
be machined to 2.047 at the same 9.843 Dia.
3. To machine Rock Valve for insert use P/N 30348121 (Machine 0.315 deeper as shown in detail A).
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Rock Valve
Small Rock Valve - Repair

Safety
When performing maintenance on Schwing Equipment, the safety regulations must be followed. The observation
of these regulations is the responsibility of the maintenance personnel. The following are some supplementary
recommendations.
WARNING
READ FIRST!
1. WARNING! Read and understand the operation manual of the machine before attempting any repairs. If in
doubt, call the manufacturer. Incorrectly done repairs endanger operational safety of the machine.
2. WARNING! Burning hazard! Never work on a hydraulic system with hot oil.
3. WARNING! Falling hazard! If you cannot work at ground level, you must use a suitable work platform.
4. WARNING! If maintenance work requires that you use a crane, hoist, fork truck, etc., you must read and
understand the safety regulations for that equipment.
5. WARNING! If working the machine requires that it be operated, and you are not qualified as an operator, you
must get someone who is qualified to assist you.
6. WARNING! If you will be working in a hidden area inside the machine, protect yourself by taking the key
from the ignition and putting a “DO NOT OPERATE” sign on the controls. In the case of electrically driven
units, disconnect the main circuit breaker and lock it in the disconnected position.
7. WARNING! Never activate the system hydraulics without checking if another workman is in a hidden
position. Always yell “CLEAR”, and allow time for response, before starting the prime mover.
8. WARNING! Never use gasoline or diesel fuel as a cleaning solvent. This is critical to remember when
cleaning hydraulic oil reservoirs, because gas and diesel fuels are highly explosive, and gasoline or diesel fuel
traces left in the oil may ignite when compressed.
9. WARNING! Always use the correct tools for the job. Tools should be kept clean, and in good condition.
10. If you see a co-worker engaging in an unsafe practice, explain the dangers. Safety is always in the hands of
those on the job.
WARNING! Never work on a pressurized hydraulic system. Stop the prime mover and relieve the accumulator
circuit (if so equipped) before you open the hydraulic system.
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Rock Valve
Parts Identification
Spectacle or Inlet Plate
Spectacle or Inlet Plate
Cutting Ring
Bushing
Seal Cover Rock Valve
Kidney or Outlet Plate
Locking Bolt
Pressure Spring
Kidney Seal
Centering Screw
Setting Disc
Tension Nut
Locking Washer
B 2.5mm
(.098") A
1.5 - .2.0mm
(.060 - .080")
Dimensions shown are

with all new wear parts.
When Dimension B
exceeds 8mm (.315") the
cutting ring is worn out
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Rock Valve
Lubrication Points
Use a grease gun with the recommended grease listed in the chart below. Locate the grease points, clean the grease
fitting before filling it, and inject grease until you see old grease displaced by the new grease. Lubricate the grease
points at 8 hour intervals and whenever the machine work is completed for the day.
Grease Points
Minimum Specifications for grease.

Lithium base high-pressure grease KP 2 K per DIN 51502.
BP Energrease LS2
MOBIL Mobilith AW 2
SHELL Alvania grease R2
TEXACO Multifak 20
ARAL HLP 2
ESSO Beacon 2
OPTIMAL Olitsa longtme 2EP
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Rock Valve
Lengthening the Service Life of the Spectacle Plate and Cutting

Ring
Conditioned by outside influences (material variations), as well as by differing work strains on partial sections, the
cutting ring and the housing lining wear out unequally.
The grooves resulting from operation are irrelevant as long as the armouring is not worn out completely.
Friction and Friction

stone crushing
Friction and
stone crushing
Friction
Figure 1
To ensure uniform wear and, thus, CONSIDERABLY LONGER SERVICE LIVES, we recommend the following:
1. Move the Rock Valve to the left and right end position once a week after thorough cleaning, and check the
condition of both the Cutting Ring and the Housing Lining.
2. Turn the Cutting Ring 90 degrees when there is a clearance greater than 1.0mm-1.5mm (.0393”-.0590”)
between the Cutting Ring and the Housing Lining.
Housing Lining
Housing Lining
max 1.5mm
0.590"
Cutting Ring Cutting Ring
max 1.5mm
0.590"
Check for the gap at several points along the Cutting Ring circumference, and always turn the Cutting Ring in the
same direction.
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Rock Valve
It is only necessary to loosen the Securing Bolts of the Housing Cover approximately 10mm
(.3937”) in order to release the Pressure Spring and turn the Cutting Ring.
3. Check the distance between the Cutting Ring and the Rock after each turn of the Cutting Ring. If it exceeds
8mm (.315”), the pretension of the Pressure Spring is not enough to correctly press the worn cutting ring up
against the Spectacle Plate. In this case, the Cutting Ring has to be replaced.

Cutting Ring
Rock Valve
Pressure Spring
B
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Rock Valve
Rebuilding of Rock Valve

1. Remove the Locking Bolt from the Tension Nut.
2. Loosen the Tension Nut.

NOTE!
It’s ok to remove the Tension Nut with a wrench, but it must never be tightened move than hand
tight.
3. Remove the Tension Nut.
Tension Nut
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Rock Valve
4. Remove the Setting Disc.
Setting Disc
5. Remove the special Centering Screws (SAI Part #10069857).

NOTE!
It is important that these Centering Screws get installed in the same holes upon reassembly.
Centering Screw
6. Install the alignment rods (SAI Part #30309007).
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Rock Valve
7. Slide the rear housing cover back slightly.
NOTE!
Some versions of the Rock Valve have a sealing cord under the cover.
8. Remove the Locking Bolt for the Cylinder Pin on the Slewing Yoke.
Locking Bolt
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Rock Valve
9. Remove the Locking Bolt for the Cylinder Pin on the barrel end of the cylinder.
Locking Bolt
10. Using a drift pinch and a hammer, drive the Cylinder Pins out and remove the hydraulic cylinder.
Drift Punch
Hammer
11. With the Rear Cover Housing moved back, remove the Kidney Seal for inspection or replacement.
Kidney Seal
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Rock Valve
12. Slide the Rock back about 1.5 inches.
13. Remove the Cutting Ring.
Cutting ring being removed
14. Remove the Pressure Spring.
Pressure spring being removed
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Rock Valve
15. Loosen the bolts and slide the Sealing Cover back on the Rock Shaft.
Sealing Cover
16. Carefully remove the Rock Valve from the housing.

NOTE!
The Slewing Yoke will be removed from the shaft at this time. It may bind up, so you will have to pry
or tap the yoke with a hammer to remove it. Upon reassembly, refer to the previous section in this
manual regarding installation of the Slewing Yoke for the proper yoke alignment procedure.
NOTE!
In the event that the Rock Shaft Bushings require replacement, proceed to steps 19 &20.
17. Remove the Seal Cover from the Rock Slewing Shaft and remove the O-ring.
Seal Cover
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Rock Valve
18. Remove the O-ring from the groove of the Rock shaft bushing on the Rear Cover Housing.
O-ring
19. Using the correct size bushing driver, drive the old Rock shaft bushing out of the front cover of the Rock
housing.
Bushing Driver
Hammer
20. Using the correct size bushing driver, drive the old Rock Shaft Bushing out of the Rear Cover Housing.
Bushing Driver
Hammer
Rear Cover Housing
21. Remove the two bolts attaching the Spectacle Plate to the Front Cover.
Counter Sunk Bolts
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Rock Valve
22. Carefully remove the Spectacle Plate from the Rock Housing.
Spectacle Plate
23. Remove the four bolts from the rear cover that attach the Kidney Plate to the rear cover.
NOTE!
On some versions of the Rock Valve, these four bolts are under the delivery pipe. The delivery pipe
will have to be unbolted to gain access.
24. Remove the Kidney Plate.

NOTE!
The Kidney Plate should have a smooth, mirror-like finish, free of any scratches, gouges, or wear
grooves.
Before reassembly, make sure that all components are thoroughly cleaned.
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Rock Valve
25. Reassemble the Rock Valve assembly in the reverse order that it was disassembled. Slide the cover back in
place.
NOTE!
Upon reassembly, generously grease the Kidney Seal and the Kidney Plate. Also, generously grease
the Cutting Ring and the Spectacle Plate. This is important, because after you have assembled the
Rock and done some necessary adjustment, you are going to have to shift the Rock several times
before making the final adjustments.
26. Adjust the Tension Nut, which is tightened only hand tight. If the Locking Bolt shown can be installed in the
Setting Disc freely, then do so. If the hole in the Tension Nut does not align with the thread hole in the Setting
Disc, loosen the Tension Nut to the previous hole, and install the Locking Bolt.
NOTE!
Check to make sure that the proper clearance is obtained between the Rock Valve and the Cutting
Ring and between the Rock Valve and the Kidney Plate. If the Rock components are worn, the
dimensions may be larger that specified.
If the dimensions are too small, loosen the Adjusting Nut and pry the Rock Valve in the direction needed. Stroke
the unit several times, and recheck the dimensions. If the dimensions are correct, reinstall the Tension Nut and re-
adjust.
Locking Bolt
IMPORTANT! At no time should you operate the Rock Valve without first lubricating the outlet wear plate.
Spraying the plate with water or oil will usually be adequate prior to start-up for pumping. Moving the kidney seal
against a dry plate will cause excessive wear and premature failure.
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Rock Valve
If the Pressure Spring has to be replaced, remove the old spring and clean the vacant area thoroughly to clear it of
concrete residue. If dust and residue is ignored, the new spring cannot be installed correctly, and the flow of
concrete could pull it out of the groove. Furthermore, the high pretension resulting from reassembling with
concrete residue in the area of the spring leads to premature wear of the Cutting Ring and Housing Lining.
B
Rock Valve Inlet Housing Lining
Pressure Spring
Cutting Ring
Figure 1
NOTE!
Slightly grease the new Pressure Spring when installing it. The same applies to the Kidney Seal. Do
not use too much grease, because grease accumulating in the spring chamber operates as a spacer,
increasing the spring pretension.
Although these components will withstand a great deal of hard usage, the Pressure Spring and Kidney Seal should
be inspected whenever the Cutting Ring is replaced.
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Rock Valve
Determining Wear on the Kidney Seal Housing Lining - Outside

Replace the kidney seal if any of the following conditions exist:
• A considerable formation of cracks are found in the areas marked by arrows. This problem is very rare.
• The lip is completely worn to the point that the pressure relief grooves are no longer recognizable.
• The distance indicated by “M” of the released kidney seal does not exceed 30mm (1.1875").
2 2
Spring installed
d 1
mm
Figure 1
Replace the outlet housing lining (kidney plate) only if scores deeper than 1.5mm are found in the area that
contacts the kidney seal. You can measure this by placing a steel ruler across the kidney plate in several places and
using a depth gauge to determine the gap.
NOTE!
Outside of the area that contacts the Kidney Seal, you may detect scores that are due to aggregate
particles stuck between the Rock Valve and the Kidney Plate. (See fig. 2 and fig. 3) THESE SCORES
DO NOT MATTER IN THE LEAST!
Figure 2 Figure 3
CAUTION! Under no circumstances should you allow the kidney seal to be run with a dry hopper. This will
destroy the kidney seal and is the primary cause of premature wear encountered at the outlet side of the Rock Valve.
If you will be repairing the Rock or troubleshooting a problem, always fill the hopper with water to the top of the
Rock Valve before switching.
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Rock Valve
Replacement of Cutting Ring and Kidney Seal

1. Remove the Locking Bolt from the Tension Nut.
2. Loosen the Tension Nut

NOTE!
It’s ok to remove the Tension Nut with a wrench, but it must never be tightened move than hand
tight.
3. Remove the Tension Nut.
Tension Nut
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Rock Valve
4. Remove the Setting Disc.
Setting Disc
5. Remove the special Centering Screws (SAI Part #10069857).

NOTE!
It is important that these centering screws get installed in the same holes upon reassembly.
Centering Screw
6. Install the Alignment Rods (SAI Part #30309007).
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Rock Valve
7. Slide the rear housing cover back slightly.

NOTE!
Some versions of the Rock Valve have a sealing cord under the cover.
8. Remove the Kidney Seal for inspection, and replace it if necessary. See the previous section of this manual
entitled Determining Wear on the Kidney Seal and Housing Lining--Outlet Side for reference.
Kidney Seal
9. Slide the Rock Valve back about 1.5 inches, and carefully remove the cutting ring.
NOTE!
If you are going to turn the Cutting Ring, you only have to move the Rock back far enough to allow
you to loosen the ring and turn it 90 degrees. To determine if your Cutting Ring needs to be turned,
refer to the previous section of this manual entitled Lengthening the Service Life of the Spectacle
Plate & Cutting Ring.
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Rock Valve
10. Make sure that all parts are thoroughly cleaned, and reassemble in reverse order. Slide the Rock cover back into
place, and secure it with bolts.
11. Adjust the Tension Nut, which is tightened only hand tight. If the Locking Bolt shown can be installed in the
Setting Disc freely, then do so. If the hole in the Tension Nut does not align with the thread hole in the Setting
Disc, loosen the Tension Nut to the previous hole, and install the Locking Bolt.
NOTE!
Check to make sure that the proper clearance is obtained between the Rock Valve and the Cutting
Ring and between the Rock Valve and the Kidney Plate. If the Rock components are worn, the
dimensions may be larger that specified.
If the dimensions are too small, loosen the Adjusting Nut and pry the Rock Valve in the direction needed. Stroke
the unit several times, and recheck the dimensions. If the dimensions are correct, reinstall the Tension Nut and re-
adjust.
Locking Bolt
IMPORTANT! At no time should you operate the Rock Valve without first lubricating the outlet wear plate.
Spraying the plate with water or oil will usually be adequate prior to start-up for pumping. Moving the kidney seal
against a dry plate will cause excessive wear and premature failure.
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Rock Valve
Adjustment of the Slewing Cylinder and Installation of the Slewing

Yoke
Please be advised that there is no possible adjustment to align the Rock Valve with the material cylinder openings.
Our service personnel have been made aware that some maintenance personnel have been unscrewing the slewing
yoke to compensate for the Rock missing the holes while shifting. This is absolutely NOT to be done! By
unscrewing the slewing yoke, you risk tearing off the threads on the end of the cylinder rod, which would cause
immediate breakdown of the unit.
2
1
Figure 1
These units were designed to have no adjustment. If you replace a shifting cylinder or a slewing yoke, you must
make sure it is screwed the full distance on the threads and then locked down. If you do notice that the Rock is
missing the material cylinder openings, you must check to see where the problem may be (i.e., articulated bearings,
shifting cylinder (internal), or Rock slewing lever may need adjustment).
Please call the Schwing Service Department at (651) 429-0999 with any questions regarding this matter.
Slewing Yoke Timing

(Viewed From Cylinder End)
CL
CL
The slewing yoke is installed properly when the center line of the hydraulic cylinder rod is in line with the center
line of both the slewing shaft and the inlet or cutting ring.
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Rock Valve
Rock Slewing Cylinder
2 13 10 11 3 9 8 4 5 1 7
6 12
1. Cylinder Pipe 8. O-Ring

2. Rod Eye 9. Snap Ring
3. Tension Ring 10. Rod Scraper Seal
4. Guide Bushing 11. Rod Seal
5. Piston and Rod Assembly 12. Tension Ring Bolt
6. Articulated Bearing 13. Clamping Bolt
7. Piston Rings
IMPORTANT! Due to the various applications of the small style Rock Valve, a variety of seals and sealing
materials are used. Please consult the parts manual for the specific machine you are working on for the correct
parts, which may differ from what has been illustrated here.
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Pumpkits
Pumpkits • A11VO 60 Boom Pump with A10VO 28 Accumu-

lator Pump with Through Drive Tandem Mounted
• 4400 Stiebel Gearbox
Specifications • Separate Cooling System(Standard on the S 45
SX)
2023-4 • High Flow DN 30 S1-S2 Control Block
• 130/80 x 2000 Pump Kit
2525H-5
• A7VO 107 Hydraulic Pumps
• 120/85 x 2500 Pump Kit
• A10VO 28 Accumulator Pump with Through Drive
• Two Tandem Mounted A11VO 130 Hydraulic
Standard 4194 Stiebel Gearbox
Pumps
• Separate Cooling System
• A11VO 60 Boom Pump with A10VO 28 Accumu-
• High Flow DN 30 S1-S2 Control Block. lator Pump with Through Drive Tandem Mounted
2023-5
• Separate Cooling System(Standard on S 45 SX)
• 130/80 x 2000 Pump Kit
• High Flow DN 30 S1-S2 Control Block
• Two tandem mounted A11VO 130 Hydraulic
Pumps
2525H-6
• 120/85 x 2500 Pump Kit, A11VO 190 with A11VO
lator Pump with Through Drive tandem mounted
130 Hydraulic Pumps Tandem Mounted
• Separate Cooling System (Standard on S 45 SX) lator Pump with Through Drive Tandem Mounted
• High Flow DN 30 S1-S2 Control Block • 4400 Stiebel Gearbox
• Separate Cooling System(Standard on S 45 SX)
2023H-6
• High Flow DN 30 S1-S2 Control Block
• 120/80 x 2000 Pump Kit
• A11VO 190 with A11VO 130 Hydraulic Pumps
Tandem Mounted
PUMPK I T PUMP DIFFERENTAL MAX. CONCRETE MAX. PRESS. MAX. THEORY STROKE
CYL. CYLINDER OUTPUT ON CONCRETE STROKES/MIN LENGTH
(Dia) (Diameter) ROD PISTON ROD PISTON ROD PISTON (IN.)
(cu. Yd/hr) (cu. Yd/hr) (psi) (psi)
500-18x 7 3.1 - 75 - 870 - 27 55
900 HDR 8 4.7 (120mm) 117 67 870 1565 30 17 63
1250 7 3.14 - 95 - 942 - 34 55
1200 HDR-20 8
1200 HDR-23 9
2023-4 9 5.1 (130mm) 170 - 1007 - 26 - 79
2023-5 9 5.1 (130mm) 209 - 1007 - 32 - 79
2023H-6 9 4.7 (120mm) 182 - 1233 - 28 - 79
2525H-5 10 4.7 (120mm) 181 - 1169 - 18 - 98
2525H-6 10 4.7 (120mm) 213 - 1169 - 22 - 98
750-18R 7 3.1 - 69 - 870 - 34 39
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Pumpkits
Change rams • The stroke limiter is set to minimum output.

• The operation stations (the rear control panel, the
When you begin to see not just cement dust in your cable remote box, the radio remote box) are
waterbox at the end of the day, but also small bits of disabled.
sand or even pebbles, it is time to change the rams. • Three LEDs (oil cooler status, oil filter status, and
When changing rams, you will have to put your hands E-Stop status) on the rear control panel will be
in the waterbox on several occasions. In the past, we flashing. These LEDs will continue to flash as
instructed you to stop the engine each and every time long as the O I switch is in the I position.
before putting your hands into the waterbox, and we
• Three LEDs (rear control, cable control, radio
still highly recommend this practice.
control) on the CPC will be OFF.
The local control on-off switch for the concrete pump
The concrete pump can only be actuated with the
and the manual handle for activating the concrete pump
Forward/Reverse switch to the right of the O I
are located in positions that make them impossible for
selector switch. This momentary switch is spring
you to activate while your hands are in the waterbox. If
loaded to the center position and activates only while it
however, another person has access to these devices, or
is being held in a forward or reverse position.
the “ram change” operation panel, the danger of
accidental activation increases. While operating in ram change mode the pistons will
move at the slowest possible speed.
ramctrl.eps
WARNING
Crushing/amputation hazard. Disable the
hydraulic system before removing
waterbox guards.
W007.eps
If you insist on changing rams with the

motor running, you must take the following
precautions to avoid amputation of hands,
arms, and fingers:
• Do not use the remote controller for this
procedure! Unplug it, and store it.
• Do not allow anyone else at the rear control panel
or the forward/reverse hand valve when you are
rd
changing rams. The chances of accidental
s e Forwa
r
amputation are greatly increased if more than one Reve
person is around. You will have fewer distractions
when you are alone. If someone approaches you
when you are changing rams, stop working until
the person leaves.
ps
tch.e
Select the ram change mode OIsw
Select local control on the rear control panel and then I = On

O = Off
select I (ON = ram change mode) with the O I selector
switch located on the ram change station (Figure 1). Figure 1
When I (ram change mode) is selected the following Ram change station on rear boom
things happen automatically: cradle “A” frame (current
• The diesel engine R.P.M. will return to idle production)
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Pumpkits
Remove the old rams.

Use the following procedure to remove the old rams. dogbone1.eps
1. Close the shutoff valve (also known as the ball

cock and quarter turn valve). The shut-off valve is
located on the concrete pump control block (Figure
2). This gives you control over the direction of
travel of the differential cylinders.
Soft switch
shutoff valve
Figure 3
Retract the driver’s side rod into the
waterbox all but about an inch and a half
5. A 55mm open end wrench and a 24 - 30 mm box
end wrench were supplied with the unit; you will
need them for this step. Locate the 55mm wrench
Concrete pump on the dog bone to hold the assembly from turning.
39
shutoff valve hif
low
.ep You can rest the handle against the side of the
s
waterbox (Figure 4). Unscrew the 4 M20 bolts that
hold the assembly together.
Figure 2
Concrete pump shutoff valve dogbone2.eps
2. Drain the waterbox. Remove the waterbox cover

and the bolt down grate.
3. Retract the driver side differential rod almost all
the way into the waterbox (Figure 3). Leave about
1.5 inches of travel, which will allow you to
remove the spacer coupling (dogbone).
4. Push the emergency stop button on the operator’s
panel. Stop the engine, and put the key in your
pocket. (Stopping the engine before putting your
hands in the waterbox is mentioned at every appro-
priate spot.)
Figure 4
Remove the bolts from the dogbone
6. Be sure all personnel and tools are out of the water-

box, then start the engine. Release the emergency
stop button. Finish retracting the driver side rod
into the waterbox. The dogbone will fall out.
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Pumpkits

pocket. ramflang.eps
8. Remove the dogbone from the waterbox (Figure

5).
.
dogbone3.eps
Figure 6
Removal bolt grooves on flanges
11. Start the engine. Release the emergency stop but-

ton, and slowly retract the cylinder rod until the
ram is clear of the material cylinder (Figure 7).
Figure 5
Remove the dogbone ram install fig 3

ton. Slowly extend the cylinder rod until it just
contacts the rubber ram flange.
NOTE!
Be careful not to drive the rubber ram into
the material cylinder. If it happens that you
accidentally knock the ram into the material
cylinder so far that you can’t reach it, you
Figure 7
will have to remove it by knocking it out
Slowly bring the ram into the
from the Rock Valve end of the unit. Call the
waterbox
Schwing America Service Department at
(651) 429-0999 for instructions on this pro- 12. Push the emergency stop button on the operator’s
cedure. panel. Stop the engine, and put the key in your
10. Push the emergency stop button on the operator’s pocket. Remove the nut and bolt, and the ram will
panel. Stop the engine, and put the key in your be free to come out of the waterbox.
pocket. There is a groove in the ram flange that will 13. Clean and inspect the bolts and cone washers, the
line up with a groove in the cylinder flange. An dogbone, and the cylinder flange. Replace any
M12 x 45 bolt with nut will drop into this groove damaged or worn parts with new ones.
and allow you to pull the ram out. The fit should be Install the new rams.
snug, but there is no need to tighten the nut with
tools (Figure 6). (Note that the ram flange and cyl- Use the following procedure to install the new rams.
inder flange are shown outside of the waterbox for 1. Apply Loc-tite primer (or equivalent) to the M20
clarity of the illustration.) bolts. Allow the primer to dry.
2. While the primer is drying, apply a liberal coat of
clean grease to the new rams. There is no such
thing as too much grease here, because the excess
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SERVICE TRAINING
Pumpkits
will be wiped off by the material cylinders during 8. Start the engine. Release the emergency stop
installation. button. Slowly move the cylinder down to where
3. With the engine still stopped, hold the new ram up the flange butts up to the dogbone. Be careful not
to the cylinder flange. Line up the grooves, and to go too far! (Figure 9).
drop your nut and bolt into place to hold the assem-
bly together. Again, you should only tighten the nut
finger tight. ram install fig 3

ton. Slowly extend the cylinder until the ram is
installed in the material cylinder but the mounting
flange is still exposed enough to remove the nut
and bolt (Figure 8).
ram install fig 2
Figure 9
Slowly move the cylinder to meet
the dogbone

pocket. You may have to slightly rotate the
Figure 8 dogbone to align the bolt holes with the cylinder
Slowly push the new ram into the flange. When aligned, coat the two remaining M20
material cylinder bolts with Loc-tite and install, including the cone
washer sets. Once all four bolts are started, you
5. Push the emergency stop button on the operator’s may tighten the bolts to the torque specification for
panel. Stop the engine, and put the key in your M20 10.9 bolts (420 ft/lbs).
pocket. Remove the nut and bolt.
10. Repeat all steps in the Remove the old rams
procedure and Install the new rams procedure for
ton. Slowly retract the rod again until there is room
the passenger side ram.
to install the dogbone.
7. Push the emergency stop button on the operator’s 11. Open the shutoff valve. Note that the unit will not
panel. Stop the engine, and put the key in your cycle with this valve closed.
pocket. Apply Loc-tite 242 or equivalent to two of
the M20 bolts. Place the dogbone up against the
flange of the new ram. Install two of the M20 bolts
(with Loc-tite) and the cone washer sets. At this
time finger tighten only.
NOTE!
It is important to install the dogbone against
the new ram first, not the cylinder flange.
This gives you an extra 6 to 8 inches of
safety margin when you extend the cylinder
to meet the dogbone. If you attach to the cyl-
inder flange first, chances are good that you
will accidentally knock the new ram into the
material cylinder so far that you won’t be
able to reach it.
Service Manual 89
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SERVICE TRAINING
Pumpkits
Changing the material cylinders

2. Select the “forward” mode of the S1 valve, AT
The material cylinders also eventually wear out. They THE SLOWEST POSSIBLE SPEED! Look into
are considered worn out when the inside diameter has the material cylinder from the valve end. The gap
grown 3 millimeters beyond the specification for new. between the alignment tool and the cylinder wall
For example, a 750-18 has 180mm material cylinders. should be seen as even rays of light. When the cyl-
When the inside diameter reaches 183 mm, they are inder gets fully extended, the alignment tool may
worn out. With 150’s they are worn out at 153, etc. drop a small amount or even barely touch the mate-
Normally, it is the end attached to the rock valve that rial cylinder wall
wears out first, because it sees the most concrete. The
waterbox end may be in brand new condition, because
that end never experiences concrete. For this reason, LIGHT RAYS
CYLINDER WALL
the material cylinders were designed to be able to flip
end for end. That way you can move the worn out part
to the waterbox and the like-new part to the concrete
valve for double the life. If you are going to do this,
you have to catch the wear on the material cylinders
before they get too thin or break through in one or
more spots. Once that happens you can’t flip them,
because they would be structurally too weak to hold the
pressure forces at the waterbox end.
The procedure for changing and aligning the material
cylinders is the subject of Service Bulletin G-102/88.
Contact the Schwing America Service Department at
(651) 429-0999 if you need a copy of the bulletin
Material Cylinder Alignment ALIGNMENT TOOL
1. To visually inspect the alignment, put a trouble NOTE!

light in the waterbox, at the opening to the cylinder
If the alignment tool should contact the cyl-
being aligned. Be careful with fingers and hands in
inder wall at any time, return the pump to
the waterbox. Put the trouble light in the waterbox,
neutral immediately! Damage may occur to
then remove your hand BEFORE proceeding to the
cylinder wall.
next step.
3. If, for example, the alignment tool contacts the cyl-
inder on the lower side, loosen the mounting bolts
at the waterbox a little bit, then tighten the
LOWER bolts first. This will lower the bottom of
the material cylinder. When the alignment is close,
tighten the top bolts and recheck the alignment.
When the alignment is within specification, the
alignment tool will travel the entire length of the
cylinder without touching the cylinder wall. If the
alignment tool is not always located exactly in the
middle of the cylinder during the travel, but DOES
NOT TOUCH, then realignment is not necessary.
Minor misalignments are compensated for with the
rubber ram. Repeat procedure for the other cylin-
der.
90 Service Manual
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SERVICE TRAINING
Pumpkits
NOTE!
If proper alignment cannot be achieved oth-
erwise, tightening torques may be exceeded
by 10% over the charts specs. If further
alignment problems persist, please contact
the Schwing Service Department.
MOUNTING
BOLTS
Figure 3.1 - Mounting Bolts

4. Grease new o-rings and insert in the valve housing.
5. Carefully slide the valve housing onto the material
cylinders, and rest the valve housing on the
machine frame.
6. Bolt the valve housing and material cylinder
flanges together making sure that the alignment is
being maintained.
7. Bolt the valve housing to the machine frame.
8. Check alignment with the tool once more, at slow-
est possible speed.
NOTE!
If a squeaking sound indicates the align-
ment tool is dragging on the material cylin-
der, turn off the pump IMMEDIATELY!
9. If there is no dragging, you may proceed to step 11.
If dragging does happen, repeat the visual checks.
10. Loosen the bolts on the material cylinders and
valve housing, and at the machine frame, and
repeat the alignment procedure.
11. Check the mounting and shimming of the pump kit
and its mounting to the pump kit frame.
12. Tighten all bolts.
13. Complete the reassembly of valves, and install the
rubber rams.
14. Reopen the ballcock or throttle valves
NOTE!
The poppet valve housing must be off to do
this alignment procedure. Also when the rod
gets fully extended, it may touch the cylin-
der walls.
Service Manual 91
HOME PRINT
SERVICE TRAINING
Pumpkits
Pumping on piston side When changing the hoses from the rod side port to the
piston side port, you must cross them. This keeps the
Piston side pumping changes your concrete pump from machine in the same sequence of events as when it is
a low-pressure, high-volume machine into a high hooked up for rod side pumping. Failure to cross the
pressure, low-volume machine. This would be handy, hoses will result in pumping in reverse whenever you
for example, to pump long distances horizontally or select forward.
vertically.
When you have finished with the need for piston side
Piston side operation dramatically raises the maximum operation, change it back to rod side immediately.
pressure on the concrete. For this reason, it is crucial
When you are configured on the piston side, the safety
that your entire material delivery system be rated to
rules for the following topics become even more
handle the available pressure and be maintained in like-
important:
new condition. Remember that pipe wall thickness
wears with each yard of concrete pumped. Inspect the • Opening lines under pressure
wall thickness regularly. The maximum material • Sucking back plugged lines before opening
pressure available on the piston side depends on which • Pressure-handling capacity of pipes, hoses, and
differential and material cylinders you purchased with clamps in your delivery system
your unit. The maximum material pressure is recorded • The dangers of blockages
on the main ID tag.
All of these items are covered in the Safety Manual.
To convert your machine to piston side operation, you Understand the rules and live by them.
must have some additional hoses and fittings, plus the
tools to install them.
Loosen for Add dead
rotation plugs
(1200’s only)
This hose
1200’s only
Add hose
and fittings
to each side
Loosen for Loosen for

rotation rotation
rod/piston change.eps
Loosen for
rotation
Rod Side Changes Piston Side

Configuration Configuration
92 Service Manual
ASSEMBLY INSTRUCTIONS FOR SEALING GLAND IN THE DIFFERENTIAL CYLINDERS
The following steps must be followed to ensure proper installation of the sealing glands (rod packings) on
differential cylinders:
1. Measure the distance from the bottom of the

bore on the guide bushing to the outside
machine surface of the cylinder housing where CYLINDER BARREL
the tension ring bolts to it (Figure 1, Dimension A

A). TENSION RING
SPACING DISK
GUIDE BUSHING
SCRAPER
PISTON ROD
SEALING GLAND SET
Sealing Gland Replacement
FIGURE 1
2. Set the packing set (unwrapped) on a at

Product: THE DIFFERENTIAL CYLINDERS
surface and set the tension ring on top of the

packing set. Measure the distance from the SCRAPER
at surf ace to the bottom side of the tension

TENSION RING
ring that mates to the cylinder housing when SPACING DISKS
AS REQUIRED
Service Manual
assembled (Figure 2, Dimension B).
SAIE STANDARD
B SEALING GLAND SET

3. Subtract Dimension A from Dimension B. The
SERVICE TRAINING
difference is the amount of thickness in

Subject: ASSEMBLY INSTRUCTIONS FOR SEALING GLAND IN
spacing disks required between the cylinder

housing and tension ring for assembly. FIGURE 2
Sheet
By: T.A.
The packings must never be under compression from the tension ring. If the packings are under
compression from the tension ring, it is possible that the cylinder rod may become scored after a short
1
period of time during operation. Therefore when Dimension A is subtracted from Dimension B, the
Date: 12-19-95
dimension of the spacing disks must equal the difference with a tolerance of minus nothing, plus 1 mm or
No.: SAIE - 5221
HOME
of 1
.039 inch.
Rev.: D
93
Pumpkits
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HOME PRINT
SERVICE TRAINING
Pumpkits
Shimming the Differential Tension Ring

Cylinders
Determining the proper shimm size
When ever you rebuild differential cylinders, it may be
necessary to add shimms to the tension ring. Adding
shimms protects the cylinder rod from the cheveron
seals in the event the cheveron seals expand. Use the
following procedure to determine the proper amount of
shimming necessary. Cheveron Seal Set
Dimension A
Using a caliper measure the distance from the top of Tape
the bushing down to the bushing seal recess. Figure 16
See Figure 1. Compacting the Cherevon seals
Use the caliper to measure the distance between the top
and the bottom of the compacted cheveron seals.
See Figure 3.
Dimension A = 57.12 mm
57.12 mm is the depth of the guide Dimension B = 57.4 mm

bushing seal recess.
Tension Ring
Bushing Seal Recess
Bushing
Dimension B
Cheveron Seal Set
Dimension B
Figure 15
Measuring for dimension A
Figure 17
Measuring for dimension B
Dimension B
Leave the tape around the cheveron seals to hold them
into place. On a solid flat surface place the Tension ring
on top of the cheveron seals. This will compact the
cheveron seals to the proper size. See Figure 2.
94 Service Manual
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SERVICE TRAINING
Pumpkits
Formula
A should equal B
B - A = shims required
In this example:
57.40
- 57.12
.28 mm (.011")
Refer to SAIE 5221
Figure 18
Formula for determining shimm size
In this example, we would need to add 1 - 0.5mm
shimm to the Tension ring. This will ensure that the
cheveron seals will not expand, thus preventing wear
on the cylinder rod. See Figure 4
NOTE!
A maximum of 5 shimms can be used.
NOTE!
Dimension B can never be greater than
dimension A or cylinder rod damage can
occur.
Service Manual 95
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SERVICE TRAINING
Pumpkits
96 Service Manual
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SERVICE TRAINING
Hydraulic Pumps
Hydraulic Pumps Schwing, we route signals to the pump from the

hydraulic stroke limiter and on single circuit units with
the dampener. The effect of these devices is to tell the
pump to put out a different amount of hydraulic oil per
Hydraulic Pump Drive revolution, to accommodate the pump operator. Your
All hydraulic pumps, such as the one for the concrete unit may be equipped with an A7VO pump or an
pump, placing boom, and agitator, are mounted on the A11VO pump.
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 of the truck. When
you are operating the unit, the distribution gearcase
interrupts the power to the rear end of the truck and
transmits it to internal gears that turn the hydraulic
pumps. Changing between travel and pumping modes
is accomplished by means of a power takeoff (PTO)
switch in the truck cab
Placing boom hydraulic pumps A7VO
The hydraulic pumps for the placing boom is a variable

displacement pump, either a swash plate (A11VO), or
an axial piston (A7VO). Both have load sensing control
and 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 directional control valves for each of the afore
mentioned 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.
A11VO
S103.eps
Concrete pump hydraulic
pumps
The hydraulic pumps for the concrete pump circuit are
bent axis, variable displacement piston pumps (A7VO)
or a swash plate pumps (A11VO). 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
Service Manual 97
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SERVICE TRAINING
Hydraulic Pumps
Hydraulic Pump Locations
PumpKit Pumps
Proportional Boom Pump
Accumulator Pump
Agitator Pump
Oil Cooler Pump Stiebel 4194
PumpKit Pumps
Proportional Boom Pump
Accumulator Pump
Oil Cooler Pump
Agitator Pump
Stiebel 4400
S0064.eps
98 Service Manual
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SERVICE TRAINING
Hydraulic Pumps
Fixed Displacement Pump the fixed displacement of the pump. The pump is
suitable for use in mobile and industrial applications.
A2FO
Fixed displacement axial piston pumps of bent axis
design for use in hydrostatic drives in open circuits.
The output flow is proportional to the input speed and
Service Manual 99
HOME PRINT
SERVICE TRAINING
Hydraulic Pumps
Rexroth/Hydromatik Model A7V

Series 2 The flow is proportional to the drive speed and the
displacement and is steplessly variable at constant
Note: After replacing any A7VO hydraulic pump, the drive speed.
unit must be bled before start-up. Comprehensive program of control devices for every
• If there is a U-Port on the pump, this is the control and regulating function.
bearing flush and that is where the pump should be
bled from.
High performance rotary group with well-proven
• If there is not a U-Port, the pump should be spherical control area offering the following
bled from the highest case drain. advantages: self-centering, low peripheral speed, high
Variable displacement pump, axial piston, bent axis efficiency.
design, fir hydraulic transmissions in open circuits.
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SERVICE TRAINING
Hydraulic Pumps
Constant Pressure Control DR Constant Horsepower Control LV

The constant pressure control maintains the pressure in The constant HP control flow in relation to pressure,
thereby maintaining hydraulic power constant.
a hydraulic system constant within its control range in
spite of changing pump flow requirements. The
variable pump supplies only the volume of fluid
required by the services. Should operating pressure P = Power [kW]
p•Q
exceed the set pressure, the pump is automatically P= = constant p = Pressure [bar]
600
swivelled back to a smaller angle and the deviation in
control corrected. Q = Flow [l/min]
The required pressure is set either direct at the pump
(valve built-in, standard model) or at the separate (Provided that the drive speed is constant)
sequence valve for the model with remote control.
Setting range from 50 to 350 bar.
Setting range for remote control 50 to 315 bar. Operating pressure acts on a pilot piston, causing it to
press on a set of springs. If the hydraulic force exceeds
the spring force, pilot oil is fed to the adjusting piston,
which swivels the pump back to a smaller angle and
Setting range from 50 to 350 bar. Setting range for remote control 50 to 315 bar
therefore a smaller flow.
max. 10 bar
P max
350
315 Commencement of control: 50 bar min.

300
150
A (B) R
Operating pressure PB (bar)
setting range
200
G
100
50
0
Flow Q (L/min.)
S
Figure 19 - Pressure Setting Ranges Figure 21 - Schematic of a A7V Variable
Displacement Pump
Summation HP control is made possible by means of
throttles via port G.
A (B) R
T
X3 A
S T
Figure 20 - Schematic of a A7V Variable

Displacement Pump With Remote Control
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SERVICE TRAINING
Hydraulic Pumps
Auxiliary Equipment: Stroke Limiter
A (B) R
X2
G
X1
S
Figure 22 - Schematic of a A7V Variable

Displacement Pump With Hydraulic Stroke Limiter
By Means of a mechanical or hydraulic stroke limiter,
the maximum displacement can be infinitely varied or
limited. Adjusting range from Vg max to Vg min.
A pilot pressure (port X1) of at least 10% of the
operating pressure is required for the hydraulic stroke
limiter. Maximum permissible pressure at port X1 =
200 bar (for all sizes).
If it is required to limit the flow at an operating
pressure < 50 bar, then a boost pressure of minimum 50
bar must be applied at port X2 (at port X1 then,
minimum 10% = 5 bar)
Q min
Q max
S0098.eps
Figure 23 - Q Min and Q Max Locations on a A7V

Variable Displacement Pump
102 Service Manual

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SERVICE TRAINING
Hydraulic Pumps
Rexroth/Hydromatik Model A7V Comprehensive programming of control devices is

available. The robust taper roller drive shaft bearings
Series 6 are designed to give long service life. Output flow is
Variable pump with axial tapered piston rotary group of proportional to drive speed and pump displacement is
bent axis design, for open circuit hydraulic drives. This steplessly variable between maximum and zero.
pump is suitable for mobile applications.
0ß
25ß -
Service Manual 103

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SERVICE TRAINING
Hydraulic Pumps
LR Constant Power Control

The constant power control controls the output volume
of the pump in relation to the operating pressure so
that, at a constant drive speed, the preset drive power is
not exceeded.
V = constant
p B = operating pressure
pB g
V = pump displacement
g
Optimum power usage is obtained by accurately following the

power hyberbola
350
Operating pressure p B (bar)
300
A (B) R
250
220 bar
200
Adjust. range
G
150
Start of control
100
50 50 bar
0
0 0.2 0.4 0.6 0.8 1.0
V Displacement V
g min g max
Figure 24 - A7VO Variable Displacement Output

Chart S
Operating pressure applies a force on a piston within Figure 25 - Schematic of a A7VO Variable
the control piston on to a rocker arm. An externally Displacement Pump
adjustable spring force is applied to the other side of
the rocker arm to determine the power setting. LRH Constant Power Control With
Should the operating pressure exceed the set spring Hydraulic Stroke Limiter
force, the pilot control valve is operated via the rocker
arm, allowing the pump to swivel towards zero output.
This in turn reduces the effective moment on the arm of X1
the rocker, thus allowing the operating pressure to rise
in the same ratio by which the output flow is reduced Y3
(Vg = constant). A
When the pump is bypassing at zero pressure, a spring A1
ensures that the pump is swivelled to max. displace-
ment (Vg max).l
S A7VO-107 LR
Figure 26 - Schematic of a A7VO Variable

Displacement Pump With Hydraulic Stroke Limiter
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Hydraulic Pumps
Variation: Hydraulic Stroke Limiter (H...)

The hydraulic stroke limiter allows the maximum
displacement to be infinitely varied or limited as
required. Control range Vg max to Vg min. The
displacement is set by means of the pilot pressure
applied at port X1. The hydraulic stroke limiter is
overridden by the constant power control, i.e. below the
power curve (power hyperbola), displacement is
adjusted in relation to pilot pressure. If the set flow or
the operating pressure is such that the power curve is
exceeded, the constant power control overrides the
stroke limiter and reduces displacement until the power
hyperbola is restored.
H1/H5 (Negative Control Function): Vg max

to Vg min
As pilot pressure increases the pump swivels towards Horsepower
lower displacement. (Starting position at zero pressure: Adjustment
Screw
Vg max).
Figure 28 - Horsepower Adjusting Screw on a A7VO
Start of control: adjustable between 4 and 15 bar. Variable Displacement Pump
H1 pilot pressure increase (Vg max - Vg min) _____ p = Q min
25 bar.
40
35
0ß
30
25ß -
25
pilot press. PSt in bar
20
setting range
15
Q max
10
4 Figure 29 - Q Min and Q Max on a A7VO Variable

Displacement Pump
0 0,2 0,4 0,6 0,8 1,0
Vg min Vg Vg max
Displacement Vg max DR Constant Pressure Control
The constant pressure control maintains the pressure in
Figure 27 - Displacement Output Chart a hydraulic system constant within it’s control range in
spite of changing pump flow requirements. The
variable pump supplies only the volume of fluid
required by the consumer. Should operating pressure
exceed the set pressure, the pump is automatically
swivelled back to a smaller angle and the deviation in
control corrected.
In un-operated (zero pressure) condition, the pump is
swivelled to it’s starting position (Vg max) by means of
a control spring.
Setting range from 50 to 350 bar.
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Hydraulic Pumps
Setting range from 50 to 350 bar. Setting range for remote control 50 to 315 bar
max. 10 bar
P max
350
315
300
150
Operating pressure PB (bar)
setting range
200
100
50
0
Flow Q (L/min.)
Figure 30 - Pressure Setting Ranges
Variation: Remote constant pressure

control (G)
A sequence valve with subplate takes over the pressure
control function. The valve is mounted separate from
the pump, and the piping length should not exceed 5 m.
High pressure is supplied from the pump to the valve
via part A1, and the valve control oil is fed back to the
pump via Port X, causing the pump to swivel back
towards Vg min. Port T of the sequence valve and T1,
the pilot drain from the pump must be connected back
to tank (cooler). Pressure may be set between 50 and
315 bar.
Sequence valve: DZ5DP2-1X/315 Y SO21 (Id.-Nr. 154
869)
Subplate: G 115/1 (Id.-Nr. 153 138)
∆ P regulator
High pressure filters
X
20
A bar ∆ P
A1
290
bar
P
A T
X3
Boom hydraulic pump
Figure 31 - Schematic of a A7VO Variable

Displacement Pump
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Hydraulic Pumps
Rexroth/Hydromatik Model transmissions in open loop circuits. Flow is

proportional to the drive speed and the displacement.
A10VO By adjusting th position of the swashplate it is possible
Variable displacement axial piston A10VO of to smoothly vary the flow.
swashplate design is designed for hydrostatic
Pressure Cut-off Screw S0081.eps
Service Manual 107

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SERVICE TRAINING
Hydraulic Pumps
DR Pressure Control
The pressure control serves to maintain a constant
pressure in the hydraulic system, within the control
range of the oump. The pump therefore supplies only
the amount of hydraulic fluid required by the actuators.
Pressure may be smoothly set at the pilot valve.
Figure 32 - Static Operating Curve
Figure 33 - Schematic of A10V0 Variable

Displacement Pump
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Hydraulic Pumps
Rexroth/Hydromatik Model pump is available with a through drive to accept a gear

pump or a second axial piston pump up to the same size
A11VO (100% through drive).
The A11VO is a variable displacement pump of axial
piston swashplate design for use in open circuit Output flow is proportional to drive speed and pump
hydrostatic drives. displacement and is steplessly variable between
Designed principally for use in mobile applications. A maximum and zero.
wide variety of controls are available. Setting of the
constant power control is possible via external
adjustments, even when the unit is operating. The
Service Manual 109

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SERVICE TRAINING
Hydraulic Pumps
p B = operating pressure
pB V = constant
g
V = pump displacement
M A G T1 R T2
g
Optimum power usage is obtained by accurately following the

power hyberbola
350
Operating pressure p B (bar)
300 320 bar
250
220 bar
200 Setting range
150 Start of control
100 Vg max Vg min
50 50 bar
0
0 0.2 0.4 0.6 0.8 1.0
V Displacement V
g min g max
Figure 34 - A11VO Variable Displacement Output

Chart s M1
The constant power control controls the output volume
of the pump in relation to the operating pressure so Figure 35 - Schematic of a A11VO Variable
that, at a constant drive speed, the preset drive power is Displacement Pump
not exceeded.
35
30
Operating pressure applies a force on a piston within
25
the control piston on to a rocker arm. An externally
20
adjustable spring force is applied to the other side of
pilot press. PSt in bar
15
the rocker arm to determine the power setting.
setting range
10
4
Should the operating pressure exceed the set spring
force, the pilot control valve is operated via the rocker 0 0,5 1,0
Vg min Vg Vg max
arm, allowing the pump to swivel towards zero output. Displacement Vg max
This in turn reduces the effective moment on the arm of
the rocker, thus allowing the operating pressure to rise Figure 36 - A11VO Variable Displacement Output
in the same ratio by which the output flow is reduced Chart
(pB • Vg = constant).
Variation: Hydraulic Stroke Limiter (LRH...)
The hydraulic stroke limiter allows the maximum
displacement to be infinitely varied or limited as
required.
Control range Vg max to Vg min.

The displacement is set by means of the pilot pressure
applied at port Y (max. 40 bar).
The hydraulic stroke limiter is overridden by the

constant power control, i.e. below the power curve
(power hyperbola), displacement is adjusted in relation
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Hydraulic Pumps
to pilot pressure. If the set flow or the operating

pressure is such that the power curve is exceeded, the Pressure Cut-Off
constant power control overrides the stroke limiter and Delta P
reduces displacement until the power hyperbola is Q min
restored. Load Sense Port
H1 bzw. H5 > function: Vg max to Vg min

(negative control)
As pilot pressure increases the pump swivels towards
lower displacement. (starting position at zero pressure:
Q max
vg max). Start of control, (at Vg max), settable _______ 4
- 10 bar.
H1 > pilot pressure increase (Vg max - Vg min), A11VO Boom Pump
________ ∆p = 25 bar.
M A G T1 R T2 Y
Stroke Regulation
Horsepower Control
Pressure Cut-Off
Stroke Regulation
Pressure Cut-Off
Horsepower
Control
Q min
Vg max Vg min
Q min
A11VO 130/190 Main Pumps
s M1
Schematic of a A11VO Variable Displacement Pump

With Stroke Limiter
Service Manual 111

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Hydraulic Pumps
Linde Hydraulik BPR 105 from 3.06 to 15.86 cid. Pressure ratings are 5000 psi
intermittent and 3000 psi continuous duty.
Our BPR, bent-axis, variable displacement pumps are
self-priming units primarily for use in open circuit
applications. Six sizes are available with displacement
112 Service Manual

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Hydraulic Pumps
Power Regulator With Hydraulic Stroke

Limiter (LRH)
P RE The LRH is similar to the constant power regulator but
has a second sensor which responds to a low-pressure
pilot signal allowing the pump to be de-stroked on
demand. The pump's reduced displacement is
PC proportional to the signal and gives overriding control
within the set power band. This control is useful where
it is necessary to alter maximum flow to accommodate
certain conditions.
RB
Q L P P Y X
Figure 37 - BPR 105 Variable Displacement Output

Chart
Constant Power Regulator (LR)

This regulator is designed so that an exact hyperbola
curve of pressure/flow is realized. Therefore, the pump
makes maximum use of available power.
Setting the required power output simply involves
setting the pressure at which the regulator begins to de-
stroke the pump. The pump then follows a constant
power curve throughout the regulated range.
It is also possible to adjust the regulator to compensate
U T
for altitude changes, prime engine options or usage
changes. Figure 39 - Schematic of a BPR 105 Variable
Displacement Pump With Stroke Limiter
L P P Y
U T
Figure 38 - Schematic of a BPR 105 Variable
Displacement Pump With Stroke Limiter
Service Manual 113

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SERVICE TRAINING
Hydraulic Pumps
Voac Variable Displacement desired displacement flow. The setting range can be
mechanically limited by setting screws. The position of
Axial Piston Pump the swash plate can be controlled via a visual
Variable displacement pumps work according to the mechanical indicator. The latest knowledge and
swash plate pricipal: 9 pistons operate in a rotating experience with regard to noise reduction has been
cylinder barrel where they fulfill one suction and one used in the development of V30D. All components
presssure stroke per rotaiton. The axial movement of used in the V30D are manufactured from high grade
the pistons is provided by an adjustable swash plate. he materials and machined with close tolerances.
setting angle (0-17˚) is varied in proportion to the
Horsepower Control
Q min Q min Q max

Q max
Pressure Cut-off (200bar) Pressure Cut-off
VOAC Accumulator Pump VOAC Main Pump
Delta P Adjustment Screw
Q min Q max
Pressure Cut-off
VOAC Boom Pump
114 Service Manual

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SERVICE TRAINING
Hydraulic Parts
Hydraulic Parts
1 4 6
3
7
* Locations dependent of model
1 Boom Handvalves 5 Control Blocks
2 Boom Holding Valves 6 Stroke Limiters

T
P
T
MG
P
G
MY Y
3 Brake Valves 7 Outrigger Handvalves
(Boom Brake Valve) (Brake Valve Slewing)
4 Boom Regulator 8 E-Stops
S0141.eps
Service Manual 115

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SERVICE TRAINING
Hydraulic Parts
Boom Handvalves
Table 1: 36 Hydrel
Item# Part How it Functions

Directs hydraulic oil from the hydraulic pump to extend or retract
1 Directional Spool
the boom cylinder
Electric/Oil Directional Control Electric solenoid controls the direction of the pilot oil, which con-
2
Solenoid trols the direction of the main spool (Item#1)
Manual override which provides a direct link to the main spool

3 Handle
(Item#1)
Limits the flow of oil returning from the piston side of boom cyl-
4 Throttle Check Valve inder #3 when the boom cylinder is retracting. Allows free flow of
oil when extending boom#3 cylinder
5 Orifice Restricted flow in both directions to the boom cylinder

Limits maximum pressure in right hand bank - As pressure
6 Main Relief - Right Hand Bank reaches 280 bar, the relief valve will open and allow oil to be
directed to tank until the proper pressure is maintained.
Limits maximum pressure in left hand bank - As pressure reaches

7 Main Relief - Left Hand Bank 280 bar, the relief valve will open and allow oil to be directed to
tank until the proper pressure is maintained.
oil when extending the rod side of boom#1
Limits pressure on the rod side of boom cylinder #1, the purpose
9 #1 Down Side Relief Valve
of which is to protect the boom cradle from excessive pressure.
Restricts the flow of oil when the hydraulic cylinder is either

11 Orifice
extending or retracting

12 Orifice
Pretension check valve that generates back pressure which is used

13 Adjustable Check Valve (Right)
for pilot oil.

14 Adjustable Check Valve (Left)
for pilot oil.
Limits the flow of oil returning from the piston side of boom #4
15 Throttle Check Valve when the boom cylinder is retracting. Allows free flow of oil
when extending the rod side of boom#4

16 Orifice
116 Service Manual

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SERVICE TRAINING
Hydraulic Parts
15
80 bar
13 9 10 4 1.3 5 0.9
12 14
11 16
1.8 1.3 1.7 3
8
2
1
280 bar
280 bar
6
13 14
7
6
15
11 8 16
1
10 4
12
5
9 HV03.eps
Service Manual 117

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SERVICE TRAINING
Hydraulic Parts
Table 2: Monson Tison Electric/Air/Oil - Black and White

Allows oil to flow to tank unrestricted when no functions are
A Open Center Passage
being used
B Pressure Passage Supplies pressure oil to each working segment
Manual override which controls the position of the directional

spool. The spool is spring centered, so if force is not applied to
1 Handle
the handle, the spool along with the handle will return to the neu-
tral position.
Limits maximum pressure in the hand valve - As pressure reaches

2 Main Relief Valve 280 bar, the relief valve will open and allow oil to be directed to
3 Check Valve in pressure passage Restricts any back flow in the pressure passage.
Electric solenoid controls the direction of the pilot air, which in

4 Electric/Air/Oil Solenoid
turn controls the direction of the main spool.
Restricts the speed of the boom cylinder by restricting the flow of

5 Orifice hydraulic oil. This allows the boom to move at specified speeds,
set by the factory.

set by the factory.
118 Service Manual

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SERVICE TRAINING
Hydraulic Parts
6 5
0.8 1.1 1.1 1.5 1.2 1.2
A4 B4 A3 B3 A2 B2 A1 B1
4
B
3
P T
A
290
bar
2 1
T T
5
6
HV01.eps
Service Manual 119

HOME PRINT
SERVICE TRAINING
Hydraulic Parts
Table 3: Monson Tison Electric/Oil/Oil - Black and White

being used

1 Handle
tral position.

3 Check Valve in pressure passage Restricts any back flow in the pressure passage.
Electric solenoid controls the direction of the pilot oil, which in

4 Electric/Oil/Oil Solenoid

set by the factory.

set by the factory.
120 Service Manual

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SERVICE TRAINING
Hydraulic Parts
35 bar 6
5
1.3 1.0 1.7 1.3 1.3 1.3
A4 B4 A3 B3 A2 B2 A1 B1
4
B
A 3
T
P
280 2 1
bar
T T
5-7
bar
5
6
3
HV08.eps
Service Manual 121

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SERVICE TRAINING
Hydraulic Parts
Table 4: 36 Rexroth - Proportional

The shuttle valve system uses passage ways to deliver the highest
1 Shuttle Valve working pressure signal to the load sensing port of the boom reg-
ulator.

2 Handle
tral position.
Maintains constant flow for an individual function. Even when

3 Pressure Compensator the pressure changes from a variation in load of the activated
function or from multiple functions being activated.
4 Proportional Solenoid Proportionally directs pilot oil to move the main spool.
5 Proportional Solenoid Proportionally directs pilot oil to move the main spool.
6 Pressure Reducing Valve Reduces pilot pressure to a maximum of 25 bar.

8 Pretension Secondary Relief Valve Limits the maximum pressure in pretension circuit to 40 bar.
9 Control Block Housing Valve Section Enclosure that houses the hand valve spools and cartridges
Enclosure that houses the cartridges and filter for the pilot oil sys-
10 Inlet Block Section tem (pretension oil), load sense output, main relief and gauge
ports.
Adjustable orifice that limits the amount of oil flow to a particular

12 Flow Limiter
function
Filters the pretension oil passing through the hand valve. Used to
13 Filter (Pretension)
protect the pilot oil system from debris in the system.
Reduces the flow of oil going into the pretension filter. Protects
14 Orifice
the pretension filter from pressure spikes.
15 Mechanical Stop Limits maximum spool movement, limiting the amount of flow
122 Service Manual

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SERVICE TRAINING
Hydraulic Parts
B4 P M P1 A5 A7 B7
15
3
160-200 12
1
13
2 2
14
6 25
bar
340
bar
15
8
4 7 4
5 40 5
bar
Y PV T
9 10 11
12
7
6
13
14 4
11
3
15
1
2
8
5
10
4
15
5
HV04.eps
Service Manual 123

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SERVICE TRAINING
Hydraulic Parts
“SP” Series directional valves A throttle installed in the place of the load-holding
SP” Series directional valves are 4-way valves. valve allows the maximum flow across the spool to be
matched to particular requirements. If a cylinder
As opposed to the normal 4-way valves, these valves requires varying flows, a mechanical stroke limiter is
have drillings for load pressure sensing, which are fitted, In the same way as for “SM” Series valves, the
connected to each other via shuttle valves. This means spool is matched to the spool boring in the valve body.
that the highest load pressure is passed through the
chain of shuttle valves to the sensing system of the
pump.
As opposed to the previous solution (with pilot oil

B A Load Sensing Port carrying plate), the new series has an internal pilot
oil supply by means of drillings in the valve body.
Pilot Oil
Xe
Leak Oil
Xa
Xe The leak oil of the pilot system is drained internally
passing directly via the return line.
B
A
P Xa T S0110.eps
S0112.eps
As opposed to the previous solution (with pilot oil The leak oil of the pilot system is drained internally
carrying plate), the new series has an internal pilot passing directly via the return line.
oil supply by means of drillings in the valve body.
Pilot Oil
Leak Oil
S0112.eps
124 Service Manual

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SERVICE TRAINING
Hydraulic Parts
Adjustable Ofifice
Mounted between the A& B port on the backside of the
handvalve. Used on all four boom sections, throttle and
outrigger functions.
Maximum Flow 70 Liters
S01
Flow Limiter
5 liter used on slewing function P/N 10062506 20 liter
used on water pump function P/N 10058993 mounted
between the A & B port on the back side of the
handvalve. If both of your flow limiters are the tall
version you can tell them apart by looking at the orifice
drilled in the poppet end of the cartridge.
Orifice in 5 liter = 1.4mm (0.055 inch)


Orifice
5 Liter S0113b.eps 5 Liter or 20 Liter
Service Manual 125

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SERVICE TRAINING
Hydraulic Parts
Table 5: 42 - Rexroth - Proportional

1 Main Relief Valve over 330 bar, the relief valve will open and allow oil to be
2 Pretension Filter
Reduces the flow of oil going into the pretension filter. Protects
3 Orifice
the pretension filter from pressure spikes.
Limits the amount of pressure allowed when boom # 1 is

retracted to 80 bar. Limiting the amount of pressure prevents the
4 #1 Down Side Relief Valve
boom cradle from being damaged, while the boom is in the
stowed position
5 Pretension Relief Limits the maximum pressure in pretension circuit to 34 bar.


7 Handle
tral position.
Proportional - Electric/Oil/Oil Sole-

9 Proportionally directs pilot oil to move the main spool.
noid
Enclosure that houses the cartridges and filter for the pilot oil sys-
10 Control Block Housing
tem (pretension oil)
12 Shuttle Valve working pressure signal to the load sensing port of the boom reg-
ulator.

13 Flow Limiter
function
14 Pretension Pressure Reducing Valve Reduces pilot pressure to a maximum of 25 bar.
126 Service Manual

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SERVICE TRAINING
Hydraulic Parts
#1 dn 4
relief
80 bar
Control block relief A B A B A B A B A B A B A B A B
P
X 1 12
13
330
bar
7
PV 2 6
25
3 bar
8
34
bar
14
9 9
5
T
10 11
13
12
11
3 1
2
5 7
14
10
8
9
HV05.eps
Service Manual 127

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SERVICE TRAINING
Hydraulic Parts
42 - Rexroth - Hand valve Shuttles
Old Style New Style

Pin Type Shuttle Ball & Seat Shuttle
A B A B A B
T P T P T P
Hand valve with shuttle and Hand valve with shuttle and flow Hand valve with shuttle and
section compensator. Used on limiter: (5 or 20 liter). Used on the adjustable orifice. Used on the
42m proportional units. water pump and slewing functions boom functions of the 42m B & W
for the 42m B & W unit.
128 Service Manual

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SERVICE TRAINING
Hydraulic Parts
Preload block for Rexroth Hand valve
Pv P T Pv (X)
Orifice Filter
O-ring
O-ring
Pv (X)
Pv
34 bar
T
25 bar 160 m
P
S0115.eps
Service Manual 129

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SERVICE TRAINING
Hydraulic Parts
Table 6: 45/47 Proportional

Limits the amount of pressure allowed when boom # 1 is

retracted to 80 bar. Limiting the amount of pressure prevents the
2 Piston Downside Relief Valve
boom cradle from being damaged, while the boom is in the
stowed position
3 Pretension Relief Limits the maximum pressure in pretension circuit to 40 bar.
4 Electric/Oil Proportional Solenoid Proportionally directs pilot oil to move the main spool.
Limits the amount of travel on the main spool, which in turn
5 Mechanical Stop
reduces the amount of flow.

9 Pretension Filter
130 Service Manual

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SERVICE TRAINING
Hydraulic Parts
A4 B4 A3 B3 A2 B2 A1 B1
P
P
X
Y
Ls
9 5 Ls
160 - 200
8 7
2 1
35
230 bar
bar
350
bar
40
bar
3 6
4 T
X Y b4 a4 b3 a3 b2 a2 b1 a1
D-G 1-b4
D-G 3-a4
C-G 2-b3
C-G 4-a3
B-G 3-b2
B-G 1-a2
A-G 2-b1
A-G 4-a1
pretension only 8
3
33-35 bar
9
4
7
4 Up
3 Up
2 Up
1Down
6
4 Down
3 Down
1
HV06.eps
2 Down 2
5
1Up
Service Manual 131

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SERVICE TRAINING
Hydraulic Parts
Table 7: 45/47 Proportional

1 Inlet Segment Enclosure that houses the load sennse check valve
2 Load Sense Check Valve
3 Pretension Filter
4 Work Segment Enclosure that houses the Pretension Filter
Electric solenoid controls the direction of the pilot oil, which in

7 Electric/Oil/Oil Solenoid
8 Handle
tral position.
Limits the maximum amount of pressure in the water pump to

9 Relief Valve 190 bar. As the pressure increases to190 bar, the relief opens and
allows oil to return to tank until the proper pressure is maintained.

11 Shuttle Valve
pressure signal to the load sensing port.
12
13 End Plate Caps off the valves body sections
132 Service Manual

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SERVICE TRAINING
Hydraulic Parts
A B b a A B A B
6
9 7
3
200
bar
2
11 10 11 10 11 30 l
max.
8 LS
5
T PST P
13 12 4 1
8
1
5
4
2
12
10 3
9
11
10
11
11 7
13
7
S0161.eps
Service Manual 133

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SERVICE TRAINING
Hydraulic Parts
Table 8: 52/55 Proportional - Main Valve

Limits maximum pressure in the hand valve - As the pressure
1 Main Relief Valve increases to 350 bar, the relief valve will open and allow oil to
escape to tank until the proper pressure is maintained.
2 Shuttle Valve

3 Flow Limiter
function

Limits the maximum amount of pressure in the slew function to

5 Slewing Relief Valve 190 bar. As the pressure increases to190 bar, the relief opens and
allows oil to return to tank until the proper pressure is maintained.
Limits the amount of travel on the main spool, which in turn

6 Mechanical Stop
reduces the amount of flow.

7 Spool
the boom cylinder
Limits the flow of oil returning from the rod side of boom cylin-
8 Throttle Check Valve der #1 when the boom cylinder is retracting. Allows free flow of
Table 9: 52/55 Proportional - Pilot Valve

1 Pretension Filter
3 Pretension Relief Limits the maximum pressure in pretension oil to 40 bar.
Electrical/Oil/Oil - Proportional
4 Proportionally directs pilot oil to move the main spool.
Solenoid
5 Shuttle Valve
pressure signal to the load sensing port of the boom regulator.
134 Service Manual

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SERVICE TRAINING
Hydraulic Parts
adjusted
to 20 bar
dynamic
pressure 8
a1 A1 B1 a2 A2 B2 a3 A3 B3 a4 A4 B4 a5 A5 B5 a6 A6 B6
T T
5 6
5
190 190
3 bar bar 7 3 7
350 bar
4 4 2
1
10146290 10146289
X (LS) X (LS)
P P
b1 b2 b3 b4 b5 b6
3
6 8
7
2
5
Shuttle valves access 1
thru hole in the bottom
under the mounting plate
4 4
Pst
Pst
3
4 4
L
2
50
bar
30 5 5
bar
1
P L(T) b1 b1 a1 a1 b2 b2 a2 a2 b3 b3 a3 a3 b4 b4 a4 a4 b5 b5 a5 a5 b6 b6 a6 a6
2
1
5 5
4 4
3 HV07.eps
Service Manual 135

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SERVICE TRAINING
Hydraulic Parts
Table 10: Hawe Handvlave

1 Handle
tral position.
Directs hydraulic oil from the hydraulic pump to either the water
2 Directional Spool
pump or high pressure water pump.
High Pressure Water Pump Relief Limits the amount of pressure allowed when the high pressure
3
Valve water pump is activated to 280 bar.
Limits the amount of pressure allowed when the water pump is

4 Water Pump Relief Valve
activated to 180 bar

6 Shuttle Valve
Electrical/Oil/Oil - Proportional
7 Proportionally directs pilot oil to move the directional spool.
Solenoid w/quarter turn type plug
Limits maximum pressure in the hand valve - As the pressure

increases to 360 bar, the relief valve will open, dropping pressure
8 Main Relief Valve
on the spring side of the inlet compensator. The inlet compensator
will open allowing a larger volume oil to escape to tank.
Used in conjugations with the main relief cartridge. When pres-

sure reaches 360 bar the main relief valve will open. This will
10 Inlet Compensator lower the pressure on the spring side of the inlet compensator.
Higher pressure oil will push the inlet compensator open allowing
oil to escape to tank.
11 Pretension Filter
Directs hydraulic oil from the hydraulic pump to either enable the
12 Directional Spool
boom or outrigger functions.
13 Boom Slewing Relief Valves Reduces boom slewing pressure to a maximum of 300 bar.
Block containing a “P” (Inflow) and “R” (Return) port as well as

14 Sub-Plate
an additional control and measurement ports LS, Z and M.

16 Check Valve
for pilot oil.
136 Service Manual

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SERVICE TRAINING
Hydraulic Parts
14
13
A B A B A B A B A B B A B A B Z R M LS T P
300 bar
16 13 300 bar
R1
6 6
5
7 7
a a a a a a a
10
360 bar
o o o o o o o
A
A 2 11
b b b b b 12 b 280 bar b 20
bar
B 15 8
230 bar 180 bar B
17 18 4
1 3 9
8
7
9
"Z"
"T" (Pretension)
10
(Tank)
11
2
"P"
(Pressure)
7
6
12 5
3
15
6
4
18
14
17
13
16
13
S0151.eps
Service Manual 137

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SERVICE TRAINING
Hydraulic Parts
Table 11: Hawe Handvlave

17 Blank Cartridge
Limits the amount of pressure allowed when boom #1 is activated

18 Boom #1 Relief Valve
to 230 bar.
138 Service Manual

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SERVICE TRAINING
Hydraulic Parts
14
13
A B A B A B A B A B B A B A B Z R M LS T P
300 bar
16 13 300 bar
R1
6 6
5
7 7
a a a a a a a
10
360 bar
o o o o o o o
A
A 2 11
b b b b b 12 b 280 bar b 20
bar
B 15 8
230 bar 180 bar B
17 18 4
1 3 9
8
7
9
"Z"
"T" (Pretension)
10
(Tank)
11
2
"P"
(Pressure)
7
6
12 5
3
15
6
4
18
14
17
13
16
13
S0151.eps
Service Manual 139

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SERVICE TRAINING
Hydraulic Parts
Table 12: Apitech Hand valve

1 Handle
(Item#2)

2 Main Spool
the boom cylinder
3 Load Sense Shuttle Valve
4 Pulsar Valve Uses pulse width modulated signal to pulse valve open and close.

5 Compensator the pressure changes from a variation in load of the activated
6 Pretension Relief Limits the maximum pressure in pretension oil to 30 bar.

tank until the proper pressure is maintained
8 Pretension (Pressure Reducing Valve) Reduces pilot pressure to a maximum of 15 bar.
10 Work Segment Enclosure that houses the spool and compensator.
Enclosure which houses the main relief valve along with the pre-
11 Inlet Segment
tension relief valves and filter.
140 Service Manual

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SERVICE TRAINING
Hydraulic Parts
C1 C2 C1 C2 PP
G1/2 G1/2
1
30 8
bar 15
2 bar
7 12
4
5 P2
350
bar
3
P
T
LS
9 10 11
Torque to:
10-30 ft. lbs.
Mechanical Stop
1 3 6
Non-Adjustable
4
10
Not Used for ITE
CH
AP
Adjustment 12
Torque to: 10-30 ft. lbs. 11

Mechanical Stop 7
Non-Adjustable
8
Torque to: 15-20 ft. lbs. HV02.eps
Service Manual 141

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SERVICE TRAINING
Hydraulic Parts
Table 13: Apitech Hand valve - Fixed Displacement

1 Handle
(Item#2)

2 Main Spool
the boom cylinder
3 Load Sense Shuttle Valve
4 Pulsar Valve Uses pulse width modulated signal to pulse valve open and close.

5 Compensator the pressure changes from a variation in load of the activated

tank until the proper pressure is maintained
8 Pretension (Pressure Reducing Valve) Reduces pilot pressure to a maximum of 15 bar.
Enclosure which houses the main relief valve along with the pre-
12 Inlet Segment
tension relief valves and filter.
13 Filter
14
142 Service Manual

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SERVICE TRAINING
Hydraulic Parts
C2 C1 C2 C1 MPS
G1/2 G1/2
15 8 13
4 bar
1 1
2 2 6 0.76
mm
14 7
0.2 mm
4 4
5 300
bar
0.61
3 mm
P
T
LS
9 10 11 12
4
9
Torque to:
10-30 ft. lbs.
2 Mechanical Stop
1
5
10
3
4
1
6
CH
ITE
AP
11
Not Used for 13
Adjustment
Torque to: 10-30 ft. lbs. 12 14

Mechanical Stop
7 HV09.eps
Torque to: 15-20 ft. lbs.
Service Manual 143

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SERVICE TRAINING
Hydraulic Parts
Apitech Cut-Away
LOAD B
LOAD A
TANK TANK
PULSARS PULSARS
MAXIMUM
MAXIMUM SET SCREW
SET SCREW
PRETENSION
COMPENSATOR
SYSTEM PRESSURE
S0121.eps
144 Service Manual

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SERVICE TRAINING
Hydraulic Parts
Boom Holding Valves If oil flowing out uniformly from the leakage oil
connection, this indicates that the auxiliary safety valve
Schwing uses a specially-designed hydraulically is not properly sealing. If this holding valve is on boom
unlockable check valve on all hydraulic cylinders section 1 cylinder, holding valve replacement is
which operate placing boom sections. These valves necessary.
seal the hydraulic cylinder to prevent it from creeping
This auxiliary safety valve protects the cylinder and the
or moving until pressure is applied to it. If too much
boom from excess pressure; therefore, this valve must
weight is applied to a boom section, it also acts as a
not be set at random. Precision setting for a specific
structural safety valve and relieves that excess pressure
placing boom model is necessary.
at a controlled rate. A holding valve is installed at both
ends of the hydraulic cylinder to prevent movement If hydraulic oil is flowing out uniformly from the
and limit pressure in either direction. working line, this indicates that the check valve is not
sealing properly, or debris in the oil has caused the
If you should have a problem with a boom section
unlocking system to hang up and not allow the check
creeping, position the boom in an area which still
valve ball to seat. If there are any questions concerning
produces pressure in the corresponding cylinder but
holding valves or other areas of your Schwing
leaves the holding valve in an accessible area. Loosen
equipment that you need answered, contact your local
the fitting of the pressure connection of the working
Schwing dealer or Schwing America, Inc. for more
line and the leakage oil connection. With the hydraulic
information.
pump not turning, you will be able to see which portion
of the valve is leaking.
Service Manual 145

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SERVICE TRAINING
Hydraulic Parts
This style valve is used on 32 meter and 42 meter black and white untis on each boom cylinder.
It is also used on 42 meter proportional units for the first boom section only. it is either fully open
or fully closed.
B
Y
X
A Y
PROPORTIONAL HOLDING VALVE
P2 P2
X X
P1 P1
X
X
P1
P1
P2 P2
(SERIES 1) Valve at normal position, and/or holding a load. (SERIES 2) Valve in freeflow position, (P1 to P2).
P2
X
P1
X
P1
P2
S0118.eps
(SERIES 3) Valve in unlocking position, and metering a load.
146 Service Manual

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SERVICE TRAINING
Hydraulic Parts
KVM 52 HOLDING VALVE

UNLOCKABLE CHECK CARTRIDGE (RATIO = 8.8 to 1)
Part #995 050 004 282
Y(T)
A1
M A
A1 A
Y(T)
X
X
KVM 52 HOLDING VALVE RELIEF CARTRIDGE
Y(T)
X
M
Y(T)
A1 A A
M
X
S0119.eps
Service Manual 147

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SERVICE TRAINING
Hydraulic Parts
A1 A A1
A
X Y
KVM 52 HOLDING VALVE CARTRIDGE (SERIES #1)
A A1
A1
X Y
A
A1
A A1
A X Y

S0120.eps
148 Service Manual

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SERVICE TRAINING
Hydraulic Parts
Load Holding Valve/Brake Valve
A2 B2 1
3 5
A2
B2
EA EB
8 6 7 9
2 4
A1 T B1
6
7
8
9
S0137.eps
Service Manual 149

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SERVICE TRAINING
Hydraulic Parts
BRAKE VALVES
Sauer Brake Valve
Jam Nut
The "Z" screw adjusts how quickly

the boom STARTS moving when the
handvalve is activated.
B
R Z
Z The large screw

adjustment found under
this cap controls how
smoothly the boom
comes down. Adjust
clockwise if the boom
X A Y R comes down in jerks,
and counter-clockwise if
the boom is smooth but
The "R" screw adjusts how quickly very slow.
the boom STOPS moving once the
hand valve is released.
#1 Boom Raising
B
R Z
R
X A
T X A B T
#2 Boom Lowering
B
R Z
R
X A
T X A B T
#3 Return to
Neutral B
R Z
R
X A
T X A B T S0122.eps
150 Service Manual

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SERVICE TRAINING
Hydraulic Parts
Beringer Brake Valve
B
1
2
3
3
F
/D
F
1 2
X A S0124.eps
Service Manual 151

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SERVICE TRAINING
Hydraulic Parts
Slewing Brake Valves Flow When Lowering:

When the driven unit is supplied with fluid, the pilot
Boom Slewing Brake Valve - Rexroth Spec Sheet pressure acts on the spool area (6) through port A.
Model MHB 10 is a load lowering valve which When the pressure exceeds the opening force required
prevents a negative load from causing hydraulic motor by the spring, the load lowering spool (2) opens and
or cylinder “run away”, and allows hydraulically connects ports B2 to B1.
controlled, cavitation-free lowering operation. The valve opening is proportional to the opening
Basically they consist of a housing (1), load lowering pressure. When the pressure in the pilot line drops, the
spool (2), check valve (3), secondary relief valve (4) load lowering spool (2) is moved into a new position by
and spring (5). the spring. Thus, due to the force balance, an automatic
load lowering operation is achieved.
Any pressure spikes caused when the load is stopped
Free Reverse Flow:
are captured by the pressure relief valve (4).
Fluid may flow port B1 via the check valve (3) to port
Leak free closure:
B2 or to the driven unit.
When the pilot signal is removed and the check valve
closes: port B2 is sealed off from port B1
4
1 M
3
B2
A B1
5 S0126.eps
152 Service Manual

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SERVICE TRAINING
Hydraulic Parts
KVM 42 Slewing Brake Valve - Model 1E80
1.5 (38)
HEX.
3
PILOT
PORT
2
VALVE
PORT
1
CYLINDER
PORT
S0125.eps
Service Manual 153

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SERVICE TRAINING
Hydraulic Parts
Table 14: Slew Brake Valve (Proportional Units)

1 Valve Body Enclosure for the slewing brake cartridges and shuttle valve.
Allows free flow of hydraulic oil into the slewing brake when a
2 Throttle Check Valve slewing function is activated. Restricts the amount of flow return-
ing from the slewing brake.
Controls the slewing movement and prevents the slewing hydrau-

lic motor from running faster than the pump. This cartridge also
3 Slewing Brake Valve
has over pressure protection and helps hold the boom in position
along with the clutch disc brake
4 Blank Cartridge Used to seal off unused ports and passages in the valve body
The shuttle valve allows the highest pressure signal from either
5 Shuttle Valve
the “A” or “B” port to pass through the valve
When a slewing function is activated, pilot oil is sent to the right

6 Reversing Valve side of the reversing valve causing it to move over and suppling
pressure to release the slew brake.
154 Service Manual

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SERVICE TRAINING
Hydraulic Parts
A1 X B1
0 - 16
! ! bar
200 bar 200 bar
$ 14 bar

A # B
$
"
# !
"
!
S0127.eps
Service Manual 155

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SERVICE TRAINING
Hydraulic Parts
Table 15: Slew Brake Valve (Black & White Units)

1 Valve Body Enclosure for the slewing brake cartridges and shuttle valve.
Allows free flow of hydraulic oil into the slewing brake when a
2 Throttle Check Valve slewing function is activated. Restricts the amount of flow return-
ing from the slewing brake.
Controls the slewing movement and prevents the slewing hydrau-

lic motor from running faster than the pump. This cartridge also
3 Slewing Brake Valve
has over pressure protection and helps hold the boom in position
along with the clutch disc brake
4 Throttle Check Valves Used to control boom slewing times

5 Shuttle Valve
the “A” or “B” port to pass through the valve
When a slewing function is activated, pilot oil is sent to the right

6 Reversing Valve side of the reversing valve causing it to move over and suppling
pressure to release the slew brake.
156 Service Manual

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SERVICE TRAINING
Hydraulic Parts
A1 X B1
0 - 16
! ! bar
200 bar 200 bar
$ 14 bar

T
" # "
A B
$ "
# !
"
!
S0150.eps
Service Manual 157

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SERVICE TRAINING
Hydraulic Parts
Boom Regulator
∆ P regulator
X
20
bar ∆ P
290
bar
P
P
A T
(Series A) - NEUTRAL, Machine (Series B) - All functions in NEUTRAL, but

shut off, or E-stop button pushed down E-stop button is in the "UP" position.
Pressure Pressure
Regulator Regulator
P P
Regulator Regulator
X 0 Bar X 0 bar
0 Bar A T 20 Bar A T
ORIFICE
ORIFICE P 0.8 mm
KVM 36X . . . . 1.6 mm
P 0.8 mm
KVM 36X . . . . 1.6 mm 0 Bar 0-15 Bar
KVM 36 LW . . 1.6 mm KVM 36 LW . . 1.6 mm
KVM 42 . . . . . .1.6 mm KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used KVM 52 . . . . . .not used
(Series C) - Boom Moving (Series D) - Boom stopped because

cylinder is fully extended.
Pressure Pressure
Regulator Regulator
P P
Regulator Regulator
X 230 bar X 290 bar

250 Bar A T 290 Bar A T
ORIFICE P 0.8 mm ORIFICE P 0.8 mm

KVM 36X . . . . 1.6 mm 0-15 Bar KVM 36X . . . . 1.6 mm 0-15 Bar
KVM 36 LW . . 1.6 mm KVM 36 LW . . 1.6 mm
KVM 42 . . . . . .1.6 mm KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used KVM 52 . . . . . .not used
S01028
158 Service Manual

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SERVICE TRAINING
Hydraulic Parts
Counter Balance Valve
COUNTERBALANCE VALVE (SERIES 1)

A M
B M
X X
A
B
A M
B M
X X
A
B

A M
B M
X X
A
B

A M
B M
X X
A
B

A M
B M
X X
A
B

A M
B M
X X
A
B S0129.eps
Service Manual 159

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SERVICE TRAINING
Hydraulic Parts
Control Blocks
Table 16: Hi-Flow S1/S2 Control Valve

Transfers oil from the 350 bar main relief valve to the 80 bar
relief valve. This allows the brain to only build 80 bar of pressure
1 Soft Switch Cartridge
before the relief valve will open up, providing a smoother rock
valve switch.
A relief valve that opens up when pressure build higher than 80

2 Soft Switch Relief Cartridge bar and allows oil to escape to tank until 80 bar of pressure is
maintained.
A relief valve that opens up when pressure build higher than 350
3 Main Relief Cartridge bar and allows oil to escape to tank until 350 bar of pressure is
maintained.
Used in conjugations with the main relief cartridge and the soft
switch cartridge. When the soft switch circuit is not engaged, it
4 Poppet Valve will take 350 bar of pressure to open the poppet valve and allow
oil to drain to tank. When the soft switch circuit is engaged, the
poppet will open when pressure climbs above 80 bar.
Controls the Forward/Neutral/Reverse direction of the concrete

5 S1 Spool
pump, by redirecting the flow of hydraulic oil in the system.
Directs the hydraulic oil to either the left or right differential cyl-
6 S2 Spool inders. The spool is moved by pilot oil coming from the MPS
control block.
160 Service Manual

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SERVICE TRAINING
Hydraulic Parts
T
1
1.1
X3
2 X3 P2
X2 80 bar
T2
P
3
R XR
X1
MX 1.4 7
350 bar
T
4 X1
T1
1.2
T2 P1
MP
PP
XA
P1 P2
X
XP S1 XR
P
0.7
0.7
mm
PP 6 5
PR
mm
A
XB XA 3.0
B
XB
3.0 S2
mm mm
B1 A1
B A
7 3
S0132.eps
Service Manual 161

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SERVICE TRAINING
Hydraulic Parts
Table 17: Single Circuit

Controls the Forward/Neutral/Reverse direction of the concrete
1 S1 Spool
pump, by redirecting the flow of hydraulic oil in the system.
Directs the hydraulic oil to either extend or retract the “Rock

Valve” or to shift the gate valves, depending on which valve is
2 S3 Spool
used. This spool is activated by pilot oil coming from the differ-
ential cylinders.
Directs the oil to cycle the differentail cylinders, this spool is acti-
3 S2 Spool
vated by pilot oil coming from the rock valve or gate valve.
Limits maximum pressure in the control block- When pressure

4 Main Relief Valve reaches over 300 bar, the relief valve will open and allow oil to
162 Service Manual

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SERVICE TRAINING
Hydraulic Parts
P1
S3 P2
X
P
1.5 mm
T
hole drilled
through spool
2
S1 1
X
R
B
3
300 bar
4 A
S2
Port size
limits flow
S-1
S-2
S-3
S0133.eps
Service Manual 163

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SERVICE TRAINING
Hydraulic Parts
S3/Accumulator Valve
Machined Block
Table 18: Accumulator Valve - Machined block

1 S3 Spool Valve”. This spool is activated by pilot oil coming from the MPS
valve.
Allows free flow of oil into S3 valve, while preventing oil from
2 Check Valve
escaping, during Accumulator discharge
When pressure enters through the “P” port, a signal line is sent to
the Hydraulically Lockable Check Valve. Pressure from the sig-
3 Hydraulically Lockable Check Valve nal line holds the checkvalve shut, preventing oil from escaping
to tank. If no pressure is applied the checkvalve is free to be
opened, allowing oil to escape to tank.
When the unit is shut-off, pressurized oil can remain trapped in

4 Manual Bleed Valve the accumulator valve. When opened the Manual Bleed valve
allows oil to escape to tank.

5 Relief Valve reaches over 300 bar, the relief valve will open and allow oil to
Drops the pressure of the hydraulic oil before it passes through

6 2.0 mm Orifice
the Hydraulically Lockable Check Valve
Controls the oil flowing through the S3 control block, determin-

ing the speed of the Rock Valve shift. With a larger orifice, the
7 8.0 mm Orifice
Rock Valve will shift faster, a smaller orifice, the Rock Valve will
switch slower.
164 Service Manual

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SERVICE TRAINING
Hydraulic Parts
A B
B
A1 B1
X
1
B
1
XA S3 XB B
A
T
1
A
7 8.0
1
P
S
M
mm
P
M
Psp Mp1
X
2.0 T
mm 6 300 Mp
bar
T
P
3 4 5
P
PS
2
3
6
2 4
S0153.eps
Service Manual 165

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SERVICE TRAINING
Hydraulic Parts
Table 19: Accumulator Valve - Cast block

1 S3 Spool Valve”. This spool is activated by pilot oil coming from the MPS
valve.
When pressure enters through the “P” port, a signal line is sent to
the Hydraulically Lockable Check Valve. Pressure from the sig-
Hydraulically Unlockable Check
2 nal line holds the checkvalve shut, preventing oil from escaping
Valve
Allows free flow of oil into S3 valve, while preventing oil from
3 Check Valve
escaping, during Accumulator discharge
When the unit is shut-off, pressurized oil can remain trapped in

4 Manual Bleed Valve the accumulator valve. When opened the Manual Bleed valve
allows oil to escape to tank.

5 Relief Valve reaches over 330 bar, the relief valve will open and allow oil to
Controls the oil flowing through the S3 control block, determin-

ing the speed of the Rock Valve shift. With a larger orifice, the
6 6.5 mm Orifice
Rock Valve will shift faster, a smaller orifice, the Rock Valve will
switch slower.
Drops the pressure of the hydraulic oil before it passes through

7 2.0 mm Orifice
the Hydraulically Lockable Check Valve
166 Service Manual

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SERVICE TRAINING
Hydraulic Parts
1
B
X
3
B
A3 A2 B2 B3
B
XA1
1
S3 A
XB1
2
P
1 A
S
M
T3
3
P
S
M
P
M
MSP3
T
A
6 6.5
X
SP mm MSP2
SP
2 2.0 5
bar mm 7 MSP1
TUV
3 2 330
P 4 bar
P P1
MP
T T MS
1
7
2
5
S0154.eps
Service Manual 167

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SERVICE TRAINING
Hydraulic Parts
Stroke Limiters
Table 20: Stroke Limiter

1 Pressure Reducing Valve Reduces the pressure coming from the “P” port to 70 bar.
The spring is set to collapse at 70 bar, but can be adjusted to col-

2 Adjustable Spring
lapse either at a higher or lower setting
A solenoid that allows for variable current levels to move the

3 Proportional Solenoid
pressure reducing valve to the desired pressure.
Reduces the pressure of the hydraulic oil, in accordance to how

4 Pressure Reducing Valve
much current is being sent to the solenoid valve
168 Service Manual

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SERVICE TRAINING
Hydraulic Parts
Remote controlled
stroke limiter
T
1
3
P
2 70
B bar 4
3
4
S0140.eps
B P A
1
Service Manual 169

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SERVICE TRAINING
Hydraulic Parts

1 Valve Body Encloser for the electric pressure reducing cartridge

much current is being sent to the solenoid valve. (Used as a stroke
2 Pressure reducing valve (Electric)
limiter to destroke the hydraulic pumps to control concrete vol-
ume)
3 Valve Body Encloser for the stroke limiter cartridge
Allows system pressure to be reduced from 0 to 55 bar, in accor-

dance to the tension setting of the spring. (Used to supply supple-
4 Pressure reducing valve (Manual)
mental pressure to the hydraulic pumps so the stroke limiter can
be used at lower operating pressures)
170 Service Manual

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SERVICE TRAINING
Hydraulic Parts
4 T
Pressure P
reducing
valve 55 bar
2 T
A
1
A
Electric
stroke limiter
14
3*
S0134.eps
* Twin Circuit units only
Service Manual 171

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SERVICE TRAINING
Hydraulic Parts
Table 22: Stroke Limiter (German)

Switches the stroke limiter from electronic control to manual
1 Manual Directional Valve
control for emegency operation.

2 Pressure Reducing Valve(Manual)

3 Pressure Reducing Valve (Electric)
ume)
4 Gauge Port (MG2) Used to check the pressure
When the Manual Directional Valve is switched to the manual

control position, signal pressure is bleeded back to tank through
6 Orifice the orifice. If signal pressure were to remain, the shuttle valve
may not seat properly when the Manual Directional Valve is
switched back to the electronic control postion.
Supplies a passage way for oil to escape in the event of a system

7 Check Valve
shutdown (E-stop button pressed)
172 Service Manual

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SERVICE TRAINING
Hydraulic Parts
4 G2
MG2
3
0-30
bar
1 X1
MX1
3.5-55
bar 5
7 2 MG1
MP
PBP PZ T
5 7
S0135.eps
Service Manual 173

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SERVICE TRAINING
Hydraulic Parts
Table 23: Stroke Limiter with Dampner(German)

Switches the stroke limiter from electronic control to manual
1 Manual Directional Valve
control for emegency operation.
Allows system pressure to be reduced from 3.5 to 40 bar, in

accordance to the tension setting of the spring. (Used to supply
2 Pressure Reducing Valve (Manual)
supplemental pressure to the hydraulic pumps so the stroke lim-
iter can be used at lower operating pressures)

ume)
Blocks the output of the stroke limiter valve (manual or electric)

6 Fast Switch Valve to the X1 port of the hydraulic pump. Allowing the hydraulic
pumps to put out maximum flow during Rock valve shifting.
Allows pressure to be reduced from 3.5 to 40 bar, in accordance

7 Pressure Reducing Valve (Dampener) to the tension setting of the spring. Prevents damage caused by
excessive speed and acceleration during Rock valve shifting.
8 Shuttle Valve
the Dampener or Stroke limiter to pass through the valve
9 Shuttle Valve
the Dampener or Stroke to pass through the valve
When the Manual Directional Valve is switched to the manual

control position, signal pressure is bleeded back to tank through
10 Orifice (0.7) the orifice. If signal pressure were to remain, the shuttle valve
may not seat properly when the Manual Directional Valve is
switched back to the electronic control postion.
When signal pressure opens the reversing valve (item 6), the ori-
fice is small enough, that it doesn’t effect the signal. When the
11 Orifice (0.7)
signal is lost, oil bleeds back to tank through the orifice. This
assists in returning the reversing valve to the at rest position.P
Supplies a passage way for oil to escape in the event of a system

12 Check Valve
shutdown (E-stop button pressed)
174 Service Manual

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SERVICE TRAINING
Hydraulic Parts
MG2 G2 6
11
3
20 0.7
bar
0-30
bar
1 9 X1
MX1
3.5-40 8
12 bar
2 10 MG1 5
0.7
MP 3.5-40
bar
7
7
6 PBP PZ T
8
4
9
2
12
1
10
11
S0152.eps
Service Manual 175

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SERVICE TRAINING
Hydraulic Parts

ume)

Used to check the pressure after it has passed through the manual
3 Gauge Port “MG”
pressure reducing valve
Used to check the pressure after it has passed through the electric
4 Gauge Port “MY”
stroke limiter valve
5 Gauge Port “P” Used to check the system pressure going into the stroke limiter
6 Valve Block Enclosure that houses the pressure reducing valves
176 Service Manual

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SERVICE TRAINING
Hydraulic Parts
5
P
P
T 2 T
Pressure 6
reducing
valve 55 bar
1
G Electric
stroke limiter
Y
MG 3
MY 4
11
T
T
P 3
5 MG
P
G
MY Y
S0136.eps
Service Manual 177

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SERVICE TRAINING
Hydraulic Parts
Table 25: E-Stroke Limiter

ume)

Used to check the pressure after it has passed through the manual
3 Gauge Port “MG”
pressure reducing valve
Used to check the pressure after it has passed through the electric
4 Gauge Port “MY”
stroke limiter valve
5 Gauge Port “P” Used to check the system pressure going into the stroke limiter
6 Valve Block Enclosure that houses the pressure reducing valves
178 Service Manual

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SERVICE TRAINING
Hydraulic Parts
6
T T
5
P 2 1 P
MG 7-105 bar 0-35 bar MY
3 G Y 4
2
6
1 5
S0160.eps
Service Manual 179

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SERVICE TRAINING
Hydraulic Parts
Outrigger Handvalves
Table 26: Outrigger Valve 45/47

being used.
Limits maximum pressure in the hand valve- As pressure reaches

1 Main Relief Valve over 300 bar, the relief valve will open and allow oil to be re-
Limits the amount of pressure going to the hose reel motor to 200
bar. As pressure rises to 200 bar, the relief valve opens and allows
2 Hose Reel Motor Relief Valves
pressure to be re-directed to tank, until the pressure drops below
200 bar. The relief valves protects the hose reel motor.
Outrigger Slewing/350 bar Second-

3 Protects hydraulic cylinders and structure from damage
ary Relief Valve
Directs hydraulic oil from the hydraulic pump to activate an out-

4 Spool
rigger function
A special fitting that blocks the system pressure flowing through

5 Fitting - Power Beyond the hand valve from returning to tank and instead allow the oil to
flow through the hand valve and unto the next one.
180 Service Manual

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SERVICE TRAINING
Hydraulic Parts

!
300
# 200 350 " bar
bar bar
P1
C )
*
T A4 B4 A3 B3 A2 B2 A1 B1
"
S0139.eps
Service Manual 181

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SERVICE TRAINING
Hydraulic Parts
Table 27: Outrigger Handvalve 52/55

being used.

1 Main Relief valve over 150 bar, the relief valve will open and allow oil to be re-
directed to tank until the proper pressure is maintained

2 Spool
rigger function
The spring returns the spool to the neutral position when a func-
3 Spring
tion in no longer being activated

ary Relief Valve
Limits the amount of pressure used to extend the Outrigger
Extension Cylinder to 50 bar, As the pressure rises to 50 bar, the
Extension Cylinder Relief Valve -
5 relief valve will open - allowing oil to be re-directed to tank, until
Piston Side
the 50 bar pressure is maintained. This relief valve protects the
extension cylinder from being damaged

6 Spool
rigger function
7 Handle Manual override which provides a direct link to the main spool

182 Service Manual

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SERVICE TRAINING
Hydraulic Parts
150
1 4 4 5
bar 350 350 50
2
bar bar bar
P C
A 8
6
3 7
B
A1 B1 A2 B2 A3 B3 A4 B4 A5 B5 T
5 1
4
3
2
S0142.eps
Service Manual 183

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SERVICE TRAINING
Hydraulic Parts
Table 28: Outrigger Handvalve 58/61 Passenger Side

being used.
Used to control the speed of the front outrigger extension and

1 Throttle Check Valves
retraction.
2 Hose Reel Motor Extends and retracts the hose reel, when activated.

3 Spool
rigger function
5 Spring/Mechanical Stop tion in no longer being activated. The mechanical stop limits the
maximum travel of the spool.

ary Relief Valve
Outrigger Jacking/210 bar Secondary

Relief Valve
9 Throttle Check Valves Used to control the speed of the rear outrigger slewing
When pressure flows through the “A1” port, the checkvalve is

opened allowing oil into the rod side of the piston. A signal line is
also sent to the piston side Hydraulically Lockable Check Valve.
10 Pressure from the signal line holds the piston side checkvalve
valves
open, allowing oil from the piston side of the cylinder to escape
184 Service Manual

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SERVICE TRAINING
Hydraulic Parts
Rear Front
Front
A A
Rear
B B
10 10 2
1
1
9 9
A1 B1 A2 B2 A3 B3 A4 B4 T
4 4 4 4
B 3 3 3 3
P
350
7 7
A 210 210
bar bar bar
200 200
5 5 8 5 8 5 bar bar
6
7
8
10
10 5
9 9
1
4
1 2
S0155.eps
Service Manual 185

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SERVICE TRAINING
Hydraulic Parts
Table 29: Outrigger Handvalve 58/61 Driver Side

A Open Center Passag
being used.
Used to control the speed of the front outrigger extension and

1 Throttle Check Valves
retraction.
2 Hose Reel Motor Extends and retracts the hose reel, when activated.

3 Spool
rigger function
5 Spring/Mechanical Stop tion in no longer being activated. The mechanical stop limits the
maximum travel of the spool.

ary Relief Valve
Outrigger Jacking/210 bar Secondary

Relief Valve
9 Throttle Check Valves Used to control the speed of the rear outrigger slewing
When pressure flows through the “A1” port, the checkvalve is

opened allowing oil into the rod side of the piston. A signal line is
also sent to the piston side Hydraulically Lockable Check Valve.
10 Pressure from the signal line holds the piston side checkvalve
valves
open, allowing oil from the piston side of the cylinder to escape
Limits maximum pressure in the hand valve- As pressure reaches

186 Service Manual

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SERVICE TRAINING
Hydraulic Parts
8 200 200 7
350 5 8 5 5 bar bar
5
bar 310
210 210 bar
6 bar bar 7 11
C
3 3 3 3
T
4 4 4 4
T A4 B4 A3 B3 A2 B2 A1 B1
9 9
1 1
A A
B B
10 10 2
Front Front
Rear
Rear
7
8
10
10
5
9 9
11
1
4
1 2
S0156.eps
Service Manual 187

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SERVICE TRAINING
Hydraulic Parts
Table 30: Outrigger Handvalve

being used.

directed to tank until the proper pressure is maintained
2 Check Valve in Pressure Passage Restricts any back flow in the pressure passage
Limits the maximum amount of spressure in a specified port to

3 Port Relief Valve
190 bar

6 Spring
188 Service Manual

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SERVICE TRAINING
Hydraulic Parts
280
bar 1 3
4
A 5
P
T
190 190 190 190
bar bar bar bar
B 6 2
S0143.eps
Service Manual 189

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SERVICE TRAINING
Hydraulic Parts
Table 31: Outrigger Handvalve

being used.

1 Main Relief Valve over 280 bar, the relief valve will open and allow oil to be direct-
ede to tank until the proper pressure is maintained
Limits the maximum amount of spressure in a specified port to

2 Port Relief Valve
140 bar
Limits the maximum amount of spressure in a specified port to 80

3 Port Relief Valve
bar
4 Check Valve in Pressure Passage Restricts any back flow in the pressure passage
5 Spring
A special fitting that allows the oil from the open center passage
6 Fitting - Power Beyond to be directed to another handvalve rather than back to tank. The
oil in the handvalve is re-directed to an auxiliary tank port
190 Service Manual

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SERVICE TRAINING
Hydraulic Parts
# *
"
80 140 80 140
$ bar bar bar bar )
P
P1 280
bar
! !
T
"
$
S0144.eps
Service Manual 191

HOME PRINT
SERVICE TRAINING
Hydraulic Parts
E-Stop Manifolds
Table 32: E-Stop Manifold

Limits maximum pressure in the E-stop block - When pressure
Pressure Relief Valve with external
1 reaches over 330 bar, the relief valve will open and allow oil to
drain and solenoid
escape to tank until the proper pressure is maintained
When a signal is sent to the solenoid valve, the dump valve will
move into the closed position and block the hydraulic oil from
Dump Valve - Solenoid Operated/ escaping to tank. When no signal is sent to the solenoid, the
2
Spring Return spring on the valve will return it to the open position, allowing the
hydraulic oil to escape to tank. This will disengage the concrete
pump
When the dump valve is closed, the relief valve will limit the
3 Secondary Pressure Relief Valve amount of pressure in the E-stop manifold, to the set amount of
the relief spring. (Example 260 bar)
When a signal is sent to the solenoid valve, the dump valve will
move into the closed position and block the hydraulic oil from
Dump Valve - Solenoid Operated/ escaping to tank. The oil will then be allowed to flow to the S3
4
Spring Return control block. When no signal is sent to the solenoid, the spring
on the valve will return it to the open position, allowing the
hydraulic oil to escape to tank. This will disengage the rock valve
192 Service Manual

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SERVICE TRAINING
Hydraulic Parts
see concrete
pump schematic
Emergency stop manifold
P1 MP1 P3 MP3 P2 MP2 10047
1 2 3 4
330
bar
2
1
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Hydraulic Parts

1 Redundant Relief Valve amount of pressure in the E-stop manifold, to the set amount of
This valve works in conjuction with the Solenoid/Manual Dump

Valve (Item#4). When this valve is open pilot pressure cannot
2 Dump Valve - Pilot Operated build on the spring side of the dump valve. Pressure from the con-
crte pump will force the valve open and allow the oil to flow to
tank.

Valve (Item#4). When this valve is open pilot pressure cannot
3 Dump Valve - Pilot Operated build on the spring side of the dump valve. Pressure from the
water pump and agitator will force the valve open and allow the
oil to flow to tank.
Normally closed when in operation. When a signal is no longer

Dump Valve - Solenoid/Manual being sent to the solenoid, the valve will open allowing pilot pres-
4
Operated - Spring Return sure within the block to be lost. This will allow the dump valves
(Item#2 and #3) to open and dump the system pressure to tank.
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Hydraulic Parts
C B A
250 bar 10045
1 2
4
3
E
OR
A
E
D
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Hydraulic Parts

1
2 Dump Valve - Pilot Operated Not used in this application
This relief is set higher the than maximum operating pressure

Redundant Relief Valve for the Boom
3 which could be set by a relief valve or pressure cutoff on the
System
pump

Valves (Items#1 and #6). When this valve is open pilot pressure
4 Dump Valve - Pilot Operated cannot build on the spring side of the dump valve. Pressure from
the water pump and agitator will force the valve open and allow
the oil to flow to tank.

Valves (Items#1 and #6). When this valve is open pilot pressure
5 Dump Valve - Pilot Operated cannot build on the spring side of the dump valve. Pressure from
the concrte pump will force the valve open and allow the oil to
flow to tank.

6
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SERVICE TRAINING
Hydraulic Parts
See boom
schematic
D C B A
250
10037
1 2 bar 4 5 6
E F
OR
4
5
A
E
F
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Hydraulic Parts

When energized the Directional Spool Valve will open a passage
way for the oil coming from the P1 port to the spring side of the
poppet valve. This pressure along with the spring will force the
poppet valve shut, allowing oil to flow to the boom system. When
1 Directional Spool Valve de-energized the Directional Spool Valve will block the flow of
oil to the spring side of the poppet valve. With no pressure on the
spring side of the poppet valve. Oil from the P1 port will open the
poppet valve and will be routed to tank. This will disable the
boom system.
way for the oil coming from the P2, P3 & P4port to the spring
side of the poppet valve. This pressure along with the spring will
force the poppet valve shut, allowing oil to flow to the concrete
2 Directional Spool Valve pumping system. When de-energized the Directional Spool Valve
will block the flow of oil to the spring side of the poppet valve.
With no pressure on the spring side of the poppet valve. Oil from
the P2 & P3 ports will open the poppet valve and will be routed to
tank. This will disable the concrete pumping system.
3 Orifice Restricts the flow of oil
The poppet valve will open, allowing oil from the P1 port to be
4 Poppet Valve
routed to tank. This will disable the boom system
When the dump valve is closed, pressure on the spring side of the
poppet valve is no longer available. When pressure from the P1
6 Poppet Valve port becomes greater than the spring tension. The poppet valve
will open, allowing oil to escape to tank, thus disabling the sys-
tem.

System
pump
9 Check Valve Allows free flow of oil into the E-stop manifold
12 Gauge Port (MP5) Used to check the pressure on the P3 Port
13 Gauge Port (MP2) Used to check the pressure on the P2 Port
14 Secondary Pressure Relief Valve amount of pressure in the E-stop manifold, to the set amount of
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Hydraulic Parts
Emergency stop
1 3 1 3
manifold
2 2
2 1
1.6 5 1.6 3
MP5 0.9 0.9

7 6 7 4
12
T 260 8
11 10 9 bar
13
14
MP2
P4
P3
P2
MP1
P1
See boom schematic
10 9 6
11
5 1
14 7
4
12
13
T
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Hydraulic Parts

System
pump
The poppet valve will open, allowing oil from the P2 and P3 port
2 Poppet Valve to be routed to tank. This will disable the concrete pumping sys-
tem
The poppet valve will open, allowing oil from the P1 port to be
3 Poppet Valve
routed to tank. This will disable the boom system

way for the oil coming from the P2 & P3 port to the spring side of
the poppet valve. This pressure along with the spring will force
the poppet valve shut, allowing oil to flow to the concrete pump-
4 Directional Spool Valve ing system. When de-energized the Directional Spool Valve will
block the flow of oil to the spring side of the poppet valve. With
no pressure on the spring side of the poppet valve. Oil from the
P2 & P3 ports will open the poppet valve and will be routed to
tank. This will disable the concrete pumping system.

way for the oil coming from the P1 port to the spring side of the
poppet valve. This pressure along with the spring will force the
poppet valve shut, allowing oil to flow to the boom system. When
5 Directional Spool Valve de-energized the Directional Spool Valve will block the flow of
oil to the spring side of the poppet valve. With no pressure on the
spring side of the poppet valve. Oil from the P1 port will open the
poppet valve and will be routed to tank. This will disable the
boom system.
6 Gauge Port Used to check the pressure of the P2 port
7 Gauge Port Used to check the pressure of the P3 port
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Hydraulic Parts
1 3 1 3
2 2
4 5
1.6 11 1.6 12
0.9 0.9
2 3
T 8 8
1
MP2
6 10 9
7
MP3 MP1
P2 P3 P1
See boom schematic
11
8 12
9
8
10
7
6
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Hydraulic Parts
Table 37: 2023-4 Hydraulic Pumps

A7V0107LRH1 Variable displacement hydraulic pump that supplies hydraulic oil
A
Variable Displacement pump to the pumpkit
A7V0107LRH1 Variable displacement hydraulic pump that supplies hydraulic oil

B
Variable Displacement pump to the pumpkit
A7V055D RG
C Proportional boom pump
Variable Displacement pump
A10VO28DR
D Accumulator pump
E W9A2-31-11-R-3-F-27/24-NN Agitator Pump

F W9A2-31-11-R-3-F-27/24-NN Oil cooler pump
A valve containing two spools. the 300 bar pressure regulator

G Pressure Regulator Valve
spool and the 20 bar Delta P spool.
The valve compares pressure before and after the orifice and
maintains the pressure drop (differential pressure ∆p) across the
orifice – and therefore the pump flow – constant. If differential
1 Delta P (20 bar) Spool
pressure ∆p increases, the pump is swivelled back towards Vg min,
and if ∆p decreases the pump is swivelled out towards Vg max until
a balance is restored within the valve.
The load sensing valve is a flow control valve which operates as a

function of the load pressure to regulate the pump displacement
Pressure Regulator Spool in order to match the requirement of the actuator. The pump flow
2
(load sensing valve) is influenced by the external orifice (control block, throttle) fitted
between pump and actuator, but is not affected by load pressure
throughout the range below the set pressure.
The pressure compensator serves to maintain a constant pressure

in the hydraulic system, within the control range of the pump.
3 Pressure Compensator
The pump therefore supplies only the amount of hydraulic fluid
required by the actuators.
The hydraulic stroke limiter is used to smoothly adjust the flow

between Vg max and Vg min. The power control overrides it.
Stroke Regulation/Begining of
4 Displacement is set by the pilot pressure existing at port X1.
Regulation Spring
The hydraulic stroke limiter takes the required positioning
pressure from the high pressure.
The Horsepower spool controls the output flow of the pump in

relation to the pressure so that the power of the drive unit is not
Horsepower Spool exceeded. As the pressure increase, the Horsepower Spool will
5
(Constant Power) open, allowing a passage way for oil to move through the Horse-
power Spool and push against the swashplate piston, destroking
the pump.
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Hydraulic Parts
X1
1 X
A 20 bar
Y3
A1
2 A
300 bar
T A1
P 4
A
X3
G See Detail 1
C
5
S
A
Detail 1 Rexroth
A7VO-LRDH
Hydraulic pumps
X1
Y3
A
A1
F E 3
4
200 bar
5
D S
B
2 4
G A
5
4
1 5
B
F 3
E
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Hydraulic Parts

A11VO130LRDH1
A Pumpkit
A11VO130LRDH1
B Pumpkit
A11VO60DRS
C Proportional Boom pump
A10VO28DR
D Accumulator pump

F W9A2-31-11-R-3-F-27/24-NN Oil Cooler Pump
Horsepower Spool exceeded. As the pressure increase, the Horsepower Spool will
1
(Constant Power) open, allowing a passage way for oil to move through the Horse-
the pump.
Pressure cut-off corresponds to a pressure control which adjusts

2 Pressure Cut-off (350 bar) the pump displacement back to Vg min when the pressure signal
reaches 350 bar.
When the pressure signal from the stroke limiter exceeds the
Stroke Regulation pressure spring. The Stroke Regulation spool
3 Stroke Regulation
will open, allowing a passage way for the oil to move through the
Stroke Regulation spool
4 Delta-P Spool
The load sensing valve is a flow control valve which operates as a

function of the load pressure to regulate the pump displacement
in order to match the requirement of the actuator. The pump flow
5 Pressure Regulator Spool
is influenced by the external orifice (control block, throttle) fitted
between pump and actuator, but is not affected by load pressure
throughout the range below the set pressure.

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Hydraulic Parts
M A Z G T1 RZ T2 Y M A G T1 R T2 Y
2 2
see see
note note
3 3
See boom
schematic 1 1
F E
D C
B A
Hydraulic pumps are Note
6 limited to noted pressures Pressure settings:
by pressure cutoff.
2023 = 350 bar
2020 = 328 bar
200 bar
C
T2 T1 X G A M
20 bar ∆ P
310 bar
5
1 2
M
3 A11VO
170 l/m
1 2 M1 S
3
A 5
4
B
C
E
F
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Hydraulic Parts

A11VO190LRDH1
A Pumpkit
B A11VO190LRDH1/11RNZD12K83 Pumpkit
C A11VO60DRS/10RNZC12K02 Proportional Boom Pump
D A10VO28DR/31R-PSC62K01 Accumulator Pump
F W9A2-31-11-R-3-F-27/24-NN Oil Cooler Pump
G W9A2-31-11-R-3-F-27/24-NN Oil Cooler Pump

1 Pressure Cut-off (330 bar) the pump displacement back to Vg min when the pressure signal
reaches 350 bar.

exceeded. As the pressure increase, the Horsepower Spool will
2 Horsepower Control
open, allowing a passage way for oil to move through the Horse-
the pump.
When the pressure signal from the stroke limiter exceeds the
Stroke Regulation pressure spring. The Stroke Regulation spool
3 Stroke Regulation
will open, allowing a passage way for the oil to move through the
Stroke Regulation spool
4 Delta-P


6 Pressure Cut-off the pump displacement back to Vg min when the pressure signal
reaches 200 bar.
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Hydraulic Parts
Y T2 R T1 G Z A M Y T2 R T1 G Z A M
1 1
see see
note note
3 3
2 2
E F G
C
200 bar
A M1 S
B M1 S 6
Note: Pressure in A11VO-LRDH hydraulic

pumps are limited by pressure cutoff. This
configuration set at 330 bar. Other
configurations have other pressure ratings.
C
T2 T1 X G A M
20 bar ∆ P
5 310 bar
M
2 A11VO
3 1
170 l/m
M1 S
3 2
1
5 4
A 6
C
D
E
F
G S0159.eps
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Hydraulic Parts
208 Service Manual

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SERVICE TRAINING
Pressure Settings
Pressure Settings
General
Stroke Limiter Adjustment
Override
Button
Pressure Reducing Valve

Pressure Adjustment
B P A
Remote controlled
stroke limiter
P
Output to hydraulic pumps 70
A
via dampner shuttle valve B bar
A
B
C
Line from manual

A
stroke limit valve

B
C
Adjustment Procedure
1. Disconnect line at A port of shuttle valve and install a 0-200 bar gauge in the end of the hose.
2. Push override button in all the way.
3. Pressure out pumpkit.
4. Set relief valve to 70 bar.
5. Set max. pressure on computer card for 35-40 bar with override button de-activated and the stroke limit
knob on remote box at min. strokes.
HOME PRINT
Pressure Settings
Check the accumulator Pre-Charge
After charging an accumulator that has had no initial
gas pre-charge, allow 20 to 30 minutes for the gas
temperature and pressure to stabilize. Recheck the gas
WARNING
pre-charge pressure and adjust if necessary.
EXPLOSION CAUSED BY
After the accumulator has been put in service it is
important that the pre-charge pressure is checked at
IMPROPER ACCUMULATOR
least once in the first week to verify the initial pre- CHARGING CAN RESULT IN
charge has not changed due to temperature and DEATH OR SERIOUS INJURY!
pressure stabilization. If the check reveals no loss in
pressure, the pre-charge should be checked on the * Follow the charging instructions exactly!
following schedule: * Use ONLY dry nitrogen to charge the
• 1st Check - 1 week accumulator!
* NEVER use oxygen or compressed air to
• 2nd Check - 3 months
charge the accumulator!
• 3rd Check - 1 year
• 4th Check and continued - yearly
Read all instructions for charging accumulators before
beginning the charging procedure. Accumulators must
be charged only with dry nitrogen. Compressed air and
oxygen must never be used, because oxygen molecules
combine with hydraulic oil, lower the flash point of the
oil to less than room temperature, and cause an
explosion. Workers have died using compressed air or
oxygen to charge accumulators (Figure 40). Use only
dry nitrogen, never liquid nitrogen.
explwarn.eps
Figure 40
Charging accumulators
improperly can cause injury or
death
The procedure for checking the accumulator charge

pressure and the procedure for charging the
accumulator are described in the following steps:
1. Before you begin, you will need a charging kit
(Figure 41). Do not attempt to charge the
accumulators without one. Order the charge valve
assembly from Schwing America using part
number 30355436.
2. You must use a high-pressure regulator with the
nitrogen bottle. If it was not supplied with the
bottle, order one before proceeding with this job.
Before beginning the charging procedure, stop the
engine, remove the key, and put a “Do Not Operate”
tag over the key switch. Put the key in your pocket, so
no one can start the engine
HOME PRINT
SERVICE TRAINING
Pressure Settings
Tank Regulated High pressure gas 45s3blck.epsL
Pressure Pressure regulator is not

included with the
kit. These are
available from the
nitrogen supplier.
Nitrogen Bottle
charge valve assy

100 150
1500 2000
1000 2500
50 200
3000
500
3500
hose
0 250
30355456
accuman1.eps
BPL
ACCUMULATOR CHARGING KIT
HYDAC bladder (Includes hose and charge valve assy)
Accumulator
SCHWING PART NUMBER:
30355436
chargkit.eps
Figure 41
Accumulator charge kit for HYDAC

bladder accumulators

.
3. The accumulators should dump pressure when the

engine is stopped, but you must still verify zero
accumulator pressure. Dump the accumulator
pressure using the manual bleed valve on the

acc
um
ma
accumulator unloading valve (Figure 42). Verify nifo

ld.e

ps
zero accumulator pressure on the concrete pump’s

accumulator pressure gauge.

S0106.eps
Figure 42
Accumulator manual bleed valves
4. Refer to Figure 13 for component location on the

charge valve assembly while performing the
following steps.
HOME PRINT
Pressure Settings
Tank Regulated
Pressure Pressure
Nitrogen Supply Valve
Regulator Adjustment
Handle
Nitrogen Bottle
Push Button
Pressure Gauge
100 150
Charge Valve Stem
1500 2000
1000 2500
50 200
3000
500
3500
0 250
Bleed Swivel Nut

Valve
HYDAC bladder
Accumulator
chgvalve.eps
Figure 43
Charge valve assembly
HOME PRINT
SERVICE TRAINING
Pressure Settings
5. Remove the valve protection cap and the valve seal 9. Be sure that the nitrogen bottle supply valve is
cap from the accumulator (Figure 44). Leave the firmly closed. Attach the high-pressure regulator to
valve protection cap on the accumulator until you the nitrogen bottle, then attach the hose to the high-
actually begin the procedure. pressure regulator. Finally, attach the other end of
the hose to the charge valve stem on the charge
valve assembly (Figure 43.
10. Do not open the nitrogen bottle supply valve yet.
Valve Protection Cap Turn the regulator adjustment handle on the high-
pressure regulator (Figure 43) counter clockwise to
its minimum setting (closed).
11. Slowly open the nitrogen bottle supply valve
(Figure 43). You will get a reading on the tank
Valve Seal Cap pressure gauge side of the regulator. If there is
enough pressure in the nitrogen bottle to do the
job, proceed to Step 13.
Valve Stem NOTE!
O-ring
If there is not at least 1450 PSI in the
nitrogen bottle (as shown on the regulator
gauge at this time), you will not be able to
charge the accumulator nitrogen to the 1450
PSI specification. If that is the case, you will
need a new bottle of nitrogen before
HYDAC bladder proceeding.
Accumulator 12. Adjust the regulator adjustment handle clockwise,
accum closeup
raising the regulated pressure. The accumulator
will begin to fill. Continue filling until the charge
Figure 44 valve assembly pressure gauge (Figure 43) reads
Detail of accumulator the desired pressure of 1450 PSI. Close the
gas valve area nitrogen bottle supply valve.
13. If you overcharge the nitrogen pressure, refer to
(Figure 43) and proceed as follows:
6. On the charge valve assembly (Figure 43, close the
bleed valve (turn it clockwise all the way in). If a • Close the nitrogen bottle supply valve.
hose is connected to the charge valve stem, • Depress the push button on the top of the charge
disconnect the hose from the charge valve stem. valve assembly.
This step closes the charge valve stem to prevent • Slowly open the bleed valve on the charge kit.
the gas pressure from escaping out of the hose. It Close the bleed valve when the correct pressure is
ensures that the initial pressure reading is accurate. reached on the charge valve pressure gauge.
7. Find the swivel nut on the charge valve assembly NOTE!
(Figure 43). Screw the swivel nut onto the Never let nitrogen out of the accumulator by
accumulator gas valve. Tighten to 10–15 in./lb. pressing the gas valve pin with a foreign
8. After the swivel nut is attached, depress the push object. The high pressure may rupture the
button on the top of the charge valve assembly valve seal!
(Figure 43). This presses a pin into the accumulator 14. Let the nitrogen sit in the accumulator for 10 to 15
gas valve and opens it. Read the pressure on the minutes. This allows the gas temperature to
charge valve assembly pressure gauge. The stabilize. Depress the push button on top of the
pressure should read 100 bar (1450 PSI). charge valve assembly. Recheck the pressure on
• If pressure must be added, proceed to Step 10. the charge valve assembly pressure gauge.
• If pressure is too high, skip to Step 14.
• If no adjustment is necessary, skip to Step 17.
HOME PRINT
Pressure Settings
15. Add or release nitrogen until the pressure is
correct. Be sure that the bleed valve is closed
before adding pressure and that the nitrogen bottle
supply valve is closed before releasing pressure.
16. When the correct pressure is reached, refer to
(Figure 43) and proceed as follows:
• Close the nitrogen bottle supply valve.
• Open the charge valve assembly bleed valve.
This releases the pressure in the hose, charge
valve assembly, and regulator.
• While holding the charge valve assembly on
the accumulator, unscrew the charge valve
swivel nut.
• Remove the charge valve assembly.
• If you are finished with the charge valve
assembly, remove the hose and regulator.
45. Make a bubbly mixture from soap and water.
Spread the mixture around the accumulator gas
valve to check for gas leaks. Gas leaks will push
the bubbles away from the area of the leak. If you
find a leak, replace the accumulator or have it
repaired by qualified personnel. Never repair an
accumulator yourself.
46. Replace the gas valve seal cap (tighten to 22 ft/lb),
and hand-tighten the valve protection cap.
47. If your concrete pump has two accumulators,
repeat this procedure for each accumulator.
HOME PRINT
SERVICE TRAINING
Pressure Settings
Hydraulic Pump
Adjustments Adjustment Knob
Main System Pumps A11VO

To perform the proper adjustments of flow, horsepower,
beginning of stroke limitation and the pressure cut-off T
P
to the tandem A11VO main system hydraulic pumps, T
MG
P
the following steps must be done in order that they are MY Y
G
listed;
Setting the Flow Rate Adjustment Knob Adjustment Knob

Before flow metering the pumps, ensure that the
Figure 48
maximum engine Rpm’s are set to the proper
Electric Stroke Limiters
specifications. All Schwing units have a metal ID tag
located inside the cab displaying the specific RPM Install the flow meter. (Consult the operation manual
settings for that particular unit. Set the supplement for proper installation and use of the flow meter). Set
system pressure to 0 bar by turning the adjustment the engine Rpm’s at maximum and set the maximum
knob all the way out on the electric stroke limiter. This flow at the Q max screw to the proper specifications per
will avoid false readings of the flow rate until the the output chart. (Check your operators manual for the
maximum flow rate and horsepower break points are proper output chart for your specific unit).
set.
A11VO130 / A11VO130
Q-max Screws
A11VO130 / A11VO190
Q-max Screws
HOME PRINT
Pressure Settings
Horsepower Setting
Adjustment Knob
After the flow rate is set, the horsepower setting then
must be done. The horsepower break point must be set
to the proper specifications per the output chart.
CONCRETE
BPL 2023-5 PRESSURE
350 or 400 HP truck PSI Bar
2000 138
PERFORMANCE CHARACTERISTICS OF 1900 131

Piston Side
Piston Side
THE AXIAL PISTON HYDRAULIC PUMP T

1800 124
PSI
Bar
PUMP SPEED
E
2100 RPM 1700 117 P
T
HYDRAULIC RELIEF VALVE IS SET AT 1600 110
350 BAR MAX. PRESSURE (5075 PSI). MG
1500 103 P
G
PL
1400 97
MY Y
1300 90
ROD SIDE 1200 83
5500 180 Kw 200 Kw 1100 76
5000 350 1000 1007 69
900 62 Adjustment Knob Adjustment Knob

M
4500
300
OIL PRESSURE
4000 800 55
250 700 48
3500
3000 200
600 41
Figure 51
SA
2500 500 34
150
2000
1500 100
400
300
27
21
Stroke Limiters (two generations)
1000
500
50
200
100
14
7
3. Increase the engine Rpm's to the maximum setting
Break Point
180 Kw = 182 bar
200 KW = 202 bar
0
10 20 30 40 50 60 70 80
208
90 100 110 120 130 140 150 160 170 180 190 200 210 220 cu yd / h
and while watching the flow meter scale, slowly
At 350 bar
180 Kw = 278 l/m
200 Kw = 309 l/m
7.5 15 23 30.5 38 46 53.5 61 69 76.5 84 92 99 107 114 122 130 137 145 153 160 168
CONCRETE OUTPUT
cu meters/ h
turn the stroke limit potentiometer to the minimum
5 10 15 20 25 30
32
Number of strokes
(stroke / min.)
material output until the maximum flow rate begins
100 200 300 400 500 535
Oil volume
(liter / min.) to drop.
Break Points
4. When the flow rate begins to drop, stop turning the
Figure 49 potentiometer and read the pressure on the 0 to 40
Sample output chart bar gauge. The reading that is seen is the
beginning of stroke limitation. The reading should
Setting Stroke Limitation be between 5 to 7 bar. If it is not, then adjust the
beginning of stroke limitation screw accordingly to
Now that the maximum flow rate and horsepower
achieve the proper pressure reading.
settings have been made, the beginning of stroke
limitation can be set. Adjust the supplement system a. If the pressure is too high, then turn the screw
pressure to the maximum pressure of 50 bar. counter-clockwise (out) to reduce the pressure.
1. Make sure the stroke limit potentiometer at the rear b. If the pressure is too low, then turn the screw
operation panel or remote box is at the maximum clockwise (in) to increase the pressure.
material output setting.
Q-min Output Flow
Once the beginning of stroke limitation is set, the next
step is to check the Q min output flow.
1. With the 0 to 40 bar gauge still in the electric
stroke limit line going to the Y port of the hydraulic
pumps. Increase the engine Rpm's to the
maximum setting and while watching the flow
meter scale, turn the stroke limit potentiometer to
the minimum material output. The 0 to 40 bar
gauge should be reading approximately 25 bar
Figure 50
more than the beginning of stroke limitation setting
Stroke Limiter Potentiometer
to ensure the hydraulic pumps are all the way to the
2. Install a 0 to 40 bar gauge in the electric stroke minimum against the Q min stop. The Q min
limit line going to the Y port of the hydraulic reading should be between 15 to 25 liters per
pumps, at this time the reading on the gauge should minute. If it is too high, turn the Q min screw out
be 0. until the reading is correct or if it is to low, turn the
HOME PRINT
SERVICE TRAINING
Pressure Settings
Q min screw in until the reading is correct. When Parts Department using part number 10004680
the Q min has been set, the flow meter can now be (valve), and number 30303432 (tube). Contact the
removed. Service Department for installation instructions.
2. Activate the agitator. With the valve closed the
A11VO190
agitator will not be able to turn and the oil will be
forced over the relief valve. At an idle (about 600
RPM), 4.5 horsepower is being converted to heat.
A11VO130

agitoff2.eps

Q min Screw
Q min Screw
Figure 52
Q-min screw locations Figure 53
2. Repeat steps 2 through 6 on the second main Agitator shutoff valve
system pump before attempting to set the pressure 3. When the oil temperature gauge shows 50˚C, open
cut-off on both pumps. the shutoff valve.
NOTE!
All screw adjustments with the system Setting pressures on Hi-flo -6 pumpkits
relief’s and pressure cut-off must be done a. To set the pressure of the main relief valve on
while the unit (pumpkit) is in the neutral Hi-flo pumpkits, you must first disable the soft
position. switch circuit. Simply locate the ball cock for
the soft switch circuit (Figure 54) and close it
Check all hydraulic pressures.
by rotating the handle 90 degrees.
Changes in pressures can indicate trouble in one or b. The quarter turn shutoff valve for the concrete
more components. The specifications for each circuit pump will also need to be closed during this
are shown on the hydraulic schematics found in the procedure.
Appendix of this manual. The hydraulic schematics are
the only documents in this manual that have been NOTE!
updated specifically for your unit, by the serial number, Main system adjustments are preset at the
so in each of the following procedures you will be told factory. The following procedure begins
with adjustment of the main relief cartridge
to refer to the schematic for the pressure required. and pressure cutoff. If proper pressures can
• Preheat the hydraulic oil not be obtained through these steps, refer to
Pressure settings must be made with the oil at normal the beginning of this procedure for specific
instructions on the adjustment of flow,
operating temperatures (40°− 60° C). In the past we horsepower, beginning of stroke regulation
could pressure out a function in the boom or outrigger and Q-min.
system to create heat, but load sensing systems no
longer allow maximum oil flow to be forced over relief.
Because of this the agitator circuit must be used to heat
the hydraulic oil.
To preheat the hydraulic oil:
1. Locate the agitator shutoff valve (Figure 53) and
close it. NOTE! If your unit does not have a
shutoff valve, order one from the Schwing Spare
HOME PRINT
Pressure Settings
Pressure setting procedure: 7. Stop the truck engine and put the key in your
pocket. Adjust the pressure cutoff screw (Figure
Soft switch 55) on each pump, by backing off the jam nut with
shutoff valve a 13mm wrench. Using a 4mm allen wrench, turn
the adjustment screw in (clockwise) one full turn
Main Pressure and tighten the jam nut. Restart the truck engine.
Gauge port
8. Adjust the engine RPM to maximum specification.
(See decal in truck cab)
9. Pressure out the system by activating the concrete
pump forward switch on the rear panel. Using the
Concrete pump
shutoff valve hif
lob
rn.
rear panel controls will allow you to read the
ep
s concrete pump main system pressure gauge, near
Figure 54 the e-stop manifold, from a safe distance.
Concrete pump and Soft switch shutoff valves NOTE!
1. Be sure that the waterbox covers and guards are in Because you turned out the pressure relief
place any time you will be working in the area cartridge in step 7, the system pressure
around the main control block. should read low at this time. If it does not
and the gauge spikes to 320 bar or more,
2. Wear safety glasses when working around a disengage the pump immediately. Turn the
concrete pump. relief cartridge out (counterclockwise)
more. For safety, it is important to adjust
NOTE! the pressure up from below the specified
It is vital that each adjustment screw be target pressure rather than down from a
properly identified prior to making any pressure which exceeds the target. Continue
adjustment. All screw adjustments for the this procedure until the main system pres-
system relief must be made with the pump- sure gauge reads lower than the specified
kit in the neutral position and adjustments target.
for pressure cutoff must be made with the 1. To increase the pressure put the pump in the
engine shut off.
neutral position and adjust the relief cartridge by
1. Start the truck engine, and put the PTO in gear just
turning it in (clockwise). When increasing the
as you would to pump a job.
pressure, the adjustments should be made in
2. If you have not already closed the soft switch quarter turn increments. If you make adjustments
shutoff valve and the concrete pump shutoff valve to increase the pressure but the pressure does not
(Figure 54) do so at this time. come up, you are probably reading the pressure
3. At the rear panel, select “local” control with the cutoff of the pumps, if so proceed to the next step
“local/remote” switch and turn the electric stroke otherwise skip to step 15.Turn the relief cartridge
limiter knob clockwise to maximum strokes per adjustment screw back out (counterclockwise)
minute. until you can no longer see a pressure drop and
4. The main system control block pressure must be tighten the jam nut.
set first to properly set the pressure cutoff on both 2. Stop the truck engine, put the key in your pocket.
pumps. Begin by backing off the jam nut of the 3. Go to the pressure cutoff screw on both hydraulic
main relief cartridge (Figure 56) with a 9/16 inch pumps (Figure 55) and back off the jam nut with a
wrench. 13mm wrench. Turn the adjustment screws in with
5. Using a 5/32 inch allen wrench, turn the a 4mm allen wrench one or two more turns, restart
adjustment screw out (counterclockwise) until you the engine and check the pressure again. Repeat
can feel no spring tension on the adjustment screw. this procedure until the main system relief can be
6. Now, turn the screw back in (clockwise) two or set to the target pressure.
three full turns to give you a proper starting point 4. When the proper main relief pressure is achieved,
and tighten the jam nut. pressure cutoff can be set. Shut off the engine, put
the key in your pocket and install 0-600 bar gauges
with whip hoses to the “M1” gauge ports on the
bottom of the two hydraulic pumps (Figure 55).
HOME PRINT
SERVICE TRAINING
Pressure Settings
You must be able to read both gauges
simultaneously to ensure that one pump is not

more dominant than the other.
NOTE!
The gauges in the M1 ports will read consid-

erably less than the cutoff pressure of the
pump. On a -6 (190/130 pump combination)
the 190 will usually read 85 to 90 bar while
the 130 reads about 110 bar. They could
read the same however, at approximately
110 bar, but the 190 must never read higher

than the 130. The actual cutoff pressure will

130ajst.eps
be read on the concrete pump main system
pressure gauge near the e-stop manifold. Figure 55
1. Activate concrete pump forward to pressure out the Adjustment screw locations
pump and read the pressure on the two gauges in
the “M1” ports. Soft switch
shutoff valve
2. Always stop the truck engine and put the key in
your pocket before making any adjustment on the Main Pressure
hydraulic pump. If the cutoff on one pump is set Gauge port
higher than the other, that pump will be more
dominant. The pressure gauge in the M1 port of the
dominant pump will however, read lower than the
other. To equalize the two pumps you must either
Concrete pump
adjust the cutoff screw in (clockwise) to increase shutoff valve hif
lob
rn.
ep
the pressure of the pump showing the higher s
reading or adjust the cutoff screw of the dominant

pump showing the lower reading out
(counterclockwise) to reduce the pressure. These Closed Open
adjustments must be made until the two gauges in
soft switch
the M1 ports are reading approximately the same.
relief valve
3. When you have achieved the same pressure on the
M1 port gauges, you can begin to adjust the
openclsd.eps
pressure cutoff screws in or out simultaneously

until you achieve the desired pressure setting of
350 bar (again, confirm the pressure specification
with the hydraulic schematic). Main relief valve
After pressure cutoff is set, return the pump to neutral, 5/32" Allen head
bring engine RPM to idle, open the soft switch quarter 9/16" jam nut
turn valve, and either proceed to other pressure settings Figure 56
or take the transmission and PTO out of gear and shut Soft switch circuit/Main relief valve
off the truck.
Setting the soft switch relief pressure
First, open the soft switch quarter turn valve (Figure
56) that you closed in the previous procedure. The rest
of the unit should still be set up as if you were going to
check the main relief valve pressure (concrete pump
shutoff valve still closed).
When you put the pump in forward now, the main
concrete pump pressure gauge should read the pressure
shown on the schematic for soft switch. If adjustment
HOME PRINT
Pressure Settings
is needed, loosen soft switch relief valve jam nut
(Figure 56) with a 9/16 open end wrench, and use a 5/
32 allen wrench to adjust the pressure. Turn the
adjustment screw in (clockwise) to raise the pressure or
out (counter clockwise), to lower the pressure. When
you attain the required pressure, tighten the jam nut
while holding the allen wrench to keep the pressure
from rising. Be sure to open the concrete pump shutoff
valve on the side of the brain (Figure 56) when you are
finished. The unit will not stroke with this valve closed
HOME PRINT
SERVICE TRAINING
Pressure Settings
BPL 500
E-Stop Manifold Valves

Concrete Pump and Gauge Ports
Shutoff Valve
Water Pump Hand
Concrete Pump Valves and Gauge Port
Soft Switch
Accumulator Unload-
ing Manifold Valve
Concrete Pump
and Gauge Port
Pressure Gauge
Main Relief Valve
Manual (forward/reverse)
Agitator Hand Valve Control Lever.
and Gauge Port
Main Control Panel
Agitator Shutoff Valve
Figure 57
General location of components used
to set hydraulic pressures
• Heating hydraulic oil. Pressure settings must be horsepower is being converted to heat. Shut off the
made with the oil at normal operating temperatures concrete pump when the temperature gauge on the
(40°– 60°C). The agitator circuit must be used to operator’s panel shows 50°C.
heat the hydraulic oil. Do not jam the paddles to 3. Open the agitator shutoff valve or remove plug and
force the oil over the relief valve by stopping the reconnect hose to agitator motor.
movement of the agitator. To preheat the
hydraulic oil using the agitator circuit, follow these NOTE!
instructions. If your unit does not have a shutoff valve,
order one, using part #10004680 (valve),
1. Locate the agitator shutoff valve and close it
and #30303432 (tube). Contact the Schwing
(Figure 58). The general location of the agitator
Service Department for installation instruc-
shutoff valve is shown in Figure 57.
tions. If you can’t wait for a shutoff valve,
2. Position the agitator hand valve in the forward or you will need to remove one of the hoses
reverse position. The agitator will not be able to from the agitator motor and plug the hose
turn, and the oil will be forced over the relief valve. and open fitting with approved hydraulic
At idle speed (about 600 RPM), about 4.5
HOME PRINT
Pressure Settings
dead plugs. Do not substitute other plugs, 6. Using the concrete pump “forward/neutral/
such as a steel bearing inside a cap fitting. reverse” control lever, put the concrete pump into
You will need: the “forward” position. The unit will cycle one
- Qty 2 VS-16S locking plugs, part number stroke, then the rock valve cylinder will retract. Oil
10016803 will have nowhere to go except over the main relief
- Qty 1 GS-16S straight fitting, part number valve.
10008088 7. Read the pressure on the concrete pump gauge,
- Qty 2 16S capnuts, part number 10001743. located on the main control block. It should read
300 bar. If no adjustment is needed, skip to Step
a
12.
CLOSED
8. If adjustment is required, loosen the jam nut on the
main relief valve adjusting screw (requires a 13-
mm spanner wrench).
9. Turn the knob on the relief valve to adjust the
pressure. Screw the handle in to raise pressure, out
to lower the pressure.
10. Retighten the jam nut. (Tightening the jam nut
tends to raise the pressure. If it becomes a problem,
Valve is shown in the hold the knob while tightening the jam nut)
OPEN position .
17mainreliefvalv
Figure 58
Agitator shut off valve
NOTE!
Pressure setting shown in these procedures
are for the BPL 500 HDR-18. Pressure set-
ting will be different for each type of pump
kit. Refer to the hydraulic schematic in the
Appendix of your Operation manual for the
correct pressure settings.
• Set the concrete pump pressure. The Schwing
concrete pump circuit on the BPL 500 is designed Jam nut
to be operated at a maximum pressure of 300 bar
(4350 PSI). It is controlled by the main relief Relief Valve
valve, which is located at the rear of the main
control block (Figure 59).
To check or set the main relief pressure:
1. Be sure that the waterbox covers are installed on
the waterbox. We do not recommend using the
remote control box for the following procedure. Figure 59
2. Wear safety glasses when setting pressures.
3. Close the concrete pump shutoff valve and the soft 11. Put the concrete pump into the “forward” position
switch shutoff valve (Figure 6-223). again. The machine will not stroke this time, but
will again develop maximum pressure. Read the
4. Put the operator’s panel “remote/local” switch into pressure on the gauge. If more adjustment is
the “local” position. needed, return the pump to “neutral,” then repeat
5. Using the switch on the operator’s panel, rev the steps 9. thru 11. until the pressure is at 300 bar.
engine up to full RPM. Return the pump to the “neutral” position.
HOME PRINT
SERVICE TRAINING
Pressure Settings
2. High-pressure the concrete pump. The control
block pressure gauge should read 100-bar (1450
17valves.epsL
Concrete pump
PSI) instead of 300 bar. If adjustment is needed,
shutoff valve loosen the 2.5-mm allen screw on the face of the
soft switch relief valve cartridge (Figure 60). Using
a screwdriver, adjust the pressure up or down as
needed, and lock into place with the 2.5-mm allen
screw. Use a screwdriver, if necessary, to prevent
the cartridge from turning while tightening the
allen screw. Be sure to open the concrete pump
shutoff valve when you are finished. The unit will
not stroke with this valve close
• Setting accumulator E-Stop manifold pressure.
The accumulator E-Stop manifold pressure circuit
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; ;@;@;@;@;@;@;@;@;@;@ is set to a maximum of 260-bar (3771 PSI) by its
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@;

Soft switch
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relief valve on the emergency stop manifold. To
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shutoff valve
@

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@;@;@;@;@
check the setting of the valve with the highest
pressure, you must first raise the pressure of the
lower three:
Soft Switch closed
1. Locate the accumulator unloading valve and its
Relief Valve relief valves (Figure 61).
@@@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;;;

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Blckgrvs.eps
@@@@@@@@@@@@@@@@@@

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;;;;;;;;;;;;;;;;;;
QQQQQQQQQQQQQQQQQQ

Concrete pump shut off valves 170-bar
138-bar
NOTE!
If you cannot adjust the pressure up to 300
bar, you have a problem. To ensure that the
pressure will not be to high when the prob-
230-bar
lem is found, turn the main relief knob OUT
several turns to lower the pressure. Contact

@@@@

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Schwing America’s service department for @@@@

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17accum.epsL
advice on how to continue.

Figure 61
12. If you will not be setting the soft switch pressure, Accumulator unloading valve
open both shutoff valves. The unit will not stroke
with closed shutoff valves.
2. Loosen the jam nut of the high pressure valve
13. Return the RPM to an idle and go on to the other (230-bar) adjustment screw. With an allen wrench
pressure settings, as required. turn the adjustment screw in one-and-a-half turns.
• Setting the soft switch circuit relief pressure. To This will raise the pressure on the valve above 260-
check or adjust the soft switch pressure setting, bar.
perform the following steps:
1. Close the concrete pump shutoff valve. Open the
soft switch shutoff valve.
HOME PRINT
Pressure Settings
3. Loosen the jam nut of the open valve (170-bar) and 3. Turn the open valve (170-bar) adjustment screw
the close valve (138-bar) pressure adjustment out two-and-a-half turns or until the gauge on the
screws. With an allen wrench turn both adjustment accumulator unloading valve reads 170-bar
screws in two-and-a-half turns. This will raise the (Figure 61).
pressure on both valves above 260-bar. 4. Turn the close valve (138-bar) adjustment screw
4. Connect the whip hose of a 0–400 or 0–600 bar out two-and-a-half turns or until the gauge on the
gauge into the gauge port of the E-Stop manifold accumulator unloading valve reads 138-bar
(Figure 62). (Figure 61
5. Tighten the jam nuts on all three adjustment
17e-stopman.epsL
screws.
• Set the water pump/agitator pressures. You will
need an assistant to perform this procedure. The
location of all the components needed for this
procedure are shown in (Figure 57). This hydraulic
circuit has a maximum pressure of 200 bar (2900
PSI), limited by the relief valve on the water pump
handvalve.
To set the water pump/agitator hydraulic circuit
pressures perform the following steps.
Relief valve
1. Stop the unit, and put the key in your pocket.
Gauge port 2. Install the whip hose of a 0–400 or 0–600 bar
gauge on to the gauge port located on the
waterpump handvalve. The location of the water
pump hand valve if shown in Figure 57. Make sure
the whip hose connection is tight.
3. To check or set the highest pressure of this circuit,
you must first raise the pressure of the agitator
Figure 62 relief valve. Turn the body of the relief valve in
E-Stop manifold accumulator relief valve (clockwise) one and one half turns on the agitator
hand valve. (The location of the water pump and
the agitator hand valve are shown in Figure 57.)
5. High-pressure the concrete pump. The pressure This will increase the circuit pressure over the 200
gauge should read 260-bar (3771 PSI) bars needed to set the water pump relief valve.
6. If adjustment is needed, loosen the jam nut and 4. Start the unit engine and set the transmission and
with a allen wrench turn the adjustment screw on PTO as you would to pump concrete.
the relief valve (Figure 62). Turn in to raise 5. Locate the relief valve on the water pump hand
pressure, turn out to lower pressure. valve. It will be on the bottom, passenger side, of
7. Repeat steps (5) and (6) until the gauge reads 260- the water pump handvalve.
bar. 6. Be sure that all personnel are clear.
8. Tighten the jam nut on the adjustment screw, 7. Bring the engine to full RPM.
remove the whip hose and gauge from the gauge
port, and replace the cap on the gauge port.
(Figure 58) The general location of the agitator
• Setting the accumulator unloading valve. Use an shutoff valve is shown in Figure 57.
allen wrench to make these adjustments
9. Position the agitator hand valve in the forward or
1. High-pressure the concrete pump. reverse position. The agitator will not be able to
2. Turn the high pressure (230-bar) adjustment screw turn, and the oil will be forced over the water pump
out one-and-a-half turns or until the gauge on the relief valve.
accumulator unloading valve reads 230-bar
(Figure 61).
HOME PRINT
SERVICE TRAINING
Pressure Settings
10. The gauge attached to the water pump hand valve pressure at which the valve relieves can be seen on
should read 200 bar. the pressure gauge attached to the agitator hand
11. To adjust the pressure, turn the outside body of the valve. It should read 150 bar (2175 PSI).
water pump pressure relief valve (shown in Figure 20. To adjust the pressure, turn the outside body of the
58) clockwise to increase, or counterclockwise to agitator pressure relief valve, located on the bottom
decrease until 200 bar is showing the pressure of the agitator hand valve. It is the smaller of the
gauge. two cartridges extending from the bottom of the
valve (Figure 63). Turn the body of the relief valve
clockwise to increase or counter clockwise to
Turn body of valve decrease until 150 bar is showing the pressure
200 bar to adjust. gauge.
Higher
Relief Valve Lower
PS
7.E
lv1
mpv
p/c
pm
wtr
Figure 63
Water pump relief valve
12. Return the agitator handvalve to the neutral

position.
13. Turn the body of the agitator relief valves out
(counter clockwise) one and one half turns. This
will return the agitator relief valve to its original
settings.
14. Remove the pressure gauge from the water pump
hand valve and replace the cap nut on the gauge
port.
15. Install the whip hose of a 0–400 or 0–600 bar
passenger side agitator hand valve. Make sure the
whip hose connection is tight.
16. Close the agitator shutoff valve (Figure 58)
17. Be sure that all personnel are clear.
18. Bring the engine to full RPM.
19. Hold the agitator lever in the forward or reverse
position. This will send the oil against the high-
pressure plug. The oil will return to the tank over
the relief valve in the agitator hand valve. The
HOME PRINT
Pressure Settings
HOME PRINT
SERVICE TRAINING
Pressure Settings
BPL 2000 4. Wear safety glasses when setting pressures.
5. Start the engine.
NOTE!
6. Close the concrete pump shut-off valve (also
Pressure settings must be made with the
known as the ballcock or quarter-turn valve). (See
hydraulic oil at normal operating tempera-
Figure 65.)
tures (40°–60°C).
7. Put the operator’s panel “remote / local” switch
To heat the oil to operating temperature use one of the into the “local” position.
following procedures:
8. Using the switch on the operator’s panel, rev the
1. When the oil is very cold (at or below the pour engine up to full RPM.
point of your hydraulic oil), bring engine RPM to
an idle. Let the engine idle until the temp. gauge on 9. Using the concrete pump “forward / neutral /
the operator’s panel reads 40°C. reverse” handle, put the concrete pump into the
“forward” position. The unit will stroke no more
2. If your concrete pump unit has an agitator shutoff than once, then the rock cylinder will retract. Oil
valve, refer to Preheating the hydraulic oil in the will have nowhere to go except over the main relief
Operation section of this manual. valve.
• Set the concrete pump pressure. The Schwing
10. Read the pressure on the concrete pump gauge,
concrete pump circuit on the BPL 2000 is designed
located on the main control panel. It should read
to be operated at a maximum pressure of 300 bar
300 bar. Return the pump to “neutral” whether in
(4350 PSI). It is controlled by the main relief
needs adjustment or not. If no adjustment is
valve, which is located on the top of the main
needed, skip to Step 13.
control block (Figure 64). To check or set the main
relief pressure: 11. If adjustment is required, loosen the jam nut on the
relief valve adjusting screw (requires a 13 mm
spanner wrench).
12.
pressure. Screw the handle in to raise pressure, out
to lower the pressure.
14. Retighten the jam nut. (This step is necessary
because tightening the nut tends to raise the
pressure. If it becomes a problem, hold the knob
while tightening the jam nut).
15. Put the concrete pump into the “forward” position
again. The machine will not stroke this time, but
will again develop maximum pressure. Read the
pressure on the gauge. If more adjustment is
needed, return the pump to “neutral,” then repeat
steps i. thru l. until the pressure is at 300 bar.
Lower Raise Return the pump to the “neutral” position.
pressure pressure 16. Open the quarter turn valve.
17. Return the RPM to an idle and go on to the other
gray valve.eps L pressure settings, as required.
Figure 64
Concrete pump circuit
main relief valve

remote control box for the following procedure.
HOME PRINT
Pressure Settings
Closed
Ball cock grooves.eps
Open
quarter turn.eps
Figure 65
Concrete pump shutoff valve
NOTE! To set the agitator/water pump/outrigger hydraulic

If you cannot adjust the pressure up to 300 circuit pressure use the following steps:
bar, you have a problem. In this case, 1. Stop the unit, and put the key in your pocket.
unscrew the adjustment knob by several 2. Install the whip hose of a 0–400 or 0–600 bar
turns so that your pressure isn’t too high gauge on to the gauge port located below the
once the problem is found. Contact Schwing outrigger handvalve. Make sure the whip hose
America’s service department for advice on connection is tight.
how to continue.
3. Start the unit engine and set the transmission and
• Set the agitator/water pump/outrigger pressure. PTO as you would to pump concrete.
The hydraulic circuit has a maximum pressure of
200 bar (2900 PSI), limited by the relief valve 4. Locate the relief valve on the outrigger handvalve.
located on the outrigger handvalve (Figure 66). It will be on back left side of the outrigger
handvalve.
6. Restart the engine and bring it to full RPM.
7. Activate the outrigger handvalve in the retract
position. Hold the handvalve in retract position to
cause the outrigger (left or right) to bottom out in
Relief Valve the retract position. This will send the oil against
the high-pressure plug. The oil will return to the
tank over the relief valve in the handvalve. The
pressure at which valve relieves can be seen on the
OU attached pressure gauge. It should read 200 bar.
TR
IG
GE
R
ET
RA
R 8. To adjust the pressure, turn the pressure relief valve
CT
•E
XT
EN
(location shown in Figure 66) clockwise to
D
increase, or counterclockwise to decrease until 200
bar is showing the pressure gauge.
9. Return the outrigger handvalve to the neutral
position.
Figure 66 10. Stop the engine and put the key in your pocket.
Outrigger handvalve
HOME PRINT
SERVICE TRAINING
Pressure Settings
11. Remove the pressure gauge and replace the cap nut
on the gauge port.
12. The unit can now be restarted, if necessary.
Remember to put the key back in the engine before
you go home.
NOTE!
If your unit is equipped with an agitator
pressure gauge on the panel below the main
control panel, you only need to perform
Steps 6, 7, and 8 of the previous procedure.
The circuit pressure can be set to 200 bar on
the agitator pressure gauge.
HOME PRINT
Pressure Settings
HOME PRINT
SERVICE TRAINING
Pressure Settings
BPL 4000

Concrete Pump and Gauge Ports
Shutoff Valve
Water Pump Hand
Concrete Pump Soft Valves and Gauge Port

Switch and Relief Valve
Main Relief Valve
Accumulator Unload-
ing Manifold Valve
Concrete Pump
and Gauge Port
Pressure Gauge
Outrigger Hand Valve Outrigger Hand Valve

and Gauge Port and Gauge Port
Main Control Panel

Agitator Hand Valve
and Gauge Port
Figure 67
to set hydraulic pressures (original
production)
HOME PRINT
Pressure Settings

and Gauge Ports
Concrete Pump Soft
Switch
Water Pump Hand
Valves and Gauge Port
Concrete Pump
Shutoff Valve Main Relief Valve and
Soft Switch Relief Valve
Accumulator Unload-
ing Manifold Valve
Concrete Pump
and Gauge Port
Pressure Gauge
Outrigger Hand Valve Outrigger Hand Valve

and Gauge Port and Gauge Port
Main Control Panel

Agitator Hand Valve
and Gauge Port
Figure 68
to set hydraulic pressures (current
production)
Pressure settings must be made with the oil at normal NOTE!

operating temperatures (40°– 60°C). The agitator If your unit does not have a shutoff valve,
circuit is used to heat the hydraulic oil. Do not jam the order one, using part #10004680 (valve),
paddles to force the oil over the relief valve by and #30303432 (tube). Contact the Schwing
stopping the movement of the agitator. To preheat Service Department for installation instruc-
the hydraulic oil using the agitator circuit, follow these tions. If you can’t wait for a shutoff valve,
instructions: you will need to remove one of the hoses
1. Locate the agitator shutoff valve and close it from the agitator motor and plug the hose
(Figure Figure 68). and open fitting with approved hydraulic
2. Position the agitator hand valve in the forward or dead plugs. Do not substitute other plugs,
reverse position. The agitator will not be able to such as a steel bearing inside a cap fitting.
turn, and the oil will be forced over the relief valve. You will need:
At idle speed (about 600 RPM), about 4.5 - Qty 2 VS-16S locking plugs, part number
horsepower is being converted to heat. Shut off the 10016803
concrete pump when the temperature gauge on the - Qty 1 GS-16S straight fitting, part number
operator’s panel shows 50°C. 10008088
3. Open the agitator shutoff valve or remove plug and - Qty 2 16S capnuts, part number 10001743.
reconnect hose to agitator motor.
HOME PRINT
SERVICE TRAINING
Pressure Settings
agit.shutoff.eps
CLOSED
Valve is shown in
the OPEN
position
Figure 69
Agitator shut off valve
• Set the concrete pump pressure (original located at the front of the main control block
production) - The concrete pump circuit on the (Figure 70). To check or set the main relief
BPL 4000 is designed to be operated at a pressure perform the following steps.
maximum pressure of 320 bar (4640 PSI). It is
controlled by the main relief valve, which is
relieflocMPS.eps
Main relief valve
Concrete pump
shutoff valve
Lower Raise
pressure pressure
gray valve.eps L
Figure 70
and main relief valve
1. Be sure that the waterbox covers are installed on 2. Wear safety glasses when setting pressures.
HOME PRINT
Pressure Settings
3. Close the concrete pump shutoff valve (Figure 6-
234) and the soft switch shutoff valve
(FigureFigure 72).
Closed
Open
quarter turn.eps
Figure 71
rock cylinder will retract. Oil will have nowhere to

4Ksoft switch.epsL go except over the concrete pump main relief
valve.
7. Read the pressure on the concrete pump pressure
gauge, located on the main control block (Figure
70.) It should read 320 bar. Position the throttle
switch to the “neutral” position. If no adjustment is
8. If adjustment is required, loosen the jam nut on the
relief valve adjusting screw with a 13-mm spanner
wrench (Figure 70).
Relief valve 9. Turn the adjustment knob on the relief valve to
adjust the pressure. Turn the adjustment knob in to
raise pressure, out to lower the pressure.
Figure 72 10. Retighten the jam nut. (tightening the jam nut
Soft switch shutoff valve and relief tends to raise the pressure. If this happens, hold the
valve adjustment knob while tightening the jam nut).
4. Position the “remote / local” switch, on the main again. The machine will not stroke this time, but
control panel, to the “local” position. will develop maximum pressure. Read the pressure
5. Use the throttle switch, on the main control panel, on the gauge. If more adjustment is needed, return
to rev the engine up to full RPM. the pump to “neutral,” then repeat Steps 8. through
6. Use the concrete pump “forward / neutral / 11. until the pressure is at 320 bar. Position the
reverse” switch to put the pump into the “forward” throttle switch to the “neutral” position.
position. The unit will stroke only once, then the NOTE!
If you cannot adjust the pressure up to 320
bar, you have a problem. In this case, turn
HOME PRINT
SERVICE TRAINING
Pressure Settings
the adjustment knob out by several turns so
that your pressure isn’t too high once the
problem is found. Contact Schwing Amer-
ica’s service department for advice on how
to continue.
12. If you are not setting the soft switch pressure, open
both shutoff valves. The unit will not stroke with
the shutoff valves closed.
• Setting the soft switch circuit relief pressure
(original production) - To check or adjust the soft
switch pressure setting, perform the following
steps:
1. Open the soft switch shutoff valve. Close the
concrete pump shutoff value.
2. Rev the engine to full RPM. The control block
pressure gauge should read 80-bar (1160 PSI)
instead of 320 bar. If adjustment is needed, loosen
the 2.5-mm allen screw on the face of the soft
switch relief valve cartridge (Figure 72). Using a
screwdriver, adjust the pressure up or down as
needed, and lock into place with the 2.5-mm allen
screw. Use a screwdriver, if necessary, to prevent
the cartridge from turning while tightening the
allen screw. Be sure to open the concrete pump
shutoff valve when you are finished. The unit will
not stroke with the shutoff valve closed.
• Set the concrete pump pressure (current
production) - The concrete pump circuit on the
BPL 4000 is designed to be operated at a
maximum pressure of 320 bar (4640 PSI). It is
controlled by the main relief valve, which is
located at the front of the main control block
(Figure 70). To check or set the main relief
pressure perform the following steps.
HOME PRINT
Pressure Settings
Soft switch
shutoff valve
Gauge or gauge port
Pressure
Concrete pump control
hif
shutoff valve low
brn
.ep
s
position
(closed)
Groove lined
up with ports - open
grooves.eps
Groove at 90°
to ports - closed
Main relief valve Jam nut

4K
op
n-c
lsd
.ep
s
Soft switch relief valve
Operating
Allen adjustment screw position
(open)
Figure 73
Concrete pump shutoff valve and soft switch shutoff valve
3. Close the concrete pump shutoff valve and the soft 7. Read the pressure on the concrete pump pressure
switch shutoff valve (Figure 73). gauge, located on the main control block (Figure
4. Position the “remote / local” switch, on the main 73.) It should read 320 bar. Position the throttle
control panel, to the “local” position. switch to the “neutral” position. If no adjustment is
5. Use the throttle switch, on the main control panel,
to rev the engine up to full RPM. 8. If adjustment is required, loosen the 9/16 inch jam
nut on the main relief valve (Figure 73).
6. Use the concrete pump “forward / neutral /
reverse” switch to put the pump into the “forward” 9. Use a 5/32 inch allen wrench to adjust the pressure
position. The unit will stroke only once, then the to 320 bar. Turn the adjustment screw in to raise
rock cylinder will retract. Oil will have nowhere to pressure, out to lower the pressure.
go except over the concrete pump main relief
valve.
HOME PRINT
SERVICE TRAINING
Pressure Settings
10. Retighten the jam nut. (tightening the jam nut the pump to “neutral,” then repeat Steps 1. through
tends to raise the pressure. If this happens, hold the 6. until the pressure is at 80 bar. Position the
allen wrench in position while tightening the jan throttle switch to the “neutral” position.
nut). 8. Be sure to open the concrete pump shutoff valve
11. Put the concrete pump into the “forward” position when you are finished. The unit will not stroke
again. The machine will not stroke this time, but with the shutoff valve closed.
will develop maximum pressure. Read the pressure • Set accumulator circuit hydraulic oil pressure
on the gauge. If more adjustment is needed, return (units with pressure- compensated pumps) - You
the pump to “neutral,” then repeat Steps 8. through will need an assistant for parts of this procedure.
11. until the pressure is at 320 bar. Position the To check or adjust the hydraulic pressure in the
throttle switch to the “neutral” position. accumulator circuit, perform the following steps:
NOTE! 1. Stop the truck, put the key in your pocket, and
If you cannot adjust the pressure up to 320 place a “Do Not Operate” sign on the windshield.
bar, you have a problem. In this case, turn 2. Loosen the jam nut on the pressure regulator of the
the adjustment knob out by several turns so accumulator hydraulic pump. Turn the screw in
that your pressure isn’t too high once the two-and-a-half turns. This will raise the regulator
problem is found. Contact Schwing Amer- pressure above 300 bar (Figure 74).
ica’s service department for advice on how .
to continue.
12. If you are not setting the soft switch pressure, open
both shutoff valves. The unit will not stroke with
the shutoff valves closed.
• Setting the soft switch circuit relief pressure
(current production) - To check or adjust the soft
switch pressure setting, perform the following Accumreg.eps
steps:
1. Open the soft switch shutoff valve. Close the
concrete pump shutoff value (Figure 73.)
2. Use the throttle switch, on the main control panel,
to rev the engine up to full RPM.
Accumulator pump
3. Use the concrete pump “forward / neutral / pressure regulator
reverse” switch to put the pump into the “forward”
position. The control block pressure gauge should
read 80-bar (1160 PSI) instead of 320 bar.
Figure 74
4. If adjustment is required, loosen the 9/16 inch jam
Accumulator pump pressure regulator
nut on the soft switch relief valve (Figure 73).
5. Use a 5/32 inch allen wrench to adjust the pressure
to 80 bar. Turn the adjustment screw in to raise 3. Connect the whip hose of a 0-600 bar gauge into
pressure, out to lower the pressure. the gauge port of the E-Stop manifold (Figure 75).
6. Retighten the jam nut. (tightening the jam nut 4. Loosen the jam nut on the accumulator relief valve,
tends to raise the pressure. If this happens, hold the located on the E-Stop manifold. Turn the screw in
allen wrench in position while tightening the jan two turns. This will raise the relief setting above
nut). 300 bar (Figure 75).
will develop maximum pressure. Read the pressure
on the gauge. If more adjustment is needed, return
HOME PRINT
Pressure Settings
e-stop/left.epsL 45s3blck.epsL
Relief Valve and

Gauge Port
Relief Valve
Figure 75
Figure 76
E-Stop manifold accumulator relief valve
Accumulator manifold pressure relief
valve
5. Clear all personnel away from the drive lines, start
the truck engine, engage the pumps, and bring 8. You will need an assistant for this step. With the
engine RPM to maximum. engine still running, adjust the relief valve of the E-
6. Read the pressure on the accumulator circuit gauge Stop manifold. Back out the adjustment screw
located just between the hopper and the A-frame. until pressure reads 260 bar (3770 PSI) on the
Pressure should read 300 bar (4350 PSI). If no gauge connected to the E-Stop manifold.
adjustment is needed, skip to (Step 8).
7. If additional pressure adjustment is needed, locate
the accumulator manifold pressure relief valve
(Figure 76). Loosen the jam nut, and turn the screw WARNING
in to increase pressure, or out to decrease pressure.
Tighten the jam nut when pressure is at 300 bar. Stop the truck engine before proceed-
ing to the next Step. Entanglement
hazard
9. After the truck engine is stopped, back out the

accumulator circuit hydraulic pump pressure
regulator two-and-a-half-turns. This restores the
pressure regulator to its original setting (Figure
74).
10. Clear all personnel from the drive line area, start
the truck, and rev the engine RPM to maximum.
11. Read the pressure on the accumulator gauge. It
should read 260 bar (3770 PSI).
12. If additional adjustment is needed, you must stop
the truck engine, each time you approach the
accumulator circuit hydraulic pump (Figure 74).
Adjust the accumulator pump pressure regulator
HOME PRINT
SERVICE TRAINING
Pressure Settings
screw in to increase pressure, or out to decrease
pressure. Lock the jam nut when pressure is e-stop/left.epsL
correct.
• Set accumulator circuit hydraulic oil pressure Relief Valve
(units with accumulator unloading valves) - You and Gauge Port
will need an assistant for parts of this procedure.
To check or adjust the hydraulic pressure in the
accumulator circuit, follow these steps:
1. Stop the truck, put the key in your pocket, and
place a “Do Not Operate” sign on the windshield.
2. Connect the whip hose of a 0-600 bar gauge into
the gauge port of the E-Stop manifold (Figure 78).
3. Locate the accumulator unloading valve. The
location of this valve on the pump unit may vary.
Loosen the jam nut on the accumulator unloading
valve. Turn the screw in two-and-a-half turns. This
will raise the pressure above 300 bar (Figure 77). Figure 78
E-Stop manifold accumulator
relief valve
Adjustment Screw

the truck engine, engage the pumps, and bring
engine RPM to maximum.
6. Read the pressure on the accumulator circuit gauge
located just between the hopper and the A-frame.
Pressure should read 300 bar (4350 PSI). If no
7. If additional pressure adjustment is needed locate
(Figure 79). Loosen the jam nut, and turn the screw
s
in to increase pressure, or out to decrease pressure.
.ep
un
lvlv
Tighten the jam nut when pressure is at 300 bar.
Figure 77
Accumulator unloading valve
4. Loosen the jam nut on the accumulator relief valve,

located on the E-Stop manifold. Turn the screw in
two turns. This will raise the relief setting above
300 bar (Figure 78).
HOME PRINT
Pressure Settings
. 2. Install the whip hose of a 0–400 or 0–600 bar
45s3blck.epsL
waterpump handvalve. The location of the water

pump hand valve if shown in Figure 57. Make sure
the whip hose connection is tight.
3. To check or set the highest pressure of this circuit,
you must first raise the pressure of the lower two
relief valves. Turn the body of the relief valves in
(clockwise) one and one half turns on the agitator
hand valve and the passenger side outrigger hand
valve. (The location of the water pump and the
agitator hand valve are shown in Figure 57.) This
will increase the circuit pressure over the 210 bars
needed to set the water pump relief valve.
Relief Valve 4. Start the unit engine and set the transmission and
PTO as you would to pump concrete.
5. Locate the relief valve on the water pump hand
Figure 79 valve. It will be on the bottom, passenger side, of
Accumulator manifold pressure relief valve the water pump handvalve.
7. Bring the engine to full RPM.
8. You will need an assistant for this step. With the
engine still running, adjust the accumulator relief 8. Push the outrigger enable push button, located next
valve on the E-Stop manifold (Figure 78). Back to the outrigger control lever. Hold the outrigger
out the adjustment screw until pressure reads 260 control lever in the retract position to cause the
bar (3770 PSI) on the gauge connected to the E- outrigger to bottom out in the retract position. This
Stop manifold. will send the oil against the high-pressure plug.
The oil will return to the tank over the relief valve
9. Back out the accumulator unloading valve
in the water pump hand valve. The pressure at
adjustment screw two-and-a-half-turns. This
which the valve relieves can be seen on the
restores it to its original setting.
pressure gauge attached to the water pump hand
10. Read the pressure on the accumulator gauge. It valve. It should read 210 bar.
11. If additional adjustment is needed, adjust the screw NOTE!
on the accumulator relief valve (Figure 63) in to You cannot use the extend position for this
increase pressure, out to decrease pressure. Lock adjustment because extend position has a
the jam nut when pressure is correct. non-adjustable, secondary relief functions
built into the valve.
12. Remove the pressure gauge from the outrigger
hand valve and replace the cap nut on the gauge 9. To adjust the pressure, turn the outside body of the
port. water pump pressure relief valve (shown in Figure
• Set the water pump/outrigger/agitator 80) clockwise to increase, or counterclockwise to
pressures - You will need an assistant to perform decrease until 210 bar is showing the pressure
this procedure. The location of all the components gauge.
needed for this procedure are shown in (Figure 57).
This hydraulic circuit has a maximum pressure of
210 bar (3045 PSI), limited by the relief valve on
the water pump handvalve.
To set the water pump/outrigger/agitator hydraulic
circuit pressures, perform the following steps:
HOME PRINT
SERVICE TRAINING
Pressure Settings
17. To adjust the pressure, turn the outside body of the
outrigger pressure relief valve, located on the back
of the outrigger hand valve (Figure 81), clockwise
Turn body of valve to increase or counter clockwise to decrease until
210 bar to adjust. 200 bar is showing the pressure gauge.
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Higher
Relief Valve Lower
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WARNING
IN Clear area
RETRACT
before activating
OUTRIGGER
outriggers
OUT
EXTEND
S
.EP
4K
vlv
/cmp
p mp
wtr
Outrigger
Figure 80 Relief Valve
Water pump relief valve and Gauge
Port
10. Return the outrigger handvalve to the neutral
position.
Figure 81
11. Turn the body of the relief valves out (counter Outrigger relief valve
clockwise) one and one half turns on the agitator
hand valve and the passenger side outrigger hand
valve. This will return the these relief valves to 18. Return the outrigger handvalve to the neutral
their original settings. position.
12. Remove the pressure gauge from the water pump 19. Remove the pressure gauge from the passenger
hand valve and replace the cap nut on the gauge side outrigger hand valve and replace the cap nut
port. on the gauge port.
13. Install the whip hose of a 0–400 or 0–600 bar 20. Close the agitator shutoff valve (Figure 82).
gauge on to the gauge port located on the 21. Install the whip hose of a 0–400 or 0–600 bar
passenger side outrigger hand valve. Make sure the gauge on to the gauge port located on the drivers
whip hose connection is tight.(Figure 65). side agitator hand valve (Figure 83). Make sure the
14. Be sure that all personnel are clear. whip hose connection is tight.
15. Rev the engine to full RPM.
16. Activate the passenger side outrigger handvalve in
the retract position. Hold the handvalve in retract
position to cause the outrigger to bottom out in the
retract position. This will send the oil against the
high-pressure plug. The oil will return to the tank
over the relief valve in the outrigger hand valve.
The pressure at which the valve relieves can be
seen on the pressure gauge attached to the
outrigger pump hand valve. It should read 200 bar
(2900 PSI).
HOME PRINT
Pressure Settings
WARNING 4Kdshppr.epsL
agit.shutoff.eps
CLOSED
Do not stand on
hopper grates.
SAFETY INSTRUCTIONS
HOPPER GRATE OR
BEFORE REMOVING
SERVICE:
PERFORMING ANY
Engines Electric Motors
Gasoline or Diesel motor.
1. Stop the electric
1. Stop the engine.
place it 2. Lock out the power an
2. Remove the key, source according to
put
in your pocket, and approved lockout-tagout
a "DO NOT OPERATE" program.
tag on the switch.
3. Check accumulator
3. Check accumulator circuit pressure gauge
circuit pressure gauge (if so equipped) to
verify
verify
(if so equipped) to zero system pressure.
zero system pressure.
Gauge Port

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Valve shown in the @@@@@@@@@@@@@@@@@@@@

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SUBSIDIARY OF F. W. GMBH.
AMERICA INC.
HERNE 2/ GERMANY
AGITATOR
WHITE BEAR, MINNESOTA
OPEN position
PHONE (02325)7871
PHONE 612-429-0999 TELEX 820 348
TWX: 910-563-3539
4.373.875
U. S. PATENTS: 3.146.721; 3.640.303; 3.409.334; REVERSE - FORWARD
SERIAL NO. YEAR

MODEL
MATERIAL
STROKES PER MINUTE MAX.
WEIGHT LBS. PRESSURE
SYSTEM SYSTEM SYSTEM

MAXIMUM HYDRAULIC PRESSURE 1 1
1
WARNING This product is covered by one or more of the following

3,409,334 4,057,373 4,392,510 4,708,288 5,257,912
U.S. patents:
Re. 32,041
4,437,817 4,852,467 5,263,828 Re. 32,657
3,580,696 4,178,142
Clear area 3,640,303
3,685,543
4,191,513
4,260,338
4,465,441
4,472,118
4,978,073
5,066,203
5,281,113
5,332,366
Re. 32,719
5,346,368
before activating 3,741,691
3,829,251
4,343,598
4,373,225
4,556,370
4,621,375
4,681,022
5,106,225
5,106,272
5,224,654
5,401,140
4,019,839 4,373,875
outriggers
Figure 82 IN
RETRACT
OUTRIGGER
OUT
EXTEND
Close agitator shutoff valve
Agitator Relief
22. Be sure that all personnel are clear. Valve
23. Rev the engine to full RPM.
24. Hold the agitator lever in the forward or reverse Figure 83
position. This will send the oil against the high- Agitator relief valve
pressure plug. The oil will return to the tank over
the relief valve in the agitator hand valve. The 26. Return the agitator handvalve to the neutral
pressure at which the valve relieves can be seen on position.
the pressure gauge attached to the agitator hand 27. Remove the pressure gauge from the outrigger
valve. It should read 200 bar (2900 PSI). hand valve and replace the cap nut on the gauge
25. To adjust the pressure, turn the outside body of the port.
agitator pressure relief valve, located on the bottom
of the agitator hand valve. It is the smaller of the
two cartridges extending from the bottom of the
valve (Figure 83). Turn the body of the relief valve
clockwise to increase or counter clockwise to
decrease until 200 bar is showing the pressure
gauge.
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 17M
• Check hydraulic pressures. Check all hydraulic
pressures. Changes in pressures can indicate
trouble in one or more components. The
specifications for all circuits are shown on the
Hydraulic Schematics in the Appendix of this
manual.
Pressure settings must be made with the oil at normal
operating temperatures (40°C – 60°C). The agitator
circuit must be used to heat the hydraulic oil. Do not
jam the paddles to force the oil over relief by stopping
the movement of the agitator. To preheat the hydraulic
oil using the agitator circuit, follow these instructions.
NOTE!
If your unit does not have a shutoff valve,
order one, using part #10004680 (valve),
and #30303432 (tube). Contact the Schwing
Service Department for installation instruc-
you will need to remove one of the hoses
from the agitator motor and plug the hose
and open fitting with approved hydraulic
dead plugs. Do not substitute other plugs,
such as a steel bearing inside a cap fitting.
2. Position the agitator lever in the forward or reverse
position (Figure 98). The agitator will not be able
to turn, and the oil will be forced over the relief
valve.
3. At idle speed (about 600 RPM), about 4.5
horsepower is being converted to heat. Shut off the
concrete pump when the temperature gauge on the
operator’s panel shows 50°C.
4. Open the agitator shutoff valve or remove plug and
reconnect hose to agitator motor.
The general location of the components used to check
or set hydraulic pressures in shown in Figure 84.
HOME PRINT
Pressure Settings
• Boom (Section #1)

Down Pressure Relief • Boom Hand Valves and
Valve and Gauge Port Gauge Port
• Boon/Outrigger Hand
Valve and Gauge Port • E- Stop Manifold Valves
and Gauge Ports
• Concrete Pump Shutoff

Valve
• Water-Pump/Compressor
• Soft Switch Shutoff Hand Valve and Gauge
Valve Port
• Accumulator Unload- • Main Relief Valve

ing Manifold Valve and
Gauge • Concrete Pump Pressure
Gauge
• Outrigger Hand Valve • Main Control Panel

and Gauge Port
• Agitator Hand Valve

and Gauge Port
• Outrigger Hand Valve
• Agitator Shutoff Valve
Figure 84
General location of components
used to set hydraulic pressures
Setting concrete pump pressure

The MPS pumpkits used on the KVM 17 are designed
to be operated at a maximum pressure of 300-bar (4350
PSI). The pressure in the system is limited by the relief
valve located on the rear (toward the hopper) of the
main control block (Figure 85).
HOME PRINT
SERVICE TRAINING
Pressure Settings
8. Read the pressure on the control block pressure
17mainreliefvalve.eps
gauge, shown in Figure 59. It should read 300-bar.
Return the pump control to “neutral,” whether it
17valves.epsL
Concrete pump
shutoff valve
Jam nut
Relief Valve
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Soft switch

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Figure 85
Concrete pump main relief valve
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shutoff valve
@

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Soft Switch
To check or set concrete pump circuit pressures, Relief Valve closed
perform the following steps.
2. Be sure that the waterbox covers and guards are Blckgrvs.eps
installed on the waterbox. Schwing does not

recommend using the remote control box when
setting the main relief pressure.
3. Start the truck engine, and put the PTO and open
transmission into gear, just as you would to pump a
job.
Figure 86
4. Locate and close the concrete pump shutoff valve Concrete pump shut off valves
(quarter-turn valve), and the soft switch shutoff
valve (quarter-turn valve) (Figure 86).
5. Put the operator’s panel “remote / local” switch 9. Using a 13-mm spanner wrench, loosen the jam
into the “local” position. nut on the relief valve adjusting screw (Figure 86).
6. Using the switch on the operator’s panel, rev the 10. Turn the knob on the relief valve to adjust the
truck engine up to full RPM. pressure. Screw the handle in to raise pressure, out
to lower pressure.
7. Put the operator’s panel “forward / neutral /
reverse” switch into the “forward” position. The 11. Retighten the jam nut. Tightening the nut tends to
unit will stroke only once, then the rock cylinder raise the pressure. If the rise in pressure becomes a
will retract. The oil leaving the hydraulic pumps problem, hold the knob while tightening the jam
will be forced over the main relief valve. This nut.
procedure is called high-pressuring the concrete
pump.
HOME PRINT
Pressure Settings
12. High-pressure the concrete pump again. Read the
pressure on the control block pressure gauge. If
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pump switch to “neutral,” then repeat Steps (5)
through (8) until the pressure is correct.
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NOTE!
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If you cannot adjust the pressure up to spec- 170-bar
ification, you have a problem. In this case,
unscrew the adjustment knob several turns 138-bar
so that your pressure is not too high when
you find the problem. Contact Schwing
America’s Service Department at (651) 429-
0999 for advice on how to continue. 230-bar
13. If you will not be setting the soft switch pressure,
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open the shutoff valves. The unit will not stroke
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17accum.epsL
Figure 87
Setting the soft switch circuit relief Accumulator unloading valve
pressure (original production)
To check or adjust the soft switch pressure setting,
perform the following steps. 1. Locate the accumulator unloading valve (Figure
87).
1. Open the soft switch shutoff valve. The rest of the
unit should still be set up as if you were going to 2. Loosen the jam nut of the high pressure valve
check or set concrete pump pressure. (230-bar) adjustment screw. With an allen wrench
turn the adjustment screw in one-and-a-half turns.
2. High-pressure the concrete pump. The control This will raise the pressure on the valve above 260-
block pressure gauge should read 100-bar (1450 bar.
PSI) instead of 300 bar. If adjustment is needed,
loosen the 2.5-mm allen screw on the face of the 3. Loosen the jam nut of the open relief valve (170-
soft switch relief valve cartridge (Figure 86). Using bar) and on the close valve (138-bar) pressure
a screwdriver, adjust the pressure up or down as adjustment screws. With an allen wrench turn both
needed, and lock into place with the 2.5-mm allen adjustment screws in two-and-a-half turns. This
screw. Recheck. Use a screwdriver, if necessary, to will raise the pressure on the valve above 260-bar.
prevent the cartridge from turning while tightening 4. Connect the whip hose of a 0–400 or 0–600 bar
the allen screw. Be sure to open the concrete pump gauge into the gauge port of the E-Stop manifold
shutoff valve when you are finished. The unit will (Figure 88).
not stroke with this valve close
Setting accumulator E-Stop manifold

pressure (original production)
The accumulator E-Stop manifold pressure circuit is
set to a maximum of 260-bar (3771 PSI) by its relief
valve on the emergency stop manifold. To check or
adjust this setting, you must first raise the pressure of
the accumulator unloading valves to 260-barr or
higher.
HOME PRINT
SERVICE TRAINING
Pressure Settings
4. Turn the close valve (138-bar) adjustment screw
17e-stopman.epsL
out two-and-a-half turns or until the gauge on the
accumulator unloading valve reads 138-bar (Figure
87).
5. Tighten the jam nuts on all three adjustment
screws.
Setting accumulator E-Stop manifold

pressure (current production)
The accumulator E-Stop manifold pressure circuit is
Relief valve set to a maximum of 260-bar (3771 PSI) by its relief
valve on the emergency stop manifold. To check or
Gauge port adjust this setting, you must first raise the pressure of
the accumulator unloading valves to 260-barr or
higher.
17accum2.eps
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Figure 88 @@@@@@@@@@@@@@@@@@@@@@@@

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Q

@
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@
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@
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Q

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E-Stop manifold accumulator relief valve ;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q;@Q
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;;;;;;;;;;;;;;;;;;;;;;;; ;@Q;@Q;@Q ;@Q;@Q;@Q ;@Q;@Q;@Q ;@Q;@Q ;@Q;@Q ;@Q;@Q ;@Q
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5. High-pressure the concrete pump. The pressure @@@@@@@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;;;;;;; Gauge
@@@@@@@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;;;;;;;
gauge should read 260-bar (3771 PSI). @@@@@@@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;;;;;;;
230-bar relief
@@@@@@@@@@@@@@@@@@@@@@

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6. If adjustment is needed, loosen the jam nut and @@@@@@@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;;;;;;;
170-bar relief
@@@@@@@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;;;;;;;
with a allen wrench turn the adjustment screw on @@@@@@@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;;;;;;;
the relief valve (Figure 88). Turn in to raise
@@@@@@@@@@@@@@@@@@@@@@

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pressure, turn out to lower pressure. Figure 89
7. Repeat steps (5) and (6) until the gauge reads 260-
(current production
bar.
8. Tighten the jam nut on the adjustment screw, 1. Locate the accumulator unloading valve (Figure
remove the whip hose and gauge from the gauge 89).
port, and replace the cap on the gauge port 2. Loosen the jam nut of the high pressure valve
(230-bar) adjustment screw. With an allen wrench
Setting the accumulator unloading valve turn the adjustment screw in one-and-a-half turns.
(original production) This will raise the pressure on the valve above 260-
Use an allen wrench to make these adjustments bar.
1. High-pressure the concrete pump. 3. Loosen the jam nut of the open relief valve (170-
bar.) With an allen wrench turn the adjustment
2. Turn the high pressure (230-bar) adjustment screw
screw in two-and-a-half turns. This will raise the
out one-and-a-half turns or until the gauge on the
pressure on the valve above 260-bar.
87). 4. Connect the whip hose of a 0–400 or 0–600 bar
gauge into the gauge port of the E-Stop manifold
3. Turn the open valve (170-bar) adjustment screw
(Figure 90.)
out two-and-a-half turns or until the gauge on the
87).
HOME PRINT
Pressure Settings
Setting the boom E-Stop manifold
17e-stopman.epsL
pressure
The boom E-Stop manifold pressure circuit is set to a
maximum of 350-bar (5076 PSI) by its relief valve on
the emergency stop manifold. To check the setting of
the valve with the highest pressure, you must first raise
the pressure of the lower two:
1. Locate the boom/outrigger hand valve (Figure 92).
2. Turn the outside body of the 300-bar relief valve
Relief valve that is located at the bottom of the boom/outrigger
hand valve in two-and-one-half turns. This will
Gauge port raise the pressure on the valve above 350-bar.
3. Locate the boom hand valves (Figure 92).
4. Turn the outside body of the (280-bar) relief valve
that is located at the back of the boom hand valve
in two-and-one-half turns. This will raise the
pressure on the valve above 350-bar.
5. Connect the whip hose of a 0–400 or 0–600 bar
Figure 90 gauge into the gauge port of the boom E-Stop
E-Stop manifold accumulator relief valve manifold valve (Figure 91).
17e-stop.epsL
GREASE TOWER BEARINGS
Gauge port and

GREASE TOWER BEARINGS ONLY GREASE WHICH HAS
THE FOLLOWING CHARACTERISTICS. USE LUBRIPLATE
5. High-pressure the concrete pump. The pressure

MO-LITH NO 2, TEXACO MOLYTEX EP 2 OR EQUAL.
BASE TYPE LITHIUM
NLGI NO 2
WORKING PENETRATION RANGE AT 77°F 265/295
MOLYBDENUM DISULPHIDE 3% MINIMUM
ASTM DROPPING POINT °F 350 MINIMUM
gauge should read 260-bar (3771 PSI) relief valve on

6. If adjustment is needed, loosen the jam nut and SAFETY INSTRUCTIONS
cab side of
with a allen wrench turn the adjustment screw on =
= STOP
WARNING
Emergency stop
switches do NOT
function when
manual bypass is
depressed.
manifold block.
the relief valve (Figure 90). Turn in to raise
pressure, turn out to lower pressure.
7. Repeat steps (5) and (6) until the gauge reads 260-
bar.
ator E!
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8. Tighten the jam nut on the adjustment screw, WARNING
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@@@@@@@@@@@@@@@@

@@@@@@@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;
Do not operate at
pressures exceeding
the rating of the
entire material
@@@@@@@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;;;;;;;
delivery system.
remove the whip hose and gauge from the gauge @@@@@@@@@@@@@@@@

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@@@@@@@@@@@@@@@@@@@@@@

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@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@@@@@@@

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port, and replace the cap on the gauge port. @@@@@@@@@@@@@@@@

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;;;;;;;;;;;;;;;;;;;;;;
Setting the accumulator unloading valve Figure 91
(current production) E-Stop manifold boom relief valve
Use an allen wrench to make these adjustments
1. High-pressure the concrete pump. 6. Pressure out any boom cylinder except #1 in a
2. Turn the high pressure (230-bar) adjustment screw retract position. You can pressure out a cylinder by
out one-and-a-half turns or until the gauge on the retracting a fully retracted cylinder or extending a
accumulator unloading valve reads 230-bar (Figure fully extended cylinder. The oil will have nowhere
89.) to go but over the relief valve.
3. Turn the open valve (170-bar) adjustment screw 7. The pressure gauge on the boom E-Stop manifold
out two-and-a-half turns or until the gauge on the should read 350-bar.
89.)
4. Tighten the jam nuts on all adjustment screws.
HOME PRINT
SERVICE TRAINING
Pressure Settings
8. If adjustment is needed, loosen the jam nut and 1. Connect the whip hose of a 0–400 or 0–600 bar to
turn the adjustment screw on the relief valve that is the gauge port of the boom/outrigger hand valve.
located on the boom E-Stop manifold valve (Figure 2. If this is not already done, start the truck engine
91). Turn in to raise pressure, turn out to lower and set the transmission and PTO as you would for
pressure. a pumping job.
9. Repeat steps (4) thorough (6) until the gauge reads 3. Locate the 300-bar relief valve on the bottom of
350-bar. the boom/outrigger hand valve.
10. Tighten the jam nut on the boom E-Stop manifold 4. Set the engine RPM to maximum.
adjustment screw, remove the whip hose and gauge
5. Push the outrigger enable pushbutton located next
from the gauge port, and replace the cap on the
to the outrigger hand valves. Hold the outrigger
gauge port.
hand valve lever in the retract position. The oil
11. Turn the outside body of the 300-bar relief valve coming from the pump has nowhere to go but over
that is located at the bottom of the boom/outrigger the relief valve on the boom/outrigger hand valve.
hand valve out two-and-one-half turns.
NOTE!
12. Turn the outside body of the (280-bar) relief valve
You cannot use the outrigger extend posi-
that is located at the back of the boom hand valve
tion for this adjustment because extend has
out two-and-one-half turns.
nonadjustable secondary relief functions
13. Set or reset the boom and the outrigger hydraulic built into the valve.
pressures.
6. The pressure on the pressure gauge should read
300-bar.
Setting the boom/outrigger pressure
7. If adjustment is needed, turn the outside body of
The outrigger circuit is set to a maximum of 300-bar
the relief valve that is located at the bottom of the
(4350 PSI) by the relief valve on the boom/outrigger
boom/outrigger hand valve. Turn in to raise
hand valve. This handvalve is located on the drivers
side of the turret (Figure 92). Due to the location of the
boom/outrigger handvalve and the outrigger control 8. Activate the enable pushbutton and the hand valve
lever used in this procedure, you will need an assistant and read the pressure on the gauge again. Repeat
to make the adjustments and read the gauge. steps (7) and (8) until the gauge reads 300-bar.
9. When the pressure is 300-bar, release the enable
pushbutton and the outrigger hand valve.
Turn body of valve 10. Remove the whip gauge from the boom/outrigger
to adjust. hand valve, and replace the cap on the gauge port.
300 bar Higher
Relief Valve Lower Setting the outrigger pressure
(4060 PSI) by the relief valve located on the drivers
side outrigger hand valve assembly (Figure 93). The
valve routes the oil to the two outrigger hand valve
banks, one on each side of the unit. A relief valve
inside the drivers side bank limits the entire outrigger
circuit to 280-bar.
PS
X.E
-28
lve
va
oom
tr ig/b
ou
Figure 92
Boom/outrigger hand valve
HOME PRINT
Pressure Settings
8. Activate the enable pushbutton and the hand valve
;;;;;;;;;;;;;
@@@@@@@@@@@@@

and read the pressure on the gauge again. Repeat
@@@@@@@@@@@@@

;;;;;;;;;;;;; WARNING 17dshopper.epsL
@@@@@@@@@@@@@

;;;;;;;;;;;;; steps (7) and (8) until the gauge reads 280-bar.
@@@@@@@@@@@@@

;;;;;;;;;;;;;
@@@@@@@@@@@@@

;;;;;;;;;;;;; 9. When the pressure is 280-bar, release the enable
@@@@@@@@@@@@@

;;;;;;;;;;;;;
Do not stand on
hopper grates.
@@@@@@@@@@@@@

;;;;;;;;;;;;; SAFETY INSTR
UCTIONS pushbutton and the outrigger hand valve.
@@@@@@@@@@@@@

;;;;;;;;;;;;;
OR
HOPPER GRATE
BEFORE REMOVING
ANY SERVICE:
PERFORMING
Electric Motors
Engines
Gasoline or Diesel 1. Stop the electric
motor.
@@@@@@@@@@@@@

;;;;;;;;;;;;;
1. Stop the engine. power
2. Lock out the
10. Remove the whip hose and gauge from the boom
key, place it to an
2. Remove the and put
source according t
in your pocket, approved lockout-tagou
a "DO NOT OPERATE" program.
tag on the switch.
@@@@@@@@@@@@@

;;;;;;;;;;;;;
3. Check accumulatorgauge
3. Check accumulator circuit pressure
gauge to verify
circuit pressure (if so equipped)
to verify
(if so equipped) zero system pressure.
zero system pressure.
WARNING
Stored hydraulic energy.
Release all hydraulic
pressure and verify zero
pressure on gauge
@@@@@@@@@@@@@

;;;;;;;;;;;;; hand valve, and replace the cap on the gauge port.
before servicing.
Setting the boom pressures

@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@

;;;;;;;;;;;;;;;; This product is covered by one or more of the following U.S. patents:
WARNING
The boom circuit is set to a maximum of 280-bar (4060
3,409,334
3,580,696
3,640,303
3,685,543
3,741,691
3,829,251
4,019,839
4,057,373
4,178,142
4,191,513
4,260,338
4,343,598
4,373,225
4,373,875
4,392,510
4,437,817
4,465,441
4,472,118
4,556,370
4,621,375
4,681,022
4,708,288
4,852,467
4,978,073
5,066,203
5,106,225
5,106,272
5,224,654
5,257,912
5,263,828
5,281,113
5,332,366
5,346,368
5,401,140
Re. 32,041
Re. 32,657
Re. 32,719
30308020 C
pressure on gauge
before servicing. PSI) by the relief valve on the boom hand valve
WARNING
Clear area
before activating
assembly (Figure 94).
outriggers
FRONT FOOT REAR FOOT
Relief Valve
Figure 93
Outrigger hand valve
1. Connect the whip hose of a 0–400 or 0–600 bar
gauge into the gauge port on the drivers side
outrigger hand valve.
2. If this is not already done, start the truck engine
and set the transmission and PTO as you would for
a pumping job. @;@; @;@;@;
;;;;;;;;;;
@@@@@@@@@@

3. Locate the 280-bar relief valve on the back of the @;@;@;@;@;@;@;@;@;@;
;;;;;;;;;;
@@@@@@@@@@

drivers side boom/outrigger hand valve, as shown @;@; @;@;@;@;@;
@;
;;;;;;;;;;
@@@@@@@@@@

in Figure 93.
@;@;@;@;@;@;@;@;@;
;;;;;;;;;;
@@@@@@@@@@

4. Set the engine RPM to maximum.
5. Push the outrigger enable pushbutton located next Figure 94
to the outrigger hand valves. Hold the outrigger Boom hand valves
hand valve lever in the retract position. The oil
coming from the pump has nowhere to go but over 1. Connect the whip hose of a 0–400 or 0–600 bar
the relief valve. gauge to the gauge port on the back of the boom
hand valve.
NOTE!
You cannot use the extend position for this
adjustment because extend has a nonadjust-
a pumping job.
able secondary relief functions built into the
valve. 3. Locate the 280-bar relief valve on the back of the
boom hand valve, as shown in Figure 95.
6. The pressure on the pressure gauge should read
280-bar.
the relief valve that is located at the back of the
drivers side outrigger hand valve. Turn in to raise
HOME PRINT
SERVICE TRAINING
Pressure Settings
Turn body of valve

Higher to adjust.
280 bar Lower

Relief Valve
ps
7.e
lk1
ntrlb
o mc
bo
Figure 95
Boom control relief valve
4. Pressure out any boom cylinder except #1 in a to the boom or the A frame when folding into the
retract position. You can pressure out a cylinder by transport position. To prevent this, there is a secondary
retracting a fully retracted cylinder or extending a relief valve that regulates only the pressure on the #1
fully extended cylinder. The oil will have nowhere retract function. The #1 boom down pressure should be
to go but over the relief valve. 170-bar (2465 PSI). To check or adjust the down side
5. Have your assistant read the pressure on the gauge relief valve:
at the boom hand valve. It should read 280-bar. If You have to raise the boom and rotate it for this
no adjustment is needed, skip to Step 8. procedure, so you must set the outriggers as you would
6. To adjust the boom pressure, locate the relief valve to pump a job. Release the boom strap. To adjust the
on the back of the boom control block (Figure 95). valve, you will need a 2.5 mm allen wrench and a
7. If adjustment is needed, turn the outside body of standard screwdriver.
the relief valve that is located at the back of the 1. Connect the whip hose of a 0-400 or 0–600-bar
boom hand valve. Turn in to raise pressure, turn gauge into the gauge port shown in Figure 96.
out to lower pressure.
8. When the pressure is 280-bar, release the boom
hand valve.
9. Remove the whip hose and gauge from the boom
hand valve, and replace the cap on the gauge port.
Set boom section #1 down pressure

Because gravity wants to pull your boom down, high
pressure is not needed to bring section #1 down.
Allowing high pressure to be available leaves open the
possibility of an inattentive operator’s causing damage
HOME PRINT
Pressure Settings
170-bar gauge
port
170-bar relief
valve

;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@
@;
@;
DA
@;@;@;@;@;@;@;@;@;@;@;@;
Ele
Sta ctr NG
@;
;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@

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;;;;;;;;;;;;;;;
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;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@

d
on safe d
@;@; @;@;@;@;@; @;@;

de ty
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;;;;;;;;;;;;;;;;
@@@@@@@@@@@@@@@@

@;@;@; @;(Hoses @;@;@; @; abbreviated for clarity)
Figure 96
Section #1 down relief valve
NOTE! screwdriver until the pressure reads just under 170-

For the following procedure, we must bring bar. Retightening the set screw will raise the
section #1 all the way down until the cylin- pressure slightly. (If it becomes a problem, hold the
der bottoms out. The cylinder does not bot- cartridge adjustment with the screwdriver while
tom out if you set the folded boom into the you tighten the set screw.) Recheck the pressure,
A-frame (travel position). Position the boom and readjust if needed.
so this can be done without hitting the 5. When the pressure is set at 170-bar, remove the
truck, electrical wires, or any other obsta- whip hose gauge and replace the cap on the gauge
cles. port.
2. Unfold section #2 from section #1 until it is 6. The boom pressure setting sequence is complete. If
straight. you are finished with the boom, slew it back into
3. Bring section #1 down until the cylinder is the transport position, and lower #1 into the A-
completely bottomed out. Activate the #1 down frame cradle. Reattach the boom strap.
(retract) hand valve. The boom will not be able to
move because the cylinder is already bottomed out. Setting water pump pressure
Read the pressure on the gauge that you just The agitator/water pump-compressor circuit has a
installed. It should read 170-bar. If no adjustment maximum pressure of 200-bar (2900 PSI), limited by
is necessary, skip to Step 7. the relief valve located in the water pump-compressor
4. If adjustment is needed, loosen the set screw with hand valve. There is a gauge port for checking or
the 2.5 mm allen wrench. While you activate #1 setting the pressure in this circuit. The port is located
down, adjust the relief cartridge with the on the water pump-compressor hand valve.
HOME PRINT
SERVICE TRAINING
Pressure Settings
To set the water pump circuit pressure perform the
following steps: Turn body of valve
1. Stop the unit, and put the key in your pocket. to adjust.
200 bar Higher
2. Connect the whip hose of a 0-400 or 0-600 bar
gauge to the gauge port on the water pump hand
Relief Valve Lower
valve.
3. If your unit does not have a compressor, skip to
Step 6.
4. If your unit has a compressor remove one of the
hoses from the water pump motor and plug the
hose and the open fitting with approved hydraulic
dead plugs. Do not improvise on these plugs. If
you don’t have any, contact Schwing’s Spare Parts
Department and order them before continuing with
this procedure. You will need: pv
lv1
7.E
PS
p/cm
• Qty 2 VS-16S locking plugs, part number wtrpm
10016803
• Qty 1 GS-16S straight fitting, part number Figure 97
10008088 Water pump relief valve
• Qty 2 16S capnuts, part number 10001743 9. If adjustment is needed, turn the outside body of
• All of these fittings and many, many more the relief valve that is located at the bottom of the
extremely useful items are included in the water pump/compressor hand valve. Turn in to
Troubleshooting Kit, part number 30308553. raise pressure, turn out to lower pressure.
We highly recommend purchase of this kit. It 10. When the pressure is set to 200-bar, stop the engine
will pay for itself many times over. and remove the key.
5. Be sure that one of the locking plugs and capnuts 11. Remove the dead plugs and store in a clean area or
are tightened on the straight fitting and that the in a plastic bag or something similar to keep dirt
dead plugs are securely tightened to the hose and from entering the fittings. Re-attach the hose to the
the open motor fitting. water pump motor fitting and tighten securely.
6. Locate the relief valve on the water pump hand (Torque is correct if you make one complete
valve. It comes out of the valve body toward the revolution after feeling initial resistance increase.)
ground, and it is the smaller of the two cartridges 12. Remove the whip hose and pressure gauge.
that you’ll see. Replace the gauge port cover.
7. Be sure that any personnel are clear, and restart the
engine. Setting the agitator pressure
8. Activate the water hand valve by pushing or The agitator circuit has a maximum pressure of 150-
pulling the handle. This will send the oil against bar (2175 PSI), limited by the relief valve located in
the high pressure plug. The oil will have nowhere the agitator hand valve (Figure 98). There is a gauge
to go, so it will return to the tank over the relief port for checking or setting the pressure. The port is
valve in the water pump hand valve. The pressure located on the agitator hand valve.
at which it relieves can be seen on the gauge. It 1. Stop the unit, and put the key in your pocket.
should read 200-bar. If no adjustment is needed,
2. Connect the whip hose of 0-400 or a 0–600-bar
skip to Step 10.
gauge to the gauge port on the agitator hand valve.
3. If your unit is equipped with a agitator shut off
valve, close it (Figure 98). Skip to Step 6.
HOME PRINT
Pressure Settings
valve in the agitator hand valve. The pressure at
which it relieves can be seen on the gauge. It
agit.shutoff.eps
should read 150-bar.

agitator hand valve. Turn in to raise pressure, turn
13. When the pressure is set at 150-bar, stop the engine
and remove the key. Open the shut off valve or
remove the dead plugs and store in a clean area or
in a plastic bag or something similar to keep dirt
from entering the fittings. Reattach the hose to the
agitator motor fitting and tighten securely. (Torque
is correct if you make one complete revolution
after feeling initial resistance increase.)
Figure 98
Agitator shutoff valve 14. Remove the whip hose and pressure gauge.
Replace the gauge port cover.
4. If your unit is not equipped with an agitator shut

off valve, remove one of the hoses from the
agitator motor and plug the hose and the open
fitting with approved hydraulic dead plugs. Do not
improvise on these plugs. If you don’t have any,
contact the Schwing’s Spare Parts Department and
order them before continuing with this procedure.
All of these fittings and many, many more
extremely useful items are included in the
Troubleshooting Kit, part number 30308553. We
highly recommend purchase of this kit. It will pay
for itself many times over. You will need:
5. - Qty 2 VS-16S locking plugs, part number
10016803
6. - Qty 1 GS-16S straight fitting, part number
10008088
7. - Qty 2 16S capnuts, part number 10001743
8. Be sure that one of the locking plugs and capnuts
are tightened on the straight fitting and that the
dead plugs are securely tightened to the hose and
the open motor fitting.
9. Locate the relief valve on the agitator hand valve. It
comes out of the valve body toward the ground,
and it is the smaller of the two cartridges that
you’ll see.
10. Be sure that any personnel are clear, and restart the
engine.
11. Activate the agitator hand valve by pushing or
pulling the handle. This will send the oil against
the high pressure plug. The oil will have nowhere
to go, so it will return to the tank over the relief
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 28X NOTE!
Check hydraulic pressure order one using part #10004680 (valve) and
#30303432 (tube). Contact the Schwing
Check all hydraulic pressures. Changes in pressures Service Department for installation
can indicate trouble in one or more components. instructions. If you can’t wait for a shutoff
NOTE! valve, you will need to remove one of the
Hydraulic pressure settings shown in the hoses from the agitator motor, and plug the
following procedures are for a 2023 twin hose and the open fitting with approved
circuit pump kit. However, because hydraulic dead plugs. Do not substitute
different pump kits may be used in this unit, other plugs, such as a steel bearing, inside a
all pressure settings should be verified with cap fitting.
the pressure settings shown on the 2. Position the agitator lever in the forward or reverse
applicable hydraulic schematic. The position. The agitator will not be able to turn, and
hydraulic schematics for your pump kit are the oil will be forced over the relief valve.
in the Appendix of this manual. 3. At idle speed (about 600 RPM), about 4.5
Read all of the instructions before beginning any horsepower is being converted to heat. Position the
pressure settings. You will need an assistant for parts of agitator lever to the off (center) position when the
the procedure. temperature gauge on the rear control panel
You and any assistants should wear eye protection indicates 50°C.
when checking or setting pressures. 4. Open the agitator shutoff valve or remove the plug,
Be sure that the waterbox covers are installed on the and reconnect the hose to the agitator motor.
waterbox.
We do not recommend using the remote control box for Closed
52qrttrn.epsL
the following procedures.

Wear safety glasses when setting pressures.
Position the “remote/local” switch on the rear control
panel to the “local” position.
circuit must be used to heat the hydraulic oil. Do not Shown in the
jam the paddles to force the oil over relief by stopping open position
oil using the agitator circuit, follow these instructions. Figure 99
1. Locate the agitator shutoff valve, and close it Agitator shutoff valve
HOME PRINT
Pressure Settings
The general location of the components used to check NOTE!
or set hydraulic pressures in shown in Figure 100. Depending on the type of pumpkit and
original or current production, your
concrete pump unit may or may not have all
the components shown in Figure 100
Boom (Section #1) Down

Pressure Relief Valve and Boom Hand Valves and Gauge
Gauge Port Port
Water Pump/Compressor
Hand Valve and Gauge Port E-Stop Manifold Valves and
Gauge Ports
Electric Stroke Limiter and
Pressure Reducing Control Boon/Outrigger Hand Valve
Block(s) and Gauge Port
Soft Switch Shutoff Valve
(twin circuit)
Concrete pump forward/reverse
Dampener Valve (single and agitator hand valves
circuit)
Concrete Pump Shutoff Soft Switch and Concrete

Valve Pump Relief Valves
Outrigger Hand Valve
Outrigger Hand Valve and
Gauge Port
Concrete Pump Pressure Gauge
Accumulator Unloading
Manifold Valve and Gauge Manual Stroke Limiter
(twin circuit)
Rear Control Panel
Agitator Hand Valve and
Electric agitator switch
Gauge Port
Agitator Shutoff Valve Accumulator Pressure Gauge

(twin circuit)
Figure 100
HOME PRINT
SERVICE TRAINING
Pressure Settings
Set the concrete pump main relief valve 8. Use the concrete pump “forward/neutral/reverse”
(single- circuit). switch to put the pump into the “forward” position.
The unit will stroke only once, then the rock
The BPL 1200 concrete pump is designed to operated
cylinder will retract. Oil will have nowhere to go
at a maximum pressure of 300 bar (4350 PSI). It is
except over the concrete pump main relief valve.
controlled by the main relief valve (Figure 101), The
main relief valve is located at the front of the control 9. Read the pressure on the concrete pump pressure
block (towards the truck cab). To check or set the main gauge, located on the main control block. It should
relief pressure perform the following steps: read 300 bar. Position the throttle switch to the
“neutral” position. If no adjustment is needed, skip
to Step 12.
Mount bolt and washer

removed for illustration
grooves2.eps
Grooves in handle should

line up with grooves
Raise in valve shaft
Lower
pressure pressure
gray valve.eps L
Figure 101
Main relief valve (single circuit)

2. Wear safety glasses when setting pressures. quarter turn.eps
3. Close the concrete pump shutoff valve (Figure 71)

Figure 102
4. Position the “remote/local” switch, on the rear Concrete pump shutoff valve
control panel, to the “local” position. (single circuit
5. Use the throttle switch, on the rear control panel, to
rev the engine up to full RPM. 10. If adjustment is required, loosen the jam nut on the
relief valve adjusting screw with a 13-mm spanner
6. Make sure the manual stroke limiter valve and the wrench (Figure 101).
dampener valve are turned, counter-clockwise, all
the way out. 11. Turn the adjustment knob on the relief valve to
adjust the pressure. Turn the adjustment knob in
7. If the unit is equipped with an electric stroke (clockwise) to raise pressure, out (counter
limiter, turn the control knob clockwise to the clockwise) to lower the pressure.
maximum output (+) position.
12. Retighten the jam nut. (Tightening the jam nut
tends to raise the pressure. If this happens, hold the
adjustment knob while tightening the jam nut.)
HOME PRINT
Pressure Settings
13. Put the concrete pump into the “forward” position 4. Position the “remote / local” switch on the rear
again. The machine will not stroke this time, but control panel to the “local” position.
will develop maximum pressure. Read the pressure 5. Use the throttle switch on the rear control panel to
on the control block pressure gauge. If more rev the engine up to full RPM.
adjustment is needed, return the pump to “neutral,”
6. Use the concrete pump “forward/neutral/reverse”
then repeat Steps 8 through 11. until the pressure is
switch to put the pump into the “forward” position.
at 300 bar. Position the throttle switch to the
“neutral” position.
cylinder will retract. Oil will have no where to go
14. Open the shutoff valve. The unit will not stroke except over the concrete pump main relief valve.
with the shutoff valve closed.
NOTE! gauge located on the main control block. It should
If you cannot adjust the pressure up to 300 read 350 bar. Position the concrete pump switch to
bar, you have a problem. In this case, turn the off (neutral) position. If no adjustment is
the adjustment knob out by several turns so needed, skip to Step 11.
that your pressure isn’t too high once the 8. If adjustment is needed, use a 9/16 inch spanner
problem is found. Contact Schwing Amer- wrench, loosen the jam nut on the main relief valve
ica’s service department for advice on how adjusting screw (Figure 103).
to continue. 9. Insert a 5/32 inch allen wrench in the adjustment
• Set the concrete pump main relief valve (twin screw. Turn the screw in to raise pressure or out to
circuit) lower the pressure.
The main relief valve is the primary pressure control 10. Once the pressure is correct (350 bar) retighten the
device on units equipped with Rexroth A7VO jam nut. Tightening the nut tends to raise the
hydraulic pumps. This pump is designed to operate at a pressure, so check pressure again after tightening.
maximum pressure of 350 bar (5075 PSI). Verify the correct pressure setting (350 bar).
11. Open the concrete pump shutoff valve and soft
switch shutoff valves. The unit will not stroke with
WARNING these valves closed.
Hot oil expulsion hazard. Stand away
from pumpkit when checking hydraulic
pressures.
W008.eps
The main relief valve is set to very high

pressure (at least 350 bar). Use the controls
on the rear control panel when checking the
pressure of the main relief valve, so you will
be out of the way if a hose or a fitting
malfunctions.
Refer to Figure 103 for the location of the components
used to set the concrete pump pressures. Use the
following steps to set the main relief valve pressure:
3. Close the concrete pump shutoff and soft switch
shutoff valves (Figure 103).
HOME PRINT
SERVICE TRAINING
Pressure Settings
w
Gauge port
Hif
lrv
vw
.ep
s
Main relief valve
Soft switch
relief valve

Soft switch
shutoff valve
grooves2.eps
Concrete pump
hif
shutoff valve low
brn
.ep
s
in valve shaft
Figure 103
Location of the main relief valve
Setting the soft switch circuit relief 3. If adjustment is needed, loosen the jam nut on the
pressure soft switch relief valve with a 9/16 inch spanner
wrench. Adjust the pressure up or down, as needed,
using a 5/32 inch Allen wrench. When the correct
proceed as follows:
pressure is achieved, re-lock the jam nut.
soft switch shutoff valve. The rest of the unit Be sure to open the concrete pump shutoff valve when
should still be set up as though you were going to you are finished. The unit cannot stroke with this valve
check concrete pump pressure. closed.
2. Increase the engine RPMs to high pressure the
concrete pump. The pressure gauge should read 80
bar (check your schematic). If no adjustment is
HOME PRINT
Pressure Settings
Set accumulator circuit hydraulic oil .
pressure (units with a pressure-
compensated pump)
You will need an assistant for parts of this procedure.
accumulator circuit, perform the following steps:
1. Stop the truck, put the key in your pocket, and Accumreg.eps

2. Loosen the jam nut on the pressure regulator of the
accumulator hydraulic pump. Turn the screw in
two-and-a-half turns. This will raise the regulator
pressure above 300 bar (Figure 74).
NOTE! Accumulator pump
pressure regulator
If your unit is a current production model
Figure 104, skip Steps 3,4, and 8 of this
procedure.
Figure 105

the gauge port of the E-Stop manifold (Figure 75).
4. Loosen the jam nut on the accumulator circuit
relief valve, located on the E-Stop manifold. Turn
no
ca
rt.e
ps
the screw in two turns. This will raise the relief
setting above 300 bar (Figure 75).
e-stop/left.epsL
Relief Valve and

Figure 104 Gauge Port
E-Stop manifold
(current production)
Figure 106
E-Stop manifold relief valve
accumulator circuit (original
production)

the truck engine, engage the pumps, and bring the
HOME PRINT
SERVICE TRAINING
Pressure Settings
6. Read the pressure on the accumulator circuit gauge 8. You will need an assistant for this step. With the
(Figure 107). Pressure should read 300 bar (4350 engine still running, adjust the relief valve on the
PSI). If no adjustment is needed, skip to Step 8. E-Stop manifold. Back out the adjustment screw
until pressure reads 260 bar (3771 PSI) on the
gauge connected to the E-Stop manifold.
accumgag.eps
WARNING
Entanglement hazard. Stop drive shafts
before adjusting the accumulator pump
pressure regulator.
W010.eps
regulator two-and-a-half-turns. This restores the
pressure regulator to its original setting (Figure
74).
the truck, and rev the engine RPM to maximum.
Figure 107 11. Read the pressure on the accumulator gauge. It
Accumulator pressure gauge should read 200 bar (2900 PSI).
12. If additional adjustment is needed, you must stop
the truck engine each time you approach the
accumulator circuit hydraulic pump (Figure 74).
Adjust the accumulator pump pressure regulator
(Figure 76). Loosen the jam nut, and turn the screw
screw in to increase pressure or out to decrease
in to increase pressure or out to decrease pressure.
pressure. Lock the jam nut when pressure is correct
Tighten the jam nut when pressure is at 300 bar.
(200 bar).
45s3blck.epsL
Relief Valve
Figure 108
Accumulator manifold pressure relief valve
HOME PRINT
Pressure Settings
Setting the outrigger pressure 3. Set the engine RPM to maximum.
With a seven place hand valve, the boom/outrigger 4. Push the outrigger enable pushbutton located next
selector valve is inside the boom control block. This to the outrigger handvalve (passenger side). Hold
valve is activated when the outrigger enable push an outrigger hand valve lever in the jacking-retract
button is pushed. There is not a separate relief for this position. The oil coming from the pump has
circuit, and therefore nothing that must be set. nowhere to go but over the outrigger relief valve.
The outrigger circuit is set to a maximum of 280-bar NOTE!
(4060 PSI) by the relief valve located on the passenger You cannot use the extend position for this
side outrigger hand valve assembly (Figure 109). The adjustment because extend has a nonadjust-
valve routes the oil to the two outrigger hand valve able secondary relief functions built into the
banks, one on each side of the unit. A relief valve valve.
inside the passenger side bank limits the entire 5. Turn the outside body of the relief valve cartridge
outrigger circuit to 280-bar. that is located at the back of the passenger side
NOTE! outrigger hand valve (Figure 109). Turn in
On some pump units the relief valve may be (clockwise) to raise pressure, turn out (counter
in a slightly different location (opposite side) clockwise) to lower pressure.
than shown in Figure 109. 6. When the pressure on the gauge connected to the
outrigger hand valve is 280-bar, release the enable
push button and the outrigger hand valve.
280 bar 7. Remove the whip hose and gauge from the
Lower outrigger handvalve, and replace the cap on the
Relief Valve gauge port.
• Pressure reducing valve
This valve is preset at the factory. Contact Schwing
Higher America’s Service Department at (651) 429-0999 for
information on checking or setting this valve.
• Electric stroke limiter
Turn body of valve
to adjust.
America’s Service Department at (651) 429-0999 for
information on checking or setting this valve.
Figure 109 • Load-sensing boom pressures (7 place
Outrigger hand valve proportional circuit)
If your unit has a load-sensing proportional system, it
1. Connect the whip hose of a 0–400 or 0–600 bar to will have different pressure adjustments than if it is
the gauge port on the back or side of the passenger equipped with a black and white boom system. The
side outrigger hand valve (Figure 109). following instructions are for load-sensing proportional
systems. If you have a unit equipped with a black and
white boom system, contact Schwing Service
Department for the correct instruction pages.
a pumping job.
In a black and white boom system, the hydraulic pump
puts out an unchanging amount of oil, and speed
WARNING control is done by restricting the oil to certain functions
with orifices. In a load-sensing system, the pump puts
Tipping hazard. Never set outrigger out more or less oil to respond to the needs of the
pressures with the boom unfolded. system. Generally, the pump puts out enough oil to
Pressure setting procedure requires maintain a 20 bar higher pressure at the pump than
retraction of an outrigger jacking what the cylinders actually require. This 20 bar is
W026.eps
cylinder. called delta P (∆P). Additionally, we set the hydraulic

HOME PRINT
SERVICE TRAINING
Pressure Settings
pump so that it always puts out a small amount of oil, fine tuned at the factory, and should not be
even if no oil is needed for the system. This oil is used adjusted unless absolutely necessary.
to ensure that you have control when you need it. The
setting to maintain this minimum amount of oil is
called Q-min (pronounced “cue min”). To set the boom
or outrigger hydraulic pressures on a load-sensing WARNING
system, begin by setting Q-min and ∆P.
The general locations of the components used to set Entanglement hazard. Stop drive shafts
before adjusting Q-min.
W009.eps
boom hydraulic pressures is shown in Figure 110.
NOTE!
Do not adjust ∆P or Q-min if your boom is Each time the Q-min screw must be
operating as you like it. The pressure setting adjusted, the engine must be stopped, or at
procedure uses a standard starting point least the transmission must be taken out of
and must be fine tuned from there. It was gear so that the drivelines stop turning.
Boom Hand Valves E-Stop Manifold ∆P Regulator Q-min Adjust Screw
Figure 110
Location of components used to
check or set boom pressures
HOME PRINT
Pressure Settings
140 bar gauge port (use 0-400

bar gauge when checking)
140 bar downside

relief cartridge
0-400 bar
gauge port
0-60 bar
gauge port
boom control
block relief valve
ps
v.e
itprd
ap
15 bar pretension
adjustment screw
Figure 111
Boom hand valves
Check or set ∆P adjusted by a screw on the boom hydraulic pump

To check or set ∆P follow these steps: (Figure 112). Turn the Q-min adjustment screw out
(counter clockwise) three full turns.
1. Stop the truck engine and place a “Do Not
Operate” sign on the truck windshield. 4. Check that all personnel are clear of the truck, then
restart the engine, engage the pumps, and leave the
Caution! When checking Delta-P, it is important to engine at an idle. Pressure should read 20 (±1) bar.
note that you be installing a low pressure gauge into
5. Increase the throttle RPM and the ∆P pressure
a high pressure port. Any activation of a boom
should remain the same. If the pressure fluctuates
function or activation of an E-stop button will
with a change in engine RPM you are probably still
damage the low pressure gauge.
reading Q-min. The Q-min adjustment screw will
2. Install a 0-100 bar gauge in the 0-400 bar gauge need to be turned out more.
port of the manual boom handvalves. Take care not
6. If no adjustment is needed, turn the Q-min
to accidently install the gauge in the 0-60 bar port.
adjustment screw in (clockwise) three full turns or
(Figure 111).
what ever amount it was turned out.
7. If adjustment is needed, continue to Step 8.
WARNING
W009.eps
3. To ensure that the pump is putting out only enough

oil needed to maintain ∆P, we need to change the
setting of the Q-min adjustment screw. Q-min is
HOME PRINT
SERVICE TRAINING
Pressure Settings
Check or set Q-min
Q-min
Q-min pressure is checked when the engine is at the
adjustment screw
maximum specified RPM, but must adjust with the
engine stopped. To check or set the Q-min follow these
steps:
1. Install a 0-600 bar gauge in the 0-400 bar gauge
port of the manual boom handvalves. Take care not
to accidently install the gauge in the 0-60 bar port.
Q-minscrew.eps (Figure 111).
Q-max
Figure 112 engine RPM to max. All boom functions must be
Q-min adjust screw in neutral, and all emergency stop buttons
should be up (not engaged).
8. Delta P is adjusted by the ∆P screw on the ∆P
3.
regulator (Figure 112). The location of the ∆P
regulator valve is shown in Figure 110. Loosen the
jam nut and adjust the screw in to increase WARNING
pressure, or out to decrease pressure until it is set
at 20 bar (±1). Contact Schwing America’s Service Entanglement hazard. Stop drive shafts
Department if you are unable to adjust the pressure before adjusting Q-min.
W009.eps
to specification.
NOTE!
4. Read the pressure on the 0 - 600 gauge. If the
If the boom does not operate smoothly at 20
pressure reads less than 100 bar, return the engine
bar, you must fine tune the adjustment.
RPM to idle speed and install a 0-100 bar gauge.If
9. Remove the gauge, and adjust ∆P until the boom is the pressure reads more than 100 bar, stop the drive
responsive and smooth. When done, the gauge shafts from tuning and turn the Q-min adjustment
(reinstalled) must read between 14 and 25 bar. The screw in until the pressure is below 100 bar.
electronics in the control system can also affect
5. Bring the engine RPM to maximum. Q-min
how the boom operates, so if ∆P adjustment does
pressure should read 40 - 45 bar.
not seem to help, reset to 20 bar and check the
electrical settings. Once electrical settings are 6. If no adjustment is needed, stop the drive lines
verified, you could again refine the boom action from turning. Tighten the jam nut on the Q-min
with the ∆P adjustment. Caution! Do not operate adjustment screw. Remove the 0-100 gauge.
any functions while setting ∆P. 7. If adjustment is needed, continue to Step 17.
10. When ∆P has been set remove the 0-100 gauge. 8. Turn the Q-min screw in to raise the pressure
(Figure 112). Turn it out to lower the pressure. Be
sure that you stop the drive shafts from turning
each time before making the adjustment. When
pressure is correct (40-45 bar), tighten the jam nut
on the Q-min adjustment screw. Remove the 0-100
deltaPvlv.eps
bar gauge.
∆P adjust
T Set boom pressures (load sensing
screw
proportional booms)
Figure 113 Now that ∆P and Q-min are set, you can check or set
∆P regulator valve the boom valve pressures. There are three pressure
settings on the boom circuit (Figure 114).
HOME PRINT
Pressure Settings
• Pressure regulator (the high-pressure adjustment • The redundant relief valve located in the
screw on the ∆P regulator valve), set at 290 bar emergency stop manifold, set at 320 bar (4640
(4205 PSI). PSI).
• The boom control block relief valve, set at 350 bar
(5075 PSI).
∆P Regulator Valve
(high pressure
adjustment screw)
0-400 bar
gauge port
0-60 bar
gauge port
deltaPvlv.eps
s
.ep
nly
ipo
ap
boom control T
block relief valve
e-stop/right.epsL
E-Stop Manifold
Redundant Relief Valve
ps
rt.e
ca
no
Original Production Current Production
Figure 114
Boom hydraulic pressure adjustment
components
HOME PRINT
SERVICE TRAINING
Pressure Settings
To check the setting of the valve with the highest the ∆P regulator out (lowering the pressure) until
pressure, you must first raise the pressure of the lower the gauge reads 290 bar. Release the pressurized
two: function and lock the jam nut. The boom pressures
1. Loosen the jam nut of the high pressure adjustment are now set. If you did not get the readings
screw of the ∆P regulator. Turn the screw in two- specified after following the instructions, contact
and-a-half turns. This will raise the pressure on the Schwing America’s Service Department at (651)
∆P regulator above 350 bar. 429-0999 for advice on how to continue.
2. Loosen the jam nut of the adjustment screw on the
Set the down side relief valve pressure
E-stop manifold redundant relief valve. Turn the
screw in one-and-a-half turns. This will raise the This valve is a secondary relief valve for #1 cylinder
pressure setting of the relief valve to above 350 bar. retract function (Figure 115). Proper adjustment
3. Pressure out any boom cylinder except #1 down by ensures that the #1 boom and the A-frame won’t be
pushing or pulling the control handle. To pressure damaged by putting the boom in the cradle. To adjust
out a cylinder, retract a fully retracted cylinder or this valve (requires a 2.5 mm Allen wrench and a
extend a fully extended cylinder. The oil is forced standard screwdriver). Set the pressure of the 140 bar
over the relief valve. down side relief valve using the following steps:
4. The tell tale hiss of an open relief valve should be 1. Install a 0 - 400 bar or 0 - 600 bar gauge into the
coming from the Apitech control block relief valve 140 bar gauge port (Figure 115).
now. If it isn’t, raise the setting of the other 2. Unfold the #2 section from #1 until it is straight.
pressure devices until the hiss originates at the For the following procedure we must bring #1 all
Apitech control block relief valve. Read the the way down until the cylinder bottoms out.
pressure on the gauge connected to the 0-400 bar Position the boom so this can be done without
gauge port on the boom hand valve block. It should hitting the truck or any other obstacle.
read 350 bar. If pressure is correct, proceed to Step 3. Bring #1 down until the cylinder is completely
5. bottomed out. The cylinder does NOT bottom out
NOTE! if you are setting the folded boom into the A-frame
(travel position).
Although the pressure specification for the
Apitech relief valve is 350 bar, you may con- 4. Activate the #1 down (retract) handvalve The
tinue to use the relief valve as long as the boom will not be able to move because the cylinder
cartridge maintains at least 330 bar. If you is already bottomed out. Read the pressure on the
must replace the valve, proceed to Step 5 gauge that you just installed. It should read 140 bar
before using the concrete pump again, and (2030 PSI). If no adjustment is necessary, skip to
re-do this entire procedure when you have Step 6.
installed the new valve. If pressure on the 5. If adjustment is needed, loosen the set screw of the
Apitech relief valve is below 290 bar, you 140 bar relief valve with the 2.5 mm allen wrench.
should not use the concrete pump until the While you activate #1 down, adjust the relief
valve is replaced. cartridge with the screwdriver until the pressure
5. Screw out the E-Stop manifold redundant relief reads just under 140 bar. Retighten the set screw.
valve adjustment screw one-and-a-half turns. The pressure may raise slightly. Recheck the
Pressure out any boom cylinder except #1 down, pressure, and readjust if needed.
and read the gauge. Pressure should read 320 bar. 6. When the pressure is set at 140 bar with the set
If it does not, turn the screw in to raise pressure, or screw tight, you can remove the whip hose gauge
out to lower pressure until it is set at 320 bar. If the and replace the cap on the gauge port.
location of this valve causes you to be near the 7. The boom pressure setting sequence is complete. If
drive lines, be sure to stop them from turning you are done with the boom, slew it back into the
before accessing the valve. transport position, and lower #1 into the cradle and
6. You will need a helper for this step. While attach the boom transport strap.
pressuring out any boom cylinder except #1 down,
have your helper adjust the high pressure screw of
HOME PRINT
Pressure Settings
140 bar
gauge port
140 bar relief valve
ps
0.e
it14
ap
Figure 115
140 bar relief valve and gauge port
Pretension
gauge port
s
.ep
rtn
itp
ap
Pretension adjustment screw
Figure 116
Pretension adjustment screw and gauge port
Set 15 bar pretension 2. Start the truck engine, but leave it at an idle.
To check or set pretension, follow these steps: Pretension adjustment is made at an idle to
establish the minimum pressure setting. (Note: As
1. Stop the truck engine. Plug the 0 - 40 bar gauge RPM is increased, pretension pressure will rise.)
into the pretension check port of the Apitech Read the pressure on the gauge. If it reads 15 bar ±
handvalve (Figure 116). 1 bar, the pressure is set correctly.
HOME PRINT
SERVICE TRAINING
Pressure Settings
3. If adjustment is needed, loosen the jam nut on the
pretension valve (Figure 116). Turn the screw in to
raise pressure, and out to lower pressure. When the Agitator Relief Valve Turn body of valve
pressure is correct, retighten the jam nut. Gauge port to adjust
Higher
4. Stop the engine, and remove the 0 - 40 bar gauge.
Pretension setting is complete.
Lower
Set water pump pressure
With a seven place hand valve, the water pump
hydraulic control is inside the boom control block.
There is not a separate relief valve for this circuit and,
therefore nothing that must be set.
Set the agitator pressure

The agitator circuit has a maximum pressure of 200 bar ag
itrlf
2.e
ps
(2900 PSI), limited by the relief valve located on the

back of the agitator hand valve (Figure 117). The
current production agitator handvalve is located on the Figure 118
passenger side of the main control block (Figure 118). Agitator hand valve
(current productions)

pres rel valv agit.wpsL

gauge to the gauge port on the agitator hand valve
(Figure 117).
Gauge Port 3. If your unit is equipped with an agitator shutoff
Relief Valve valve, close it (Figure 119). Skip to Step 5.
52qrttrn.epsL
Closed
Shown in the
open position
Figure 117 Figure 119

Agitator hand valve Agitator shutoff valve
(original production)
4. If your unit is not equipped with an agitator shutoff
valve, remove one of the hoses from the agitator
motor and plug the hose and the open fitting with
approved hydraulic dead plugs. Do not improvise
on these plugs. If you don’t have any, contact
HOME PRINT
Pressure Settings
5. Schwing’s Spare Parts Department and order them
before continuing with this procedure. All of these
fittings and many, many more extremely useful
items are included in the Troubleshooting Kit, part
number 30308553. We highly recommend
purchase of this kit. It will pay for itself many
times over. You will need:
• Qty 2 VS-16S locking plugs, part number
10016803
• Qty 1 GS-16S straight fitting, part number
10008088
• Qty 2 16S capnuts, part number 10001743
7. Locate the relief valve on the back of the agitator
hand valve.
8. Be sure that all personnel are clear, and restart the
engine.
agitator hand valve. Turn in to raise pressure or
turn out to lower pressure.
and remove the key. Open the shutoff valve or
remove the dead plugs and store them in a clean
area or in a plastic bag or something similar in
order to keep dirt from entering the fittings.
Reattach the hose to the agitator motor fitting and
tighten securely. (Torque is correct if you make one
complete revolution after feeling initial resistance
increase.)
12. Remove the whip hose and pressure gauge.
HOME PRINT
SERVICE TRAINING
Pressure Settings
31 EZ handle as well as on the handle itself, which will
indicate the open or closed configuration of the
valve (Figure 120). If the handle is removed from
Check all hydraulic pressures
the agitator shutoff valve (Figure 120) or the
Changes in pressure can indicate trouble in one or concrete pump shutoff valve (Figure 122) and
more components and will serve as early warning replaced in a different configuration, the grooves in
indicators if you check them on a regular basis. The the handle may no longer indicate the proper open/
specifications for each circuit are shown on the closed orientation of the valve. The grooves in the
hydraulic schematics found in the Appendix section of shaft give the only true indication of the valve’s
this manual. The hydraulic schematics are the only position.
documents in this manual that have been updated
specifically for your unit, by the serial number, so in NOTE!
each of the following procedures you will be told to If your unit is an early production model
refer to the schematic for the pressure required. and does not have an agitator shutoff valve,
order one from the Schwing Spare Parts
Preheat the hydraulic oil Department, using part number 10004680
(valve) and number 30303432 (tube).
Contact the Service Department for
operating temperatures (50° to 60° C). In the past we
installation instructions.
could pressure out a function in the boom or outrigger
system to create heat, but today, load sensing systems 2. Activate the agitator. With the valve closed, the
no longer allow maximum oil flow to be forced over agitator will not be able to turn and the oil will be
relief. Because of this, the agitator circuit must be used forced over the relief valve. At an idle (about 600
to heat the hydraulic oil. RPM) you will be converting 4.5 horsepower to
To heat the oil to operating temperature: heat.
1. Locate the agitator shutoff valve (Figure 120), and 3. When the oil temperature gauge shows 50˚ C, open
close it. The quarter turn shutoff valve has a the shutoff valve.
grooved line on the shaft or pivot point of the
Grooves in handle Closed

000174.eps
Agitator quarter turn
shutoff valve (open position)
Grooves in shaft 000273.eps
Motor Open
Mounting screw and washer
Figure 120
Agitator shutoff valve (left) and Open/closed orientation of shutoff valve (right)
HOME PRINT
Pressure Settings
Check the concrete pump pressure -4 8. Place the concrete pump “forward / neutral /
pumpkits reverse” switch on the rear control panel into the
“forward” position. The unit will stroke no more
than once, then the rock cylinder will retract. Oil
leaving the hydraulic pumps will be blocked in the
WARNING brain. This is called high-pressuring the concrete
pump.
Wear safety glasses any time you check 9. Read the pressure on the gauge. The target pressure
or set pressures. Oil expulsion hazard!
000438.eps
for the concrete pump circuit main relief valve is
shown on the hydraulic schematic in the Appendix
section of this manual. Return the pump control to
“neutral” whether the pressure needs adjustment or
Because the Hi-flow pumpkits have the ability to create
not. If no adjustment is needed, skip to step 5. If
high pressure on the concrete, the pressure settings
adjustment is needed, proceed to next paragraph.
have to be tailored specifically for each model. This
means that we cannot simply list a pressure
Setting the main relief valve
specification for all units. The correct pressure
specifications for your unit are shown on the hydraulic The main relief valve is the primary pressure control
schematic in the Appendix, section of this manual. device on units equipped with Rexroth A7VO
hydraulic pumps.
NOTE!
If the main relief valve needs adjustment, proceed as
Do not use the remote control box for the
follows:
following pressure setting procedure.
1. Wear safety glasses when checking or adjusting
To check or set the concrete pump pressure pressures.
adjustments, follow these steps:
2. Using a 9/16” spanner wrench, loosen the jam nut
1. Be sure that the waterbox covers and guards are
on the main relief valve adjusting screw (Figure
installed on the waterbox.
123).
2. Start the truck engine, and put the PTO and
transmission into gear just as you would to pump a Gauge port
job.
3. Locate and close the concrete pump shutoff valve 00
02
97
.ep
and the soft switch shutoff valve (Figure 122). s
(These valves are also known as quarter turn

valves).
Main relief valve
4. If your concrete pump pressure gauge is not
already plumbed into the gauge port (Figure 218), Soft switch
install a 0 - 400 or 0 - 600 bar gauge in the gauge relief valve
port.
5. The “remote / local” switch located on the rear
control panel must be in the “local” position.
Figure 121
6. Be sure that all emergency stop switches are in the Location of the concrete pump circuit
up (not activated) position. Reset the E-stop circuit. main relief valve and soft switch relief
7. Using the throttle switch on the rear control panel, valve
bring the truck engine up to full RPM.
The main relief valve (Figure 123) is set to very high 3. Insert a 5/32” Allen wrench in the adjustment
pressure (at least 350 bar). Use the rear control panel screw. Turn the screw in to raise pressure and out
switch when checking the pressure of the main relief to lower the pressure. Always go back to the rear
valve, so you will be out of the way if a hose or fitting panel before checking the pressure.
blows.
HOME PRINT
SERVICE TRAINING
Pressure Settings
4. Once the pressure is correct to the hydraulic 5. If you will not be setting the soft switch pressure,
schematic, retighten the jam nut. Tightening the open the shutoff valves. The unit will not stroke
nut tends to raise the pressure, so check pressure with closed shutoff valves.
again after tightening.
Soft switch
shutoff valve
Main Pressure
Gauge port
Concrete pump
shutoff valve 00
02
74
.e
ps
Figure 122
Showing the concrete pump and soft switch shutoff
valves

Closed Open
soft switch
relief cartridge
Grooves in shaft 000273.eps Main relief cartridge
000276.eps
9/16" jam nut
Open
5/32" Allen head
removed for illustration 9/16" jam nut
Figure 123
Shutoff valve open / closed orientation
HOME PRINT
Pressure Settings
Setting the soft switch circuit relief
pressure
Gauge port
00
04
32
.ep
s
Figure 124
Location of the Main relief valve
main relief valve
Soft switch
relief valve
To check or adjust the soft switch pressure setting, Preheat the oil
proceed as follows:
When you set pressures for any circuit on any unit, the
1. Open the soft switch shutoff valve (Figure 123). hydraulic oil should be at normal operating
The rest of the unit should still be set up as though temperature (40° - 60° C). Instructions for heating the
you were going to check concrete pump pressure. hydraulic oil are found on page 495.
2. High pressure the concrete pump. The pressure
gauge should read 60 or 80 bar (check your About proportional boom systems
schematic). If adjustment is needed, proceed to In a black and white boom system, the hydraulic pump
step (3). If no adjustment is needed, skip to step (). puts out an unchanging amount of oil, and speed
3. Loosen the jam nut on the soft switch relief valve control is done by restricting the oil to certain functions
(Figure 103) with a 9/16” spanner wrench. Adjust with orifices. In a load-sensing system, the pump puts
out more or less oil to respond to the needs of the
the pressure up or down, as needed, using a 5/32”
system. Generally, the pump puts out enough oil to
Allen wrench. When the correct pressure is maintain a 20 bar higher pressure at the pump than
achieved, tighten the jam nut. what the cylinders actually require. This 20 bar is
4. Be sure to open the concrete pump shutoff valve called delta P (∆P). Additionally, we set the hydraulic
(Figure 123) on the side of the brain when you are pump so that it always puts out a small amount of oil,
finished. The unit cannot stroke with this valve even if no oil is needed for the system. This oil is used
closed. to ensure that you have control when you need it. The
Setting pressures on load-sensing booms called Q-min (pronounced “cue min”). To set the boom
If your unit has a load-sensing proportional system, it or outrigger hydraulic pressures on a load-sensing
will have different pressure adjustments than if it is system, begin by setting Q-min and ∆P.
equipped with a black and white boom system. The Read all of the instructions before beginning any
following instructions are for seven place, load-sensing pressure settings. General locations of the components
proportional systems. If you have a unit equipped with for the following procedures are shown in Figure 125.
a black and white boom system, contact Schwing You will need an assistant for parts of the procedure.
Service for the correct instruction pages. You and any assistants should wear eye protection
when checking or setting pressures.
HOME PRINT
SERVICE TRAINING
Pressure Settings
Manual boom hand valves,

Delta P adjustment
and E-Stop manifold
Figure 125
Locations of
components used to
check and set boom
pressures 000433.eps
Q-min adjustment screw
Setting ∆P 1. Stop the truck engine and place a “Do Not

Operate” sign on the truck windshield.
NOTE!
Do not adjust ∆P or Q-min if your boom is 2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar
running as you like it. The pressure setting gauge port (Figure 126) of the manual boom
procedure uses a standard starting point handvalves. Take care not to accidently install the
and must be fine tuned from there. It was gauge in the 0-60 bar port.
fine tuned at the factory and should not be
adjusted unless absolutely necessary. If it CAUTION
becomes necessary, do not adjust Q-min
with the drive shafts turning! Do not operate any function during this
000442.eps
procedure. Gauge damage possible!
Each time the Q-min screw is adjusted, the engine must
be stopped, or at least the transmission must be taken
out of gear so that the drive lines stop turning. To check
or set ∆P, follow these steps:
Boom control
block relief valve
0-400 bar (non-adjustable)
gauge port
0-60 bar 15 bar pretension

gauge port adjusment screw
30 bar
pilot pressure 448
.ep
s
000
relief cartridge
140 bar downside
relief cartridge (non-adjustable)
Figure 126
Location of the boom circuit pressure devices (Hoses removed for clarity.)
HOME PRINT
Pressure Settings
Q-min
adjustment screw
000434.eps
Q-max
Figure 127
Location of the Q-min adjustment screw on A11VO (left)
and A7VO (right)
3. To be sure that the pump is putting out only enough end wrench) and adjusting the screw (3mm Allen
oil to maintain ∆P, we need to change the setting of wrench) clockwise to increase pressure or counter
the Q-min screw. Q-min is adjusted by a screw on clockwise to decrease it.
the boom hydraulic pump (Figure 127). Unscrew 5. The delta P adjustment screw on the A11VO boom
the Q-min screw three full turns. Make sure that all pump, also shown in Figure 225 below, requires a
emergency stop switches are in the up (not 13mm open end wrench and a 4mm allen wrench.
activated) position. Check that all personnel are
clear of the truck; then restart the engine, engage NOTE!
the pumps, and leave the engine at an idle. Pressure If the boom is not smooth at 20 bar, you
can be read on the 0 - 40 bar gauge that you must fine tune the adjustment. In that case,
installed. Pressure should read 20 bar. If no REMOVE THE GAUGE and adjust ∆P
adjustment is needed, simply reset the Q-min until the boom is responsive and smooth.
screw as described on page 357. If adjustment is The gauge (reinstalled) must now read
needed, continue to step (4). between 14 and 25 bar. The electronics in
the control system can also affect how the
4. Delta P is adjusted on the bottom (smaller) screw
boom operates, so if ∆P adjustment does not
of the pressure regulator shown in Figure 225
seem to help, reset to 20 bar and check the
below. If your unit has an A7VO boom pump, you
electrical settings. Once electrical settings
can do so by loosening the jam nut (10mm open
are verified, you could again refine the boom
action with the ∆P adjustment.
Delta-p
000435.eps
T
P adjustment screw
000281.eps
Figure 128
Location of the delta P adjustment screw for a unit
with A7VO pump (left) and A11VO pump (right)
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting Q-min each time before making the adjustment. When
Check Q-min pressure when the engine is at the pressure is correct, tighten the jam nut on the
maximum specified RPM, but the engine must be adjustment screw before continuing with the other
stopped to adjust the screw. procedures.
1. If you unscrewed the Q-min screw as the first step Setting boom pressures
of ∆P adjustment, begin by returning the screw to
its original position (Figure 127). (Load sensing proportional booms)
2. Remove the 0 - 40 bar gauge from the 0 - 400 bar Now that ∆P and Q-min are set, you can check or set
gauge port, and install the 0 - 600 bar gauge in its the boom valve pressures.
place.
There are several devices on the boom circuit
3. Clear all personnel away from the drive lines, start which control boom pressure (Figure 226):
the truck engine, engage the pumps, and bring 1. Pressure regulator (the high-pressure adjustment
engine RPM to max. All boom functions must be in
screw on the ∆P regulator valve on units with
neutral, and all emergency stop buttons should be
A7VO boom pumps), set at 300 bar.
up (not engaged).
2. Pressure cut-off on units with A11VO pumps.
4. Read the pressure on the 0 - 600 bar gauge.
Pressure should be at 40 - 45 bar. If no adjustment 3. The boom control block relief valve, pre-set at 350
is needed, stop the drive lines from turning, be sure bar.
the jam nut on the Q-min screw is tight, and NOTE!
proceed to Setting boom pressures. If adjustment is This relief valve is nonadjustable. If
needed, continue to the next step. pressure is not maintained with the
5. Turn the Q-min screw in to raise the pressure specification limits, the valve must be
(Figure 127). Turn it out to lower the pressure. Be replaced.
Boom control
block relief valve
0-400 bar (non-adjustable)
000436.eps
gauge port
T High pressure
adjustment screw
0-60 bar 15 bar pretension

gauge port adjusment screw
30 bar
pilot pressure 448
.ep
s
000
relief cartridge
140 bar downside
relief cartridge (non-adjustable)
Figure 129
The boom pressure devices
HOME PRINT
Pressure Settings
Raise the pressure of the lowest circuit Setting the outrigger pressures
To check the setting of the valve with the highest After the boom pressures are set, you can set the
pressure, you must first raise the pressure of the lower: outrigger pressure.
1. Loosen the jam nut of the high pressure adjustment The boom, outriggers, water pump, and compressor
screw (Figure 129) of the ∆P regulator. Turn the circuits have all been put together in the boom valve
screw in two-and-a-half turns. This will raise the manifold. When the outrigger selector push button is
pressure on the regulator above 350 bar. pushed, the boom/outrigger control handle is activated
2. Pressure out any boom cylinder except #1 down by (Figure 129), which routes oil to the two outrigger
activating the control handle. To pressure out a hand valve banks (one on each side of the unit). A
cylinder, retract a fully retracted cylinder or extend relief valve inside the passenger side bank limits the
a fully extended cylinder. The oil is then forced entire outrigger circuit to 280 bar (4060 PSI) instead of
over the relief valve. the 300 bar (4350 PSI) of the boom relief valve.
The telltale hiss of an open relief valve should be
To set the 280 bar relief valve for the outrigger
coming from the Apitech control block relief valve circuit:
now. If it isn’t, raise the setting of the delta P
regulator a little more until the hiss originates at
the Apitech control block relief valve. Read the
pressure on the gauge. It should read 350 bar. If
pressure is correct, proceed to the next step.
WARNING
NOTE!
Although the pressure specification for the Wear safety glasses any time you check
Apitech relief valve is 350 bar, you may or set pressures. Oil expulsion hazard!
000438.eps
continue to use the relief valve as long as the
cartridge maintains at least 330 bar. If you
must replace the valve and don’t have one
on hand, proceed to the next step before 1. Plug the whip hose of a 0-400 or 0-600 bar gauge
using the machine again. Redo this entire (Figure 227) into the gauge port.
procedure when you have installed the new 2. If not already done, start the truck engine and set
valve. If pressure on the Apitech relief valve the transmission and PTO as you would for a
is below 290 bar, you should not use the pumping job.
machine until the valve is replaced. 3. Locate the 280 bar relief valve (Figure 130) on the
back of the outrigger valve.
3. You will need a helper for this step. While
pressuring out any boom cylinder except #1 down, 4. Set the engine RPM to maximum.
have your helper adjust the high pressure screw of 5. Select “outrigger” with the outrigger push button.
the ∆P regulator out (lowering the pressure) until This will route oil to the outrigger handvalves.
the gauge reads 300 bar. Release the pressurized 6. With the outriggers folded into the travel position,
function, and lock the jam nut. The boom pressures activate the passenger side hand valve “jacking
are now set. If you did not get the readings cylinder retract” for either the front or rear
specified after following the instructions, contact outrigger.
Schwing America’s Service Department at (651)
429-0999 for advice on how to continue.
NOTE!
You will get an incorrect reading if you select any
other outrigger function. The handles are spring
loaded and will return to neutral as soon as you let
go.
HOME PRINT
SERVICE TRAINING
Pressure Settings
000452.eps
0-400 bar
gauge port
Boom/Outrigger
control handle
AGITATOR
CONCRETE PUMP
Boom 1
Boom 2
Boom 3
Boom 4
Boom 1 Telescope
Slewing
Boom / Outrigger
Water / Compressor
10189517
DANGER WARNING
s Electrocution hazard.
.ep
Do not operate this
Stay back from high machine without
451
voltage wires at least training. Understand
17 feet (5 meters).
000
the warnings in safety
manuals and on decals.
Figure 130
Position of the 0-400 bar gauge port and boom/outrigger control handle
7. Read the pressure on the gauge. It should read 280 10. When the pressure is correct, either go on to other
bar (4060 PSI). If no adjustment is needed, skip to pressure settings or remove the whip hose and
step 4. gauge, and cap the gauge port with the attached
8. If adjustment is needed, turn the outside body of cap.
the relief valve that is located at the back of the 11. Return the RPM of the truck to an idle, take the
outrigger valve. Turn in to raise pressure and out to transmission and PTO out of gear, and shut off the
lower pressure. There is no jam nut on this valve. truck, or go on to the other pressure settings as
9. Activate the outrigger “jacking retract” hand valve, required.
steps (8) and (9) until the gauge reads 280 bar.
000453.eps
280 bar
Relief valve
AGITATOR
CONCRETE PUMP
Boom 1
Boom 2
Boom 3
Boom 4
Boom 1 Telescope
Slewing
Boom / Outrigger
Water / Compressor
10189517
DANGER WARNING
Electrocution hazard.
4 Stay back from high
Do not operate this
machine without
voltage wires at least
Outrigger control block

training. Understand
17 feet (5 meters). the warnings in safety
3
WARNING
Clear area
before activating
outriggers
REAR EXTEND REAR JACKING FRONT JACKING FRONT EXTEND
00
04
40
.ep
s
Figure 131
Location of the 280 bar outrigger pressure relief valve
(Hoses removed for clarity)
HOME PRINT
Pressure Settings
Setting 15 bar pretension 2. Start the truck engine, but leave it at an idle.
(Pretension adjustment is made at an idle to
establish the minimum pressure setting. As RPM is
CAUTION increased, pressure will rise. Damage to the 0 - 40
bar gauge is possible if RPM is raised while the
Truck engine must be at idle to set
gauge is connected.)
000439.eps
pretension. Gauge damage possible!
3. If the pressure reads 15 bar ± 1 bar, the pressure is
set correctly. If adjustment is needed, proceed to
To check or set pretension, follow these the next step.
steps: 4. Loosen the jam nut on the pretension valve. Turn
1. Stop the truck engine. Plug the 0 - 40 bar gauge the screw in to raise pressure and out to lower
into the 0-60 bar pretension check port of the pressure. When the pressure is correct, retighten
Apitech hand valve (Figure 130). the jam nut.
5. Stop the engine, and remove the 0 - 40 bar gauge.
15 bar pretension
adjustment screw
0-60 bar
gauge port
s
.ep
450
000
Figure 132
and gauge port
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting the agitator circuit pressure
000447.eps
Agitator Relief Valve

Turn body of valve
Gauge port Higher to adjust.
Lower
AGITATOR
CONCRETE PUMP
Agitatior Hand Valve Boom 1

Boom 2
Boom 3
Boom 4
Boom 1 Telescope
Slewing
Boom / Outrigger
Water / Compressor
10189517
DANGER WARNING
Do not operate this
machine without
3
Agitator
1
Fwd/Reverse WARNING
Clear area
before activating
outriggers
Concrete pump REAR EXTEND REAR JACKING FRONT JACKING FRONT EXTEND
Fwd/Reverse 88
.ep
s
02
00
Figure 133
Agitator hand valve (location right, blowup left)
The agitator relief valve is located in the agitator

forward / neutral / reverse hand valve block. The Agitator quarter turn
000174.eps
agitator relief valve limits the pressure in the agitator shutoff valve (open position)
circuit to 200 bar (2900 PSI). There is a gauge port for
checking or setting the pressure in this circuit. The port
is located on the agitator hand valve block and shown
on top in Figure 230. The gauge port may be mounted
on the side of the block on some units. To check or set
the agitator pressure, follow these steps:
Motor
1. Unscrew the cover from the gauge port. Plug in the
0-600 bar gauge and whip hose that came in the Figure 134
toolbox. The agitator shutoff valve
2. Start the engine if it’s not already running. 4. Activate the agitator, and read the pressure on the
3. Close the agitator shutoff valve (Figure 53). gauge.
NOTE! 5. If adjustment is needed, put your wrench on the
body of the relief valve (Figure 230), which is
located on the back of the agitator hand valve.
you can order one using part number
While reading the gauge, turn the body in to raise
10004680 (valve) and part number
pressure or out to lower pressure until 200 bar is
30303432 (tube). Contact Schwing
achieved.
America’s Service Department at (651) 429-
0999 for installation instructions. 6. Put the agitator handle in neutral.
HOME PRINT
Pressure Settings
Setting accumulator circuit pressure 4. Read the pressure on the accumulator circuit
To check or adjust the hydraulic pressure in the pressure gauge (Figure 136). The pressure should
accumulator circuit: read the value shown on the hydraulic schematic. If
no adjustment is needed, skip to step (7). If
1. Stop the truck, put the key in your pocket, and additional pressure adjustment is needed, continue
place a “Do Not Operate” sign on the windshield. with step (5).
@@@@@@@@

;;;;;;;;
QQQQQQQQ
@@@@@@@@

;;;;;;;;
QQQQQQQQ

000292.eps
accumulator hydraulic pump (Figure 135). Turn

the screw in two-and-one-half turns. This will raise
@@@@@@@@

;;;;;;;;
QQQQQQQQ

@@@@@@@@

;;;;;;;;
QQQQQQQQ

the regulator pressure above 300 bar.
;;;;;;;;
@@@@@@@@

QQQQQQQQ

@@@@@@@@

;;;;;;;;
QQQQQQQQ

;;;;;;;;
@@@@@@@@

QQQQQQQQ

;;;;;;;;
@@@@@@@@

QQQQQQQQ

Figure 136
Accumulator circuit pressure gauge
000289.eps
5. Locate the accumulator manifold pressure relief

cartridge (Figure 137). Loosen the jam nut, and
turn the screw clockwise to increase the pressure or
counter clockwise to decrease the pressure. Tighten
Accumulator pump
pressure regulator
the jam nut when the pressure reaches the value
required, and shut off the truck engine.
000449.eps
Figure 135
Accumulator pump pressure regulator for
A7VO (above) and for A11VO (below) Manual bleed
valve
Boom Pump
Accumulator Pump
Pressure relief
cartridge
Accumulator Pump
Pressure Regulator Figure 137
Standby 000446.eps cartridge and manual bleed valve
Pressure Screw hgacugc.psd
HOME PRINT
SERVICE TRAINING
Pressure Settings
WARNING
000075.eps
pressure regulator.
6. After the truck engine is stopped, go back to the

regulator (Figure 136), and turn the screw back out
two-and-one-half turns. This restores it to its
original setting.
the truck, and bring the engine RPM up to
maximum.
should now read the proper accumulator system
pressure.
9. If adjustment is needed, you must stop the truck
engine, or a least stop the drive lines from turning,
each and every time you approach the accumulator
circuit hydraulic pump. Turn the screw in to
increase the pressure or out to decrease pressure.
Lock the jam nut when the pressure is correct.
NOTE!
The accumulator circuit hydraulic pump
pressure regulator is sometimes referred
to as the pressure cut-off.
HOME PRINT
Pressure Settings
HOME PRINT
SERVICE TRAINING
Pressure Settings
32XL Single Circuit 2. Turn on the agitator. The agitator will not be able
to turn, and the oil will be forced over the relief
valve.
Check hydraulic pressures
3. At an idle (approx. 600 rpm), about 5.4 horsepower
Check all hydraulic pressures. Changes in pressures
is being converted to heat. Shut off the concrete
can indicate trouble in one or more components.
pump when the temperature gauge on the rear
control panel shows 40° C.
operating temperatures (40° to 60° C).The
specifications for all circuit pressures are found on the
Check the concrete pump pressure (900 or
hydraulic schematics in the appendix section of this
1200)
manual.
The Schwing concrete pump circuit on the BPL 900 or
Preheat the hydraulic oil 1200, KVM 32 XL is designed to be operated at a
maximum pressure of 300 bar (4350 PSI). Pressure is
Because of the new load sensing and pressure cutoff
limited by the main relief valve which is located on the
regulated hydraulic systems, you can’t use the concrete
forward (towards the truck cab) end of the main control
pump or boom circuit to preheat the hydraulic oil (they
block. To check or set the main relief pressure: (See
stop putting out oil if you try). To heat the oil to
Figure 138).
operating temperature:
1. Locate the agitator shutoff valve and close it. Note!
If your unit does not have a shutoff valve, you can
order one using part number 10004680 (valve) and
part number 30303432 (tube). Install as shown in
figure 231 on page 6-362.
s
.ep
in2
Bra
Pressure gauge
Main relief valve
Jam nut
Lower Raise
pressure pressure
Adjustment
handle scmnrlf2.eps
Figure 138
The main relief valve, concrete pump
HOME PRINT
Pressure Settings
1. Be sure that the waterbox covers are installed on 3. Start the truck engine, and put the PTO and
the waterbox. Use of the remote control box for the transmission into gear just as you would to pump a
following procedure is NOT recommended. job.
2. Wear safety glasses when checking or setting 4. See figure 139. Close the shutoff valve (also known
pressures. as the ball cock or quarter turn valve).
Figure 139
Showing the concrete pump shutoff valve
5. Put the rear control panel switch “remote / local” bar, there is a hydraulic problem. In this case,
into the “local” position. unscrew the adjustment knob by several turns so
6. Using the switch on the rear control panel, rev the that your pressure isn’t too high once the problem
truck engine up to full RPM. is found. Contact Schwing America’s Service
Department at (651) 429-0999 for advice on how
7. Using the concrete pump “forward / neutral /
to continue.
reverse” switch on the rear control panel, put the
concrete pump into the “forward” position. The 13. Return the pump to the “neutral” position.
unit will stroke no more than once, then the rock 14. Open the shutoff valve.
cylinder will retract. Oil will have nowhere to go 15. Return the RPM of the truck to an idle, take the
except over the main relief valve. transmission and PTO out of gear, and shut off the
8. Read the pressure on the gauge, as shown. It truck, or go on to the other pressure settings, as
should read 300 bar. Return the pump to “neutral” required.
whether in needs adjustment or not. If no
adjustment is needed, skip to step 14. Setting boom pressures
9. Loosen the jam nut on the relief valve adjusting (7 place proportional circuit) If your unit has a load-
screw (requires a 13 mm spanner wrench). sensing proportional system, it will have different
10. Turn the knob on the relief valve to adjust the pressure adjustments than if it is equipped with a black
pressure. Screw the handle in to raise pressure, out and white boom system. The following instructions are
to lower the pressure. for load-sensing proportional systems. If your unit is
11. Retighten the jam nut. (This step is necessary equipped with a black and white boom system, these
because tightening the nut tends to raise the instructions will be wrong. Contact Schwing America’s
pressure. If it becomes a problem, hold the knob Service Department to obtain correct instructions.
while tightening the jam nut). Preheat the oil
NOTE!
will again develop maximum pressure. Read the Whenever you set pressures for any circuit
pressure on the gauge. If more adjustment is on any unit, the hydraulic oil should be at
needed, return the pump to “neutral”, then repeat normal operating temperature (40° - 60° C).
steps 8. thru 12. until the pressure is at 300 bar. Instructions for heating he hydraulic oil
NOTE! If you cannot adjust the pressure up to 300 are found in section on page 6-285.
HOME PRINT
SERVICE TRAINING
Pressure Settings
About proportional boom systems called delta P (∆P). Additionally, we set the hydraulic
In a black and white boom system, the hydraulic pump pump so that it always puts out a small amount of oil,
puts out an unchanging amount of oil, and speed even if no oil is needed for the system. This oil is used
control is done by restricting the oil to certain functions to ensure that you have control when you need it. The
with orifices. In a load-sensing system, the pump puts setting to maintain this minimum amount of oil is
out more or less oil to respond to the needs of the called Q-min (pronounced “cue min”). To set the boom
system. Generally, the pump puts out enough oil to or outrigger hydraulic pressures on a load-sensing
maintain a 20 bar higher pressure at the pump than system, begin by setting Q-min and ∆P. See figure 142.
what the cylinders actually require. This 20 bar is
Manual P regulator Q-min adjustment screw

boom handvalves
Figure 140
Locations of components
CONCRETE PUMP
REV FWD
s
.ep
used to check and set
loc
XL
32
boom pressures
E-Stop manifold
Check that all personnel are clear of the truck, then

Read all of the instructions before beginning any restart the engine, engage the pumps, and leave the
pressure settings. You will need an assistant for parts of engine at an idle. CAUTION! If you activate any
the procedure. You and any assistants should wear eye boom or outrigger functions, you will damage
protection when checking or setting pressures. the 0 - 40 bar gauge. Make sure that all
emergency stop switches are in the up (not
Setting ∆P activated) position. Pressure can be read on the 0 -
Note! Do not adjust ∆P or Q-min if your boom is 40 bar gauge that you installed. Pressure should
running as you like it. The pressure setting procedure read 20 bar. If no adjustment is needed, simply
uses a standard starting point and must be fine tuned reset the Q-min screw as described in . If
from there. It was fine tuned at the factory, and should adjustment is needed, continue to step (2.).
not be adjusted unless absolutely necessary. 4. Delta P is adjusted by the ∆P screw on the ∆P
You must not adjust Q-min with the drive shafts regulator (see Figure 143). Loosen the jam nut and
turning! Each time the Q-min screw must be adjusted, adjust the screw inward to increase pressure, or
the engine must be stopped, or at least the transmission outward to decrease pressure until it is set at 20 bar
must be taken out of gear so that the drivelines stop (±1). Contact Schwing America’s Service
turning. To check or set ∆P, follow these steps: Department at (651) 429-0999 if you are unable to
adjust the pressure to spec. NOTE! If the boom is
1. Stop the truck engine and place a “Do Not not smooth at 20 bar, you must fine tune the
Operate” sign on the truck windshield. adjustment. In that case, REMOVE THE GAUGE,
2. Install a 0 - 40 or 0 - 60 bar gauge in the 0 - 400 bar and adjust ∆P until the boom is responsive and
gauge port of the manual boom handvalves. Take smooth. When done, the gauge (reinstalled) must
care not to accidently install the gauge in the 0 - 60 read between 14 and 25 bar. The electronics in the
bar port. (See Figure 141.) control system can also affect how the boom
3. To be sure that the pump is putting out only enough operates, so if ∆P adjustment does not seem to
oil needed to maintain ∆P, we need to change the help, reset to 20 bar and check the electrical
setting of the Q-min screw. Q-min is adjusted by a settings. Once electrical settings are verified, you
screw on the boom hydraulic pump (see Figure could again refine the boom action with the ∆P
142). Unscrew the Q-min screw three full turns. adjustment.
HOME PRINT
Pressure Settings

140 bar downside

relief cartridge
0-400 bar
gauge port
0-60 bar
gauge port
boom control
block relief valve
s
ep
dv.
itpr
ap
15 bar pretension
adjustment screw
Figure 141
Showing the location of the boom circuit pressure devices
(Hoses removed for clarity.)
Q-min
adjustment screw
Q-minscrew.eps
Q-max
Figure 142
Location of the Q-min adjustment screw
Setting Q-min 2. Clear all personnel away from the drive lines, start
You must check Q-min pressure when the engine is at the truck engine, engage the pumps, and bring
the maximum specified RPM, but you must adjust it engine RPM to max. All boom functions must be in
with the engine stopped. neutral, and all emergency stop buttons should be
up (not engaged).
1. If you unscrewed the Q-min screw as the first step
of ∆P adjustment, begin by returning the screw to 3. Read the pressure on the 0 - 600 gauge. Pressure
its original position (see Figure 142).Remove the 0 should be at 40 - 45 bar. If no adjustment is needed,
- 40 bar gauge from the 0 - 400 bar gauge port, and stop the drivelines from turning, be sure the jam
install the 0 - 600 bar gauge in its place. nut on the Q-min screw is tight, then continue to
HOME PRINT
SERVICE TRAINING
Pressure Settings
CAUTION
Do not operate any functions while setting ∆P.
∆P adjustment screw
deltaPvlv.eps
T Figure 143
The ∆P regulator valve
paragraph to check the rest of the boom and 5. Loosen the jam nut of the adjustment screw of the
outrigger pressures. If adjustment is needed, redundant relief valve in the emergency stop
continue to step (5.). manifold. Turn the screw in one-and-a-half turns.
4. Turn the Q-min screw in to raise the pressure This will raise the pressure setting of the relief
(Figure 142). Turn it out to lower the pressure. Be valve to above 350 bar.
sure that you stop the drive shafts from turning 6. Pressure out any boom cylinder except #1 down by
each time before making the adjustment. When pushing or pulling the control handle. To pressure
pressure is correct, tighten the jam nut on the out a cylinder, retract a fully retracted cylinder or
adjustment screw before continuing with the other extend a fully extended cylinder. The oil is forced
procedures. over the relief valve.
Setting boom pressures The telltale hiss of an open relief valve should be
(Load sensing proportional booms.) Now that ∆P and coming from the Apitech control block relief valve
Q-min are set, you can check or set the boom valve now. If it isn’t, raise the setting of the other
pressures. pressure devices until the hiss originates at the
Apitech control block relief valve. Read the
There are three pressure settings on the boom circuit: pressure on the gauge. It should read 350 bar. If
(see Figure 144) pressure is correct, proceed to step (4.).
1. Pressure regulator (the high-pressure adjustment
screw on the ∆P regulator valve), set at 300 bar. NOTE! Although the pressure specification for the
2. The redundant relief valve located in the Apitech relief valve is 350 bar, you may continue
emergency stop manifold, set at 330 bar. to use the relief valve as long as the cartridge
3. The boom control block relief valve, set at 350 bar. maintains at least 330 bar. If you must replace the
NOTE! This relief valve is nonadjustable. If valve, proceed to step (4.) before using the
pressure is not maintained with the specification machine again, and redo this entire procedure
limits, the valve must be replaced. when you have installed the new valve. If pressure
on the Apitech relief valve is below 290 bar, you
• To check the setting of the valve with the highest
should not use the machine until the valve is
replaced.
lower two:
7. Screw out the e-stop manifold redundant relief
4. Loosen the jam nut of the high pressure adjustment
valve adjustment screw one-and-a-half turns.
screw of the ∆P regulator. Turn the screw in two- Pressure out any boom cylinder except #1 down,
and-a-half turns. This will raise the pressure on the and read the gauge. Pressure should read 330 bar.
regulator above 350 bar. If it does not, turn the screw in to raise pressure, or
out to lower pressure until it is set at 330 bar. If the
location of this valve causes you to be near the
drivelines, be sure to stop them from turning before
accessing the valve.
HOME PRINT
Pressure Settings
Redundant
deltaPvlv.eps
High pressure relief valve

adjustment screw
T
MP
1
TT
M
10
16
78
P1
92
-7.
ep
s
P4
P2
P3
0-400 bar
gauge port
0-60 bar
gauge port
s
.ep
nly
ipo
ap
boom control Figure 144
block relief valve The three boom pressure
8. You will need a helper for this step. While on how to continue. If the problem was found to be
pressuring out any boom cylinder except #1 down, the e-stop manifold, repair it before using the unit
have your helper adjust the high pressure screw of again. Remember, the emergency stop switches do
the ∆P regulator out (lowering the pressure) until nothing if the e-stop manifold is plumbed out of
the gauge reads 300 bar. Release the pressurized the system.
function and lock the jam nut. The boom pressures 9. Remove the whip hose from the 300 bar gauge
are now set. If you did not get the readings port. Before folding up the boom, proceed to the
specified after following the instructions it is instructions for setting the 140 bar down side relief
possible that there is a problem with the emergency valve.
stop manifold (see Figure 145). You can plumb the
malfunctioning circuit out of the system to test it. Setting the 140 bar down side relief valve
Use only approved hydraulic dead plugs to plug pressure
the inlet hose to the malfunctioning circuit. If
Set the pressure of the 140 bar down side relief valve.
pressure can now be achieved, the e-stop manifold
This valve is a secondary relief valve for #1 cylinder
is the source of the problem. If pressure still cannot
retract function. Proper adjustment ensures that the #1
be achieved, the problem is elsewhere. Contact
boom and the A-frame won’t be damaged by putting
Schwing America’s Service Department for advice
HOME PRINT
SERVICE TRAINING
Pressure Settings
Concrete pump Boom dump valve

dump valve
Outlet to tank
Boom /
Outriggers
Pilot drain
Concrete pump Accumulator
Water pump / compressor / agitator

estophartbm.eps
S
MP
Boom/outrigger
T circuit dump
valve
S
MP
P3
ps
s.e
oppre
est
P2
Boom
P4 P1
override
button
Boom/outrigger
inlet port
Figure 145
original production (top), current production
the boom in the cradle. (See figure 146.) To adjust this 2. Unfold the #2 section from #1 until it is straight.
valve (requires a 2.5 mm Allen wrench and a standard For the following procedure we must bring #1 all
screwdriver): the way down until the cylinder bottoms out.
1. Install a 0 - 400 bar or 0 - 600 bar gauge into the Position the boom so this can be done without
140 bar gauge port (shown in Figure 146). hitting the truck or any other obstacle.
HOME PRINT
Pressure Settings
3. Bring #1 down until the cylinder is completely cartridge with the screwdriver until the pressure
bottomed out. The cylinder does NOT bottom out reads just under 140 bar. Retightening the set screw
if you are setting the folded boom into the A-frame will raise the pressure slightly. Recheck the
(travel position). pressure, and readjust if needed.
4. Activate the #1 down (retract) handvalve The 6. When the pressure is set at 140 bar with the set
boom will not be able to move because the cylinder screw tight, you can remove the whip hose gauge
is already bottomed out. Read the pressure on the and replace the cap on the gauge port.
gauge that you just installed. It should read 140 7. The boom pressure setting sequence is complete. If
bar. If no adjustment is necessary, skip to step 6. you are done with the boom, slew it back into the
5. If adjustment is needed, loosen the set screw of the transport position, and lower #1 into the cradle.
140 bar relief valve with the 2.5 mm Allen wrench. Reattach the boom strap.
While you activate #1 down, adjust the relief
140 bar
gauge port
ps
0.e
it14
ap
Figure 146
location of the 140 bar relief
valve and gauge port
Setting the outrigger • To set the 280 bar relief valve for the outrigger
pressures (7 place boom valve systems) circuit: (See Figure 227 and Figure 228).
After the boom pressures are set, you can set the 1. Wear safety glasses whenever you check or set
outrigger pressure. pressures.
• In this system, the boom, outriggers, water pump, 2. Plug the whip hose of a 0 - 400 or 0 - 600 bar
and compressor circuits have all been put together gauge into the gauge port. Location is shown in
in the boom valve manifold. (See Figure 227). figure 227.
When the outrigger selector push-button is 3. If not already done, start the truck engine and set
activated, the outrigger valve routes oil to the two the transmission and PTO as you would for a
outrigger handvalve banks, one on each side of the pumping job.
unit. A relief valve inside the passenger side bank 4. Locate the 280 bar relief valve on the back of the
limits the entire outrigger circuit to 280 bar (4060 outrigger valve, as shown in Figure 228.
PSI) instead of the 300 bar (4350 PSI) of the boom
5. Set the engine RPM to maximum.
relief valve.
HOME PRINT
SERVICE TRAINING
Pressure Settings
Gauge port
Figure 147 hd
.ep
s
itor
ap
Position of the outrigger selector valve
Outrigger handle
6. Select “outrigger” with the outrigger pushbutton.

This will route oil to the outrigger handvalves.
280 bar
Lower Relief Valve
PS
oc
bb
ck.
Higher ep
s
Turn body of valve

to adjust. Figure 149
Location of the outrigger circuit relief valve
7. Assuming that the outriggers are folded into the 8. Read the pressure on the gauge. It should read 280
travel position, activate the passenger side bar (4060 PSI). If no adjustment is needed, skip to
handvalve “jacking cylinder retract” for either the step 4.
front or rear outrigger. Note! You will get an 9. If adjustment is needed, turn the outside body of
incorrect reading if you select “extension cylinder the relief valve that is located at the back of the
retract” by mistake. If you select “extend” by outrigger valve. Turn in to raise pressure, turn out
mistake, the outriggers will extend instead of to lower pressure. There is no jam nut on this
reading the relief valve setting. The handles are valve.
spring loaded and will return to neutral as soon as
10. Activate the outrigger “jacking retract” handvalve
you let go.
steps 8. and 9. until the gauge reads 280 bar.
HOME PRINT
Pressure Settings
32Porct5.eps
REAR EXTEND FRONT EXTEND REAR FOOT FRONT FOOT
Figure 148
Location of the passenger
side outrigger control block
11. When the pressure is correct, either go on to other 3. Read the pressure on the gauge. If it reads 15 bar ±
pressure settings, or remove the whip hose and 1 bar, the pressure is set correctly. If adjustment is
gauge, and cap the gauge port with the attached needed, proceed to step (4.).
cap. 4. Loosen the jam nut on the pretension valve. Turn
12. Return the RPM of the truck to an idle, take the the screw in to raise pressure, and out to lower
transmission and PTO out of gear, and shut off the pressure. When the pressure is correct, retighten
truck, or go on to the other pressure settings, as the jam nut.
required. 5. Stop the engine, and remove the 0 - 40 bar gauge.
Setting 15 bar pretension
• To check or set pretension, follow these steps: To set the agitator circuit pressure:
1. Stop the truck engine. Plug the 0 - 40 bar gauge The agitator relief valve is located in the agitator
into the pretension check port of the Apitech forward / neutral / reverse handvalve, at the rear of the
handvalve (Figure 150). unit on the driver’s side. The relief valve limits the
2. Start the truck engine, but leave it at an idle. pressure in the agitator circuit to 200 bar (2900 PSI).
(Pretension adjustment is made at an idle to (See Figure 230). There is a gauge port for checking or
establish the minimum pressure setting. As RPM is setting the pressure in this circuit. The port is located
increased, pressure will rise. Damage to the 0 - 40 on the agitator handvalve. To check or set the agitator
bar gauge is possible if RPM is raised while the pressure, follow these steps:
gauge is connected.) 1. Remove the aluminum diamond plate cover from
over the agitator handvalve.
HOME PRINT
SERVICE TRAINING
Pressure Settings
CAUTION
Truck engine must be at an idle while setting pretension.
Pretension
gauge port
s
.ep
rtn
itp
ap
Figure 150
Pretension adjustment screw and gauge
agitator pressure check.eps L
Relief valve on this

side (not visible from
this angle).
Gauge port
Figure 151
Showing the agitator handvalve
and gauge port
(Diamond plate removed
for this illustration.)
2. Unscrew the cover from the gauge port. Plug in the (valve) and part number 30303432 (tube). Contact
0 - 600 bar gauge and whip hose that came in the Schwing’s Service Department at (651) 429-0999
toolbox. for installation instructions.
3. Start the engine, if not already running. 5. Activate the agitator in forward. Read the pressure
4. Close the agitator shutoff valve. (See Figure 152.) on the gauge.
Note! If your unit does not have a shutoff valve,
you can order one using part number 10004680
HOME PRINT
Pressure Settings
closed
s
ep
o.
its
ag
open
Figure 152
The agitator shutoff valve
6. If adjustment is needed, put your wrench on the

body of the relief valve, which is located on the
back of the agitator handvalve. While reading the
gauge, turn the body in to raise pressure, or out to
lower pressure until 200 bar is achieved.
7. Put the agitator handle in neutral.
9. Replace the aluminum diamond plate over the
agitator handvalve.
HOME PRINT
SERVICE TRAINING
Pressure Settings
32 XL Twin Circuit off, and the key in your pocket, remove the plug
(item 2). The oil should be at the level of the
Units up to 450 l/m bottom of the hole in the case. If oil is needed, add
• Check the fluid level of the distribution gearcase. by removing the breather (item 1) and pouring in
(See Figure 153). Be sure the truck is on through the top. This gearcase uses 90W gearlube.
reasonably level ground. With the truck engine
2
4194.e
ps
Figure 153
Check, drain and fill ports of the Stiebel 4194
• Check the mounting hardware of the subframe, the 1. Locate the agitator shutoff valve and close it. There
oil and water tanks, the delivery pipeline, the is a picture of the location on page 6-362. Note! If
pumpkit, the differential cylinders, the material your unit does not have a shutoff valve, you can
cylinders and the driveline hardware. Check for order one using part number 10004680 (valve) and
bolt tightness, cracks and other abnormalities. part number 30303432 (tube). Contact Schwing’s
Service Department at (651) 429-0999 for
Check hydraulic pressures installation instructions.
• Check all hydraulic pressures. Changes in 2. Turn on the agitator. The agitator will not be able
pressures can indicate trouble in one or more to turn, and the oil will be forced over the relief
components. Pressure settings must be made with valve.
the oil at normal operating temperatures (40° to 3. At an idle (approx. 600 rpm), about 5.4 horsepower
60° C).The specifications for all circuit pressures is being converted to heat. Shut off the agitator
are found on the hydraulic schematics in the when the temperature gauge on the rear control
appendix section of this manual. panel shows 40° C. Don’t forget to open the shutoff
Preheat the hydraulic oil
valve when the procedure is finished.
• Because of the new load sensing and pressure cut-
Check the concrete pump pressure (900-
off regulated hydraulic systems, you can’t use the
1200 - MPS pumpkits)
concrete pump or boom circuit to preheat the
hydraulic oil (they stop putting out oil if you try). Schwing concrete pumps with MPS pumpkits are
To heat the oil to operating temperature: designed to be operated at a maximum pressure of 320
bar (4640 PSI). Pressure is limited by the main relief
valve which is located on the forward end (towards the
HOME PRINT
Pressure Settings
truck cab) of the main control block. (See Figure 154). 9. Read the pressure on the gauge, located as shown
To check or set the concrete pump relief pressure, in figure 154. It should read 320 bar. Return the
follow these steps: pump control to “neutral” whether the pressure
needed, skip to step 5.
1. Wear safety glasses when checking or setting
pressures. 10. Using a 13 mm spanner wrench, loosen the jam nut
on the relief valve adjusting screw (Figure 154).
installed on the waterbox. Use of the remote 11. Turn the knob on the relief valve to adjust the
control box for the following pressure setting pressure. Screw the handle in to raise pressure, out
procedure is NOT recommended. to lower the pressure.
3. Start the truck engine, and put the PTO and 12. Retighten the jam nut. Tightening the nut tends to
transmission into gear just as you would to pump a raise the pressure. If the pressure rise becomes a
job. problem, hold the knob while tightening the jam
nut.
4. See Figure 139. Close the concrete pump shutoff
valve, and the soft switch shutoff valve. (These 13. High pressure the concrete pump again. Read the
valves are also known as quarter turn valves). pressure on the gauge. If more adjustment is
needed, return the pump control to “neutral”, then
5. Put the rear control panel switch “remote / local”
repeat steps (8.) thru (13.) until the pressure is
into the “local” position.
correct. NOTE! If you cannot adjust the pressure
6. Be sure that all emergency stop switches are in the up to specification, there is a hydraulic problem. In
up (not activated) position. Reset the e-stop circuit. this case, unscrew the adjustment knob several
7. Using the switch on the rear control panel, rev the turns so your pressure isn’t too high when you find
truck engine up to full RPM. the problem. Contact Schwing America’s Service
8. Put the concrete pump “forward / neutral / reverse” Department for advice on how to continue.
switch on the rear control panel into the “forward” 14. If you will not be setting the soft switch pressure,
position. The unit will stroke no more than once, open the shutoff valves. The unit will not stroke
then the rock cylinder will retract. Oil leaving the with closed shutoff valves.
hydraulic pumps will be forced over the main relief
valve. This is called high-pressuring the concrete
pump.
relieflocMPS.eps
Main relief valve
Pressure
Gauge Jam Nut
Lower Raise
pressure pressure Adjustment
Handle
gray valve.eps L
Figure 154
The main relief valve, concrete pump circuit.
HOME PRINT
SERVICE TRAINING
Pressure Settings
soft switch.epsL
Figure 155
Showing the concrete pump shut-off valve (left) and soft switch shutoff valve (right)
Groove lined
grooves.eps
Groove at 90°
to ports - closed
Figure 156
Shutoff valve orientation
Setting the soft switch circuit relief 3. Be sure to open the concrete pump shutoff valve on
pressure the side of the brain (shown in Figure 155) when
• To check or adjust the soft switch pressure setting, you are finished. The unit cannot stroke with this
proceed as follows: valve closed.
1. Open the soft switch shutoff valve, as shown in
Setting the boom pressures
figures 155 and 156. The rest of the unit should
still be set up as though you were going to check (7 place black and white circuit) If your unit has a
concrete pump pressure. black and white boom system, it will have different
pressure adjustments than if it is equipped with a load-
sensing proportional system. The following
gauge should read 80 bar (1160 PSI) instead of 320
instructions are for black and white systems. If you
bar. If adjustment is needed, loosen the set screw
have a proportional unit, skip to page 6- 355. To set the
on the face of the relief valve cartridge with a 2.5
300 bar boom circuit relief valve proceed as follows:
mm allen wrench. Using a screwdriver, adjust the
(See Figure 157)
pressure up or down as needed, and lock the set
screw into place with the 2.5 mm allen wrench. 1. We have to raise the boom and rotate it 180° for
Recheck. Use a screwdriver, if necessary, to this procedure, so you must set the outriggers as
prevent the cartridge from turning while tightening you would to pump a job. Be sure that you set up
the allen screw. well away from electrical wires and other
obstructions.
HOME PRINT
Pressure Settings
7plcpres.eps
Use #2, 3, or 4
140 bar port
3
140 bar relief
300 bar port SECTION 1 SECTION 2 SECTION 3 SECTION 4 SLEWING AIR / WATER BOOM / OUTRIG.
Turn body of valve

DANGER WARNING
Do not operate this
Higher to adjust.
voltage wires at least SAFETY

17 feet (5 meters). MANUAL
Lower
300 bar
Relief Valve
Figure 157
Showing the location of the boom ep
s
m.
oo
circuit pressure devices. 7p
lcb
2. Once the outriggers are set, unlock the boom strap, 6. If adjustment is needed, put your wrench on the
and raise the #1 boom far enough that you won’t 300 bar relief valve at the back of the boom control
hit anything on the truck. Leave the rest of the valve bank. While you are holding the function in
boom folded. Rotate the boom so that you have retract mode, adjust the cartridge in or out until the
safe and easy access to the boom control valves. pressure reads 300 bar.
3. Remove the control block cover, held on by 2 M6 7. If you cannot achieve 300 bar, it is possible that
screws. there is a problem with the emergency stop
4. Install the whip hose of a 0-400 or 0-600 bar gauge manifold (see Figure 158). You can plumb the
in the 300 bar gauge port (Item 1 in Figure 157). malfunctioning circuit out of the system to test it.
Use only approved hydraulic dead plugs to plug
5. Assuming that your boom is completely folded up
the inlet hose to the malfunctioning circuit. If
(except for #1), select a handle, and retract #2, #3
pressure can now be achieved, the e-stop manifold
or #4 section. Do NOT use #1 retract, slewing left
is the source of the problem. Contact Schwing
right, outrigger, water pump, or any extend
America’s Service Department for advice on repair
function. (Again, when you try to retract a fully
of the e-stop manifold. Repair the e-stop manifold
retracted cylinder, the oil has no where to go except
before using the unit again. Remember, the
over the relief valve - this allows us to read the
emergency stop switches do nothing if the e-stop
relief valve setting on a gauge). Read the pressure
manifold is plumbed out of the system. Remove
on the whip gauge that you installed in step 4,
the whip hose from the 300 bar gauge port. Before
above. It should read 300 bar. If no adjustment is
folding up the boom, proceed to the instructions
necessary, skip to step 7.
for setting the 140 bar down side relief valve.
HOME PRINT
SERVICE TRAINING
Pressure Settings
Concrete pump Boom dump valve

dump valve
Outlet to tank
Boom /
Outriggers
Pilot drain
Concrete pump Accumulator
Water pump / compressor / agitator

estophartbm.eps
S
MP
Boom/outrigger
T circuit dump
valve
S
MP
P3
s
.ep
ppres
esto
P2
Boom
P4 P1
override
button
Figure 158
Boom/outrigger
original production (top),
inlet port
current production (bottom)
Load-sensing boom pressures Preheat the oil

(7 place proportional circuit) If your unit has a load- Note! Whenever you set pressures for any circuit on
sensing proportional system, it will have different any unit, the hydraulic oil should be at normal
pressure adjustments than if it is equipped with a black operating temperature (40° - 60° C). Instructions for
and white boom system. The following instructions are heating the hydraulic oil are found in section on
for load-sensing proportional systems. page 351.
About proportional boom systems

control is done by restricting the oil to certain functions
HOME PRINT
Pressure Settings
with orifices. In a load-sensing system, the pump puts even if no oil is needed for the system. This oil is used
out more or less oil to respond to the needs of the to ensure that you have control when you need it. The
system. Generally, the pump puts out enough oil to setting to maintain this minimum amount of oil is
maintain a 20 bar higher pressure at the pump than called Q-min (pronounced “cue min”). To set the boom
what the cylinders actually require. This 20 bar is or outrigger hydraulic pressures on a load-sensing
called delta P (∆P). Additionally, we set the hydraulic system, begin by setting Q-min and ∆P. See figure 161.
pump so that it always puts out a small amount of oil,

boom handvalves
CONCRETE PUMP
REV FWD
sp
loc.e
XL
32
E-Stop manifold
Figure 159
Locations of components used to check and set boom pressures
Read all of the instructions before beginning any

pressure settings. You will need an assistant for parts of
the procedure. You and any assistants should wear eye
protection when checking or setting pressures.
Setting ∆P
Note! Do not adjust ∆P or Q-min if your boom is
running as you like it. The pressure setting procedure
uses a standard starting point and must be fine tuned
from there. It was fine tuned at the factory, and should
not be adjusted unless absolutely necessary.
• You must not adjust Q-min with the drive shafts
turning! Each time the Q-min screw must be
adjusted, the engine must be stopped, or at least the
transmission must be taken out of gear so that the
drivelines stop turning. To check or set ∆P, follow
these steps:
HOME PRINT
SERVICE TRAINING
Pressure Settings
2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar
gauge port of the manual boom handvalves. Take
care not to accidently install the gauge in the 0-60
bar port. (See Figure 157.)

140 bar downside

relief cartridge
0-400 bar
gauge port
0-60 bar
gauge port
boom control
block relief valve
s
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dv.
itpr
ap
15 bar pretension
adjustment screw
Figure 160
Showing the location of the boom circuit pressure devices.
3. To be sure that the pump is putting out only enough boom or outrigger functions, you will damage
oil needed to maintain ∆P, we need to change the the 0 - 40 bar gauge. Make sure that all
setting of the Q-min screw. Q-min is adjusted by a emergency stop switches are in the up (not
screw on the boom hydraulic pump (see Figure activated) position. Pressure can be read on the 0 -
161). Unscrew the Q-min screw three full turns. 40 bar gauge that you installed. Pressure should
Check that all personnel are clear of the truck, then read 20 bar. If no adjustment is needed, simply
restart the engine, engage the pumps, and leave the reset the Q-min screw as described in . If
engine at an idle. CAUTION! If you activate any adjustment is needed, continue to step (2.).
Q-min
adjustment screw
Q-minscrew.eps
Q-max
Figure 161
HOME PRINT
Pressure Settings
4. Delta P is adjusted by the ∆P screw on the ∆P boom is responsive and smooth. When done, the
regulator (see Figure 162). Loosen the jam nut and gauge (reinstalled) must read between 14 and 25
adjust the screw inward to increase pressure, or bar. The electronics in the control system can also
outward to decrease pressure until it is set at 20 bar affect how the boom operates, so if ∆P adjustment
(±1). Contact Schwing America’s Service does not seem to help, reset to 20 bar and check the
Department if you are unable to adjust the pressure electrical settings. Once electrical settings are
to spec. NOTE! If the boom is not smooth at 20 verified, you could again refine the boom action
bar, you must fine tune the adjustment. In that case, with the ∆P adjustment.
REMOVE THE GAUGE, and adjust ∆P until the
CAUTION
deltaPvlv.eps
Figure 162
Setting Q-min 1. Turn the Q-min screw in to raise the pressure

• You must check Q-min pressure when the engine (Figure 161). Turn it out to lower the pressure. Be
is at the maximum specified RPM, but you must sure that you stop the drive shafts from turning
adjust it with the engine stopped. each time before making the adjustment. When
pressure is correct, tighten the jam nut on the
adjustment screw before continuing with the other
procedures.
its original position (see Figure 161).
1. Remove the 0 - 40 bar gauge from the 0 - 400 bar Setting boom pressures
gauge port, and install the 0 - 600 bar gauge in its (Load sensing proportional booms.) Now that ∆P
place. and Q-min are set, you can check or set the boom valve
1. Clear all personnel away from the drive lines, start pressures.
the truck engine, engage the pumps, and bring • There are three pressure settings on the boom
engine RPM to max. All boom functions must be in circuit: (see Figure 163)
neutral, and all emergency stop buttons should be 1. Pressure regulator (the high-pressure adjustment
up (not engaged). screw on the ∆P regulator valve), set at 300 bar.
1. Read the pressure on the 0 - 600 gauge. Pressure 2. The redundant relief valve located in the
should be at 40 - 45 bar. If no adjustment is needed, emergency stop manifold, set at 330 bar.
stop the drivelines from turning, be sure the jam
nut on the Q-min screw is tight, then continue to
paragraph to check the rest of the boom and
outrigger pressures. If adjustment is needed,
continue to step (5.).
HOME PRINT
SERVICE TRAINING
Pressure Settings
3. The boom control block relief valve, set at 350 bar.
NOTE! This relief valve is nonadjustable. If
pressure is not maintained with the specification
limits, the valve must be replaced.
deltaPvlv.eps
Redundant
High pressure adjust-
relief valve
ment screw
T
MP
1
TT
M
10
16
78
P1
92
-7.
ep
s
P4
P2
P3
0-400 bar
gauge port
0-60 bar
gauge port
s
.ep
nly
ipo
ap
block relief valve The three boom pressure devices
• To check the setting of the valve with the highest over the relief valve.
lower two: The telltale hiss of an open relief valve should be
1. Loosen the jam nut of the high pressure adjustment coming from the Apitech control block relief valve
screw of the ∆P regulator. Turn the screw in two- now. If it isn’t, raise the setting of the other
and-a-half turns. This will raise the pressure on the pressure devices until the hiss originates at the
regulator above 350 bar. Apitech control block relief valve. Read the
2. Loosen the jam nut of the adjustment screw of the
pressure is correct, proceed to step (4.).
redundant relief valve in the emergency stop
manifold. Turn the screw in one-and-a-half turns.
This will raise the pressure setting of the relief NOTE! Although the pressure specification for the
valve to above 350 bar. Apitech relief valve is 350 bar, you may continue to
use the relief valve as long as the cartridge maintains at
3. Pressure out any boom cylinder except #1 down by
least 330 bar. If you must replace the valve, proceed to
pushing or pulling the control handle. To pressure
step (4.) before using the machine again, and redo this
out a cylinder, retract a fully retracted cylinder or
entire procedure when you have installed the new
extend a fully extended cylinder. The oil is forced
HOME PRINT
Pressure Settings
valve. If pressure on the Apitech relief valve is below 5. If adjustment is needed, loosen the set screw of the
290 bar, you should not use the machine until the valve 140 bar relief valve with the 2.5 mm Allen wrench.
is replaced. While you activate #1 down, adjust the relief
4. Screw out the e-stop manifold redundant relief cartridge with the screwdriver until the pressure
valve adjustment screw one-and-a-half turns. reads just under 140 bar. Retightening the set screw
Pressure out any boom cylinder except #1 down, will raise the pressure slightly. Recheck the
and read the gauge. Pressure should read 330 bar. pressure, and readjust if needed.
If it does not, turn the screw in to raise pressure, or 6. When the pressure is set at 140 bar with the set
out to lower pressure until it is set at 330 bar. If the screw tight, you can remove the whip hose gauge
location of this valve causes you to be near the and replace the cap on the gauge port.
drivelines, be sure to stop them from turning before 7. The boom pressure setting sequence is complete. If
accessing the valve. you are done with the boom, slew it back into the
5. You will need a helper for this step. While transport position, and lower #1 into the cradle.
pressuring out any boom cylinder except #1 down, Reattach the boom strap.
have your helper adjust the high pressure screw of
the ∆P regulator out (lowering the pressure) until Setting the outrigger
the gauge reads 300 bar. Release the pressurized pressures (7 place boom valve system)
function and lock the jam nut. The boom pressures After the boom pressures are set, you can set the
are now set. If you did not get the readings outrigger pressure.
specified after following the instructions, contact
• In this system, the boom, outriggers, water pump,
Schwing America’s Service Department at (651)
and compressor circuits have all been put together
429-0999 for advice on how to continue.
in the boom valve manifold. (See Figure 227).
When the outrigger selector pushbutton is
Setting the 140 bar down side relief valve
activated, the outrigger valve routes oil to the two
pressure outrigger handvalve banks, one on each side of the
Set the pressure of the 140 bar down side relief valve. unit. A relief valve inside the passenger side bank
This valve is a secondary relief valve for #1 cylinder limits the entire outrigger circuit to 280 bar (4060
retract function. Proper adjustment ensures that the #1 PSI) instead of the 300 bar (4350 PSI) of the boom
boom and the A-frame won’t be damaged by putting relief valve.
the boom in the cradle. (See figure 146.) To adjust this • To set the 280 bar relief valve for the outrigger
valve (requires a 2.5 mm Allen wrench and a standard circuit: (See Figure 166).
screwdriver):
1. Install a 0 - 400 bar or 0 - 600 bar gauge into the
140 bar gauge port (shown in Figure 164). 1. Wear safety glasses whenever you check or set
2. Unfold the #2 section from #1 until it is straight. pressures.
For the following procedure we must bring #1 all 2. Plug the whip hose of a 0-400 or 0-600 bar gauge
the way down until the cylinder bottoms out. into the gauge port. Location is shown as item 1 in
Position the boom so this can be done without figure 227.
hitting the truck or any other obstacle. 3. If not already done, start the truck engine and set
3. Bring #1 down until the cylinder is completely the transmission and PTO as you would for a
bottomed out. The cylinder does NOT bottom out pumping job.
if you are setting the folded boom into the A-frame 4. Locate the 280 bar relief valve on the back of the
(travel position). outrigger valve, as shown in Figure 166.
4. Activate the #1 down (retract) handvalve The 5. Set the engine RPM to maximum.
boom will not be able to move because the cylinder 6. Select “outrigger” with the outrigger pushbutton.
is already bottomed out. Read the pressure on the This will route oil to the outrigger handvalves.
gauge that you just installed. It should read 140
bar. If no adjustment is necessary, skip to step 6.
HOME PRINT
SERVICE TRAINING
Pressure Settings
7plc140.eps
140 bar gauge port
SECTION 1 SECTION 2 SECTION 3 SECTION 4 SLEWING AIR / WATER BOOM / OUTRIG.
DANGER WARNING
Electrocution hazard. Do not operate this

140 bar
gauge port
ps
0.e
it14
ap
Figure 164
location of the 140 bar relief valves and gauge
ports. - B & W (top)
proportional (bottom)
7. Assuming that the outriggers are folded into the 8. Read the pressure on the gauge. It should read 280
travel position, activate the passenger side bar (4060 PSI). If no adjustment is needed, skip to
handvalve “jacking cylinder retract” for either the step 4.
front or rear outrigger. Note! You will get an 9. If adjustment is needed, turn the outside body of
incorrect reading if you select “extension cylinder the relief valve that is located at the back of the
retract” by mistake. If you select “extend” by outrigger valve. Turn in to raise pressure, turn out
mistake, the outriggers will extend instead of to lower pressure. There is no jam nut on this
reading the relief valve setting. The handles are valve.
you let go.
HOME PRINT
Pressure Settings
7plcORhndl.eps
Outrigger handle
1
Gauge port
DANGER WARNING

1
Gauge port
Figure 165
.ep
s Position of the outrigger selector valve
hd
itor
ap Monsun-Tyson black & white (top right)
Outrigger handle Apitech proportional (bottom left)
10. Activate the outrigger “jacking retract” handvalve pressure in the agitator circuit to 200 bar (2900 PSI).
and read the pressure on the gauge again. Repeat (See Figure 167). There is a gauge port for checking or
steps 8. and 9. until the gauge reads 280 bar. setting the pressure in this circuit. The port is located
11. When the pressure is correct, either go on to other on the agitator handvalve. To check or set the agitator
pressure settings, or remove the whip hose and pressure, follow these steps:
gauge, and cap the gauge port with the attached 1. Remove the aluminum diamond plate cover from
cap. over the agitator handvalve.
12. Return the RPM of the truck to an idle, take the 2. Unscrew the cover from the gauge port. Plug in the
transmission and PTO out of gear, and shut off the 0-600 bar gauge and whip hose that came in the
truck, or go on to the other pressure settings, as toolbox.
required. 3. Start the engine, if not already running.
4. Close the agitator shutoff valve. (See Figure 168.)
Setting the water pump hyd. pressure
Note! If your unit does not have a shutoff valve,
• With a seven place handvalve, the water pump you can order one using part number 10004680
hydraulic control is inside the boom control block. (valve) and part number 30303432 (tube). Contact
There is not a separate relief for this circuit. Schwing’s Service Dept. for installation
instructions.
To set the agitator circuit
5. Activate the agitator in forward. Read the pressure
pressure:
on the gauge.
The agitator relief valve is located in the agitator
forward / neutral / reverse handvalve, at the rear of the
unit on the driver’s side. The relief valve limits the
HOME PRINT
SERVICE TRAINING
Pressure Settings
32Porct5.eps
280 bar
Lower Relief Valve
PS
oc
bb
ck.
Higher ep
s
Turn body of valve

to adjust.
Figure 166
Location of the 280 bar outrigger
pressure relief valve.
(Hoses removed for clarity).

this angle).
Gauge port
Figure 167
Showing the agitator handvalve and
gauge port.
HOME PRINT
Pressure Settings
closed
s
ep
o.
its
ag
open
Figure 168

agitator handvalve.
HOME PRINT
SERVICE TRAINING
Pressure Settings
32 XL Hi-Flow B&W off, and the key in your pocket, remove the plug
bottom of the hole in the case. If oil is needed, add
Units up to 450 l/m
by removing the breather (item 1) and pouring in
• Check the fluid level of the distribution gearcase. through the top. This gearcase uses 90W gearlube.
(See Figure 153). Be sure the truck is on
Breather filter
1
filler spout
Oil check plug
4194 gearcase scan.eps

Drain plug 2
Figure 169
Check, drain and fill ports of the Stiebel 4194 gearcase.
• Check the mounting hardware of the subframe, the part number 30303432 (tube). Contact Schwing’s
oil and water tanks, the delivery pipeline, the Service Department at (651) 429-0999 for
pumpkit, the differential cylinders, the material installation instructions.
cylinders and the driveline hardware. Check for 2. Turn on the agitator. The agitator will not be able
bolt tightness, cracks and other abnormalities. to turn, and the oil will be forced over the relief
valve.
• Check all hydraulic pressures. Changes in is being converted to heat. Shut off the agitator
pressures can indicate trouble in one or more when the temperature gauge on the rear control
components. Pressure settings must be made with panel shows 40° C. Don’t forget to open the shutoff
the oil at normal operating temperatures (40° to valve when the procedure is finished.
60° C).The specifications for all circuit pressures
are found on the hydraulic schematics in the
appendix section of this manual.

• To heat the oil to operating temperature:
1. Locate the agitator shutoff valve and close it. There
is a picture of the location on page 6-362. Note! If
your unit does not have a shutoff valve, you can
HOME PRINT
Pressure Settings
Location of pressure setting/checking devices eral location of the devices needed to check pressures
See Figure 170. The illustration below shows the gen- on the concrete pump, boom, and outriggers,
Boom control
block
32
prs
loc
.ep
s
E-Stop manifold
Soft Switch ball cock
Ball cock
CONCRETE PUMP
REV
FWD
(quarter-turn valve)
Outrigger pushbutton
Outrigger pushbutton
Passenger side
outrigger controls
Driver's side
outrigger controls
Agitator control Control panel

valve
Agitator shutoff valve
Figure 170
Location of the pressure setting devices
HOME PRINT
SERVICE TRAINING
Pressure Settings
Check the concrete pump pressure (2020, model. This means that we cannot simply list a
2023, 2525 pumpkits) pressure specification for all units. The correct
• Because the Hi-flo pumpkits have the ability to pressure specifications for your unit are shown on
create high pressure on the concrete the pressure the hydraulic schematic in section 7 of this
settings have to be tailored specifically for each manual..
Gauge port
Hif
lrv
vw
.ep
s
Main relief valve
Soft switch
relief valve
Figure 171
Location of the concrete pump circuit main relief
valve and soft switch relief valve
To check or set the concrete pump pressure 5. Install a 0 - 400 or 0 - 600 bar gauge in the gauge
adjustments, follow these steps: port.
6. Put the rear control panel switch “remote / local”
1. Wear safety glasses when checking or setting into the “local” position.
pressures. 7. Be sure that all emergency stop switches are in the
2. Be sure that the waterbox covers and guards are up (not activated) position. Reset the e-stop circuit.
installed on the waterbox. Use of the remote 8. Using the switch on the rear control panel, rev the
control box for the following pressure setting truck engine up to full RPM.
procedure is NOT recommended. 9. Put the concrete pump “forward / neutral / reverse”
3. Start the truck engine, and put the PTO and switch on the rear control panel into the “forward”
transmission into gear just as you would to pump a position. The unit will stroke no more than once,
job. then the rock cylinder will retract. Oil leaving the
4. See figures 219, 173, and 174. Locate and close the hydraulic pumps will be blocked in the brain. This
concrete pump shutoff valve, and the soft switch is called high-pressuring the concrete pump.
shutoff valve. (These valves are also known as
quarter turn valves).
HOME PRINT
Pressure Settings
Soft switch
shutoff valve
Concrete pump
shutoff valve
hif
lob
r2.
ep
s
Figure 172
Showing the concrete pump and soft switch shutoff valves
Groove lined
grooves.eps
Groove at 90°
to ports - closed
Figure 173
Orientation of the concrete pump shutoff valve open/closed positions
10. Read the pressure on the gauge. Pressure shown on valve so you will be out of the way if a hose or fitting
the gauge should be the same as the specification blows. See Figure 174. If the main relief valve needs
for the concrete pump circuit on the hydraulic adjustment, proceed as follows:
schematic. Return the pump control to “neutral” 1. Always wear eye protection when checking or
whether the pressure needs adjustment or not. If no setting pressures.
adjustment is needed, skip to step (5.) on page 6-
352. If adjustment is needed, proceed to step (1.). 2. Using a 9/16” spanner wrench, loosen the jam nut
on the main relief valve adjusting screw (Figure
Setting the main relief valve 174).
The main relief valve is the primary pressure control 3. Insert a 5/32” Allen wrench in the adjustment
device on units equipped with Rexroth A7VO screw. Turn the screw in to raise pressure, out to
hydraulic pumps. lower the pressure. Always go back to the rear
CAUTION! The main relief valve is set to very high panel before checking the pressure.
pressure (at least 350 bar). Use the rear control panel
switch when checking the pressure of the main relief
HOME PRINT
SERVICE TRAINING
Pressure Settings
op
n-c
lsd
2.e
ps
closed
open
Main relief valve

Soft switch
relief valve
Figure 174
Orientation of the soft switch valve open/closed positions
4. Once the pressure is correct to the hydraulic 4. Be sure to open the concrete pump shutoff valve on
schematic, retighten the jam nut. Tightening the the side of the brain (shown in Figure 175) when
nut tends to raise the pressure, so check pressure you are finished. The unit cannot stroke with this
again after tightening. valve closed.
open the shutoff valves. The unit will not stroke Setting the boom pressures
with closed shutoff valves. (7 place black and white circuit) If your unit has a
black and white boom system, it will have different
Setting the soft switch circuit relief pressure adjustments than if it is equipped with a load-
pressure sensing proportional system. The following
• To check or adjust the soft switch pressure setting, instructions are for black and white systems. If you
proceed as follows: have a proportional unit, contact Schwing American’s
1. Open the soft switch shutoff valve, as shown in Service Department at (651) 429-0999 for correct
figure 174. The rest of the unit should still be set up instructions.
as though you were going to check concrete pump To set the 300 bar boom circuit relief valve proceed as
pressure. follows: (See Figure 176)
2. High pressure the concrete pump. The pressure 1. The boom must be raised and rotated 180° for this
gauge should read 60 or 80 bar (check your procedure, so you must set the outriggers as you
schematic). If adjustment is needed, proceed to would to pump a job. Be sure that you set up well
step (3), below. If no adjustment is needed, skip to away from electrical wires and other obstructions.
step (.). 2. Once the outriggers are set, unlock the boom strap,
3. Loosen the jam nut on the soft switch relief valve and raise the #1 boom far enough that you won’t
hit anything on the truck. Leave the rest of the
with a 9/16” spanner wrench. Adjust the pressure up boom folded. Rotate the boom so that you have
or down, as needed, using a 5/32” Allen wrench. safe and easy access to the boom control valves.
When the correct pressure is achieved, re-lock the 3. Remove the control block cover, held on by 2 M6
jam nut. screws.
HOME PRINT
Pressure Settings
Gauge port
Hif
lrv
2.e
ps
Main relief valve
Soft switch
relief valve
Figure 175
4. Install the whip hose of a 0 - 400 or 0 - 600 bar 7. If you cannot achieve 300 bar, it is possible that
gauge in the 300 bar gauge port (see Figure 177). there is a problem with the emergency stop
5. Assuming that your boom is completely folded up manifold (see Figure 178). You can plumb the
(except for #1), select a handle, and retract #2, #3 malfunctioning circuit out of the system to test it.
or #4 section. Do NOT use #1 retract, slewing left Use only approved hydraulic dead plugs to plug
right, outrigger, water pump, or any extend the inlet hose to the malfunctioning circuit. If
function. (Again, when you try to retract a fully pressure can now be achieved, the e-stop manifold
retracted cylinder, the oil has no where to go except is the source of the problem. Contact Schwing
over the relief valve; this allows the relief valve America’s Service Department for advice on repair
setting to be read on a gauge). Read the pressure on of the e-stop manifold. Repair the e-stop manifold
the whip gauge that you installed in step 4, above. before using the unit again. Remember, the
It should read 300 bar. If no adjustment is emergency stop switches do nothing if the e-stop
necessary, skip to step 8. manifold is plumbed out of the system.
300 bar relief valve at the back of the boom control
valve bank. While you are holding the function in
retract mode, adjust the cartridge in or out until the
pressure reads 300 bar.
HOME PRINT
SERVICE TRAINING
Pressure Settings
7plcpres.eps
Use #2, 3, or 4
140 bar port
140 bar relief
300 bar port SECTION 1 SECTION 2 SECTION 3 SECTION 4 SLEWING AIR / WATER BOOM / OUTRIG.
DANGER WARNING

Figure 176
Turn body of valve

Higher to adjust.
Lower
300 bar
Relief Valve
s
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m.
oo
lcb
7p
Figure 177
Location of the boom relief valve
HOME PRINT
Pressure Settings
8. Remove the whip hose from the 300 bar gauge
port. Before folding up the boom, proceed to the
instructions for setting the 140 bar down side relief
valve on page 318.
S
MP
Boom/outrigger
T circuit dump
valve
S
MP
P3
ps
res.e
opp
est
P2
Boom
P4 P1
override
button
Boom/outrigger
inlet port
Figure 178
Setting the 140 bar down side relief valve 3. Bring #1 down until the cylinder is completely
pressure bottomed out. The cylinder does NOT bottom out
if you are setting the folded boom into the A-frame
(travel position).
retract function. Proper adjustment ensures that the #1 4. Activate the #1 down (retract) handvalve The
boom and the A-frame won’t be damaged by putting boom will not be able to move because the cylinder
the boom in the cradle. (See figure 179.) To adjust this is already bottomed out. Read the pressure on the
valve (requires a 2.5 mm Allen wrench and a standard gauge that you just installed. It should read 140
screwdriver): bar. If no adjustment is necessary, skip to step 6.
1. Install a 0 - 400 bar or 0 - 600 bar gauge into the 5. If adjustment is needed, loosen the set screw of the
140 bar gauge port (shown in Figure 146). 140 bar relief valve with the 2.5 mm Allen wrench.
2. Unfold the #2 section from #1 until it is straight.
cartridge with the screwdriver until the pressure
For the following procedure we must bring #1 all
reads just under 140 bar. Retightening the set screw
the way down until the cylinder bottoms out.
will raise the pressure slightly. Recheck the
Position the boom so this can be done without
pressure, and readjust if needed.
hitting the truck or any other obstacle.
HOME PRINT
SERVICE TRAINING
Pressure Settings
6. When the pressure is set at 140 bar with the set 7. The boom pressure setting sequence is complete. If
screw tight, you can remove the whip hose gauge you are done with the boom, slew it back into the
and replace the cap on the gauge port. transport position, and lower #1 into the cradle.
Reattach the boom strap.
7plc140.eps
140 bar gauge port
DANGER WARNING

Figure 179
location of the 140 bar relief valve and gauge port
Setting the outrigger pressures (7 place 2. Plug the whip hose of a 0 - 400 or 0 - 600 bar
boom valve systems) gauge into the gauge port. Location is shown in
figure 227.
After the boom pressures are set, you can set the
outrigger pressure. 3. If not already done, start the truck engine and set
• In this system, the boom, outriggers, water pump, the transmission and PTO as you would for a
and compressor circuits have all been put together pumping job.
in the boom valve manifold. (See Figure 227). 4. Locate the 280 bar relief valve on the back of the
When the outrigger selector pushbutton is outrigger valve, as shown in Figure 228.
activated, the outrigger valve routes oil to the two 5. Set the engine RPM to maximum.
outrigger handvalve banks, one on each side of the 6. Select “outrigger” with the outrigger pushbutton.
unit. A relief valve inside the passenger side bank This will route oil to the outrigger handvalves.
limits the entire outrigger circuit to 280 bar (4060
7. Assuming that the outriggers are folded into the
PSI) instead of the 300 bar (4350 PSI) of the boom
travel position, activate the passenger side
relief valve.
handvalve “jacking cylinder retract” for either the
• To set the 280 bar relief valve for the outrigger front or rear outrigger. Note! You will get an
circuit: (See Figure 182). incorrect reading if you select “extension cylinder
retract” by mistake. If you select “extend” by
mistake, the outriggers will extend instead of
1. Wear safety glasses whenever you check or set
reading the relief valve setting. The handles are
pressures.
you let go.
HOME PRINT
Pressure Settings
7plcORhndl.eps
Outrigger handle
Gauge port
DANGER WARNING

Figure 180
Position of the outrigger selector valve
32Porct5.eps
Figure 181
Location of the passenger side outrigger control block
HOME PRINT
SERVICE TRAINING
Pressure Settings
280 bar
Lower Relief Valve
PS
oc
bb
ck.
Higher ep
s
Turn body of valve

to adjust.
Figure 182
Location of the outrigger relief valve
8. Read the pressure on the gauge. It should read 280 2. Unscrew the cover from the gauge port. Plug in the
bar (4060 PSI). If no adjustment is needed, skip to 0 - 600 bar gauge and whip hose that came in the
step 4. toolbox.
9. If adjustment is needed, turn the outside body of 3. Start the engine, if not already running.
the relief valve that is located at the back of the 4. Close the agitator shutoff valve. (See Figure 184.)
outrigger valve. Turn in to raise pressure, turn out Note! If your unit does not have a shutoff valve,
to lower pressure. There is no jam nut on this you can order one using part number 10004680
valve. (valve) and part number 30303432 (tube). Contact
10. Activate the outrigger “jacking retract” handvalve Schwing’s Service Dept. for installation
and read the pressure on the gauge again. Repeat instructions.
steps 8. and 9. until the gauge reads 280 bar. 5. Activate the agitator in forward. Read the pressure
11. When the pressure is correct, either go on to other on the gauge.
pressure settings, or remove the whip hose and 6. If adjustment is needed, put your wrench on the
gauge, and cap the gauge port with the attached body of the relief valve, which is located on the
cap. back of the agitator handvalve. While reading the
12. Return the RPM of the truck to an idle, take the gauge, turn the body in to raise pressure, or out to
transmission and PTO out of gear, and shut off the lower pressure until 200 bar is achieved.
truck, or go on to the other pressure settings, as 7. Put the agitator handle in neutral.
required.
To set the agitator circuit pressure:
The agitator relief valve is located in the agitator agitator handvalve.
forward / neutral / reverse handvalve, at the rear of the
unit on the driver’s side. The relief valve limits the
pressure in the agitator circuit to 200 bar (2900 PSI).
(See Figure 183). There is a gauge port for checking or
setting the pressure in this circuit. The port is located
on the agitator handvalve. To check or set the agitator
pressure, follow these steps:
1. Remove the aluminum diamond plate cover from
over the agitator handvalve.
HOME PRINT
Pressure Settings

this angle).
Gauge port
Figure 183
Showing the agitator handvalve and gauge port.
(Diamond plate removed for this illustration.)
closed
s
ep
o.
its
ag
open
Figure 184
HOME PRINT
SERVICE TRAINING
Pressure Settings
32 XL High Flow Proportional engine off, and the key in your pocket,
remove the plug (item 2). The oil should be at
the level of the bottom of the hole in the case.
Units up to 450 l/m If oil is needed, add by removing the breather
5.3-6 Check the fluid level of the distribution gear- (item 1) and pouring in through the top. This
case. (See Figure 185). Be sure the truck is on gearcase uses 90W gearlube.
reasonably level ground. With the truck
2
4194.e
ps
Figure 185
Check, drain and fill ports of the Stiebel 4194 gearcase
• Check the mounting hardware of the subframe, the 1. Locate the agitator shutoff valve and close it. There
oil and water tanks, the delivery pipeline, the is a picture of the location on page 6-362. Note! If
pumpkit, the differential cylinders, the material your unit does not have a shutoff valve, you can
cylinders and the driveline hardware. Check for order one using part number 10004680 (valve) and
bolt tightness, cracks and other abnormalities. part number 30303432 (tube). Contact Schwing’s
Service Department at (651) 429-0999 for
Check hydraulic pressures installation instructions.
• Check all hydraulic pressures. Changes in 2. Turn on the agitator. The agitator will not be able
pressures can indicate trouble in one or more to turn, and the oil will be forced over the relief
components. Pressure settings must be made with valve.
the oil at normal operating temperatures (40° to 3. At an idle (approx. 600 rpm), about 5.4 horsepower
60° C).The specifications for all circuit pressures is being converted to heat. Shut off the agitator
are found on the hydraulic schematics in the when the temperature gauge on the rear control
appendix section of this manual. panel shows 40° C. Don’t forget to open the shutoff
valve when the procedure is finished.
Check the concrete pump pressure (2020,
2023, 2525 pumpkits)
hydraulic oil (they stop putting out oil if you try). • Because the Hi-flow pumpkits have the ability to
To heat the oil to operating temperature: create high pressure on the concrete the pressure
settings have to be tailored specifically for each
model. This means that we cannot simply list a
HOME PRINT
Pressure Settings
pressure specification for all units. The correct manual. (See Figure 218).
pressure specifications for your unit are shown on
the hydraulic schematic in Section 7 of this
Gauge port
Hif
lrv
vw
.ep
s
Main relief valve
Soft switch
relief valve
Figure 186
Location of the concrete pump circuit main
relief valve and soft switch relief valve
To check or set the concrete pump pressure 9. Put the concrete pump “forward / neutral / reverse”
adjustments, follow these steps: switch on the rear control panel into the “forward”
position. The unit will stroke no more than once,
then the rock cylinder will retract. Oil leaving the
1. Wear safety glasses when checking or setting
hydraulic pumps will be blocked in the brain. This
pressures.
is called high-pressuring the concrete pump.
10. Read the pressure on the gauge. Pressure should
installed on the waterbox. Use of the remote
read as shown for the concrete pump circuit main
control box for the following pressure setting
relief valve setting on the hydraulic schematic.
procedure is NOT recommended.
Return the pump control to “neutral” whether the
3. Start the truck engine, and put the PTO and pressure needs adjustment or not. If no adjustment
transmission into gear just as you would to pump a is needed, skip to step (5.) on page 6-352. If
job. adjustment is needed, proceed to step (1.).
4. See Figure 186. Locate and close the concrete
pump shutoff valve, and the soft switch shutoff Setting the main relief valve
valve. (These valves are also known as quarter The main relief valve is the primary pressure control
turn valves). device on units equipped with Rexroth A7VO
5. Install a 0 - 400 or 0 - 600 bar gauge in the gauge hydraulic pumps.
port. CAUTION! The main relief valve is set to very high
6. Put the rear control panel switch “remote / local” pressure (at least 350 bar). Use the rear control panel
into the “local” position. switch when checking the pressure of the main relief
7. Be sure that all emergency stop switches are in the valve so you will be out of the way if a hose or fitting
up (not activated) position. Reset the e-stop circuit. blows. See Figure 103. If the main relief valve needs
8. Using the switch on the rear control panel, rev the adjustment, proceed as follows:
truck engine up to full RPM.
HOME PRINT
SERVICE TRAINING
Pressure Settings
Figure 187
closed
Groove lined
up with ports - open open
grooves.eps
Groove at 90°
to ports - closed
op
n-c
lsd
.ep
s
Figure 188
HOME PRINT
Pressure Settings
Gauge port
Hif
lrv
vw
.ep
s
Main relief valve
Soft switch
relief valve
Figure 189
1. Open the soft switch shutoff valve, as shown in

1. Wear safety glasses when checking or adjusting Figure 188. The rest of the unit should still be set
pressures. up as though you were going to check concrete
pump pressure.
on the main relief valve adjusting screw (Figure gauge should read 60 or 80 bar (check your
189). schematic). If adjustment is needed, proceed to
3. Insert a 5/32” allen wrench in the adjustment screw. step (), below. If no adjustment is needed, skip to
Turn the screw in to raise pressure, out to lower the step (.).
pressure. Always go back to the rear panel before 3. Loosen the jam nut on the soft switch relief valve
checking the pressure. with a 9/16” spanner wrench. Adjust the pressure up
4. Once the pressure is correct to the hydraulic or down, as needed, using a 5/32” Allen wrench.
schematic, retighten the jam nut. Tightening the
When the correct pressure is achieved, re-lock the
nut tends to raise the pressure, so check pressure
jam nut.
again after tightening. Don’t forget to turn the
pressure cut-off adjustment screws back out 1 turn 4. Be sure to open the concrete pump shutoff valve on
each and verify the correct pressure setting before the side of the brain (shown in Figure 188) when
unplugging the gauge. you are finished. The unit cannot stroke with this
valve closed.
Load-sensing boom pressures
(7 place proportional circuit) If your unit has a load-
Setting the soft switch circuit relief sensing proportional system, it will have different
pressure pressure adjustments than if it is equipped with a black
• To check or adjust the soft switch pressure setting, and white boom system. The following instructions are
proceed as follows: for load-sensing proportional systems. If you have a
unit equipped with a black and white boom system,
contact Schwing Service for the correct instruction
pages.
HOME PRINT
SERVICE TRAINING
Pressure Settings
Preheat the oil system. Generally, the pump puts out enough oil to
Note! Whenever you set pressures for any circuit on maintain a 20 bar higher pressure at the pump than
any unit, the hydraulic oil should be at normal operat- what the cylinders actually require. This 20 bar is
ing temperature (40° - 60° C). Instructions for heating called delta P (∆P). Additionally, we set the hydraulic
the hydraulic oil are found in section on page 351. pump so that it always puts out a small amount of oil,
even if no oil is needed for the system. This oil is used
About proportional boom systems to ensure that you have control when you need it. The
In a black and white boom system, the hydraulic pump setting to maintain this minimum amount of oil is
puts out an unchanging amount of oil, and speed called Q-min (pronounced “cue min”). To set the boom
control is done by restricting the oil to certain functions or outrigger hydraulic pressures on a load-sensing
with orifices. In a load-sensing system, the pump puts system, begin by setting Q-min and ∆P. See figure 192.

boom handvalves
CONCRETE PUMP
REV FWD
s
.ep
loc
XL
32
Figure 190
used to check and set
boom pressures
E-Stop manifold
Read all of the instructions before beginning any pres-

sure settings. You will need an assistant for parts of the
procedure. You and any assistants should wear eye pro-
tection when checking or setting pressures.
Setting ∆P
Note! Do not adjust ∆P or Q-min if your boom is
running as you like it. The pressure setting procedure
from there. It was fine tuned at the factory, and should
not be adjusted unless absolutely necessary.
• You must not adjust Q-min with the drive shafts
turning! Each time the Q-min screw must be
drivelines stop turning. To check or set ∆P, follow
these steps:
2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar
gauge port of the manual boom handvalves. Take
care not to accidently install the gauge in the 0-60
bar port. (See Figure 191.)
HOME PRINT
Pressure Settings

140 bar downside

relief cartridge
0-400 bar
gauge port
0-60 bar
gauge port
boom control
block relief valve
s
ep
dv.
itpr
ap
15 bar pretension
adjustment screw
Figure 191
Location of the boom circuit pressure devices
3. To be sure that the pump is putting out only enough boom or outrigger functions, you will damage
oil needed to maintain ∆P, we need to change the the 0 - 40 bar gauge. Make sure that all
setting of the Q-min screw. Q-min is adjusted by a emergency stop switches are in the up (not
screw on the boom hydraulic pump (see Figure activated) position. Pressure can be read on the 0 -
192). Unscrew the Q-min screw three full turns. 40 bar gauge that you installed. Pressure should
Check that all personnel are clear of the truck, then read 20 bar. If no adjustment is needed, simply
restart the engine, engage the pumps, and leave the reset the Q-min screw as described in . If
engine at an idle. CAUTION! If you activate any adjustment is needed, continue to step (2.).
Q-min
adjustment screw
Q-minscrew.eps
Q-max
Figure 192
4. Delta P is adjusted by the ∆P screw on the ∆P outward to decrease pressure until it is set at 20 bar
regulator (see Figure 193). Loosen the jam nut and (±1). Contact Schwing America’s Service
adjust the screw inward to increase pressure, or Department if you are unable to adjust the pressure
HOME PRINT
SERVICE TRAINING
Pressure Settings
to spec. NOTE! If the boom is not smooth at 20 affect how the boom operates, so if ∆P adjustment
bar, you must fine tune the adjustment. In that case, does not seem to help, reset to 20 bar and check the
REMOVE THE GAUGE, and adjust ∆P until the electrical settings. Once electrical settings are
boom is responsive and smooth. When done, the verified, you could again refine the boom action
gauge (reinstalled) must read between 14 and 25 with the ∆P adjustment.
bar. The electronics in the control system can also
CAUTION
deltaPvlv.eps
T Figure 193
Setting Q-min Setting boom pressures

• You must check Q-min pressure when the engine (Load sensing proportional booms.) Now that ∆P and
is at the maximum specified RPM, but you must Q-min are set, you can check or set the boom valve
adjust it with the engine stopped. pressures.
1. If you unscrewed the Q-min screw as the first step • There are three pressure settings on the boom
of ∆P adjustment, begin by returning the screw to circuit: (see Figure 194)
its original position (see Figure 192). 1. Pressure regulator (the high-pressure adjustment
2. Remove the 0 - 40 bar gauge from the 0 - 400 bar screw on the ∆P regulator valve), set at 300 bar.
gauge port, and install the 0 - 600 bar gauge in its 2. The redundant relief valve located in the
place. emergency stop manifold, set at 330 bar.
engine RPM to max. All boom functions must be in
neutral, and all emergency stop buttons should be
up (not engaged).
4. Read the pressure on the 0 - 600 gauge. Pressure
should be at 40 - 45 bar. If no adjustment is needed,
stop the drivelines from turning, be sure the jam
nut on the Q-min screw is tight, then continue to
paragraph to check the rest of the boom and
outrigger pressures. If adjustment is needed,
continue to step (5.).
5. Turn the Q-min screw in to raise the pressure
(Figure 192). Turn it out to lower the pressure. Be
each time before making the adjustment. When
adjustment screw before continuing with the other
procedures.
HOME PRINT
Pressure Settings
deltaPvlv.eps
High pressure Redundant

adjustment screw relief valve
T
MP
1
TT
M
10
16
78
P1
92
-7.
ep
s
P4
P2
P3
0-400 bar
gauge port
0-60 bar
gauge port
s
.ep
nly
ipo
ap
block relief valve The three boom pressure devices
• To check the setting of the valve with the highest over the relief valve.
lower two: The telltale hiss of an open relief valve should be
4. Loosen the jam nut of the high pressure adjustment coming from the Apitech control block relief valve
screw of the ∆P regulator. Turn the screw in two- now. If it isn’t, raise the setting of the other
and-a-half turns. This will raise the pressure on the pressure devices until the hiss originates at the
regulator above 350 bar. Apitech control block relief valve. Read the
pressure is correct, proceed to step (4.).
NOTE! Although the pressure specification for the
This will raise the pressure setting of the relief
Apitech relief valve is 350 bar, you may continue
valve to above 350 bar.
to use the relief valve as long as the cartridge
6. Pressure out any boom cylinder except #1 down by maintains at least 330 bar. If you must replace the
pushing or pulling the control handle. To pressure valve, proceed to step (4.) before using the
out a cylinder, retract a fully retracted cylinder or machine again, and redo this entire procedure
HOME PRINT
SERVICE TRAINING
Pressure Settings
when you have installed the new valve. If pressure 5. If adjustment is needed, loosen the set screw of the
on the Apitech relief valve is below 290 bar, you 140 bar relief valve with the 2.5 mm allen wrench.
should not use the machine until the valve is While you activate #1 down, adjust the relief
replaced. cartridge with the screwdriver until the pressure
7. Screw out the e-stop manifold redundant relief reads just under 140 bar. Retightening the set screw
valve adjustment screw one-and-a-half turns. will raise the pressure slightly. Recheck the
Pressure out any boom cylinder except #1 down, pressure, and readjust if needed.
and read the gauge. Pressure should read 330 bar. 6. When the pressure is set at 140 bar with the set
If it does not, turn the screw in to raise pressure, or screw tight, you can remove the whip hose gauge
out to lower pressure until it is set at 330 bar. If the and replace the cap on the gauge port.
location of this valve causes you to be near the 7. The boom pressure setting sequence is complete. If
drivelines, be sure to stop them from turning before you are done with the boom, slew it back into the
accessing the valve. transport position, and lower #1 into the cradle.
8. You will need a helper for this step. While Reattach the boom strap.
pressuring out any boom cylinder except #1 down,
have your helper adjust the high pressure screw of Setting the outrigger pressures
the ∆P regulator out (lowering the pressure) until After the boom pressures are set, you can set the
the gauge reads 300 bar. Release the pressurized outrigger pressure.
function and lock the jam nut. The boom pressures • In this system, the boom, outriggers, water pump,
are now set. If you did not get the readings and compressor circuits have all been put together
specified after following the instructions, contact in the boom valve manifold. (See Figure 227).
Schwing America’s Service Department at (651) When the outrigger selector pushbutton is
429-0999 for advice on how to continue. activated, the outrigger valve routes oil to the two
outrigger handvalve banks, one on each side of the
Setting the 140 bar down side relief valve unit. A relief valve inside the passenger side bank
pressure limits the entire outrigger circuit to 280 bar (4060
Set the pressure of the 140 bar down side relief valve. PSI) instead of the 300 bar (4350 PSI) of the boom
This valve is a secondary relief valve for #1 cylinder relief valve.
retract function. Proper adjustment ensures that the #1 • To set the 280 bar relief valve for the outrigger
boom and the A-frame won’t be damaged by putting circuit: (See Figure 227 & Figure 228).
the boom in the cradle. (See figure 195.) To adjust this
valve (requires a 2.5 mm Allen wrench and a standard
screwdriver): 1. Wear safety glasses whenever you check or set
1. Install a 0 - 400 bar or 0 - 600 bar gauge into the pressures.
140 bar gauge port (shown in Figure 195). 2. Plug the whip hose of a 0-400 or 0-600 bar gauge
2. Unfold the #2 section from #1 until it is straight. into the gauge port. Location is shown as item 1 in
For the following procedure we must bring #1 all figure 227.
the way down until the cylinder bottoms out. 3. If not already done, start the truck engine and set
Position the boom so this can be done without the transmission and PTO as you would for a
hitting the truck or any other obstacle. pumping job.
3. Bring #1 down until the cylinder is completely 4. Locate the 280 bar relief valve on the back of the
bottomed out. The cylinder does NOT bottom out outrigger valve, as shown in Figure 197.
if you are setting the folded boom into the A-frame 5. Set the engine RPM to maximum.
(travel position).
6. Select “outrigger” with the outrigger pushbutton.
4. Activate the #1 down (retract) handvalve The This will route oil to the outrigger handvalves.
boom will not be able to move because the cylinder
is already bottomed out. Read the pressure on the
HOME PRINT
Pressure Settings
140 bar
gauge port
ps
0.e
it14
ap
Figure 195
Location of the 140 bar relief valve and gauge port
1
Gauge port
s
.ep
hd
itor
ap
Outrigger handle
Figure 196
Position of the outrigger selector valve on units
equipped with Apitech proportional valves
HOME PRINT
SERVICE TRAINING
Pressure Settings
280 bar
Lower Relief Valve
32Porct5.eps
PS
oc
bb
ck.
Higher ep
s
Turn body of valve

to adjust.
Figure 197
7. Assuming that the outriggers are folded into the 11. When the pressure is correct, either go on to other
travel position, activate the passenger side pressure settings, or remove the whip hose and
handvalve “jacking cylinder retract” for either the gauge, and cap the gauge port with the attached
front or rear outrigger. Note! You will get an cap.
incorrect reading if you select “extension cylinder 12. Return the RPM of the truck to an idle, take the
retract” by mistake. If you select “extend” by transmission and PTO out of gear, and shut off the
mistake, the outriggers will extend instead of truck, or go on to the other pressure settings, as
reading the relief valve setting. The handles are required.
you let go. Setting the water pump hyd. pressure
8. Read the pressure on the gauge. It should read 280 With a seven place handvalve, the water pump
bar (4060 PSI). If no adjustment is needed, skip to hydraulic control is inside the boom control block.
step 4. There is not a separate relief for this circuit, and
9. If adjustment is needed, turn the outside body of therefore nothing that must be set.
outrigger valve. Turn in to raise pressure, turn out Setting 15 bar pretension
to lower pressure. There is no jam nut on this • To check or set pretension, follow these steps:
valve.
1. Stop the truck engine. Plug the 0 - 40 bar gauge
10. Activate the outrigger “jacking retract” handvalve into the pretension check port of the Apitech
and read the pressure on the gauge again. Repeat handvalve (Figure 195).
steps 8. and 9. until the gauge reads 280 bar.
2. Start the truck engine, but leave it at an idle.
HOME PRINT
Pressure Settings
CAUTION
increased, pressure will rise. Damage to the 0 - 40 3. Read the pressure on the gauge. If it reads 15 bar ±
bar gauge is possible if RPM is raised while the 1 bar, the pressure is set correctly. If adjustment is
gauge is connected.) needed, proceed to step (4.).
Pretension
gauge port
s
.ep
rtn
itp
ap
Figure 198
Pretension adjustment screw and gauge port
4. Loosen the jam nut on the pretension valve. Turn 2. Unscrew the cover from the gauge port. Plug in the
the screw in to raise pressure, and out to lower 0-600 bar gauge and whip hose that came in the
pressure. When the pressure is correct, retighten toolbox.
the jam nut. 3. Start the engine, if not already running.
5. Stop the engine, and remove the 0 - 40 bar gauge. 4. Close the agitator shutoff valve. (See Figure 200.)
Pretension setting is complete. Note! If your unit does not have a shutoff valve,
you can order one using part number 10004680
To set the agitator circuit pressure: (valve) and part number 30303432 (tube). Contact
The agitator relief valve is located in the agitator Schwing America’s Service Department at (651)
forward / neutral / reverse handvalve, at the rear of the 429-0999 for installation instructions.
unit on the driver’s side. The relief valve limits the 5. Activate the agitator in forward. Read the pressure
pressure in the agitator circuit to 200 bar (2900 PSI). on the gauge.
(See Figure 199). There is a gauge port for checking or 6. If adjustment is needed, put your wrench on the
setting the pressure in this circuit. The port is located body of the relief valve, which is located on the
on the agitator handvalve. To check or set the agitator back of the agitator handvalve. While reading the
pressure, follow these steps: gauge, turn the body in to raise pressure, or out to
1. Remove the aluminum diamond plate cover from lower pressure until 200 bar is achieved.
over the agitator handvalve. 7. Put the agitator handle in neutral.
HOME PRINT
SERVICE TRAINING
Pressure Settings

Gauge port Relief valve on this
this angle).
Figure 199
Showing the agitator handvalve and gauge port.
(Diamond plate removed for this illustration.)
closed ag
its
o.
ep
s
open
Figure 200

agitator handvalve.
HOME PRINT
Pressure Settings
HOME PRINT
SERVICE TRAINING
Pressure Settings
32 XL Hi-Flow Prop, A11VO off, and the key in your pocket, remove the plug
bottom of the hole in the case. If oil is needed, add
Units above 450 l/m (-5 and -6 units)
by removing the breather (item 1) and pouring in
• Check the fluid level of the distribution gearcase. through the top. This gearcase uses 90W gearlube.
(See Figure 201). Be sure the truck is on
Breather / filler TOP VIEW
grbx-5-6.eps
Spline flange breather/filler
Check port Oil check plug

inlinoil.eps
Figure 201
Drain port
Check, drain and fill ports of the Stiebel
gearcase.
Main ports (left illustration)
Spline flange ports (right illustration)
• Check the mounting hardware of the subframe, the part number 30303432 (tube). Contact Schwing’s
oil and water tanks, the delivery pipeline, the Service Department at (651) 429-0999 for
pumpkit, the differential cylinders, the material installation instructions.
cylinders and the driveline hardware. Check for 2. Turn on the agitator. The agitator will not be able
bolt tightness, cracks and other abnormalities. to turn, and the oil will be forced over the relief
valve.
• Check all hydraulic pressures. Changes in is being converted to heat. Shut off the agitator
pressures can indicate trouble in one or more when the temperature gauge on the rear control
components. Pressure settings must be made with panel shows 40° C. Don’t forget to open the shutoff
the oil at normal operating temperatures (40° to valve when the procedure is finished.
60° C).The specifications for all circuit pressures
are found on the hydraulic schematics in the Check the concrete pump pressure (2020,
appendix section of this manual. 2023, 2525 pumpkits)
Preheat the hydraulic oil Because the Hi-flow pumpkits have the ability to create
high pressure on the concrete the pressure settings have
to be tailored specifically for each model. This means
that we cannot simply list a pressure specification for
all units. The correct pressure specifications for your
hydraulic oil (they stop putting out oil if you try).
unit are shown on the hydraulic schematic in section 7
To heat the oil to operating temperature:
of this manual. (See Figure 218). Additionally, the
1. Locate the agitator shutoff valve and close it. There pressure is not limited by the main relief valve, but
is a picture of the location on page 6-362. Note! If rather by a pressure cutoff adjustment on the concrete
your unit does not have a shutoff valve, you can
HOME PRINT
Pressure Settings
pump circuit hydraulic pumps.
To check or set the concrete pump pressure
Gauge port
Hif
lrv
vw
.ep
s
Main relief valve
Soft switch
relief valve
Figure 202
Location of the concrete pump circuit
main relief valve and soft switch relief
then the rock cylinder will retract. Oil leaving the

1. Wear safety glasses when checking or setting hydraulic pumps will be blocked in the brain. This
pressures. is called high-pressuring the concrete pump.
2. Be sure that the waterbox covers and guards are 10. Read the pressure on the gauge. Pressure shown on
installed on the waterbox. Use of the remote the gauge is actually the hydraulic pump cutoff
control box for the following pressure setting pressure, because it is set to the lowest setting.
procedure is NOT recommended. Pressure should be as shown for the concrete pump
3. Start the truck engine, and put the PTO and circuit hydraulic pumps on the hydraulic
transmission into gear just as you would to pump a schematic. Return the pump control to “neutral”
job. whether the pressure needs adjustment or not. If no
adjustment is needed, skip to step (5.) on page 6-
4. See Figure 219. Locate and close the concrete 352. If adjustment is needed, proceed to step (11.).
pump shutoff valve, and the soft switch shutoff
valve. (These valves are also known as quarter 11. Shut off the truck, put the key in your pocket, and
turn valves). put a “Do not operate” sign on the truck
windshield.
5. Install a 0 - 400 or 0 - 600 bar gauge in the gauge
port. 12. See Figure 204. Loosen the jam nut (13mm
spanner wrench) on both pressure cutoff
6. Put the rear control panel switch “remote / local” adjustment screws. Using a 4mm Allen wrench,
into the “local” position. turn the screw in to raise pressure, or out to lower
7. Be sure that all emergency stop switches are in the
up (not activated) position. Reset the e-stop circuit.
8. Using the switch on the rear control panel, rev the
truck engine up to full RPM.
9. Put the concrete pump “forward / neutral / reverse”
switch on the rear control panel into the “forward”
position. The unit will stroke no more than once,
HOME PRINT
SERVICE TRAINING
Pressure Settings
Groove lined
grooves.eps
Groove at 90° closed

to ports - closed
open
Figure 203
Showing the concrete pump and soft switch shutoff valves
and their open/closed orientation Soft switch op
n-c
shutoff valve lsd
.ep
s
pressure. Turn the screw on each pump an equal Setting the main relief valve
amount. On these screws, very small adjustments The main relief valve is not the primary pressure con-
make a big pressure difference. trol device on units with Hi-flo pumpkits.
Pressure cut-off adjustment screws CAUTION! The main relief valve is set to very high
pressure (at least 350 bar). Use the rear control panel
switch when checking the pressure of the main relief
valve so you will be out of the way if a hose or fitting
blows. Always wear eye protection when setting
pressures! See Figure 103. If the main relief valve
needs adjustment, proceed as follows:
1. If you ever need to check or adjust the main relief
valve, you must first screw in the pressure cut-off
screws on the hydraulic pumps by 1 turn each.
A11ctoff.eps
Then, when you high pressure the concrete pump,
Figure 204 you will be reading the setting of the main relief
Location of the pressure cut- valve.
off adjustment screws
13. Clear the area around the drivelines, then restart

the truck. Repeat steps (7.) through (12.) until the
pressure is as specified on the hydraulic schematic.
HOME PRINT
Pressure Settings
Gauge port
Hif
lrv
vw
.ep
s
Main relief valve
Soft switch
relief valve
Figure 205
2. Using a 9/16” spanner wrench, loosen the jam nut 2. High pressure the concrete pump. The pressure
on the main relief valve adjusting screw (Figure gauge should read 60 or 80 bar (check your
205). schematic). If adjustment is needed, proceed to
step (), below. If no adjustment is needed, skip to
3. Insert a 5/32” allen wrench in the adjustment screw. step (.).
Turn the screw in to raise pressure, out to lower the 3. Loosen the jam nut on the soft switch relief valve
pressure. Always go back to the rear panel before
with a 9/16” spanner wrench. Adjust the pressure up
checking the pressure.
4. Once the pressure is correct to the hydraulic or down, as needed, using a 5/32” allen wrench.
schematic, retighten the jam nut. Tightening the When the correct pressure is achieved, re-lock the
nut tends to raise the pressure, so check pressure jam nut.
again after tightening. Don’t forget to turn the 4. Be sure to open the concrete pump shutoff valve on
pressure cut-off adjustment screws back out 1 turn the side of the brain (shown in Figure 203) when
each and verify the correct pressure setting before you are finished. The unit cannot stroke with this
unplugging the gauge. valve closed.
open the shutoff valves. The unit will not stroke Setting boom pressures
with closed shutoff valves. (7 place proportional circuit) If your unit has a load-
sensing proportional system, it will have different
Setting the soft switch circuit relief pressure adjustments than if it is equipped with a black
pressure and white boom system. The following instructions are
• To check or adjust the soft switch pressure setting, for load-sensing proportional systems. If your unit is
proceed as follows: equipped with a black and white boom system, these
1. Open the soft switch shutoff valve, as shown in instructions will be wrong. Contact Schwing America’s
figure 203. The rest of the unit should still be set up Service Department at (651) 429-0999 to obtain
as though you were going to check concrete pump correct instructions.
pressure.
HOME PRINT
SERVICE TRAINING
Pressure Settings
Preheat the oil out more or less oil to respond to the needs of the
Note! Whenever you set pressures for any circuit on system. Generally, the pump puts out enough oil to
any unit, the hydraulic oil should be at normal maintain a 20 bar higher pressure at the pump than
operating temperature (40° - 60° C). Instructions for what the cylinders actually require. This 20 bar is
heating the hydraulic oil are found in section on page called delta P (∆P). Additionally, we set the hydraulic
6-351. pump so that it always puts out a small amount of oil,
About proportional boom systems to ensure that you have control when you need it. The
In a black and white boom system, the hydraulic pump setting to maintain this minimum amount of oil is
puts out an unchanging amount of oil, and speed called Q-min (pronounced “cue min”). To set the boom
control is done by restricting the oil to certain functions or outrigger hydraulic pressures on a load-sensing
with orifices. In a load-sensing system, the pump puts system, begin by setting Q-min and ∆P. See figure 222.

boom handvalves
CONCRETE PUMP
REV FWD
Figure 206
used to check and set 32XLHF+.eps
boom pressures
E-Stop manifold
3. To be sure that the pump is putting out only enough

Read all of the instructions before beginning any oil needed to maintain ∆P, we need to change the
pressure settings. You will need an assistant for parts of setting of the Q-min screw. Q-min is adjusted by a
the procedure. You and any assistants should wear eye screw on the boom hydraulic pump (see Figure
protection when checking or setting pressures. 207). Unscrew the Q-min screw three full turns.
Check that all personnel are clear of the truck, then
Setting ∆P restart the engine, engage the pumps, and leave the
Note! Do not adjust ∆P or Q-min if your boom is engine at an idle. CAUTION! If you activate any
running as you like it. The pressure setting procedure boom or outrigger functions, you will damage
uses a standard starting point and must be fine tuned the 0 - 40 bar gauge. Make sure that all
from there. It was fine tuned at the factory, and should emergency stop switches are in the up (not
not be adjusted unless absolutely necessary. activated) position. Pressure can be read on the 0 -
• You must not adjust ∆P or Q-min with the drive 40 bar gauge that you installed. Pressure should
shafts turning! Each time the ∆P or Q-min screw read 20 bar. If no adjustment is needed, simply
must be adjusted, the engine must be stopped, or at reset the Q-min screw as described in . If
least the transmission must be taken out of gear so adjustment is needed, continue to step (2.).
that the drivelines stop turning. To check or set ∆P, 4. Delta P is adjusted by the ∆P screw on the boom
follow these steps: pump regulator (see Figure 207). Loosen the jam
1. Stop the truck engine and place a “Do Not nut and adjust the screw inward to increase
Operate” sign on the truck windshield. pressure, or outward to decrease pressure until it is
set at 20 bar (±1). Contact Schwing America’s
2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar Service Department if you are unable to adjust the
gauge port of the manual boom handvalves. Take pressure to spec. NOTE! If the boom is not smooth
care not to accidently install the gauge in the 0-60 at 20 bar, you must fine tune the adjustment. In that
bar port. (See Figure 207.) case, REMOVE THE GAUGE, and adjust ∆P until
the boom is responsive and smooth. When done,
HOME PRINT
Pressure Settings
the gauge (reinstalled) must read between 14 and and check the electrical settings. Once electrical
25 bar. The electronics in the control system can settings are verified, you could again refine the
also affect how the boom operates, so if ∆P boom action with the ∆P adjustment.
adjustment does not seem to help, reset to 20 bar
Pressure Cut-off P adjustment screw

adjustment screw
Q-min.
adjustment screw
Hi
pm
pb
m.
ep
s
Figure 207
Boom pump adjustment screws
CAUTION

140 bar downside

relief cartridge
0-400 bar
gauge port
0-60 bar
gauge port
boom control
block relief valve
ps
dv.e
itpr
ap
15 bar pretension
adjustment screw
Figure 208
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting Q-min 4. With the drive shafts stopped, loosen the jam nut of
• You must check Q-min pressure when the engine the high pressure adjustment screw of the boom
is at the maximum specified RPM, but you must hydraulic pump pressure regulator. Turn the screw
adjust it with the engine stopped. in two-and-a-half turns. This will raise the pressure
of the regulator above 350 bar.
of ∆P adjustment, begin by returning the screw to 5. Loosen the jam nut of the adjustment screw of the
its original position (see Figure 207). redundant relief valve in the emergency stop
2. Remove the 0 - 40 bar gauge from the 0 - 400 bar
This will raise the pressure setting of the relief
gauge port, and install the 0 - 600 bar gauge in its
valve to above 350 bar.
place.
3. Clear all personnel away from the drive lines, start Pressure out any boom cylinder except #1 down by
the truck engine, engage the pumps, and bring pushing or pulling the control handle. To pressure out a
engine RPM to max. All boom functions must be in cylinder, retract a fully retracted cylinder or extend a
neutral, and all emergency stop buttons should be fully extended cylinder. The oil is forced over the relief
up (not engaged). valve.
4. Read the pressure on the 0 - 600 gauge. Pressure The telltale hiss of an open relief valve should be
should be at 40 - 45 bar. If no adjustment is needed, coming from the Apitech control block relief valve
stop the drivelines from turning, be sure the jam now. If it isn’t, raise the setting of the other pressure
nut on the Q-min screw is tight, then continue to devices until the hiss originates at the Apitech control
paragraph to check the rest of the boom and block relief valve. Read the pressure on the gauge. It
outrigger pressures. If adjustment is needed, should read 350 bar. If pressure is correct, proceed to
continue to step (5.). step (4.).
5. Turn the Q-min screw in to raise the pressure
(Figure 225). Turn it out to lower the pressure. Be NOTE! Although the pressure specification for the
sure that you stop the drive shafts from turning Apitech relief valve is 350 bar, you may continue to
each time before making the adjustment. When use the relief valve as long as the cartridge maintains at
pressure is correct, tighten the jam nut on the least 330 bar. If you must replace the valve, proceed to
adjustment screw before continuing with the other step (4.) before using the machine again, and redo this
procedures. entire procedure when you have installed the new
valve. If pressure on the Apitech relief valve is below
Setting boom pressures 290 bar, you should not use the machine until the valve
(Load sensing proportional booms.) Now that ∆P is replaced.
and Q-min are set, you can check or set the boom valve 6. Screw out the e-stop manifold redundant relief
pressures. valve adjustment screw one-and-a-half turns.
• There are three pressure settings on the boom Pressure out any boom cylinder except #1 down,
circuit: (see Figure 209) and read the gauge. Pressure should read 330 bar.
1. Pressure regulator (the high-pressure adjustment If it does not, turn the screw in to raise pressure, or
screw on the boom hydraulic pump), set at 300 bar. out to lower pressure until it is set at 330 bar. If the
2. The redundant relief valve located in the
emergency stop manifold, set at 330 bar.
7. With the truck engine off, adjust the high pressure
screw of the boom hydraulic pump regulator out
(lowering the pressure) two-and-a-half turns. Start
limits, the cartridge valve must be replaced.
the engine, pressure out any boom cylinder except
• To check the setting of the valve with the highest #1 down, and read the pressure on the gauge. It
pressure, you must first raise the pressure of the should read 300 bar. If not, repeat step (7.),
lower two: adjusting the screw a small amount each time, until
the gauge reads 300 bar when a cylinder is
pressured out.
HOME PRINT
Pressure Settings
Redundant
relief valve
MP
1
TT
10
16
78
P1
92
-7.
ep
s
P4
P2
P3
0-400 bar
gauge port
0-60 bar
gauge port
Pressure Cut-off
adjustment screw
s
.ep
nly
ipo
ap
boom control
block relief valve
ILbmpmp.eps
Figure 209
The three boom pressure devices
8. With the truck engine off, lock the jam nut on the
high pressure screw you were adjusting in step (7.).
The boom pressures are now set. If you did not get
the readings specified after following the
instructions it is possible that there is a problem
with the emergency stop manifold (see Figure
210). You can plumb the malfunctioning circuit out
of the system to test it. Use only approved
hydraulic dead plugs to plug the inlet hose to the
malfunctioning circuit. If pressure can now be
achieved, the e-stop manifold is the source of the
problem. If pressure still cannot be achieved, the
problem is elsewhere. Contact Schwing America’s
Service Department for advice on how to continue.
If the problem was found to be the e-stop manifold,
repair it before using the unit again. Remember, the
emergency stop switches do nothing if the e-stop
HOME PRINT
SERVICE TRAINING
Pressure Settings
manifold is plumbed out of the system. Remove
the whip hose from the 300 bar gauge port. Before
folding up the boom, proceed to the instructions
for setting the 140 bar down side relief valve.
S
MP
Boom/outrigger
T circuit dump
valve
S
MP
P3
ps
res.e
opp
est
P2
Boom
P4 P1
override
button
Boom/outrigger Figure 210

inlet port Emergency stop manifold
Setting the 140 bar down side relief valve 5. If adjustment is needed, loosen the set screw of the
pressure 140 bar relief valve with the 2.5 mm allen wrench.
cartridge with the screwdriver until the pressure
reads just under 140 bar. Retightening the set screw
retract function. Proper adjustment ensures that the #1
will raise the pressure slightly. Recheck the
boom and the A-frame won’t be damaged by putting
pressure, and readjust if needed.
the boom in the cradle. (See figure 211.) To adjust this
valve (requires a 2.5 mm Allen wrench and a standard 6. When the pressure is set at 140 bar with the set
screwdriver): screw tight, you can remove the whip hose gauge
and replace the cap on the gauge port.
1. Install a 0 - 400 bar or 0 - 600 bar gauge into the
140 bar gauge port (shown in Figure 211). 7. The boom pressure setting sequence is complete. If
you are done with the boom, slew it back into the
2. Unfold the #2 section from #1 until it is straight.
transport position, and lower #1 into the cradle.
For the following procedure we must bring #1 all
Attach the boom strap.
the way down until the cylinder bottoms out.
Position the boom so this can be done without
hitting the truck or any other obstacle.
3. Bring #1 down until the cylinder is completely
bottomed out. The cylinder does NOT bottom out
if you are setting the folded boom into the A-frame
(travel position).
4. Activate the #1 down (retract) handvalve The
HOME PRINT
Pressure Settings
140 bar
gauge port
ps
0.e
it14
ap
Figure 211
location of the 140 bar relief valve and gauge port.
Setting the outrigger 3. If not already done, start the truck engine and set
pressures (7 place boom valve systems) the transmission and PTO as you would for a
pumping job.
After the boom pressures are set, you can set the
outrigger pressure. 4. Locate the 280 bar relief valve on the back of the
• In this system, the boom, outriggers, water pump, outrigger valve, as shown in Figure 213.
and compressor circuits have all been put together 5. Set the engine RPM to maximum.
in the boom valve manifold. (See Figure 211). 6. Select “outrigger” with the outrigger pushbutton.
When the outrigger selector push-button is This will route oil to the outrigger handvalves.
activated, the outrigger valve routes oil to the two 7. Assuming that the outriggers are folded into the
outrigger handvalve banks, one on each side of the travel position, activate the passenger side
unit. A relief valve inside the passenger side bank handvalve “jacking cylinder retract” for either the
limits the entire outrigger circuit to 280 bar (4060 front or rear outrigger. Note! You will get an
PSI) instead of the 300 bar (4350 PSI) of the boom incorrect reading if you select “extension cylinder
relief valve. retract” by mistake. If you select “extend” by
• To set the 280 bar relief valve for the outrigger mistake, the outriggers will extend instead of
circuit: (See Figure 213). reading the relief valve setting. The handles are
you let go.
1. Wear safety glasses whenever you check or set
8. Read the pressure on the gauge. It should read 280
pressures.
bar (4060 PSI). If no adjustment is needed, skip to
2. Plug the whip hose of a 0-400 or 0-600 bar gauge step 4.
into the gauge port. Location is shown as item 1 in
figure 213.
HOME PRINT
SERVICE TRAINING
Pressure Settings
7plcORhndl.eps
Outrigger handle
Gauge port
1
Gauge port
DANGER WARNING
1
Figure 212
h d.e
ps Position of the outrigger selector valve
itor
ap
Monsun-Tyson black & white (right)
Outrigger handle Apitech proportional (left)
280 bar
Lower Relief Valve
32Porct5.eps
PS
oc
bb
ck.
Higher ep
s
Turn body of valve

to adjust.
Figure 213
HOME PRINT
Pressure Settings
outrigger valve. Turn in to raise pressure, turn out Setting 15 bar pretension
to lower pressure. There is no jam nut on this • To check or set pretension, follow these steps:
valve. 1. Stop the truck engine. Plug the 0 - 40 bar gauge
10. Activate the outrigger “jacking retract” handvalve into the pretension check port of the Apitech
and read the pressure on the gauge again. Repeat handvalve (Figure 214).
steps 8. and 9. until the gauge reads 280 bar. 2. Start the truck engine, but leave it at an idle.
11. When the pressure is correct, either go on to other (Pretension adjustment is made at an idle to
pressure settings, or remove the whip hose and establish the minimum pressure setting. As RPM is
gauge, and cap the gauge port with the attached increased, pressure will rise. Damage to the 0 - 40
cap. bar gauge is possible if RPM is raised while the
12. Return the RPM of the truck to an idle, take the gauge is connected.)
transmission and PTO out of gear, and shut off the 3. Read the pressure on the gauge. If it reads 15 bar ±
truck, or go on to the other pressure settings, as 1 bar, the pressure is set correctly. If adjustment is
required. needed, proceed to step (4.).
CAUTION
Pretension
gauge port
Figure 214 .ep

s
rtn
Pretension adjustment screw and gauge ap
itp
port Pretension adjustment screw
4. Loosen the jam nut on the pretension valve. Turn setting the pressure in this circuit. The port is located
the screw in to raise pressure, and out to lower on the agitator handvalve. To check or set the agitator
pressure. When the pressure is correct, retighten pressure, follow these steps:
the jam nut. 1. Remove the aluminum diamond plate cover from
5. Stop the engine, and remove the 0 - 40 bar gauge. over the agitator handvalve.
Pretension setting is complete. 2. Unscrew the cover from the gauge port. Plug in the
0-600 bar gauge and whip hose that came in the
To set the agitator circuit pressure: toolbox.
The agitator relief valve is located in the agitator 3. Start the engine, if not already running.
forward / neutral / reverse handvalve, at the rear of the 4. Close the agitator shutoff valve. (See Figure 216.)
unit on the driver’s side. The relief valve limits the Note! If your unit does not have a shutoff valve,
pressure in the agitator circuit to 200 bar (2900 PSI). you can order one using part number 10004680
(See Figure 215). There is a gauge port for checking or
HOME PRINT
SERVICE TRAINING
Pressure Settings

this angle).
Gauge port
Figure 215
Showing the agitator handvalve and
gauge port.
(valve) and part number 30303432 (tube). Contact

Schwing’s Service Dept. for installation
instructions.
closed
s
ep
o.
its
ag
open
Figure 216
5. Activate the agitator in forward. Read the pressure

on the gauge.
agitator handvalve.
HOME PRINT
Pressure Settings
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 34X Check the concrete pump pressure (2020,
2023, 2525 pumpkits)
Check hydraulic pressures Because the Hi-flow pumpkits have the ability to create
The following pages provide the proper techniques for high pressure on the concrete, the pressure settings
checking and setting hydraulic pressures of each have to be tailored specifically for each model. This
system included on units up to 450 l/m. means that we cannot simply list a pressure
specification for all units. The correct pressure
Check all hydraulic pressures. Changes in pressures specifications for your unit are shown on the hydraulic
can indicate trouble in one or more components. schematic in Appendix, Section 7 of this manual.
operating temperatures (40° to 60° C). The NOTE: Use of the remote control box for the
specifications for all circuit pressures are found on the following pressure setting procedure is NOT
hydraulic schematics in the Appendix section of this recommended.
manual. To check or set the concrete pump pressure
Because of the new load-sensing hydraulic systems WARNING
regulated by pressure cut-off, you can’t use the
concrete pump or boom circuit to preheat the hydraulic Always wear safety glasses when checking or
oil (they stop putting out oil rather than send it over setting pressures.
relief). To heat the oil to operating temperature:
1. Locate the agitator shutoff valve (Figure 217) and 1. Be sure that the waterbox covers and guards are
close it. Note! If your unit does not have a shutoff installed on the waterbox.
valve, you can order one using part number 2. Start the truck engine, and put the PTO and
10004680 (valve) and part number 30303432 transmission into gear just as you would to pump a
(tube). Contact the Schwing Service Department at job.
(651) 429-0999 for installation instructions.
3. Locate and close the concrete pump shutoff valve
2. Turn on the agitator. The agitator will not be able and the soft switch shutoff valve (Figure 219).
to turn, and the oil will be forced over the relief (These valves are also known as quarter turn
valve. valves).
3. At an idle (approximately 600 rpm), about 5.4 4. If your concrete pump pressure gauge is not
horsepower is being converted to heat. Shut off the already plumbed into the gauge port (Figure 218),
agitator when the temperature gauge on the rear install a 0 - 400 or 0 - 600 bar gauge in the gauge
control panel shows 40° C. Don’t forget to open port.
the shutoff valve when the procedure is finished.
5. The “remote / local” switch located on the rear
agitoff.eps
control panel must be in the “local” position.
6. Be sure that all emergency stop switches are in the
up (not activated) position. Reset the E-stop circuit.
7. Using the throttle switch on the rear control panel,
bring the truck engine up to full RPM.
CAUTION! The main relief valve (Figure 220) is set
to very high pressure (at least 350 bar). Use the rear
control panel switch when checking the pressure of the
Agitator quarter turn main relief valve, so you will be out of the way if a
shutoff valve (open position) Motor hose or fitting blows.
8. Place the concrete pump “forward / neutral /
Figure 217 reverse” switch on the rear control panel into the
Agitator shutoff valve “forward” position. The unit will stroke no more
than once, then the rock cylinder will retract. Oil
HOME PRINT
Pressure Settings
leaving the hydraulic pumps will be blocked in the 1. Wear safety glasses when checking or adjusting
brain. This is called high-pressuring the concrete pressures.
pump.
9. Read the pressure on the gauge. The target pressure on the main relief valve adjusting screw (Figure
for the concrete pump circuit main relief valve is 218).
shown on the hydraulic schematic in the Appendix
section of this manual. Return the pump control to 3. Insert a 5/32” allen wrench in the adjustment screw.
“neutral” whether the pressure needs adjustment or Turn the screw in to raise pressure and out to lower
not. If no adjustment is needed, skip to step 5. If the pressure. Always go back to the rear panel
adjustment is needed, proceed to next paragraph. before checking the pressure.
4. Once the pressure is correct to the hydraulic
Setting the main relief valve schematic, retighten the jam nut. Tightening the
The main relief valve is the primary pressure control nut tends to raise the pressure, so check pressure
device on units equipped with Rexroth A7VO again after tightening.
hydraulic pumps. 5. If you will not be setting the soft switch pressure,
If the main relief valve needs adjustment, proceed as open the shutoff valves. The unit will not stroke
follows: with closed shutoff valves.
Gauge port
Hif
lo_
4.e
ps
Main relief valve
Soft switch
relief valve
Figure 218
Location of the concrete pump circuit main relief
valve and soft switch relief valve
HOME PRINT
SERVICE TRAINING
Pressure Settings
Soft switch
shutoff valve
Main Pressure
Gauge port
Concrete pump
hif
shutoff valve low
br
n.
ep
s
Figure 219
valves

Closed Open
soft switch
relief cartridge
Grooves in shaft grooves2.eps Main relief cartridge
openclsd.eps
9/16" jam nut
Open
5/32" Allen head
removed for illustration 9/16" jam nut
Figure 220
HOME PRINT
Pressure Settings
Setting the soft switch circuit relief 3. Loosen the jam nut on the soft switch relief valve
pressure (Figure 103) with a 9/16” spanner wrench. Adjust
To check or adjust the soft switch pressure setting, the pressure up or down, as needed, using a 5/32”
proceed as follows: Allen wrench. When the correct pressure is
1. Open the soft switch shutoff valve (Figure 219). achieved, tighten the jam nut.
The rest of the unit should still be set up as though 4. Be sure to open the concrete pump shutoff valve
you were going to check concrete pump pressure. (Figure 219) on the side of the brain when you are
2. High pressure the concrete pump. The pressure finished. The unit cannot stroke with this valve
gauge should read 60 or 80 bar (check your closed.
schematic). If adjustment is needed, proceed to
step (3) below. If no adjustment is needed, skip to
step ().
Gauge port
Hif
lo_
4.e
ps
Main relief valve
Soft switch
relief valve
Figure 221
HOME PRINT
SERVICE TRAINING
Pressure Settings
Load-sensing boom pressures You will need an assistant for parts of the procedure.
If your unit has a load-sensing proportional system, it You and any assistants should wear eye protection
will have different pressure adjustments than if it is when checking or setting pressures.
equipped with a black and white boom system. The
following instructions are for seven place, load-sensing Setting ∆P
proportional systems. If you have a unit equipped with Note! Do not adjust ∆P or Q-min if your boom is
a black and white boom system, contact Schwing running as you like it. The pressure setting procedure
Service for the correct instruction pages. uses a standard starting point and must be fine tuned
from there. It was fine tuned at the factory and should
Preheat the oil not be adjusted unless absolutely necessary.
Note! Whenever you set pressures for any circuit on Do not adjust Q-min with the drive shafts turning!
any unit, the hydraulic oil should be at normal Each time the Q-min screw is adjusted, the engine must
operating temperature (40° - 60° C). Instructions for be stopped, or at least the transmission must be taken
heating the hydraulic oil are found on page 351. out of gear so that the drivelines stop turning. To check
or set ∆P, follow these steps:
About proportional boom systems
In a black and white boom system, the hydraulic pump Operate” sign on the truck windshield.
puts out an unchanging amount of oil, and speed 2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar
control is done by restricting the oil to certain functions gauge port (Figure 223) of the manual boom
with orifices. In a load-sensing system, the pump puts handvalves. Take care not to accidently install the
out more or less oil to respond to the needs of the gauge in the 0-60 bar port.
maintain a 20 bar higher pressure at the pump than CAUTION! If you activate any boom or outrigger
what the cylinders actually require. This 20 bar is functions, you will damage the 0 - 40 bar gauge.
called delta P (∆P). Additionally, we set the hydraulic 1. To be sure that the pump is putting out only enough
pump so that it always puts out a small amount of oil, oil to maintain ∆P, we need to change the setting of
even if no oil is needed for the system. This oil is used the Q-min screw. Q-min is adjusted by a screw on
to ensure that you have control when you need it. The the boom hydraulic pump (Figure 224). Unscrew
setting to maintain this minimum amount of oil is the Q-min screw three full turns. Make sure that all
called Q-min (pronounced “cue min”). To set the boom emergency stop switches are in the up (not
or outrigger hydraulic pressures on a load-sensing activated) position. Check that all personnel are
system, begin by setting Q-min and ∆P. clear of the truck, then restart the engine, engage
Read all of the instructions before beginning any the pumps, and leave the engine at an idle. Pressure
pressure settings. General locations of the components can be read on the 0 - 40 bar gauge that you
for the following procedures are shown in Figure 222. installed. Pressure should read 20 bar. If no
adjustment is needed, simply reset the Q-min
screw as described on page 357. If adjustment is
needed, continue to step (4).
Manual boom handvalves,

Delta P adjustment
and E-Stop manifold
Figure 222
Locations of
components used to
check and set boom 34cmploc.eps
pressures Q-min adjustment screw

HOME PRINT
Pressure Settings
15 bar pretension
adjustment screw 140 bar gauge port (use 0-400
0-60 bar
gauge port
0-400 bar
gauge port
Figure 223
Location of the boom circuit
pressure devices boom control 140 bar downside
(Hoses removed for clarity.) block relief valve relief cartridge 34blck.eps
Q-min
CAUTION adjustment screw
Do not operate any functions while setting

Delta P.
2. Delta P is adjusted by the ∆P screw on the ∆P

regulator (Figure 225). Loosen the jam nut, and
adjust the screw inward to increase pressure or Q-minscrew.eps
outward to decrease pressure, until it is set at 20

bar (±1). Contact Schwing America’s Service Q-max
Department if you are unable to adjust the pressure Figure 224
to specification. NOTE! If the boom is not smooth Location of the Q-min adjustment screw
at 20 bar, you must fine tune the adjustment. In that
case, REMOVE THE GAUGE, and adjust ∆P until
the boom is responsive and smooth. When done,
the gauge (reinstalled) must read between 14 and
25 bar. The electronics in the control system can
also affect how the boom operates, so if ∆P ∆P adjustment
adjustment does not seem to help, reset to 20 bar
deltaPvlv.eps
screw
and check the electrical settings. Once electrical
settings are verified, you could again refine the
boom action with the ∆P adjustment. T
Figure 225
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting Q-min 5. Turn the Q-min screw in to raise the pressure
Check Q-min pressure when the engine is at the (Figure 224). Turn it out to lower the pressure. Be
maximum specified RPM, but the engine must be sure that you stop the drive shafts from turning
stopped to adjust the pressure. each time before making the adjustment. When
1. If you unscrewed the Q-min screw as the first step adjustment screw before continuing with the other
of ∆P adjustment, begin by returning the screw to procedures.
its original position (Figure 224).
2. Remove the 0 - 40 bar gauge from the 0 - 400 bar Setting boom pressures
gauge port, and install the 0 - 600 bar gauge in its (Load sensing proportional booms.) Now that ∆P and
place. Q-min are set, you can check or set the boom valve
3. Clear all personnel away from the drive lines, start pressures.
the truck engine, engage the pumps, and bring There are three pressure settings (Figure 226) on the
engine RPM to max. All boom functions must be in boom circuit:
neutral, and all emergency stop buttons should be 1. Pressure regulator (the high-pressure adjustment
up (not engaged). screw on the ∆P regulator valve), set at 300 bar.
4. Read the pressure on the 0 - 600 bar gauge. 2. The redundant relief valve located in the
Pressure should be at 40 - 45 bar. If no adjustment emergency stop manifold, set at 330 bar.
is needed, stop the drivelines from turning, be sure
the jam nut on the Q-min screw is tight, and
proceed to Setting boom pressures. If adjustment is
needed, continue to the next step.
deltaPvlv.eps
High pressure Redundant

adjustment screw relief valve
T
MP
1
15 bar pretension TT
adjustment screw 140 bar gauge port (use 0-400

M
10
16
78
P1
92
-7.
ep
s
P4
P2
P3
0-60 bar
gauge port
0-400 bar
gauge port
Figure 226
The three boom pressure
boom control devices
140 bar downside
block relief valve relief cartridge 34blck.eps
HOME PRINT
Pressure Settings
To check the setting of the valve with the highest function, and lock the jam nut. The boom pressures
pressure, you must first raise the pressure of the lower are now set. If you did not get the readings
two: specified after following the instructions, contact
1. Loosen the jam nut of the high pressure adjustment Schwing America’s Service Department at (651)
screw (Figure 226) of the ∆P regulator. Turn the 429-0999 for advice on how to continue.
screw in two-and-a-half turns. This will raise the
pressure on the regulator above 350 bar. Setting the 140 bar down side relief valve
pressure
redundant relief valve (Figure 226) in the Set the pressure of the 140 bar (Figure 226) down side
emergency stop manifold. Turn the screw in one- relief valve. Down side relief is a secondary relief valve
and-a-half turns. This will raise the pressure setting for #1 cylinder retract function. Proper adjustment
of the relief valve to above 350 bar. ensures that the #1 boom and the A-frame won’t be
3. Pressure out any boom cylinder except #1 down by damaged by putting the boom in the cradle. To adjust
activating the control handle. To pressure out a this valve (requires a 2.5 mm Allen wrench and a
cylinder, retract a fully retracted cylinder or extend standard screwdriver):
a fully extended cylinder. The oil is then forced 1. Install a 0 - 400 bar or 0 - 600 bar gauge into the
over the relief valve. 140 bar gauge port shown in Figure 226.
2. Unfold the #2 section from #1 until it is fully
The telltale hiss of an open relief valve should be extended. For the following procedure we must
coming from the Apitech control block relief valve bring #1 all the way down until the cylinder
now. If it isn’t, raise the setting of the other bottoms out. Position the boom so this can be done
pressure devices until the hiss originates at the without hitting the truck or any other obstacle.
Apitech control block relief valve. Read the 3. Bring #1 down until the cylinder is completely
pressure on the gauge. It should read 350 bar. If bottomed out. The cylinder does NOT bottom out
pressure is correct, proceed to the next step. if you are setting the folded boom into the A-frame
(travel position).
NOTE! Although the pressure specification for the
4. Activate the #1 down (retract) handvalve. The
Apitech relief valve is 350 bar, you may continue
to use the relief valve as long as the cartridge
maintains at least 330 bar. If you must replace the
valve and don’t have one on hand, proceed to the
next step before using the machine again. Redo this
entire procedure when you have installed the new 5. If adjustment is needed, loosen the set screw of the
valve. If pressure on the Apitech relief valve is 140 bar relief valve (Figure 226) with the 2.5 mm
below 290 bar, you should not use the machine Allen wrench. While you activate #1 down, adjust
until the valve is replaced. the relief cartridge with the screwdriver until the
pressure reads just under 140 bar. Retightening the
4. Screw out the e-stop manifold redundant relief
set screw will raise the pressure slightly. Recheck
valve (Figure 226) adjustment screw one-and-a-
the pressure, and readjust if needed.
half turns. Pressure out any boom cylinder except
#1 down, and read the gauge. Pressure should read 6. When the pressure is set at 140 bar with the set
330 bar. If it does not, turn the screw in to raise screw tight, you can remove the whip hose gauge
pressure or out to lower pressure until it is set at and replace the cap on the gauge port.
330 bar. If the location of this valve causes you to 7. The boom pressure setting sequence is complete. If
be near the drivelines, be sure to stop them from you are done with the boom, fold it back into the
turning before accessing the valve. transport position, and reattach the boom strap.
pressuring out any boom cylinder except #1 down, Setting the outrigger pressures
have your helper adjust the high pressure screw of After the boom pressures are set, you can set the
the ∆P regulator out (lowering the pressure) until outrigger pressure.
the gauge reads 300 bar. Release the pressurized
HOME PRINT
SERVICE TRAINING
Pressure Settings
Outrigger handle
0-400 bar
gauge port
otrghndl.eps
Figure 227
Position of the outrigger selector valve on units
equipped with Apitech proportional valves
In this system, the boom, outriggers, water pump, and 6. Assuming that the outriggers are folded into the
compressor circuits have all been put together in the travel position, activate the passenger side
boom valve manifold. When the outrigger selector handvalve “jacking cylinder retract” for either
pushbutton is pushed, the outrigger valve handle is the front or rear outrigger.
activated, which routes oil to the two outrigger Note! You will get an incorrect reading if you
handvalve banks (one on each side of the unit). A relief select any other outrigger function. The handles are
valve inside the passenger side bank limits the entire spring loaded and will return to neutral as soon as
outrigger circuit to 280 bar (4060 PSI) instead of the you let go.
300 bar (4350 PSI) of the boom relief valve. 7. Read the pressure on the gauge. It should read 280
To set the 280 bar relief valve for the outrigger circuit: bar (4060 PSI). If no adjustment is needed, skip to
step 4.
WARNING the relief valve that is located at the back of the
outrigger valve. Turn in to raise pressure, turn out
Always wear safety glasses when checking or
to lower pressure. There is no jam nut on this
setting pressures.
valve.
9. Activate the outrigger “jacking retract” handvalve
1. Plug the whip hose of a 0-400 or 0-600 bar gauge
(Figure 227) into the gauge port.
steps (8) and (9) until the gauge reads 280 bar.
2. If not already done, start the truck engine and set
4. When the pressure is correct, either go on to other
the transmission and PTO as you would for a
pressure settings, or remove the whip hose and
pumping job.
gauge and cap the gauge port with the attached
3. Locate the 280 bar relief valve (Figure 228) on the cap.
back of the outrigger valve.
5. Return the RPM of the truck to an idle, take the
4. Set the engine RPM to maximum. transmission and PTO out of gear, and shut off the
5. Select “outrigger” with the outrigger pushbutton. truck, or go on to the other pressure settings as
This will route oil to the outrigger handvalves. required.
HOME PRINT
Pressure Settings
34manco3.eps
280 bar
10 9 Relief valve
2 4 6 8
AGITATOR
3 5 7
CONCRETE PUMP
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SLEWING
AIR / WATER
BOOM / OUTRIG.
DANGER WARNING
Do not operate this
machine without
3
WARNING
Clear area
before activating
outriggers
REAR EXTEND REAR JACKING FRONT JACKING FRONT EXTEND
otr
gb
lk.e
ps
200
100 300
bar 400
WIKA
Figure 228
Setting the water pump hydraulic pressure

With a seven place handvalve, the water pump
There is not a separate relief for this circuit, and
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting 15 bar pretension
CAUTION
To check or set pretension, follow these steps: 5. Stop the engine, and remove the 0 - 40 bar gauge.
1. Stop the truck engine. Plug the 0 - 40 bar gauge Pretension setting is complete.
into the pretension check port of the Apitech
handvalve (Figure 229). Setting the agitator circuit pressure
2. Start the truck engine, but leave it at an idle. The agitator relief valve is located in the agitator
(Pretension adjustment is made at an idle to forward / neutral / reverse handvalve (Figure 230). The
establish the minimum pressure setting. As RPM is relief valve (not completely visible in Figure 230)
increased, pressure will rise. Damage to the 0 - 40 limits the pressure in the agitator circuit to 200 bar
bar gauge is possible if RPM is raised while the (2900 PSI). There is a gauge port (not visible in Figure
gauge is connected.) 230) for checking or setting the pressure in this circuit.
3. If the pressure reads 15 bar ± 1 bar, the pressure is The port is located on the agitator handvalve. To check
set correctly. If adjustment is needed, proceed to or set the agitator pressure, follow these steps:
the next step. 1. Unscrew the cover from the gauge port. Plug in the
4. Loosen the jam nut on the pretension valve. Turn 0-600 bar gauge and whip hose that came in the
the screw in to raise pressure, and out to lower toolbox.
pressure. When the pressure is correct, retighten 2. Start the engine, if it’s not already running.
the jam nut.
15 bar pretension
adjustment screw
0-60 bar
gauge port
Figure 229
and gauge port
pretnsn.eps
HOME PRINT
Pressure Settings
3. Close the agitator shutoff valve (Figure 231).
34manco3.eps
agitator 10 9
handvalve
2 4 6 8
Gauge port Relief valve
AGITATOR
3 5 7
CONCRETE PUMP
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SLEWING
AIR / WATER
BOOM / OUTRIG.
DANGER WARNING
Do not operate this
machine without
1
WARNING
Clear area
AGITATOR before activating
outriggers
eps
dv.
forward/reverse agit
han REAR EXTEND REAR JACKING FRONT JACKING FRONT EXTEND
CONCRETE PUMP
forward/reverse
200
Figure 230
100 300
bar 400
WIKA
Agitator handvalve
Note! If your unit does not have a shutoff valve, 5. If adjustment is needed, put your wrench on the
you can order one using part number 10004680 body of the relief valve (Figure 230), which is
(valve) and part number 30303432 (tube). Contact located on the back of the agitator handvalve.
Schwing America’s Service Department at (651) While reading the gauge, turn the body in to raise
429-0999 for installation instructions. pressure or out to lower pressure until 200 bar is
4. Activate the agitator, and read the pressure on the achieved.
gauge. 6. Put the agitator handle in neutral.
agitoff.eps

Figure 231 shutoff valve (open position) Motor
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting accumulator circuit pressure
S
MP
45Accreg.eps S
MP
P3
eps
un drl.
red
P2 P4 P1
Accumulator pump Redundant

pressure regulator relief cartridge
Figure 233
Figure 232
Accumulator redundant relief cartridge
Accumulator pump pressure regulator for
A7VO (above) and for A11VO (below)
You will need an assistant for parts of this procedure. 4. Clear all personnel away from the drive lines, start
There are three relief settings for the accumulator the truck engine, engage the pumps, and bring the
circuit. engine RPM to maximum.
To check or adjust the hydraulic pressure in the 5. Read the pressure on the accumulator circuit
accumulator circuit: pressure gauge (Figure 234). The pressure should
1. Stop the truck, put the key in your pocket, and read the value shown on the hydraulic schematic. If
place a “Do Not Operate” sign on the windshield. no adjustment is needed, skip to step (7). If
2. Loosen the jam nut on the pressure regulator of the additional pressure adjustment is needed, continue
accumulator hydraulic pump (Figure 232). Turn with step (6).
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QQQQQQQQ

45acumpr.epsL
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QQQQQQQQ

3. Loosen the jam nut (Figure 233) on the
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QQQQQQQQ

accumulator redundant relief cartridge, located on
@@@@@@@@

;;;;;;;;
QQQQQQQQ

the emergency stop manifold. Turn the screw in
300 bar.
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QQQQQQQQ

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QQQQQQQQ

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;;;;;;;;
Figure 234 QQQQQQQQ

HOME PRINT
Pressure Settings
regulator (Figure 232) and turn the screw back out
accuman1.eps
original setting.
maximum.
should read the proper accumulator system
pressure.
Pressure Relief Cartridge circuit hydraulic pump. Turn the screw in to
Manual bleed valve increase the pressure or out to decrease pressure.
Note: The accumulator circuit hydraulic pump pressure
regulator is sometimes referred to as the pressure cut-
off.
Figure 235
Accumulator manifold pressure
relief cartridge

counter clockwise to decrease the pressure.
Tighten the jam nut when the pressure reaches the
value required.
engine still running, one person must go to the
redundant relief valve on the emergency stop
manifold (Figure 233) and back out the adjustment
screw while the other person stands by the pressure
gauge to let him know when the pressure reads the
value shown on the schematic for accumulator
redundant relief.
WARNING
Stop the engine before proceeding to
the next step. Entanglement hazard.
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 36X-42M (pre-1998) As mentioned earlier before we check or adjusts
settings of the pressure limit valve or the two relief
valves, we must make sure the Delta-P and Q-
Pressure Settings for KVM 36X
minimum settings are correct.
Proportional Load Sensing
NOTE!
NOTE:All pressure settings must be done
when the hydraulic oil is at 50 to 70 degrees
Celsius.
Please read all instructions before attempting to check
or set pressures.
There is a pressure limit valve and two different relief
valves in the KVM 36X boom circuit. Before checking
or setting these 3 valves, you should make sure that the
Delta-P setting on the pressure regulator and the Q
minimum setting on the hydraulic pump are properly
set. In order to help you better understand this, we will
describe the functions of each valve and the hydraulic
pump before attempting to set or check pressures.
Refer to Illustration 1on Page- D2 for the location of
each item as it is mounted on the unit.
Figure 1 of this page, is called the pressure regulator.
Adjusting screw (item 4) is the pressure limit function
of the pressure regulator. Adjusting screw (item 3) is
the Delta-P function of the regulator. The Delta-P
function senses pressure on both sides of the boom
handvalve, and adjusts the output flow of the hydraulic
pump.
Figure 2 of this page is the "normally open" relief
valve. (Normally open denotes that unless the coil is
energized, the relief valve will not develop any
pressure). This is the valve that opens and vents your
boom circuit to tank when you hit the red emergency
shut off button on your remote control box or
operations panel.
Figure 3 of this page is the boom handvalve. (Item
10) is pointing to the relief valve located on the
handvalve. It's function is to protect the handvalves
from any pressure spikes that might be in the system.
(Item G2) is a gauge port.
Figure 4 of this page is the boom circuit hydraulic
pump. This style of hydraulic pump has a variable
output depending on the requirements of the boom,
which is controlled by the pressure regulator described
in Figure 1 (above).
HOME PRINT
Pressure Settings
Component Location Guide KVM 36 X W/
Rexroth Handvalves
FIGURE 1 FIGURE 2 FIGURE 4 FIGURE 3
1200 / 36 X
Illustration 1
item
4
item 3
FIGURE 1
item
2
item
STOP for Q min 1
STOP for Qmax
FIGURE 4 FIGURE 2
item
10
24V
item
G2
24V
FIGURE 3
HOME PRINT
SERVICE TRAINING
Pressure Settings
Pressure Settings for KVM 36X 2. Q Minimum setting: the Q minimum stop on the
Proportional Load Sensing hydraulic pump, (Figure 4, item 1).
1. 1.Delta-P setting on the pressure regulator. With all boom functions in the neutral position,
(Figure 1, Item 3) emergency stop buttons up, the engine at
With all boom functions in the neutral position, maximum specified RPM's, the pressure on the
emergency stop buttons up, the engine at minimum main gauge (0-600 bar) should be:
RPM's (idle), the pressure that will be read on both
a) . . . KVM 32 & 36 = 40 Bar;
the pretension gauge and the main pressure gauge
b) . . . KVM 42 = 40-45 Bar;
is either Delta-P or an idle Q-minimum. To
determine what indeed is creating this pressure, we c) . . . KVM 52 = 50-55 Bar.
must do at least ONE of the three following If the pressure is incorrect, the Q-min. screw on the
procedures: hydraulic pump must be adjusted accordingly. Turn
a. A.Back off the Q-min. screw at least 3 turns on the Q-min screw inward to increase the pressure and
the hydraulic pump to insure that it is only outward to decrease the pressure.
producing the amount of flow that the regulator
is requiring to maintain Delta-P pressure. Now
read an accurate Delta-P pressure on either the
pretension gauge or the main pressure gauge.
This requires that the Q-min. be re-adjusted;
(refer to paragraph 2. for Q minimum setting).
b. B.While observing the pretension or the main
pressure gauge you increase the engine RPM
by 300 RPM in 3 increments of 100 RPM
each, making sure that the pressure does not
increase. This will assure that you are indeed
observing accurate Delta-P. If the pressure
does increase, then the pressure observed is an
idle Q-min. and not a true Delta-P. You should
then follow the procedures in paragraph 1. A.
c. C.Install a high pressure (0-600 Bar) gauge in
the X port of the regulator with a "T" fitting.
While operating a boom function, monitor the
pressure between the main pressure gauge and
the gauge at the X port of the regulator. There
should be exactly 20 Bar less pressure at the X
port continuously.
Adjusting Delta-P: The Delta-P pressure should be 20
Bar plus or minus 1 Bar; (this is the same for KVM 32,
KVM 36X, KVM 42 and KVM 52 machines). If the
Delta-P pressure is incorrect, then the regulator must
be adjusted accordingly. Turn the small screw (Figure
1, item 3) on the regulator inward to increase or
outward to decrease the Delta-P pressure. If the Delta-
P pressure cannot be adjusted to proper pressure, then
the regulator is probably defective. Do not replace the
regulator until the orifices in the base plate have been
checked to make sure they are not obstructed or
improperly sized. Refer to Figure 5 on Page - D4 for
proper orifice sizes.
HOME PRINT
Pressure Settings
Pressure Regulator Cutaway
Pressure
Regulator
P
Regulator
X
A T
P 0.8 mm
ORIFICE
KVM 36X . . . . 1.6 mm
KVM 36 LW . . 1.6 mm
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
Figure 236
HOME PRINT
SERVICE TRAINING
Pressure Settings
Pressure Settings for Regulator and Releif
Valves
Now that we know our delta-P and Q-minimum are set
correct we can check and reset the pressure limit and
two relief valves. The correct pressure settings are as
follows:
1. PRESSURE REGULATOR (Figure 1, item 4)310
Bar
2. NORMALLY OPEN BYPASS VALVE (Figure 2,
item 2)330 Bar
3. HANDVALVE RELIEF (Figure 3, item 10)340
Bar
In order to reset the valve with the highest pressure, we
must first raise the pressure of the other two valves.
a. A.Install a 0-600 Bar gauge in the gauge port
(Figure 3, item G2) of the handvalve.
b. B.To set the pressure regulator (Figure 1),
loosen the lock nut (Item 4), and turn the
adjusting screw inward approximately two
turns. This will raise the pressure of this valve
higher than 340 bar.
c. C.To set the normally open bypass valve
(Figure 2), loosen the lock nut (Item 2), and
turn the adjusting screw inward approximately
one turn. This will raise the pressure of this
valve higher than 340 bar.
d. D.Pressure out any boom section except main
down. The pressure can now be read on the 0-
600 Bar gauge that you have installed on the
handvalves. The gauge should read 340 Bar. If
it does not, adjust the relief valve on the boom
handvalves (Figure 3, item 10). After you
have this relief set to 340 Bar you can lock the
locknut and move on to the normally open
bypass valve.
e. E.While you continue to hold a function
pressured out you can adjust the normally open
bypass valve (Figure 2, item 2), until the
pressure gauge now reads 330 Bar. After this
pressure is set and the locknut is locked,
proceed to the pressure regulator.
f. F.While still holding a function pressured out
you can now adjust the pressure regulator (Fig.
1, Item 4), until the pressure gauge reads 310
Bar. When this pressure has been set and the
locknut is locked, you are finished setting the
main circuit pressures on the boom.
Handvalve
OUT- WTR SLEW BOOM BOOM BOOM BOOM
BOOM HANDVALVE RIG CMP R&L 4 3 2 1
KVM 36LW & 36X

Pressure Settings
(Waterpump/Compressor & Outrigger)
5 3 1 1 1 1
1 - BOOM EXTEND SPEED

9 9 G1
KVM 36 LW & 36 X W/Rexroth Boom
2 - BOOM RETRACT SPEED
24V
3 - SWING RIGHT SPEED
4 - SWING LEFT SPEED 8 8

5 - WATERPUMP RPM
11 7
6 - COMPRESSOR RPM
7 - OUTRIGGER SPEED 10 10
8 - PRETENTION VALVE
24V
9 - PRETENTION RELIEF G2
10 - HIGH PRESS. RELIEF (340 Bar)

6 4 Orifice 2 2 2 2
11 - SECTION COMPENSATORS
O-ring
G1 - PRETENTION GAUGE PORT Filter
G2 - HIGH PRESS. GAUGE PORT O-ring

HOME
PRINT
HOME PRINT
SERVICE TRAINING
Pressure Settings
Pressure Settings for KVM 42 (B&W Load
sensing and Proportional Load Sensing
NOTE!
Celsius.
or set pressures.
valves in the KVM 42 boom circuit. Before checking
Refer to Illustration 2 on Page- D8 for the location of
handvalve, and adjusts the output flow of the hydraulic
pump.
operations panel.
Figure 3 of this page is the boom handvalve. (Item 9)
designates the main pressure relief valve located on the
handvalve. It's function is to protect the handvalves
from any pressure spikes that might be in the system.
(Item 11) designates the relief valve for the main
section down.
As mentioned earlier before we check or adjusts
HOME PRINT
Pressure Settings
Component Location Guide KVM 42 W/
Rexroth Handvalves
FIGURE 1 FIGURE 4 FIGURE 2 FIGURE 3
Illustration 2
item
4
item 3
FIGURE 1
item
2
item
STOP for Q min 1
STOP for Qmax
FIGURE 4 FIGURE 2
item 11
item 9
FIGURE 3
HOME PRINT
SERVICE TRAINING
Pressure Settings
Pressure Settings for KVM 42LW 2. Q Minimum setting: the Q minimum stop on the
Proportional Load Sensing hydraulic pump, (Figure 4, item 1).
1. Delta-P setting on the pressure regulator. (Figure With all boom functions in the neutral position,
1, Item 3) emergency stop buttons up, the engine at
With all boom functions in the neutral position, maximum specified RPM's, the pressure on the
emergency stop buttons up, the engine at minimum main gauge (0-600 bar) should be:
RPM's (idle), the pressure that will be read on both
a) . . . KVM 32 & 36 = 40 Bar;
the pretension gauge and the main pressure gauge
b) . . . KVM 42 = 40-45 Bar;
is either Delta-P or an idle Q-minimum. To
determine what indeed is creating this pressure, we c) . . . KVM 52 = 50-55 Bar.
must do at least ONE of the three following If the pressure is incorrect, the Q-min. screw on the
procedures: hydraulic pump must be adjusted accordingly. Turn
a. A.Back off the Q-min. screw at least 3 turns on the Q-min screw inward to increase the pressure and
the hydraulic pump to insure that it is only outward to decrease the pressure.
producing the amount of flow that the regulator
is requiring to maintain Delta-P pressure. Now
b. B.While observing the pretension or the main
c. C.Install a high pressure (0-600 Bar) gauge in
the X port of the regulator with a "T" fitting.
port continuously.
Bar plus or minus 1 Bar; (this is the same for KVM 32,
KVM 36X, KVM 42 and KVM 52 machines). If the
outward to decrease the Delta-P pressure. If the Delta-
P pressure cannot be adjusted to proper pressure, then
the regulator is probably defective. Do not replace the
regulator until the orifices in the base plate have been
checked to make sure they are not obstructed or
improperly sized. Refer to Figure 5 on Page - D10 for
proper orifice sizes.
HOME PRINT
Pressure Settings
Pressure Regulator Cutaway
Pressure
Regulator
P
Regulator
X
A T
P 0.8 mm
ORIFICE
KVM 36X . . . . 1.6 mm
KVM 36 LW . . 1.6 mm
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
Figure 237
Regulator Valve
HOME PRINT
SERVICE TRAINING
Pressure Settings
Pressure Settings for Regulator and Relief e. While still holding a function pressured out
Valves KVM 42 you can now adjust the pressure regulator
(Figure 1, Item 4), until the pressure gauge
Now that we know our delta-P and Q-minimum are set
reads 310 Bar on Black & White units or 290
correct we can check and reset the pressure limit and
Bar on Proportional units. When this pressure
two relief valves. The correct pressure settings are as
has been set and the locknut is locked, you are
follows:
finished setting the main circuit pressures on
1) PRESSURE REGULATOR (Figure the boom.
1, item 4): f. There is also a relief valve for the main boom
down function (Figure 3, item 11); (this relief
KVM 42 B&W 310 Bar valve is either located in the handvalve housing
KVM 42 Prop. 290 Bar directly in front of the manual hand lever for
the main section), or: (is T’d into the steel tube
2) NORMALLY OPEN BYPASS VALVE that comes out of the "A" port on the frontside
(Figure 3, item 2): of the main section handvalve). Before setting
All 42 Meters 320 Bar the downside relief valve, you must bring the
boom to it’s fully retracted position. This is
3) HANDVALVE HIGH PRESSURE best accomplished with the boom swung off to
RELIEF (Figure 3, item 9): the side of the truck with the outriggers fully
extended. While holding the main section
All 42 Meters 330 Bar
pressured out in the fully retracted position,
you can now adjust the downside relief
In order to reset the valve with the highest pressure, we cartridge until you read 100 Bar on the 0-600
must first raise the pressure of the other two valves. Bar gauge.
a. To set the pressure regulator (Figure 1), loosen

the lock nut (Item 4), and turn the adjusting
screw inward approximately two turns. This
will raise the pressure of this valve higher than
330 bar.
b. To set the normally open bypass valve (Figure
2), loosen the lock nut (Item 2), and turn the
adjusting screw inward approximately one
turn. This will raise the pressure of this valve
higher than 330 bar.
c. Pressure out any boom section except the main
down. The pressure can now be read on the 0-
600 Bar gauge that is near the handvalves. The
gauge should read 330 Bar. If it does not,
adjust the relief valve on the boom handvalves
(Figure 3, item 9). After you have this relief
set to 330 Bar you can lock the locknut and
move on to the normally open bypass valve.
d. While you continue to hold a function
pressured out you can adjust the normally open
bypass valve (Figure 2, item 2), until the
KVM 42LW BOOM HANDVALVE
(Waterpump/Compressor,Throttle, & Outrigger)
1 - BOOM EXTEND SPEED

Pressure Settings
2 - BOOM RETRACT SPEED

3 - SWING RIGHT SPEED
4 - SWING LEFT SPEED BOOM BOOM BOOM BOOM SWING RPM WTR/ OUT-
1 2 3 4 R/L COMP. RIGGER
5 - WATERPUMP RPM
6 - COMPRESSOR RPM
7 - OUTRIGGER SPEED
8 - PRETENTION VALVE
9 - HIGH PRESS. RELIEF (330 Bar)
10 - SECTION COMPENSATORS 1 1 1 1 3 5
KVM 42 LW, W/Rexroth BoomHandvalve
11 11 - DOWN-SIDE RELIEF VALVE
9 24V 24V 24V 24V 24V 24V 24V
24V
7
O-ring O-ring
8 8
10
Filter Orifice
24V 24V 24V 24V 24V 24V 24V
24V
2 2 2 2 4 6
HOME
PRINT
HOME PRINT
SERVICE TRAINING
Pressure Settings
KKVM 36X such as a steel bearing, inside a cap fitting.
Check hydraulic pressure position The agitator will not be able to turn, and
the oil will be forced over the relief valve.
can indicate trouble in one or more components. 3. At idle speed (about 600 RPM), about 4.5
horsepower is being converted to heat. Position the
NOTE! agitator lever to the off (center) position when the
Hydraulic pressures setting shown in the temperature gauge on the main control panel
following procedures are for a 1200 single indicates 50°C.
circuit pump kit and a 2023 twin circuit 4. Open the agitator shutoff valve or remove the plug,
pump kit. However, because different pump and reconnect the hose to the agitator motor.
kits may be used in this unit, all pressure
settings should be verified with the pressure
settings shown on the applicable hydraulic OFF
52qrttrn.epsL
schematic. The hydraulic schematics for

your pump kit are in the Appendix of this
manual.
the procedure.
You and any assistants should wear eye protection
Be sure that the waterbox covers are installed on the
waterbox. Figure 238
We do not recommend using the remote control box for Agitator shutoff valve
Wear safety glasses when setting pressures. The general location of the components used to check
Position the “remote/local” switch on the main control
1. Locate the agitator shutoff valve, and close it
NOTE!
order one using part #10004680 (valve) and
#30303432 (tube). Contact the Schwing Ser-
vice Department for installation instruc-
you will need to remove one of the hoses
from the agitator motor, and plug the hose
and the open fitting with approved hydrau-
lic dead plugs. Do not substitute other plugs,
HOME PRINT
Pressure Settings
36Xdside.eps
Boom (Section #1) Down
Pressure Relief Valve and Boom Hand Valves and
Gauge Port Gauge Port
Concrete Pump Shutoff

Valve
Concrete Pump Pressure
Soft Switch Shutoff Valve Gauge
(twin circuit)
Side panel box
Main Relief Valve • Concrete pump forward/
reverse hand valve
• Outrigger hand valves and
Outrigger Hand Valves t gauge port
• E-Stop Manifold and Gauge
Accumulator Unloading • Remote Control Connector
Manifold Valve and Gauge
(twin circuit)
Agitator Shutoff Valve Rear Control Panel
Agitator Hand Valve and

Gauge Port
Figure 239
• Set the concrete pump main relief valve (single-

circuit)
The BPL 1200 concrete pump is designed to operated
at a maximum pressure of 300 bar (4350 PSI). It is
controlled by the main relief valve (Figure 240), which
valve is located at the front of the control block
(towards the truck cab). To check or set the main relief
pressure perform the following steps:
HOME PRINT
SERVICE TRAINING
Pressure Settings

grooves2.eps

in valve shaft
Lower Raise
pressure pressure
gray valve.eps L
Figure 240
Concrete pump main relief valve
1. Close the concrete pump shutoff valve (Figure

241)
2. Use the throttle switch on the main control panel to quarter turn.eps
rev the engine up to full RPM.

Figure 241
The unit will stroke only once, then the rock 5. If adjustment is required, loosen the jam nut on the
cylinder will retract. Oil will have nowhere to go relief valve adjusting screw with a 13-mm spanner
except over the concrete pump main relief valve. wrench (Figure 242).
4. Read the pressure on the concrete pump pressure 6. Turn the adjustment knob on the relief valve to
gauge, located on the main control block. It should adjust the pressure. Turn the adjustment knob in to
read 300 bar. Position the concrete pump switch to raise pressure or out to lower the pressure.
the off (neutral) position. If no adjustment is
needed, skip to Step 8. 7. Retighten the jam nut. (Tightening the jam nut
tends to raise the pressure. If this happens, hold the
adjustment knob while tightening the jam nut.)
will develop maximum pressure. Read the pressure
on the control block pressure gauge. If more
adjustment is needed, return the pump to “neutral,”
then repeat Steps 5 through Step 8 until the
pressure is at 300 bar.
9. Open the shutoff valve. The unit will not stroke
with the shutoff valve closed.
10.
HOME PRINT
Pressure Settings
NOTE! 7. Read the pressure on the concrete pump pressure
If you cannot adjust the pressure up to 300 gauge located on the main control block. It should
bar, you have a problem. In this case, turn read 350 bar. Position the concrete pump switch to
the adjustment knob out by several turns so the off (neutral) position. If no adjustment is
that your pressure isn’t too high once the needed, skip to Step 11.
problem is found. Contact Schwing Amer- 8. If adjustment is needed, use a 9/16 inch spanner
ica’s Service Department for advice on how wrench, loosen the jam nut on the main relief valve
to continue. adjusting screw (Figure 242).
• Set the concrete pump main relief valve (twin 9. Insert a 5/32 inch allen wrench in the adjustment
circuit) screw. Turn the screw in to raise pressure or out to
The main relief valve is the primary pressure control lower the pressure.
device on units equipped with Rexroth A7VO 10. Once the pressure is correct (350) bar retighten the
hydraulic pumps. This pump is designed to operate at a jam nut. Tightening the nut tends to raise the
maximum pressure of 350 bar (5075 PSI). pressure, so check pressure again after tightening.
Verify the correct pressure setting (350 bar).
WARNING 11. Open the concrete pump shutoff and soft switch
valves. The unit will not stroke with theses valves
Hot oil expulsion hazard. stand away closed.
pressures.
W008.eps

be out of the way if a hose or a fitting mal-
functions.
valves (Figure 242).
4. Position the “remote / local” switch on the main
control panel to the “local” position.
5. Use the throttle switch on the main control panel to
HOME PRINT
SERVICE TRAINING
Pressure Settings
w
Gauge port
39
hif
lw1
.ep
s
Main relief valve
Soft switch
relief valve

Soft switch removed for illustration
shutoff valve
grooves2.eps
Concrete pump Grooves in handle should

39
shutoff valve hif
low
.ep
s
in valve shaft
Figure 242
Set the soft switch circuit relief pressure 2. High pressure the concrete pump. The pressure
To check or adjust the soft switch pressure setting, gauge should read 60 or 80 bar (check your
proceed as follows: schematic). If no adjustment is needed, skip to Step
4.
soft switch shutoff valve. The rest of the unit 3. If adjustment is needed, loosen the jam nut on the
should still be set up as though you were going to soft switch relief valve with a 9/16 inch spanner
check concrete pump pressure. wrench. Adjust the pressure up or down, as needed,
HOME PRINT
Pressure Settings
4. Be sure to open the concrete pump shutoff valve
e-stop/left.epsL
when you are finished. The unit cannot stroke with
this valve closed. Relief Valve and
Gauge Port
Set accumulator circuit hydraulic oil
compensated pump)
accumulator hydraulic pump. Turn the screw in
Figure 244
. E-Stop manifold accumulator

Accumreg.eps
6. Read the pressure on the accumulator circuit gauge
located on the accumulator manifold block (Figure
76). Pressure should read 300 bar (4350 PSI). If no
Accumulator pump (Figure 244). Loosen the jam nut, and turn the
pressure regulator
pressure. Tighten the jam nut when pressure is at
300 bar.
Figure 243

the gauge port of the E-Stop manifold (Figure
244).
4. Loosen the jam nut on the accumulator relief valve,
located on the E-Stop manifold. Turn the screw in
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting the outrigger pressure
SAFETY INSTRUCTIONS
Accumulator Safety Rules
2. Always relieve the
the system is relieved
of oil pressure.
1. Never assume that hydraulic system of pressure before
dis-assembly for clean
out, repair, or maintenance.
WARNING
With a seven place hand valve, the boom/outrigger
circuit pressure gauge
to verify zero
selector valve is inside the boom control block. This

3. Check accumulator
system pressure.
4. Never assume that
it is safe to put your hands
in the concrete
valve. does not guarantee zero
system pressure.
5. Stopping the engine pump electrically does not de-pressurize
pressure on gauge before
6. Stopping the concrete servicing.
the accumulator circuit.compressed air to charge the accumulator!
or pressure
7. NEVER use oxygen without the correct nitrogen
the machine
8. Operation of Before charging the accumulator,
valve is activated when the outrigger enable push

could damage the accumulator.Read the operation manual.
understand the procedure.
button is pushed. There is not a separate relief for this

circuit and, therefore nothing that must be set.
(4060 PSI) by the relief valve located on the passenger
side outrigger hand valve assembly (Figure 246). The
inside the passenger side bank limits the entire
Relief Valve outrigger circuit to 280-bar.
36accum.eps
Lower
Figure 245 Turn body of valve
Accumulator manifold pressure relief Higher
to adjust.
valve
8. You will need an assistant for this step. With the 280 bar
engine still running, adjust the relief valve of the E-
Stop manifold. Back out the adjustment screw Relief Valve
until pressure reads 260 bar (3770 PSI) on the
gauge connected to the E-Stop manifold.
WARNING
pressure regulator.
W010.eps
Figure 246
regulator two-and-a-half-turns. This restores the 1. Connect the whip hose of a 0–400 or 0–600 bar to
pressure regulator to its original setting (Figure the gauge port on the right side of the outrigger
243). hand valve.
10. Clear all personnel from the drive line area, start 2. If it is not already done, start the truck engine and
the truck, and rev the engine RPM to maximum. set the transmission and PTO as you would for a
pumping job.
should read 200 bar (2900 PSI). 3. Set the engine RPM to maximum.
12. If additional adjustment is needed, you must stop 4. Push the outrigger enable pushbutton located next
the truck engine each time you approach the to the outrigger hand valve (passenger side). Hold
accumulator circuit hydraulic pump (Figure 243). one of the outrigger hand valve levers in the
Adjust the accumulator pump pressure regulator jacking-retract position. The oil coming from the
screw in to increase pressure or out to decrease pump has nowhere to go but over the outrigger
pressure. Lock the jam nut when pressure is correct relief valve.
(200 bar).
HOME PRINT
Pressure Settings
NOTE! boom hydraulic pressures is shown in Figure 247.
You cannot use the extend position for this NOTE!
adjustment because extend has a nonadjust- Do not adjust ∆P or Q-min if your boom is
able secondary relief functions built into the running as you like it. The pressure setting
valve. procedure uses a standard starting point
5. Turn the outside body of the relief valve that is and must be fine tuned from there. It was
located at the back of the passenger side outrigger fine tuned at the factory and should not be
hand valve (Figure 246). Turn in to raise pressure adjusted unless absolutely necessary.
or turn out to lower pressure.
6. When the pressure on the gauge connected to the
outrigger hand valve is 280-bar, release the enable WARNING
7. Remove the whip hose and gauge from the before adjusting Q-min.
W009.eps
outrigger handvalve, and replace the cap on the
gauge port
• Pressure reducing valve
This valve is preset at the factory. Contact Schwing Each time the Q-min screw must be
America’s Service Department at (651) 429-0999 for adjusted, the engine must be stopped, or at
information on checking or setting this valve. least the transmission must be taken out of
• Electric stroke limiter gear so that the drivelines stop turning.
America’s Service Department at (651) 429-0999 for
information on checking or setting this valve
• Load-sensing boom pressures (7 place
proportional circuit)
will have different pressure adjustments than if it is
equipped with a black and white boom system. The
following instructions are for load-sensing proportional
systems. If you have a unit equipped with a black and
white boom system, contact Schwing Service
with orifices. In a load-sensing system, the pump puts
maintain a 20 bar higher pressure at the pump than
what the cylinders actually require. This 20 bar is
called delta P (∆P). Additionally, we set the hydraulic
pump so that it always puts out a small amount of oil,
or outrigger hydraulic pressures on a load-sensing
The general locations of the components used to set
HOME PRINT
SERVICE TRAINING
Pressure Settings
Boom Hand Valves Q-min Adjust Screw ∆P Regulator E-Stop Manifold
36Xdside.eps
Figure 247
0-400 bar
gauge port
0-60 bar
gauge port
boom control
block relief valve
s
ep
dv.
itpr
ap
36
15 bar pretension
adjustment screw
Figure 248
Boom hand valves
HOME PRINT
Pressure Settings
Check or set ∆P NOTE!
To check or set ∆P follow these steps: If the boom does not operate smoothly at 20
bar, you must fine tune the adjustment.
1. Stop the truck engine, and place a “Do Not
Operate” sign on the truck windshield. Remove the gauge, and adjust ∆P until the boom is
2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar responsive and smooth. When done, the gauge
gauge port of the manual boom handvalves. Take (reinstalled) must read between 14 and 25 bar. The
care not to accidently install the gauge in the 0-60 electronics in the control system can also affect how
bar port (Figure 248). the boom operates, so if ∆P adjustment does not seem
to help, reset to 20 bar and check the electrical settings.
3. To be sure that the pump is putting out only enough Once electrical settings are verified, you could again
oil needed to maintain ∆P, we need to change the refine the boom action with the ∆P adjustment.
setting of the Q-min screw. Q-min is adjusted by a CAUTION! Do not operate any functions while
screw on the boom hydraulic pump (Figure 249). setting ∆P.
Unscrew the Q-min screw three full turns. Check
that all personnel are clear of the truck, then restart
the engine, engage the pumps, and leave the engine
at an idle. CAUTION! If you activate any boom
or outrigger functions, you will damage the 0 -
deltaPvlv.eps
40 bar gauge. Make sure that all emergency stop
switches are in the up (not activated) position. ∆P adjust
T
Pressure can be read on the 0 - 40 bar gauge that screw
you installed. Pressure should read 20 bar. If no
adjustment is needed, simply reset the Q-min Figure 250
screw as described in the Check or set Q-min steps. ∆P regulator valve
If adjustment is needed, continue to Step 2.
• Check or set Q-min
Q-min You must check Q-min pressure when the engine is at
adjustment screw the maximum specified RPM, but you must adjust it
with the engine stopped. To check or set the Q-min
follow these steps:
Q-minscrew.eps
Q-max place (Figure 248).
Figure 249 the truck engine, engage the pumps, and bring
Q-min adjust screw engine RPM to max. All boom functions must be
in neutral, and all emergency stop buttons
should be up (not engaged).
should be at 40 - 45 bar. If no adjustment is needed,
4. Delta P is adjusted by the ∆P screw on the ∆P stop the drive lines from turning, be sure the jam
regulator (Figure 250). Loosen the jam nut, and nut on the Q-min screw is tight, then continue to
adjust the screw inward to increase pressure or Set boom pressures to check the rest of the boom
outward to decrease pressure until it is set at 20 bar pressures.
(±1). Contact Schwing America’s Service 5. If adjustment is needed, turn the Q-min screw in to
Department if you are unable to adjust the pressure raise the pressure (Figure 249). Turn it out to lower
to specification. the pressure. Be sure that you stop the drive shafts
HOME PRINT
SERVICE TRAINING
Pressure Settings
from turning each time before making the
adjustment. When pressure is correct, tighten the
jam nut on the adjustment screw before continuing
with the other procedures.
Set boom pressures (load sensing

proportional booms)
Now that ∆P and Q-min are set, you can check or set 0-400 bar
the boom valve pressures.There are three pressure gauge port
settings on the boom circuit (Figure 251). 0-60 bar
gauge port
screw on the ∆P regulator valve), set at 290 bar boom control
(4205 PSI). block relief valve
2. The redundant relief valve located in the Bo
om
Va
.eps
36
emergency stop manifold, set at 320 bar (4640 15 bar pretension

PSI). adjustment screw
3. The boom control block relief valve, set at 350 bar
(5075 PSI).
NOTE! (high pressure
The boom control block relief valve is non- adjustment screw)
adjustable. If pressure is not maintained
within the specification limits, the valve
must be replaced.
deltaPvlv.eps
e-stop/right.epsL
E-Stop Manifold
Redundant Relief Valve
Figure 251
components
HOME PRINT
Pressure Settings
To check the setting of the valve with the highest tinue to use the relief valve as long as the
pressure, you must first raise the pressure of the lower cartridge maintains at least 330 bar. If you
two: must replace the valve, proceed to Step 5
1. Loosen the jam nut of the high pressure adjustment before using the concrete pump again, and
screw of the ∆P regulator. Turn the screw in two- redo this entire procedure when you have
and-a-half turns. This will raise the pressure on the installed the new valve. If pressure on the
∆P regulator above 350 bar. Apitech relief valve is below 290 bar, you
should not use the concrete pump until the
2. Loosen the jam nut of the adjustment screw on the
valve is replaced.
E-stop manifold redundant relief valve. Turn the
screw in one-and-a-half turns. This will raise the 5. Screw out the E-Stop manifold redundant relief
pressure setting of the relief valve to above 350 bar. valve adjustment screw one-and-a-half turns.
Pressure out any boom cylinder except #1 down,
and read the gauge. Pressure should read 320 bar.
If it does not, turn the screw in to raise pressure or
over the relief valve.
drive lines, be sure to stop them from turning
4. The tell tale hiss of an open relief valve should be before accessing the valve.
coming from the Apitech control block relief valve
now. If it isn’t, raise the setting of the other
pressuring out any boom cylinder (except #1
pressure devices until the hiss originates at the
down) have your helper adjust the high pressure
screw of the ∆P regulator out (lowering the
pressure on the gauge connected to the 0-400 bar
pressure) until the gauge reads 290 bar. Release the
gauge port on the boom hand valve block. It should
pressurized function and lock the jam nut. The
read 350 bar. If pressure is correct, proceed to Step
boom pressures are now set. If you did not get the
5.
readings specified after following the instructions,
NOTE! contact Schwing America’s Service Department at
Although the pressure specification for the (651) 429-0999 for advice on how to continue.
Apitech relief valve is 350 bar, you may con-
0-400 bar
gauge port
0-60 bar
gauge port
boom control
block relief valve
s
ep
dv.
itpr
ap
36
15 bar pretension
adjustment screw
Figure 252
and gauge port
HOME PRINT
SERVICE TRAINING
Pressure Settings
• Set 15 bar pretension AgitHdVl.eps
To check or set pretension, follow these steps:

1. Stop the truck engine. Plug the 0 - 40 bar gauge
into the 0-60 bar gauge port of the Apitech hand
valve (Figure 252). Relief Valve
2. Start the truck engine, but leave it at an idle.
increased, pressure will rise. Read the pressure on
the gauge. If it reads 15 bar ± 1 bar, the pressure is
set correctly. Gauge Port
NOTE!
Damage to the 0 - 40 bar gauge is possible if
RPM is raised while the gauge is connected.
3. If adjustment is needed, loosen the jam nut on the
pretension valve (Figure 252). Turn the screw in to
raise pressure and out to lower pressure. When the
pressure is correct, retighten the jam nut. Figure 253
4. Stop the engine, and remove the 0 - 40 bar gauge. Agitator hand valve
#1 boom down - brake valve
With a seven place hand valve, the #1 down brake -
valve is inside the boom control block. There is not a 2. Connect the whip hose of 0-400 or a 0–600-bar
separate relief valve for this circuit and, therefore, gauge to the gauge port on the agitator hand valve
nothing that must be set. (Figure 117).
3. If your unit is equipped with an
Set water pump pressure 4. agitator shut off valve, close it (Figure 119). Skip
With a seven place hand valve, the water pump to Step 6.
There is not a separate relief valve for this circuit and, 52qrttrn.epsL

Closed
The agitator circuit has a maximum pressure of 200 bar
(2900 PSI), limited by the relief valve located in the
agitator hand valve (Figure 117). The gauge port for
checking or setting the agitator pressure is located on Shown in the
the agitator hand valve. open position
Figure 254
5. If your unit is not equipped with an agitator shut
off valve, remove one of the hoses from the
agitator motor and plug the hose and the open
fitting with approved hydraulic dead plugs. Do not
improvise on these plugs. If you don’t have any,
contact the Schwing’s Spare Parts Department and
order them before continuing with this procedure.
HOME PRINT
Pressure Settings
All of these fittings and many, many more
extremely useful items are included in the
Troubleshooting Kit, part number 30308553. We
highly recommend purchase of this kit. It will pay
for itself many times over. You will need:
- Qty 2 VS-16S locking plugs, part number
10016803
- Qty 1 GS-16S straight fitting, part number
10008088
- Qty 2 16S capnuts, part number 10001743
7. Locate the relief valve on the agitator hand valve.
engine.
agitator hand valve. Turn in to raise pressure or
turn out to lower pressure.
and remove the key. Open the shut off valve or
area or in a plastic bag or something similar to
keep dirt from entering the fittings. Reattach the
hose to the agitator motor fitting and tighten
securely. (Torque is correct if you make one
increase.)
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 39X 52qrttrn.epsL
Closed
NOTE!
Hydraulic pressure settings shown in the
following procedures are for a 2023 twin Shown in the
circuit pump kit. However, because open position
different pump kits may be used in this unit,
all pressure settings should be verified with
Figure 255
the pressure settings shown on the
applicable hydraulic schematic. The
hydraulic schematics for your pump kit are
in the Appendix of this manual.
the procedure.
You and any assistants should wear eye protection
Be sure that the waterbox covers are installed on the
waterbox.
We do not recommend using the remote control box for
Wear safety glasses when setting pressures.
Position the “remote/local” switch on the rear control
1. Locate the agitator shutoff valve, and close it
position. The agitator will not be able to turn, and
the oil will be forced over the relief valve.
3. At idle speed (about 600 RPM), about 4.5
horsepower is being converted to heat. Position the
agitator lever to the off (center) position when the
temperature gauge on the rear control panel
indicates 50°C.
4. Open the agitator shutoff valve or remove the plug,
and reconnect the hose to the agitator motor.
HOME PRINT
Pressure Settings
The general location of the components used to check
39Xtop.eps
Hydraulic Controls
Enclosure
• Boom Hand Valves
Soft Switch Shutoff Valve and Gauge Port
(twin circuit) • Forward/Reverse
Hand Valve
• Agitator Hand
Valve and Gauge
Port
Main Relief Valve • E-Stop Manifold
Soft Switch Relief Valve and Gauge port
• Pilot Air Regulator
Concrete Pump Shutoff • Stroke Limiter
Valve
Outrigger Hand Valves Outrigger Hand Valves

and Gauge Port
Accumulator Unloading
Manifold Valve (twin Rear Control Panel
circuit)
Accumulator Gauge
Concrete Pump
Pressure Gauge
Figure 256
HOME PRINT
SERVICE TRAINING
Pressure Settings
• Set the concrete pump main relief valve (twin 9. Insert a 5/32 inch allen wrench in the adjustment
circuit) screw. Turn the screw in to raise pressure or out to
The main relief valve is the primary pressure control lower the pressure.
device on units equipped with Rexroth A7VO 10. Once the pressure is correct (350 bar) retighten the
hydraulic pumps. This pump is designed to operate at a jam nut. Tightening the nut tends to raise the
maximum pressure of 350 bar (5075 PSI). pressure, so check pressure again after tightening.
Verify the correct pressure setting (350 bar).
11. Open the concrete pump shutoff valve and soft
WARNING switch shutoff valve. The unit will not stroke with
these valves closed.
Hot oil expulsion hazard. Stand away
pressures.
W008.eps
be out of the way if a hose or a fitting
malfunctions.
shutoff valves (Figure 257).
4. Position the “remote / local” switch on the rear
control panel to the “local” position.
5. Use the throttle switch on the rear control panel to
gauge located on the main control block. It should
read 350 bar. Position the concrete pump switch to
the off (neutral) position. If no adjustment is
8. If adjustment is needed, use a 9/16 inch spanner
wrench, loosen the jam nut on the main relief valve
adjusting screw (Figure 257).
HOME PRINT
Pressure Settings
w
Gauge port
39
hif
lw1
.ep
s
Main relief valve
Soft switch
relief valve

Soft switch
shutoff valve
grooves2.eps
Concrete pump Grooves in handle should

39
shutoff valve hif
low
.ep line up with grooves
s
in valve shaft
Figure 257
Set the soft switch circuit relief pressure 2. Increase the engine RPM to high pressure the
To check or adjust the soft switch pressure setting, concrete pump. The pressure gauge should read 80
proceed as follows: bar (check your schematic). If no adjustment is
soft switch shutoff valve. The rest of the unit 3. If adjustment is needed, loosen the jam nut on the
should still be set up as though you were going to soft switch relief valve with a 9/16 inch spanner
check concrete pump pressure. wrench. Adjust the pressure up or down, as needed,
HOME PRINT
SERVICE TRAINING
Pressure Settings
4. Be sure to open the concrete pump shutoff valve .
when you are finished. The unit cannot stroke with
this valve closed.
Set accumulator circuit hydraulic oil

compensated pump)
Accumreg.eps
2. Loosen the jam nut on the pressure regulator of the Accumulator pump
accumulator hydraulic pump. Turn the screw in pressure regulator
NOTE! Figure 259
If your unit is a current production model Accumulator pump pressure regulator
Figure 104, skip Steps 3,4, and 8 of this
procedure. 3. Connect the whip hose of a 0-600 bar gauge into
the gauge port of the E-Stop manifold (Figure
260).
4. Loosen the jam nut on the accumulator circuit
relief valve, located on the E-Stop manifold. Turn
the screw in two turns. This will raise the relief
setting above 300 bar (Figure 260).
ps
rt.e
ca
no
e-stop/left.epsL
Relief Valve and

Gauge Port
Figure 258
E-Stop manifold
(current production)
Figure 260
E-Stop manifold relief valve,
accumulator circuit (original
production)
HOME PRINT
Pressure Settings
5. Clear all personnel away from the drive lines, start 9. After the truck engine is stopped, back out the
the truck engine, engage the pumps, and bring the accumulator circuit hydraulic pump pressure
engine RPM to maximum. regulator two-and-a-half-turns. This restores the
6. Read the pressure on the accumulator circuit gauge pressure regulator to its original setting (Figure
located below the rear control panel. Pressure 74).
should read 300 bar (4350 PSI). If no adjustment is 10. Clear all personnel from the drive line area, start
needed, skip to Step 8. the truck, and rev the engine RPM to maximum.
7. If additional pressure adjustment is needed, locate 11. Read the pressure on the accumulator gauge. It
the accumulator manifold pressure relief valve should read 200 bar (2900 PSI).
(Figure 261). Loosen the jam nut, and turn the 12. If additional adjustment is needed, you must stop
screw in to increase pressure or out to decrease the truck engine each time you approach the
pressure. Tighten the jam nut when pressure is at accumulator circuit hydraulic pump (Figure 259).
300 bar. Adjust the accumulator pump pressure regulator
45s3blck.epsL
pressure. Lock the jam nut when pressure is correct
(200 bar).
Set the outrigger pressure

With a seven place hand valve, the boom/outrigger
selector valve is inside the boom control block. This
valve is activated when the outrigger enable push
button is pushed. There is not a separate relief for this
circuit and, therefore, nothing that must be set.
(4060 PSI) by the relief valve located on the passenger
Relief Valve side outrigger hand valve assembly (Figure 262). The
Figure 261 inside the passenger side bank limits the entire
Accumulator manifold pressure relief outrigger circuit to 280-bar.
valve
Lower
Turn body of valve
Higher
to adjust.
engine still running, adjust the relief valve on the
E-Stop manifold. Back out the adjustment screw
until pressure reads 260 bar (3771 PSI) on the 280 bar
gauge connected to the E-Stop manifold. Relief Valve
WARNING
pressure regulator.
W010.eps
Figure 262
HOME PRINT
SERVICE TRAINING
Pressure Settings
will have different pressure adjustments than if it is
WARNING equipped with a black and white boom system. The
following instructions are for load-sensing proportional
Tipping hazard. Never set outrigger systems. If you have a unit equipped with a black and
pressures with the boom unfolded. white boom system, contact Schwing Service
Pressure setting procedure requires
retraction of an outrigger jacking
W026.eps
cylinder.
1. Connect the whip hose of a 0–400 or 0–600 bar to with orifices. In a load-sensing system, the pump puts
the gauge port on the right side of the outrigger out more or less oil to respond to the needs of the
hand valve. system. Generally, the pump puts out enough oil to
2. If it is not already done, start the truck engine and maintain a 20 bar higher pressure at the pump than
set the transmission and PTO as you would for a what the cylinders actually require. This 20 bar is
pumping job. called delta P (∆P). Additionally, we set the hydraulic
3. Set the engine RPM to maximum. pump so that it always puts out a small amount of oil,
4. Push the outrigger enable pushbutton located next
to the outrigger hand valve (passenger side). Hold
one of the outrigger hand valve levers in the
jacking-retract position. The oil coming from the
or outrigger hydraulic pressures on a load-sensing
pump has nowhere to go but over the outrigger
relief valve.
The general locations of the components used to set
NOTE! boom hydraulic pressures is shown in Figure 247.
You cannot use the extend position for this
adjustment because extend has NOTE!
nonadjustable secondary relief functions Do not adjust ∆P or Q-min if your boom is
built into the valve. running as you like it. The pressure setting
procedure uses a standard starting point
5. Turn the outside body of the relief valve that is
and must be fine tuned from there. It was
located at the back of the passenger side outrigger
fine tuned at the factory and should not be
hand valve (Figure 262). Turn in to raise pressure
adjusted unless absolutely necessary.
or turn out to lower pressure.
6. When the pressure on the gauge connected to the
outrigger hand valve is 280-bar, release the enable WARNING
7. Remove the whip hose and gauge from the before adjusting Q-min. W009.eps
outrigger handvalve, and replace the cap on the

gauge port.
• Pressure reducing valve Each time the Q-min screw must be
This valve is preset at the factory. Contact Schwing adjusted, the engine must be stopped, or at
America’s Service Department at (651) 429-0999 for least the transmission must be taken out of
information on checking or setting this valve. gear so that the drivelines stop turning.
• Electric stroke limiter
The stroke limiter valve is preset at the factory. Contact
Schwing America’s Service Department at (651) 429-
0999 for information on checking or setting this valve.
• Load-sensing boom pressures (7 place
proportional circuit)
HOME PRINT
Pressure Settings
Boom Hand Valves ∆P Regulator E-Stop Manifold Q-min Adjust Screw
39Xtop.eps
Figure 263
0-400 bar
gauge port
0-60 bar
gauge port
boom control
block relief valve
s
ep
dv.
itpr
ap
36
15 bar pretension
adjustment screw
Figure 264
Boom hand valves
HOME PRINT
SERVICE TRAINING
Pressure Settings
Check or set ∆P Remove the gauge, and adjust ∆P until the boom is
To check or set ∆P follow these steps: responsive and smooth. When done, the gauge
(reinstalled) must read between 14 and 25 bar. The
1. Stop the truck engine, and place a “Do Not electronics in the control system can also affect how
Operate” sign on the truck windshield. the boom operates, so if ∆P adjustment does not seem
2. Install a 0-40 or 0-60 bar gauge in the 0-400 bar to help, reset to 20 bar and check the electrical settings.
gauge port of the manual boom handvalves. Take Once electrical settings are verified, you could again
care not to accidently install the gauge in the 0-60 refine the boom action with the ∆P adjustment.
bar port (Figure 264). CAUTION! Do not operate any functions while
3. To be sure that the pump is putting out only enough setting ∆P.
oil needed to maintain ∆P, we need to change the
setting of the Q-min screw. Q-min is adjusted by a
screw on the boom hydraulic pump (Figure 265).
Unscrew the Q-min screw three full turns. Check
deltaPvlv.eps
that all personnel are clear of the truck, then restart
the engine, engage the pumps, and leave the engine
at an idle. CAUTION! If you activate any boom ∆P adjust
T
or outrigger functions, you will damage the 0 - screw
40 bar gauge. Make sure that all emergency stop Figure 266
switches are in the up (not activated) position. ∆P regulator valve
Pressure can be read on the 0 - 40 bar gauge that
you installed. Pressure should read 20 bar. If no Check or set Q-min
adjustment is needed, simply reset the Q-min
screw as described in the Check or set Q-min steps. You must check Q-min pressure when the engine is at
If adjustment is needed, continue to Step 2. the maximum specified RPM, but you must adjust it
with the engine stopped. To check or set the Q-min
Q-min follow these steps:
adjustment screw 1. If you unscrewed the Q-min screw as the first step
place (Figure 264).
Q-minscrew.eps
Q-max engine RPM to max. All boom functions must be
in neutral, and all emergency stop buttons must
Figure 265 be up (not engaged).
Q-min adjust screw
4. Delta P is adjusted by the ∆P screw on the ∆P should be at 40 - 45 bar. If no adjustment is needed,
regulator (Figure 266). Loosen the jam nut, and stop the drive lines from turning, be sure the jam
adjust the screw inward to increase pressure or nut on the Q-min screw is tight, then continue to
outward to decrease pressure until it is set at 20 bar Set boom pressures to check the rest of the boom
(±1). Contact Schwing America’s Service pressures.
Department if you are unable to adjust the pressure
5. If adjustment is needed, turn the Q-min screw in to
to specification.
raise the pressure (Figure 265). Turn it out to lower
NOTE! the pressure. Be sure that you stop the drive shafts
If the boom does not operate smoothly at 20 from turning each time before making the
bar, you must fine tune the adjustment. adjustment. When pressure is correct, tighten the
jam nut on the adjustment screw before continuing
with the other procedures.
HOME PRINT
Pressure Settings
Set boom pressures (load sensing 3. The redundant relief valve located in the
proportional booms) emergency stop manifold, set at 330 bar (4786
PSI).
Now that ∆P and Q-min are set, you can check or set
the boom valve pressures. There are three pressure NOTE!
settings on the boom circuit (Figure 267 and Figure The boom control block relief valve is
251). nonadjustable. If pressure is not maintained
1. The boom control block relief valve, set at 350 bar within the specification limits, the valve
(5075 PSI). must be replaced.
screw on the ∆P regulator valve), set at 300 bar
(4350 PSI).
e-stop/right.epsL
E-Stop manifold
redundant relief valve
ps
rt.e
ca
no
E-Stop manifold
redundant relief
valve
Figure 267
E-Stop manifold (current production left - original production right
HOME PRINT
SERVICE TRAINING
Pressure Settings
4. The tell tale hiss of an open relief valve should be
now. If it isn’t, raise the setting of the other
pressure devices until the hiss originates at the
pressure on the gauge connected to the 0-400 bar
0-400 bar
gauge port on the boom hand valve block. It should
gauge port
read 350 bar. If pressure is correct, proceed to Step
0-60 bar
gauge port
5.
NOTE!
boom control
block relief valve Although the pressure specification for the
.eps
Apitech control block relief valve is 350 bar,
Va
om
36
Bo
you may continue to use the concrete pump
15 bar pretension as long as the relief valve cartridge
adjustment screw
maintains at least 330 bar. If pressure on the
relief valve is below 290 bar, you should not
use the concrete pump until the relief valve
is replaced. If you need to replace the relief
(high pressure
valve, repeat this entire procedure before
adjustment screw)
using the concrete pump again.
5. Screw out the E-Stop manifold redundant relief
valve adjustment screw one-and-a-half turns.
deltaPvlv.eps
If it does not, turn the screw in to raise pressure or

T location of this valve causes you to be near the
before accessing the valve.
Figure 268
pressuring out any boom cylinder (except #1
components
down) have your helper adjust the high pressure
To check the setting of the valve with the highest screw of the ∆P regulator out (lowering the
pressure, you must first raise the pressure of the lower pressure) until the gauge reads 300 bar. Release the
two: pressurized function, and lock the jam nut. The
1. Loosen the jam nut of the high pressure adjustment boom pressures are now set. If you did not get the
screw of the ∆P regulator. Turn the screw in two- readings specified after following the instructions,
and-a-half turns. This will raise the pressure on the contact Schwing America’s Service Department at
∆P regulator above 350 bar. (651) 429-0999 for advice on how to continue.
2. Loosen the jam nut of the adjustment screw on the • Boom holding valves
E-stop manifold redundant relief valve. Turn the The boom holding valves are adjusted at the factory.
screw in one-and-a-half turns. This will raise the Never adjust a holding valve while it is on the boom. If
pressure setting of the relief valve to above 350 bar. you suspect that a holding valve is not functioning
3. Pressure out any boom cylinder except #1 down by properly contact Schwing America’s Service
pushing or pulling the control handle. To pressure Department at (651) 429-0999.
HOME PRINT
Pressure Settings
0-400 bar
gauge port
0-60 bar
gauge port
boom control
block relief valve
s
ep
dv.
itpr
ap
36
15 bar pretension
adjustment screw
Figure 269
and gauge port
Set 15 bar pretension 4. Stop the engine, and remove the 0 - 40 bar gauge.
To check or set pretension, follow these steps: With a seven place hand valve, the #1 down brake -
valve is inside the boom control block. There is not
1. Stop the truck engine. Plug the 0 - 40 bar gauge a separate relief valve for this circuit and,
into the 0-60 bar gauge port of the Apitech hand therefore, nothing that must be set.
valve (Figure 269).
2. Start the truck engine, but leave it at an idle. Set water pump pressure
With a seven place hand valve, the water pump
increased, pressure will rise. Read the pressure on
There is not a separate relief valve for this circuit and,
the gauge. If it reads 15 bar ± 1 bar, the pressure is
set correctly.
NOTE! Set the agitator pressure
Damage to the 0 - 40 bar gauge is possible if The agitator circuit has a maximum pressure of 200 bar
RPM is raised while the gauge is connected. (2900 PSI), limited by the relief valve located on the
3. If adjustment is needed, loosen the jam nut on the back of the agitator hand valve (Figure 270). The gauge
pretension adjustment screw (Figure 269). Turn the port for checking or setting the agitator pressure is
screw in to raise pressure and out to lower located on top of the agitator hand valve.
pressure. When the pressure is correct, retighten
the jam nut.
HOME PRINT
SERVICE TRAINING
Pressure Settings
39Xcont3.eps 52qrttrn.epsL
Closed
Shown in the
open position
Figure 271
Agitator Hand Valve
39Xcontr.eps
5. Locate the relief valve on the back of the agitator
hand valve.
engine.
AGITATOR CONCRETE PUMP
DANGER WARNING

Do not operate this
Electrocution hazard. machine without
Stay back from high training. Understand

Figure 270 8. If adjustment is needed, turn the outside body of
Agitator hand valve (current production top the relief valve that is located at the back of the
and original production bottom) agitator hand valve. Turn in to raise pressure or
turn out to lower pressure (Figure 272).
gauge to the gauge port on the agitator hand valve
(Figure 272).
3. If your unit is equipped with an agitator shutoff
valve, close it (Figure 271). Skip to Step 5.
HOME PRINT
Pressure Settings
Agitator Relief Valve Turn body of valve

Gauge port to adjust.
Higher
Lower
ps
2.e
itrlf
ag
Figure 272
Agitator relief valve

and remove the key. Open the shutoff valve or
area or in a plastic bag or something similar in
order to keep dirt from entering the fittings.
Reattach the hose to the agitator motor fitting and
tighten securely. (Torque is correct if you make one
increase.)
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 42SX 2. Activate the agitator. With the valve closed, the
agitator will not be able to turn, and the oil will be
forced over the relief valve. At an idle (about 600
Setting Pressures RPM), 4.5 horsepower is being converted to heat.
The following pages provide the proper techniques for
checking and setting hydraulic pressures of each
system included on your unit.

agitoff2.eps

Changes in pressures can indicate trouble in one or
more components. The specifications for each circuit
are shown on the hydraulic schematics found in the
the only documents in this manual that have been
updated specifically for your unit, by the serial number, Figure 1
so in each of the following procedures you will be told Agitator shutoff valve
to refer to the schematic for the pressure required.
If you wish to order a CD ROM which explains the
pressure setting procedure for a specific model (all
pumpkits), call SAI Spare Parts Department at (800)
328 - 9635 and request the CD using the following part 3. When the oil temperature gauge shows 50˚C, open
numbers: the shutoff valve.
• 61/58 meter. . . . . . . . . . . . . . . . . . . . . . . 30365860
• 52 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30354732
• 45/47 meter. . . . . . . . . . . . . . . . . . . . . . . 30356770
• 42 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30355485
• 39 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30365861
• 34 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30356772
• 32 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30355486
• 31 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30365862

operating temperatures (40°− 60° C). In the past we
longer allow maximum oil flow to be forced over relief.
the hydraulic oil.
close it.
NOTE!
Department using part number 10004680
(valve), and number 30303432 (tube).
Contact the Service Department for
installation instructions.
HOME PRINT
Pressure Settings
Setting pressures on Hi-flo -6 pumpkits 4. If you have not already closed the soft switch
To set the pressure of the main relief valve on Hi-flo shutoff valve and the concrete pump shutoff valve
pumpkits, you must first disable the soft switch circuit. (Figure 320) do so at this time.
Simply locate the ball cock for the soft switch circuit 5. At the rear panel, select “local” control with the
(Figure 320) and close it by rotating the handle 90 “local/remote” switch and turn the electric stroke
degrees. limiter knob clockwise to maximum strokes per
minute.
The quarter turn shutoff valve for the concrete pump
(Figure 320) will also need to be closed during this 6. The main system control block pressure must be
procedure. set first to properly set the pressure cutoff on both
pumps. Begin by backing off the jam nut of the
NOTE! main relief cartridge (Figure 322) with a 9/16 inch
Main system adjustments are preset at the wrench.
factory. The following procedure begins
with adjustment of the main relief cartridge 7. Using a 5/32 inch allen wrench, turn the
and pressure cutoff. If proper pressures can adjustment screw out (counterclockwise) until you
not be obtained through these steps, contact can feel no spring tension on the adjustment screw.
the Schwing Service Department for specific
instructions on the adjustment of flow, 8. Now, turn the screw back in (clockwise) two or
horsepower, beginning of stroke regulation, three full turns to give you a proper starting point
and Q-min. and tighten the jam nut.
Pressure setting procedure: 9. Stop the truck engine and put the key in your
pocket. Adjust the pressure cutoff screw (Figure
Soft switch 321) on each pump, by backing off the jam nut
shutoff valve
with a 13mm wrench. Using a 4mm allen wrench,
turn the adjustment screw in (clockwise) one full
turn and tighten the jam nut. Restart the truck
engine.
Concrete pump
shutoff valve hif
low
brn
.e
ps
(See decal in truck cab)
Figure 2 pump forward switch on the rear panel. Using the
Concrete pump and Soft switch rear panel controls will allow you to read the
shutoff valves concrete pump main system pressure gauge, near
the e-stop manifold, from a safe distance.
1. Be sure that the waterbox covers and guards are in NOTE!
place any time you will be working in the area
Because you turned out the pressure relief
around the main control block. cartridge in step 7, the system pressure
2. Wear safety glasses when working around a should read low at this time. If it does not
concrete pump. and the gauge spikes to 320 bar or more,
disengage the pump immediately. Turn the
NOTE! relief cartridge out (counterclockwise)
It is vital that each adjustment screw be more. For safety, it is important to adjust
properly identified prior to making any the pressure up from below the specified
adjustment. All screw adjustments for the target pressure rather than down from a
system relief must be made with the pressure which exceeds the target. Continue
pumpkit in the neutral position and this procedure until the main system
adjustments for pressure cutoff must be pressure gauge reads lower than the
made with the engine shut off. specified target.
3. Start the truck engine, and put the PTO in gear just 12. To increase the pressure put the pump in the
as you would to pump a job. neutral position and adjust the relief cartridge by
turning it in (clockwise). When increasing the
pressure, the adjustments should be made in
quarter turn increments. If you make adjustments
HOME PRINT
SERVICE TRAINING
Pressure Settings
to increase the pressure but the pressure does not (counterclockwise) to reduce the pressure. These
come up, you are probably reading the pressure adjustments must be made until the two gauges in
cutoff of the pumps, if so proceed to the next step the M1 ports are reading approximately the same.
otherwise skip to step 15.Turn the relief cartridge 18. When you have achieved the same pressure on the
adjustment screw back out (counterclockwise) M1 port gauges, you can begin to adjust the
until you can no longer see a pressure drop and pressure cutoff screws in or out simultaneously
tighten the jam nut. until you achieve the desired pressure setting of
13. Stop the truck engine, put the key in your pocket. 350 bar (again, confirm the pressure specification
14. Go to the pressure cutoff screw on both hydraulic with the hydraulic schematic).
pumps (Figure 321) and back off the jam nut with a After pressure cutoff is set, return the pump to neutral,
13mm wrench. Turn the adjustment screws in with bring engine RPM to idle, open the soft switch quarter
a 4mm allen wrench one or two more turns, restart turn valve, and either proceed to other pressure settings
the engine and check the pressure again. Repeat or take the transmission and PTO out of gear and shut
this procedure until the main system relief can be off the truck.
set to the target pressure.
15. When the proper main relief pressure is achieved,
pressure cutoff can be set. Shut off the engine, put
with whip hoses to the “M1” gauge ports on the 1 STROKE REGULATION 2 PRESSURE CUT OFF
3 HORSE POWER 4 Q-MIN
2
You must be able to read both gauges 2
1
1 3
simultaneously to ensure that one pump is not 3
4
4
NOTE! M1 GAUGE PORT
The gauges in the M1 ports will read (BOTTOM OF EACH PUMP)
considerably less than the cutoff pressure of 130ajst.eps
the pump. On a -6 (190/130 pump

combination) the 190 will usually read 85 to Figure 3
90 bar while the 130 reads about 110 bar. A11VO adjustment screws for Hi-flo – 6
They could read the same however, at units 190/130
approximately 110 bar, but the 190 must
never read higher than the 130. The actual
cutoff pressure will be read on the concrete
pump main system pressure gauge near the
e-stop manifold.
16. Activate concrete pump forward to pressure out the
the “M1” ports.
your pocket before making any adjustment on the
hydraulic pump. If the cutoff on one pump is set
other. To equalize the two pumps you must either
adjust the cutoff screw in (clockwise) to increase
the pressure of the pump showing the higher
HOME PRINT
Pressure Settings
Soft switch
shutoff valve Closed Open
soft switch
relief valve
openclsd.eps
Concrete pump Main relief valve
shutoff valve hif
low
br
n.
5/32" Allen head
ep
s
9/16" jam nut
Figure 4
Soft switch components
Setting the soft switch relief pressure Load-sensing boom hydraulic controls
First, open the soft switch quarter turn valve (Figure This unit is equipped with a load-sensing, proportional
322, right) that you closed in the previous procedure. boom hydraulic system. In a black-and-white system,
The rest of the unit should still be set up as if you were the hydraulic pump puts out an unchanging amount of
going to check the main relief valve pressure (concrete oil, and speed control is done by restricting the oil to
pump shutoff valve still closed). certain functions with orifices. In a load-sensing
When you put the pump in forward now, the main system, the pump puts out more or less oil to respond
concrete pump pressure gauge should read the pressure to the needs of the system. Generally, the pump puts
shown on the schematic for soft switch. If adjustment out enough oil to maintain 20 bar higher pressure at the
is needed, loosen the soft switch relief valve jam nut pump than the cylinders actually require. This 20 bar is
(Figure 322, right) with a 9/16 open end wrench, and called delta P (∆P). Additionally, we set the hydraulic
use a 5/32 allen wrench to adjust the pressure. Turn the pump so that it always puts out a small amount of oil,
adjustment screw in (clockwise) to raise the pressure or even if no oil is needed for the system. This oil is used
out (counter clockwise) to lower the pressure. When to ensure that you have control when you need it. The
you attain the required pressure, tighten the jam nut setting to maintain this minimum amount of oil is
while holding the allen wrench to keep the pressure called Q-min (pronounced “cue min”). To set the boom
from rising. Be sure to open the concrete pump shutoff or outrigger hydraulic pressures on a load-sensing
valve on the side of the brain (Figure 322, left) when system, begin by setting ∆P and Q-min.
you are finished. The unit will not stroke with this
valve closed.
Setting boom circuit pressures WARNING

NOTE! Entanglement hazard. Stop drive shafts
Any time you set pressures for any circuit before adjusting Delta P on A11VO pump.
W020.eps
on any unit, the hydraulic oil should be at

normal operating temperature (40°–60° C).
Instructions on heating the hydraulic oil are
found in the first step of this “checking
hydraulic pressures” segment.
protection when setting pressures.
HOME PRINT
SERVICE TRAINING
Pressure Settings
0-600 bar
gauge port
ps
0.e
60
top
es
pretension
only Boom pressure
33-35 bar relief cartridge
0-600 bar
gauge port
45bmcnbl.epsL
Figure 5
(Left) The 0–60 bar gauge port is located at the top of the boom control block, and the 0-600
bar port is at the bottom. (Right) A 0–600 bar gauge port is located on the E-stop manifold.
Setting delta P pressure bar. After achieving proper ∆P, tighten the jam nut
Do not adjust ∆P or Q-min if your boom is running as and bring the engine RPM up. If the pressure
you like it. The pressure setting procedure uses a gauge continues to read 20 bar, you are reading the
standard starting point and must be fine tuned from that true ∆P pressure and may move on to setting the Q-
point. The pressure was fine tuned at the factory and min. If the pressure rises with the RPM, however,
should not be adjusted unless absolutely necessary. you may be reading the Q-min pressure instead of
true ∆P. If that happens, stop the engine, put the
1. Start by turning off the engine and putting the key key in your pocket, and place a “Do Not Operate”
in your pocket; then place a “Do Not Operate” sign sign on the windshield of the truck before
on the windshield of the truck. proceeding.
2. Install a 0-100 bar gauge in the high pressure test
port at the bottom of the boom control block
(Figure 279).
pressreg.eps
Regulator pressure
NOTE! adjustment
Do not activate any boom/outrigger
T
functions or release any e-stops with a low Adjustment for P pressure
pressure gauge attached to a high pressure
port. Delta-P
3. Delta P is adjusted on the pressure regulator

(Figure 307, top) if your unit has an A7VO pump
or (Figure 307, bottom) if your unit has an A11VO
boom pump. When all personnel are clear of the
truck, restart the engine, engage the pumps, and
leave the engine at an idle. ∆P pressure should read smdeltap.eps
17 bar, which is the standard starting point.

Figure 6
4. There are two adjustment screws on the pressure
Pressure regulator for A7VO boom pumps
regulator (Figure 307, top) for A7VO pumps. The
(top) and A11VO pumps (bottom)
smaller screw is used in this procedure to adjust
∆P. On the A11VO pumps there is only one ∆P
screw (Figure 307, bottom).
5. If adjustment is required, loosen the jam nut, and
adjust the screw inward to increase pressure or
outward to decrease pressure until it is set at 20
HOME PRINT
Pressure Settings
Q-min
Delta-P Pressure cut-off
adjustment screw
A7VX section min.top.eps
hifloreg.eps
Q max Q-min Q-max (bottom of pump)
Figure 7
Location of Q-min screw on the A7VO (left) and all adjustment screws of the A11VO (right)
6. Unscrew the Q-min screw (Figure 325) three full

turns. This step will help ensure that the pump
produces only the amount of flow needed to
maintain ∆P pressure. Once all personnel are clear
of the truck, restart the engine, engage the pumps,
and recheck at an idle. Pressure should now read
17 bar. If it does not, go back and adjust ∆P until it
does.
pressreg.eps
Regulator pressure
If pressure cannot be set correctly, there is a problem adjustment
either with the orifices in the base of the regulator or
with the regulator itself. Contact the Schwing Service T
Adjustment for P pressure
Department to determine how to continue.
If the boom does not run smoothly at 17 bar, you
must fine tune the adjustment. Remove the gauge, and Figure 8
turn the ∆P adjustment screw until the boom is Boom pressure regulator for units
responsive and smooth. After adjusting, the gauge with A7VO pumps
(reinstalled) must read between 14-25 bar. The
electronics in the control system can also affect how
the boom operates, so if ∆P adjustment does not seem
Once electrical settings are verified, you could again
try to refine the boom action with the ∆P adjustment. WARNING
NOTE!
The pressure regulator (Figure 326) is before adjusting Q-min.
W009.eps
usually mounted on the inside of the

subframe, near the cab end of the
differential cylinders.
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting Q-min 4. Identify the main boom pressure relief cartridge on
Check Q-min when the engine is at maximum specified the boom control block (Figure 328) and loosen the
RPM. You must not adjust Q-min with the drive jam nut. Then unscrew the adjustment two full
shafts turning! Each time the Q-min screw must be turns.
adjusted, the engine must be stopped or, at least, the 5. Take engine RPM to full throttle and activate boom
transmission must be taken out of gear so that the retract for any boom section except #1.
drivelines stop turning. 6. Now adjust pressure, which is read at the main
1. If you unscrewed the Q-min screw as part of the ∆P boom gauge port, to the setting found on the
adjustment, begin by returning the screw to its schematic by turning the boom pressure relief
original position. cartridge in, or clockwise, using no more than 1/4
2. All boom functions must be in neutral, and all turn increments.
emergency stop buttons should be up (not 7. When desired pressure is achieved, lock down the
engaged). Clear away all personnel, start the truck jam nut.
engine, engage the pumps and bring engine RPM
to max. Read the pressure at the 0–600 bar main
boom gauge port (Figure 327) with a 0-100 bar
gauge. Pressure should be at 30 bar. If no
adjustment is needed, be sure the jam nut on the 0-600 bar
Q-min screw is tight; then continue to set the rest gauge port
of the boom and outrigger pressures. If adjustment ps
0.e
60
is needed, continue to the next step. es
top
3. Turn the Q-min screw (Figure 325) in to raise the

pressure. Turn it out to lower the pressure. Be sure
that you stop the drive shafts from turning each
Boom pressure
time before making the adjustment. When pressure
relief cartridge
is correct, tighten the jam nut on the adjustment
screw before continuing with the other procedures;
then recheck ∆P to make sure that it hasn’t
changed during the Q-min adjustment.
NOTE!
If you don’t have a 0-100 bar gauge you can Figure 9
order one from Schwing Spare Parts
Department at (800) 328-9635, part # Boom pressure relief cartridge
10004659.
8. The next step is to return to the e-stop manifold
Setting boom pressures boom pressure relief cartridge (Figure 327) and
Now that ∆P and Q-min are set, you can remove the 0- back off the jam nut (30 mm). Turn the relief
100 bar pressure gauge and proceed to check and cartridge (32mm) out, or counter clockwise, until
adjust the main boom pressures. you achieve the pressure shown on the schematic,
for the boom pressure relief cartridge. When the
1. Loosen jam nut of the boom pressure relief
proper pressure is achieved, lock the jam nut.
cartridge (Figure 327) with a 30mm open end
wrench.
2. Turn the adjustment cartridge clockwise all the
way in with a 32mm wrench.
3. Loosen the jam nut on the pressure relief screw of
the regulator (Figure 326) or the pressure cut-off
(Figure 325), and tighten the screw all the way
down.
HOME PRINT
Pressure Settings
Setting outrigger pressure
mainrlf.eps
After the boom circuit is properly set, you can set the
outrigger pressure. Find the relief cartridge
located on the front of the passenger side outrigger
control valve (Figure 312).
WARNING
#1 down side
Tipping hazard. Never set outrigger
relief cartridge pressures with the boom unfolded.
Pressure setting procedure requires
Main boom pressure retraction of an outrigger jacking
W026.eps
relief cartridge cylinder.
1. Attach 0-600 bar whip gauge to the gauge port

(Figure 312) below the outrigger valve bank.
2. Push the outrigger enable button.
Figure 10 3. Activate an outrigger jacking cylinder to retract.
Main boom pressure adjustment and By retracting a fully retracted cylinder, the oil
piston side relief coming from the pump has nowhere to go but over
the relief valve. You cannot use an extension or
slewing cylinder because they have secondary
relief functions (nonadjustable) built into the valve.
While holding the handle to retract, read the
9. The next pressure setting is the regulator pressure.
pressure gauge.
Locate the regulator adjustment screw (Figure 325)
or pressure cut-off screw (Figure 326). Back off the 4. The pressure should read the bar value shown on
jam nut, and turn the screw counterclockwise until the hydraulic schematic. Adjust by loosening the
you achieve the pressure shown on the schematic; jam nut with a 9/16” open end wrench and turning
then lock the jam nut. the cartridge (Figure 312) in or out with 5/32 allen
wrench. When the proper pressure is achieved, let
10. The final boom pressure setting is the #1 boom rod
go of the handle and release the outrigger enable
side relief setting. This relief cartridge is in close
button.
proximity to the main boom relief (Figure 328), so
be sure to locate the proper adjustment. This testport.eps
procedure should be performed with the outriggers

extended and the boom unfolded over the cab.
Disconnect all gauges from gauge ports prior to REAR SLEW REAR JACKING FRONT JACKING FRONT EXTEND
operating any boom or outrigger functions.

30354359
Bring section #1 all the way down until the

cylinder bottoms out. Install a 0-600 bar gauge in
the main boom gauge port of the e-stop manifold
Relief
(Figure 327), and activate boom #1 down. The Cartridge
pressure should read the setting shown on the Gauge Port
schematic. If adjustment is required, back off the
jam nut and turn the relief cartridge in or out as
required until the desired pressure is achieved; then
lock down the jam nut. Figure 11
Outrigger valve bank relief cartridge
and gauge port
HOME PRINT
SERVICE TRAINING
Pressure Settings
CONCRETE PUMP
FORWARD/REVERSE
AGITATOR
Relief valve
Gauge port
Figure 12
Agitator component location
Setting the agitator pressure

The agitator circuit has a maximum pressure shown on

agitoff2.eps
the hydraulic schematic, which is limited by the relief

cartridge (Figure 314) in the agitator hand valve. The

relief cartridge is located on the back side of the
agitator manual control handle (Figure 314). The
cartridge is adjustable with just an 19mm open end
wrench.
1. Plug the 0–600 bar whip gauge into the gauge port
(Figure 314) for checking or setting agitator
pressure.
2. Locate the agitator shutoff (Figure 331) valve and
Figure 13
close it. If your unit does not have a shutoff valve,
Department using part numbers 10004680 (valve)
and 30303432 (tube). Contact the Service
Department for installation instructions, or if you Plugs Straight Fitting
can’t wait for a shutoff valve, you will need to
remove one of the hoses from the agitator motor Figure 14
and plug the hose and open fitting with approved Approved hydraulic
hydraulic dead plugs (Figure 332). dead plugs capplug.eps
NOTE!
Do not jam the paddles to force the oil over
relief by stopping the movement of the Cap Nuts
agitator.
3. Increase the throttle to any speed above idle.
Activate the agitator valve handle in either forward
or reverse, and read the gauge. If it does not read
HOME PRINT
Pressure Settings
the specified pressure, adjustment is required. Turn January 1, 2000, it will have an emergency stop
the entire valve body (Figure 314) in to increase manifold similar to the illustration shown in the bottom
pressure or out to decrease pressure. of Figure 233, which no longer has a redundant relief
4. When the pressure is set, deactivate the agitator by cartridge, and you must skip steps 3. and 7. in the
placing the manual control handle in the neutral following procedure.
position. To check or adjust the hydraulic pressure in the
5. Remove the whip gauge. accumulator circuit:
6. Reopen the shutoff valve or remove the dead plugs 1. Stop the truck, put the key in your pocket, and
and reconnect the capped hydraulic line. place a “Do Not Operate” sign on the windshield.
Setting accumulator circuit pressure accumulator hydraulic pump (Figure 232). Turn
accumulator redundant relief cartridge located on
000289a.eps
300 bar.
Accumulator pump
pressure regulator accurlf2.eps
Accumulator redunant
relief cartridge
Figure 15
Accumulator pump pressure regulator for Figure 16
A7VO (above) and for A11VO (below) Accumulator redundant relief cartridge
(above) is only present on early production
Boom Pump models. New e-stop (below) has no redundant
relief cartridge.
Accumulator Pump
Pressure Regulator
ps
rt.e
ca
no
Accumulator Pump 000446a.eps

There are three relief settings for the accumulator
circuit if your unit is equipped with an accumulator
redundant relief cartridge in the emergency stop
manifold(Figure 233, top). If your pump was built after
HOME PRINT
SERVICE TRAINING
Pressure Settings
5. Read the pressure on the accumulator circuit screw while the other person stands by the pressure
pressure gauge (Figure 234). The pressure should gauge to let him know when the pressure reads the
read the value shown on the hydraulic schematic. If value shown on the schematic for accumulator
no adjustment is needed, skip to step number 7. If redundant relief.
additional pressure adjustment is needed, continue
with step number 6.
@@@@@@@@

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QQQQQQQQ WARNING
@@@@@@@@

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QQQQQQQQ

45acumpr.epsL
@@@@@@@@

;;;;;;;;
QQQQQQQQ
@@@@@@@@

;;;;;;;;
QQQQQQQQ

;;;;;;;;
@@@@@@@@

QQQQQQQQ

pressure regulator.
W010.eps
@@@@@@@@

;;;;;;;;
QQQQQQQQ

;;;;;;;;
@@@@@@@@

QQQQQQQQ

;;;;;;;;
@@@@@@@@

QQQQQQQQ

Figure 17 regulator (Figure 232), and turn the screw back out
Accumulator circuit pressure gauge two-and-one-half turns. This restores it to its
original setting.
acumrlf.epsL
maximum.
pressure.
NOTE!
The accumulator circuit hydraulic pump
pressure regulator is referred to as the
pressure cut-off.
Figure 18
relief cartridge
counterclockwise to decrease the pressure. Tighten
the jam nut when the pressure reaches the value
required.
engine still running, one person must go to the
redundant relief valve on the emergency stop
HOME PRINT
Pressure Settings
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 42M - Proportional pocket, remove the check plug from the check port. The
oil should be at the level of the bottom of the hole in
(Apitech) Single Circuit the case. If oil is needed, add it by removing the
Check the fluid level of the distribution gearcase breather and pouring the oil through the top of the fill
(Figure 273). Be sure the truck is on reasonably level port. This gearcase uses 90W gear lube.
ground. With the truck engine off and the key in your
Breather (fill port)

Check port
Drain port
Figure 273
Fill, check, and drain ports
of Stiebel 4194 gearcase
Check the mounting hardware of the subframe, the oil 1. Place a 4-by-4 in front of the agitator paddle.
and water tanks, the delivery pipeline, the pumpkit, the 2. Turn on the agitator. The agitator will not be able
differential cylinders, the material cylinders, and the to turn, and the oil will be forced over the relief
driveline hardware. Check for bolt tightness, cracks, valve.
and other abnormalities.
At an idle (about 600 RPM), you are converting about
4.5 horsepower to heat, which is a good-sized heater.
Shut off the concrete pump when the oil shows 40°C
Check all hydraulic pressures. Changes in pressures on the temperature gauge of the operator’s panel.
Pressure settings must be made with the oil at normal Setting concrete pump pressure (single-
operating temperature (40°–60°C). The specifications circuit units)
for all circuits are shown on the hydraulic schematics
in the appendix of this manual. Schwing single-circuit pumpkits are designed to be
operated at a maximum pressure of 300 bar (4350 PSI).
Preheat the hydraulic oil The pressure in the system is controlled by the main
relief valve on the forward end (toward the truck cab)
Pressure settings must be made with the oil at normal of the main control block (Figure 274).
operating temperatures (40°– 60°C). Because the
system is load-sensing, the boom circuit cannot be used
to heat the hydraulic oil. The agitator circuit must be
used instead. To preheat the hydraulic oil using the
agitator circuit, follow these instructions:
HOME PRINT
Pressure Settings
Jam nut
Lower Raise
pressure pressure Adjustment handle
gray valve.eps L
Figure 274
Concrete pump circuit main relief valve

1. When setting pressures, always wear safety

glasses.
job.
4. Close the shutoff valve (also known as the
“ballcock” or “quarter-turn valve”)(Figures 275).
Shutoff valve
quarter turn.eps
Figure 275
5. Put the main operator’s panel “remote / local” will retract. Oil will be forced over the main relief
switch into the “local” position. valve. This procedure is called high-pressuring the
6. Using the switch on the main operator’s panel, rev concrete pump.
the truck engine up to full RPM.
reverse” switch into the “forward” position. The
unit will stroke only once; then the rock cylinder
HOME PRINT
SERVICE TRAINING
Pressure Settings
Groove at 90° to ports—

Closed
Groove lined up with ports—

Open
Figure 276
Open/closed orientation of concrete pump shutoff valve
8. Read the pressure on the gauge. It should read 300 12. Put the concrete pump into the “forward” position
bar. Return the pump to “neutral” whether it needs again. The machine will not stroke this time, but it
adjustment or not. If no adjustment is needed, skip will high-pressure again. Read the pressure on the
to step (n). gauge. If more adjustment is needed, return the
9. Using a 13-mm spanner wrench, loosen the jam pump to “neutral,” then repeat steps (i) through (l)
nut on the relief valve adjusting screw (Figure until the pressure is correct.
274). Note! If you cannot adjust the pressure up to
specification, you have a problem. In this case,
unscrew the adjustment handle several turns so that
pressure. Screw the handle in to raise pressure, and
your pressure is not too high when you find the
problem. Contact Schwing America’s Service
11. Retighten the jam nut. Tightening the nut tends to Department for advice on how to continue.
raise the pressure setting. If the rise in pressure
13. Return the pump to the “neutral” position.
becomes a problem, hold the knob while tightening
the jam nut. 14. Open the concrete pump shutoff valve (Figure
277).
Shutoff valve
quarter turn.eps
Figure 277
HOME PRINT
Pressure Settings
15. Return the RPM of the truck to idle, take the Load-sensing boom hydraulic controls
transmission and PTO out of gear, and shut off the This unit is equipped with a load-sensing, proportional
truck, or go on to other pressure settings. boom hydraulic system. In a black-and-white system,
the hydraulic pump puts out an unchanging amount of
Setting boom circuit pressures oil, and speed is controlled by restricting the oil to
Note! Whenever you set pressures for any circuit on certain functions with orifices. In a load-sensing
any unit, the hydraulic oil should be at normal system, the pump puts out more or less oil to respond
operating temperature (40°–60°C). Instructions on to the needs of the system. Generally, the pump puts
preheating the hydraulic oil for this procedure are in out enough oil to maintain 20 bar higher pressure at the
section • on page 6-243. Read all of the instructions pump than what the cylinders actually require. This 20
before beginning any pressure settings. You will need bar is called delta P (∆P). Additionally, we set the
an assistant for parts of the procedure. You and any hydraulic pump so that it always puts out a small
assistants should wear eye protection when setting amount of oil, even if no oil is needed for the system.
pressures. This oil ensures that you have control when you need
it. The setting to maintain this minimum amount of oil
is called Q-min (pronounced “cue min”). To set the
boom or outrigger hydraulic pressures on a load-
sensing system, begin by setting Q-min and ∆P (Figure
278).
Figure 283 Figure 281 Figure 280 Figure 279
42 Location Page 1
Component Locations
Figure 279—Boom control hand-
valves
Figure 280—Q-min adjustment screw
Figure 281—∆P regulator
Figure 278
Locations of components used to check boom pressures
Setting ∆P 2. Install a 0–40 bar gauge in the pressure check port

You must not adjust Q-min with the drive shafts of the boom handvalve. Take care not to accidently
turning! Each time the Q-min screw must be adjusted, install the gauge in the pretension check port
the engine must be stopped, or at least the transmission (Figure 279).
must be taken out of gear so that the drivelines stop
turning. To check or set ∆P, follow these steps:
Operate” sign on the windshield of the truck.
HOME PRINT
SERVICE TRAINING
Pressure Settings
42 apitech back.epsL
Adjustment screw
(15 bar pretension)
Pretension check
port (0–40)
Pressure check port (except pretension)

0-40 and 0-600
Figure 279
Boom control handvalve (Apitech)
3. To be sure that the pump is only putting out the oil
needed to maintain ∆P, we need to change the
Q-min
adjustment screw
Q-minscrew.eps
Q-max
Figure 280
Location of the Q-min adjustment screws
CAUTION
4. Unscrew the Q-min screw three full turns. Check Make sure that all emergency stop switches are in
that all personnel are clear of the truck, then restart the up (not engaged) position. Pressure can be read
the engine, engage the pumps, and leave the engine on the 0–40 bar gauge that you installed. Pressure
at an idle. If you activate any boom or outrigger should read 20 bar. If no adjustment is needed,
functions, you will damage the 0–40 bar gauge.
HOME PRINT
Pressure Settings
simply reset the Q-min screw as described in 5. Delta P is adjusted by the ∆P adjustment screw on
paragraph . If adjustment is needed, continue to the boom pump (Figure 281). Loosen the jam nut,
step (5). and adjust the screw inward to increase pressure, or
outward to decrease pressure until it is set at 20 bar
± 1.
deltaPvlv.eps
pressreg.eps
Regulator pressure
adjustment
T
Figure 281
∆P regulator valve
6. If pressure cannot be set correctly, contact the each time before making the adjustment. When
Schwing Service Department to determine how to pressure is correct, tighten the jam nut on the
continue. adjustment screw before continuing with the other
procedures.
Setting Q-min
You must check Q-min pressure when the engine is at Setting boom pressure
the maximum specified RPM, but you must adjust it Now that ∆P and Q-min are set, you can check or set
with the engine stopped. the main boom pressures. There are three pressure
1. If you unscrewed the Q-min screw as the first step settings:
its original position (see Figure 280).
2. Remove the 0–40 bar gauge from the pressure
check port, and install the 0–600 bar gauge in its
place.
engine RPM to max. All boom functions must be
in neutral, and all emergency stop buttons should
be up (not engaged). Read the pressure on the 0–
600 bar gauge. Pressure should be at 40–45 bar. If
no adjustment is needed, stop the drivelines, be
sure the jam nut on the Q-min screw is tight, then
continue to paragraph to check the rest of the
boom and outrigger pressures. If adjustment is
needed, continue to step (4).
4. Turn the Q-min screw in to raise the pressure (see
Figure 280). Turn it out to lower the pressure. Be
HOME PRINT
SERVICE TRAINING
Pressure Settings
screw on the ∆P regulator valve), set at 290 bar
(Figure 281)
deltaPvlv.eps
pressreg.eps
Regulator pressure
adjustment
T
Figure 282
2. Redundant relief valve located in the emergency

stop manifold, set at 320 bar (Figure 283).
10167892-3.eps
P3
P2
P4
P1
M
TT
1
MP
Figure 283
Emergency stop manifold,
and boom redundant relief
HOME PRINT
Pressure Settings
3. Boom control block relief, set at 350 bar.

pressure is not maintained within the specification
limits, the valve must be replaced (Figure 284).
42 apitech relief.eps
350 bar
relief
30 bar relief
Figure 284
Apitech boom control block relief
To check the setting of the valve with the highest NOTE! Although the pressure specification for the
pressure, you must first raise the pressure of the lower Apitech relief valve is 350 bar, you may continue
two: to use the relief valve as long as the cartridge
1. Loosen the jam nut of the high-pressure adjustment maintains at least 330 bar. If you must replace the
screw of the ∆P regulator (see Figure 281). Turn valve, proceed to step (4) before using the machine
the screw in two-and-a-half turns. This will raise again, and redo this entire procedure when you
the pressure on the regulator above 350 bar. have installed the new valve. If pressure on the
Apitech relief valve is below 290 bar, you should
not use the machine until the valve is replaced.
manifold (see Figure 283). Turn the screw in one- 4. Screw out the redundant relief valve adjustment
and-a-half turns. This will raise the pressure on the screw (see Figure 283) one-and-a-half turns.
relief valve to above 350 bar. Pressure out any boom cylinder except #1 down,
If does not, turn the screw in to raise pressure, or
out to lower pressure until it is at 320 bar. If the
coming from the Apitech control block relief valve 5. You will need a helper for this step. While
now. If it isn’t, raise the setting of the other pressuring out any boom cylinder except #1 down,
pressure devices until the hiss originates at the have your helper adjust the high-pressure screw of
Apitech control block relief valve. Read the the ∆P regulator out (lowering the pressure) until
pressure on the gauge. It should read 350 bar. If the gauge reads 290 bar (see Figure 281). Release
pressure is correct, proceed to step (4). the pressurized function and lock the jam nut. The
boom pressures are now set. If you did not get the
HOME PRINT
SERVICE TRAINING
Pressure Settings
readings specified after following the instructions, 2. Stop the truck engine. Plug the 0–40 bar gauge into
contact Schwing’s Service Department for advice the pretension gauge port of the Apitech handvalve
on how to continue. (Figure 285).
3. Start the truck engine, but leave it at an idle. Read
Setting pretension the pressure on the gauge. If it reads 15 bar ± 1 bar,
To check or set pretension follow these steps: the pressure is set correctly. If the pressure is not
1. Remember that the oil must be at normal operating set correctly, continue to point (4.)
temperature (40°–60°C). See point • for
information about preheating the oil.
CAUTION
Truck engine must be at idle when pretension is set.
4. Loosen the jam nut on the pretension valve. Turn

the screw in to raise pressure, and out to lower
the jam nut (Figure 285).
Adjustment screw
Gauge port
Apitech pretnscrw.eps
Figure 285
Pretension adjustment
screw and gauge port
5. Stop the engine, and remove the 0–40 bar pressure

gauge. Pretension setting is now complete.
HOME PRINT
Pressure Settings
HOME PRINT
SERVICE TRAINING
Pressure Settings
(Apitech) Twin Circuit the case. If oil is needed, add it by removing the
Check the fluid level of the distribution gearcase breather and pouring in the oil through the top. This
(Figure 286). Be sure the truck is on reasonably level gearcase uses 90W gear lube.

Check port
Drain port
Figure 286
Fill, check, and drain ports of Stiebel 4194 gear
Check the mounting hardware of the subframe, the oil 2. Turn on the agitator. The agitator will not be able
and water tanks, the delivery pipeline, the pumpkit, the to turn, and the oil will be forced over the relief
differential cylinders, the material cylinders, and the valve.
driveline hardware. Check for bolt tightness, cracks, 3. At an idle (about 600 RPM), you are converting
and other abnormalities. about 4.5 horsepower to heat, which is a pretty
good-sized heater. Shut off the concrete pump
Check hydraulic pressures when the oil shows 40°C on the temperature gauge
Check all hydraulic pressures. The specifications for of the operator’s panel.
each circuit are shown on the hydraulic schematics in
the appendix of this manual. Changes in pressures can Setting concrete pump pressure (High-
indicate trouble in one or more components. flow pumpkits)
Schwing units with high-flow pumpkits are designed to
Preheat the hydraulic oil be operated at a maximum pressure of 320 bar (4640
Pressure settings must be made with the oil at normal PSI). The pressure in the system is limited by the relief
operating temperatures (40°– 60°C). Because the valve located on the forward end (toward the truck cab)
system is load-sensing, the boom circuit cannot be used of the main control block (Figure 287). In addition, the
to heat the hydraulic oil. The agitator circuit must be hydraulic pumps have a pressure cutoff function, set at
used instead. To preheat the hydraulic oil using the 350 bar.
agitator circuit, follow these instructions: To check or set concrete pump circuit pressures, follow
1. Place a 4-by-4 in front of the agitator paddle. these steps:
HOME PRINT
Pressure Settings
2. Be sure that the waterbox covers and guards are 9. Loosen the jam nut on the relief valve adjusting
installed on the waterbox. Schwing does not screw (Figure 287).
recommend using the remote control box when 10. Insert a hex key (allen) wrench into the screw, and
setting the main relief pressure. turn the screw to adjust the pressure. Turn the
3. Start the truck engine, and put the PTO and screw in to raise pressure, out to lower pressure.
transmission into gear, just as you would to pump a 11. Retighten the jam nut. (Tightening the nut tends to
job. raise the pressure. If the rise in pressure becomes a
4. Locate and close the concrete pump shutoff valve problem, hold the hex key wrench while tightening
(quarter-turn valve), and the soft switch shutoff the jam nut.)
valve (quarter-turn valve) (Figures 288 and 289). 12. High-pressure the concrete pump again. Read the
5. Put the operator’s panel “remote / local” switch pressure on the gauge. If more adjustment is
into the “local” position. needed, return the concrete pump switch to
6. Using the switch on the operator’s panel, rev the “neutral,” then repeat steps (i) through (l) until the
truck engine up to full RPM. pressure is correct.
Note! If you cannot adjust the pressure up to
reverse” switch into the “forward” position. The
specification, you have a problem. In this case,
unit will stroke only once, then the rock cylinder
unscrew the adjustment knob several turns so that
will retract. The oil leaving the hydraulic pumps
your pressure is not too high when you find the
will be forced over the main relief valve. This
problem. Contact Schwing America’s Service
procedure is called high-pressuring the concrete
Department at (612) 429-0999 for advice on how
pump.
to continue.
8. Read the pressure on the gauge, as shown. It
should read 320 bar. Return the pump control to
“neutral,” whether it needs adjustment or not. If no
adjustment is needed, skip to step (13).
Soft switch Closed Open

shutoff valve

Main Pressure

Gauge port

Concrete pump Figure 287

hif
shutoff valve lob
rn
.e
Locations of the concrete pump
ps
and soft switch relief valves
HOME PRINT
SERVICE TRAINING
Pressure Settings
Soft switch
shutoff valve
Main Pressure
Gauge port
Concrete pump
hif
shutoff valve lob
rn
.e
ps
Figure 288
Locations of the concrete pump and soft switch shutoff valves
Groove lined up with ports Closed Open

- open
grooves.eps
openclsd.eps
Groove at 90° to ports
- closed
Figure 289
Open/closed orientation of the concrete pump shutoff
valve (left) and the soft switch shutoff valve (right)
Setting the soft switch circuit relief concrete pump shutoff valve on the side of the
pressure brain (shown in Figure 288) when you are finished.
The unit will not stroke with this valve closed.
proceed as follows:
1. Open the soft switch shutoff valve. The rest of the
unit should still be set up as if you were going to
check concrete pump pressure (Figure 290).
2. High-pressure the concrete pump. The pressure
gauge should read 80 bar (1160 PSI) instead of 320
bar. If adjustment is needed, loosen the jam nut of
the relief valve cartridge. Using the hex key
wrench, adjust the pressure up or down as needed,
and lock into place with the jam nut. Recheck.
Hold the screw with the hex key wrench, if
necessary, to prevent the screw from turning while
tightening the jam nut. Be sure to open up the
HOME PRINT
Pressure Settings
Soft switch
shutoff valve Open
Main Pressure
Gauge port
sftopen.eps
Soft switch
relief valve
Concrete pump
hif
shutoff valve lob
rn Figure 290
.e
ps
Soft switch circuit components
reheat the oil to check pressures

Note! Any time you set pressures for any circuit on any
unit, the hydraulic oil should be at normal operating
temperature (40°–60°C). Instructions on heating the
hydraulic oil for this procedure are found in section •
on page 6-243. Read all of the instructions before
beginning any pressure settings. You will need an
assistant for parts of the procedure. You and any
assistants should wear eye protection when setting
pressures.
Load-sensing boom hydraulic controls

This unit is equipped with a load-sensing, proportional
boom hydraulic system. In a black-and-white system
such as the 28X, the hydraulic pump puts out an
unchanging amount of oil, and speed control is done by
restricting the oil to certain functions with orifices. In a
load-sensing system, the pump puts out more or less oil
to respond to the needs of the system. Generally, the
pump puts out enough oil to maintain 20 bar higher
pressure at the pump than what the cylinders actually
require. This 20 bar is called delta P (∆P).
Additionally, we set the hydraulic pump so that it
always puts out a small amount of oil, even if no oil is
needed for the system. This oil is used to ensure that
you have control when you need it. The setting to
maintain this minimum amount of oil is called Q-min
(pronounced “cue min”). To set the boom or outrigger
hydraulic pressures on a load-sensing system, begin by
setting Q-min and ∆P (Figure 278).
HOME PRINT
SERVICE TRAINING
Pressure Settings
42 Location Page 1
Component Locations
Figure 279—Boom control hand-
valves
Figure 281—∆P regulator
Figure 291
Setting ∆P 1. Stop the truck engine and place a “Do Not

You must not adjust Q-min with the drive shafts Operate” sign on the windshield of the truck.
turning! Each time the Q-min screw must be adjusted, 2. Install a 0–40 bar gauge in the pressure check port
the engine must be stopped, or at least the transmission of the boom handvalve. Take care not to accidently
must be taken out of gear so that the drive lines stop install the gauge in the pretension check port
turning. To check or set ∆P, follow these steps: (Figure 292).
42 apitech back.epsL
Adjustment screw
(15 bar pretension)
Pretension check
port (0–40)
Pressure check port (except pretension)

0-40 and 0-600
Figure 292
Boom control handvalve (Apitech)
HOME PRINT
Pressure Settings
3. To be sure that the pump is only putting out the oil
needed to maintain ∆P, we need to change the
Q-min
adjustment screw
Q-minscrew.eps
Q-max
Figure 293
Locations of the Q-min adjustment screws
CAUTION
Do not operate any functions while setting 20 bar ∆P.
4. Unscrew the Q-min screw three full turns. Check simply reset the Q-min screw as described in
that all personnel are clear of the truck, then restart paragraph . If adjustment is needed, continue to
the engine, engage the pumps, and leave the engine step (5).
at an idle. If you activate any boom or outrigger 5. Delta P is adjusted by the ∆P adjustment screw on
functions, you will damage the 0–40 bar gauge. the ∆P regulator (Figure 294). Loosen the jam nut,
Make sure that all emergency stop switches are in and adjust the screw inward to increase pressure, or
the up (not engaged) position. Pressure can be read outward to decrease pressure until it is set at 20 bar
on the 0–40 bar gauge that you installed. Pressure ± 1.
should read 20 bar. If no adjustment is needed,
deltaPvlv.eps
pressreg.eps
Regulator pressure
adjustment
T
Figure 294
Delta P regulator valve
6. If pressure cannot be set correctly, contact the continue.

Schwing Service Department to determine how to
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting Q-min continue to paragraph to check the rest of the
You must check Q-min pressure when the engine is at boom and outrigger pressures. If adjustment is
the maximum specified RPM, but you must adjust it needed, continue to step (4).
with the engine stopped. 4. Turn the Q-min screw in to raise the pressure (see
1. If you unscrewed the Q-min screw as the first step Figure 293). Turn it out to lower the pressure. Be
of ∆P adjustment, begin by returning the screw to sure that you stop the drive shafts from turning
its original position (see Figure 293). each time before making the adjustment. When
2. Remove the 0–40 bar gauge from the pressure adjustment screw before continuing with the other
check port, and install the procedures.
0–600 bar gauge in its place.
3. Clear all personnel away from the drive lines, start Setting boom pressure
Now that ∆P and Q-min are set, you can check or set
engine RPM to max. All boom functions must be
the main boom pressures.
in neutral, and all emergency stop buttons should
be up (not engaged). Read the pressure on the 0– There are three pressure settings:
600 bar gauge. Pressure should be at 40–45 bar. If 1. Pressure regulator (the large adjustment screw on
no adjustment is needed, stop the drive lines, be the ∆P regulator valve), set at 290 bar (Figure 295).
sure the jam nut on the Q-min screw is tight, then
deltaPvlv.eps
pressreg.eps
Regulator pressure
adjustment
T
Figure 295
2. Redundant relief valve located in the emergency

stop manifold, set at 320 bar (Figure 296).
10167892-3.eps
P3
P2
P4
P1
M
TT
1
MP
Figure 296
Emergency stop manifold, and
boom redundant relief valve
HOME PRINT
Pressure Settings
3. Boom control block relief, set at 350 bar.

pressure is not maintained within the specification
limits, the valve must be replaced (Figure 297).
42 apitech relief.eps
350 bar
relief
30 bar relief
Figure 297
Apitech boom control block relief valve
To check the setting of the valve with the highest

pressure, you must first raise the pressure of the lower NOTE! Although the pressure specification for the
two: Apitech relief valve is 350 bar, you may continue
1. Loosen the jam nut of the high-pressure adjustment to use the relief valve as long as the cartridge
screw of the ∆P regulator (see Figure 295). Turn maintains at least 330 bar. If you must replace the
the screw in two-and-a-half turns. This will raise valve, proceed to step (4) before using the machine
the pressure on the regulator above 350 bar. again, and redo this entire procedure when you
have installed the new valve. If pressure on the
Apitech relief valve is below 290 bar, you should
not use the machine until the valve is replaced.
manifold (see Figure 283). Turn the screw in one-
and-a-half turns. This will raise the pressure on the 4. Screw out the redundant relief valve adjustment
relief valve to above 350 bar. screw one-and-a-half turns (see Figure 298).
If does not, turn the screw in to raise pressure, or
out to lower pressure until it is at 320 bar. If the
before accessing the valve.
now. If it is not, raise the setting of the other 5. You will need a helper for this step. While
pressure devices until the hiss originates at the pressuring out any boom cylinder except #1 down,
Apitech control block relief valve. Read the have your helper adjust the high-pressure screw
pressure on the gauge. It should read 350 bar. If (see Figure 284) of the ∆P regulator out (lowering
pressure is correct, proceed to step (4). the pressure) until the gauge reads 290 bar. Release
HOME PRINT
SERVICE TRAINING
Pressure Settings
the pressurized function and lock the jam nut. The 1. Stop the truck engine. Plug the 0–40 bar gauge into
boom pressures are now set. If you did not get the the pretension check port of the Apitech handvalve
readings specified after following the instructions, (Figure 297).
contact Schwing’s Service Department for advice 2. Start the truck engine, but leave it at an idle. Read
on how to continue. the pressure on the gauge. If it reads 15 bar ± 1 bar,
the pressure is set correctly. If the pressure is not
Setting 15 bar pretension set correctly, continue to point (4.)
To check or set pretension follow these steps:
CAUTION
Truck engine must be at idle when pretension is set.
3. Loosen the jam nut on the pretension valve. Turn

the screw in to raise pressure, and out to lower
the jam nut (Figure 298).
Apitech pretnscrw.eps
Figure 298
Pretension adjustment
screw and check port
4. Stop the engine, and remove the 0–40 bar pressure

gauge. Pretension setting is now complete.
HOME PRINT
Pressure Settings
HOME PRINT
SERVICE TRAINING
Pressure Settings
(Rexroth) the case. If oil is needed, add it by removing the
Check the fluid level of the distribution gearcase breather and pouring the oil through the top of the fill
(Figure 299). Be sure the truck is on reasonably level port. This gearcase uses 90W gear lube.

Check port
Drain port
Figure 299
Check, drain, and fill ports of Stiebel 4194 gearcase
• Check the mounting hardware of the subframe, the number 30303432 (tube). Contact the Schwing
oil and water tanks, the delivery pipeline, the America Service Department for installation
pumpkit, the differential cylinders, the material instructions.
cylinders, and the driveline hardware. Check for 2. Turn on the agitator. The agitator will not be able
bolt tightness, cracks, and other abnormalities. to turn, and the oil will be forced over the relief
valve.
At an idle (about 600 RPM), about 4.5 horsepower is
Check all hydraulic pressures. Changes in pressures being converted to heat. Shut off the concrete pump
can indicate trouble in one or more components. The when the oil temperature gauge on the operator’s panel
specifications for all circuits are shown on the shows 40°C.
hydraulic schematics in the appendix of this manual.
Setting concrete pump pressure (single-
Preheat the hydraulic oil circuit units)
Pressure settings must be made with the oil at normal Schwing single-circuit pumpkits are designed to be
operating temperature (40°– 60°C). The agitator circuit operated at a maximum pressure of 300 bar (4350 PSI).
must be used to heat the hydraulic oil. To preheat the The pressure in the system is controlled by the main
hydraulic oil using the agitator circuit, follow these relief valve on the forward end (toward the truck cab)
instructions: of the main control block (Figure 300).
1. Locate the agitator shutoff valve and close it.
NOTE! If your unit does not have a shutoff valve,

order one, using part number 10004680 (valve) and
HOME PRINT
Pressure Settings
Jam nut
Lower Raise
pressure pressure Adjustment handle
gray valve.eps L
Figure 300
Concrete pump circuit main relief valve
1. When setting pressures, always wear safety

glasses.
job.
4. Close the shutoff valve (also known as the
“ballcock” or “quarter-turn valve”) (Figures 301
and 302).
Shutoff valve
quarter turn.eps
Figure 301
5. Put the rear operation panel “remote / local” switch

into the “local” position.
6. Using the switch on the rear operation panel, rev
the truck engine up to full RPM.
7. This procedure is called high-pressuring the
concrete pump. Put the main operation panel
“forward / neutral / reverse” switch into the
HOME PRINT
SERVICE TRAINING
Pressure Settings
“forward” position. The unit will stroke only once;
then the rock cylinder will retract. Oil will be
forced over the main relief valve.
Groove at 90° to ports—

Closed
Groove lined up with ports—

Open
Figure 302
Open/closed orientation of concrete pump shutoff valve
8. Read the pressure on the gauge. It should read 300

bar. Return the pump to “neutral,” whether it needs
adjustment or not. If no adjustment is needed, skip
to step (14).
9. Using a 13-mm spanner wrench, loosen the jam
nut on the relief valve adjusting screw (see Figure
13).
pressure. Screw the handle in to raise pressure, and
11. Retighten the jam nut. Tightening the nut tends to
raise the pressure setting. If the rise in pressure
becomes a problem, hold the knob while tightening
the jam nut.
again. The machine will not stroke this time, but it
will high-pressure again. Read the pressure on the
gauge. If more adjustment is needed, return the
pump to “neutral,” then repeat steps (9) through
(11) until the pressure is correct.
IMPORTANT! If you cannot adjust the pressure

up to specification, you have a problem. In this
case, unscrew the adjustment handle several turns
so that your pressure is not too high when you find
the problem. Contact Schwing America’s Service
Department for advice on how to continue.
13. Return the pump to the “neutral” position.
HOME PRINT
Pressure Settings
14. Open the concrete pump shutoff valve (Figure
303).
Shutoff valve
quarter turn.eps
Figure 303
15. Return the RPM of the truck to idle, take the
transmission and PTO out of gear, and shut off the
truck, or go on to other pressure settings.
Setting boom circuit pressures

NOTE! Any time you set pressures for any circuit on
any unit, the hydraulic oil should be at normal
operating temperature (40°–60° C). Instructions on
heating the hydraulic oil for this procedure are found
on page 6-243. Read all of the instructions before
beginning any pressure settings. You will need an
assistant for parts of the procedure. You and any
assistants should wear eye protection when setting
pressures.
Load-sensing boom hydraulic controls

This unit is equipped with a load-sensing, proportional
boom hydraulic system. In a black-and-white system,
the hydraulic pump puts out an unchanging amount of
oil, and speed control is done by restricting the oil to
certain functions with orifices. In a load-sensing
system, the pump puts out more or less oil to respond
to the needs of the system. Generally, the pump puts
out enough oil to maintain 20 bar higher pressure at the
pump than what the cylinders actually require. This 20
bar is called delta P (∆P). Additionally, we set the
hydraulic pump so that it always puts out a small
amount of oil, even if no oil is needed for the system.
This oil is used to ensure that you have control when
you need it. The setting to maintain this minimum
amount of oil is called Q-min (pronounced “cue min”).
HOME PRINT
SERVICE TRAINING
Pressure Settings
To set the boom or outrigger hydraulic pressures on a
load-sensing system, begin by setting Q-min and ∆P
(Figure 306).
42 Location Page 1
Component Locations
Figure 279—Boom control handvalves
Figure 307—∆P regulator (original location—inside frame; current location—outside frame)
Figure 309—Normally open bypass valve
Figure 304
Setting ∆P
You must not adjust Q-min with the drive shafts
turning! Each time the Q-min screw must be adjusted,
the engine must be stopped, or at least the transmission
turning.
To check or set ∆P, follow these steps:
1. Stop the truck engine, put the key in your pocket,
and place a “Do Not Operate” sign on the
windshield of the truck.
2. Install a 0-600 bar gauge and a 0-40 bar gauge in
the boom control hand valve (Figure 305).
HOME PRINT
Pressure Settings
SECTION 1 SECTION 2 SECTION 3 SECTION 4 SLEWING OUTPUT + / - AC / WP BOOM / OUTRIG.

FORWARD / REV.
WARNING
Do not operate at DANGER WARNING
pressures exceeding Electrocution hazard. Do not operate this
the rating of the Stay back from high machine without
entire material the warnings in safety
delivery system. 17 feet (5 meters).
0-40
42 rexman.epsL
0-600
Figure 305
Boom control handvalve (Rexroth)
3. To be sure that the pump is putting out only enough the boom hydraulic pump (Figure 306).
oil to maintain ∆P, we need to change the setting of
the Q-min screw. Q-min is adjusted by a screw on
Q-min
adjustment screw
Q max
Figure 306
Location of Q-min screw
CAUTION
Do not operate any functions when setting ∆P.
HOME PRINT
SERVICE TRAINING
Pressure Settings
Unscrew the Q-min screw three full turns. Check 20 bar. If no adjustment is needed, simply reset the
that all personnel are clear of the truck, then restart Q-min screw. If adjustment is needed, continue
the engine, engage the pumps, and leave the engine with step (5).
at an idle. If you activate any boom or outrigger 4. Delta P is adjusted on the ∆P adjustment screw of
functions, you will damage the 0–40 bar gauge. the ∆P regulator (Figure 307). There are two
Make sure that all emergency stop switches are in adjustment screws on the ∆P regulator. The smaller
the up (not engaged) position. Pressure can be read screw is used to adjust ∆P. Loosen the jam nut, and
on either the main boom gauge (0–600 bar) or the adjust the screw inward to increase pressure, or
pretension (0–40 bar) gauge. Pressure should read outward to decrease pressure, until it is set at 20
bar (±1).
High-pressure
adjustment screw
∆P
T
Figure 307
Delta P regulator.
5. If pressure cannot be set correctly, contact the Setting Q-min
Schwing Service Department to determine how to You must check Q-min pressure when the engine is at
continue. the maximum specified RPM, but you must adjust it
with the engine stopped.
Q-min
adjustment screw
Q-minscrew.eps
Q-max
Figure 308
Q-min screw
2. Clear all personnel away from the drivelines, start no adjustment is needed, stop the drivelines, be
the truck engine, engage the pumps and bring sure the jam nut on the Q-min screw is tight, then
engine RPM to max. All boom functions must be continue to “Setting boom pressure” to set the rest
in neutral, and all emergency stop buttons should of the boom and outrigger pressures. If adjustment
be up (not engaged). Read the pressure on the 0– is needed, continue to step 3.
600 bar gauge. Pressure should be at 40–45 bar. If
HOME PRINT
Pressure Settings
3. Turn the Q-min screw in to raise the pressure. Turn • High-pressure adjustment screw of the ∆P regula-
it out to lower the pressure. Be sure that you stop tor (the large adjustment screw on the ∆P regula-
the drive shafts from turning each time before tor), set at 290 bar (see Figure 307).
making the adjustment. When pressure is correct, • Normally open bypass valve (the valve that opens
tighten the jam nut on the adjustment screw before when an E-stop switch is activated), set at 320 bar
continuing with the other procedures. (see Figure 309).
• Handvalve relief (located in the boom control
Setting boom pressure
block), set at 330 bar (Figure 310).
Now that ∆P and Q-min are set, you can check or To check or adjust the high pressure settings on the
adjust the boom circuit high pressure settings. boom circuit, follow these steps:
1. Loosen the jam nut of the large adjustment screw
NOTE! These instructions apply to units built of the ∆P regulator. (see Figure 307). Turn the
before January, 1997. screw in two full turns. This will raise the pressure
on the regulator above 330 bar.
There are three pressure settings on the boom circuit:
WARNING
If the ∆P regulator is located inside the frame, stop the drivelines
from turning before making adjustments.
2. Loosen the jam nut on the normally open bypass adjusting screw in one full turn. This will raise the
valve adjustment screw (see Figure 309). Turn the pressure of this valve above 330 bar.
Jam nut
Adjustment
screw
3
age
Protective
nP
atio
Loc
cover
42
Figure 309
Normally open bypass valve
3. Pressure out any boom cylinder except #1 down, tings of the other pressure devices until the hiss
by pushing or pulling the control handle. To pres- originates at the boom control block relief valve.
sure out a cylinder, retract a fully retracted cylinder Read the pressure on the gauge. It should read 330
or extend a fully extended cylinder. The oil is bar. If no adjustment is needed, skip to step (4). If
forced over the relief valve. The telltale hiss of an adjustment is needed, proceed to step (4).
open relief valve should be coming from the con-
trol block relief valve now. If it isn’t, raise the set-
HOME PRINT
SERVICE TRAINING
Pressure Settings
4. Adjust the pressure by turning the adjustment pressure. When pressure is correct, lock the jam
screw on the boom handvalve relief valve (Figure nut, and continue to step (4).
310). Screw in to raise pressure, or out to lower
Handvalve relief valve

is located here.
rxboomblk.eps Front view Side view

Figure 310
Boom hand valve relief valve
5. You will need a helper for this step. Pressure out the A-frame when the boom is being folded into the
any boom cylinder except #1 down, as described in transport position. To prevent this, there is a secondary
(3) above. Read the gauge while your helper turns relief valve that regulates only the pressure on the #1
the adjustment screw of the normally open bypass retract function (Figure 311).
valve out (lowering the pressure). Continue adjust-
ing until the pressure reads 320 bar. Lock the jam
nut before proceeding.
6. While pressuring out any boom cylinder except #1
down, have your helper turn the high-pressure
adjustment screw of the pressure regulator out
(lowering the pressure) until the gauge reads 290
bar. Lock the jam nut. The boom pressures are now
set. If you did not get the readings specified after
following the instructions, contact Schwing’s Ser-
vice Department for advice on how to continue.
Set the #1 down side pressure

Because gravity pulls the boom down, high pressure is
not needed to bring section #1 down. Allowing high
pressure to be available leaves open the possibility of
an inattentive operator causing damage to the boom or
HOME PRINT
Pressure Settings
Down side relief valve is located

behind this section.
rxdnside.eps Front view Side view
Figure 311
Down side relief valve
1. Set up the unit as if to pump a job. Put down the 7. Stop the truck engine. Remove the gauges from the
outriggers, avoiding overhead wires and other boom control block. The job is now complete.
obstructions.
2. Bottom out the #1 cylinders completely. No posi- Setting outrigger pressure
tion can allow the boom to do this without hitting After the boom circuit is properly set, you can set the
something unless the boom is unfolded. Unfold outrigger pressure. Find the relief valve on the back
side of the passenger side outrigger control bank relief
sections #2, #3, and #4 away from section #1. valve (Figure 312).
3. Slew the boom to a position that will allow section
#1 to come all the way down without hitting any-
thing, then bring section #1 down.
4. When the #1 cylinders have completely bottomed
out, the oil coming from the pump will have
nowhere to go except over the relief valve. Read
the gauge; it should say 100 bar. (Although pres-
sure is specified as 80 bar, the gauge will read 100
bar because of the 20 bar ∆P that we set earlier.) If
no adjustment is needed, skip to step (6). If adjust-
ment is needed, proceed to step (5).
5. Loosen the jam nut on the down side relief car-
tridge. Adjust the pressure by turning the screw in
to increase pressure, or out to decrease pressure.
When the gauge reads 100 bar, retighten the jam
nut.
6. Fold up the boom, stow the outriggers, and refasten
the tie-down strap, or move on to other mainte-
nance procedures.
HOME PRINT
SERVICE TRAINING
Pressure Settings
280 Bar
280 Bar
relief valve
relief valve
Lower Lower
Higher PS
ou
trig Higher 6p
lc
cn ou
trb tri
lk- g
42 cn
.ep trb
s
lk
-4
2.
ep
s
Turn body of Turn body of

valve to adjust. valve to adjust.
Manitrol valve system Pushbutton system

Figure 312
Outrigger valve bank relief valves
To check the pressure, follow these steps:
1. On original units, pull the outrigger/boom selector
valve to the outrigger position. On units in current
production, push the outrigger enable button (Fig-
ure 26).
Outrigger
enable button
EXTEND REAR EXTEND FRONT FOLD REAR FOLD FRONT FOOT REAR FOOT FRONT
42 p.s. outrigger.epsL
Figure 313
Passenger side outrigger enable button (current production)
2. Pressure out an outrigger jacking cylinder. Pressure into the valve. While holding the handle, have your
out by retracting a retracted cylinder. The oil from helper read the pressure gauge installed on the
the pump will be forced over the relief valve. You boom control block.
cannot use an extension cylinder, because these
have secondary, nonadjustable relief functions built
HOME PRINT
Pressure Settings
3. The pressure should read 280 bar. Adjust by turn- Set agitator pressure
ing the body of the valve in or out. When 280 bar is The agitator circuit has a maximum pressure of 200 bar
reached, let go of the handle. (2900 PSI), which is limited by the relief valve in the
4. On original units, restore the outrigger/boom selec- agitator handvalve (Figure 314).
tor valve to the boom position. On units in current 1. There is a gauge port for checking or setting agita-
production, release the pushbutton. tor pressure. Plug the 0–600 bar whip gauge into
the port.
AGITATOR
FORWARD REVERSE
Gauge port
behind here
Relief valve
42 E Stop & PS Agit Lever.eps
Figure 314
Agitator relief valve
2. With the engine shut off and the key in your number 30308553. Schwing recommends that you
pocket, remove one of the hoses from the agitator purchase this kit. It will pay for itself many times
motor and plug the hose and the open fitting with over.
approved hydraulic dead plugs. Do not substitute Be sure that one of the locking plugs and cap nuts
other plugs. If you have no hydraulic dead plugs, are tightened on the straight fitting, and that the
contact the Schwing America Spare Parts Depart- dead plugs are securely tightened to the hose and
ment and order them before continuing with this the open motor fitting.
procedure. You will need:
3. Restart the engine, engage the pumps, and bring
the throttle anywhere above idle. Activate the agi-
• Qty. 2 VS-16S locking plugs, part number tator valve handle in either forward or reverse.
10016803 Read the gauge. If adjustment is needed, turn the
• Qty. 1 GS-16S straight fitting, part number entire valve body in to increase pressure, or out to
10008088 decrease pressure.
• Qty. 2 16S cap nuts, part number 10001743 4. When the pressure is set, stop the engine and
or remove the key. Remove the dead plugs and store
• Qty. 1 size 16 shutoff valve, part number 10004680 in a clean area or in a plastic bag or another con-
tainer to keep dirt out of the fittings. Reattach the
• Qty. 1 size 16 tube, part number 30303432.
hose to the agitator motor fitting and tighten
If you install the shutoff valve, you can leave it
securely. (Torque is correct if you make one com-
installed for future use.
plete revolution after initial resistance increases.)
All of these fittings and many more useful
items are included in the troubleshooting kit, part
HOME PRINT
SERVICE TRAINING
Pressure Settings
5. Remove the whip gauge. Restart the engine, if nec- b. Loosen the jam nut on the accumulator unloading
essary. valve. Turn the accumulator unloading valve
adjustment screw in two-and-a-half turns. This will
Set accumulator circuit hydraulic oil raise the pressure above 300 bar (Figure 77).
pressure (units with accumulator
unloading valves)
5.3-7 You will need an assistant for parts of this pro-
cedure. To check or adjust the hydraulic pres-
sure in the accumulator circuit, follow these
steps:
a. Stop the truck, put the key in your pocket, and
Jam nut
Accumulator unloading
valve adjustment screw
s
.ep
Figure 315 un
lvlv
c. Loosen the jam nut on the accumulator redundant

relief valve. (This valve is located on the emer-
gency stop manifold.)
NOTE: The emergency stop manifold was added

to units built after January 1, 1997.) Turn the screw
in two turns. This will raise the relief setting above
HOME PRINT
Pressure Settings
s
ep
rl.
an
cm
Accumulator relief valve
ac
P1 P4 P2
P3
MP
S
MP
S
Figure 316
Accumulator redundant relief valve
d. Clear all personnel away from the drive lines, start adjustment is needed, skip to (g). If additional
the truck engine, engage the pumps, and bring pressure adjustment is needed, continue to (f).
engine RPM to maximum. f. Locate the accumulator manifold pressure relief
e. Read the pressure on the accumulator circuit gauge valve (Figure 317). Loosen the jam nut, and turn
located just between the hopper and the A-frame. the screw in to increase pressure, or out to decrease
Pressure should read 300 bar (4350 PSI). If no pressure. Tighten the jam nut when pressure is at
300 bar.
Pressure relief valve
acc
ma
nrlf
.ep
s
Figure 317
g. You will need an assistant for this step. With the redundant relief valve on the emergency stop mani-
engine still running, one person must go to the fold and back out the adjustment screw. The other
HOME PRINT
SERVICE TRAINING
Pressure Settings
person should stand by the pressure gauge to let
him know when pressure reads 260 bar (3770 PSI).
h. After the truck engine is stopped, go back to the
accumulator circuit hydraulic pump pressure regu-
lator and the turn the screw back out two-and-one-
half turns. This restores it to its original setting.
i. Read the pressure on the accumulator gauge. It
j. If adjustment is needed, you must stop the truck
engine, or at least stop the drivelines from turning
increase pressure, or out to decrease pressure. Lock
the jam nut when the pressure is correct.
HOME PRINT
Pressure Settings
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 45/47SX
Spline flange breather
Figure 318
Oil check plug for spline flange cavity Oil check plug
(4400 gearcase) flange.eps
Setting Pressures

agitoff2.eps

checking and setting hydraulic pressures of each
system included on your unit.
Check all hydraulic pressures.

Changes in pressures can indicate trouble in one or
Figure 319
updated specifically for your unit, by the serial number,
so in each of the following procedures you will be told
3. When the oil temperature gauge shows 50˚C, open
the shutoff valve.
• Preheat the hydraulic oil
Pressure settings must be made with the oil at normal Setting pressures on Hi-flo -6 pumpkits
operating temperatures (40°− 60° C). In the past we a. To set the pressure of the main relief valve on
could pressure out a function in the boom or outrigger Hi-flo pumpkits, you must first disable the soft
system to create heat, but load sensing systems no switch circuit. Simply locate the ball cock for
longer allow maximum oil flow to be forced over relief. the soft switch circuit (Figure 320) and close it
Because of this the agitator circuit must be used to heat by rotating the handle 90 degrees.
the hydraulic oil. b. The quarter turn shutoff valve for the concrete
To preheat the hydraulic oil: pump (Figure 320) will also need to be closed
1. Locate the agitator shutoff valve (Figure 319) and during this procedure.
close it. NOTE! If your unit does not have a Note: Main system adjustments are preset at the
shutoff valve, order one from the Schwing Spare factory. The following procedure begins with
Parts Department using part number 10004680 adjustment of the main relief cartridge and pressure
(valve), and number 30303432 (tube). Contact the cutoff. If proper pressures can not be obtained through
Service Department for installation instructions. these steps, contact the Schwing Service Department
2. Activate the agitator. With the valve closed the for specific instructions on the adjustment of flow,
agitator will not be able to turn and the oil will be horsepower, beginning of stroke regulation and Q-min.
forced over the relief valve. At an idle (about 600 Pressure setting procedure:
RPM), 4.5 horsepower is being converted to heat.
HOME PRINT
Pressure Settings
turn the adjustment screw in (clockwise) one full
Soft switch turn and tighten the jam nut. Restart the truck
shutoff valve engine.
Main Pressure 10. Adjust the engine RPM to maximum specification.
Gauge port (See decal in truck cab)
Concrete pump
concrete pump main system pressure gauge, near
shutoff valve hif
lob
rn
.e
ps
Note: Because you turned out the pressure relief

Figure 320 cartridge in step 7, the system pressure should read low
Concrete pump and Soft switch at this time. If it does not and the gauge spikes to 320
shutoff valves bar or more, disengage the pump immediately. Turn the
1. Be sure that the waterbox covers and guards are in relief cartridge out (counterclockwise) more. For
place any time you will be working in the area safety, it is important to adjust the pressure up from
around the main control block. below the specified target pressure rather than down
from a pressure which exceeds the target. Continue this
2. Wear safety glasses when working around a procedure until the main system pressure gauge reads
concrete pump. lower than the specified target.
Note! It is vital that each adjustment screw be properly 12. To increase the pressure put the pump in the
identified prior to making any adjustment. All screw neutral position and adjust the relief cartridge by
adjustments for the system relief must be made with turning it in (clockwise). When increasing the
the pumpkit in the neutral position and adjustments for pressure, the adjustments should be made in
pressure cutoff must be made with the engine shut off. quarter turn increments. If you make adjustments
3. Start the truck engine, and put the PTO in gear just to increase the pressure but the pressure does not
as you would to pump a job. come up, you are probably reading the pressure
4. If you have not already closed the soft switch cutoff of the pumps, if so proceed to the next step
shutoff valve and the concrete pump shutoff valve otherwise skip to step 15.Turn the relief cartridge
(Figure 320) do so at this time. adjustment screw back out (counterclockwise)
5. At the rear panel, select “local” control with the until you can no longer see a pressure drop and
“local/remote” switch and turn the electric stroke tighten the jam nut.
limiter knob clockwise to maximum strokes per 13. Stop the truck engine, put the key in your pocket.
minute. 14. Go to the pressure cutoff screw on both hydraulic
6. The main system control block pressure must be pumps (Figure 321) and back off the jam nut with a
set first to properly set the pressure cutoff on both 13mm wrench. Turn the adjustment screws in with
pumps. Begin by backing off the jam nut of the a 4mm allen wrench one or two more turns, restart
main relief cartridge (Figure 322) with a 9/16 inch the engine and check the pressure again. Repeat
wrench. this procedure until the main system relief can be
7. Using a 5/32 inch allen wrench, turn the set to the target pressure.
adjustment screw out (counterclockwise) until you 15. When the proper main relief pressure is achieved,
can feel no spring tension on the adjustment screw. pressure cutoff can be set. Shut off the engine, put
8. Now, turn the screw back in (clockwise) two or the key in your pocket and install 0-600 bar gauges
three full turns to give you a proper starting point with whip hoses to the “M1” gauge ports on the
and tighten the jam nut. bottom of the two hydraulic pumps (Figure 321).
9. Stop the truck engine and put the key in your simultaneously to ensure that one pump is not
pocket. Adjust the pressure cutoff screw (Figure more dominant than the other.
321) on each pump, by backing off the jam nut
with a 13mm wrench. Using a 4mm allen wrench,
HOME PRINT
SERVICE TRAINING
Pressure Settings
Note: The gauges in the M1 ports will read After pressure cutoff is set, return the pump to neutral,
considerably less than the cutoff pressure of the pump. bring engine RPM to idle, open the soft switch quarter
On a -6 (190/130 pump combination) the 190 will turn valve, and either proceed to other pressure settings
usually read 85 to 90 bar while the 130 reads about 110 or take the transmission and PTO out of gear and shut
bar. They could read the same however, at off the truck.
approximately 110 bar, but the 190 must never read
higher than the 130. The actual cutoff pressure will be 2 PRESSURE CUT OFF
1 STROKE REGULATION
read on the concrete pump main system pressure gauge
3 HORSE POWER 4 Q-MIN
near the e-stop manifold.
16. Activate concrete pump forward to pressure out the 2 2
1
pump and read the pressure on the two gauges in 1 3
3
the “M1” ports. 4
4
hydraulic pump. If the cutoff on one pump is set M1 GAUGE PORT
higher than the other, that pump will be more (BOTTOM OF EACH PUMP)
dominant. The pressure gauge in the M1 port of the 130ajst.eps

other. To equalize the two pumps you must either Figure 321
adjust the cutoff screw in (clockwise) to increase A11VO adjustment screws for Hi-flo – 6
the pressure of the pump showing the higher units 190/130
(counterclockwise) to reduce the pressure. These
with the hydraulic schematic).
HOME PRINT
Pressure Settings
Soft switch Closed Open

shutoff valve

Main Pressure

Gauge port

Concrete pump
shutoff valve hif
lob

rn
.e
ps

Figure 322
322 right) that you closed in the previous procedure. boom hydraulic system. In a black-and-white system,
is needed, loosen soft switch relief valve jam nut pump than the cylinders actually require. This 20 bar is
(Figure 322 right) with a 9/16 open end wrench, and called delta P (∆P). Additionally, we set the hydraulic
out (counter clockwise), to lower the pressure. When to ensure that you have control when you need it. The
while holding the allen wrench to keep the pressure called Q-min (pronounced “cue min”). To set the boom
valve on the side of the brain (Figure 322 left) when system, begin by setting ∆P and Q-min.
you are finished. The unit will not stroke with this Note: The illustration in Figure 323 shows a gauge port
valve closed. in the center of the main control block. Your main con-
crete pump pressure gauge should be plumbed to that
Setting boom circuit pressures port.
unit, the hydraulic oil should be at normal operating WARNING
temperature (40°–60° C). Instructions on heating the
hydraulic oil are found in the first step of this Entanglement hazard. Stop drive shafts
“checking hydraulic pressures” segment. before adjusting Delta P on A11VO pump.
W020.eps

tection when setting pressures.
HOME PRINT
SERVICE TRAINING
Pressure Settings
0-600 bar
gauge port
ps
0.e
60
top
es
pretension
only
Boom pressure
33-35 bar
relief cartridge
0-600 bar
gauge port
45bmcnbl.epsL
Figure 323
(Left) The 0–60 bar gauge port is located at the top of the boom control block, and the 0-600
bar port is at the bottom. (Right) A 0–600 bar gauge port is located on the E-stop manifold.
Setting delta P pressure 5. If adjustment is required, loosen the jam nut, and
Note! Do not adjust ∆P or Q-min if your boom is adjust the screw inward to increase pressure or
running as you like it. The pressure setting procedure outward to decrease pressure until it is set at 20
uses a standard starting point and must be fine tuned bar. After achieving proper ∆P, tighten the jam nut
from that point. The pressure was fine tuned at the and bring the engine RPM up. If the pressure
factory and should not be adjusted unless absolutely gauge continues to read 20 bar, you are reading the
necessary. true ∆P pressure and may move on to setting the Q-
min. If the pressure rises with the RPM however,
1. Start by turning off the engine and putting the key you may be reading the Q-min pressure instead of
in your pocket; then place a “Do Not Operate” sign true ∆P. If that happens, stop the engine, put the
on the windshield of the truck. key in your pocket, and place a “Do Not Operate”
2. Install a 0-100 bar gauge in the high pressure test sign on the windshield of the truck before
port at the bottom of the boom control block proceeding .
(Figure 323). NOTE! Do not activate any boom/

outrigger functions or release any e-stops with a
low pressure gauge attached to a high pressure
pressreg.eps
port. Regulator pressure

adjustment
3. Delta P is adjusted on the pressure regulator
(Figure 324 top) if your unit has an A7VO pump or T
(Figure 324 bottom) if your unit has an A11VO Adjustment for P pressure
boom pump. When all personnel are clear of the Delta-p
truck, restart the engine, engage the pumps, and
leave the engine at an idle. ∆P pressure should read
20 bar, which is the standard starting point.
4. There are two adjustment screws on the pressure
regulator (Figure 324 top) for A7VO pumps. The
smaller screw is used in this procedure to adjust smdeltap.eps
∆P. On the A11VO pumps there is only one ∆P

screw (Figure 307 bottom). Figure 324
Pressure regulator for A7VO boom pumps
(top) and A11VO pumps (bottom)
HOME PRINT
Pressure Settings
Q-min
Delta-p Pressure Cut-off
adjustment screw
hifloreg.eps
Q max Q-min Q-max (Bottom Of Pump)
Figure 325
Location of Q-min screw on the A7VO (left) and all adjustment screws of the A11VO (right)
6. Unscrew the Q-min screw (Figure 325) three full

turns. This step will help ensure that the pump
produces only the amount of flow needed to
maintain ∆P pressure. Once all personnel are clear
of the truck, restart the engine, engage the pumps,
and recheck at an idle. Pressure should now read
20 bar. If it does not, go back and adjust ∆P until it
does.
pressreg.eps
Regulator pressure
If pressure cannot be set correctly, there is a problem adjustment
either with the orifices in the base of the regulator or
with the regulator itself. Contact the Schwing Service T
Department to determine how to continue. Adjustment for P pressure

Note: If the boom does not run smoothly at 20 bar,
you must fine tune the adjustment. Remove the gauge, Figure 326
and turn the ∆P adjustment screw until the boom is Boom pressure regulator for units
responsive and smooth. After adjusting, the gauge with A7VO pumps
(reinstalled) must read between 14-25 bar. The elec-
tronics in the control system can also affect how the
boom operates, so if ∆P adjustment does not seem to
help, reset to 20 bar and check the electrical settings.
Once electrical settings are verified, you could again
try to refine the boom action with the ∆P adjustment.
WARNING
Note: The pressure regulator (Figure 326) is usually
mounted on the inside of the subframe, near the cab Entanglement hazard. Stop drive shafts
W009.eps
end of the differential cylinders.

HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting Q-min 5. Identify the main boom pressure relief cartridge on
Check Q-min when the engine is at maximum specified the boom control block (Figure 328) and loosen the
RPM. You must not adjust Q-min with the drive jam nut. Then unscrew the adjustment two full
shafts turning! Each time the Q-min screw must be turns.
adjusted, the engine must be stopped, or at least the 6. Take engine RPM to full throttle and activate boom
transmission must be taken out of gear so that the retract for any boom section except #1.
drivelines stop turning. 7. Now adjust pressure, which is read at the main
1. If you unscrewed the Q-min screw as part of the ∆P boom gauge port, to the setting found on the
adjustment, begin by returning the screw to its schematic by turning the boom pressure relief
original position. cartridge in, or clockwise, using no more than 1/4
2. All boom functions must be in neutral, and all turn increments.
emergency stop buttons should be up (not 8. When desired pressure is achieved, lock down the
engaged). Clear away all personnel, start the truck jam nut.
engine, engage the pumps and bring engine RPM
gauge. Pressure should be at 40–45 bar. If no
adjustment is needed, be sure the jam nut on the 0-600 bar
Q-min screw is tight, then continue to set the rest gauge port
of the boom and outrigger pressures. If adjustment ps
0.e
60
is needed, continue to the next step. es
top

Boom pressure
relief cartridge
screw before continuing with the other procedures,
then recheck ∆P to make sure that it hasn’t
Note: If you don’t have a 0-100 bar gauge you can
order one from Schwing Spare Parts Department at
Figure 327
(800) 328-9635, part # 10004659.
Boom pressure relief cartridge
Setting boom pressures
9. The next step is to return to the e-stop manifold
Now that ∆P and Q-min are set, you can remove the 0- boom pressure relief cartridge (Figure 327), and
100 bar pressure gauge and proceed to check and back off the jam nut (30 mm), and turn the relief
adjust the main boom pressures. cartridge (32mm) out, or counter clockwise, until
1. Loosen jam nut of the boom pressure relief the pressure shown on the schematic, for the boom
cartridge (Figure 327) with a 30mm open end pressure relief cartridge, is achieved. When the
wrench. proper pressure is achieved, lock the jam nut.
2. Turn the adjustment cartridge clockwise all the
way in with a 32mm wrench.
3. Loosen the jam nut on the pressure relief screw of
the regulator (Figure 326) or the pressure cut-off
(Figure 325), and tighten the screw all the way
down.
4.
HOME PRINT
Pressure Settings
Setting outrigger pressure
mainrlf.eps
After the boom circuit is properly set, you can set the
outrigger pressure. Find the relief cartridge
located on the front of the passenger side outrigger
control valve (Figure 312).
#1 down side
WARNING
relief cartridge Tipping hazard. Never set outrigger
pressures with the boom unfolded.
Main boom pressure Pressure setting procedure requires
relief cartridge retraction of an outrigger jacking
W026.eps
cylinder.
1. Attach 0-600 bar whip gauge to the gauge port

(Figure 312) below the outrigger valve bank.
Figure 328 2. Push the outrigger enable button.
Main boom pressure adjustment and 3. Activate an outrigger jacking cylinder to retract.
piston side relief By retracting a fully retracted cylinder, the oil
coming from the pump has nowhere to go but over
10. The next pressure setting is the regulator pressure.
Locate the regulator adjustment screw (Figure 325)
slewing cylinder because they have secondary
or pressure cut-off screw (Figure 326). Back off the
relief functions (nonadjustable) built into the valve.
jam nut, and turn the screw counter clockwise until
While holding the handle to retract, read the
you achieve the pressure shown on the schematic;
pressure gauge.
then lock the jam nut.
4. The pressure should read the bar value shown on
11. The final boom pressure setting is the #1 boom
the hydraulic schematic. Adjust by loosening the
piston side relief setting. This relief cartridge is in
jam nut with a 9/16” open end wrench and turning
close proximity to the main boom relief (Figure
the cartridge (Figure 329) in or out with 5/32 allen
328), so be sure to locate the proper adjustment.
wrench. When the proper pressure is achieved, let
This procedure should be performed with the
go of the handle and release the outrigger enable
outriggers extended and the boom unfolded over
button.
the cab. Disconnect all gauges from gauge ports
prior to operating any boom or outrigger testport.eps
functions. Bring section #1 all the way down until

the cylinder bottoms out. Install a 0-600 bar gauge
in the main boom gauge port of the e-stop manifold
REAR SLEW REAR JACKING FRONT JACKING FRONT EXTEND
(Figure 327), and activate boom #1 down. The

30354359
pressure should read the setting shown on the

schematic. If adjustment is required, back off the
jam nut and turn the relief cartridge in or out as
required until the desired pressure is achieved; then
Relief Valve
lock down the jam nut.
Gauge Port
Figure 329
Outrigger valve bank relief cartridge
and gauge port
HOME PRINT
SERVICE TRAINING
Pressure Settings
CONCRETE PUMP
FORWARD/REVERSE
AGITATOR
Relief valve
Gauge port
Figure 330
Agitator component location


agitoff2.eps
the hydraulic schematic, which is limited by the relief


relief cartridge is located on the back side of the
agitator manual control handle (Figure 331). The
cartridge is adjustable with just an 19mm open end
wrench.
1. Plug the 0–600 bar whip gauge into the gauge port
(Figure 330) for checking or setting agitator
pressure.
2. Locate the agitator shutoff (Figure 331) valve and
Figure 331
close it. If your unit does not have a shutoff valve,
Department using part numbers 10004680 (valve)
and 30303432 (tube). Contact the Service Plugs Straight Fitting
Department for installation instructions, or if you
can’t wait for a shutoff valve, you will need to Figure 332
remove one of the hoses from the agitator motor Approved hydraulic
and plug the hose and open fitting with approved dead plugs capplug.eps
hydraulic dead plugs (Figure 332).
NOTE! Do not jam the paddles to force the oil over
relief by stopping the movement of the agitator. Cap Nuts
HOME PRINT
Pressure Settings
3. Increase the throttle to any speed above idle. redundant relief cartridge in the emergency stop
Activate the agitator valve handle in either forward manifold(Figure 233 top). If your pump was built after
or reverse, and read the gauge. If it does not read January 1, 2000. It will have an emergency stop
the specified pressure, adjustment is required. Turn manifold similar to the illustration shown in the bottom
the entire valve body (Figure 330) in to increase of Figure 233 which no longer has a redundant relief
pressure or out to decrease pressure. cartridge and you must skip steps 3. and 7. in the
4. When the pressure is set, deactivate the agitator by following procedure.
placing the manual control handle in the neutral To check or adjust the hydraulic pressure in the
position. accumulator circuit:
5. Remove the whip gauge. 1. Stop the truck, put the key in your pocket, and
6. Reopen the shutoff valve or remove the dead plugs
and reconnect the capped hydraulic line. 2. Loosen the jam nut on the pressure regulator of the
Set accumulator circuit pressure the screw in two-and-one-half turns. This will raise
accumulator redundant relief cartridge located on
300 bar.
45Accreg.eps
accurlf2.eps
Accumulator pump Accumulator redunant

pressure regulator relief cartridge
Figure 333
Accumulator pump pressure regulator for Figure 334
A7VO (above) and for A11VO (below) Accumulator redundant relief cartridge
(above) is only present on early production
Boom Pump models. New e-stop (below) has no redundant
Accumulator Pump relief cartridge.
Standby rt.e
ps
ca
no
Pressure Screw
Accumulator Pump
Pressure Regulator accumpmp.eps
hgacugc.psd
You will need an assistant for parts of this procedure. 4. Clear all personnel away from the drive lines, start
There are three relief settings for the accumulator the truck engine, engage the pumps, and bring the
circuit if your unit is equipped with an accumulator, engine RPM to maximum.
HOME PRINT
SERVICE TRAINING
Pressure Settings
5. Read the pressure on the accumulator circuit counter clockwise to decrease the pressure.
pressure gauge (Figure 335). The pressure should Tighten the jam nut when the pressure reaches the
read the value shown on the hydraulic schematic. If value required.
no adjustment is needed, skip to step number 7. If 7. You will need an assistant for this step. With the
additional pressure adjustment is needed, continue engine still running, one person must go to the
with step number 6. redundant relief valve on the emergency stop
@@@@@@@@

;;;;;;;;
QQQQQQQQ
@@@@@@@@

;;;;;;;;
QQQQQQQQ

45acumpr.epsL
screw while the other person stands by the pressure
@@@@@@@@

;;;;;;;;
QQQQQQQQ

gauge to let him know when the pressure reads the
value shown on the schematic for accumulator
@@@@@@@@

;;;;;;;;
QQQQQQQQ

;;;;;;;;
@@@@@@@@
redundant relief.

QQQQQQQQ

@@@@@@@@

;;;;;;;;
QQQQQQQQ

;;;;;;;;
@@@@@@@@

QQQQQQQQ

;;;;;;;;
@@@@@@@@
WARNING

QQQQQQQQ

Figure 335 Entanglement hazard. Stop drive shafts
Accumulator circuit pressure gauge before adjusting the accumulator pump
pressure regulator.
W010.eps
acumrlf.epsL

regulator (Figure 333), and turn the screw back out
original setting.
maximum.
pressure.
Figure 336 regulator is referred to as the pressure cut-off.
relief cartridge

HOME PRINT
Pressure Settings
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 45SX Hi-Flow - 6
Breather
Breather filter grbx-5-6.eps
filler spout
Oil check plug
Oil Check Plug
Oil Drain Plug
Drain plug 4194 gearcase scan.eps
Figure 337
Check fluid level of distribution gearcase Stiebel
box 4194 (left) or 4400 (right)
Spline flange breather
Figure 338
Oil check plug for spline flange cavity Oil check plug
(4400 gearcase) flange.eps
Setting Pressures Pressure settings must be made with the oil at normal
operating temperatures (40°− 60° C). In the past we
The following pages provide the proper techniques for could pressure out a function in the boom or outrigger
checking and setting hydraulic pressures of each system to create heat, but load sensing systems no
system included on your unit. longer allow maximum oil flow to be forced over relief.
Check all hydraulic pressures. the hydraulic oil.
Changes in pressures can indicate trouble in one or To preheat the hydraulic oil:
close it. NOTE! If your unit does not have a
shutoff valve, order one from the Schwing Spare
Parts Department using part number 10004680
updated specifically for your unit, by the serial number,
(valve), and number 30303432 (tube). Contact the
so in each of the following procedures you will be told
Service Department for installation instructions.
• Preheat the hydraulic oil
HOME PRINT
Pressure Settings
2. Activate the agitator. With the valve closed the 1. Be sure that the waterbox covers and guards are in
agitator will not be able to turn and the oil will be place any time you will be working in the area
forced over the relief valve. At an idle (about 600 around the main control block.
RPM), 4.5 horsepower is being converted to heat. 2. Wear safety glasses when working around a
concrete pump.

agitoff2.eps

Note! It is vital that each adjustment screw be properly
identified prior to making any adjustment. All screw
adjustments for the system relief must be made with
the pumpkit in the neutral position and adjustments for
pressure cutoff must be made with the engine shut off.
3. Start the truck engine, and put the PTO in gear just
as you would to pump a job.
4. If you have not already closed the soft switch
Figure 339 Agitator shutoff valve shutoff valve and the concrete pump shutoff valve
3. When the oil temperature gauge shows 50˚C, open (Figure 320) do so at this time.
the shutoff valve. 5. At the rear panel, select “local” control with the
“local/remote” switch and turn the electric stroke
Setting the main relief pressure and limiter knob clockwise to maximum strokes per
pressure cutoff on Hi-flo -6 pumpkits minute.
a. To set the pressure of the main relief valve on 6. The main system control block pressure must be
Hi-flo pumpkits, you must first disable the soft set first to properly set the pressure cutoff on both
switch circuit. Simply locate the ball cock for pumps. Begin by backing off the jam nut of the
the soft switch circuit (Figure 340) and close it main relief cartridge (Figure 342) with a 9/16 inch
by rotating the handle 90 degrees. wrench.
b. The quarter turn shutoff valve for the concrete 7. Using a 5/32 inch allen wrench, turn the
pump (Figure 340) will also need to be closed adjustment screw out (counterclockwise) until you
during this procedure. can feel no spring tension on the adjustment screw.
Note: Main system adjustments are preset at the 8. Now, turn the screw back in (clockwise) two or
factory. The following procedure begins with three full turns to give you a proper starting point
adjustment of the main relief cartridge and pressure and tighten the jam nut.
cutoff. If proper pressures can not be obtained through 9. Stop the truck engine and put the key in your
these steps, contact the Schwing Service Department pocket. Adjust the pressure cutoff screw (Figure
for specific instructions on the adjustment of flow, 321) on each pump, by backing off the jam nut
horsepower, beginning of stroke regulation and Q-min. with a 13mm wrench. Using a 4mm allen wrench,
Pressure setting procedure: turn the adjustment screw in (clockwise) one full
turn and tighten the jam nut. Restart the truck
Soft switch engine.
shutoff valve
Main Pressure (See decal in truck cab)
Gauge port
concrete pump main system pressure gauge, near
Concrete pump the e-stop manifold, from a safe distance.
shutoff valve hif
lob
rn.
ep
s Note: Because you turned out the pressure relief
Figure 340 cartridge in step 7, the system pressure should read low
Concrete pump, Soft switch shutoff valves at this time. If it does not and the gauge spikes to 320
bar or more, disengage the pump immediately. Turn the
relief cartridge out (counterclockwise) more. For
HOME PRINT
SERVICE TRAINING
Pressure Settings
safety, it is important to adjust the pressure up from dominant pump will however, read lower than the
below the specified target pressure rather than down other. To equalize the two pumps you must either
from a pressure which exceeds the target. Continue this adjust the cutoff screw in (clockwise) to increase
procedure until the main system pressure gauge reads the pressure of the pump showing the higher
lower than the specified target. reading or adjust the cutoff screw of the dominant
12. To increase the pressure put the pump in the pump showing the lower reading out
neutral position and adjust the relief cartridge by (counterclockwise) to reduce the pressure. These
turning it in (clockwise). When increasing the adjustments must be made until the two gauges in
pressure, the adjustments should be made in the M1 ports are reading approximately the same.
quarter turn increments. If you make adjustments 18. When you have achieved the same pressure on the
to increase the pressure but the pressure does not M1 port gauges, you can begin to adjust the
come up, you are probably reading the pressure pressure cutoff screws in or out simultaneously
cutoff of the pumps, if so proceed to the next step until you achieve the desired pressure setting of
otherwise skip to step 15.Turn the relief cartridge 350 bar (again, confirm the pressure specification
adjustment screw back out (counterclockwise) with the hydraulic schematic).
until you can no longer see a pressure drop and After pressure cutoff is set, return the pump to neutral,
tighten the jam nut. bring engine RPM to idle, open the soft switch quarter
13. Stop the truck engine, put the key in your pocket. turn valve, and either proceed to other pressure settings
14. Go to the pressure cutoff screw on both hydraulic or take the transmission and PTO out of gear and shut
pumps (Figure 341) and back off the jam nut with a off the truck.
13mm wrench. Turn the adjustment screws in with
a 4mm allen wrench one or two more turns, restart
the engine and check the pressure again. Repeat
this procedure until the main system relief can be
set to the target pressure.
-6adjust.eps
Note: The gauges in the M1 ports will read
considerably less than the cutoff pressure of the pump.
On a -6 (190/130 pump combination) the 190 will Figure 341
usually read 85 to 90 bar while the 130 reads about 110 A11VO adjustment screws for Hi-flo – 6
bar. They could read the same however, at units 190/130
approximately 110 bar, but the 190 must never read
higher than the 130. The actual cutoff pressure will be
read on the concrete pump main system pressure gauge
near the e-stop manifold.
16. Activate concrete pump forward to pressure out the
the “M1” ports.
hydraulic pump. If the cutoff on one pump is set
HOME PRINT
Pressure Settings
Main and soft switch

relief cartridges Concrete pump Closed Open
gauge port
soft switch
NOTE: The main control relief cartridge
Main relief cartridge
block (brain) of a 2525
opencls.eps
pumpkit will be rotated 9/16" jam nut
180 degrees from the
illustration shown
5/32" Allen head
ga
ug
pr
t.e
ps
9/16" jam nut
Figure 342
Location of soft switch shutoff and relief cartridges
342 right) that you closed in the previous procedure. boom hydraulic system. In a black-and-white system,
is needed, loosen Soft switch relief valve jam nut pump than the cylinders actually require. This 20 bar is
adjustment screw in (clockwise), to raise the pressure even if no oil is needed for the system. This oil is used
or out (counter clockwise), to lower the pressure. When to ensure that you have control when you need it. The
you attain the require pressure, tighten the jam nut setting to maintain this minimum amount of oil is
while holding the allen wrench, to keep the pressure called Q-min (pronounced “cue min”). To set the boom
valve on the side of the brain (Figure 342 left) when system, begin by setting ∆P and Q-min.
you are finished. The unit will not stroke with this Note: The illustration in Figure 342 shows a gauge port
valve closed. in the center of the main control block. Your main
concrete pump pressure gauge should be plumbed to
Setting boom circuit pressures that port
unit, the hydraulic oil should be at normal operating
temperature (40°–60° C). Instructions on heating the
hydraulic oil are found in the first step of this
“checking hydraulic pressures” segment.
tection when setting pressures.
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 52M (pre-1998) As mentioned earlier before we check or adjusts
Pressure Settings for KVM 52 Proportional
Load Sensing
NOTE!
Celsius.
or set pressures.
valves in the KVM 52 boom circuit. Before checking
Refer to Illustration 3 on Page- E2 for the location of
control blocks, and adjusts the output flow of the
hydraulic pumps.
operations panel.
Figure 3 of this page shows one of the two boom
control blocks. (Item 5) is pointing to the primary
relief valve located on the control block. It's function
is to protect the block from any pressure spikes that
might be in the system.
Figure 5 of this page is the pre-control block. (Item 6)
designates the gauge port. (Item 7) designates the 34
Bar pressure reducing valve. (Item 8) designates the
50 Bar pretension relief valve.
HOME PRINT
Pressure Settings
Component Location Guide- KVM 52
FIGURE 2 FIGURE 4 FIGURE 1 FIGURE 3 FIGURE 5
KVM 52M
Illustration 3
item item 5
4
item 3 a6 b6
A6
T
FIGURE 1 a5 b5
A5 B5
item 2 a4
b4
24V A4 B4
FIGURE 2 FIGURE 3
item item
1 8
STOP for Q min
L
P
item
6
STOP for Qmax
item
7
FIGURE 4 FIGURE 5
Pressure Settings for KVM 52 Proportional is either Delta-P or an idle Q-minimum. To

Load Sensing determine what indeed is creating this pressure, we
1. .Delta-P setting on the pressure regulator. (Figure must do at least ONE of the three following
1, Item 3) procedures:
With all boom functions in the neutral position, a. .Back off the Q-min. screw at least 3 turns on
emergency stop buttons up, the engine at minimum the hydraulic pump to insure that it is only
RPM's (idle), the pressure that will be read on both producing the amount of flow that the regulator
the pretension gauge and the main pressure gauge is requiring to maintain Delta-P pressure. Now
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SERVICE TRAINING
Pressure Settings
b. While observing the pretension or the main
c. Install a high pressure (0-600 Bar) gauge in the
X port of the regulator with a "T" fitting.
port continuously.
Bar, plus or minus 1 Bar; (this is the same for KVM 32,
KVM 36 X, KVM 42 and KVM 52 machines). If the
outward to decrease the Delta-P pressure. If Delta-P
pressure cannot be adjusted to proper pressure, the
regulator may be defective.
2. Q Minimum setting: the Q minimum stop on the
hydraulic pump, (Figure 4, item 1).
With all boom functions in the neutral position,
emergency stop buttons up, the engine at
maximum specified RPM's, the pressure on the
main gauge (0-600 bar) should be:
a) KVM 32 & 36 = 40 Bar;
b) KVM 42 = 40-45 Bar;
c) KVM 52 = 50-55 Bar.

If the pressure is incorrect, the Q-min. screw on the
hydraulic pump must be adjusted accordingly. Turn
the Q-min screw inward to increase the pressure and
outward to decrease the pressure.
HOME PRINT
Pressure Settings
Pressure Regulator Cutaway KVM 52
Pressure
Regulator
P
Regulator
X
A T
P 0.8 mm
NOTE:
NO ORIFICE
USED ON KVM 52
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SERVICE TRAINING
Pressure Settings
Pressure Settings for Regulator and Releif Setting Pretension Pressure(Refer to
Valves KVM 52 Figure 5)
Now that we know our delta-P and Q-minimum are set a. To set the pretension pressure, install a 0-250
correct we can check and reset the pressure limit and Bar gauge and connection hose on the gauge
two relief valves. The correct pressure settings are as port (item 6). Loosen the locknut on the
follows: pressure reducing valve (item 7), and turn the
adjusting screw inward approximately two
1) PRESSURE REGULATOR (Figure turns. This will raise the valve’s pressure
1, item 4)320 Bar higher than 50 Bar.
b. While holding a function pressured out, adjust
2) CONTROL BLOCK RELIEF (Figure the pretension relief valve (item 8), until the
3, item 5)350 Bar gauge reads 50 Bar.
c. Remove 0-250 Bar gauge, and install a 0-40
3) NORMALLY OPEN BYPASS VALVE
Bar gauge. With all boom functions in neutral
(Figure 2, item 2)360 Bar and engine at full rpm’s (this provides Q-Min),
In order to reset the valve with the highest pressure, we adjust the pressure reducing valve (item 7),
must first raise the pressure of the other two valves. until the gauge reads 34 Bar.
a. To set the pressure regulator (Figure 1), loosen (CAUTION!!! - do not activate any boom
the lock nut (Item 4), and turn the adjusting functions during this operation or damage
screw inward approximately two turns. This to the 0-40 Bar gauge will result).
will raise the pressure of this valve higher than
360 bar.
b. To set the control block (Figure 3), loosen the
lock nut (item 5), and turn the adjusting screw
inward approximately one turn. This will raise
the relief pressure higher than 360 Bar.
c. Pressure out any boom section. The pressure
can now be read on the 0-600 Bar gauge that is
near the control blocks. The gauge should read
360 Bar. If not, adjust the normally open
bypass valve, (Figure 2, item 2). After you
have this relief set to 360 Bar, you can lock the
locknut and move on to the control block
relief. (Be careful not break off the electrical
connections or over-torque the locknuts on this
valve.
d. While you continue to hold a function
pressured out you can adjust the control block
relief valve (Figure 3, item 5), until the
e. While still holding a function pressured out
you can now adjust the pressure regulator (Fig.
1, Item 4), until the pressure gauge reads 320
Bar. When this pressure has been set and the
locknut is locked, you are finished setting the
main circuit pressures on the boom.
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Pressure Settings
Control Block 1 for KVM 52 Boom 3, Boom 4, & Slewing
52 METER CONTROL BLOCK 1

BOOM 3, BOOM 4, SLEWING
a3 b3
A3 B3 BOOM #3
BOOM DOWN TIME
SPEED ADJUSTMENT a2 b2
A2 B2 BOOM #4
a1
b1
A1 B1 SLEWING
BOOM UP TIME
SPEED ADJUSTMENT
A1-A3 B1-B3
SLEWING RELIEF-190 BAR SLEWING RELIEF-190 BAR

BLEED SCREW BLEED SCREW
T
a1-a3 b1-b3
P
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Pressure Settings
Control Block 2 for KVM 52 Boom 1, Boom 2, & Outriggers
52 METER CONTROL BLOCK 2

BOOM 1, BOOM 2, OUTRIGGER
350 BAR PRIMARY RELIEF
a6 b6
A6
OUTRIGGER
a5 b5
A5 B5 BOOM #1
a4
b4
BOOM DOWN TIME
A4 B4 BOOM #2
SPEED ADJUSTMENT
BOOM UP TIME
SPEED ADJUSTMENT
A4-A6 B4-B6
BLEED SCREW BLEED SCREW
T
a4-a6 b4-b6
P
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Pressure Settings
Pre-Control Block 1-A for KVM 52
52 PRE-CONTROL BLOCK 1-A

FILTER
PRETENSION RELIEF
O-ring
50 Bar
Filter
O-ring
Orifice
NOT USED
24V
L
PV (PST)
24V
PRESSURE
REDUCING
NOTE: 34 Bar
GAUGE PORT FOR CHECKING THESE PRESSURES
IS ON THE PRE-CONTROL BLOCK 2-A.
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SERVICE TRAINING
Pressure Settings
Pre-Control block 1-B for KVM 52
52 PRE-CONTROL BLOCK 1-B
24V 24V 24V
TOP VIEW
b3 b2 b1
a1- #3 Boom Extend

b1- #3 Boom Retract
b3 b2 b1
a2- #4 Boom Extend INPUT INPUT INPUT
b2- #4 Boom Retract
a3- #1 Boom Extend
b3- #1 Boom Retract
24V 24V 24V
PV
BOTTOM VIEW
REXROTH a1 a2 a3
M10-100S
a1 a2 a3
INPUT INPUT INPUT
Pressure Settings
52 PRE-CONTROL BLOCK 1-C

PART # 995 120 002 651 (Complete)
Pre-Control Block 1-C for KVM 52
PV
(PST)
50
BAR
34
BAR
P L b1 b1 a1 a1 b2 b2 a2 a2 b3 b3 a3 a3
HOME
PRINT
52 PRE-CONTROL BLOCK 2-A
b4- #2 Boom retract a4- #2 Boom Extend
b5- Slewing - Right a5- Slewing Left
b6- Outriggers
SIDE VIEW TOP VIEW SIDE VIEW

Pre-Control Block 2-A for KVM 52
24V 24V 24V 24V 24V 24V 24V
PV PV
SERVICE TRAINING
(PST) (PST)
b4 a4 b5 a5 b6
L REXROTH L
Quick
M10-1006
Gauge
Port
HOME
b4 a4 b5 a5 b6
INPUT INPUT INPUT INPUT INPUT
Pressure Settings
PRINT
Pressure Settings
52 PRE-CONTROL BLOCK 2-B

PART #995 120 003 651 (Complete)
Pre-Control Block 2-B for KVM 52
PV (PST) PV (PST)
GAUGE PORT
L X L
b4 b4 a4 a4 b5 b5 a5 a5 b6 b6
HOME
PRINT
HOME PRINT
SERVICE TRAINING
Pressure Settings
Electric Bypass Valve for KVM 52
52 METER ELECTRIC BYPASS

360 Bar RELIEF
A A
360 Bar
CAUTION: OVER TIGHTENING WILL CAUSE

DAMAGE TO THE VALVE!
24V 24V
TORQUE VALUES:
PRESSURE ADJUSTMENT
15 FT.LBS.
LOCK NUT
7.5 FT.LBS.
CARTRIDGE(COMPLETE)
37 FT.LBS.
Y X
A A A
SAI ITEM#
(Cartridge Only)
B 10055188
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Pressure Settings
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SERVICE TRAINING
Pressure Settings
KVM 52M replaced in a different configuration the grooves in
the handle may no longer indicate the proper open/
Preheat the hydraulic oil. Pressure settings must be closed orientation of the valve. The grooves in the
made with the oil at normal operating temperatures shaft give the only true indication of the valves
(50° to 60° C). In the past we could pressure out a position.
function in the boom or outrigger system to create heat, Note! If your unit is an early production model,
but today, load sensing systems no longer allow and does not have an agitator shutoff valve, order
maximum oil flow to be forced over relief. Because of one from the Schwing Spare Parts Department,
this, the agitator circuit must be used to heat the using part number 10004680 (valve) and number
hydraulic oil. 30303432 (tube). Contact the Service Department
To heat the oil to operating temperature: for installation instructions.
1. Locate the agitator shutoff valve (Figure 343) and 2. Activate the agitator. With the valve closed, the
close it. The quarter turn shutoff valve has a agitator will not be able to turn and the oil will be
grooved line (Figure 343) on the shaft or pivot forced over the relief valve. At an idle (about 600
point of the handle as well as on the handle itself, RPM) you will be converting 4.5 horsepower to
which will indicate the open or closed heat.
configuration of the valve. If the handle is removed 3. When the oil temperature gauge shows 50˚ C, open
from the agitator shutoff valve (Figure 343) or the the shutoff valve.
concrete pump shutoff valve (Figure 344) and
agitoff.eps
Grooves in shaft grooves2.eps

shutoff valve (open position) Open
Motor
Figure 343
Setting relief pressure and pressure cutoff

on Hi-flo -6 pumpkits
a. To set the pressure of the main relief valve on
Hi-flo pumpkits, you must first disable the soft
switch circuit. Simply locate the ball cock for
the soft switch circuit (Figure 320) and close it
by rotating the handle 90 degrees.
b. The quarter turn shutoff valve for the concrete
pump (Figure 344) will also need to be closed
during this procedure.
HOME PRINT
Pressure Settings
Soft switch
shutoff valve
Main Pressure
Gauge port
Figure 344
Concrete pump and Soft switch shutoff
valves
Concrete pump
hif
shutoff valve low
br
n.
ep
s
Note: Main system adjustments are preset at the 8. Now, turn the screw back in (clockwise) two or
factory. The following procedure begins with three full turns to give you a proper starting point
adjustment of the main relief cartridge and pressure and tighten the jam nut.
cutoff. If proper pressures can not be obtained through 9. Stop the truck engine, put the key in your pocket
these steps, contact the Schwing Service Department and adjust the pressure cutoff screw (Figure 345)
for specific instructions on the adjustment of flow, on each pump, by backing off the jam nut with a
horsepower, beginning of stroke regulation and Q-min. 13mm wrench. Using a 4mm allen wrench, turn the
Pressure setting procedure: adjustment screw in (clockwise) one full turn and
1. Be sure that the waterbox covers and guards are in tighten the jam nut. Restart the truck engine.
place any time you will be working in the area 10. Adjust the engine RPM to maximum specification.
around the main control block. (See decal in truck cab)
2. Wear safety glasses when working around a 11. Pressure out the system by activating the concrete
concrete pump. pump forward switch on the rear panel. Using the
Note! It is vital that each adjustment screw be properly rear panel controls will allow you to read the
identified prior to making any adjustment. All screw concrete pump main system pressure gauge, near
adjustments for the system relief must be made with the e-stop manifold, from a safe distance.
the pumpkit in the neutral position and adjustments for Note: Because you turned out the pressure relief
pressure cutoff must be made with the engine shut off. cartridge in step 7, the system pressure should read low
3. Start the truck engine, and put the PTO in gear just at this time. If it does not and the gauge spikes to 320
as you would to pump a job. bar or more, disengage the pump immediately. Turn the
4. If you have not already closed the soft switch relief cartridge out (counterclockwise) more. For
shutoff valve and the concrete pump shutoff valve safety, it is important to adjust the pressure up from
(Figure 344) do so at this time. below the specified target pressure rather than down
from a pressure which exceeds the target. Continue this
5. At the rear panel, select “local” control with the
procedure until the main system pressure gauge reads
“local/remote” switch and turn the electric stroke
lower than the specified target.
limiter knob clockwise to maximum strokes per
minute. 12. To increase the pressure put the pump in the
6. The main system control block pressure must be neutral position and adjust the relief cartridge by
set first to properly set the pressure cutoff on both turning it in (clockwise). When increasing the
pumps. Begin by backing off the jam nut of the pressure, the adjustments should be made in
main relief cartridge (Figure 345) with a 9/16 inch quarter turn increments. If you make adjustments
wrench. to increase the pressure but the pressure does not
7. Using a 5/32 inch allen wrench, turn the come up, you are probably reading the pressure
adjustment screw out (counterclockwise) until you cutoff of the pumps, if so proceed to the next step
can feel no spring tension on the adjustment screw. otherwise skip to step 15.Turn the relief cartridge
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SERVICE TRAINING
Pressure Settings
adjustment screw back out (counterclockwise) 16. Activate concrete pump forward to pressure out the
until you can no longer see a pressure drop and pump and read the pressure on the two gauges in
tighten the jam nut. the “M1” ports.
13. Stop the truck engine, put the key in your pocket. 17. Always stop the truck engine and put the key in
14. Go to the pressure cutoff screw on both hydraulic your pocket before making any adjustment on the
pumps and back off the jam nut with a 13mm hydraulic pump. If the cutoff on one pump is set
wrench. Turn the adjustment screws in with a 4mm higher than the other, that pump will be more
allen wrench one or two more turns, restart the dominant. The pressure gauge in the M1 port of the
engine and check the pressure again. Repeat this dominant pump will however, read lower than the
procedure until the main system relief can be set to other. To equalize the two pumps you must either
the target pressure. adjust the cutoff screw in (clockwise) to increase
the pressure of the pump showing the higher
(counterclockwise) to reduce the pressure. These
simultaneously to ensure that one pump is not 18. When you have achieved the same pressure on the
more dominant than the other. M1 port gauges, you can begin to adjust the
Note: The gauges in the M1 ports will read
considerably less than the cutoff pressure of the pump.
On a -6 (190/130 pump combination) the 190 will
with the hydraulic schematic).
usually read 85 to 90 bar while the 130 reads about 110
bar. They could read the same however, at After pressure cutoff is set, return the pump to neutral,
approximately 110 bar, but the 190 must never read bring engine RPM to idle, open the soft switch quarter
higher than the 130. The actual cutoff pressure will be turn valve, and either proceed to other pressure settings
read on the concrete pump main system pressure gauge or take the transmission and PTO out of gear and shut
near the e-stop manifold. off the truck.

relief cartridges Closed Open
Concrete pump
soft switch
gauge port
relief cartridge
openclsd.eps
9/16" jam nut
5/32" Allen head

ga
ug
pr
t.e
ps
9/16" jam nut
Figure 345
HOME PRINT
Pressure Settings
130-6.eps
1 Stroke Regulation 2 Pressure Cut Off

3 Horse Power 4 Q-Min
2
2
3
1 1
3
4 4
M1 GAUGE PORT
(BOTTOM OF EACH PUMP)
Figure 346
A11VO adjustment screws for Hi-flo – 6 units 190/130
NOTE: The main control block (brain) of a 2525 Set boom circuit pressures
pumpkit will be rotated 180 degrees from the NOTE! Any time you set pressures for any circuit on
illustration shown in Figure 321. any unit, the hydraulic oil should be at normal
operating temperature (50 to 60° C). Instructions on
Setting the soft switch circuit relief heating the hydraulic oil for this procedure are found in
pressure step on page 6-483.
a. If you haven’t already done so, open the soft
Please read all of the instructions before beginning any
switch quarter turn valve (Figure 345). The rest
of the unit should still be set up as though you
the following procedure. You and any assistants should
were going to check the main relief valve
wear eye protection when setting pressures.
pressure (concrete pump shutoff valve still
closed). Current production model 52 meter pumps are
b. When you put the pump in forward now, the equipped with a load sensing, proportional boom
pressure gauge should read the pressure shown hydraulic system. If the system were black and white,
on the schematic for soft switch. If adjustment the hydraulic pump would put out an unchanging
is needed, loosen the jam nut of the soft switch amount of oil and speed control is done by restricting
relief cartridge (Figure 321) with a 9/16 inch the oil to certain functions with orifices. With a load
open end wrench, and use a 5/32 inch allen sensing system, the pumps put out more or less oil to
wrench to adjust the pressure. Turn the respond to the needs of the system. Generally, the
adjustment screw in (clockwise) to raise the pump always puts out enough oil to maintain 20 bar
pressure or out (counter clockwise) to lower higher pressure at the pump than the boom cylinders
the pressure. When you attain the required actually require. This 20 bar is called delta P. You may
pressure, tighten the jam nut while holding the see it referred to by a symbol (∆ P). Additionally, we
allen wrench, to keep the pressure from rising. set the hydraulic pump so that it always puts out a
Be sure to open the concrete pump quarter turn small amount of oil, even if none is needed for the
valve on the side of the brain (Figure 321) system. This oil is used to ensure that you have control
when you are finished. The unit will not stroke when you need it. The setting to maintain this
with this valve closed. minimum amount of oil is called Q-min (pronounced
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SERVICE TRAINING
Pressure Settings
“cue min”). To set the boom or outrigger hydraulic
CAUTION! When checking Delta P, it is important to
pressures on a load sensing system, begin by checking note that you will be installing a low pressure gauge into
∆ P and Q-min.t a high pressure port. Any activation of a boom function
or activation of an e-stop, while this gauge is attached
Checking and Setting ∆P pressure will destroy your gauge. On Comfort control units,
Note! Do not adjust delta P or Q-min if your boom is always center the boom speed switch on the remote box
running as you like it. The pressure setting procedure to prevent accidental activation of a joy stick.
uses a standard starting point and must be fine tuned 1. Install a 0-100 bar whip gauge in the high pressure
from that point. The pressure was fine tuned at the test port (Figure 347) located on the inside of the
factory, and should not be adjusted unless absolutely right boom control block as you face the three
necessary. valve blocks.
rtblock2.eps
Figure 347
The high pressure gauge
port is located between the
blocks on the inside edge of
the right boom control
High pressure
gauge port
2. With the engine at idle, turn the adjustable relief turns. Remember exactly how much you move this
cartridge (Figure 348) on the boom pilot control cartridge because it will need to be returned to the
valve, out (counter clockwise) approximately three original position.
adjustable relief
cartridge
P
L
52pilot.eps
preset pressure
reducing valve
gauge port
Figure 348
Location of adjustable relief cartridge on the boom pilot control valve
3. With the engine running and the relief cartridge showing Delta P. The pressure could be anywhere
backed out, the gauge (Figure 279) should be from 16-25 bar.
HOME PRINT
Pressure Settings
4. Increase the throttle RPM and the pressure should and adjusting the screw (3mm allen wrench)
remain the same. If the pressure fluctuates with clockwise to increase pressure or counter
engine RPM you are probably still reading Q-min, clockwise to decrease it.
and the adjustable relief cartridge (Figure 349) will 7. The delta P adjustment screw on the A11VO boom
need to be turned out more. pump also shown in Figure 307 below, requires a
5. If no further adjustment is needed, return the pilot 13mm open end wrench and a 4mm allen wrench.
valve relief cartridge to its original position. If 8. If no further adjustment is needed, return the pilot
adjustment is required, proceed to the next step. valve relief cartridge to its original position, and
6. Delta P is adjusted on the bottom (smaller) screw proceed to Q-min.
of the pressure regulator shown in Figure 349 9. If pressure cannot be correctly set, there is a
below, if your unit has an A7VO boom pump, by problem, contact Schwing Service Department to
loosening the jam nut (10mm open end wrench), determine how to continue.
Delta-p
pressreg.eps
Regulator pressure
adjustment
T
smdeltap.eps
Figure 349
Location of the delta P adjustment screw for a unit with A7VO pump
(left) and A11VO pump (right)
Set Q-min
WARNING
Stop the engine before adjusting
the Q-min screw or Delta P on A11.
Driveline entanglement hazard!
Check Q-min with the engine at maximum specified 2. All boom functions must be in neutral, and all
RPM. Each time the Q-min screw must be adjusted, the emergency stop buttons should be up (not
engine must be stopped, or at least the transmission engaged). Clear away all personnel, start the truck
must be taken out of gear so that the drivelines stop engine, engage the pumps and bring engine RPM
turning. to maximum specification.
1. Before proceeding, remove the 0-100 bar whip 3. Read the pressure. If the pressure reads less than
gauge from the high pressure gauge port (Figure 100 bar, remove the high pressure gauge and
279) and install a 0-400 or 0-600 bar gauge to the reinstall the 0-100 bar gauge. Pressure should be at
same port, to make certain that the higher pressure 50-55 bar. If adjustment is needed, continue to
won’t destroy your 0-100 bar gauge. point 4.
4. Stop the engine and turn the Q-min screw (Figure
350) in (clockwise) to raise the pressure, or out
(counter-clockwise) to lower the pressure. Be sure
HOME PRINT
SERVICE TRAINING
Pressure Settings
time before making the adjustment. When pressure Note! If you don’t have a 0-100 bar gauge you can
is correct, tighten the jam nut on the adjustment order one from Schwing Spare Parts Department at
screw before continuing with the other procedures. (800) 328-9635, part #10004659.

Q-min
adjustment screw
hifloreg.eps
Q-min Q-max (Bottom Of Pump) Q max

Figure 350
Location of Q-min screw on A11VO (left) and A7VO (right)
Checking boom pressures 3. Read the gauge. It should be showing the lowest
After the Delta P and Q-min are set, remove the 0-100 relief pressure setting of the boom circuit (pressure
bar gauge and proceed to check and adjust, if regulator or cutoff) + or - 5 bar (See schematic). If
necessary, the main boom pressures. it does not, a minor adjustment can be made by
going to the pressure regulator (large screw) for
1. To check the boom pressure, install a 0-600 bar units with A7VO pumps or after stopping the
gauge in the boom circuit high pressure gauge port engine, the pressure cutoff screw for units with
(Called out but not visible in Figure 351). A11VO pumps, backing off the jam nut and
2. With the engine at full RPM and the boom folded, turning the adjustment screw to achieve the desired
activate boom #2, #3, or #4 to the in position, pressure. If the pressure can not be reached, return
which will pressure out the function. A function the screw to the original setting and proceed to
must be pressured out each time you want to check Setting boom circuit pressures.
the pressure.
Down side dynamic
gauge port
Main boom pressure

gauge port (Hidden)
Figure 351
Main boom circuit high pressure gauge port
(not visible on illustration)
lftblock.eps
HOME PRINT
Pressure Settings
Setting main boom circuit pressures 2. Since the gauge will always show you the lowest of
1. Review the hydraulic schematic and identify the the three settings, it is necessary to raise the two
three different pressure settings involved in this lowest pressures enough to allow us to see the
circuit. 1) Boom block main relief, 2) e-stop highest one, which will be the main relief at the
manifold relief, and boom block (Figure 352).
3) pressure regulator.
Down side dynamic
gauge port
Main boom pressure

gauge port (Hidden)
Figure 352
Main relief adjustment screw and gauge ports
lftblock.eps
3. Loosen the jam nut on the large screw of the

pressure regulator or the pressure cutoff screw
(Figure 353), depending which one your unit has,
and turn the adjustment screw clockwise, all the
way in.
pressreg.eps
Regulator pressure
adjustment
T
hifloreg.eps
Q-min Q-max (Bottom Of Pump)
Figure 353
Pressure regulator adjustment (A7VO left) and Pressure cutoff screw (A11VO right)
4. Loosen the jam nut on the boom circuit relief If the pressure reading is still lower than the maximum
cartridge located on the e-stop manifold (Figure shown on the schematic, loosen the jam nut on the
354) using a 9/16 wrench and turn the adjustment control block main relief (Figure 352) adjustment
screw using a 5/32 allen wrench in until you can screw and turn the adjusting screw in. This will raise
see the maximum pressure of the boom block main the pressure of the main relief valve until the desired
relief showing on the gauge while pressuring out a pressure is achieved. Tighten the jam nut to secure the
boom function. adjustment screw.
HOME PRINT
SERVICE TRAINING
Pressure Settings
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Figure 354
Boom circuit relief cartridge on e-stop @@

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5. Now return to the boom circuit relief cartridge Checking pretension pressure
(Figure 354) and turn the adjustment screw back This procedure is to check the pretension pressure only.
out (counter-clockwise) until the second highest The pressure you will be reading is from the factory
pressure on the boom circuit schematic is achieved, preset pressure reducing valve (Figure 355) which can
and tighten the jam nut to secure the adjustment not be adjusted.
screw.
1. Install a 0-60 bar whip gauge on the gauge port of
6. Finally, return to the pressure regulator or pressure the precontrol block (Figure 355) and bring the
cutoff (Figure 353) and turn the adjustment screw engine RPM to full throttle. The gauge should read
out until the lowest pressure on the schematic is 33-35 bar. If the pressure reading is different than
achieved, and lock the jam nut. that, contact the Schwing Service Department for
instructions on how to proceed.
adjustable relief
cartridge
P
L
lrgpilot.eps
preset pressure
reducing valve
gauge port
Figure 355
Showing the precontrol valve gauge port and adjustment points
HOME PRINT
Pressure Settings
Set the outrigger pressure use an extension cylinder because they have
To set the outrigger pressure. Find the relief cartridge secondary relief functions (non-adjustable) built
(Figure 356) located on the passenger side outrigger into the valve. While holding the push-button and
control valve. activating either handle number 4 or 5 Figure 312,
to retract position, read the pressure on the gauge.
1. Attach 0-600 bar whip gauge to gauge port shown
in Figure 312. 4. Check the schematic to see what the pressure
should read. Adjust by loosening the jam nut with a
2. Push the outrigger button. 9/16 open end wrench and turning the cartridge
3. Activate an outrigger jacking cylinder to retract. with a 5/32 allen wrench. When the desired
By attempting to retract a cylinder which is already pressure is reached, let go of the handle and the
retracted the oil coming from the pump has no push-button.
where to go but over the relief valve. You cannot 5. Remove the whip gauge when the job is complete.
PScntrl#.eps
1 2 3 4
EXTEND FOLD - REAR FOLD - FRONT FOOT
Relief cartridge PULL PULL PULL PULL
Relief cartridge
Gauge port
Gauge port
1 2 3 4 5 otrgrlf2.eps
Outrigger controls after mid 1999

Outrigger controls prior to mid 1999
1. Front extend
1. Front extend
2. Rear fold
2. Rear fold
3. Front fold
3. Front fold
4. Rear foot
4. Foot
5. Front foot
Figure 356
Passenger side outrigger valve bank for units built after mid 1999 (left) and prior
to mid 1999 (right)
HOME PRINT
SERVICE TRAINING
Pressure Settings
Set the agitator pressure 1. Plug the 0 - 600 bar whip gauge into the gauge port
The agitator circuit has a maximum pressure, shown on which is located on the front of the agitator hand
the schematic, which is limited by the relief cartridge valve (not shown in this illustration).
(Figure 357) in the agitator hand valve. The cartridge is
adjustable with a 19mm socket or wrench.
Relief cartridge
Figure 357
Location of the agitator
relief cartridge
agitrlf.eps
2. Locate the agitator shutoff valve (Figure 358) and • qty 1 GS-16S straight fitting, part number
close it. If your unit does not have a shutoff valve, 10008088
order one from the Schwing Spare Parts • qty 2 16S capnuts, part number 10001743.
Department using part number 10004680 (valve),
All of these fittings and many, many more extremely
and number 30303432 (tube). Contact the Service
useful items are included in the trouble shooting kit,
Department for installation instructions. If you
part number 30308553.
can’t wait for a shutoff valve, you will need to shut
off the engine and place the key in your pocket as 3. Be sure that one of the locking plugs and capnuts
you remove one of the hoses from the agitator are tightened on the straight fitting, and that the
motor and plug the hose and open fitting with dead plugs are securely tightened to the hose and
approved hydraulic dead plugs (Figure 358). the open motor fitting.
• qty 2 VS-16S locking plugs, part number 4. Be sure that all personnel are clear, and restart the
10016803 engine.
WARNING
Do not jam agitator paddles to force
oil over relief. Entanglement hazard!
HOME PRINT
Pressure Settings
agitoff.eps
Plugs Straight Fitting
capplug.eps
Agitator quarter turn Cap Nuts

shutoff valve (open position) Motor
Figure 358
Agitator shutoff valve and approved hydraulic dead plugs
5. Increase the engine RPM to full throttle and

activate the agitator hand valve in either forward or
reverse and read the gauge. If it does not read the
specified pressure, turn the body of the relief valve
using a 19mm socket or wrench. The cartridge
should be turned in (clockwise) to increase
pressure or out (counterclockwise) to decrease
pressure.
6. After the pressure is set, deactivate the agitator
system by placing the manual control handle in the
neutral position.
7. Remove the whip gauge.
Reopen the shutoff valve or stop the engine and remove
the key. Remove the dead plugs and store them in a
clean area. Re-attach the hose to the agitator motor
fitting and tighten securely. (Torque is correct if you
make one complete revolution after feeling initial
resistance increase).
HOME PRINT
SERVICE TRAINING
Pressure Settings
KVM 55M point of the handle as well as on the handle itself,
which will indicate the open or closed
configuration of the valve. If the handle is removed
from the agitator shutoff valve (Figure 359) or the
Changes in pressure can indicate trouble in one or concrete pump shutoff valve (Figure 360) and
more components and will serve as early warning replaced in a different configuration, the grooves in
indicators if you check them on a regular basis. The the handle may no longer indicate the proper open/
specifications for each circuit are shown on the closed orientation of the valve. The grooves in the
hydraulic schematics found in the Appendix section of shaft give the only true indication of the valves
this manual. The hydraulic schematics are the only position.
documents in this manual that have been updated NOTE:
specifically for your unit, by the serial number, so in If your unit is an early production model and does
each of the following procedures you will be told to not have an agitator shutoff valve, order one from
refer to the schematic for the pressure required. the Schwing Spare Parts Department, using part
number 10004680 (valve) and number 30303432
Preheat the hydraulic oil (tube). Contact the Service Department for
Pressure settings must be made with the oil at normal installation instructions.
operating temperatures (50° to 60° C). In the past we 2. Activate the agitator. With the valve closed, the
could pressure out a function in the boom or outrigger agitator will not be able to turn and the oil will be
system to create heat, but today, load sensing systems forced over the relief valve. At an idle (about 600
no longer allow maximum oil flow to be forced over RPM) you will be converting 4.5 horsepower to
relief. Because of this, the agitator circuit must be used heat.
to heat the hydraulic oil. 3. When the oil temperature gauge shows 50˚ C, open
To heat the oil to operating temperature: the shutoff valve.
1. Locate the agitator shutoff valve (Figure 359), and
close it. The quarter turn shutoff valve has a
grooved line (Figure 359) on the shaft or pivot

agitoff2.eps
Grooves in shaft grooves2.eps
Motor Open
Figure 359
HOME PRINT
Pressure Settings
Soft switch
shutoff valve
Main Pressure
Gauge port
Figure 360
Concrete pump and Soft switch shutoff
valves
Concrete pump
hif
shutoff valve low
br
n.
ep
s
Setting relief pressure and pressure cutoff 6. If you have not already closed the soft switch
on Hi-flo -6 pumpkits shutoff valve and the concrete pump shutoff valve
1. To set the pressure of the main relief valve on Hi- (Figure 360), do so at this time.
flo pumpkits, you must first disable the soft switch 7. At the rear panel, select “local” control with the
circuit. Simply locate the ball cock for the soft “local/remote” switch, and turn the electric stroke
switch circuit (Figure 360), and close it by rotating limiter knob clockwise to maximum strokes per
the handle 90 degrees. minute.
2. The quarter turn shutoff valve for the concrete 8. The main system control block pressure must be
pump (Figure 360) will also need to be closed set first to properly set the pressure cutoff on both
during this procedure. pumps. Begin by backing off the jam nut of the
main relief cartridge (Figure 361) with a 9/16 inch
Note: Main system adjustments are preset at the
wrench.
factory. The following procedure begins with
adjustment of the main relief cartridge and pressure 9. Using a 5/32 inch allen wrench, turn the
cutoff. If proper pressures cannot be obtained through adjustment screw out (counterclockwise) until you
these steps, contact the Schwing Service Department can feel no spring tension on the adjustment screw.
for specific instructions on the adjustment of flow, 10. Now, turn the screw back in (clockwise) two or
horsepower, beginning of stroke regulation, and Q-min. three full turns to give you a proper starting point,
Pressure setting procedure: and tighten the jam nut.
3. Be sure that the waterbox covers and guards are in 11. Stop the truck engine, put the key in your pocket,
place any time you will be working in the area and adjust the pressure cutoff screw (Figure 321)
around the main control block. on each pump, by backing off the jam nut with a
4. Wear safety glasses when working around a 13mm wrench. Using a 4mm allen wrench, turn the
concrete pump. Note! It is vital that each adjustment screw in (clockwise) one full turn, and
adjustment screw be properly identified prior to tighten the jam nut. Restart the truck engine.
making any adjustment. All screw adjustments for 12. Adjust the engine RPM to maximum specification.
the system relief must be made with the pumpkit in (See decal in truck cab)
the neutral position, and adjustments for pressure 13. Pressure out the system by activating the concrete
cutoff must be made with the engine shut off. pump forward switch on the rear panel. Using the
5. Start the truck engine, and put the PTO in gear just rear panel controls will allow you to read the
as you would to pump a job. concrete pump main system pressure gauge, near
HOME PRINT
SERVICE TRAINING
Pressure Settings
NOTE: 16. Activate the concrete pump forward to pressure out
Because you turned out the pressure relief cartridge in the pump and read the pressure on the two gauges
step 7, the system pressure should read low at this time. in the M1 ports.
If it does not and the gauge spikes to 320 bar or more, 17. Always stop the truck engine, and put the key in
disengage the pump immediately. Turn the relief your pocket before making any adjustment on the
cartridge out (counterclockwise) more. For safety, it is hydraulic pump. If the cutoff on one pump is set
important to adjust the pressure up from below the higher than the other, that pump will be more
specified target pressure rather than down from a dominant. The pressure gauge in the M1 port of the
pressure which exceeds the target. Continue this dominant pump will, however, read lower than the
procedure until the main system pressure gauge reads other. To equalize the two pumps, you must either
lower than the specified target. adjust the cutoff screw in (clockwise) to increase
14. To increase the pressure, put the pump in the the pressure of the pump showing the higher
neutral position and adjust the relief cartridge by reading, or adjust the cutoff screw of the dominant
turning it in (clockwise). When increasing the pump showing the lower reading out
pressure, the adjustments should be made in (counterclockwise) to reduce the pressure. These
quarter turn increments. If you make adjustments adjustments must be made until the two gauges in
to increase the pressure but the pressure does not the M1 ports are reading approximately the same.
come up, you are probably reading the pressure 18. When you have achieved the same pressure on the
cutoff of the pumps. If so, proceed to the next step; M1 port gauges, you can begin to adjust the
otherwise skip to step 15. pressure cutoff screws in or out simultaneously
• Turn the relief cartridge adjustment screw back out until you achieve the desired pressure setting of
(counterclockwise) until you can no longer see a 350 bar (again, confirm the pressure specification
pressure drop, and tighten the jam nut. with the hydraulic schematic).
• Stop the truck engine, and put the key in your After pressure cutoff is set, return the pump to neutral,
pocket. bring engine RPM to idle, open the soft switch quarter
• Go to the pressure cutoff screw on both hydraulic turn valve, and either proceed to other pressure settings
pumps, and back off the jam nut with a 13mm or take the transmission and PTO out of gear; then shut
wrench. Turn the adjustment screws in with a 4mm off the truck.
allen wrench one or two more turns, restart the
engine, and check the pressure again. Repeat this
procedure until the main system relief can be set to
the target pressure.
the key in your pocket, and install 0-600 bar
gauges with whip hoses to the M1 gauge ports on
the bottom of the two hydraulic pumps (Figure
321). You must be able to read both gauges
NOTE:
The gauges in the M1 ports will read considerably less
than the cutoff pressure of the pump. On a -6 (190/130
pump combination) the 190 will usually read 85 to 90
bar while the 130 reads about 110 bar. They could read
the same at approximately 110 bar, but the 190 must
never read higher than the 130. The actual cutoff
pressure will be read on the concrete pump main
system pressure gauge near the e-stop manifold.
HOME PRINT
Pressure Settings

relief cartridges Closed Open
Concrete pump
soft switch
gauge port
relief cartridge
openclsd.eps
9/16" jam nut
5/32" Allen head

ga
ug
pr
t.e
ps
9/16" jam nut
Figure 361
130-6.eps

2
2
3
1 1
3
4 4
M1 GAUGE PORT
(BOTTOM OF EACH PUMP)
Figure 362
A11VO adjustment screws for Hi-flo – 6 units 190/130
NOTE: The main control block (brain) of a 2525 Setting the soft switch circuit relief
pumpkit will be rotated 180 degrees from the pressure
illustration shown in Figure 361. 1. If you haven’t already done so, open the soft
switch quarter turn valve (Figure 361). The rest of
the unit should still be set up as though you were
going to check the main relief valve pressure
(concrete pump shutoff valve still closed).
HOME PRINT
SERVICE TRAINING
Pressure Settings
2. When you put the pump in forward now, the from that point. The pressure was fine tuned at the
pressure gauge should read the pressure shown on factory and should not be adjusted unless absolutely
the schematic for soft switch. If adjustment is necessary.
needed, loosen the jam nut of the soft switch relief
cartridge (Figure 321) with a 9/16 inch open end rtblock2.eps
wrench, and use a 5/32 inch allen wrench to adjust

the pressure. Turn the adjustment screw in
(clockwise) to raise the pressure or out (counter
clockwise) to lower the pressure. When you attain
the required pressure, tighten the jam nut while
holding the allen wrench to keep the pressure from
rising. Be sure to open the concrete pump quarter
turn valve on the side of the brain (Figure 359)
when you are finished. The unit will not stroke
with this valve closed.
Setting boom circuit pressures High pressure

NOTE! Any time you set pressures for any circuit on gauge port
any unit, the hydraulic oil should be at normal
operating temperature (50 to 60° C). Instructions on
heating the hydraulic oil for this procedure are found
on page 495.
Please read all of the instructions before beginning any
the following procedure. You and any assistants should Figure 363
wear eye protection when setting pressures. The high pressure gauge
Current production model 55 meter pumps are port is located between the
equipped with a load sensing, proportional boom blocks on the inside edge of
hydraulic system. If the system were black and white, the right boom control
the hydraulic pump would put out an unchanging block.
amount of oil, and speed control would be done by
restricting the oil to certain functions with orifices. CAUTION! When checking delta P, it is important to
With a load sensing system, the pumps put out more or note that you will be installing a low pressure gauge
less oil to respond to the needs of the system. into a high pressure port. Any activation of a boom
Generally, the pump always puts out enough oil to function or activation of an e-stop while this gauge is
maintain 20 bar higher pressure at the pump than the attached will destroy your gauge. On Comfort Control
boom cylinders actually require. This 20 bar is called units, always center the boom speed switch on the
delta P. You may see it referred to by a symbol (∆ P). remote box to prevent accidental activation of a joy
Additionally, we set the hydraulic pump so that it stick.
always puts out a small amount of oil, even if none is
needed for the system. This oil is used to ensure that
you have control when you need it. The setting to WARNING
maintain this minimum amount of oil is called Q-min
(pronounced “cue min”). To set the boom or outrigger Entanglement hazard. Stop drive shafts
hydraulic pressures on a load sensing system, begin by before adjusting Delta P on A11VO pump.
W020.eps
checking ∆ P and Q-min.

1. Install a 0-100 bar whip gauge in the high pressure
Checking and setting ∆P pressure test port (Figure 363), located on the inside of the
NOTE: Do not adjust delta P or Q-min if your boom is right boom control block as you face the three
running as you like it. The pressure setting procedure valve blocks.
HOME PRINT
Pressure Settings
2. With the engine at idle, turn the adjustable relief 4. Increase the throttle RPM, and the pressure should
cartridge (Figure 364) on the boom pilot control remain the same. If the pressure fluctuates with
valve out (counter clockwise) approximately three engine RPM, you are probably still reading Q-min,
turns. Remember exactly how much you move this and the adjustable relief cartridge (Figure 365) will
cartridge, because it will need to be returned to the need to be turned out more.
original position. 5. If no further adjustment is needed, return the pilot
valve relief cartridge to its original position. If
adjustable relief adjustment is required, proceed to the next step.
cartridge 6. Delta P is adjusted on the bottom (smaller) screw
of the pressure regulator shown in Figure 365
L
P below, if your unit has an A7VO boom pump you
can do so by loosening the jam nut (10mm open
end wrench) and adjusting the screw (3mm allen
52pilot.eps wrench) clockwise to increase pressure or counter
preset pressure clockwise to decrease it.
reducing valve
7. The delta P adjustment screw on the A11VO boom
pump, also shown in Figure 307 below, requires a
gauge port 13mm open end wrench and a 4mm allen wrench.
8. If no further adjustment is needed, return the pilot
Figure 364 valve relief cartridge to its original position, and
Location of adjustable relief cartridge proceed to Q-min.
on the boom pilot control valve 9. If pressure cannot be correctly set, there is a
problem; contact Schwing Service Department to
3. With the engine running and the relief cartridge determine how to continue.
backed out, the gauge (Figure 365) should be
showing delta P. The pressure could be anywhere
from 16-25 bar.
Delta-p
pressreg.eps
Regulator pressure
adjustment
T
smdeltap.eps
Figure 365
Location of the delta P adjustment screw for a unit with A7VO pump
(left) and A11VO pump (right)
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting Q-min

Q-min
adjustment screw
hifloreg.eps
Q-min Q-max (Bottom Of Pump) Q max

Figure 366
Location of Q-min screw on A11VO (left) and A7VO (right)
Check Q-min with the engine at maximum specified NOTE: If you don’t have a 0-100 bar gauge, you can
RPM. Each time the Q-min screw must be adjusted, the order one from Schwing Spare Parts Department at
engine must be stopped, or at least the transmission (800) 328-9635, part #10004659.
turning. Checking boom pressures
After the delta P and Q-min are set, remove the 0-100
WARNING bar gauge, and proceed to check and adjust the main
boom pressures, if necessary.
Entanglement hazard. Stop drive shafts 1. To check the boom pressure, install a 0-600 bar
W009.eps
gauge in the boom circuit high pressure gauge port

(called out but not visible in Figure 367).
1. Before proceeding, remove the 0-100 bar whip 2. With the engine at full RPM and the boom folded,
gauge from the high pressure gauge port (Figure activate boom #2, #3, or #4 to the in position,
364), and install a 0-400 or 0-600 bar gauge to the which will pressure out the function. A function
same port to make certain that the higher pressure must be pressured out each time you want to check
won’t destroy your 0-100 bar gauge. the pressure.
2. All boom functions must be in neutral, and all Read the gauge. It should be showing the lowest relief
emergency stop buttons should be up (not pressure setting of the boom circuit (pressure regulator
engaged). Clear away all personnel, start the truck or cutoff) + or - 5 bar (see schematic). If it does not, a
engine, engage the pumps, and bring engine RPM minor adjustment can be made by going to the pressure
to maximum specification. regulator (large screw) for units with A7VO pumps
3. Read the pressure. If the pressure reads less than (Figure 368), backing off the jam nut and turning the
100 bar, remove the high pressure gauge and adjustment screw to achieve the desired pressure. For
reinstall the 0-100 bar gauge. Pressure should be at units with A11VO pumps, after stopping the engine,
50-55 bar. If adjustment is needed, continue to back off the jam nut on the pressure cutoff screw
point 4. (Figure 368) and make the adjustment. If the pressure
4. Stop the engine, and turn the Q-min screw (Figure cannot be reached, return the screw to the original
365) in (clockwise) to raise the pressure or out setting, and proceed to Setting boom circuit pressures.
(counter-clockwise) to lower the pressure. Be sure
screw before continuing with the other procedures.
HOME PRINT
Pressure Settings
Down side dynamic

gauge port
Main boom pressure

gauge port (Hidden)
Figure 367
Main relief adjustment screw and
gauge ports. (High pressure gauge
port not visible on illustration) lftblock.eps
Setting main boom circuit pressures 3. Loosen the jam nut on the large screw of the
1. Review the hydraulic schematic, and identify the pressure regulator or the pressure cutoff screw
three different pressure settings involved in this (Figure 368), depending which one your unit has,
circuit. 1) boom block main relief, 2) e-stop and turn the adjustment screw clockwise, all the
manifold relief, and 3) pressure regulator. way in.
2. Since the gauge will always show you the lowest of
the three settings, it is necessary to raise the two WARNING
lowest pressures enough to allow us to see the
highest one, which will be the main relief at the Entanglement hazard. Stop drive shafts
boom block (Figure 367). before adjusting Pressure cut-off on
W021.eps
A11VO pump.

pressreg.eps
Regulator pressure
adjustment
T
hifloreg.eps
Figure 368
Pressure regulator adjustment (A7VO left) and Pressure cutoff screw (A11VO right)
HOME PRINT
SERVICE TRAINING
Pressure Settings
Boom circuit
relief cartridge
s
ep
trl.
crc
bm
Figure 369
Boom circuit relief cartridge
on e-stop manifold
4. Loosen the jam nut on the boom circuit relief 7. Finally, return to the pressure regulator or pressure
cartridge located on the e-stop manifold (Figure cutoff (Figure 368), and turn the adjustment screw
369) using a 9/16 wrench, and turn the adjustment out until the lowest pressure on the schematic is
screw in using a 5/32 allen wrench until you can achieved. Lock the jam nut.
see the maximum pressure of the boom block main
relief showing on the gauge while pressuring out a Checking pretension pressure
boom function. This procedure is to check the pretension pressure only.
5. If the pressure reading is still lower than the The pressure you will be reading is from the factory
maximum shown on the schematic, loosen the jam preset pressure reducing valve (Figure 370), which can
nut on the control block main relief adjustment not be adjusted.
screw, (Figure 352) and turn the adjusting screw in. 1. Install a 0-60 bar whip gauge on the gauge port of
This will raise the pressure of the main relief valve the precontrol block (Figure 370), and bring the
until the desired pressure is achieved. Tighten the engine RPM to full throttle.
jam nut to secure the adjustment screw.
The gauge should read 33-35 bar. If the pressure
6. Now return to the boom circuit relief cartridge reading is different than that, contact the Schwing
(Figure 369), and turn the adjustment screw back Service Department for instructions on how to proceed.
out (counter-clockwise) until the second highest
pressure on the boom circuit schematic is achieved.
Tighten the jam nut to secure the adjustment screw.
adjustable relief
cartridge
P
L
lrgpilot.eps
preset pressure
reducing valve
Figure 370
The precontrol valve gauge gauge port
port and adjustment points
HOME PRINT
Pressure Settings
Setting the outrigger pressure use an extension cylinder because they have
To set the outrigger pressure, find the relief cartridge secondary relief functions (non-adjustable) built
(Figure 371) located on the passenger side outrigger into the valve. While holding the push-button and
control valve. activating handle number 4 (Figure 371) to retract
position, read the pressure on the gauge.
1. Attach a 0-600 bar whip gauge to the gauge port
shown in Figure 371. 4. Check the schematic to see what the pressure
should read. Adjust by loosening the jam nut with a
2. Push the outrigger button. 9/16 open end wrench and turning the cartridge
3. Activate an outrigger jacking cylinder to retract. with a 5/32 allen wrench. When the desired
By attempting to retract a cylinder which is already pressure is reached, let go of the handle and the
retracted, the oil coming from the pump has no push-button.
where to go but over the relief valve. You cannot 5. Remove the whip gauge when the job is complete.
PScntrl#.eps
Outrigger controls on units

built in U.S. prior to 2000 EXTEND FOLD - REAR FOLD - FRONT FOOT
PULL PULL PULL PULL
1. Front extend
Relief cartridge
2. Rear fold
3. Front fold
4. Foot (jacking) 1 2 3 4
Gauge port
Figure 371
Passenger side outrigger valve bank
HOME PRINT
SERVICE TRAINING
Pressure Settings
Agitator Relief Valve Turn body of valve

Gauge port to adjust.
Higher
Lower
Figure 372 2.e

ps
itrlf
Location of the agitator relief ag
cartridge and gauge port
Set the agitator pressure you remove one of the hoses from the agitator
The agitator circuit has a maximum pressure, shown on motor and plug the hose and open fitting with
the schematic, which is limited by the relief cartridge approved hydraulic dead plugs (Figure 373).
(Figure 372) in the agitator hand valve. The cartridge is • Qty 2 VS-16S locking plugs, part number
adjustable with a 19mm socket or wrench. 10016803
1. Plug the 0 - 600 bar whip gauge into the gauge • Qty 1 GS-16S straight fitting, part number
port, which is located on the top of the agitator 10008088
hand valve. • Qty 2 16S capnuts, part number 10001743
2. Locate the agitator shutoff valve (Figure 372), and 3. All of these fittings and many, many more
close it. If your unit does not have a shutoff valve, extremely useful items are included in the trouble
order one from the Schwing Spare Parts shooting kit, part number 30308553.
Department using part number 10004680 (valve) 4. Be sure that one of the locking plugs and capnuts
and number 30303432 (tube). Contact the Service are tightened on the straight fitting, and that the
Department for installation instructions. If you dead plugs are securely tightened to the hose and
can’t wait for a shutoff valve, you will need to shut the open motor fitting.
off the engine and place the key in your pocket as 5. Be sure that all personnel are clear, and restart the
engine.
agitoff2.eps
Agitator quarter turn Plugs Straight Fitting
capplug.eps
Motor Cap Nuts
Figure 373
Agitator shutoff valve and approved hydraulic dead plugs
HOME PRINT
Pressure Settings
6. Increase the engine RPM to full throttle, activate
the agitator hand valve in either forward or reverse,
and read the gauge. If it does not read the specified
pressure, turn the body of the relief valve using a
19mm socket or wrench. The cartridge should be 45Accreg.eps
turned in (clockwise) to increase pressure or out

(counterclockwise) to decrease pressure.
7. After the pressure is set, deactivate the agitator
system by placing the manual control handle in the
neutral position.
Accumulator pump
8. Remove the whip gauge. pressure regulator
9. Reopen the shutoff valve or stop the engine and
remove the key. Remove the dead plugs and store
Figure 374
them in a clean area. Re-attach the hose to the
agitator motor fitting and tighten securely. (Torque
for A7VO (above) and for A11VO (below)
is correct if you make one complete revolution
after feeling initial resistance increase). Boom Pump
Accumulator Pump
Set accumulator circuit pressure
There are three relief settings for the accumulator
circuit if your unit is equipped with an accumulator
redundant relief cartridge in the emergency stop
manifold (Figure 375). If your pump was built after
Standby
January 1, 2000. It will have an emergency stop
Pressure Screw
manifold which no longer has a redundant relief
cartridge. In that case, you must skip steps 3 and 7 in Accumulator Pump
the following procedure. Pressure Regulator accumpmp.eps
hgacugc.psd

accumulator circuit:
place a “Do Not Operate” sign on the windshield. accurlf2.eps

Accumulator redunant
accumulator redundant relief cartridge located on relief cartridge
300 bar.
Figure 375
Accumulator redundant relief
cartridge
HOME PRINT
SERVICE TRAINING
Pressure Settings
the truck engine, engage the pumps, and bring the acumrlf.epsL

5. Read the pressure on the accumulator circuit
pressure gauge (Figure 376). The pressure should
read the value shown on the hydraulic schematic. If
no adjustment is needed, skip to step number 7. If
with step number 6.

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QQQQQQQQ

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@@@@@@@@

QQQQQQQQ

Figure 376
Accumulator circuit pressure gauge Figure 377
6. Locate the accumulator manifold pressure relief relief cartridge
turn the screw clockwise to increase the pressure or 8. After the truck engine is stopped, go back to the
counter clockwise to decrease the pressure. accumulator circuit hydraulic pump pressure
Tighten the jam nut when the pressure reaches the regulator (Figure 374), and turn the screw back out
value required. two-and-one-half turns. This restores it to its
7. You will need an assistant for this step. With the original setting.
engine still running, one person must go to the 9. Clear all personnel from the drive line area, start
redundant relief valve on the emergency stop the truck, and bring the engine RPM up to
manifold (Figure 375) and back out the adjustment maximum.
screw while the other person stands by the pressure 10. Read the pressure on the accumulator gauge. It
gauge to let him know when the pressure reads the should read the proper accumulator system
value shown on the schematic for accumulator pressure.
redundant relief. 11. If adjustment is needed, you must stop the truck
WARNING circuit hydraulic pump. Turn the screw in to
Entanglement hazard. Stop drive shafts Lock the jam nut when the pressure is correct.
pressure regulator. NOTE: The accumulator circuit hydraulic pump
W010.eps
pressure regulator is referred to as the pressure cut-off.

HOME PRINT
Pressure Settings
HOME PRINT
SERVICE TRAINING
Pressure Settings
S 58/61SX RPM), 4.5 horsepower is being converted to heat.
3. When the oil temperature gauge shows 50˚C, open
the shutoff valve.
checking and setting hydraulic pressures of each Agitator quarter turn
000174.eps
system included on your unit. shutoff valve (open position)
Check all hydraulic pressures Figure 378

Agitator shutoff
Changes in pressures can indicate trouble in one or valve
more components. The specifications for each circuit Motor

the only documents in this manual that have been Setting pressures on Hi-flo -6 pumpkits
updated specifically for your unit by the serial number, • To set the pressure of the main relief valve on
so in each of the following procedures you will be told Hi-flo pumpkits, you must first disable the soft
to refer to the schematic for the pressure required. switch circuit. Simply locate the ball cock
If you wish to order a CD ROM which explains the shutoff for the soft switch circuit (Figure 320),
pressure setting procedure for a specific model (All and close it by rotating the handle 90 degrees.
pumpkits), call SAI Spare Parts Department at (800) • The quarter turn shutoff valve for the concrete
328 - 9635 and request the CD using the following part pump (Figure 320) will also need to be closed
numbers: during this procedure.
• 61/58 meter. . . . . . . . . . . . . . . . . . . . . . . 30365860 NOTE!
• 52 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30354732 Main system adjustments are preset at the
• 45/47 meter. . . . . . . . . . . . . . . . . . . . . . . 30356770 factory. The following procedure begins
with adjustment of the main relief cartridge
• 42 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30355485 and pressure cutoff. If proper pressures can
• 39 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30365861 not be obtained through these steps, contact
• 34 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30356772 the Schwing Service Department for specific
instructions on the adjustment of flow,
• 32 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30355486 horsepower, beginning of stroke regulation
• 31 meter . . . . . . . . . . . . . . . . . . . . . . . . . 30365862 and Q-min.
Preheat the hydraulic oil Pressure setting procedure:

operating temperatures (40°− 60° C). In the past we Soft switch
shutoff valve
Main Pressure
longer allow maximum oil flow to be forced over relief. Gauge port
the hydraulic oil.
close it. Concrete pump
NOTE! shutoff valve 00
02
74
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ps

order one from the Schwing Spare Parts Figure 379
Department using part number 10004680 Concrete pump and Soft switch shutoff
(valve) and number 30303432 (tube). Con-
tact the Service Department for installation 1. Be sure that the waterbox covers and guards are in
instructions. place any time you will be working in the area
2. Activate the agitator. With the valve closed, the around the main control block.
agitator will not be able to turn and the oil will be 2. Wear safety glasses when working around a
forced over the relief valve. At an idle (about 600 concrete pump.
HOME PRINT
Pressure Settings
NOTE! pressure which exceeds the target. Continue
It is vital that each adjustment screw be this procedure until the main system pres-
properly identified prior to making any sure gauge reads lower than the specified
adjustment. All screw adjustments for the target.
system relief must be made with the pump- 12. To increase the pressure put the pump in the
kit in the neutral position, and adjustments neutral position, and adjust the relief cartridge by
for pressure cutoff must be made with the turning it in (clockwise). When increasing the
engine shut off. pressure, the adjustments should be made in
3. Start the truck engine, and put the PTO in gear just quarter turn increments. If you make adjustments
as you would to pump a job. to increase the pressure but the pressure does not
4. If you have not already closed the soft switch come up, you are probably reading the pressure
shutoff valve and the concrete pump shutoff valve cutoff of the pumps. If so, proceed to the next step;
(Figure 320), do so at this time. otherwise skip to step 15. Turn the relief cartridge
5. At the Vector controller, select “local” control with adjustment screw back out (counterclockwise)
the “local/remote” switch, and activate the electric until you can no longer see a pressure drop, and
stroke limiter switch to maximum strokes per tighten the jam nut.
minute. 13. Stop the truck engine and put the key in your
6. The main system control block pressure must be pocket.
set first to properly set the pressure cutoff on both 14. Go to the pressure cutoff screw on both hydraulic
pumps. Begin by backing off the jam nut of the pumps (Figure 321), and back off the jam nut with
main relief cartridge (Figure 322) with a 9/16 inch a 13mm wrench. Turn the adjustment screws in
wrench. with a 4mm allen key one or two more turns,
7. Using a 5/32 inch allen key, turn the adjustment restart the engine, and check the pressure again.
screw out (counterclockwise) until you can feel no Repeat this procedure until the main system relief
spring tension on the adjustment screw. can be set to the target pressure.
8. Now, turn the screw back in (clockwise) two or 15. When the proper main relief pressure is achieved,
three full turns to give you a proper starting point, pressure cutoff can be set. Shut off the engine, put
and tighten the jam nut. the key in your pocket, and install 0-600 bar
9. Stop the truck engine, and put the key in your gauges with whip hoses to the “M1” gauge ports
pocket. Adjust the pressure cutoff screw (Figure on the bottom of the two hydraulic pumps (Figure
321) on each pump by backing off the jam nut with 321). You must be able to read both gauges
a 13mm wrench. Using a 4mm allen key, turn the simultaneously to ensure that one pump is not
adjustment screw in (clockwise) one full turn, and more dominant than the other.
tighten the jam nut. Restart the truck engine. NOTE!
10. Adjust the engine RPM to maximum specification. The gauges in the M1 ports will read consid-
(See decal in truck cab) erably less than the cutoff pressure of the
pump. On a -6 (190/130 pump combina-
11. Pressure out the system by activating the concrete tion), the 190 will usually read 85 to 90 bar,
pump forward switch on the rear panel. Using the while the 130 reads about 110 bar. They
rear panel controls will allow you to read the could read the same, however, at approxi-
concrete pump main system pressure gauge, near mately 110 bar, but the 190 must never read
the e-stop manifold, from a safe distance. higher than the 130. The actual cutoff pres-
sure will be read on the concrete pump main
NOTE! system pressure gauge near the e-stop mani-
Because you turned out the pressure relief fold.
cartridge in step 7, the system pressure 16. Activate concrete pump forward to pressure out the
should read low at this time. If it does not, pump, and read the pressure on the two gauges in
and the gauge spikes to 320 bar or more, the “M1” ports.
disengage the pump immediately. Turn the
relief cartridge out (counterclockwise) 17. Always stop the truck engine and put the key in
more. For safety, it is important to adjust your pocket before making any adjustment on the
the pressure up from below the specified hydraulic pump. If the cutoff on one pump is set
target pressure rather than down from a higher than the other, that pump will be more
HOME PRINT
SERVICE TRAINING
Pressure Settings
dominant. The pressure gauge in the M1 port of the pressure cutoff screws in or out simultaneously
dominant pump will, however, read lower than the until you achieve the desired pressure setting of
other. To equalize the two pumps, you must either 350 bar (again, confirm the pressure specification
adjust the cutoff screw in (clockwise) to increase with the hydraulic schematic).
the pressure of the pump showing the higher After pressure cutoff is set, return the pump to neutral,
reading or adjust the cutoff screw of the dominant bring engine RPM to idle, open the soft switch quarter
pump showing the lower reading out turn valve, and either proceed to other pressure settings
(counterclockwise) to reduce the pressure. These or take the transmission and PTO out of gear and shut
adjustments must be made until the two gauges in off the truck.
000277.eps

2
2
3
1 1
3
4 4
Figure 380
A11VO adjustment screws M1 GAUGE PORT
for Hi-flo – 6 units 190/130 (BOTTOM OF EACH PUMP)
HOME PRINT
Pressure Settings
Soft switch
shutoff valve Closed Open
soft switch
Main Pressure
relief cartridge
Gauge port Main relief cartridge
000276.eps
9/16" jam nut
Concrete pump 5/32" Allen head

shutoff valve 00
02
74
.e
ps
9/16" jam nut
Figure 381
322, right) that you closed in the previous procedure. boom hydraulic system. In a black-and-white system,
is needed, loosen soft switch relief valve jam nut pump than the cylinders actually require. This 20 bar is
use a 5/32 allen key to adjust the pressure. Turn the pump so that it always puts out a small amount of oil,
out (counterclockwise) to lower the pressure. When to ensure that you have control when you need it. The
while holding the allen key to keep the pressure from called Q-min (pronounced “cue min”). To set the boom
rising. Be sure to open the concrete pump shutoff valve or outrigger hydraulic pressures on a load-sensing
on the side of the brain (Figure 322, left) when you are system, begin by setting ∆P and Q-min.
finished. The unit will not stroke with this valve closed. Note: The illustration in Figure 322 shows a gauge port
in the center of the main control block. Your main
Setting boom circuit pressures concrete pump pressure gauge should be plumbed to
Read all of the instructions before beginning any that port.
protection when setting pressures.
NOTE! WARNING
Any time you set pressures for any circuit
on any unit, the hydraulic oil should be at Entanglement hazard. Stop drive shafts
normal operating temperature (40°–60° C).
before adjusting Delta P on A11VO pump.
000004.eps
Instructions on heating the hydraulic oil are

found in the first step of this “checking
hydraulic pressures” segment.
HOME PRINT
SERVICE TRAINING
Pressure Settings
gauge ports
for Delta P
Figure 382
Gauge ports for setting Delta P
delta/p.eps
Setting Delta P pressure

NOTE! Delta-p
Do not adjust Delta P or Q-min if your
boom is running as you like it. The pressure
setting procedure uses a standard starting
point and must be fine tuned from that
point. The pressure was fine tuned at the
factory and should not be adjusted unless
absolutely necessary.
1. Start by turning off the engine and putting the key
in your pocket; then place a “Do Not Operate” sign
000281.eps
on the windshield of the truck.
2. Install a 0-400 bar gauge in the high pressure test Figure 383
port at the bottom of the boom control block Pressure regulator for A11VO pumps
(Figure 279).
3. Install a second 0-400 bar gauge (Figure 279) in 7. When the proper Delta P is achieved, use the
the port marked “LS” (load-sensing). following spaces to document the pressure.
4. Delta P is adjusted on the pressure regulator NOTE!
(Figure 307) if your unit has an A11VO boom Remember that the documented Delta P
pump. When all personnel are clear of the truck, pressure applies only to the unit with the
restart the engine, engage the pumps, and increase serial number shown in the front of this
the engine speed to max RPM. book.
5. Activate any boom cylinder to maximum speed
and read both gauges as the boom section moves. Date__________________ ∆P__________bar
The difference between the two pressures should Date__________________ ∆P__________bar
be 20 bar + or - 5.
Date__________________ ∆P__________bar
6. If adjustment is required, loosen the jam nut, and
Date__________________ ∆P__________bar
adjust the screw inward to increase pressure or
outward to decrease pressure until the boom runs Date__________________ ∆P__________bar
smoothly.
HOME PRINT
Pressure Settings
If pressure cannot be set correctly, there is a problem NOTE!
with the regulator itself. Contact the Schwing Service If you don’t have a 0-100 bar gauge, you can
Department to determine how to continue. order one from Schwing Spare Parts
Department at (800) 328-9635, part #
If the boom does not run smoothly at 20 bar, you must 10004659.
fine tune the adjustment. Remove the gauge, and turn
the ∆P adjustment screw until the boom is responsive
and smooth. After adjusting, the difference between the
gauges (reinstalled) must read between 14-25 bar. The
electronics in the control system can also affect how
the boom operates, so if ∆P adjustment does not seem
Boom pressure
relief cartridge
When the electrical settings are verified, you could
again try to refine the boom action with the ∆P
adjustment.
ps
lf.e
ssr
pre
WARNING
0-600 bar
Wear safety glasses any time you check gauge port
or set pressures. Oil expulsion hazard!
000438.eps
Figure 384
0-600 bar gauge port
Setting Q-min
Check Q-min when the engine is at maximum specified
RPM. You must not adjust Q-min with the drive
shafts turning! Each time the Q-min screw must be
drivelines stop turning. Delta-p Pressure Cut-off
1. All boom functions must be in neutral, and all
emergency stop buttons should be up (not
engaged). Clear away all personnel, start the truck
engine, engage the pumps, and bring engine RPM
gauge. Pressure should be at 40–45 bar. If no
adjustment is needed, be sure the jam nut on the
Q-min screw is tight, then continue to set the rest
of the boom and outrigger pressures. If adjustment
000282.eps
is needed, continue to the next step.
that you stop the drive shafts from turning each Figure 385
time before making the adjustment. When pressure Location of Q-min screw
screw before continuing with the other procedures;
then, recheck ∆P to make sure that it hasn’t
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting boom pressures
Now that ∆P and Q-min are set, you can remove the 0-
100 bar pressure gauge and proceed to check and
adjust the main boom pressures.
Setting main pressure

1. The main pressure is the highest pressure of the
three boom system settings. The only way you will
be able to see the main pressure on the gauge is to
turn the pressure of the two lower systems up to a
level which is higher than that of the main pressure
relief valve.
2. Loosen the jam nut of the boom pressure relief
cartridge (Figure 386) with a 30mm open end Disconnect hose
hose1.eps
wrench, turn the adjustment cartridge in all the
way with a 32mm wrench, and lock the jam nut Figure 387
back down. Hose for boom section number two
Plugs Straight Fitting
Boom pressure
relief cartridge
Figure 388 000257.eps
Approved dead
plugs
ssr
lf.e
ps Cap Nuts
pre
0-600 bar 6. Install a 0 - 600 bar gauge in the main pressure

gauge port gauge port (Figure 389).
7. Increase the engine speed to maximum RPM, and
activate the manual control handle for boom
Figure 386 number two in the direction that will pressurize the
Boom pressure relief cartridge disconnected and plugged hose.
on the e-stop manifold
8. Now adjust the pressure to the setting found on the
schematic by turning the main boom pressure relief
3. Loosen the jam nut on the pressure cut-off screw cartridge on the boom control block (Figure 389)
(Figure 391), tighten the screw all the way down, with a 4mm allen key. Read the pressure on the 0-
and tighten the jam nut back down. 600 bar gauge installed in step 6. When desired
4. Identify the main boom pressure relief cartridge on pressure is achieved, lock down the jam nut with a
the control block (Figure 389), loosen the jam nut 12mm wrench.
with a 12mm wrench, then unscrew the adjustment
Setting boom pressure (redundant) relief
two full turns with a 4mm allen key.
9. Return to the e-stop manifold boom pressure relief
5. Setting the main pressure will require cartridge (Figure 386), and back off the jam nut
disconnecting a hose for boom section number two (30mm). Turn the cartridge (32mm) out, or counter
(Figure 387) and installing an approved dead plug clockwise, until the pressure gauge reads the
on each of the open fittings. number shown on the schematic for the boom
pressure relief cartridge. Lock down the jam nut.
HOME PRINT
Pressure Settings
Setting pressure cut-off
10. Return to the pressure cut-off screw (Figure 391). Delta-p Pressure Cut-off
Back off the jam nut, and turn the screw counter
clockwise until you achieve the pressure shown on
the schematic, then lock the jam nut.
Setting slewing pressure

11. The slewing function has two relief valves which
must be set individually. Since there is no way to
block the slewing function, it is also necessary to
disconnect the supply hoses which go to the
slewing motor one at a time and install an approved 000282.eps
dead plug to the open fitting. Q-min Q-max (Bottom Of Pump)

12. Install a 0 - 600 bar gauge in line on the open hose.
Figure 391
Pressure cut-off screw
14. The final boom pressure setting is the #1 boom
Gauge Main piston side relief setting. The relief cartridge is
port relief shown in Figure 328. This procedure should be
performed with the outriggers extended and the
boom unfolded over the cab. Extend section #1 all
the way until the cylinder bottoms out. Install a 0-
600 bar gauge in the gauge port shown in Figure
389. Activate boom #1 extend. The pressure should
read 230 bar. If adjustment is required, back off the
jam nut with a 12mm wrench, and turn the relief
cartridge (Figure 328) in or out using a 4mm allen
key as required until the desired pressure is
mainrlf.eps
achieved; then, lock down the jam nut.
Figure 389
Main boom control block
13. Activate the slewing handle in a direction which
will pressurize the disconnected hose and read the
gauge. If the pressure is not what the schematic
calls for, adjust the appropriate relief valve located
directly under the valve (Figure 390).
dwnsdrlf.eps
Figure 392
Piston side relief
NOTE!
Figure 390 HWslew.eps
If you are unable to achieve 230 bar by
Boom slewing adjusting the relief valve in Figure 328, call
Boom Slewing the Schwing Service Department and ask if
relief valves relief valves
the unit has a redundant relief valve.
HOME PRINT
SERVICE TRAINING
Pressure Settings
Setting outrigger pressure Setting the agitator pressure
WARNING the hydraulic schematic, which is limited by the relief
Tipping hazard. Never set outrigger relief cartridge is located on the back side of the
pressures with the boom unfolded. agitator manual control handle (Figure 314). The
Pressure setting procedure requires cartridge is adjustable with just a 19mm open end
retraction of an outrigger jacking wrench.
000359.eps
cylinder. 1. Plug the 0–600 bar whip gauge into the gauge port
(Figure 314) for checking or setting agitator pres-
After the boom circuit is properly set, you can set the sure.
outrigger pressure. Find the relief cartridge 2. Locate the agitator shutoff valve (Figure 331), and
located on the front of the passenger side outrigger close it. If your unit does not have a shutoff valve,
control valve (Figure 312). order one from the Schwing Spare Parts Depart-
1. Attach 0-600 bar whip gauge to the gauge port ment using part numbers 10004680 (valve) and
below the outrigger valve bank. 30303432 (tube). Contact the Service Department
2. Push the outrigger enable button. for installation instructions. If you can’t wait for a
shutoff valve, you will need to remove one of the
3. Activate an outrigger jacking cylinder to retract.
hoses from the agitator motor and plug the hose
By retracting a fully retracted cylinder, the oil
and open fitting with approved hydraulic dead
coming from the pump has nowhere to go but over
plugs (Figure 332).
slewing cylinder because they have secondary NOTE!
relief functions (nonadjustable) built into the valve. Do not jam the paddles to force the oil over
While holding the handle to retract, read the relief by stopping the movement of the
pressure gauge. agitator.
4. The pressure should read the bar value shown on 3. Increase the throttle to any speed above idle. Acti-
the hydraulic schematic. Adjust by loosening the vate the agitator valve handle in either forward or
jam nut and turning the cartridge (Figure 312) in or reverse, and read the gauge. If it does not read the
out. When the proper pressure is achieved, let go of specified pressure, adjustment is required. Turn the
the handle, and release the outrigger enable button. entire relief valve cartridge (Figure 314) in to
increase pressure or out to decrease pressure.
4. When the pressure is set, deactivate the agitator by
placing the manual control handle in the neutral
position.
5. Remove the whip gauge.
6. Reopen the shutoff valve or remove the dead plugs,
and reconnect the capped hydraulic line.
Outrigger valve Agitator Relief Valve

relief cartridge

otrigrlf.eps

Outrigger valve bank relief cartridge Agitator relief cartridge located on
back side hand valve
HOME PRINT
Pressure Settings
000174.eps
000289.eps
Motor
Accumulator pump
Figure 395 pressure regulator
Figure 397
Plugs Straight Fitting Accumulator pump pressure regulator for
A7VO (above) and for A11VO on a unit
with a stiebel gearcase (below)
Figure 396
Approved hydraulic
Boom Pump
dead plugs 000257.eps
Accumulator Pump
Cap Nuts
Setting accumulator circuit pressure

accumulator circuit: Accumulator Pump
1. Stop the truck, put the key in your pocket, and Pressure Regulator
Standby 000446.eps
2. Loosen the jam nut on the pressure regulator of the Pressure Screw hgacugc.psd

HOME PRINT
SERVICE TRAINING
Pressure Settings
000449.eps
Manual bleed
valve
Boom pressure
relief cartridge
ps
lf.e
ssr
pre
Pressure relief
0-600 bar cartridge
gauge port

New e-stop has no redundant Accumulator manifold pressure
relief cartridge. relief cartridge
3. Clear all personnel away from the drive lines, start 5. Locate the accumulator manifold pressure relief
the truck engine, engage the pumps, and bring the cartridge (Figure 235). Loosen the jam nut, and
engine RPM to maximum. turn the screw clockwise to increase the pressure or
4. Read the pressure on the accumulator circuit pres- counterclockwise to decrease the pressure. Tighten
sure gauge (Figure 234). The pressure should read the jam nut when the pressure reaches the value
the value shown on the hydraulic schematic. If no required.
adjustment is needed, skip to step number 7. If
with step number 5.
000292.eps
Figure 399
HOME PRINT
Pressure Settings
WARNING
000075.eps
pressure regulator.

accumulator circuit hydraulic pump pressure regu-
lator (Figure 232), and turn the screw back out
two-and-one-half turns. This restores it to its origi-
nal setting.
the truck, and bring the engine RPM up to maxi-
mum.
should read the proper accumulator system pres-
sure.

regulator is referred to as the pressure cut-off.
HOME PRINT
SERVICE TRAINING
Electrical
Electrical Information
Boom Control Systems and the Advantages of Each
Manual Controls
Manual Black and White (On-Off) System:
• Totally, completely reliable.
• Electrical malfunctions are impossible.
Cable Remote Controls
Remote Controlled Black and White System:
• Operator can go to the location with the best possible view of the boom and job.
• Allows mobility to move around the unit.
Analog Proportional Remote Control System:
• Infinitely variable speed control.
• No need to use the “feathering” technique of speed control.
• Start and stop the boom with smooth acceleration and deceleration.
• Hydraulic stroke limiter can be adjusted from the remote box.
Digital Proportional Remote Control System:
• Less susceptible to external noise interference (from radio transmitters, for example).
• Cable requires only 6 wires, instead of 25. One for power, one for ground, two for the emergency stop cir-
cuit, and two for data transfer.
• More precise adjustment of boom speed than previous systems.
• Troubleshooting a non-working system can be done in minutes via a hand held test device.
• Increased safety because of numeric operating principles. (Cannot go out of adjustment).
• A digital system can be updated or expanded by E-prom replacement or reprogramming. (Analog sys-
tems are not possible to improve without hardware replacement).
• The proportional valve amplifiers are self diagnosing via L.E.D.’s.
• The boom can go slower before shut-off than with an analog system.
• Digital system has built in ramp functions, which makes it impossible to accidentally go to full speed by
bumping a joystick.
Comfort Proportional Remote Control System
• Has the Schwing information system
1. Pumped volume determination by means of stroke counter and pumped volume calculation.
2. Extensive operational data acquisition and display.
3. Safely stored malfunction list of last 100 malfuction messages.
4. Manual operation of lubricating cycles.
5. Status display of all signals of the electronic control.
6. Password-protected parameter setting for the central lubricating system
7. Password-protected parameter setting for the proportional boom fuctions.
• Has the Schwing diagnostic system.
1. The diagnosis system monitors the control unit, the machine and partly also the vehicle for mal-
functions or inadmissible states of operation.
2. The system recognizes e.g. parting of cables or short-circuits in electric lines of solenoids, Fault
sensors, contaminated oil filters or critical hydraulic oil or diesel engine temperatures and displays
different operating conditions.
3. The system is to assist the concrete pump operator in his work on site and to inform him about the
possible causes of malfunctions when they occur.
Service Manual 521

HOME PRINT
SERVICE TRAINING
Electrical
4. The malfunction messages are displayed as continuous text in the form of an easily understand-
able plain language message with additional fault code.
Radio Remote Controls
Digital Black and White Radio Remote Control System FW 16:
• Operator doesn’t have to drag around a cable when moving.
• The operator is not connected to the unit if a power line is contacted. (This does not protect others
around the unit if contact is made).
Digital Radio Remote Control System FW18:
• Quicker response time than FW 16.
• Greater safety than FW16, because of binary code transmissions.
• Higher power output gives greater range than FW16.
Digital Radio Remote Control System FW 20/24:
• Radio receiver is built into the digital proportional system (no separate receiver)
• Radio receiver has 2 separate frequency drivers, selectable by the operator with a switch. If interference
is shutting down the system, just switch to the other frequency.
• The receiver has many indicating lamps that tell the status of the radio systems.
• Higher power output gives greater range and fewer interference shut-downs than FW 18.
• Advanced filtration circuits cut down on interference shut-downs versus FW 18.
• The antenna is internal to the remote box. Nothing external to get broken.
Spread Spectrum Radio Remote System
• The Schwing Spread Radio system employ frequency hopping spread spectrum technology to provide
the optimum performance allowable under present FCC and ISC regulations. This technology provides a
unigue performance advantage compared to conventional fixed frequency systems. The major benefits
are listed below:
1. Interference Free: It cannot be jammed by other RF transmitters or extraneous noise source.
2. Coordination Free: All Schwing-spread spectrum transmitters are factory coded. The user does not
need to worry about which frequency the unit is operating on. It operates as if there ia s unique fre-
quency for each unit in existence. Any number of these units can be operated in the same location
at the same time.
3. License Free: These radios are certified by the U.S. and Canadian governments to meet their crite-
ria for license-free operation. With Spread Spectrum Technology, these radios are allowed to trans-
mit as much power and sometimes more than conventional licensed products. This makes for very
high performance reliable RF links through many types of material and over very great distances
should the application require it.
4. Security: Combine the Spread Spectrum robustness with the added 16-bit address space and
CRC16 error-detection code built into the data protocol, and these units provide extremely reliable,
error-free control.
522 Service Manual

HOME PRINT
SERVICE TRAINING
Electrical
Boom Control Systems
A
MANUAL - BLACK
AND WHITE
TO
BOOM
lts
B
vo
12
REMOTE CONTROL Switches +
s
BLACK AND WHITE +12 volt Relay Box
TO
BOOM
1000 mA
to
C
0
20
ANALOG Potentiometers
lt s
PROPORTIONAL 6 to 9 vo Proportional
Amplifiers TO
BOOM
0 1 1 0100 1 1 0 1 1 0 0 1 0
0 1 0 10 0 1 0
011 0
D
0 101 1
0 01
DIGITAL
PROPORTIONAL
A/D Converters
Radio
0 10
1000 mA
to
D
0
20
DIGITAL A/D Converters D/A Converter

PROPORTIONAL 01010010 & Proportional
Cable TO
Amplifiers BOOM
Service Manual 523

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Introduction to Proportional Controls
The difference between the proportional and the black and white control is the function performed from the signal.
With the black and white control, the signal will be either on or off only. With the proportional control, the function
will vary according to the movement given to the potentiometer by the Joystick.
The proportional system can be broken down into 3 major components. They are as follows:
A. The Joystick with the Potentiometer.
B. The Proportional amplifier
C. The Solenoid valves.
The Joystick with Potentiometer

There is a 15 volt supply at connection 1 of the potentiometer (See Figure). If you tilt the Joystick up and down, the
voltage going into the amplifier will be changed (input signal - connection 2 of the potentiometer). Simultaneously,
when the N.O. micro-switch is closed the relay on the power supply card is switched and the circuit is activated.
BOOM FUNCTION
7.5 VOLTS
UP DOWN
+ 1.5 VOLTS
MICROSWITCH -
OPEN DOWN TO 6 VOLTS UP TO 9 VOLTS

CLOSED CLOSED (BOOM DOWN) (BOOM UP)
I MIN I MIN
I MAX I MAX
1 3
7.5 VOLTS 7.5 VOLTS
V V
15 VOLTS
1 3
2
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The Proportional Amplifier
The proportional amplifier receives a voltage signal from the potentiometer and amplifies the input voltage signal
to the desired output current (See Figure).
24 VOLTS
MICROSWITCH
7.5 VOLTS
15 VOLTS 0 VOLTS
PROPORTIONAL AMPLIFIER CARD
SIGNAL COMMON SIGNAL

BOOM UP GROUND BOOM DOWN
RELAY
GROUND PILOT VALVES

BOOM BOOM
UP DOWN
The Solenoid Valves

Schematic of a proportional valve with a current to pressure ratio diagram.
PRESSURE RANGE UP TO 30 BAR
30
28
26
24
22
PRESSURE AT PORT "A" IN BAR
20
18
A T
16
14
12
10
8
P
6
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
CURRENT IN AMPS
More current = More pressure at port “A.”

More pressure at port “A” = Increase the hydraulic flow at the slave valve.
Increased hydraulic flow = Boom acceleration
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The Proportional Amplifier in Use with the Radio
The signal from the radio remote control to the proportional amplifier is 12 V±6 V, instead of 7.5 V± 1.5 V as
with the cable remote control. For instance:
• Boom up 12 V → 6V
• Boom down 12 V → 18 V
In order to make the proportional controls work with these input voltages, we need to switch relays on the
proportional amplifier cards. This is accomplished with a bridge wired into the connecting cable for the radio
remote, from the receiver to the operator’s control panel. The bridge is wired in the plug that connects to the control
panel. It is because of this bridge that two different cables are required.
TRANSMITTER
MICRO-
SWITCH
RADIO
SIGNAL
CONNECTING CABLE
RELAY
RECEIVER
BRIDGE FOR
RADIO REMOTE
12 21 22 24
PROPORTIONAL CARD
PILOT VALVES
BOOM BOOM
UP DOWN
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Motherboard for Proportional Units
POWER SUPPLY CARD

(PART# BEFORE 1992 10074135 AFTER 1992 10023316)



ADAPTER CARD
FOR TEST METER
(PART# BEFORE 1992 10074136
AFTER 1992 10023317)
EMPTY
SLOT
9 1 2 3 5
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Power Supply - Slot 9
CARD 9
LED Voltage Function

1 7.5 V Must be on at all times.
2 15 V Must be on at all times.
3 18 V Must be on at all times.
4 24 V Emergency Stop. Must be on

when the Emergency Stop has
LED 1 been activated.
LED 2 5 Fuse for voltage regulation. It

should be off. When it is on,
LED 3 check the fuse.
LED 4
LED 5
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Proportional Amplifier - Slot 1,2,3
CARD 1, 2, 3
MIN
MAX
LED Function
LED 1
Channel 1 1 Illuminates when the corresponding function has
MIN been activated.
MAX
2 Illuminates when the corresponding function has
LED 2 been activated.
MIN 3 Illuminates when the corresponding function has

MAX been activated.
LED 3 4 Illuminates when the corresponding function has

Channel 2 been activated.
MIN
MAX 5 Should be off. If it illuminates when a channel 1
function has been activated, check fuse.
LED 4
6 Should be off. If it illuminates when a channel 1
LED 5 function has been activated, check fuse.
LED 6
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Calibration of Proportional Amplifier Cards
Note:
The average Proportional solenoid valve operates between 300 and 800 mA.
1. Push the emergency stop button (Only if not using the Schwing proportional card test meter).
2. Connect Amp meter in the circuit of the proportional function that is to be calibrated. The most convenient way
to measure the current is using the Schwing proportional card test meter
(ID 77706).
3. Release the Emergency Stop button.
4. Tilt the Joystick to the point that the
micro-switch is in the closed position (trigger point is at I min). The circuit is now in a closed position, the LED
on the proportional amplifier card is illuminated, and the current can be read on the test meter.
5. Adjust the minimum current (at the min potentiometer) to the point where the boom section just starts to move
(approximately 300 - 450 mA).
6. Tilt the Joystick all the way (I max.). Adjust your maximum current (at the max potentiometer) on the propor-
tional amplifier card (approximately 700 - 800 mA).
After adjusting the maximum current, repeat steps 4 though 6 until the correct result has been achieved. The reason
for this is because as the min or max is adjusted, the other is effected.
CARD 1, 2, 3
BOOM FUNCTION
UP DOWN
MICROSWITCH
CLOSED OPEN CLOSED

I MIN I MIN
I MAX I MAX MIN
MAX
LED 1
Channel 1
MIN
MAX
LED 2
MIN
MAX
LED 3
Channel 2
MIN
MAX
LED 4
LED 5
LED 6
1 3
2
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Linear Signal Diagram
1000
MAXIMUM CURRENT OUTPUT (mA)
900
800
MAX
700
600
500
MIN
400
300
200
100
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
MIN MAX
PRETENSION PRESSURE (Bar)
The optimum adjustment makes full use of the joystick’s range of travel. Other adjustments
result in poor response and on/off switching of valves, which in turn causes jerky motion of the
bomm and possible structure damage.
MIN
0¡ 5¡ 0¡
MIN
MAX MAX
36¡ 36¡ 36¡ 36¡
1 3 1 3
2 2
IMPROPERLY ADJUSTED PROPERLY ADJUSTED
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Decal of Proportional Motherboard
POSITIONING OF THE CIRCUIT BOARDS IN THE BASE PALTE
PN
2 4 6 8 10 12 14 16 18 20 22
327524
9 SLOT 1 2 3 4 5
MIN
MAX
Slew Boom 2 Boom 4
SERVICE CARD SLOT

RIGHT DOWN DOWN
Slew Boom 2 Boom 4 EMPTY SLOT

LEFT UP UP
7.5v
Output
15v Main Boom 3 volume
DOWN DOWN CABLE
18v
24v
ES
Output
Main Boom 3 volume
UP UP RADIO
FU
FUSE 1 FUSE 1 FUSE 1
FUSE 2 FUSE 2 FUSE 2
+ + - - 20 18 16 14 12 10 8 6 4 2
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Electrical
Wiring Diagram - DUVAC II 12V / 24V Transformer
Truck batteries
GND
IGN.
24v 12v
30A 30A + 12V - + 12V -
+ 12V - + 12V -
Ignition
switch
(on)
PTO (on)
switch
12V 12V
ACTUATED ACTUATED
24v solenoid 12v solenoid
24v output 12v output

to Schwing unit to Schwing unit
DUVAC II . . . . . . . . . . . . . . Part #319438

SOLENOID . . . . . . . . . . . . .Part #302563
(continuous duty)
01/26/95
PTO SWITCH . . . . . . . . . . .Part #302178 GRP
(cam type)
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Wiring Diagram - DUVAC II 12V / 24V Transformer
Truck batteries
GND
IGN.
24v 12v A C
30A 30A + 12V - + 12V -
+ 12V - + 12V -
B D
Ignition
switch
(on)
PTO (on)
switch
12V 12V
ACTUATED ACTUATED
24v solenoid 12v solenoid

24v output 12v output 01/26/95
to Schwing unit to Schwing unit GRP
1. Determine which battery doesn’t have any accessary power leads. This will be the battery used
to create the 24V power.
2. Disconnect the truck cables from that battery (BE CERTAIN THERE ISN’T ANY OTHER WIRES
CONNECTED TO THE 24V BATTERY OR SEVERE DAMAGE COULD RESULT TO OTHER
CIRCUITS ON THE UNIT).
3. Connect jumper from Battery "A" (+ positive) to Battery "B" (- negative) and then connect Battery
"B" (+ positive) to the 24V wire disconnected from the Duvac’s 24V post.
4. It may be required to swap Battery "B" with Battery "D" if operated in this mode for an extended
period of time because the battery used to create 24V isn’t being charged.
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Digital Proportional - Overview (1 of 5)
Overview
The term DigiProp is used to describe Schwing Americas digital proportional control system. Proportional refers to the fact
that the boom adjusts it's speed in response to the movement of the joysticks. The farther the joystick is moved, the faster the
boom moves. Digital means that the movement of the joystick is translated (by an analog to digital converter) to numbers (zeros
and ones). Once translated to numbers the signal moves into a processor not unlike a computer. The processor responds to the
joystick movements and compares them to a set of values that are preprogrammed into memory. It then translates the numbers
into a signal that is fed to the coils of the hydraulic valves. See Figure 1.
ANALOG 1000 mA
PROPORTIONAL
o
0t
20
Potentiometers
15 volts Proportional
Amplifiers
6 to 9 v olts TO
BOOM
DIGITAL 1000 mA
o
PROPORTIONAL
0t
20
A/D Converters 010 Digital control

01010
system
1 10 1 0 110 TO
BOOM
Figure 1
ana/digi compare.eps
Digital systems have definite advantages over the analog proportional system found on older machines. Because
everything is translated into numbers, there can be no mis-adjustments. Instead of adjusting a trim pot to fine tune
the response, you simply enter in the parameters that you want, and the processor takes care of the rest. In addition,
the zeros and ones (referred to as “bits”) travel to the processor in groups (referred to as “bytes”). Each bit in the
byte tells the processor something about the condition of the machine. If you could translate one of the bytes into
plain English, it would look something like this:
“I am a Schwing with an ID number of 7. Emergency stop is not activated. Concrete pump is activated in forward.
Boom #3 retract joystick is activated to 48% travel. Boom #2 extend joystick is activated to 85% travel.”
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The processor updates these signals many times per second. The byte always starts with the identification of the
system (“I am a Schwing”) so that electrical “noise” from the surrounding area cannot activate a function. Some
types of noise that could send a false signal are cellular phones, garage door openers, police radar, etc. Because of
the identification process, however, these false signals are ignored. See Figure 2.
Digital Code
10101110011000010100100011000100101010010100010 11010001
Identifier
SCHWING F W 20 K28 V24
NG NF MC2 MC1
ST 1
UF K1 TEL ST 2
UE1 K2 REL
UCC1 PROP
UE2 TEL
UCC2 TST 3
NOT1 TST 2
K1 TST 1
A/D Converters RADIO CONTROL FW20

FCC ID. DA87G6 FW20RL
T2 T1

GERMANY
SERIAL NR 003 143
FREQ. 456.962S
(mHZ) 457.762S
Figure 2
M.A.T.
The M.A.T. is a hand held programmer that can be plugged into the digital controller. It consists of an 8 digit
alphanumeric display and a 4 button keypad. Its used to access information and program the system. This is
important because you can’t troubleshoot a digital system with a test light. However, the advantage of a digital
system is that in most cases the processor already knows what is wrong by the time you notice a problem. See
Figure 3.
*scv
P
C
M.A.T.
Figure 3
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Processor Unit
The digital control system is housed in the device called the Processor unit. The processor unit replaces the relay
enclosure found on analog systems.
This processor unit contains various types of electronic function cards and the optional radio receiver.
The SCV9 card is the master card in the system. Its function is to coordinate the entire system by decoding
instructions from the operator control panels, then sending commands to the appropriate slave cards.
The SCV9 card holds all the programmed settings. It has been programmed at the factory for your specific
machine. Replacement cards contain generic settings. In an emergency, they can be used as is, but they should be
programmed to match the hydraulic system on your machine.
The HC2 and DG8 cards are known as slave cards because they receive commands from the master card, SCV9.
See Figure 4
+ .A12 + A11 + .A10 + .A9 + .A8 + .A7 + .A6 + .A5 + .A4 + .A3
REC 2 SCV HC2L-1 HC2L-1 HC2L-1 HC2L-1 HC2L-1 HC2L-1 DG8-1 DG8-1
M.A.T.
CONNECTOR
DG 8
SCV 9 HC 2
(slave card
(master card) (slave card
Figure 4
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Card Functions
The HC2 cards provide proportional control of the placing boom and concrete pump output. The HC2 cards send
a 50 milliamp diagnostic signal, generated by the SCV9 card, which continuously tests the various proportional
electrical circuits.
The DG8 cards provide on/off control of the concrete pump, horns, motors and other accessories.
Each of the slave cards control specific functions which are determined by their location in the
digital processor unit. The card positions (numbered horizontally) are also used when troubleshooting with the
M.A.T. to indicate the location of communication errors. The vertical numbers on the right of the drawing indicate
the output channels for the slave card functions. See Figure 5.
1 2 3 4 5 6 7 8
+ .A12 + A11 + .A10 + .A9 + .A8 + .A7 + .A6 + .A5 + .A4 + .A3
1
2
3
M.A.T.
CONNECTOR
DIGITAL INPUTS
4
+
5
MIN RES.
6
7
MOTOR
8
Figure 5
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Control System Arrangement
The arrangement of the control systems is shown in Figure 6 below. You can see that the control system is made up
of individual function blocks. Each block is an electronic card. Data is transferred between the cards via the RS485
bus shown in the diagram. The entire coordination of the system is performed by the SCV card which is the
“MASTER” of the control system. The HC2 and DG8 cards are “SLAVE” cards that receive commands from the
MASTER and pass them on to the machine. All parameters, i.e. machine-specific settings and functions are stored
in and managed by the MASTER, which is the SCV card, therefore, it is possible to exchange any SLAVE card for
another SLAVE card of the same type without altering any functions or settings in the control system. All
parameters can only be adjusted or changed in the SCV card. All external control instructions are sent by either the
BDI-F (cable remote control), the BDI-A (rear panel control), or radio remote interface in the SCV card to the SCV
MASTER via the bus system. The SCV master card accepts these control instructions, and based on the parameters
stored, sends them via the RS 485 bus to the appropriate slave card (HC2 or DG8). The slave cards then send an
acknowledgment back to the SCV card as to whether or not they can properly follow the control instruction
.
Digital Control Unit
Proportional Control On/Off Control

Throttle Con pump Machines with
Boom 1 Boom 2 Boom 3 Boom 4 Slewing Stroke Limiter Etc. For/Rev Etc. Agitators only
HC2 HC2 HC2 HC2 HC2 HC2 DG8 DG8 DG8

1 2 3 4 5 6 7 8 12
RS 485 BUS
SCV RS232/V24 FW 20/RC

Relay Radio Reciever
Board 9
M.A.T. Push FW 20/R

BDI_A BDI_F
Buttons Transmitter
REC____Relay card (p/n 126442) SBP BUS____Motherboard (p/n 126390)

HC2____Prop. output, 2 function (p/n 125849) FW20RC____Radio control receiver (36X, 42 p/n 130877)
DG8 ____Digital output, 8 function (p/n 125848) FW20TR____Radio control transmitter (52 p/n 147676)
SCV____Interface converter and central processing MAT____Manual adjustment terminal (p/n132426)
unit (p/n 125851) Cable remote control box complete (p/n 13539)
BDI_S____(can be programmed for either BDI_A or BDI_F) Cable remote control cable (p/n 124956)
BDI_A____Rear operators panel interface card (p/n 125846)
BDI_F____Cable remote control interface card (p/n 125847)
Figure 6
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Digital Proportional - Programming
Programming
To get the most from the programming and self-diagnostic capabilities of the system, you must be able to use the
hand-held M.A.T. and menu survey to navigate to specific locations. See Figure 7.
Think of the menu survey as a road map that allows you to navigate through the system software and the M.A.T. as
the vehicle that takes you from place to place.
Software
*scv
CUSTOMER MENU Version 2.4X
Controller Main Menu Submenus Display Translation
To cable
remote &
back
panel
P *SCV 9 ?PAR ?AUSL ?AUSL 1H 1H1 200

1H2 300
1H3 900
Min. stop current (mA.)
Min. start current (mA.)

Max. current (mA.)
Boom up
Section 1
?AUSL 1S 1S1 200 Min. stop current (mA.)

Boom down
To slave 1S2 300 Min. start current (mA.) Section 1
C cards
?AUSL 2H
1S3 900
2H1 200
2H2 300
Max. current (mA.)
Min. start current (mA.)

Boom up
Section 2
2H3 900 Max. current (mA.)

M.A.T. ?AUSL 2S 2S1 200 Boom down

2S2 300 Min. start current (mA.) Section 2
2S3 900 Max. current (mA.)
?AUSL 3H 3H1 200 Min. stop current (mA.)

Boom up
3H2 300 Min. start current (mA.) Section 3

Boom down

Boom up
Boom down
?MAST L ML1 200 Min. stop current (mA.)
ML2 300 Min. start current (mA.) Slew

left
ML3 900 Max. current (mA.)
?MAST R MR1 200 Min. stop current (mA.)
Slew
MR2 300 Min. start current (mA.)
right
MR3 900 Max. current (mA.)
?F.MENGE FM1 200 Min. stop current (mA.)
Stroke
FM2 300 Min. start current (mA.) limiter
FM3 900 Max. current (mA.)
Figure 7 (PG-1)
MAT Operation
The MAT (Manual Adjustment Terminal) is the setting and diagnostic unit for the digital proportional control
system.When plugged into the 9 pin front panel connector it goes through an initializing phase, then “*SCV 9” or
”? SCV 9” appears in the 8-digit, alphanumeric display.
There are 4 keys on the M.A.T. which allow you to scroll through the menu structure in order to set system parameters to there
required values, observe the non-adjustable entries, or perform well aimed signal tracing while troubleshooting.
The symbols on the keys stand for the following:
P = Program = Up
C = Clear = Down
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Menu Structure
Looking at the menu structure you can see it is laid out in columns. This was done to make it easier to follow the
multitude of existing parameters and entries, that are combined into the submenus and main menus. See Figure 8.
The menu system consists of:
• Controller Selection
• Main Menu
• Submenus
• Parameters
• Entries
The controller selection is marked by an asterisk (*) in the first digit of the M.A.T. display when using software
version 2.4. In software versions 2.2 and 2.3, a question mark will display in the first digit.
Menus have a question mark (?) displayed in the first digit.
Entries are information from the system that cannot be externally changed (similar to measured values obtained by
the connection of instruments).
Parameters are adjustable values which must be set to the conditions found on the machine (e.g., valve currents).
Software
MENU STRUCTURE Version 2.4X
To cable
remote &
back
panel
*SCV 9 ?PAR ?AUSL ?AUSL 1H 1H1 200 Min. stop current (mA.)
Boom up

Boom down
cards 1S3 900 Max. current (mA.)
2H1 200 Min. stop current (mA.)

?AUSL 2H Boom up
2S1 200 Min. stop current (mA.)

?AUSL 2S Boom down

Boom up

Boom down

Boom up
Boom down

left
Slew
right
Stroke
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Moving Through The Menu Survey
Using the M.A.T. to navigate through the menu survey is simply a matter of pressing the buttons on the key pad and
noting your location with the alphanumeric display. See Figures 9, 10, & 11.
To scroll to the right, press the “P” or program key.
?PAR ?AUSL ?AUSL 1H 1H1 200 M
1H2 300 M
1H3 900 M
?AUSL 1S 1S1 200 M
1S2 300 M
Figure 9 1S3 900 M
To scroll to the left, press the “C” or clear key once.

To return to the SCV 9 starting point, press “C” twice.
?PAR ?AUSL ?AUSL 1H 1H1 200

1H2 300
1H3 900
?AUSL 1S 1S1 200
1S2 300
Figure 10 1S3 900
Use the arrow keys to scroll up and down.
?PAR ?AUSL ?AUSL 1H 1H1 200

1H2 300
1H3 900
?AUSL 1S 1S1 200
1S2 300
1S3 900
?AUSL 2H 2H1 200
2H2 300
Figure 11
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Access The Service Menu
Versions 2.4 and later have two levels of menu access. Connecting the M.A.T. automatically brings you to the
customer menu. The second menu level called the service menu, is hidden. See Figure 12.
To access the service menu:
• Press the letter “P” to enter main menu
• Scroll down the main menu to “system”
• Then, press “P” again
The M.A.T. display now reads SCV S. Press the “P” key once, the “C” key once, and the “up arrow” key once.
The display will now read NR500.
Press the “P” key again; a dotted line will appear in the display.
Use the “up arrow” key to change the value in the display to 530. Press “P” again, a dashed line will replace the
dotted line meaning the setting has been saved.
You now have access to the service menu items.
?RAMPE ?RAMP UP T1LU 1.0

T1RU 1.0
T2LU 1.0
T2RU 1.0
T3LU 1.0
T3RU 1.0
?RAMP DN T1LD 0.5
T1RD 0.5
T2LD 0.5
T2RD 0.5
T3LD 0.5
Customer T3RD 0.5
Menu RP1 25
RP2 50
(White) RP3 75
?INS ?V24 OK 0
CE 0
FE 0
PE 0
OE 0
VE 0
?TELEGR. W0 0000
W1 0000
W2 0000
W3 0000
W4 0000
W5 0000
Service CRC 00
Menu ?SELECT A1Hs ON

A1Ss ON
(Gray) A2Hs ON
A2Ss ON
A3Hs ON
A3Ss ON
A4Hs ON
A4Ss ON
MLs ON
MRs ON
FMs ON
CERR
NA_F OFF
NA_C OFF
STOER 0
(PG-2) PERR
Figure 12
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Identifying the Entries and Parameters
Each entry or parameter is shown in the 8-digit display of the MAT. The left side shows an alphanumerical abbreviation with
a maximum of four digits which serves to explain the value shown on the right. Within this abbreviation, lower case letters are
used to describe the origin or the type of representation of the value. The individual letters stand for the following:
a Signal from the rear panel

f Signal from remote control (radio or cable)
r Signal from the rack
s Function selection (this parameter serves to activate or deactivate certain functions)
p Display value in percent
“SCV” Card Main Menus
Note: Some of the definitions listed are common to both menu structures, while others are specific to the 2.4 menu.
After selecting the “*SCV 9” controller, you can scroll the individual main menu items with the “⇑” and “⇓” keys.
The following main menus can be found in the “*SCV 9” controller:
“?PAR” = “Parameter Setting” main menu display or selection.
“?INS” = “Installation or Start-Up Auxiliary Functions” submenu display or selection.
“?DIN” = “Digital Input Data” submenu display or selection.
“?SOUT1” = “First Menu Digital Switching Outputs” submenu display or selection.
“?SOUT2” = “Second Menu Digital Switching Outputs” submenu display or selection.
“?POUT1” = “First Menu Proportional Valve Outputs” submenu display or selection.
“?POUT2” = “Second Menu Proportional Valve Outputs” submenu display or selection.
“?DIAG” = “Diagnostic Information” submenu display or selection.
“?SYSTEM”= “System Control” submenu display or selection.
“?GERAET”= “Unit Control” submenu display or selection.
“?PAR” Main Menu
After selecting the “?PAR” main menu, you can scroll the individual submenus with the “⇑” and “⇓” keys.
The following submenus can be found in the “?PAR” main menu:
“?AUSL”= “Boom Settings” submenu display or selection including:
“?AUSL_H”= “Boom 1 Up Current Value Settings” submenu display

or selection.
“?AUSL_S”= “Boom 1 Down Current Value Settings” submenu display

or selection
“?AUSL_H”= “Boom 2 Up Current Value Settings” submenu display or
selection.
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“?AUSL_S”= “Boom 2 Down Current Value Settings” submenu display or

selection.

selection.
“?AUSL_S”= “Boom 3 Down Current Value Settings” submenu display or

selection.

selection.
“?MAST_L” = “Slewing Left Current Value Settings” submenu display or selection.
“?MAST_R” = “Slewing Right Current Value Settings” submenu display or selection.
“?F.MENGE” = “Stroke Limiter Current Value Settings” submenu display or selection.
“?RAMPE” = “Ramp Value and Time Settings” submenu display or selection

(for “R_A2”)
Submenus Functions and Parameters
“?AUSL_XY” = Settings the XY boom current values, where: X = 1 - 4; Y = H or S

The individual parameters are:
“XY1 200” =Here, the jump-out or minimum stop current can be set within the
range from 50 to 1100 mA.
Default 200 mA.
“XY2 300”=Here, the jump-in or minimum start current can be set within the range
from 50 to 1100mA.
Default 300 mA.
“XY3 900” = Here, the maximum current can be set within the range from 50 to
1100 mA.
Default 900 mA.
“?MAST_X ” = Setting the current values for boom slewing X, where: X = L (left) or R (eight).
“MX1 200” = Here, the jump-out or minimum stop current can be set within the
Default 200 mA.
“MX2 300” = Here, the jump-in or minimum start current can be set within the
Default 300 mA.
“MX3 900” = Here, the jump-in or minimum start current can be set within the
Default 900 mA.
“F.MENGE” = Setting the stroke limiter current values
“FM1 200” = Here, the jump-out or minimum stop current can be set within the
Default 200 mA.
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Default 300 mA.
Default 900 mA.
“RAMPE” = Setting ramp control data

(For “R_A2” or “R_MD” types only.)
including:
“?RAMP_UP”= Submenu with the ramp-uptimes (when push-button is belong pressed,
or when changing over from low ramp value to higher one while
push-button is being held depressed).
“TXYU 1.0” = Here, the ramp-up time for speed step X, triggered by control
switch Y, can be set within the range from 0.1 to 5.0 sec/100%.
Default 1.0.
Where: X = 1 - 3; Y = L (left)(/ R (ight).
“?RAMP_DN”= Submenu with the ramp-down times (when push-button is being

released, or when changing over from high ramp value to lower one
while push-button is being held depressed).
“TXYD 1.0”= Here, the ramp- time for speed step X, triggered by
control switch Y, can be set within the range from 0.1 to
5.0 sec/100%.
Default 1.0.
Where: X = 1 - 3; Y = L (eft)( / R (ight).
“RP1 25” = Here, the speed step 1 ramp value can be set within the range from 0 to 99%.
Default: 25.
Default: 50.
Default: 75.
“?SELECT ”
Submenu Functions and Parameters (In Service Menu Only!)
“?SELECT” = Submenu for locking or unlocking prop channels (In service menu only!).
“AXYsON” = Parameter, by means of which the prop output for boom XY

(X = 1 - 4; Y = U/D) can be activated or deactivated.
“MX ON”= Parameter, by means of which the prop output for boom slewing X
(X = L/R) can be activated or deactivated.
“FM ON”= Parameter, by means of which the prop output for the stroke limiter
can be activated or deactivated.
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“?V24” Submenu Functions and Parameters
“?V24” = V 24 (radio remote) interface state display submenu.
The individual displays are:
“OK 00” = Indicating the number of correctly received data blocks.
For proper operation, this number must continuously grow.
“CE 00” = Indicating the number of errors determined when the checksum was
checked (Checksum Error).
For proper operation, this number must not grow or may only grow
slowly.
“FE 00” = Indicating the number of errors determined when the length of a data
block was checked (Framing Error).
slowly.
“PE 00” = Indicating the number of errors determined when the parity was
checked (Parity Error).
slowly.
“OE 00” = Indicating the number of errors caused by telegram buffer overflow
(Overflow Error).
slowly.
“VE 00” = Indicating the number of errors caused by software telegram buffer
overflow buffer Overflow Error).
slowly.
“?TELEGR.”=“RS 232 Interface Original Telegram” submenus display or selection

(In service menu only!)
“W0 0000”= Original data word 0 in hexadecimal representation.
Start and mode ID.

Pulse channels 16 - 1.

Pulse channels 32 - 17.

Prop channels 1 + 2.


“CRC 00”= Original data byte 13 in hexadecimal representation.

Checksum.
“?DIN” Main Menu

After selecting the “?DIN” main menu, you can scroll the individual entries with the “⇑” and “⇓” keys.
In the “?DIN” main menu, all the input signals recognized by the system are represented. They are divided into submenus as-
signed to the individual signal sources.
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The following submenus can be found:
“?BDI_A”= “Input Date from BDI_A (Rear Panel) Display” submenu display or selection.
“?BDI_F”= “Input Date from BDI_F (Cable or Radio Remote Control) Display” submenu
display or selection.
“?RACK”= “Input Date from Rack Display” submenu display or selection.
“?RACK” Submenu Functions and Parameters

“?RACK”= Submenu for the display of input date from the rack.
“LDK O/F” = Entry indicating how the system recognized the “alternator (D+)”
input nstruction.
“UMSO/F”= Entry indicating how the system recognized the “outrigger” input
instruction.
“DWLO/F”= Entry indicating how the system recognized the “limit switch slewing
left” input instruction.
“DWRO/F”= Entry indicating how the system recognized the “limit switch slewing
right” input instruction.
“BPVO/F”= Entry indicating how the system recognized the “concrete pump
forward” input instruction from site control.
“BRPO/F”= Entry indicating how the system recognized the “concrete pump
reverse”input instruction from site control.
“WMNrO/F”= Entry indicating how the system recognized the “water level
minimum”input instruction.
“RWKO/F” = Entry indicating how the system recognized the “agitator ON” input
instruction.
(Input active for AGRs = 1 function.)
“REPO/F”= Entry indicating how the system recognized the “Maintenance ON” input
instruction.
(Input active for MTNs = ON function.
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“?BDI A” Submenu Functions and Parameters
“?BDI_A”= Submenu for the display of the input data from the rear panel.
“Sxa 0000”= Entry indicating the hexadecimal code of the rear panel input ports.
Detailed hardware knowledge is necessary to understand this entry. One can

determine the following guideline for servicing: Each actuation of a switching
element must cause a digit in the display to change.
“?DIGa” = “Digital Inputs from BDI_A (Rear Panel)” submenu display or

selection.
“ASWO/F”= Entry indicating how the system recognized the “spotlight ON”
input instruction.
“HUPaO/F”= Entry indicating how the system recognized the “horn”

(communication) input instruction.
“RTHaO/F”= Entry indicating how the system recognized the “vibrator

manual” input instruction.
“RTAaO/F”= Entry indicating how the system recognized the “vibrator

automatic” input instruction.
“KPRaO/F”= Entry indicating how the system recognized the “compressor
ON” input instruction.
“WPEaO/F”= Entry indicating how the system recognized the “water pump
ON” input instruction.
“BPVaO/F”= Entry indicating how the system recognized the “concrete pump
forward” input instruction.
“BPRaO/F”= Entry indicating how the system recognized the “concrete pump
reverse” input instruction.
“MONaO/F”= Entry indicating how the system recognized the “motor ON”
input instruction.
“MOFaO/F”= Entry indicating how the system recognized the “motor OFF”
input instruction.
“MUPaO/F”= Entry indicating how the system recognized the “rpm +” input
instruction.
“MDNaO/F”= Entry indicating how the system recognized the “rpm -” input
instruction.
“FSTaO/F”= Entry indicating how the system recognized the “remote control
OFF” input instruction.
“REiaO/F”= Entry indicating how the system recognized the “spare X”
input instruction. Where X = 1 to 3.
“FMpaO” = Entry representing the “stroke limiter” potentiometer setting
recognized. 0...99 = MIN...MAX potentiometer setting in %.
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“?BDI F” Submenu Functions and Parameters
“?BDI_F” = Submenu for the display of the remote control input data (cable or radio).
“Sxf 0000”=Entry indicating the hexadecimal code of the remote control input ports.
Detailed hardware knowledge is necessary to understand this entry. One can determine the following guideline for
servicing: Each actuation of a switching element must cause a digit in the display to change.
“DIGf” = “Digital inputs from BDI_A (Remote Control)” submenu display or selection.
“MSTS”= “Switches from Joystick” submenu display or selection.

“M1 O/F”= Entry indicating how the system recognized the “boom 1”
input instruction.
“M23O/F”= Entry indicating how the system recognized the “boom 2/3”
input instruction.
“M4 O/F”= Entry indicating how the system recognized the “boom 4”
input instruction.
“MMO/F”= Entry indicating how the system recognized the “slewing”
input instruction.
“DSLO/F”= Entry indicating how the system recognized the “push-button
left” input instruction.
“DSRO/F”= Entry indicating how the system recognized the “push-button
“HUPO/F”= Entry indicating how the system recognized the “horn”
(communication) input instruction.
“BPVO/F” = Entry indicating how the system recognized the “concrete pump
forward” input instruction.
“BPRO/F” = Entry indicating how the system recognized the “concrete pump
reverse” input instruction.
“MONfO/F”= Entry indicating how the system recognized the “motor ON”
input instruction.
“MOFfO/F”= Entry indicating how the system recognized the “motor ON”
input instruction.
“MUPfO/F”= Entry indicating how the system recognized the “rpm +” input
instruction.
“MDNfO/F”= Entry indicating how the system recognized the “rpm -” input
instruction.
“RTAfO/F”= Entry indicating how the system recognized the “vibrator automatic”
input instruction.
“RP1fO/F”= Entry indicating how the system recognized the “ramp 1” input
instruction.
For the “FBP” type, this entry is substituted by:
“SP2fO/F”= Entry indicating how the system recognized the “drum speed 2”
input instruction.
“RP3fO/F”= Entry indicating how the system recognized the “ramp 3” input
instruction.
For the “FBP” type, this entry is substituted by:
“AUTfO/F”= Entry indicating how the system recognized the “automatic”
input instruction.
“RWVfO/F”= Entry indicating how the system recognized the “agitator forward”
input instruction.
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“RWRfO/F”= Entry indicating how the system recognized the “agitator reverse”
input instruction.
“A1p 0”= Entry representing the “boom 1” control switch actuation converted into
percent.
0... 99 = Control switch “up” actuation.
0...-99 = Control switch “down” actuation.
percent.
percent.
percent.
“MDp 0”= Entry representing the “slewing” control switch actuation converted into
percent.
0... 99 = Control switch “right” actuation.
0...-99 = Control switch “left” actuation.
“FMpf 0”= Entry representing the “stroke limiter” potentiometer setting converted
into percent.
0... 99 = MIN...MAX potentiometer setting.
“?SOUT" Main Menu
After selecting the “?SOUT_1” main menu, you can scroll the individual entries with the “⇑” and “⇓” keys.
In the “?SOUT_1” main menu, the first group of the digital outputs as to be given out by the system is represented. The fol-
lowing individual entries can be found:
“MOF O/F” = Entry indicating whether the system wants to give out the “motor OFF”
output instruction.
“MON O/F” = Entry indicating whether the system wants to give out the “motor ON”
output instruction.
“MDN O/F” = Entry indicating whether the system wants to give out the “rms -” output
instruction.
“MUP O/F” = Entry indicating whether the system wants to give out the “rms +” output
instruction.
“HP1 O/F” = Entry indicating whether the system wants to give out the “horn 1”
(communication) output instruction.
“HP2 O/F” = Entry indicating whether the system wants to give out the “horn 2”
(slewing mechanism end position) output instruction.
“ASW O/F” = Entry indicating whether the system wants to give out the “spotlight” output
instruction.
“RTE O/F” = Entry indicating whether the system wants to give out the “vibrator”
output instruction.
After selecting the “?SOUT_2” main menu, you can scroll the individual entries with the “⇑” and “⇓” keys.
In the “?SOUT_2” main menu, the second group of the digital outputs as to be given out by the system is represented. The
following individual entries can be found:
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“BPR O/F” = Entry indicating whether the system wants to give out the “concrete pump
reverse”output instruction.
“BPV O/F” = Entry indicating whether the system wants to give out the “concrete pump
forward”output instruction.
“UMS O/F” = Entry indicating whether the system wants to give out the “outrigger” output
instruction.
“WPE O/F” = Entry indicating whether the system wants to give out the “water pump”
output instruction.
“KPR O/F” = Entry indicating whether the system wants to give out the “compressor”
output instruction.
“RWK O/F” = Entry indicating whether the system wants to give out the “agitator” output
instruction.
“MFU O/F” = Entry indicating whether the system wants to give out the “boom movement”
output instruction.
“BPK O/F” = Entry indicating whether the system wants to give out the “oil cooler”
output instruction.
“?POUT” Main Menu

After selecting the “?POUT_1” main menu, you can scroll the individual entries with the “⇑” and “⇓” keys.
In the “?POUT_1” main menu, the first group of the proportional outputs as to be given out by the system is represented. The
following individual entries can be found:
“A1H XXX” = Entry indicating what current the system wants to drive through the “boom
1 up” valve.
“A1S XXX” = Entry indicating what current the system wants to drive through the “boom
1 down” valve.
2 up” valve.
2 down” valve.
3 up” valve.
3 down” valve.
4 up” valve.
4 down” valve.
After selecting the “?POUT_2” main menu, you can scroll the individual entries with the “⇑” and “⇓” keys.
In the “?POUT_2” main menu, the second group of the proportional outputs as to be given out by the system is represented.
The following individual entries can be found:
“MR XXX” = Entry indicating what current the system wants to drive through the
“slewing right” valve.
“ML XXX” = Entry indicating what current the system wants to drive through the
“slewing left” valve.
“FM XXX” = Entry indicating what current the system wants to drive through the
“stroke limiter” valve.
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“?DIAG” Main Menu
After selecting the “?DIAG ” main menu, you can scroll the individual submenus and entries with the “⇑” and “⇓” keys.
In the “?DIAG ” main menu, a few entries can be found for easier diagnosing. The following individual entries can be found:
“WAS O/F” = This entry indicates whether the control system is under restart protection
for the time being, i.e. no output signal is given unless all instruction
sources of the newly selected mode (LOCAL or REMOTE) are at their
neutral positions.
“NAH O/F” = Entry indicating whether the control system is in “LOCAL” mode.
“FERN O/F” = Entry indicating whether the control system is in “REMOTE” mode.
“REPB O/F” = Entry indicating whether the control system is in “maintenance” mode.
(On-site control active!)
“MAST O/F” = Entry indicating whether the control system wants to five out the
“boom active” output instruction.
“DWL O/F” = Entry indicating how the system recognized the “limit switch slewing left”
input instruction.
“DWR O/F” = Entry indicating how the system recognized the “limit switch slewing
“LDK O/F” = Entry indicating how the system recognized the “alternator (D+)” input
instruction.
“WMH O/F” = Entry indicating how the system recognized the “water level minimum”
input instruction.
“?SYSTEM” Main Menu

After selecting the “?SYSTEM” main menu, you can scroll the individual submenus and entries with the aid of the “⇑” and “⇓”
keys.
In the “?SYSTEM” main menu, some system information and setting aids can be found. This menu should only be used by
especially trained personnel as system data can be changed here that may result in system failure when entered in the wrong
way!!! The following individual entries can be found:
“SCV_S” = This entry indicates which hardware (which card) and which software
(program) can be found.
This entry allows for opening the service menu:

1.Pressing key “P” once: “SCV_S menu”
2.Pressing key “C” once: “SCV_S menu”
3.Pressing key “⇑” once: “NO500”
4.Enter and save the code number (530) as for normal parameters
“V2.4x” = This entry indicates what software version is found. (See Explanation of Different Software Versions).
“TYPXXX” = This entry indicates what type of unit the card is currently programmed to.
No re-programming is possible here!

Types of units which can be indicated:NORMBoom 2 / 3 changeover
R_A2Boom 2 ramp control
“hh : mm : ss” = This entry indicates the time of operation since the last reset or restart.
“USAGE XX” = This entry indicates the current usage of the bus system in percent (0...99).
“!RESET” = By selecting this item, a so-called warm start can be initiated, i.e. the system
is brought to the same condition as after turning on the supply voltage.
! N E W” = Selecting this item brings all parameters in the system to factory-set default.
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In such case, the system will request you to acknowledge by the same keys
if you really want to change the parameters.
“?GERAET” Main Menu (In Service Menu Only!)

After selecting the “?GERAET” main menu, you can scroll the individual submenus and entries with the “⇑” and “⇓” keys.
In the “?GERAET” main menu, all unit-specific settings are concentrated. The following
individual entries can be found:
“TYP XXX” = The type of equipment can be selected here:

NORM Boom 2 / 3 changeover
R_A2 Boom 2 ramp control
Default: NORM
“REP OFF” = This serves to select the concrete pump on-site control mode.
If on-site control is to be activated by a release switch, this parameter must be programmed “ON”.
Default: OFG
“RWK 0” = This switches off the optional agitator (0), and activates it for simple functioning forward only / 1), or for
extended functioning (forward and reverse / 2).
Default: 0
“FHYS 2.0” = This serves to set the hysteresis compensation factory within the range from 1.0 to 10.0.
Default 2.0
“IVOR 50” = This serves to set the driver current within the range from 0 to 200mA.
Default: 50 mA
V2.4 Menus
The V2.4x software version has two different levels of access, the customer menu and the service menu. The customer menu
has the parameter settings for the current that is used for driving the hydraulic valves. These settings are changeable from the
customer menu in the “?PAR” portion of the main menu. The customer menu also allows you to view non-changeable entries
such as inputs to and outputs from the “SCV” card. The customer menu only allows you access to the “SCV” card.
The service menu allows you to access some extra troubleshooting entries in the “SCV” card along with all HCL and DG cards.
Along with this, you can also view the BDI_A (rear operators panel card and the BDI_F (cable remote) card.
On the following pages containing the 2.4 menu structure, the service menu entries are all the entries in the shaded boxes. All
the entries in the unshaded boxes can be accessed from the customer or the service menu. To access the service menu, do the
following:
1. From the “SCV” entry in the controller column, you press the “P” button. This will bring
up the “?PAR” entry in the main menu column.
2. Press the arrow key down “⇓” until the “?SYSTEM” entry is displayed on the mat.
3. Press “P” to display “SCV_S”.
4. Press the “P” key one, then the “C” key once, and finally the arrow up “⇑” key once.
The display should now read NR500.
5. Press the “P” key and a dotted line will appear under the NR500.
6. Press the arrow up “⇑” key until the display reads NR530.
7. Press the “P” key and a dashed line will appear under the NR530. You now have access
to all entries in the customer and service entries.
Every time the unit is reset, either by shutting off the power and turning it back on, or my using the reset function in the mat,
you will automatically be in the customer menu and must re-enter the code to access the service menu.
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Software Versions
There are a few different software versions used on the digital proportional units. The SCV cards have versions
2.2x, 2.3x and 2.4x. The x denotes that there could be another digit in that location, for example 2.46 or 2.48. The
earlier versions (2.2x and 2.3x) have a ? in front of the SCV display on the MAT. The 2.4x version will have a * in
front of the SCV displayed on the MAT. You can also see what version software you have by scrolling to the
“system” entry in the main menu column. Version 2.3x and 2.4x can be used in place of a version 2.2x. The 2.2x
and 2.3x version cannot be used in a unit that has ramp functions for boom controls or remote agitator control, as
used in the 52m’s. The 2.2x and 2.3x also cannot be used in units that have on site activation switches.
On the following pages there is one menu structure for the 2.2x and 2.3x version and one menu structure for the
2.4x version.
The BDI cards or the cards used for the rear panel and remote control box can also have various versions. The
versions are either 1.xx or 2.xx. In the 1.xx version the cards were specific to their location, ie., the BDIA card was
used for the rear panel and the BDIF card was used for the remote box. The 2.xx version is called BDI S and it can
be programmed to be used in the rear panel or remote box. The versions are interchangeable, however the 1.xx
version cannot be used in systems with remote agitator controls as used in the 52m.
The HCL and DG cards have different versions and they are interchangeable and compatible with all SCV card
version
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Software
MENU STRUCTURE Version 2.4X
To cable
remote &
back
panel
*SCV 9 ?PAR ?AUSL ?AUSL 1H 1H1 200 Min. stop current (mA.)
Boom up

Boom down
cards 1S3 900 Max. current (mA.)

?AUSL 2H Boom up
2S1 200 Min. stop current (mA.)

?AUSL 2S Boom down

Boom up

Boom down

Boom up
Boom down

left
Slew
right
Stroke
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?RAMPE ?RAMP UP T1LU 1.0 Only when ramp function is

activated
T1RU 1.0
T2LU 1.0
T2RU 1.0
T3RU 1.0
T3RU 1.0
?RAMP DN T1LD 0.5
T1RD 0.5
T2LD 0.5
T2RD 0.5
T3LD 0.5
T3RD 0.5
RP1 25
RP2 50
RP3 75
?INS ?V24 OK 0 No. of correctly received data blocks.

For proper operation, no. must cont. grow.
No. of errors determined when the checksum
CE 0 was checked. No. must not grow/grow slowly.
No. of errors determined when lengh of a data
FE 0 block checked. No. must not grow/grow slowly.
No. of errors determined when parity was checked.
PE 0 No. must not grow/grow slowly.
No. of errors caused by telegram buffer overflow.
OE 0 No. must not grow/grow slowly.
VE 0 No. of errors caused by software telegram
buffer overflow. No. must not grow/grow slowly.
?TELEGR. W0 0000
W1 0000
W2 0000
W3 0000
W4 0000
W5 0000
CRC 00
?SELECT A1Hs ON
A1Ss ON
A2Hs ON Lock/Unlock
A2Ss ON Proportional
A3Hs ON Outputs
A3Ss ON
A4Hs ON
A4Ss ON
MLs ON
MRs ON
FMs ON
CERR Communication error (See Pg. 4 )
NA_F OFF --------

NA_C OFF --------
STOER 0 --------
Version 2.4X Prop. output
PERR Hardware error
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Rear panel all functions
Sxa 0000 Hexidecimal code
?DIN ?BDI-A
?DIGa Spotlight
ASWa O/F
Horn
HUPa O/F
RTHa O/F Vibrator Manual
Vibrator Automatic
RTAa O/F
Compressor
KPRa O/F
Water Pump
WPEa O/F
Concrete Pump Forward
BPVa O/F
Concrete Pump Reverse
BPRa O/F
Engine Start
MONa O/F
Engine Stop
MOFa O/F
RPM Up
MUPa O/F
RPM Down
MDNa O/F
Local (on)/Remote (off)
FSTa O/F
RE1a O/F Spare
RE2a O/F Spare

Spare
RE3a O/F
FMpa O Stroke Limiter
Remote control all functions
Sxf 0000 hexidecimal code
?BDI_F
?DIGf ?MSTS M 1 O/F Boom 1 Joystick Microswitch
M 23 O/F Boom 2/3 Joystick Microswitch
M 4 O/F Boom 4 Joystick Microswitch
MM O/F Slewing
DSL O/F Push button Left
DSR O/F Push button Right
HUPf O/F Horn

BPV f O/F Concrete Pump Forward
BPRf O/F Concrete Pump Reverse
MON f O/F Engine Start
MOF f O/F Engine Stop
MUPf O/F RPM Up
MDN f O/F RPM Down

RTAf O/F Vibrator Automatic
RP1f O/F Ramp 1
RP3f O/F Ramp 3
RWVf O/F Agitator Forward

RWRf O/F Agitator Reverse
A1p 0 Boom 1 Potentiometer

MDp 0 Slewing Potentiometer
FMpfs 0 Stroke Limiter Potentiometer
Version 2.4X
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?RACK LDKr O/F Alternator D+

UMSr O/F Outrigger
DWLr O/F Slew Left Limit Switch
DWRr O/F Slew Right Limit Switch
BPVr O/F Concrete Pump Forward
BPRr O/F Concrete Pump Reverse
WMNr O/F Water Level Min

RWKr O/F Agitator
REPr O/F Maintenance On
?SOUT 1 MOFo O/F Engine Stop

MONo O/F Engine Start
MDNo O/F RPM Down
MUPo O/F RPM Up
HP1o O/F Horn 1
HP2o O/F Horn 2
ASWo O/F Spotlight
RTEo O/F Vibrator
?SOUT 2 BPRo O/F Concrete Pump Reverse

BPVo O/F Concrete Pump Forward
UMSo O/F Outrigger
WPEo O/F Water Pump
KPRo O/F Compressor
RWKo O/F Agitator
MFUo O/F Boom Movement
BPK o O/F Oil Cooler
RWVo O/F Agitator Forward
RWRo O/F Agitator Reverse
?POUT 1 A1Ho 0 Boom 1 Up Prog. Output Current
A1So 0 Boom 1 Dn Prog. Output Current
A2Ho 0 Boom 2 Up Prog. Output Current

?POUT 2 MR o 0 Slewing R. Programmed Current

ML o 0 Slewing L. Programmed Current
FM o 0 Stroke Limiter Progammed Current
Version 2.4X
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?DIAG WAS ON Restart Protection

NAH O/F Local Mode
FERN O/F Remote Mode
REPB O/F Maintenance Mode

MAST O/F Boom
DWL r O/F Slewing Limit Switch Left
DWR r O/F Slewing Limit Switch Right
LDK r O/F Alternator
WMH r O/F Water Level Min
?SYSTEM SCVS Hardware Version

V2.48 Software Version
TYP NORM Type of Unit
HH:MM:SS Time of Operation Since Last Reset

USAGE XX Current Usage by Bus System in %
! RESET Reset the System
! NEW Return to Factory Setting
Norm R_A2 Boom 2/3 Change

?GERAET TYP NORM Boom 2 Ramp
REPs ON
RWKs 2 Agitator For/Rev mode
FHYs 2.0 Refer to balancing valve currents
IVOR 50 Refer to balancing valve currents
Version 2.4X
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Electrical
Software Rear Panel Card - Controller No. 10 BDI - s

Version 2.1X Card Menu
?BD12 10 SWH HHHH All functional hexadecimal code
?DIGITAL
ASW O/F Spotlight
HUP O/F Horn
RTH O/F Vibrator manual
RTA O/F Vibrator automatic

RPR O/F Compressor
WPE O/F Water pump
BPV O/F Concrete pump forward

BPR O/F Concrete pump reverse
MON O/F Engine start
MOF O/F Engine stop

MUP O/F RPM up
MDH O/F RPM down
FST O/F Remote control/Manual

RE1 O/F Spare
RE2 O/F Spare
RE3 O/F
FMpa XX Stroke limiter set value
"System information" Main Menus

?SYS BDI S Card type/hardware
V2.10 Software version
hh:mm:ss Time of operation since last RESET
USP XX Percentage bus employment

!RESET Reset system / warm start
!N E W Reset parameter to default
TYP A 10 Type selection parameter
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Electrical
Software Rear Panel Card - Controller No. 10 BDI - A

Version 1.30 Card Menu
?BD12 10 SWH HHHH All functional hexadecimal code
% FM XX Stroke limiter set value
?DIGITAL
ASW O/F Spotlight
HUP O/F Horn
RTH O/F Vibrator manual

RPR O/F Compressor
WPE O/F Water pump

MOF O/F Engine stop

MUP O/F RPM up
MDH O/F RPM down
FST O/F Remote control/Manual

RE1 O/F Spare
RE2 O/F Spare
RE3 O/F Spare
?SYS
USP XX Percentage bus employment
TAS XX Task posed by bus communication
BDI A Card type/hardware

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Electrical
Software Remote Control Panel - BDI - S Card Menu

Version 2.1x Programmed Type: F11
Controller No. 11
*BDI 11 SWH HHHH All functional hexadecimal code
?DIGITAL ?MSTS
M1 O/F Boom 1 microswitch
M23 O/F Boom 2/3 microswitch

MM O/F Slewing microswitch
DSL O/F Lt-hand pushbutton
DSR O/F Rt-hand pushbutton
HUPf O/F Horn
BPVf O/F Concrete pump forward
BPRf O/F Concrete pump reverse

MONf O/F Engine start
MOFf O/F Engine stop
MUPf O/F RPM up
MDHf O/F RPM down
RTAf O/F Vibrator automatic input

RP1f O/F Ramp step 1
RP3f O/F Ramp step 3
RWVf O/F Agitator forward
RWRf O/F Agitator reverse
?ANALOG
A1p XX Boom 1 potentiometer (-99 to 99%)

MDp XX Slewing potentiometer (-99 to 99%)
FMp XX Stroke limiter potentiometer (0 - 99%)
?HEXIN
A1x HHH Boom 1 input value
A23xHHH Boom 2/3 input value

A4x HHH Boom 4 input value
MDx HHH Slewing input value
FMx HHH Stroke limiter input value
?CALIB "Calibration" Main Menu
!C START Start automatic calibration
!C STOP Stop automatic calibration

OFS HHHH ADC offset setting
To be continued on next page ...
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Software Remote Control Panel - BDI - S Card Menu

Version 2.1x Programmed Type: F11
Controller No. 11
Continued
?PARM1
1PN HHHH Calibration (do not change)
1PX HHHH Calibration (do not change)
1NN HHHH Calibration (do not change)
1NX HHHH Calibration (do not change)
?PARM2
MPN HHHH Calibration (do not change)
MPX HHHH Calibration (do not change)
MNN HHHH Calibration (do not change)
MNX HHHH Calibration (do not change)
FPN HHHH Calibration (do not change)
FPX HHHH Calibration (do not change)
FNN HHHH Calibration (do not change)
FNX HHHH Calibration (do not change)
MI1 HHHH Calibration (do not change)
MIM HHHH Calibration (do not change)
MF1 HHHH Calibration (do not change)
?SYSTEM "System Information" Main Menu
BDI S Version/ hardware

USAGE XX Percent bus usage
!RESET Reset system / warm start
! NEW Reset parameter to default
TYP F 11 Type selection parameter
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Software Remote Control Panel - BDI - F

Controller No. 11
?BDI1 11
?ANALOG
%A1 XX Boom 1 potentiometer (-99% - 99%)

%MD XX Slewing potentiometer (-99% - 99%)
%FM XX Strk lmtr potentiometer (-99% - 99%)
?HEXIN
A1 HHH Boom 1 (Hexidecimal code)
A23 HHH Boom 2/3 (Hexidecimal code)

MD HHH Slewing (Hexidecimal code)
FM HHH Stroke limiter (Hexidecimal code)
?DIGITAL
SWH HHHH All function hexadecimal code
M23 O/F Boom 2/3

M4 O/F Boom 4
MM O/F Boom slewing
U23 O/F Boom 2/3 pushbutton
HUP O/F Horn

MOF O/F Engine stop
MUP O/F RPM up
MDN O/F RPM down

RE1 O/F Spare 1
RE2 O/F Spare 2
RE3 O/F Spare 3
To be continued on next page ...
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Software Remote Control Panel - BDI - F

Controller No. 11
Continued
?CALIB ?PARMS
1PN HHHH Calibration (don’t change)
1PX HHHH Calibration (don’t change)
1NN HHHH Calibration (don’t change)
1NX HHHH Calibration (don’t change)
BDI 11
!C START Calibration (don’t change)
!C STOP Calibration (don’t change)

OFS HHHH Calibration (don’t change)
?SYS
USP XX Percentage bus usage
TASK XX Task posed by bus communication
BDI F Version type / hardware

?NEW P Reset parameter to default
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.
Software Proportional Current Output Card - HC2L

Version 1.1x Card Menu
Controller Nos. 1 ... 6
*HC2 X ?DATA I1 XXXX Current 1 output

I2 XXXX Current 2 output
S14 :::: Inputs S1, S2, S3, S4
S58 :::: Inputs S5, S6, S7, S8
ER EOK Error message
?CONFIG DFQ XXX Dither frequency in Hz

RPV XXX Solenoid coil initial resistance
?SYSTEM HC2 S Card type / hardware

HH:MM:SS Time of operation since last RESET
USP XX Percent bus usage
! RESET Reset system / warm start

! NEW Set parameter to default
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Software Proportional Current Output Card - HC2L

Version 1.0x Card Menu
Controller Nos. 1 ... 6
?HC2 X ?SERV HH:MM:SS Time of operation since last RESET

HC2L S Hardware version
V1.0x Software version
?CALIB I1L HHHH (Don’t change)

I1H HHHH (Don’t change)
I2L HHHH (Don’t change)
I2H HHHH (Don’t change)
PV 3.0 ----------------
TN 0.06 ----------------
!NEW ENA ----------------
!NEW Return to factory setting
?VARI I1 XXXX Real current 1
I2 XXXX Real current 2
S41 Digital input (4-1)

ER EOK Error indication
?ALLG DF XXX Frequency setting (Hz)
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Switching Valve Output Card -

Software Controller Nos. 7, 8 and 12. Resp. DG8 Card Menu
Version 1.0x (For Agitator FWD/REV Only)
?DG8 X
?SERV "Service Data" Main Menu

DG8 S Card type / hardware
V1.0x Software version
?VARI "Variables" Main Menu
V41 - - - - Outputs V4, V3, V2, V1

V85 - - - - Outputs V8, V7, V6, V5
S41 : : : : Inputs S4, S3, S2, S1
S85 : : : : Inputs S8, S7, S6, S5
ER EOK Error message
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Electrical
Switching Valve Output Card -

Software Controller Nos. 7, 8 and 12. Resp. DG8 Card Menu
Version 1.1x (For Agitator FWD/REV Only)
*DG8 X Controller type w/ network no. (7, 8 or 12)

?VARI "Data" Main Menu
V14 - - - - Outputs V1, V2, V3, V4
V58 - - - - Outputs V5, V6, V7, V8
S14 : : : : Inputs S1, S2, S3, S4
S58 : : : : Inputs S5, S6, S7, S8
?SYSTEM "System Information" Main Menu
DG8 S Card type / hardware

V1.1X Software version
USP XX Percent bus usage
! RESET Reset system / warm start
?TEST "Output Test" Main Menu
TFREE Teset enable

TEST 0/1 Activate test output
TV1 0/1 Act. or deact. V1 output test

Act. or deact. V7 output test
TV7 0/1
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Software Version
MENU STRUCTURE 2.2X & 2.3X

To cable
remote &
back
panel
?SCV 9 ?PAR ?ALLGEM. Fhys 2.0 Refer to balancing valve current

IVOR 50 Refer to balancing valve current
RWK Software version 2.3 only

RAMP Software version 2.3 only
?AUSL.1H 1H1 200 Min. stop current (mA.)

To slave Boom up
cards 1H3 900 Max. current (mA.)
?AUSL.1S 1S1 200 Min. stop current (mA.)

Boom down

?AUSL.2H Boom up

?AUSL.2S 2S1 200 Boom down

Boom up

Boom down

Boom up
Boom down

Slew
ML2 300 Min. start current (mA.)
left

Slew
MR2 300 Min. start current (mA.) right

Stroke
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?INS ?V24 INTS 0

Data received from radio.
bytes.
Amount of received
OK 0 Data received from radio. Amount of correctly

received data.
Data received from radio. Amount of partity
PY 00 faults.
Data received from radio. Amount of reoccuring
OV 00 faults.
FR 00 Data received from radio. Amount of format
faults.
Data received from radio.
W0 0000
W1 0000 Data received from radio.
W3 0000 Original data bytes.
CRC 00 Check overall sum
CERR 0 Communication error (See Pg. 4)
NA_F AUS --------

NA_C AUS --------
STOER 0 --------
Proportional output.
PERR 0 Hardware error.
A1H EIN
A1S EIN
A2H EIN
A2S EIN
A3H EIN
A3S EIN Lock/unlock proportional output
A4H EIN
A4S EIN
ML EIN
MR EIN
FM EIN
?DIN AS 0000 Hexidecimal code from rear panel

FB 0000 Hexidecimal code from remote box
A1 0 Boom 1 Potentiometer (-99 ... 99)

A5 0 Slewing Potentiometer (-99 ... 99)
FM 0 Strk. Limt. Potentiometer (0 ... 99)
Version 2.2X & 2.3X
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?SOUT MOF AUS Engine stop

MON AUS Engine start
MDN AUS RPM Down

MUP AUS RPM Up
HP1 AUS Boom horn
HP2 AUS Slewing horn
ASW AUS Spot light
RTE AUS Vibrator
BPR AUS Concrete Pump Reverse
BPV AUS Concrete pump forward

UMS AUS Boom/outrigger
WPE AUS Water pump
KRP AUS Compressor
RS1 AUS Spare

RS2 AUS Spare
BPK AUS Oil cooler
?POUT A1H 0 Boom 1 Up Prog. Output Current
A1S 0 Boom 1 Down Prog. Output Current
A2H 0 Boom 2 Up Prog. Output Current


MR 0 Slew Rt. Prog. Output Current
ML 0 Slew Lft. Prog. Output Current

FM 0 Strk. Limit. Prog. Output Current
?SYS !RESET Reset system (power off)
USP XX -------------
TASK XX -------------
SCV_S Hardware Version
HH:MM:SS Time since last reset
? NEW P Return to the factory setting
Version 2.2X & 2.3X
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?DG8 8 ?SERV Time since last reset

HH:MM:SS
DG8_S Hardware version
USAGE XX --------------
TASK XX -------------
?VARI V41 Output transistor status (4-1)
V85 Output transistor status (8-5)

?DG8 7 (SAME AS THE "DG8 8")
?HC2 6 ?SERV HH:MM:SS Time of operation since last reset
HC2L_S Hardware version
USAGE XX Percent of bus usage
TASK XX Task passed by bus comm.
?CALIB I1L XXXX (Don’t change)
I1H XXXX (Don’t change)
I2L XXX (Don’t change)
I2H XXXX (Don’t change)
PV 3.0 --------------
TN 0.06 --------------
!NEW ENA --------------
!NEW Return to factory setting
?VARI I1 XXXX Real current 1
I2 XXXX Real current 2

?ALLG DF 200 Frequency setting (Hz)
?HC2 5 (SAME AS THE "HC2 6")

Version 2.2X & 2.3X
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?BDI1 11 ?ANALOG %A1 XX Boom 1 Potentiometer (-99% = 99)

%A2 XX Boom 2 Potentiometer (-99% = 99)
%MD XX Slewing Potentiometer (-99% = 99)
%FM XX StrkLimiter Pot (-99% = 99)
?HEXIN A1 HHH Boom 1 (Hexidecimal code)
A23 HHH Boom 2/3 (Hexidecimal code)

MD HHH Slewing (Hexidecimal code)

FM HHH Strk. Limit. (Hexidecimal code)
?DIGITAL SWH HHHH All functions (Hexidecimal code)

M1 OFF Boom 1 Microswitch
M23 OFF Boom 2/3 Microswitch
M4 OFF Boom 4 Microswitch

MM OFF Slewing Microswitch
U23 OFF Boom 2/3 Pushbutton
HUP OFF Horn
BPV OFF Concrete pump forward

BPR OFF Concrete pump reverse
MON OFF Engine start
MOF OFF Engine stop
MUP OFF RPM Up
MDN OFF RPM Down
RTA OFF Vibrator Automatic
RE1 OFF Spare
RE2 OFF Spare
RE3 OFF Spare
?CALIB ?PRAMS 1PN HHHH Calibration (don’t change)
1PX HHHH Calibration (don’t change)

1NN HHHH Calibration (don’t change)
1NX HHH Calibration (don’t change)

BDI 11 Calibration (don’t change)
!C_START Calibration (don’t change)
!C_STOP Calibration (don’t change)

OFS HHHH Calibration (don’t change)
?SYS USP XX ----------------
TASK XX ----------------
BDI_F Hardware Version

?NEW P Return to factory setting
Version 2.2X & 2.3X
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?BDI2 10 %FM XX Stroke Limiter (%)
?DIGITAL SWH HHHH All Functions (Hexidecimal code)

ASW OFF Spotlight
HUP OFF Horn
RTH OFF Vibrator Manual
RTA OFF Vibrator Automatic
KPR OFF Compressor
WPE OFF Water Pump

BPV OFF Concrete Pump Forward
BPR OFF Concrete Pump Reverse

MON OFF Engine Start
MOF OFF Engine Stop

MUP OFF RPM Up
MDN OFF RPM Down
FST OFF Remote Control/Manual

RE1 OFF Spare
RE2 OFF Spare
RE3 OFF Spare
?SYS USP XX ---------------

TASK XX ---------------
BDI_A Hardware version
Version 2.2X & 2.3X
576 Service Manual

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Digital Proportional - Balancing Valve Currents
Balancing The Valve Currents
With the digital proportional control system, you no longer have to adjust trim pots to fine tune control response.
You can now simply enter the parameters you want and the microprocessor takes care of the rest.
This is called balancing the valve currents, and it is necessary to provide precise synchronization between joystick
control and boom movement.
Incorrect valve current settings will have an adverse affect on the proportionality of the boom.
There are three adjustments or parameters to set for each boom section as well as for slewing and concrete output.
They are the:
• Minimum start current.
• Minimum stop current.
• And maximum driver current.
The minimum start current controls how the boom reacts as the joystick is moved from the neutral position. It is
the lowest level of driver current required to start the boom moving.
Moving the joystick from the neutral position activates a micro switch. Immediately after the micro switch is
activated the current should be at the minimum start level.
This will provide linear proportional control when setting the boom in motion. See Figure 13.
mA MINIMUM START CURRENT
1000
MAXIMUM CURRENT OUTPUT
900
800
MAX
700
600
500
MIN
400
300
200
100
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
MIN MAX
PRETENSION PRESSURE (BAR)
MAX MIN
MICROSWITCH
CLOSED
Figure 13
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If the minimum start current is set too low, the boom will not move with the joystick. This results in a “dead spot”
as the joystick is moved off the neutral position and the micro switch is activated.
Setting the minimum start current too high will cause the boom to start abruptly and bounce after the micro switch
has been activated.
The minimum stop current controls how the boom slows to a stop as the joystick is moved to the neutral position. It
is the precise point at which the driver current falls below the level necessary to keep the boom in motion.
When the driver current reaches this setting, the micro switch should open. This causes the system to go to the 50
milliamp diagnostic level.
If the minimum stop current is set too high, the boom will be moving too fast when the micro switch closes,
causing it to stop abruptly and bounce.
If it is set too low, the boom will stop before the micro switch closes, and you will have an increased dead area.
1000
900
800
MAX
700
600
500
MIN
400
300
200
MIN, START
100
SETTING
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
MIN MAX
MAX MIN
"DEAD" AREA
MICROSWITCH
CLOSED
Figure 14
The maximum current setting controls the amount of driver current available. When properly adjusted, the
hydraulic valve should just contact the mechanical stop as the joystick reaches the 100% position. See Figure 15.
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1000

900
800
MAX
700
600
500
MIN
400
300
200
100
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
MIN MAX
MAX MIN
MICROSWITCH
CLOSED
Figure 15
Hysteresis
Because of the inertia generated by the weight of the boom, the system responds differently when increasing the
driver current (accelerating the boom) than it does to decreasing driver current (slowing the boom). This difference
in response is referred to as hysteresis. To provide smooth transitions when controlling boom speed, a hysteresis
compensation factor is programmed into the system. This setting is located in the “FHYS 2.0” submenu, but the
value should not be changed.
Diagnostic Signal
Part of the systems self diagnostic ability is a result of a 50 mA driver current programmed into the system. This
diagnostic current is applied to both values on axis at the same time. This small amount of current is not enough to
run the boom; however, it does allow the system to detect an open circuit such as a broken wire or faulty solenoid.
Setting Valve Currents

The procedure for setting the valve currents requires the use of the M.A.T. and menu survey. First, find the value
you want to adjust in the display column of the menu survey. These are located in the P-A-R section of the main
menu.Then chart a course back to the SCV9 starting point. Use the M.A.T. to scroll to the desired location and
observe the current value.
Use the following procedure to change the setting:
7. press the program key once. A dotted line appears under the alpha numeric display, the value can now be changed.
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8. Press the arrow keys to adjust the value up or down to the desired setting. If you make a mistake, press the “C” key to start
over.
9. When the parameter is set to the desired value, press the program key again. The dotted line changes to a dashed line indi-
cating the change has been saved.
After setting the driver currents, check the operation of the hydraulic valve by watching the boom and the handle
on the hydraulic valve as you move the joy stick. The boom should just start to move as you move the joy stick off
neutral and you hear the micro switch activate. Then move the joy stick to the 100% position, the handle on the
hydraulic valve should just contact the maximum stop.
Correctly balancing the valve currents precisely tailors the digital controller to the hydraulic system on your unit.
This provides smooth proportional control of boom functions and concrete output.
The initial settings that were programmed into your machine are located on a decal near the digital processor. See
Figure 16.
CURRENT MEASUREMENT DATA

PROPORTIONAL BOOM - DIGITAL
MODEL:
SERIAL NO.
MIN STOPPING CURRENT MIN STARTING CURRENT MAXIMUM CURRENT
FUNCTION (mA) (mA) (mA)
1H1 1H2 1H3
1S1 1S2 1S3
2H1 2H2 2H3
2H1 2H2 2H3
3H1 3H2 3H3
3S1 3S2 3S3
4H1 4H2 4H3
4S1 4S2 4S3
ML1 ML2 ML3
MR1 MR2 MR3
FM1 FM2 FM3
HYSTERESIS COMPENSATION:
DRIVER CURRENT:
Figure 16
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Digital Proportional - Troubleshooting
The digital proportional control is designed with self-diagnostic capabilities built-in to help you quickly and
efficiently locate faults in the system.
When the unit is activated, it continuously monitors the systems and communicates their status using LED’s
located on the digital processor. See Figure 17.
Troubleshooting
LED’s
+ .A12 + A11 + .A10 + .A9 + .A8 + .A7 + .A6 + .A5 + .A4 + .A3
M.A.T.
CONNECTOR
Figure 17
If a problem exists, the first step is to check the status of the LED’s on the digital controller. Use the charts to
interpret the messages communicated by the LED’s, then follow the appropriate troubleshooting (T.S.) procedure
on the following page.
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Troubleshooting
Message Meaning
procedure
None (If a boom function is

All LED’s steady green No faults, system ready inoperative see T. S. proce-
dure 1)
“E” Stop pressed, Main

All LED’s off No power to unit
power switch off
SCV 9 steady green all

Communication error T. S. procedure 2
others off
SCV 9 & HC 2 flashing Hardware fault T. S. procedure 3
SCV 9 flashing Intermit hardware fault T. S. procedure 4
SCV Red M.A.T. plugged in None
Rear panel card off

No faults None
(inside rear panel)
Rear panel blinking Matching blinking error T. S. procedure 4

(inside rear panel) from SCV card
Red LED on cable remote Matching blinking error

T. S. procedure 4
box or LED on card inside from SCV card
cable remote box blinking.
Rear card or cable card

Problem in card Replace card
steady red
NOTE: The rear panel board will light for approximately 1 second on system activation or restart.
Note: The troubleshooting procedures listed below pertain to the electrical system. Make sure that there are no
problems with the hydraulic system before performing any of these procedures.
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Troubleshooting procedure 1
If one boom function is not working and the LED’s are steady green, you’ll need to use the M.A.T. and menu
survey to pinpoint the problem.
To do this, first connect the M.A.T. and scroll to the P-A-R main menu, then to the affected boom display. Check
the minimum start, stop and max current parameters. They should approximate the values written on the decal. If
not, reprogram the function to the correct values. If the parameters are set correctly, scroll to the P-OUT main
menu, then to the affected boom display. Move the joystick and watch the value. When the joystick is at the
neutral position, the reading should be 50, indicating the 50 milliamp diagnostic current. As the joystick is moved
towards the 100% position, the reading should rise to the max current setting. If these functions are not correct, try
using the other remote control panel. If that doesn’t help or the readings are correct but the boom function still is
not working, check the output current of the affected HC 2 card.
If none of the control functions are working and the SCV9 card is steady green, but the other cards are off, it
indicates a communication error between SCV9 and one or more of the slave cards.
To locate the problem, connect the M.A.T. and scroll to the INS main menu. Then scroll to the C-E-R-R display
which is the entry for communication errors. The number in the display indicates the position to the right of the
SCV 9 card where the first error occurred. To determine if the problem is on the card, swap it into another position
of the same card type and reset the system. If the error follows to the new position, the board is defective. If the
error is still in the same position, call Schwing Service for assistance.
If the card that controls the problem function is flashing, along with the SCV9 card, there is a hardware fault
somewhere between the output of the digital processor and the hydraulic valve. To determine if the problem is the
solenoid or the wiring, swap the solenoid caps. If the problem is unchanged, replace the solenoid. If the problem
follows the solenoid caps, the problem is in the wiring. If this is the case, you should consult the electrical
schematics to track the faulty wire.
If the SCV9 is the only card flashing, it means the problem is intermittent, possibly a bad connection. It continues
to flash because it stores fault information in its memory until the system is reset.
Because of the sensitivity of the system the SCV light may blink for various reasons, if resetting the system does
not clear the problem refer to troubleshooting procedure 3.
Resetting the system can be accomplished either by turning the power off and on, or by using the M.A.T.
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Troubleshooting The Radio
The radio remote consists of a transmitter built into the battery powered remote control and a receiver built into the
digital processing unit.
All commands transmitted are safety coded, that is they contain an identifier, so that the unit will only respond to
commands from the correct remote control. The receiver checks the command and passes it on only if it is
complete and correct.
If there is interference, the unit will automatically shut down, however, there are two frequencies available that can
be switched at the remote control. See Figure 18.
When using the radio remote, it is important to stay within a safe operating range, always knowing where the boom
is.
Low Battery Communications E- stop

LED LED LED
Emergency Stop Frequency Selector

Figure 18
There are 3 LED’s on the radio remote. The one on the left warns you when the radio battery voltage is getting low.
The center LED indicates when a digital message is being sent. The E-stop LED lights when the emergency stop
on the transmitter has been pressed.
The rechargeable transmitter battery will operate the system for about 8 hours, depending on the age of the
batteries and the operating conditions.
When the battery warning light starts to flash, you have about thirty minutes operating time left before the unit
shuts down due to low battery voltage. The battery charger is located in the cab of the truck. See Figure 19.
POWER
Figure 19
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The other half of the radio remote control is the receiver, which is located in the truck mounted digital processor. It
receives the digital code from the transmitter, checks to make sure the instructions are correct and complete, then
passes them on to the digital processor. See Figure 20.
SCHWING 20 K28
NG NF MC2 MC1
ST 1
UF K1 TEL ST 2
UE1 K2 REL
UCC1 PROP
UE2 TEL
UCC2 TST 3
NOT1 TST 2
K1 TST 1
T 2 T 1
RADIO CONTROL
FCC ID. DA87G6 FW
SCHWING AMERICA .
GERMANY
SERIAL NR 003 143
FREQ. 456.962S
(mHZ) 457.762S
Radio Receiver
Figure 20
Operation
With the Local/Remote switch located on the rear operators panel in the local mode:
1. Connect the Funk plug or cable remote to the remote receptacle (one or the other must be connected to operate a digital
machine). See Figure 21.
2. Properly set the machine, as described in the operators manual, then turn the mode switch back to the remote position.
FUNK
Figure
3. Make sure all the function switches on the remote control transmitter are in the neutral position.
4. Turn the remote control power supply on. (the LED on the right should start flashing)
5. Turn the power switch located on the transmitter to the “on” position. (the E-stop LED should flash faster) See Figure 22.
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6. Pull the emergency stop button. (the communication LED should now be on)
7. Activate one of the control functions. (the communication LED should start flashing, indicating messages are being sent)
Low Battery Communications E- stop

LED LED LED
Emergency Stop Frequency Selector
Figure 22
Emergency Stop
Pushing the emergency stop button stops the main functions of the machine.
Automatic Shut down

The unit will automatically shut down in case of:
• Low battery voltage
• Message errors.
• Electronic module failure.
• No command messages sent for 30 minutes.
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Trouble-shooting
Many problems with the radio remote control can be identified by interpreting the LED’s on the radio receiver.
The following is a brief explanation of the LED’s:
NG= power supply
UF= vehicle system voltage
UE 1= controller 1 supply
UCC 1= controller 1 supply (+5V)
UE 2= controller 2 supply
UCC 2= controller 2 supply (+5V)
NOT 1= EMERGENCY STOP circuit of controller 1 for controller MC 1
NOT 2 = EMERGENCY STOP circuit of controller 1 for controller MC 2
HF= receiver
K1= RF-channel 1 selected
K2= RF-channel 2 selected
MC 2= controller 2
data message reception
TEL= data message recepton
MC 1= controller 1
ST 1= controller 1 failure
ST 2= controller 2 failure
REL= relay output defective
PROP= proportional control output defective
TEL= data message recepton
TST3= data message error 3
TST2= data message error 2
TST1= data message error1
SCHWING F W 20 K28 V24
NG HF MC2 MC1
ST 1
UF K1 TEL ST 2
UE1 K2 REL
UCC1 PROP
UE2 TEL
UCC2 TST 3
NOT1 TST 2
NOT2 TST 1
T2 T1
RADIO CONTROL FW20

FCC ID. DA87G6 FW20RL
GERMANY
SERIAL NR 003 143
FREQ. 456.962S
(mHZ) 457.762S
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Troubleshooting tables
REMEDIAL
LED DISPLAY MESSAGE
ACTION
UF, UE1, UCC1, UE2, Switch in, check power
None lit Machine power failure
UCC2 supply
UF, On Power supply failure, short-

Call Schwing Service
UE1, UCC1, UE2, UCC2 One off circuit in receiver
Emergency stop activated

Unlock “E” stop
NOT1, NOT2 ON Fault detected by electronic
See MC1
system
NOT1, NOT2 Off but no function Fuse defective Replace fuse
REMEDIAL
LED DISPLAY MESSAGE
ACTION
Switch on transmitter,
Transmitter scan, no radio
choose better transmitter
K1, K2 Alternately flashing contact
location, check antenna
Message format error
See MC1
REMEDIAL
LED DISPLAY MESSAGE
ACTION
Transmitter off, no radio Switch on transmitter,
contact choose better transmitter
TEL Irregular flashing
Transmitter defective, RF location, check antenna
section defective Call Schwing Service
REMEDIAL
LED DISPLAY MESSAGE
ACTION
Failure in MC1 or in periph-
ST1 On ery module, e.g. REL, NG, Call after Schwing Service
PROP
Failure in MC2, no
ST2 On Call after Schwing Service
exchange of data
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REMEDIAL
LED DISPLAY MESSAGE
ACTION
Vehicle power supply volt-
PROP On Check vehicle power supply
age <20V resp.>28V
TEL No radio reception

Irregular flashing Check transmitter and
Transmitter off or defective
antenna
TST2 On Antenna not installed or
defective
REMEDIAL
TST TST TST
MESSAGE ACTION
3 2 1
❍ ❍
No empty message after switch-on emergency Set control element to “0” position
● shut-off activated Unlock “E” stop
HF interference3 Call Schwing Service
❍ ● ❍ Format error in pulse-coded message

Change frequency if fault cannot be rectified
❍ ● ● Format error in proportional message

✸ ✸ ❍ Another transmitter with the same frequency

nearby, message affected by address error
✸ ✸ ✸ Message affected by mode error, encoder

switch in wrong position
Change frequency check encoder switch.
● ● ❍ Message affected by cyclic redundancy check

error
● ● ● Emergency stop message Rectify fault, unlock “E” stop
● = LED ON ❍ = LED OFF ✸ = LED Flashing
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590 Service Manual

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Comfort Control Manual

Chp. Contents Page
1.0 Working with the info & diagnosis system

1.1 Introduction into the info & diagnosis system 2
1.2 Menu structure of the info & diagnosis system / Operation data display 4
2.0 Parameter setting concrete pump efficiency / Central lubricating system /

Prop characteristics
2.1 Password entry and parameter selection menu 9
2.2 Setting the concrete pump efficiency for pumped volume determination 10
2.3 Setting the central lubricating system 11
2.4 Setting proportional parameters for boom functions 12
3.0 I/O status display signals & references

3.1 Machine control 15
3.2 Concrete pump control 17
3.3 Boom control 18
3.4 Rear panel 20
3.5 Extension module (central lubricating system) 22
4.0 Fault messages and fault causes

4.1 Introduction / Structure of error codes 23
4.2 Control diagnosis electronic modules (fault code S) 24
4.3 Remote control system diagnosis (fault code F) 25
4.4 Machine diagnosis - General (fault code A) 26
4.5 Diesel engine diagnosis / P.T.O. (fault code D) 28
4.6 Concrete pumpe diagnosis (fault code B) 30
4.7 Boom control diagnosis (fault code M) 31
4.8 Central lubricating system
diagnosis / Extension (fault code Z / E) 34
5.0 Interdependence list of most important output signals 35
Annex :Overview info center menu
Vers.: 1.2 Status:02.10.97 U.Weber (TEW)
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1.0 Working with the info & diagnosis system
1.1 Introduction into the info & diagnosis system
The SCHWING info & diagnosis system for truck-mounted concrete pumps is located in the rear panel unit at the
rear step-ladder of the machine and is operated with the display and the 6 function buttons below.
The info system offers the following functions :
-Pumped volume determination by means of stroke counter and pumped volume calculation
(cf. 1.2.3)
-Extensive operational data acquisition and display (cf. 1.2.4)
-Safely stored malfunction list of the last 100 malfunction messages (cf. 1.2.5)
-Manual operation of lubricating cycles (cf. 1.2.6)
-Status display of all signals of the electric control (cf. 1.2.7 & 3.0)
-Password-protected efficiency adjustment for the pumped volume determination of the concrete pump (cf. 2.0)
-Password-protected parameter setting for the central lubricating system (cf. 2.0)
-Password-protected parameter setting for the proportional boom functions (cf. 2.0)
The diagnosis system monitors the control unit, the machine and partly also the vehicle for malfunctions or
inadmissible states of operation.
The system recognizes e.g. parting of cables or short-circuits in electric lines of solenoids, Fault sensors,
contaminated oil filters or critical hydraulic oil or diesel engine temperatures and displays different operating
conditions.
The system is to assist the concrete pump operator in his work on site and to inform him about the possible causes
of malfunctions when they occur.
The malfunction messages are displayed as continuous text in the form of an easily understandable plain language
message with additional fault code. The manual contains a detailed description of the faults for each fault code (cf
4.0)
In case of recognized malfunctions, the diagnosis system distinguishes between minor faults and severe faults.
Minor faults do not require immediate elimination of the fault cause and the machine can be used - possibly with
some restrictions - until the job is finished
A severe fault bears the risk that the machine or the vehicle may be severely damaged. An immediate elimination of
the fault cause is therefore necessary.
If the integrated diagnosis system recognizes a malfunction or an inadmissible state of operation of the machine, a
horn sounds intermittently and a fault message appears on the display of the rear panel unit.
Moreover, the last 100 recognized malfunctions are stored safely in a malfunction list together with date and time.
They can be recalled at any time.
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In case of a minor fault, the horn signal and the fault message can be switched off by means of the "Hupe / quitt"
button on the remote control box or the cable control box. Switching off the horn does not delete the fault message.
To prevent fault messages from getting lost, a fault message is recalled whenever one of the two "hydraulic on
outriggers" buttons (at the outrigger control block) is recalled and displayed, and until the operator has read the
fault message displayed and acknowledged the message at the rear panel stand with the [QUITT] button below the
display.
Pressing the [QUITT] button once only shuts off the horn signal with the fault message still being displayed. Only
after the [QUITT] button has been depressed a second time, the fault message is deleted from the display.
In the event of severe faults, the horn signal cannot be cancelled with the buttons on the remote control box.
The operator can therefore recognize severe faults by the fact that the horn signal continues to sound although the
[Hupe / quitt] button on the remote control box or the cable control box has been actuated.
Since severe faults cause considerable damage of the machine, the concrete pump operator must inform himself at
the display of the diagnosis system on the machine about the fault occurred. In the event of severe faults, the horn
signal can be cancelled and the fault message be deleted only with the [QUITT] button below the diagnosis display.
Fault messages are also definitely cancelled when the electric control system is switched off.
The operator himself is responsible for the elimination of indicated faults in order to prevent the machine from
being damaged.
If the message of a fault that has not been eliminated is being cancelled, there is no new fault indication.
A persistant fault will however be recognized and reported again by the diagnosis system after the machine has
been de-activated with the EMERGENCY SHUT-OFF button on the machine or on the remote control box.
SCHWING is not responsible for damage caused by non-eliminated faults of the machine !
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1.2 Menu structure info & diagnosis system / Operation data display
The SCHWING diagnosis system is operated with 6 buttons below the display at the rear panel stand.
The diagnosis system is based on an easily understandable menu system in form of a so-called tree structure.
Depressing the [ENTER] button always branches into the next menu level or recalls the displayed function. The
[CLEAR] button returns to the previous menu level. If further branching into another sub-menu is possible, the
second line in the display shows " ↓ / ↑ / ENTER / CLEAR ".
Depressing [ENTER] switches the info & diagnosis system on, displaying the main menu after the standard
window.
(cf. annex : Overview info center menu)
The buttons on the display have the following functions :

[ ↓ ] or [ ↑ ]menu up or down
[ENTER]menu item selection / confirmation / activation of next menu level
[CLEAR]interrupt actual function and back to previous level in menu system
[QUITT]fault message acknowledge / horn shut-off
[START]start of a function (pumped volume counter / manual lubrication)
The operation of the diagnosis system on all menu levels is explained on the following pages.
The message displayed is shown in a frame. The menu functions and the selection of special functions is described
by the key symbols in brackets and the pertaining explanantions.
1.2.1 Standard display & malfunction messages
INFO SYSTEM [ ENTER ] → Call up main menu (cf. 1.2.2)

ENTER = On
When the diagnosis system recognizes a malfunction of the machine or the electrical system, the actual
message on the display is overwritten with the actual fault message.
MALFUNCTION 1. x [ QUITT ] → Shut off horn signal

(CODE) FAULT MESSAGE
2. x [ QUITT ] → Fault message cancel / acknowledge !
Please observe also the detailed description of fault acknowledgement in 1.1.
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1.2.2 Main menu
PUMPED VOLUME [ ENTER ] → Sub-menu "Pump Volume" for

↓ / ENTER / CLEAR
pump volume calculation (cf. 1.2.3)
[↓] [ CLEAR ] → Back to start window
OPERATION DATA [ ENTER ] → Call up "Operation Data" sub-menu

↓ / ↑ / ENTER / CLEAR
(cf. 1.2.4)
[ ↓ ] [ ↑ ] [ CLEAR ] → Back to start window
MALFUNCTION LIST [ ENTER ] → Call up "Malfunction List" sub-menu

(cf. 1.2.5)
LUBRICATION-UNIT [ ENTER ] → Call up "Central Lubrication" sub-menu

(cf. 1.2.6)
I/O STATUS DISPL [ ENTER ] → Call up "I/O display" sub-menu

(cf. 1.2.7)
INTERNAL TIMER [ ENTER ] → Display of date and time of internal timer

(CLEAR = back)
SCROLLING [ ENTER ] → Scrolling rate fault message adjust

(cf. 1.2.8)
PARAMETERS [ ENTER ] → Call up "Parameter" menu

↑ / ENTER / CLEAR
(cf. 2.0)
[ ↑ ] [ CLEAR ] → Back to start window
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1.2.3 "PUMP VPUME" sub-menu
PUMPED ON JOB (S) [ START ] → Start new pump volume determination &
≈ 1723.5 cbm
delete old value (cf. 2.2)
[ CLEAR ] → Back to main menu
1.2.4 "OPERATION DATA" sub-menu
HYD OIL TEMP Display of actual oil temperature in hydraulic oil reservoir
062 ßC
[↓] [ CLEAR ] → Back to main menu
PTO SHAFT RPM Display of actual rpm of PTO.

1270 rpm
[↓] [↑] [ CLEAR ] → Back to main menu
HYD PRESSURE CP Display of actual oil pressure in concrete pump circuit

159 bars
CONCR-PUMP HOURS Display of stored operating hours concrete pump

328.3 h
BOOM HOURS Display of stored operating hours

406.1 h
placing boom
PTO HOURS Display of stored operating hors

469.8 h
PTO.
TOTAL STROKES CP Display of stored total number of strokes of concrete pump

18529417 strokes
TOTAL VOL. PUMPED Display of stored total pumped quantity of concrete pump
1491258 cbm
STROKES PER MIN Display of actual number of strokes of concrete pump in strokes/
21.4 S/min
min
[↑] [ CLEAR ] → Back to main menu
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1.2.5 "MALFUNCTION LIST" sub-menu
16.03.93 / 12:34 [ ↓ ] / [ ↑ ] → Scrolling up & down malfunction list

(CODE) FAULT TEXT (cf. 4.0)
1.2.6 "LUBRICATION-UNIT" sub-menu
MANUAL LUBRIC. [ START ] → Manual lubrication starts

CP & Agitator

Boom

Outriggers
1.2.7 "I/O DISPLAY" sub-menu
MACHINE-CONTROL [ ENTER ] → Call up I/O display for machine control module (cf.
↓ / ENTER / CLEAR
3.1)
CP-CONTROL [ ENTER ] → Call up I/O display for concrete pump control mod-
ule (cf. 3.2)
BOOM-CONTROL [ ENTER ] → Call up I/O display for boom control module (cf.
3.3)
REAR PANEL [ ENTER ] → Call up I/O display for rear panel module (cf. 3.4)
EXTENSION I/O [ ENTER ] → Call up I/O display for extension module
↑ / ENTER / CLEAR
(cf. 3.5)
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1.2.8 SCROLLING" sub-menu
This sub-menu can be used to adjust the so-called "SCROLLING rate" (running speed) of fault message texts in the
display.
For easier checking during adjustment, the "SCROLL-speed" text always moves through the first line of the display
at the actually set speed.
Depressing [ ENTER ] activates the adjusting mode for the scrolling rate.
The activation of the adjusting mode is indicated by a flashing scrolling rate (300 ms) in the display.
By depressing the [ ↓ ] [ ↑ ] keys, the scrolling-speed rate can be changed by 50 ms at a time. Depressing [ ENTER
] stores the set value and quits the adjusting mode.
Scrolling speed [ ENTER ] → Activate adjusting mode

300 ms
[ ENTER ] ← Store set value
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2.0 Concrete pump efficiency parameter setting / Central lubrication / Prop
characteristics
2.1 Password entry and parameter selection menu
Unintentional or unauthorized access to the adjustment of set values (parameters) for the pumped volume
determination of the concrete pump for the central lubrication and the prop current characteristics of the boom
functions is protected by a password.
After selecting "PARAMETER" in the main menu, the password must be entered first.
PASSWORD **** [ ↓ ] [ ↑ ] → Enter password and then press

[ ENTER ]
Explanation :
The password can be entered with the [ ↓ ] [ ↑ ] keys. If one of the keys is kept depressed, the password display
starts incrementing slowly. After abt. 5 seconds, the display starts incrementing faster and after further 5 seconds,
the speed increases once again.
After pressing [ ENTER ] and after the correct password has been selected, the display shows "Password OK" and
jumps to the parameter selection menu.
In the event of a wrong password, the display shows "Password wrong" and the diagnosis system goes back to the
standard display.
CP EFFICIENCY [ ENTER ] → Parameter setting for pumped volume calculation

↓ / / ENTER / CLEAR
of concrete pump
(cf. 2.2)
[↓] [ CLEAR ] → Back to PASSWORD entry
LUBRIC. PARAM [ ENTER ] → Call up parameter menu for central lubrication (cf.
2.3)
PROP-CUR SLEW [ ENTER ] → Select parameter setting for BOOM SLEW function
PROP-CUR BOOM 1 [ ENTER ] → Select parameter setting for boom function BOOM
1
[↓] [↑] [ CLEAR ] → Back to PASSWORD entry
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2
3
4
/ ↑ / ENTER / CLEAR
5
[↑] [ CLEAR ] → Back to PASSWORD entry
2.2 Setting the concrete pump efficiency for pumped volume determination
The volumetric efficiency of the pumped volume calculation (efficiency CP) of the concrete pump can be set in this
parameter menu.
The setting acts on the pumped volume counter (PUMPED VOLUME) and on the total pumped quantity of the
concrete pump (TOTAL VOL. PUMPED).
The pumping volume of the concrete pump is determined by counting the pump strokes and by calculating the
delivery rate by means of the pumped volume of the pumping cylinder and the CP EFFICIENCY:
EFFICIENCY CP should therefore be an average value for the pump efficiency of the concrete pump depending on
the most often pumped concrete qualities.
[ ENTER ] activates the setting mode for the "Concrete pump efficiency" parameter.
The activation of the adjusting mode is indicated by a flashing percentage for the pumped quantity efficiency in the
display.
The efficiency concrete pump value can then be changed in steps of 1% by pressing the [ ↓ ] [ ↑ ] keys.
Depressing [ ENTER ] stores the set value and quits the adjusting mode.
EFFICIENCY CP [ ENTER ] → Activate adjusting mode

92 %
[ ENTER ] ← Store set value
[ CLEAR ] → Back to parameter selection menu
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2.3 Adjusting the central lubrication
The lubricant amount of the individual circuits of the central lubrication system can be set individually by
presetting the number of greasing cycles if the supplementary module for intelligent central lubrication is installed.
[ ENTER ] activates the adjusting mode for one lubricating circuit.

The activation of the adjusting mode is indicated by a flashing lubricating cycle number in the display.
The number of lubricating cycles can be re-adjusted for the selected lubricating circuit within a range of 0 and 20
greasing cycles by depressing the [ ↓ ] [ ↑ ] keys. Depressing [ ENTER ] stores the set value and quits the adjusting
mode.
If "0" lubricating cycles have been preset, the corresponding lubricating circuit is shut off.
LUBRIC. CYCLE [ ENTER ] → Activate parameter setting for placing boom greas-
BOOM 09
ing circuit
[↓] [ CLEAR ] → Back to parameter selection menu
LUBRIC. CYCLE [ ENTER ] → Activate parameter setting for concrete pump/agita-

CP/AGITATOR 12
tor greasing circuit
[ ↓ ] [ ↑ ] [ CLEAR ] → Back to parameter selection menu
LUBRIC. CYCLE [ ENTER ] → Activate parameter setting for outrigger greasing

OUTRIGGERS 07
circuit
[ ↑ ] [ CLEAR ] → Back to parameter selection menu
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2.4 Adjusting the proportional parameters for boom functions
The electrical characteristics of the proportional valves can be individually adjusted for each boom function.
The correct adjustment of a proportional characteristics curve requires profound machine knowledge and should
only be carried out by specially trained personnel.
Since a machine with wrong settings may get into unsafe operating states, SCHWING GMBH assumes no liability
for events occurring as a consequence of proportional characteristics settings modified by the customer.
After selection of a boom function, 4 parameters can be adjusted for each axis.
For each direction (extend / retract or slew right / left) the pertaining MIN and MAX value of the proportional
characteristics curve can be set.
Depending on the proportional valves installed in the machine, there are two different methods of setting the prop
value parameters.
For prop-current-controlled valves (e.g. REXROTH) the characteristic values are set as current values in mA (valve
type: PROP).
For PWM-controlled valves (e.g. APITECH) the characteristic values are set as percentages of the PWM ratio
(valve type: PULSAR).
[ ENTER ] activates the adjusting mode for a prop parameter.

The activation of the adjusting mode is indicated by a flashing prop parameter value in the display.
The set value can then be changed by depressing [ ↓ ] [ ↑ ] by 10 mA resp. 1 % for the selected prop parameter.
Depressing [ ENTER ] stores the set value and quits the adjusting mode.
The adjusting ranges of the prop current values are limited as follows :
- Current value for "I min" within 250 mA to 1000 mA.
(The set value must be less than the value for "I max")
- Current value for "I max" within 500 mA to 1500 mA.
(The set value must be greater than the value for "I min")
The adjusting ranges of the PWM percentages are limited as follows :

- Value for "PWM min" in a range of 20 % to 60 %.
(The set value must be less than the value for "PWM max")
- Value for "PWM max" in a range of 40 % to 100 %.
(The set value must be greater than the value for "PWM min")
The following examples illustrate changes of the proportional values for the BOOM SLEWING MECHANISM for
valves of the PROP type and for BOOM SECTION 1 for valves of the PULSAR type.
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Proportional characteristics adjustment for the BOOM SLEW function with PROP valve
types :
BOOM SLEW RIGHT → Display of actual value for proportional current boom slew
I act 510 mA
right !
[↓] [ CLEAR ] → Back to boom functions selection menu
BOOM SLEW RIGHT [ ENTER ] → Activate parameter adjustment for MIN current of
I min 340 mA
boom slew right function
[ ↓ ] [ ↑ ] [ CLEAR ] → Back to boom functions selection menu
BOOM SLEW RIGHT [ ENTER ] → Activate parameter adjustment for MAX current of
I max 850 mA
boom slew right function
BOOM SLEW LEFT → Display of actual value for proportional current boom slew left
I act 470 mA
BOOM SLEW LEFT [ ENTER ] → Activate parameter adjustment for MIN current of
I min 340 mA
boom slew left function
BOOM SLEW LEFT [ ENTER ] → Activate parameter adjustment for MAX current of
I max 850 mA
boom slew left function
[ ↑ ] [ CLEAR ] → Back to boom functions selection menu
etc. for all boom sections
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Proportional characteristics adjustment for the BOOM 1 function with PULSAR valve
types :
BOOM 1 EXTEND → Display of actual value for the actual PWM boom 1 extend
PWM act 43 %
value
[↓] [ CLEAR ] → Back to boom functions selection menu
BOOM 1 EXTEND [ ENTER ] → Activate parameter adjustment for MIN value of

PWM min 31 %
boom 1 extend function
BOOM 1 EXTEND [ ENTER ] → Activate parameter adjustment for MAX value of

PWM max 87 %
boom 1 extend function
BOOM 1 RETRACT → Display of actual value for the actual PWM boom 1 retract
PWM act 49 %
value
BOOM 1 RETRACT [ ENTER ] → Activate parameter adjustment for MIN value of

PWM min 23 %
boom 1 retract function
BOOM 1 RETRACT [ ENTER ] → Activate parameter adjustment for MAX value of

PWM max 67 %
boom 1 retract function
[ ↑ ] [ CLEAR ] → Back to boom functions selection menmu
etc. for all boom sections
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3.0 I/O status display - signals & references
The status display of all inputs & outputs shows the real state of the respective input or output!
( ■ = high = +24 V / ❏ = Low = 0 V )
The arrow keys [ ↓ ] [ ↑ ] are used to move between the status displays !
[ CLEAR ] returns to the module selection of the I/O displays !
3.1 Machine control
INP MACHINE-C1
1■2❏3❏4■5■6❏7❏8■
LED Signal Module / Assembly Connector / Pin

1 ??? Gearbox in neutral position Machine control 1 (-A231) -X231 / 05
2 Battery charge monitor (signal at D+) Machine control 1 (-A231) -X231 / 17
3 Pushbutton "Hydraulic on outriggers" Machine control 1 (-A231) -X231 / 19
4 Signal "High truck coolant temperature" Machine control 1 (-A231) -X231 / 28
5 Signal "Engine safety stop" Machine control 1 (-A231) -X231 / 10
6 Signal "Low truck oil pressure" Machine control 1 (-A231) -X231 / 23
7 Reserve Machine control 1 (-A231) -X231 / 21
8 Prox-switch PTO RPM Machine control 1 (-A231) -X231 / 13
OUTP MACHINE-C1
1■2❏3❏4■5■6❏7❏8■

1 Engine Start Machine control 1 (-A231) -X231 / 04
2 Engine Stop Machine control 1 (-A231) -X231 / 16
3 Engine RPM speed up Machine control 1 (-A231) -X231 / 06
4 Engine RPM speed down Machine control 1 (-A231) -X231 / 15
5 Solenoid "Agitator forwards" Machine control 1 (-A231) -X231 / 08
6 Solenoid "Agitator backwards" Machine control 1 (-A231) -X231 / 18
7 Solenoid "Hydraulic on outriggers" Machine control 1 (-A231) -X231 / 27
8 Relay oil cooler on Machine control 1 (-A231) -X231 / 07
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INP MACHINE-C2
1■2❏3❏4■5■6❏7❏8■

1 Level switch water reservoir Machine control 2 (-A251) -X251 / 05
2 Signal "PTO engaged" Machine control 2 (-A251) -X251 / 17
3 Oil filter monitor concrete pump Machine control 2 (-A251) -X251 / 19
4 Oil filter monitor boom hydraulics Machine control 2 (-A251) -X251 / 28
5 Level switch hydraulic reservoir Machine control 2 (-A251) -X251 / 10
6 Over-temperature switch compressor Machine control 2 (-A251) -X251 / 23
7 Engine Start ch. pump rams Machine control 2 (-A251) -X251 / 21
8 Engine Stop ch. pump rams Machine control 2 (-A251) -X251 / 13
OUTP MACHINE-C2
1■2❏3❏4■5■6❏7❏8■

1 Relay "Agitator on" Machine control 2 (-A251) -X251 / 04
2 Solenoid "Water pump on" Machine control 2 (-A251) -X251 / 16
3 Relay "Boom horn" Machine control 2 (-A251) -X251 / 06
4 Relay "Slewing-gear horn" Machine control 2 (-A251) -X251 / 15
5 Solenoid "Compressor on" Machine control 2 (-A251) -X251 / 08
6 Solenoid "High-pressure water pump" Machine control 2 (-A251) -X251 / 18
7 Solenoid "End-hose unlock" Machine control 2 (-A251) -X251 / 27
8 Alarm output (optional !) Machine control 2 (-A251) -X251 / 07
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3.2 Concrete pump control
INP CP-CONTROL
1■2❏3❏4■5■6❏7❏8■
LED Signal Module / Assembly _____ Connector / Pin

1 Local switch concrete pump on Concrete-pump control (-A201) -X201 / 05
2 Local switch concrete pump forwards Concrete-pump control(-A201) -X201 / 17
3 Local switch concrete pump reverse Concrete-pump control(-A201) -X201 / 19
4 ??? Hopper-grate limit switch Concrete-pump control (-A201) -X201 / 28
5 Soft-start limit switch on Concrete-pump control (-A201) -X201 / 10
6 Soft-start limit switch off Concrete-pump control (-A201) -X201 / 23
7 CP stroke count limit switch Concrete-pump control (-A201) -X201 / 21
8 Reserve Concrete-pump control (-A201) -X201 / 13
OUTP CP-CONTROL
1■2❏

1 Switch valve CP forwards ON Concrete-pump control (-A201) -X201 / 04
2 Switch valve CP reverse ON Concrete-pump control (-A201) -X201 / 16
STROKE LIMITER Tendency display prop current stroke limiter

■■■■■■■
adjustment for concrete pump!
[↓]
PRESS LIMITER CP Tendency display prop current pressure

■■■■■■
limiting valve! (at present not relevant)
[↓]
HYD PRESSURE CP Tendency display for pressure pick-up signal

■■■■■
concrete pump hydraulics!
[↓]
HYD OIL TEMP Tendency display temperature sensor signal

■■■■■■■■■■
hydraulic reservoir!
Signal Module / Assembly Connector / Pin
Output pressure-regulating valve stroke lim. CP Concrete pump control (-A201) -X201 / 11
Output pressure-regulating valve soft-start Concrete pump control (-A201) -X201 / 02
Analog input oil pressure concrete pump Concrete pump control (-A201) -X201 / 25
Analog input oil temperature hydraulics Concrete pump control (-A201) -X201 / 14
Service Manual 607

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Electrical
3.3 Boom control
INP BOOM-C1
1■2❏3❏4■5■6❏
LED Signal Module / Assembly Connector/Pin

1 Cam switch boom-slew right 1 Boom control 1 (-A161) -X161 / 07
2 Cam switch boom-slew right 2 Boom control 1 (-A161) -X161 / 17
3 Cam switch boom-slew left 1 Boom control 1 (-A161) -X161 / 26
4 Cam switch boom-slew left 2 Boom control 1 (-A161) -X161 / 08
5 Boom-slew cab protection switch 1 Boom control 1 (-A161) -X161 / 25
6 Boom-slew cab protection switch 2 Boom control 1 (-A161) -X161 / 27
INP BOOM-C2
1■2❏3❏4■5■6❏
LED Signal Module / Assembly Connector/Pin

1 Cab protection switch boom 1 < 50 grd 1 Boom control 2 (-A181) -X181 / 07
5 Cab protection switch boom 1 > 180 grd 1 Boom control 2 (-A181) -X181 / 25
6 Cab protection switch boom 1 > 180 grd 2 Boom control 2 (-A181) -X181 / 27
BOOM-SLEW RIGHT Tendency display prop output value boom- slewing!

■■■■■■■■■■
[↓]
BOOM-SLEW LEFT
■■■■■
[↓]
BOOM 1 EXTEND Tendency display prop output value

■■■■■■■■■■
boom 1
[↓]
BOOM 1 RETRACT ■■■■

[↓]

■■■■■■■■■■ boom 2!
[↓]
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BOOM 2 RETRACT
■■■■■■
[↓]

■■■■ boom 3!
[↓]
BOOM 3 RETRACT
■■■■■■■■■■
[↓]

■■■■■ boom 4!
[↓]
BOOM 4 RETRACT
■■■■■
[↓]

■■ boom 5
[↓]
BOOM 5 RETRACT
■■■■■■■
Output "boom-slew right" solenoid Boom control (-A161) -X161 / 21
Output "boom-slew left" solenoid Boom control 1 (-A161) -X161 / 12
Output "boom 1 extend" solenoid Boom control 1 (-A161) -X161 / 03
Output "boom 1 retract" solenoid Boom control 1 (-A161) -X161 / 13
Service Manual 609

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3.4 Rear panel
INP REAR PANEL 1

1■2❏3❏4■5■6❏7❏8■

1 Switch signal "Rear panel" Panel at step-ladder (-A1) -1X / 01
2 Pushbutton signal "Engine start" Panel at step-ladder (-A1) -1X / 02
3 Pushbutton signal "Engine stop" Panel at step-ladder (-A1) -1X / 03
4 Pushbutton signal "r.p.m.speed up" Panel at step-ladder (-A1) -1X / 04
5 Pushbutton signal "r.p.m. speed down" Panel at step-ladder (-A1) -1X / 05
6 Switch signal "CP forwards" Panel at step-ladder (-A1) -1X / 06
7 Switch signal "CP backwards" Panel at step-ladder (-A1) -1X / 07
8 Switch signal "Agitator forwards" Panel at step-ladder (-A1) -1X / 08
INP REAR PANEL 2

1■2❏3❏4■5■6❏7❏8■

1 Switch signal "Agitator backwards" Panel at step-ladder (-A1) -1X / 09
2 Switch signal "Agitator manual ON" Panel at step-ladder (-A1) -1X / 10
3 Switch signal "Agitator automatic ON" Panel at step-ladder (-A1) -1X / 11
4 Pushbutton signal"Boom-horn ON" Panel at step-ladder (-A1) -1X / 12
5 Switch signal "Water pump ON" Panel at step-ladder (-A1) -1X / 13
6 Switch signal "Compressor ON" Panel at step-ladder (-A1) -1X / 14
7 Switch signal "High-pressure WP ON" Panel at step-ladder (-A1) -1X / 15
8 Pushbutton signal "End-hose unlock" Panel at step-ladder (-A1) -1X / 16
INP REAR PANEL 3

1■2❏3❏4■

1 Agitator reverse Panel at step-ladder (-A1) -1X / 17
2-4 Reserve Panel at step-ladder (-A1) -1X / 18 - 20
OUTP REAR PANEL

1■2❏3❏4■

1 Cab protection warning lamp Panel at step-ladder (-A1) -1X / 21
2-4 Reserve Panel at step-ladder (-A1) -1X / 22 - 24
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POT REAR PAN SL Tendency display potentiometer input signal

■■■■■■■
stroke limiter concrete pump !

Potentiometer input "Stroke limiter CP" Panel at step-ladder (-A1) -1X / 25
3.5 Extension module
INP EXTENSION
1■2❏3❏4■5■6❏7❏8■

1 Cycle switch lubric. circuit 1 (boom) Machine control 3 (-A271) -X271 / 05
2 Cycle switch lubric. circuit 2 (CP) Machine control 3 (-A271) -X271 / 17
3 Cycle switch lubric. circuit 3 (outriggers) Machine control 3 (-A271) -X271 / 19
4 Input "Central lubrication inhibit" Machine control 3 (-A271) -X271 / 28
5 Free digital input 1 Machine control 3 (-A271) -X271 / 10
OUTP EXTENSION
1■2❏3❏4■5■6❏7❏8■

1 Lubricating pump on Machine control 3 (-A271) -X271 / 04
2 Lubric. distrib. valve circuit 1 (boom) Machine control 3 (-A271) -X271 / 16
3 Lubric. distrib. valve circuit 2 (CP) Machine control 3 (-A271) -X271 / 06
4 Lubric. distrib. valve circuit 3 (outriggers) Machine control 3 (-A271) -X271 / 15
5 Free digital output 1 Machine control 3 (-A271) -X271 / 08
Service Manual 611

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4.0 Fault messages and fault causes
4.1Introduction
Each fault message has its own fault code permitting to obtain further information about a special fault from this
list.
This fault code consists of the machine section identification, a number and the fault category !
A fault message is shown on the rear panel display as follows :
MALFUNCTION !!! "MALFUNCTION" flashing

(CODE) FAULT MESSAGE
Fault code and continuous malfunction message text !
The following letters identify the machine section:

S = System B = Concrete pump
F = Remote control M = Boom control
A = General machine Z = Central lubrication
D = Truck engine or PTO E = Extensions
Three fault categories can be displayed:

L = minor fault, horn cancelling from control box possible.
(rectification of fault cause required only upon completion of job !)
S = severe fault, horn cancelling from control box not possible.
(immediate rectification of fault cause required !)
M = operating fault, only message displayed, cancelling not required.
(no storage of fault in diagnosis system !)
Example : B01S B = machine section "concrete pump"

01 = number 01
S = fault category "severe"
Meaning of the "Disconnected" or "Overload" fault messages
The "Disconnected" fault is reported when the cable from this output to the relay / solenoid is broken.
This fault can only be detected when the output is not activated !
The cause of this fault is either a broken cable or a disconnected solenoid connector !
The "Overload" fault is reported when an inadmissibly high current has been detected for this output.
This fault can only be detected when the output is activated!
The cause of this fault is either a short-circuit in the electric cable to the relay / solenoid or a defect of the solenoid
coil (charred) !
This applies to all following faults reported as "Disconnected" or "Overload" faults !!!
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4.2 Control diagnosis electronic modules(fault code S !)
Code Message / source of fault message / fault detection time

S01L Boom-Control Board 1 Fault (system fault !)
Module monitoring by central board !
S02L Boom-Control Board 2 Fault (system fault !)

S03L Machine-Control Board 1 Fault (system fault !)



S06L Concrete-Pump Control Board Fault (system fault !)

S07L Rear Panel Board Fault (system fault !)

S08L Info-Center Board Fault (system fault !)

S09L Network-Fault / Central-Board Fault (system fault !)

When network monitor on central board detects
a malfunction of the CAN network !
S10L Network-Fault Central Board - Info-Center (system fault !)

Detected by Info-Center if CAN communication with
Central Board cannot be established !
System faults are reported when the module in question does not work perfectly. All modules are regularly checked
by the central module !
In the event of a system fault, the electric control of the truck-mounted concrete pump should be switched off once
for ca. 5 secs. with the key-operated switch in the driver's cab.
This fault message may have the following causes:

- power supply to one of the modules interrupted (check fuse !)
- electronic components on module Fault, e.g. storage defect(replace module !)
- communication fault with central module(replace module!)
Service Manual 613

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4.3 Remote-control system diagnosis (fault code F!)
F01M Emergency-Stop on Radio Control Box active

Source: REMOTE-CONTROL DIAGNOSIS
Indicated when emergency shut-off button on radio control box has been actuated !
F02M Actuator Switches on Control Box out of Neutral Position

Indicated when control box actuators after activation of radio control box have not been once in neutral
position !
F03M No Radio Control Transmission

Indicated when radio control box is off or when - for other reasons - there is no radio contact between
transmitter and revceiver.
F05L Joy-Stick 1 from Remote-Control Fault

Indicated when control box has detected a fault at joy-stick 1 !


F08M CAN-Transmission with Remote-Control Fault

Indicated after 30 seconds when CAN data transmission between control unit and remote-control sys-
tem is interrupted
F09L Emergency-Stop Switch on Radio Control Box Fault

Indicated when control box has detected a fault at emergency-stop button !
F10M Radio Control Signal with Faulty Address received

Indicated when radio receiver has received a radio data telegram from another radio control box or from
a wrongly adjusted radio control box.
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4.4 Machine diagnosis-General (fault code A!)

A01M Emergency-Stop on Machine active
Source: DIAGNOSIS SYSTEMfault detection time :20 sec.!
Indicated when central board detects that all electronic modules except the central module, operating
panel at step-ladder and Info-Center have been shut off !
A02S Hydraulic Oil Temperature exceeded

Source: HYD OIL TEMP / CPfault detection time:5 sec.!
Indicated when oil temperature sensor detects that the maximum oil temperature hzas been exceeded
(set value CP module) !
A03L Temperatur Transmitter Hydraulic Oil Fault

Source: HYD OIL TEMP / CP inputfault detection time:30 sec.!
Indicated when monitor detects sensor oil temperature outside the valid range ( 500 - 2000 ohms ) !
A04L Exchange Hydraulic Oil Filter Boom

Source: Input 4 / INP MACHINE-C2fault detection time :10 Sek.!
Indicated when pressure filter monitor (differential pressure switch in oil filter) detects excessive pres-
sure drop in hydraulic oil filter at an oil temperature above 30˚ C !
A05L Exchange Hydraulic Oil Filter Concrete Pump

Indicated when pressure filter monitor (differential pressure switch in oil filter) detects excessive pres-
sure drop in hydraulic oil filter at an oil temperature above 30˚ C !
A06L Low Level Hydraulic Oil

Indicated when level switch in hydraulic oil reservoir (option !) detects insufficient oil level !
A07M Low Level Water Reservoir

Indicated when level switch in water tank (option !) detects insufficient level in tank for cleaning water
(dry-run protection) !
A08L High Temperature Air-Compressor

Indicated when over-temperature protection in compressor (bi-metal switch) responds !
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A09M Operating Mode for Changing Pump Rams active

Source: Input 1 / INP CONCRETE PUMPoperating mode display !
Indicated when "ram change" mode has been selected at separate controls for "CP inching" !
A10M Actuator Switches on Rear Panel out of Neutral Position

Source: DIAGNOSIS SYSTEM
Indicated when actuators on rear panel have not been at least once in neutral position after an EMER-
GENCY SHUT-OFF or after switching over from REMOTE to LOCAL (rear panel!) control.
A30L Disconnected Oil-Cooler Relay

A31L Overload Oil-Cooler Relay
A32L Disconnected Vibrator Relay
A33L Overload Vibrator Relay
A34L Disconnected Boom-Horn Relay
A35L Overload Boom Horn Relay
A36L Disconnected Slew-Horn Relay
A37L Overload Slew-Horn Relay
A38L Disconnected Alarm Output
A39L Overload Alarm Output
A40L Disconnected Waterpump Solenoid

A41L Overload Waterpump Solenoid
A42L Disconnected Compressor Solenoid
A43L Overload Compressor Solenoid
A44L Disconnected Agitator Forwards Solenoid
A45L Overload Agitator Forwards Solenoid
A46L Disconnected Agitator Reverse Solenoid
A47L Overload Agitator Reverse Solenoid
A48L Disconnected Hydraulic-on-Outriggers Solenoid
A49L Overload Hydraulic-on-Outriggers Solenoid
A50L Disconnected High-Pressure Waterpump Solenoid

A51L Overload High-Pressure Waterpump Solenoid
A52L Disconnected End-Hose unlocking Solenoid
A53L Overload End-Hose unlocking Solenoid
For "Disconnected" and "Overload" faults cf. "Introduction" (4.1) !
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4.5 Engine/PTO Diagnosis (fault code D!)
D01S Engine Safety Stop / High Coolant Temperature

Source: Input 4 / INP MACHINE-C1fault detection time:5 sec.!
Indicated when engine saftety stop (option !) has occurred because of excessive temperature of vehicle
engine (cooling-water temperature switch) !
D02S Engine Safety Stop

Indicated when engine safety stop has occurred from customer-specific option (e.g. hydraulic oil level-
falling)
D03S Engine Safety Stop / Low Truck Oil Pressure

Indicated when engine safety stop (option !) has occurred from insufficient vehicle engine oil pressure
(oil pressure switch) !
D04L PTO is not working or Prox-Switch PTO-RPM Fault

Source: DIAGNOSIS SYSTEMfault detection time:120 sec.!
Indicated when - in spite of engine running (D+ signal) and PTO engaged (PTO limit switch) - no pulses
are transmitted from RPM sensor at pump transfer gearbox (inductive proximity switch) for more than 30
seconds.
D05L PTO RPM Exceeded

Indicated when PTO RPM exceeds the set maximum limit (set value machine control 1 module) !
D06S Battery Charging on Truck Fault

Indicated when - in spite of PTO RPM detected (pulses from prox-switch and PTO engaged) - there is
no D+ signal (alternator running) !
D07L Indicator switch PTO=ON/OFF Fault

Indicated when - in spite of engine running (D+ signal) and PTO RPM detected (pulses from prox-
switch) - there is no signal from "PTO engaged" indicator switch.
D30L Disconnected Engine Start Relay

D31L Overload Engine Start Relay
D32L Disconnected Engine Stop Relay
D33L Overload Engine Stop Relay
D34L Disconnected Engine Speed-Up Relay
D35L Overload Engine Speed-Up Relay
D36L Disconnected Engine Speed-Down Relay
D37L Overload Engine Speed-Down Relay
Service Manual 617

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4.6 Concrete pump diagnosis (fault code B!)
Code Message / source of fault message / fault 0detection time
B01L Power Limiter Concrete Pump active

Source: Input HYD OIL TEMPfault detection time:5 sec.!
Indicated when the temperature of the hydraulic oil in the reservoir has exceeded the set limit (set value
CP module) and after the concrete pump power limiter has been activated !
B02L Pressure Limiter Concrete Pump active

Source: Input CP OIL PRESSUREfault detection time:15 sec.!
Indicated when the pressure of the concrete pump hydraulic oil has exceeded the set limit (set value CP
module) and after the electronic pressure limiter has been activated !
B03L Pressure Transmitter CP Hydraulics Fault

Source: Input CP OIL PRESSUREfault detection time:30 sec.!
Indicated when monitor detects that measured value of hydraulic oil pressure transmitter is out of valid
range ( 4 - 20 mA ) !
B04L Prox-Switch Soft-Start / Pumped Volume Fault

Quelle : DIAGNOSIS SYSTEMfault detection time:120 sec.!
Indicated when - within 120 seconds of concrete pump operation (engine running, PTO engaged and
CP forwards or backwards ON) no pulses from the soft-start / pump volume proximity switches are
being detected !
B05L Hopper Grate open / CP jammed / Prox-Switch Stroke Counter Fault

Indicated when - within 120 seconds of concrete pump operation (engine running, PTO engaged and
CP forwards or backwards ON) no pulses from the stroke counter proximity switch on the concrete
pump are being detected!
ATTENTION, hopper grate must be closed and CP must not be jammed !
B30L Disconnected CP Forwards Solenoid

B31L Overload CP Forwards Solenoid
B32L Disconnected CP Reverse Solenoid
B33L Overload CP Reverse Solenoid
B34L Disconnected CP Stroke Limiter Solenoid
B35L Overload CP Stroke Limiter Solenoid
B36L Disconnected CP Pressure Limiter CP Solenoid
B37L Overload CP Pressure Limiter CP Solenoid
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4.7 Boom control diagnosis (fault code M!)
M01L Limit Switch Boom Slewing Right 1 Fault

Source: Input 1 / INP BOOM-C1statistical function: (5 x 5 sec.!)
Indicated when limit switch monitor detects that the redundant limit switches "boom-slew right" 1 & 2 are
in different signal states.
M02L Limit Switch Boom Slewing Right 2 Fault

Indicated when limit switch monitor detects that the redundant limit switches "boom-slew right" 1 & 2 are
M03L Limit Switch Boom Slewing Left 1 Fault

Indicated when limit switch monitor detects that the redundant limit switches "boom-slew left" 1 & 2 are
M04L Limit Switch Boom Slewing Left 2 Fault

Source: Input 4 / INP BOOM-C1statistical function : (5 x 5 sec.!)
Indicated when limit switch monitor detects that the redundant limit switches "boom-slew left" 1 & 2 are
M05L Truck Cab Protection Switch 1 Boom 2 < 20 Degree Fault (cab protection)
Indicated when limit switch monitor detects that the redundant limit switches "boom 2 < 20 degrees" 1 &
2 are in different signal states.
M08L Truck Cab protection Switch 2 Boom 1 < 50 Degree Fault (cab protection)
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M09L Truck Cab Protection Switch 1 Boom 1 > 180 Degree Fault (cab protection)
Source: Input 5 / INP BOOM-C2statistical function : (5 x 5 sec.!)
Indicated when limit switch monitor detects that the redundant limit switches "boom 1 > 180 degrees" 1
& 2 are in different signal states.
M10L Truck Cab Protection Switch 2 Boom 1 > 180 Degree Fault (cab protection)
Indicated when limit switch monitor detects that the redundant limit switches "boom 1 > 180 degrees" 1
& 2 are in different signal states.
M11L Truck Cab Protection Switch 1 Boom Slewing Fault (cab protection)
Indicated when limit switch monitor detects that the redundant limit switches "cab protection boom slew-
ing" 1 & 2 are in different signal states.
M12L Truck Cab Protection Switch 2 Boom Slewing Fault (cab protection)
Indicated when limit switch monitor detects that the redundant limit switches "cab protection boom slew-
ing" 1 & 2 are in different signal states.
M30L Disconnected Boom Slewing Right Solenoid

M31L Overload Boom Slewing Right Solenoid
M32L Disconnected Boom Slewing Left Solenoid
M33L Overload Boom Slewing Left Solenoid
M34L Disconnected Boom 1 Extend Solenoid
M35L Overload Boom 1 Extend Solenoid
M36L Disconnected Boom 1 Retract Solenoid
M37L Overload Boom 1 Retract Solenoid
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4.8 Central lubrication/extension diagnosis (fault code Z/E!)
Z01L Malfunction Lubrication Boom / Slewing Gear

Source: Input 1 / INP EXTENSIONfault detection time : Parameter !
Indicated when - after activation of the "boom / slewing gear" greasing circuit - there are no pulses com-
ing from the corresponding cycle switch in the progressive distributor after a certain time.
Z02L Malfunction Lubrication CP / Agitator

Indicated when - after activation of the "CP / agitator" greasing circuit - there are no pulses coming from
the corresponding cycle switch in the progressive distributor after a certain time.
Z03L Malfunction Lubrication Outriggers

Indicated when - after activation of the "outrigger" greasing circuit - there are no pulses coming from the
corresponding cycle switch in the progressive distributor after a certain time.
Z04L Lubrication Switched OFF

Source: Input 4 / INP EXTENSIONfault detection time :5 sec.!
Indicated when central lubrication has been switched off with the service switch.
Z30L Disconnected Lubrication Pump Relay

Z31L Overload Lubrication Pump Relay
Z32L Disconnected Lubrication Boom Solenoid
Z33L Overload Lubrication Boom Solenoid
Z34L Disconnected Lubrication CP / Agitator Solenoid
Z35L Overload Lubrication CP / Agitator Solenoid
Z36L Disconnected Lubrication Outriggers Solenoid
Z37L Overload Lubrication Outriggers Solenoid
E30L Disconnected PLC-Outp 1

E31L Overload PLC-Outp 1
Service Manual 621

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5.0 Output signal interdependence list
The present list supplies information about the input signals and control states governing the most important output
signals !
Boom control
Boom-slewing right / left (prop. or switched output !)depends on :
- Emergency-stop not actuated !
- Restart protection after emergency-stop or change of Local / Remote mode of operation !
- Slewing gear limit switch 1 or 2 on slewing ring not actuated !
- Boom limiting (cab protection at KVM 52 & S 45 SX) not active !
- REMOTE mode selected and RAM CHANGE mode not activated !
- Slewing function on remote-control box activated, [HARE/SNAIL] switch not in "0" position !
Boom 1/2 retract/extend (prop. or switched output !)depends on:

- Boom limiting (cab protection at KVM 52 & S 45 SX) not active !
- Boom function 1/2 on remote-control box activated, [HARE/SNAIL] switch not in "0" position !
Boom 3/4/5 retract/extend (prop. or switched output !)depends on:

- Boom function 3/4/5 on remote-control box activated, [HARE/SNAIL] switch not in "0" position !
Concrete pump control

Concrete pump forwards/backwards ON (switched output !) depends on:
- Limit switch at hopper grate not actuated and CP not blocked at control block !
- Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation !
- Correct mode of operation LOCAL / REMOTE selected and RAM CHANGE mode not activated !
- Concrete pump FORWARDS or BACKWARDS activated on remote-control box or at rear panel !
CP stroke limiting (prop. output !) depends on:

- Concrete pump FORWARDS or BACKWARDS activated !
- Stroke limiter adjustment on remote-control box or at rear panel !
- Limiting functions and soft-start / automatic pumping rate increase, if activated !
Agitator ON (switched output !) depends on:

- Limit switch at hopper grate not actuated !
- Correct mode of operation LOCAL / REMOTE selected !
- Agitator activated on remote-control box or at rear panel !
- Momentary contact functions "Agitator reversing" !
Vibrator ON (switched output !) depends on:
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- Vibrator activated on remote-control box or at rear panel in MANUAL mode or vibrator
in AUTO mode and CP FORWARDS activated at the same time !
Cleaning systems
Water pump ON (switched output !) depends on:
- Water tank level switch indicates sufficient amounts of water in tank !
(dry running protection for water pump !)
- Water pump activated on remote-control box or at rear panel !
Compressor ON (switched output !) depends on:

- Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation!
- Compressor activated on remote-control box or at rear panel!
Truck engine control

Engine Start (switched output !) depends on:
- Gearbox in neutral position !
- Engine not yet running (D+ signal) !
- Safety delay of "Engine Stop" command (ca. 5 seconds) already elapsed !
- Engine Start activated on remote-control box or at rear panel !
Engine Stop (switched output !) depends on:

- Gearbox in neutral position !
- Engine Stop activated on remote-control box or at rear panel!
Engine RPM +/- adjust (switched output !) depends on:

- Restart protection after emergency-stop or change of LOCAL / REMOTE mode of operation!
- Correct mode of operation LOCAL / REMOTE selected and RAM CHANGE mode not activated!
- Engine RPM +/- adjust activated on remote-control box or at rear panel!
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Info-Center Menu Overview Status: 03.02.97
INFO-SYSTEM [ ... ] = key !

Enter=On
[ENTER]
PUMPED VOLUME → [ENTER] → PUMPED ON JOB (S !) → [START] → Restart delivery-rate mea-

↓/ /Enter/Clear ← [CLEAR] ← ~ 1752.3 cbm surement!
[↓] [↑] ------------------------------------------------------------------------------------------------------------------------
OPERATION DATA → [ENTER] → HYD OIL TEMP Display temperature of oil in

↓/↑/Enter/Clear ← [CLEAR] ← 62 ß C hydraulic reservoir !
[↓] [↑]
PTO SHAFT RPM Display RPM of PTO shaft !

1270 rpm
[↓] [↑]
HYD PRESSURE CP Display concrete pump

159 bars hydraulic oil pressure !
[↓] [↑]
CONCR-PUMP HOURS Concrete pump operating

328.3 h hours !
[↓] [↑]
BOOM HOURS Placing boom operating

406.1 h hours !
[↓] [↑] [↓] [↑]
PTO HOURS PTO operating hours !

469.8 h
[↓] [↑]
TOTAL STROKES CP Total number of concrete

1398743 strokes pump strokes !
[↓] [↑]
TOTAL VOL. PUMPED Total pumped volume of

109125 cbm concrete pump !
[↓] [↑]
STROKES PER MIN Actual number of strokes of

21 strokes/min concrete pump unit !
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MALFUNCTION LIST → [ENTER] → 16.03.95 / 12:34 Display of last stored fault

↓/↑/Enter/Clear ← [CLEAR] ← (Code) fault text message !
[↓] [↑]
14.02.95 / 10:17 Display of previous fault
(Code) fault text message !
[↓] [↑] [↓] [↑] etc !
------------------------------------------------------------------------------------------------------------------------
LUBRICATION-UNIT → [ENTER] → MANUAL LUBRIC. → [START] → Manual lubrication of con-

↓/↑/Enter/Clear ← [CLEAR] ← CP & Agitator crete pump and agitator !
[↓] [↑]
MANUAL LUBRIC. Manual lubrication of boom

Boom and slewing gear !
[↓] [↑] [↓] [↑]
MANUAL LUBRIC. Manual lubrication of outrig-

Outriggers gers!
------------------------------------------------------------------------------------------------------------------------
I/O-STATUS DISPL → [ENTER] → MACHINE-CONTROL Display of I/O status of indi-

↓/↑/Enter/Clear ← [CLEAR] ← ↓/ /Enter/Clear vidual control modules
[↓] [↑]
CP-CONTROL Cf. page 3

↓/↑/ENTER/CLEAR I/O display sub-menu
[↓] [↑]
BOOM-CONTROL
↓/↑/ENTER/CLEAR
[↓] [↑] [↓] [↑]
REAR PANEL
↓/↑/ENTER/CLEAR
[↓] [↑]
EXTENSION I/O
/↑/ENTER/CLEAR
------------------------------------------------------------------------------------------------------------------------
INTERNAL TIMER → [ENTER] → DATE 23.08.95 Display of date & time

↓/↑/Enter/Clear ← [CLEAR] ← TIME 16:32
[↓] [↑] ------------------------------------------------------------------------------------------------------------------------
SCROLLING → [ENTER] → Scroll rate → [ENTER] → Setting of scroll rate

↓/↑/Enter/Clear ← [CLEAR] ← 400 ms ← [ENTER] ← with ↓ & ↑ keys
[↓] [↑] ------------------------------------------------------------------------------------------------------------------------
Service Manual 625

HOME PRINT
SERVICE TRAINING
Electrical
PARAMETER → [ENTER] → PASSWORD **** Password entry for

/↑/Enter/Clear ← [CLEAR] ← ↓/↑/Enter/Clear parameter adjustment
[↓] [↑]
EFFICIENCY CP Cf. page 5

↓/↑/Enter/Clear Parameter adjustment menu
[↓] [↑]
LUBRIC. PARAM
↓/↑/Enter/Clear
[↓] [↑]
PROP-CUR SLEW
↓/↑/Enter/Clear
[↓] [↑]
PROP-CUR BOOM 1
↓/↑/Enter/Clear
[↓] [↑]
PROP-CUR BOOM 2
↓/↑/Enter/Clear
[↓] [↑]
PROP-CUR BOOM 3
↓/↑/Enter/Clear
[↓] [↑]
PROP-CUR BOOM 4
↓/↑/Enter/Clear
[↓] [↑]
PROP-CUR BOOM 5
↓/↑/Enter/Clear
626 Service Manual

HOME PRINT
SERVICE TRAINING
Electrical
Sub-menu I/O display overview Status : 03.02.97
MACHINE-CONTROL → [ENTER] → INP MACHINE-C1 Machine-control 1

↓/ /ENTER/CLEAR ← [CLEAR] ← 1■2❏3■4❏5❏6■7■8❏ Digital-inputs
[↓] [↑]
OUTP MACHINE-C1 Machine-control 1

1■2❏3■4❏5❏6■7■8❏ Digital-outputs
[↓] [↑] [↓] [↑]
INP MACHINE-C2 Machine-control 2

1■2❏3■4❏5❏6■7■8❏ Digital-inputs
[↓] [↑]
OUTP MACHINE-C2 Machine-control 2

------------------------------------------------------------------------------------------------------------------------
CP-CONTROL → [ENTER] → INP CP-CONTROL Concrete pump control

↓/↑/ENTER/CLEAR ← [CLEAR] ← 1■2❏3■4❏5❏6■7■8❏ Digital-inputs
[↓] [↑]
OUTP CP-CONTROL Concrete pump control

1■2❏ Digital-outputs
[↓] [↑]
STROKE LIMITER Concrete pump control

■■■■■■■ Prop-output stroke limiter
CP
[↓] [↑] [↓] [↑]
PRESS LIMITER CP Concrete pump control

■■ Prop-output pressure limit-
ing
[↓] [↑]
HYD PRESSURE CP Concrete pump control

■■■■■■ Analogue-input oil pressure
CP
[↓] [↑]
HYD OIL TEMP Concrete pump control

■■■ Analogue-input hydraulic oil
temperature
------------------------------------------------------------------------------------------------------------------------
Service Manual 627

HOME PRINT
SERVICE TRAINING
Electrical
BOOM-CONTROL → [ENTER] → INP BOOM-C1 Boom-control 1

↓/↑/ENTER/CLEAR ← [CLEAR] ← 1■2❏3■4❏5❏6■ Digital-inputs
[↓] [↑]
INP BOOM-C2 Boom-control 2

1■2❏3❏4■5❏6❏ Digital-inputs
[↓] [↑]
BOOM-SLEW RIGHT Boom-control 1

■■ Prop-output boom-slew right
[↓] [↑]
BOOM-SLEW LEFT Boom-control 1

■■■■■■■ Prop-output boom-slew left
[↓] [↑]
BOOM 1 EXTEND Boom-control 1

■■■■■■■ Prop-output boom 1 extend
[↓] [↑]
BOOM 1 RETRACT Boom-control 1

■■■■■■■ Prop-output boom 1 retract
[↓] [↑]

■■■■■ Prop-output boom 2 extend
[↓] [↑] [↓] [↑]

■■■■■ Prop-output boom 2 retract
[↓] [↑]

■■■■■■ Prop-output boom 3 extend
[↓] [↑]

■■■ Prop-output boom 3 retract
[↓] [↑]

■■■■■■ Prop-output boom 4 extend
[↓] [↑]

■■■■■■ Prop-output boom 4 retract
[↓] [↑]
628 Service Manual

HOME PRINT
SERVICE TRAINING
Electrical

■■■■■■■ Prop-output boom 5 extend
[↓] [↑]

■■■■ Prop-output boom 5 retract
------------------------------------------------------------------------------------------------------------------------
REAR PANEL → [ENTER] → INP REAR PANEL 1 Rear panel

↓/↑/ENTER/CLEAR ← [CLEAR] ← 1■2❏3■4❏5❏6■7■8❏ Digital-inputs 1
[↓] [↑]
INP REAR PANEL 2 Rear panel

1■2❏3■4❏5❏6■7■8❏ Digital-inputs 2
[↓] [↑]
INP REAR PANEL 3 Rear panel

1■2❏3■4❏ Digital-inputs 3
[↓] [↑] [↓] [↑]
OUTP REAR PANEL Rear panel

1■2❏3❏4❏ Digital-outputs
[↓] [↑]
POT REAR PAN SL Rear panel

■■■■■■■ Analogue-input stroke limiter
CP
------------------------------------------------------------------------------------------------------------------------
EXTENSION I/O → [ENTER] → INP EXTENSION Machine-control 3

/↑/ENTER/CLEAR ← [CLEAR] ← 1■2❏3■4❏5❏6■7■8❏ Digital-inputs
[↓] [↑]
OUTP EXTENSION Machine-control 3

Service Manual 629

HOME PRINT
SERVICE TRAINING
Electrical
Parameter adjustment menu overview Status : 03.02.97
Entry of PASSWORD and access to parameter adjustment menu
PARAMETER → [ENTER] → PASSWORD **** Enter password with

/↑/ENTER/CLEAR ← [CLEAR] ← ↓/↑/ENTER/CLEAR [↓] [↑] keys
[↓] [↑]
PASSWORD 1234 End password entry with

↓/↑/ENTER/CLEAR [ENTER] key
[↓] [↑] [ENTER]
PASSWORD 1234 Correct password entry con-

Password OK firmed
[↓] [↑]
EFFICIENCY CP Display of PARAMETER

↓/↑/ENTER/CLEAR ADJUSTMENT MENU
Parameter adjustment menu for EFFICIENCY concrete pump / Central lubrication / Prop cur-
rent values
EFFICIENCY CP → [ENTER] → EFFICIENCY CP → [ENTER] → Parameter adjustment ON

↓/↑/ENTER/CLEAR ← [CLEAR] ← 94 % ← [ENTER] ← [↓] [↑] change EFFICIENCY
CP
[↓] [↑] ------------------------------------------------------------------------------------------------------------------------
LUBRIC. PARAM → [ENTER] → LUBRIC. CYCLES → [ENTER] → Parameter adjustment ON

↓/↑/ENTER/CLEAR ← [CLEAR] ← BOOM 07 ← [ENTER] ← [↓] [↑] change number of
cycles
[↓] [↑]
LUBRIC. CYCLES → [ENTER] → Parameter adjustment ON

CP / AGITATOR 09 ← [ENTER] ← [↓] [↑] change number of
cycles
[↓] [↑] [↓] [↑]
LUBRIC. CYCLES → [ENTER] → Parameter adjustment ON

OUTRIGGERS 12 ← [ENTER] ← [↓] [↑] change number of
cycles
------------------------------------------------------------------------------------------------------------------------
The parameter adjustment menu for prop current values of the current control (Rexroth valves) please turn over
630 Service Manual

HOME PRINT
SERVICE TRAINING
Electrical
PROP-CUR SLEW → [ENTER] → BOOM-SLEW RIGHT Online-display of effective

↓/↑/ENTER/CLEAR ← [CLEAR] ← I act 530 mA prop-current
[↓] [↑]
BOOM-SLEW RIGHT → [ENTER] → Parameter adjustment ON

I min 450 mA ← [ENTER] ← [↓] [↑] adjust MIN-current
[↓] [↑]
BOOM-SLEW RIGHT → [ENTER] → Parameter adjustment ON

I max 820 mA ← [ENTER] ← [↓] [↑] adjust MAX-current
[↓] [↑] [↓] [↑]
BOOM-SLEW LEFT Online-display of effective

I act 610 mA prop-current
[↓] [↑]
BOOM-SLEW LEFT → [ENTER] → Parameter adjustment ON

[↓] [↑]
BOOM-SLEW LEFT → [ENTER] → Parameter adjustment ON

------------------------------------------------------------------------------------------------------------------------
PROP-CUR BOOM 1 → [ENTER] → BOOM 1 EXTEND Online-display of effective

↓/↑/ENTER/CLEAR ← [CLEAR] ← I act 530 mA prop-current
[↓] [↑]
BOOM 1 EXTEND → [ENTER] → Parameter adjustment ON

[↓] [↑]

[↓] [↑]
BOOM 1 RETRACT Online-display of effective

I act 610 mA prop-current
[↓] [↑] [↓] [↑]
BOOM 1 RETRACT → [ENTER] → Parameter adjustment ON

[↓] [↑]

------------------------------------------------------------------------------------------------------------------------
Service Manual 631

HOME PRINT
SERVICE TRAINING
Electrical
PROP-CUR BOOM 2 → [ENTER] → Cf. boom section 1!

↓/↑/ENTER/CLEAR ← [CLEAR] ←
[↓] [↑] ------------------------------------------------------------------------------------------------------------------------
PROP-CUR BOOM 3 → [ENTER] → Cf. boom section 1

[↓] [↑] ------------------------------------------------------------------------------------------------------------------------

[↓] [↑] ------------------------------------------------------------------------------------------------------------------------

The parameter adjustment menu for prop-current values PWM-controlled (Apitech valves) please turnover
PROP-CUR SLEW → [ENTER] → SLEW RIGHT Online-display of effective
↓/↑/ENTER/CLEAR ← [CLEAR] ← PWM act 33 % current value of valve
[↓] [↑]
SLEW RIGHT → [ENTER] → Parameter adjustment ON

PWM min 10 % ← [ENTER] ← [↓] [↑] adjust MIN-value
[↓] [↑]
SLEW RIGHT → [ENTER] → Parameter adjustment ON

PWM max 95 % ← [ENTER] ← [↓] [↑] adjust MAX-value
[↓] [↑] [↓] [↑]
SLEW LEFT Online-display of effective

PWM act 48 % current value of valve
[↓] [↑]
SLEW LEFT → [ENTER] → Parameter adjustment ON

[↓] [↑]
SLEW LEFT → [ENTER] → Parameter adjustment ON

------------------------------------------------------------------------------------------------------------------------
632 Service Manual

HOME PRINT
SERVICE TRAINING
Electrical
PROP-CUR BOOM 1 → [ENTER] → BOOM 1 EXTEND Online-display of effective

↓/↑/ENTER/CLEAR ← [CLEAR] ← PWM act 29 % current value of valve
[↓] [↑]

[↓] [↑]

[↓] [↑]
BOOM 1 RETRACT Online-display of effective

PWM IST 63 % current value of valve
[↓] [↑] [↓] [↑]

[↓] [↑]

------------------------------------------------------------------------------------------------------------------------

[↓] [↑] ------------------------------------------------------------------------------------------------------------------------
PROP-CUR BOOM 3 → [ENTER] → Cf. boom section 1!

[↓] [↑] ------------------------------------------------------------------------------------------------------------------------

[↓] [↑] ------------------------------------------------------------------------------------------------------------------------

Service Manual 633

HOME PRINT
SERVICE TRAINING
Electrical
634 Service Manual

HOME PRINT
Service Manual
SCHWING Control system “VECTOR”

SERVICE MANUAL
2
1
OK OFF
0 x1000 3
PTO 1500 rpm 62˚C
Menu: [ENTER]=ON
HOME + HELP START
CLEAR - ENTER QUIT
PART 1: OPERATION
PART 2: TEACH MODE
PART 3: EASY OPERATION
5900 Centerville Road
White Bear, Mn. 55127
Tel. (651) 429-0999
Fax (651) 429-3464
www.schwing.com
Copyright © 2005, Schwing America, Inc.

All rights reserved
VECTOR CONTROLLER-SERVICE MANUAL

HOME PRINT
Service Manual
START SCREEN:
Control status
Oil cooler "On"
PTO Speed OK System is running
Hydraulic oil temperature
Start
Start up control unit
Control switches not
1 2
OK Off?
in neutral position
Emergency stop
STOP!
activated
Entry expected
0 x1000 3
Modes of operation
PTO 1350 rpm 62˚C
Remote mode
Menu: [ENTER]=ON
Local mode
Menu bar for Concrete pump Ram change mode

further screens delivery rate Teach
mode! Teach mode
StartScreen.eps
636 VECTOR CONTROLLER-SERVICE MANUAL

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Service Manual
PART 1
SCHWING control system 'VECTOR'
OPERATION
The present instructions are intended to serve as a 'memory aid'. They do not refer to any
particular type of machine and do not relieve the user of familiarizing himself with the operating
manual of the machine in question.
CONTENTS
Commissioning .......................................................................................638
Selecting local control .............................................................................639
Selecting remote control .........................................................................640
Ram change mode:.................................................................................641
Emergency stop buttons .........................................................................642
Override of the E-stop manifold ..............................................................642
Options box .............................................................................................643
Control and monitoring components .......................................................644
Menu control ...........................................................................................645
Local control............................................................................................646
Remote control........................................................................................647
Menu overview - Main menu ...................................................................648
Menu overview - submenus ....................................................................652
Menu operation - Example: .....................................................................653
Diagnostic system/”Fault handling” .........................................................654
Acknowledging faults ..............................................................................656
Fault definition.........................................................................................656
Summary of messages ...........................................................................664
Heat the oil first .......................................................................................676
VECTOR CONTROLLER-SERVICE MANUAL 637

HOME PRINT
Service Manual
Part 1 Operation • Select the desired mode of operation with the

switch in the lower right corner of the vector
cover. The mode will then be indicated in the
Commissioning
display window at the right side, center of the
The electrical machine control system can only be start screen (Figure 1).
activated if the drive configuration has been properly
selected:
• Parking brake set
• Ignition key on, engine running at idle.
• Transmission in neutral
• Activate the PTO switch
vectorramchange.eps
• When Indicator light comes on, put

transmission in proper pumping gear. • When the control mode is selected, the display
• will indicate that with a picture (Figure 2).
A bar graph on the display will indicate that the system

is being initialized.
The start screen (Figure 1) will be displayed after
localcontrol.eps
initialization.
remotecontrol.eps
1 2
Start OFF
0 x1000 3
NA 1760 U/min 52˚C
Menu: [ENTER]=ON
HOME + HELP START
CLEAR - ENTER QUIT

Figure 2
Vector control mode display, local (top)
commissionart2.eps
remote (center) ram change (bottom)
1 2
Start
0 x1000 3
PTO 1760 rpm 52˚C
Menu: [ENTER]=ON
vectornormal.eps
Figure 1
Vector start screen

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Service Manual
Selecting local control
1 2
OK
0 x1000 3 2
PTO 1500 rpm 62˚C
Menu: [ENTER]=ON
Figure 3
Vector display window
This symbol is displayed in section #2 of Figure 3 Start up the system by activating the “I” switch on the
when local control is selected. front panel of the controller (Figure 1).
localcontrol.eps
Iswitch.eps
This symbol will flash in section 1 of Figure 3 when

any E-stop on the machine is activated. Check that all Starting is confirmed by a brief beep and the symbol
E-stop buttons are released. below is displayed in section 1 of Figure 3.
OK
STOP!
estop.eps
This symbol flashes in section 1 when a switch on the

rear operaors panel is on.
Set all switches to neutral.
This symbol flashes in section 1 of Figure 3 when the

system is ready for start-up.
Start
Istart.eps

HOME PRINT
Service Manual
Selecting remote control
2
1
OK
1
30356 534 C
0 x1000 3 2 2
3
PTO 1500 rpm 62˚C 303 623

48
4
5 6
displayID.eps
7
3
8
2
9
1
0 10
Menu: [ENTER]=ON remotebox.eps
Figure 4
Display screen for remote control
This symbol is displayed in section 2 of

the screen (Figure 4).
remotecontrol.eps
This symbol flashes in section 1 (Figure

4) when an emergency stop button on
the machine or on the remote control
STOP! box has been pressed.
estop.eps
The symbol flashes also when the
remote control box is off.
Unlock all E-stops or turn on the remote.

4) when a switch on the remote control
box is on.
Set all switches to neutral.

Start 4) when the system is ready for start-up:
Istart.eps
Start up the control with this switch on

the remote control box.
activate"I".eps
The starting is confirmed by a brief beep

OK and the symbol on the left is displayed in
section 1(Figure 4).

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Service Manual
Ram change mode: The ram change position disables both local (rear
panel) and remote control, brings the engine to idle,
reduces the stroke limiter to minimum output, and
gives complete concrete pump control to the concrete
pump fwd/rev switch located at the ram change station
vectorramchange.eps
(Figure 6). See the Maintenance section of the
This symbol is displayed in section 2 of operation manual for ram change instructions.
the screen (Figure 4).

4) when any E-stop on the machine is
STOP! pushed. Unlock all E-stops. 2
estop.eps 1
OK OFF
0 x1000 3
PTO 1500 rpm 62˚C
Menu: [ENTER]=ON

4) when the system is ready for start-up.
Start HOME + HELP START
Istart.eps
CLEAR - ENTER QUIT
panelID.eps
“ ” switch
Start up the controller with the “I” switch
in (Figure 5). Figure 5
Iswitch.eps
Vector control panel
Starting is confirmed by a brief beep and

OK the symbol on the left is displayed in
section 1 (Figure 4).
32ramchange.eps
Figure 6
Ram change station

HOME PRINT
Service Manual
Emergency stop buttons

BY-PASS
NORM. BY-PASS
E_Stopbutton.eps
Figure 7
E-stop button by-pass2.eps
When and E-stop is pushed, all hydraulic functions of If the problem is actually a bad solenoid, the pilot
the machine will stop. Do not use the emergency stop signal to the dump valve can be overridden by having
for an on/off switch. It is for emergencies only. one person push and hold the override handle on the E-
In normal operating conditions, always stop the stop manifold while the other person activates the
machine functions with the controls provided for that manual controls for the nonworking system.
purpose.
Override of the E-stop manifold

Bypass mode Bypass
Key
OFF
2
1
OK
WARNING 0 x1000 3
PTO 1500 rpm 62˚C
Menu: [ENTER]=ON
Emergency stop switches are disabled

HOME HELP START
when manual override is activated. +
CLEAR ENTER QUIT

Use the by-pass key switch only for -
folding the boom in an emergency and

000360.eps
bypasskeyswitch.eps
for clean out
Figure 8
• Use override only for emergency fold-up Bypass key switch location
and cleaning.
• Emergency stop buttons do not function
when the bypass mode is used.
If there is a malfunction in the E-stop circuit and the
dump valves (in the E-stop manifold) open, oil will be
routed from the hydraulic pump directly back to the
tank. The dump valves also open when any emergency
stop button is pushed.
If the dump valves open and the machine cannot be
repaired immediately, the power supply to the dump
valves can be reactivated by using the bypass switch
(Figure 8).
By activating the bypass key switch to the bypass
position, you send power to the solenoid of the
normally open dump valve. If the solenoid is functional
the dump valve will close and you should be able to
fold up the boom and outriggers with the manual
controls.

HOME PRINT
Service Manual
Options box The bottom of the two switches (Figure 11) is used to
control the function of the optional concrete shut-off
valve.
The three position switch allows the operator to control
the function of the valve in three different modes:
• Position number “1” is “Auto-mode”. This
mode should be used for normal operation. The
shut-off valve will work in relationship to the
concrete pump on-off switch. When the
machine is pumping, the concrete shut-off
valve is open and when the pump is stopped,
power is removed from the solenoid and the
valve inflates to stop concrete from draining
out of the boom. The valve can be overridden
via the remote box. If you are standing near the
boom with the remote box and wish to drain
the concrete from the boom, activate the switch
in Figure 12 to the down position which is the
concrete shut-off icon and the valve will open.
The switch is located to the left of the E-stop
button on the remote box.
optionsbox.eps Concrete shut-off valve
disable switch
Figure 9
Electrical options box for Vector units
shutoffswtch.eps
Night light switch
1
3035653 4 C
2
3
3036 2348
5 6
4
7
3
8
2
9
1
0 10
switchlocation.eps
valveicon.eps
Figure 10 Figure 12
Switch to activate the Switch on the remote box (left)
night light kit shut-off valve icon (right)
The switch shown in Figure 10 is used to activate the
• Position number “2” closes the valve full time.
optional night light kit.
NOTE!
Concrete shut-off valve switch Do not activate the concrete pump in this
mode with full air pressure on the valve.
Damage could occur!
• Position number three supplies power to the
concrete shut-off valve full time and disables
the valve. This position can be used instead of
the disable switch shown in Figure 12, to allow
Figure 11 the boom to drain prior to inserting a cleanout
Concrete shut-off ball, or any time the concrete needs to be
valve switch removed from the boom by gravity.

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Service Manual
Control and monitoring components On start-up the following data is displayed on screen
(Figure 14):
Controller cabinet (Figure 13)
1. PTO speed
6 2. Hydraulic oil temperature
1 3. Oil cooler “ON”
4. Control status
5 5. Selected mode of operation
6. Concrete pump delivery rate
2
1
OK OFF
0 x1000 3
PTO 1500 rpm 62˚C
7. Menu options
Menu: [ENTER]=ON
NOTE!
2 4 After pressing arrow down key on the menu
HOME + HELP START
control panel, further operational data will
CLEAR - ENTER QUIT
3 be displayed:
- Concrete pump hydraulic oil
panelID.eps
pressure -
Figure 13
- Hydraulic oil level indication menuarrowdwn.eps
Component locations on the (optional equipment)
controller cabinet
- Engine load factor (optional
1. Display window equipment.)
2. Key: menu control Control status indications
3. Operating mode selector Section 4 (Figure 14) of the screen displays the
• Local mode following conditions:
• Remote mode
• Ram change mode OK Control system is running
4. Momentary contact “I” switch (Start switch)
5. Key switch: E-stop bypass
6. Connector: radio or remote control System ready for start up.
Display window (Figure 14) Start
Istart.eps
1 2 3 4 Starting not possible: switches not in

neutral position.
2
1
OK Starting not possible: emergency stop
STOP! activated
0 x1000 3 5 estop.eps
PTO 1500 rpm 62˚C Operating mode display

allcallouts.eps
Section 5 (Figure 14) of the screen displays one of

Menu: [ENTER]=ON these modes of operation: Local-Remote-Ram change
7 6
Figure 14
localcontrol.eps
Display window data remotecontrol.eps
information

HOME PRINT
Service Manual
Menu control Fast selection/abbreviated function keys

(shortcuts):
Basic functions of the keys (Figure 15) Press the following keys at the same time:
HOME + -
and or
HOME + HELP START home.eps down.eps
• To set the contrast of the LCD display

CLEAR - ENTER QUIT manually.
menubuttons.eps
• During setting, the contrast is indicated on
display between 0 and 99%.
Figure 15
Menu Keys HOME
and HELP
home.eps help.eps
• To go to the manual language selection for all

displays.
Each key performs a different function as follows:
Full return to start screen HOME
home.eps
Up one item in the menu selection list +
Down one item in the menu selection list -

down.eps
Supplementary information for certain

screens of the diagnostic function. Presently HELP
help.eps
not implemented.
Execution of certain actions, e.g. resetting S TAR T

start.eps
of the concrete pump delivery rate counter.
One step back in menu. CLEAR

clear.eps
Select indicated menu item or activate

change. E NTE R
enter.eps
Confirmation and reset of diagnostic

messages. QUIT
quit.eps

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Service Manual
Local control
HP
RPM engine
(-) = down Compressor
(+) = up
Concrete pump delivery rate

Vehicle engine (-) = decrease
(0) = stop (+) = increase
(I) = start
Agitator
Work light
(R) = reverse (suction)
(0) = off R
(I) = on
Agitator
Water pump (P) = forwards (pumping)
P
(T)= momentary (special control)
(0) = off
(I) = locked (continuous)
Concrete pump
Vibrator reverse (suction)
Concrete pump
forwards (pumping)
Ball injection system
High-pressure water pump

HOME PRINT
Service Manual
Remote control
1
30356534 C
2
3
48
303623
5 6
4
7
3
8
2
9
1
0 10
RPM engine
(-) = down Water pump
(+) = up
Agitator in:
Vehicle engine ( ) = forward
( ) = reverse
(0) = off (stopping)
(I) = on (starting)
Concrete pump
forwards (pumping)
Control on
Diagnostic horn signal confirm
Concrete pump
(shut-off)
reverse (suction)
Vehicle signal horn on

boom speed slow
(placing operations)
End hose shutoff valve (0) boom functions off
boom speed fast
(set-up and take-down)
Ball injection system Radio remote control only:
LED:
Concrete pump delivery rate charge condition of transmitter battery
(-) = decrease
(+) = increase LED:
tansmitter state of operation:
continuously on = transmitter ready
Vibrator in automatic mode(on)
flashing = transmitting control
signals

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Service Manual
Menu overview - Main menu
2 E-Stop Chain OK Oil Temp. Hydr. 84˚C

1
OK 1 2
OK Dump Valve BOOM On OK Diesel Engine Off OK
Dump Valve CP On
Dump Valve MPS On Output 0
0 x1000 3 0 x1000 3
PTO 1500 rpm PTO 1500 rpm 33
Function: Function: h
Menu: [ENTER]=Ein Status-Screen? E-Stop C Oilcooler C
CP Hydraulic Engine Active :Radio Outrigger Station 0

2 100 100 OK Error :No CAN Data! OK Brakes Lim-Sw right 0 OK
1 3 SigPTOl : =OK Brakes Lim-Sw left 0
50 75 Valve Output 0
0%
p 0˚C
0 4 0 50 0 0
0 bar ---% ---% Function: h Function: h
Radio Remote C Outrigger C
Command Switch Command OFF

Valve A: 0 B: 0 OK Hopper Grate close OK
Valve C: 0 D: 0 Rever. Station No
Valve DW: 0 E: 0 Valve Output OFF
0 0
Function: h Function: h
Boom C Agitator C
Switch/Command OFF Switch Command 0

Hopper Grate CLOSE OK Hopper Grate close OK
Stroke Limiter 0%
Valve Output OFF Output 0
33 0
Function: h Function: h
Concrete Pump C Vibrator C
Switch/Command 0 Manufacturer/Type
Water Tank OK OK KFZ.-TYP OK
Valve Output 0 Truck Serial Number
KFZ.-NR
0
Function: h
Water Pump C Truck Data C
Switch/Command 0 Main ID : 03.09.002

Water Tank OK OK SW : V01.10 OK
MMI ID : 03.09.002
Valve Output 0 SW : V01.10
Remote ID : PROTOTYP
0 Manufact. : OX
Function: h
HP-Water Pump C System Data C
Switch/Command 0 Mach.-Nr. :TEST SHE

Overheating No OK Mach.Type :03.09.001 OK
CP-Type :LS
Valve Output 0 Hyd.-Type :.-.-.-.-.-.-
O Hotline 1-888-292-0262
Function: h
Compressor C Machine Data C
Switch/Command 0 interPTOl clock!!!

Output 0 OK cond. batt. :OK OK
Switch/Command 0
Output 0 date d.m.y :
time h.m.s :
33
Function: h
Diesel Engine C System Clock C
Pumped Volume?

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Service Manual
Menu overview - Main menu (continued)
Status-Screen?
Pumped Volume Counter

2
1
OK Start
Pumped on the job:
2.4 cbm
0 x1000 3
PTO 1500 rpm Reset ? - > [START]
Pumped Volume? Pumped Volume C
2
1
OK Malfunction List
Start
! n/a !!
0 x1000 3
PTO 1500 rpm
Malfunct.List? Malfunct.List! C
Oil Pressure CP 69.8 bar

2
1
OK Oil Temperature
Oil Tank Level
64
---.-
˚C
%
PTO Hours 33.84 h
0 x1000 3 CP Hours 0.09 h
PTO 1500 rpm Boom Hours 0.10 h
Oper.Data? Oper. Data! C
Water Pump Hrs 0.00 h

Hp-Water Pump Hrs 0.00 h
Compressor Hrs 0.00 h
Agitator Hrs 0.05 h
Oilcooler Hrs 33.51 h
Vibrator Hrs 0.00 h
Oper. Data! C
Pumped Vol. Job 2.4 cbm

Pumped Vol. Ttl 3.0 cbm
Strokes CP Ttl 40
Stroke Rate CP 00.0 st/m
Central Lubr. Hrs 0.00 h
Oper. Data! C
! Hours when moving !
Boom 0.00 h
Slewing 0.00 h
Outrigger 0.00 h
Oper. Data! C
I/O-Readout?

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Oper.Data?
2
1
OK
Dig. Input?
0 x1000 3
NA 1350 U/min
I/O-Readout?
-- Silent Diagnostic ?--

2
1
OK 1 2
OK Current: No OK
------------------------
Change? [ENTER]
0 x1000 3 0 x1000 3 Select Y/N [ ] [ ]
NA 1350 U/min NA 1350 U/min Store? [ENTER]
Parameters? Silent Diagn? Silent Diagn!
2 --- System-Language ---

1
OK Current: English OK
------------------------
Change? [ENTER]
0 x1000 3
Select Language [ ] [ ]
NA 1350 U/min Store? [ENTER]
Language MMI? Language MMI!
2
1
OK Pumped Volume shown in:
Current: cbm OK
------------------------
0 x1000 3 Change? [ENTER]
NA 1350 U/min Select Language [ ] [ ]
Store? [ENTER]
Display cbm/cby?
Displ cbm/cby!
2 Please Enter Password

1
OK **** OK
------------------------
0 x1000 3
Input [ ] [ ]
NA 1350 U/min
Store? [ENTER]
Password?
Password!

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I/O-Readout?
2
1
OK
0 x1000 3
NA 1350 U/min DI11 F31 Pwr Supply Dig Out 1 PO41 Slew right 0 mA
2
DI12 F32 Pwr Supply PropOut 1
1
OK PO42 Slew left 0 mA
Dig. Input? DI13 F20 Pwr Supply Dig Out 1 PO43 Boom A extend 0 mA
DI14 F18 Pwr Supply Inputs 1 PO44 Boom A retract 0 mA
0 x1000 3
DI15 Dump Valve Boom 1 PO45 Boom B extend 0 mA
DI16 Dump Valve CP 1 NA 1350 U/min PO46 Boom B retract 0 mA
DI17 Dump Valve MPS 1 PO47 Boom C extend 0 mA
DI18 E-STOP Chain 1 Prop. Output? PO48 Boom C retract 0 mA
DI21 D+ Signal Diesel 0 PO51 Boom D extend 0 mA

DI22 PTO On 0 PO52 Boom D retract 0 mA
DI23 Overheating Diesel 0 PO53 Boom E extend 0 mA
DI24 Oil Press. Diesel LOW 0 PO54 Boom E retract 0 mA
DI25 Limit Sw Boom A<22˚ 0
DI26 Limit Sw Outr. right 0
DI27 Limit Sw Outr. left 0 PO55 StrokeLimiter CP 704 mA
DI28 Prox Sw Stroke Counter 0 PO56 Outrigger Prop. 2 mA
DI31 Limit Sw Slew 180˚ 0

DI32 Limit Sw Boom A<50˚ 0 SI11 Switch Water Pump 0
2
DI33 Limit Sw Boom A<20˚ 0
1
OK SI12 Switch CP Forw. 0
DI34 Boom above the Hopper 0 SI13 Switch BP Rev 0
DI35 Limit Sw Slew 0˚ 0 SI14 Switch St. Limiter + 0
0 x1000 3
DI36 Agitator Rever.Station 0 SI15 Switch St. Limiter - 0
NA 1350 U/min SI16 Switch Agitator Forw. 0
DI37 Horn Station 0
DI38 Limit Sw Hopper Grate 1 SI17 Switch Agitator Rev. 0
MMI Input? SI18 Switch Compressor 0
DI41 Oil Filter Boom 1
SI21 Switch HD-Water Pump 0
DI42 Oil Filter CP 1
SI22 Switch Engine Start 0
DI43 Limit Sw Slew right 1
SI23 Switch Engine Stop 0
DI44 Limit Sw Slew left 1
SI24 Switch Cl. Ball Inject 0
DI45 Outrigger Station 0
SI25 Switch Vibrator On 0
DI46 Water Tank MIN 1
SI26 Switch rpm (+) 0
DI47 Overheating Compressor 1
SI27 Switch rpm (-) 0
DI48 PTO rpm Prox Switch 0
SI28 Switch Option 0
DI51 RC Station Eng. Start 0 SI31 Rear Panel Detection 0
DI52 RC Station Eng. Stop 0 SI32 Switch Control Start 0
DI53 RC Station CP Forw. 0 SI33 Switch Op.Mode Local 0
DI54 RC Station CP Rev. 0 SI34 Switch Op.Mode Ch.rams 0
DI55 Dump Valves Bypassed! 0
DI56 Telescope Disabled! 0
DI57 Boom disabled! 0
DI58 Boom on Rest 0 Set Valve Stroke Lim. CP 30%
DO11 Start E-Stop Module 1 RI11 Switch Ctl. Start/Quit 0

2
1 2
OK DO12
DO13
BTS Driver Vibrator
BTS Driver Oilcooler
0
0
1
OK RI12 Switch Horn 0
RI13 Switch CP Reverse 0
DO14 Relay K01 Power MainB 1 RI14 Switch CP Forward 0
0 x1000 3 DO15 BTS Driver CP Lub.Sys. 0 0 x1000 3 RI15 Switch Vibrator Auto 0
NA 1350 U/min DO16 BTS Driver Horn Boom C 0 NA 1350 U/min RI16 Switch Open Air Cuff 0
DO17 BTS Driver Horn Slew 0 RI17 Switch Rabbit 0
Dig. Output? DO18 Buzzer Power Board 0 Remote Input? RI18 Switch Snail 0
DO21 Valve Agitator Forw. 0
DO22 Valve Agitator Rev. 0 RI21 Switch rpm (+) 0
DO23 Valve CP Forw. 0 RI22 Switch rpm (-) 0
DO24 Valve CP Rev. 0 RI23 Switch Engine Start 0
DO25 Valve Outriggers 0 RI24 Switch Engine Stop 0
DI26 Valve Water Pump 0 RI25 Switch Agitator Auto 0
DI27 Valve HP-Water Pump 0 RI26 Switch C1. Ball Inject.0
DI28 Valve Compressor 0 RI27 Switch Compressor 0
RI28 Switch Water Pump 0
DO31 engine Start 0
DO32 Engine Stop 0 RI31 Prop Boom A +000 %
DO33 rpm (+) 0 RI32 Prop Boom B +000 %
DO34 rpm (-) 0 RI33 Prop Boom C +000 %
DO35 Valve Boom Lub. Sys. 0 RI34 Prop Boom D +000 %
DO36 LED Slew Stowed Pos. 0 RI35 Prop Boom E /Tel. +000 %
DO37 Air Cuff 0 RI36 Prop Slew +000 %
DO38 Cleaning Ball Injector 0 RI37 Prop Str. Limiter +000 %
RI38 Prop Option +000 %
AI11 87 mV
2
1
OK AI12
AI13
5100
9810
mV
mV
AI14 9790 mV
0 x1000 3 AI15 4330 mV
NA 1350 U/min AI16 9800 mV
AI17 06.8 mV
Analog Input? AI18 06.4 mV

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Menu overview - submenus
Status Screen? Pumped Volume? Fault list? Oper. data? I/O readout? Parameters?
E-stop pumping Malfunction list oil parame- digital input? silent

volume counter ters - DI11-DI58 diagnostic
remote con-
trol operating digital output? language
boom hours: - DO11-DO38 MMI?
concrete - P.T.O
pump - CP analog input?
display
water pump - boom - AI11-AI22
- cbm / cby?
high-pressure
water pump operating prop output?
password:
compressor hours: - PO41-PO56
- limit SR CP
- other
diesel engine
MMI input?
oil cooler
CP delivery - SI11-SI34 - Efficiency
outrigger rate: CP?
agitator - day / total
remote con-
vibrator - strokes trol?
- RI11-RI38
machine data
moving
truck data
hours:
system data - boom
system clock - slew drive
- stabilizers

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Menu operation - Example:
RESETTING THE CONCRETE PUMP DAILY DELIVERY RATE
ACTION: RESULT:
menu line on opening screen:

Press:
••••• Menu: [ENTER] = ON
next menu line:

Press:
• • • • Status Screens? • E•• C••
next menu line:

Press:
• • • • • Pumped Volume?•• E•• C••
Press: display of daily pumping rate, e.g.:

18.0 m³
Press: daily pumping rate reset to

0.0 m³
Press: return to opening screen

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Service Manual
Diagnostic system/”Fault handling”
The integrated diagnostic system informs the The following message origins are available
operator about certain operating states, displays (1st column):
faults, and indicates the possible causes.
B = Boom (placing boom control)
The corresponding messages are displayed on
the screen of the control unit 1 (Fig. 1). D = Diesel engine (truck diesel engine)
The information displayed is always composed M = Machine

of a code and the corresponding message. (general machine control)
0 = Optional
(Optional control functions)
MESSAGE
P = Pump (concrete pump)
CODE
R = Remote (remote control system)
CODE S = System
The four-digit code is composed as follows:

The following types of message are existing:
X xx X
M = Message
X............: Origin of message
L = Low-level fault (minor fault)
xx........: Number of message
X : Type of message H = High-level fault (severe fault)
Example: 8
1
P01M
P............: Pump (concrete pump) 7
6
01.......: Number of message 1 2
OK OFF
0 x1000 3
M.....: Message PTO 1500 rpm 62˚C
Menu: [ENTER]=ON
5
2 4
HOME + HELP START
CLEAR - ENTER QUIT

3
Fig. 1

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Service Manual
Display language
Texts can be displayed in three languages; Text messages, as well as international symbols,
English, German, and Spanish. may include additional information for service
personnel.
The language of text displays can be selected in
the "Parameter?" menu under "Language
Example 1: Text display
MMI?".
If "International" is selected, the messages are Disconnected / Overload
displayed without text by means of symbols. Solenoid Slewing Right
- PO41 !
The “Summary of Messages” section of this book
contains a complete list of the text messages
together with the international symbols. Example 2: International display
The messages are sorted by their code in alpa-
betical order.
PO41
Example 1: Text display
PO41 designates, for instance:

Message: Pressure Limiter
Concrete Pump
Activated ! Proportional Output 41
P01M The following additional information is possible:

Code:
PO = Proportional Output
Example 2: International display DO = Digital Output
K = Relay
Message: F = Fuse
Code: P01M
Important:
Since the international display makes multiple
use of the various symbols, it is absolutely
essential to consult “Summary of Messages”
for a clear identification of the message.

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Service Manual
Acknowledging messages
NOTE!
Messages are not faults! They
are announced only visually on
CLEAR
the display and can be
clear.eps acknowledged with the
“CLEAR” key.
Acknowledging faults
Low level faults are announced visually on the screen
and acoustically by an intermittent tone from the
controller and the warning horn. These faults can be
acknowledged via remote control or directly on the
control cabinet.
High level faults are also announced visually on
display and acoustically by an intermittent tone from
the controller and the warning horn. They can only be
acknowledged on the control cabinet
NOTE!
In both cases the acoustic signal can be shut
off via remote control.
Fault definition
Low level fault
In the event of a low level fault, the job can still be
finished even if only with certain restrictions.
High level faults

High level faults can cause direct damage to the
machine. The control system will go to E-stop mode.
The operator must then decide if the fault displayed
will affect operational safety.
NOTE!
The operator is responsible for rectifying
any fault reported as soon as he possible
can, in order to prevent possible damage to
the machine. After a fault message has been
canceled, it will not be repeated.
Schwing assumes no liability for damage
caused by faults that have not been rectified.
When a low level fault is reported, this does
not mean that it can be ignored completely,
only that the job can be finished with
possible restrictions.

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Silent diagnostic
In the "Parameter?" m u u d r "Silent a ?"

en n e di g ,
the op ra or ca s l c w
e t n r a faul is sig all d i
ee t hethe t n e n
the "REMOTE" mod of op ra io by

e or or wi
e t n the h n th the buzzer in the control cabinet.
MENU OVERVIEW Ð Silent a nostic di g
D splay menu l ne / Key:

i i
• • • • • Menu: [ENTER] = EIN

[ENTER]
• • • • Status screen? • E• C•
[ ]
• • • • • Pumped Volume?• E• C•
[ ]
••••• Fault l st?
i • E• C •
[ ]
••••• Oper. d ata? • E• C•
[ ]
••••• I/O splay?
di • E• C •
[ ]
• ••• Parameter? • E• C • [ENTER] > • • • • Silent diagnostic? • E• C•
[ENTER]
Current : No
Change? [ENTER]
Select y/n [ ][ ]
Store? [ENTER]
• • • Silent Diagn? • E• C •
d
Silent iagnostic: Yes
Ð m e ssage displayed on the screen
Ð acoustic signal from buzzer
Silent diagnostic: No
Ð m e ssage displayed on the screen
Ð acoustic signal from horn

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Service Manual
Reporting and acknowledging of faults
The way faults are acknowledged depends on the 2. Mode of operation : LOCAL
se lected mode of operation (LOCAL or REMOTE)
and on the severity of the fault: Silent diagnostic : Yes or No
1. Mode of operation : LOCAL Severe fault
Silent diagnostic : Yes or No

In the LOCAL mode of operation, severe faults
Minor fault are reported and acknowledged in the same
manner as described for minor faults.
In the LOCAL mode of operation, minor faults
are reported and acknowledged in the same In addition, the control system goes to e-stop
way, irrespective of whether Yes or No has mode.
been selected for the silent diagnostic:. Optional shutdown of the engine is also
possible.
The fault is displayed on the screen and A severe fault can only be acknowledged from
an nounced by the buzzer in the control cabinet. LOCAL.
- Depress the "QUIT" key on the

control panel (Fig. 1) once. ATTENTION:
RISK OF ACCIDENT AND DAMAGE
The buzzer stops sounding. After shut-off by a severe fault, the
control system and, if applicable,
The message continues to be the drive engine must be restarted.
displayed and can be read without • It is absolutely vital to have a
hurry. severe fault rectified before re-
starting. Otherwise there is the
- Depress "QUIT" once more. risk of irreparable damage to the
machine.
The fault message is definitely
acknowledged.
The message is deleted from

the display and logged in the
faults list.
2
1
OK OFF
0 x1000 3
PTO 1500 rpm 62˚C
Menu: [ENTER]=ON
HOME + HELP START
CLEAR - ENTER QUIT
Fig. 1
QUIT key

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3. Mode of operation : REMOTE
Silent diagnostic : No
Minor fault
The fault is displayed on the screen and an-

nounced by a horn signal.
- Activate "QUIT" on the remote Important:

control box (Fig. 1) once. Minor faults acknowledged
immediately with the "QUIT"
The horns stop sounding. key on the control cabinet
in the REMOTE mode are not
The message is deleted from the reported again when changing
display. modes.
- After switching the mode of op-

eration from Remote to Local,
the fault is displayed on the
screen and announced by the
buzzer in the control cabinet.
- Depress the "QUIT" key on the 1
control cabinet (Fig. 2) once. 2

3
30356534 C
48
303623
5 6
The buzzer stops sounding.

4
7
3
8
2
9
1
0 01
The message continues to be

QUIT switch
displayed and can be read without Fig. 1
hurry.
- Depress "QUIT" once more.

acknowledged.
The message is deleted from the 2

1
OK
display and logged in the faults 0 x1000 3
PTO 1500 rpm
OFF
62˚C
list. Menu: [ENTER]=ON
HOME + HELP START
CLEAR - ENTER QUIT
QUIT key Fig. 2

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4. Mode of operation : R E MOTE
Silent diagnostic : Yes
Minor fault
T he fault is displayed on the screen and an-

nounced by the buzzer in the control cabinet.
- Activate "QUIT" on the remote Important:

control box (F ig. 1) once. Low- level faults acknowledged
immediately with the "QUIT"
T he buzzer stops sounding (if not key on the control cabinet
switched off manually, the buzzer in the R E MOTE mode are not
will be stopped automatically after reported again when switching
60 seconds). over from LOC AL to R E MOT E mode.
T he message is deleted from the

display.
- After switching the mode of op-

eration from R EM O TE to LO CAL,
the fault is displayed on the
screen and announced by the
1
buzzer in the control cabinet. 2

3
30356 534 C
48
303623
- Depres s the "QUIT" key on the 4

5 6
7
3
8
2
control cabinet (F ig. 2) once.
9
1
0 10
QUIT switch
T he buzzer stops sounding. Fig. 1
T he message continues to be
displayed and can be read without
hurry.

control cabinet (F ig. 2) once
more. 2
1
OK OFF
0 x1000 3
PTO 1500 rpm 62˚C
T he fault message is definitely Menu: [ENTER]=ON
acknowledged.
HOME + HELP START
T he message is deleted from the CLEAR - ENTER QUIT
display and logged in the faults

list.
QUIT key Fig. 2

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5. Mode of operation : REMOTE
Silent diagnostic : No
Severe fault
The fault is displayed on the screen and an- Important:

nounced by the horns.
High-level faults can only be acknowl-
In addition, the control system goes to e-stop
edged with the "QUIT" key on the
mode. control cabinet, irrespective of the
Optional shutdown of the engine is also selected mode LOCAL or REMOTE.
possible.
- Activate "QUIT" on the remote
control box (Fig. 1) once.
The horns stop sounding.
The message continues to be

displayed and can be read without 1
2
30356 534 C
hurry. 3
48
303623
5 6
4
7
8
2
9
1
0 10
control cabinet (Fig. 2).

QUIT switch
The fault message is definitely Fig. 1
acknowledged.
The message is deleted from the

display and logged in the faults
list.
2
1
OK
ATTENTION: 0 x1000 3
OFF
PTO 1500 rpm
RISK OF ACCIDENT AND DAMAGE

62˚C
Menu: [ENTER]=ON
After shut-off by a high- level fault,

the control system and, if applicable, HOME + HELP START
the drive engine must be restarted. CLEAR - ENTER QUIT
• It is absolutely vital to have a

severe fault rectified before re- QUIT key Fig. 2
starting. Otherwise there is the
risk of irreparable damage to the
machine.

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6. Mode of operation : REMOTE Important:

Silent diagnostic : Yes Severe faults can only be acknowl-
edged with the "QUIT" key on the
Severe fault control cabinet irrespective of the
selected mode LOCAL or REMOTE.
The fault is displayed on the screen and an-
nounced by the buzzer in the control cabinet.
In addition, the control system goes to e-stop
mode.
Optional shutdown of the engine is also 1
303565 34 C
possible.
2
3
48
303 623
5
• Activate "QUIT" on the remote

4 6
7
3
8
2
9
1
0 10
control box (Fig. 1) once.

QUIT switch
Fig. 1
The buzzer stops sounding (if
not switched off manually, the
buzzer will be stopped auto-
matically after 60 seconds).
2
1
OK OFF
The message continues to be 0 x1000 3

PTO 1500 rpm 62˚C
displayed and can be read

Menu: [ENTER]=ON
without hurry. HOME + HELP START
CLEAR - ENTER QUIT
• Depress the "QUIT" key on the

control cabinet (Fig. 2). QUIT key Fig. 2
VECTOR REMOTE DATA ABBREVIATIONS

acknowledged. = NO DATA SEND
= HYD. PRESSURE IN BAR
The message is deleted from = PTO RPM (all digits are numbers)
the display and logged in the = STROKES/MINUTE
faults list. = HYD. OIL TEMP (Degrees Celsius)
= EMERGENCY STOP ACTIVATED

ATTENTION: = START CONTROL SYSTEM
RISK OF ACCIDENT AND DAMAGE = MACHINE in LOCAL MODE
After shut-off by a high- level fault, = MACHINE in RAM CHANGE MODE
the control system and, if applicable, = MACHINE in TEACH MODE
the drive engine must be restarted. = MACHINE IN CLEANING MODE
• It is absolutely vital to have a = PUT SWITCHES TO NEUTRAL
severe fault rectified before re- = HOPPER GRATE OPEN

Fig. 3
starting. Otherwise there is the = WATER TANK LOW
30364527
risk of irreparable damage to the
• The LCD window on the Radio remote will have
machine.
abbreviated codes which are explained in Figure 3.
NOTE:
Cable remote has no LCD window.

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Acknowledging of several faults

ACKNOWLEDGING SEVERAL FAULTS
If several messages are existing, a

symbol appears in the lower right-
hand corner of the display:
– Acknowledge the first message

as usual.
The next message appears and

the buzzer sounds.
– Acknowledge this as well as any

following message until no further
message is displayed.
Switching off the control system

Switching off electrical control to the system, any
existing faults will be stored to memory.
Any fault will be re-detected and reported again when
the diagnostic system is restarted.

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Summary of messages
Code international version (symbolic) plain text messages
B = Boom
Limitation
Slewing Gear
B01M Activated !
BOOM Limitation
Activated !
B02M
Disconnected / Overload
E-Stop Solenoid BOOM !
B04L
Solenoid Slewing Right
PO41 - PO41 !
B05L
Solenoid Slewing Left
PO42 - PO42 !
B06L
Solenoid BOOM A extend
PO43 - PO43 !
B07L
Solenoid BOOM A retract
PO44 - PO44 !
B08L
Solenoid BOOM B extend
PO45 - PO45 !
B09L

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Solenoid BOOM B retract
PO46 - PO46 !
B10L
Solenoid BOOM C extend
PO47 - PO47 !
B11L
Solenoid BOOM C retract
PO48 - PO48 !
B12L
Solenoid BOOM D extend
PO51 - PO51 !
B13L
Solenoid BOOM D retract
PO52 - PO52 !
B14L
Solenoid BOOM E extend
PO53 - PO53 !
B15L
Solenoid BOOM E retract
PO54 - PO54 !
B16L
! Machine Safety Stop !
BOOM Control Fault !

B17H
D = Diesel Engine
Some Hydraulic Functions

Not In Neutral!
Diesel Start Disabled!
D01M
Power Limitation
Diesel Engine
Activated !
D02M
PTO is not working or
Prox-Switch PTO-RPM
Fault !
D03L

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PTO RPM-Limit exceeded !

D04L
Indicator-Switch
PTO = ON/OFF
Fault !
D05L
Indicator-Signal
Engine Load
Fault !
D06L
Indicator Lvel
Diesel-Reservoir
Fault !
D07L
Disconnected
Truck Interface
DO31 Diesel Start - D031 !
D08L
Overload
Truck Interface
DO31 Diesel Start - D031 !
D09L
Disconnected
Truck Interface
DO32 Diesel Stop - D032 !
D10L
Overload
Truck Interface
DO32 Diesel Stop - D032 !
D11L
Disconnected
Truck Interface
DO33 RPM (+) - D033 !
D12L
Overload
Truck Interface
DO33 RPM (+) - D033 !
D13L
Disconnected
Truck Interface
DO34 RPM (-) - D034 !
D14L
Overload
Truck Interface
DO34 RPM (-) - D034 !
D15L

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High Truck Coolant
Temperature !
D16H
Low Truck Oil Pressure !
D17H
Low Level
Hydraulic Oil !
D18H
Battery charging
On Truck Fault !
D19H
M = Machine
Ball Injector
Activated !
M01M
End-Hose Shut-Off
Activated !
M02M
Temperature Transmitter
Hydraulic Oil Fault !
M03L
Hydraulic Oil Filter
BOOM Contaminated !
Please Exchange Filter!
M04L
Hydraulic Oil Filter
CP Contaminated !
Please Exchange Filter!
M05L
Low Level
Hydraulic Oil
Reservoir !
M06L
High Temperature
Air Compressor !
M07L

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Level Transmitter
Hydraulic Reservoir
Fault !
M08L
Transmitter
Oil Pressure Service
Fault !
M09L
Transmitter
Cleaning Ball Detection
Fault !
M10L
Disconnected PowerOutput
DO13 Oil Cooler - DO13 !
M11L
Overload / Fuse
PowerOutput
DO13 Oil Cooler - DO13 !
M12L
DO12 Vibrator - DO12 !
M13L
Overload / Fuse
PowerOutput
DO12 Vibrator - DO12 !
M14L
DO16 Horn Boom C - DO16 !
M15L
Overload / Fuse
PowerOutput
DO16 Horn Boom C - DO16 !
M16L
DO17 Horn Slew - DO17 !
M17L
Overload / Fuse
PowerOutput
DO17 Horn Slew - DO17 !
M18L
Disconnected Solenoid
Ball-Injector
DO38 - DO38 !
M19L

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Overload Solenoid
Ball-Injector
DO38 - DO38 !
M20L
DO26 Water Pump - DO26 !
M21L
Overload Solenoid
M22L
Kabelbruch Schaltventil
Kompressor - DO28 !
DO28
M23L
DO28 Air-Compressor - DO28 !
M24L
Agitator
DO21 Forward - DO21 !
M25L
Overload Solenoid
Agitator
M26L
Agitator
DO22 Reverse - DO22 !
M27L
Overload Solenoid
Agitator
M28L
Hydraulic On Outriggers
DO25 - DO25 !
M29L
Overload Solenoid
Hydraulic On Outriggers
DO25 - DO25 !
M30L
High Pressure
M31L

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Overload Solenoid
High Pressure
M32L
End-Hose Shut-Off
DO37 - DO37 !
M33L
Overload Solenoid
End-Hose Shut-Off
DO37 - DO37 !
M34L
Solenoid Hydraulic On
PO56 Outrigger - PO56 !
M35L
Hydraulic Oil
Temperature Exceeded !
M36H
O = Optional
Central Lubrication
DO15 CP active / Pump - DO15!
O01L
Overload PowerOutput
Central Lubrication
DO15 CP active / Pump - DO15!
O02L
Disconnected Output
Central Lubrication
DO35 BOOM active - DO35 !
O03L
Overload Output
Central Lubrication
DO35 BOOM active - DO35 !
O04L
Disconnected LED-Output
DO36 BOOM above rest - DO36 !
O05L
Overload LED-Output
DO36 BOOM above rest - DO36 !
O06L

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P = Pump
Pressure Limiter
Concrete Pump
Activated !
P01M
Stroke Rate Limitation
Concrete Pump
Activated !
P02M
Hopper Grate Open !

P03M
Low Level
Water Reservoir !
P04M
Oil Temperature High,
Power Limiter Concrete
Pump Activated !
P05L
Transmitter
Oil Pressure Concrete
Pump Fault !
P06L
Prox-Switch Stroke
Counter Fault or
CP jammed !
P07L
E-Stop Solenoid CP !
P08L
E-Stop Solenoid MPS !
P09L
Concrete Pump
P10L
Overload Solenoid
Concrete Pump
P11L

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Service Manual
Concrete Pump
P12L
Overload Solenoid
Concrete Pump
P13L
Solenoid Stroke Limiter
PO55 - PO55 !
P14L
R = Remote
R01M Emergency-Stop On
Radio Control Box
Activated !
R02M Low Battery In Radio
Control Box !
R03M CAN-FST /
Transmission With
Remote Control Fault !
R04M No Radio Control
Transmission !
R05L Joy-Stick 1 From



R08L Emergency-Stop Switch

On Radio Control Box
Fault !

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Radio Control Signal

With Faulty Address
Received !
R09L
Disconnected
Boom Release
Solenoid !
R10L
Overload
Boom Release
Solenoid !
R11L
Hydraulic Enable Fault!
R12H
S = System
Disconnected
Rear Panel !
S01M
Power Supply
MAIN-Board
Fault !
S02L
Power Supply
MMI-Board
Fault !
S03L
CAN-Communication to MMI
or MMI-Board Fault !
S04L
Relay Contact
K 13
K 13 Override / Fault !
S05L
Fuse F 18 Fault !
F 18
S06L

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Service Manual
Fuse F 20 Fault !
F 20
S07L
Fuse F 16 Fault !
F 16
S08L
Fuse F 31 Fault !
F 31
S09L
Fuse F 32 Fault !
F 32
S10L
MF1 : Power Supply
Diagnosis E-Stop Board
MF1 DI15 - DI18 Fault !
S11L
MF2 : Power Supply
Truck Interface etc.
MF2 DI21 - DI27 Fault !
S12L
MF3 : Power Supply
DI28,DI38,DI46,DI48
MF3 Fault !
S13L
MF4 : Power Supply
DI31-DI37,DI43,DI44
MF4 Fault !
S14L
MF5 : Power Supply
DI36,DI37,DI45
MF5 Fault !
S15L
MF6 : Power Supply
DI41,DI42,DI47,AI21,AI22
MF6 Fault !
S16L
MF7 : Power Supply
RAM-Change Station
MF7 DI51-DI54 Fault !
S17L
MF8 : Power Supply
DI55 - DI58
MF8 Fault !
S18L

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Service Manual
Reference Voltage for

analog Sensors AI12,
AI13,AI14,AI16 Fault !
S19L
Multi Fuse
MMI-Board
Fault !
S20L

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Service Manual
PART 2
SCHWING control system 'VECTOR'
TEACH MODE
NOTE! Restore original factory settings
Setting the parameters in “Teach Mode” When setting parameters you will need to take your
should only be done by persons with a remote control with you and go to the main controller.
complete understanding of the vector
control system. If your boom parameters have been changed and you
would like to have them revert to where they were
Teach mode offers the user the opportunity to teach the
originally, you can perform a simple procedure to
main controller how he or she would prefer to have the
restore the original factory settings.
boom respond to the remote control joystick
movements by setting parameters for minimum and 1. Open the front cover and without activating the “I”
maximum response times of each boom movement. switch, insert the “Teach Key” into the connector
MIN being the amount of signal it takes to start boom shown in Figure 17.
movement and MAX is the signal required to make the 2. The display window on the front cover should now
boom manual control handle travel all the way to the be showing you the screen shown in Figure 16.
mechanical stop. Setting these parameters requires
setting up the unit and unfolding the boom. Be certain
Restore parameters
that the boom has room to move safely during this
procedure.
to factory setting Start
NOTE! no yes
When the unit is in teach mode, the concrete [CLEAR] [ENTER]
pump and agitator are disabled to prevent
the operator from accidentally trying to
pump while the teach mode key is installed.
Teach Mode E C
vectorrestore.eps
Figure 16
WARNING Vector display window for restoring
to factory settings
Improper setup causes job site accidents:
• Look for power lines before unfolding 3. Push the ENTER button to select yes. The
W024.eps
• Be sure of unit's stability

controller will then restore the parameters to the
values set in the Schwing Test Department. After
about 10 seconds the system will reset itself.
NOTE!
When the system restart screen appears
Heat the oil first after setting the parameters, allow the
When setting the boom parameters the hydraulic oil controller time to complete the process
temperature must be at least 50˚ C and the engine RPM before performing any other system
should be increased to normal operating speed. functions to prevent losing your stored
information.

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Service Manual
4. Select the Remote mode and activate the reset “I”

switch on the remote box.
5. Operate each function of the boom to see if it is
1 2
now responding the way you prefer. If it is, no Start
further action is required. Teach
NOTE! 0 x1000 3 mode!
The boom operates normally while in teach NA 1760 U/min 52˚C
mode so the key can be left in while testing
each boom function. Menu: [ENTER]=ON
6. If the boom is still not performing as you prefer, it teachmode.eps
will be necessary to continue with setting each

Figure 18
parameter individually by completing the steps that
Teach mode screen
follow.
NOTE!
Setting parameters If the unit is in local control when the teach
1. Place controller in Remote mode and activate the key is inserted the display will tell you that
“I” switch on the remote box. you must change to remote control to enter
the teach mode. Switch the local/remote
2. Open the front cover of the Vector controller and switch to the remote position and activate
plug in the hardware “Teach Key” to the connector the “I” switch on the remote box. If the
shown in Figure 17. display again asks the question “Restore the
parameters to factory setting?”, Press the
Clear button to say no.
Vector Teach Key
4. The display on the radio remote will display the
Connector
code shown in Figure 19.
1
303565 34 C
2
3
48
303 623
5 6
4
7
3
8
2
connectorlocation.eps
9
1
0 10
Figure 17 Teach mode

Location of “Teach key” connector
3. The display window on the controller cover will Figure 19

show that the unit is in teach mode and the “I” in Teach mode display
the upper right hand corner will be flashing, which
indicates that you need to activate the reset “I”
switch to start the “teach mode” process (Figure
18).

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Service Manual
5. After activating the “I” switch, the display window 7. Start by holding down the “I” switch on the remote
will show you the screen in Figure 20. This chart box while you activate the right hand joystick
shows you RPM, Oil temperature, a picture of a forward to the extend positon.
boom cylinder, and six different boom options. The
far left column is where the boom slewing
adjustment will show, while columns A through E
represent each boom section A=1, B=2, C=3, D=4,
and E=5 if you have a five section boom.
activate"I".eps
1760 rpm 52 ˚C
OK Figure 22
Activate “I” switch and hold
A B C D E
Teach NOTE!
mode! Boom movement is not proportional in
“Teach mode” so the joystick can be moved
all the way to extend or half way, it doesn’t
Teach Mode matter as long as the boom function is
teachfunctionscreen.eps
activated.
Figure 20 8. When the joystick is activated and the “I” switch is
Teach mode parameter screen still being held down, the display will show a bar
graph like the one shown in Figure 23, at which
6. You are now ready to teach the controller what time the “I” switch can be released. The joystick
parameters you prefer. We’ll use boom #1 extend however, must remain activated or the screen will
as an example. Before you activate the function to revert to the one shown in Figure 20 and you will
be adjusted, you must decide which parameter you need to start over at the previous step. The
want to adjust (MIN or MAX). The selection is percentage shown on the graph indicates the
made with the “Rabbit/Off/Snail” switch. Choose amount of signal to this particular function (45%).
Rabbit for MAX or Snail for MIN. So to set the #1
boom extend MIN, you must first place the switch
to the Snail position (Figure 21). Engine speed (RPM) Oil temperature
1760 rpm 52 ˚C
OK
snailspeed.eps
Figure 21
A
15
45 %
50
Teach
mode!
Choose Snail speed to set MIN
45
Teach Mode
minparameterscreen.eps
Cylinder ID Cylinder extend

MIN
Figure 23
#1 boom extend MIN screen

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Service Manual
9. If the boom is not moving you should increase the 11. If you felt that the boom took off too fast when
percentage to this function by activating the joystick was activated and the percentage needs to
throttle switch to the “+” position. Each time you be decreased, tap the throttle switch Figure 24 to
tap the switch the duty cycle percentage will the “-” position until the boom responds as you like
increase by 1%. and store with the horn button as explained in the
previous step before releasing the joystick.
12. You should now activate the #1 boom joystick to
the retract position and adjust the percentage the
same way as you did for extend, and after storing
vectorthrtlpicto.eps
the parameter with the horn switch, the display

should look like Figure 26.
Figure 24 1760 rpm 52 ˚C

Throttle switch on remote box OK
A B C D E
Teach
mode!
Teach Mode
10. When the boom just begins to move, you have minretractstored.eps
attained the required MIN signal and you will be Retract MIN
required to push up on the horn switch Figure 22 to stored
store the number. If you release the joystick before
Figure 26
beeping the horn, the percentage will revert to
Boom #1 retract MIN stored
where it was when you began. After you store the
information for “#1 boom extend MIN” the screen
will display a single mark in the “A” column as 13. You now have the option of continuing on to set the
shown in Figure 25. MIN on the other boom sections or moving the
rabbit/snail switch to the rabbit position (Figure
27) and set the MAX for boom #1 as follows.
1760 rpm 52 ˚C
OK
A B C D E
Teach rabbitspeed.eps
mode!
Figure 27
Rabbit speed
Teach Mode NOTE!
extendstored.eps
Extend MIN Setting the MAX parameters requires

opening the hydraulic enclosure to gain
stored access to the boom hand valve (Figure 28).
Figure 25 This procedure applies to all units except
the 45/47 meter units which have no visible
Boom #1 extend MIN stored hand valve handles to view. The MAX
parameter on those units must be set by
checking the boom times found in the
Specification section of the operation
manual and operating each boom section to
monitor those times.

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1760 rpm 52 ˚C
OK
A
60
80 %
95
Teach
mode!
80
Teach Mode
maxparameterscreen.eps
s
Figure 29
V.ep
vlvR
MAX parameter screen
xbm
42s
16. The handle on the boom valve should now have

Figure 28 moved to the full extend position. Grab the handle
Manual boom control handles and pull or push it in the same direction it has
already moved. If the handle will not move any
further, it has reached the mechanical stop. If you
feel it is solidly against the stop and should be
backed off slightly, tap the throttle switch to the “-”
position until the pressure is relieved from the
14. Activate the “I” switch on the remote box and hold mechanical stop. If on the other hand the handle
it down. Move the right hand joystick to the extend moves freely and is not in contact with the
position. mechanical stop, tap the throttle switch to the “+”
NOTE! position until the handle comes in light contact
Boom movement is not proportional in with the stop. When you feel that the handle is
“Teach mode” so the joystick can be moved properly adjusted activate the horn button to store
all the way to extend or half way, it doesn’t the parameter and release the joystick. The display
matter as long as the boom function is should now look like the one in Figure 30.
activated.
NOTE!
15. When the joystick is activated (Figure 28) and the
With the apitech hand valve it is necessary
“I” switch is still being held down, the display will to have pulsation in the handle after MAX
show a bar graph like the one shown in Figure 29, parameter is set. If pulsation stops, the
at which time the “I” switch can be released. The MAX is too high.
joystick however, must remain activated or the
screen will revert to the one shown in Figure 26
and you will need to start over at the previous step.

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18. The procedure is the same for all functions, so

1760 rpm 52 ˚C activate the “I” switch and move to the next
OK function until you have completed all parameter
settings. Any time you have entered information
A B C D E and then change the position of the local/remote
Teach
switch, the controller will first ask if you want to
mode! store the new parameters Figure 32.
Teach Mode
Extend MAX
stored
maxextendstored.eps
Store new parameters ?
no yes
?
Figure 30 [CLEAR] [ENTER]
Boom #1 MAX extend stored
17. Now activate the “I” switch again and move the Teach Mode E C
right hand joystick to the retract position. Follow Storenew.eps
the same procedure adjusting the manual control

handle to the mechanical stop on the opposite side.
When the adjustment is complete and you have Figure 32
stored the information by sounding the horn, Window for storing new parameters
release the joystick and the display window should
look like the one in Figure 31.
19. IF you answer yes, the system will restart and store
the new parameters Figure 33. If you answer no,
the window will ask If you want to restore to the
original factory settings. If you answer no to that
1760 rpm 52 ˚C question the system will remain unchanged.
OK
A B C D E
Teach
mode! SYSTEM MESSAGE
!!! Attention !!!
Teach Mode Parameter changed

maxretractstored.eps
by Terminal !
Retract MAX
stored MAIN Board will
restart automatically !
Figure 31
rebootscreen.eps
Boom #1 MAX retract stored
Figure 33
System restart screen will appear when the
local/remote switch is moved

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Service Manual
NOTE!
When the system restart screen appears
after setting the parameters, allow the
controller time to complete the process
before performing any other system
functions to prevent losing your stored
information. The restart takes only seconds
and when completed the display will again
show the screen below (Figure 34).
1 2
Start
0 x1000 3
PTO 1760 rpm 52˚C
Menu: [ENTER]=ON
vectornormal.eps
Figure 34
Vector normal operation screen

REVISED
1/25/94
CROSS REFERENCE CHART FOR S.A.I. CABLE REMOTE CONTROL SYSTEMS GRP
REMOTE CONTROL FUNCTIONS * PIN ASSIGNMENTS FOR CONNECTORS USED ON S.A.I. REMOTE BOXES, PRIMARY CABLES AND EXTENSION REELS
HARTING WEILAND BURNDY HARTING AMPHENOL INTERCON 16 POLE HARTING 15 POLE INTERCON 12 POLE
PROPORTIONAL UNITS BLACK & WHITE UNITS w/throttle without
42 POLE 24 POLE 23 POLE 25 POLE 19 POLE BPL’s S.P.B.’s S.P.B.’s BPL’s
up & down throttle
#1 POTENTIOMETER # 1 BOOM EXTEND 1 1 A A-7 G 1 1 A-1 A-1 1 1

BOOM MICRO-SWITCH # 1 BOOM RETRACT 8 2 B A-8 H 2 2 A-2 A-2 2 2
BOOM # 2 AND # 3 RELAY # 2 BOOM EXTEND 2 3 C A-1 A 7 7 B-2 B-2 7 7
REMOTE HORN SWITCH # 2 BOOM RETRACT 9 4 D A-2 B 8 8 B-3 B-3 8 8
Radio Remotes
#2 & 3 POTENTIOMETER # 3 BOOM EXTEND 3 5 E A-3 C 5 5 A-5 A-5 5 5

BOOM MICRO-SWITCH # 3 BOOM RETRACT 10 6 F A-4 D 6 6 B-1 B-1 6 6
#4 POTENTIOMETER # 4 BOOM EXTEND 4 7 G A-5 E
BOOM MICRO-SWITCH # 4 BOOM RETRACT 11 8 H A-6 F
Cross Reference Wiring Chart
POTENTIOMETER BOOM SLEWING (CCW) 6 9 J A-9 J 3 3 A-3 A-3 3 3

BOOM
SLEW MICRO-SWITCH BOOM SLEWING (CW) 13 10 K B-2 K 4 4 A-4 A-4 4 4
ENGINE START (KVM 52M) BOOM SLEW SPEED I 15 16 L
ENGINE STOP (KVM 52M) BOOM SLEW SPEED II 22 17 M B-3 L
HOPPER VIBRATOR BOOM SLEW SPEED III 32 15 R B-4 M
Service Manual
POT. VOLTAGE + 15V UN-ASSIGNED 31 11 S
POT. VOLTAGE + 0V UN-ASSIGNED 42 12 T
ELEC. STROKE LIMITER CONCRETE PUMP POWER 7 21 X 14 C-4 C-2 12 9
MAIN POWER 24 VOLTS MAIN POWER 12 VOLTS 36 22 Z B-5 N 11 11 C-1 C-1 11 11
SERVICE TRAINING
UN-ASSIGNED MOTOR "ON" (S.P.B.) 9 B-4

UN-ASSIGNED MOTOR "OFF" (S.P.B.) 10 B-5
INDICATOR LAMP (NOT USED) 30 18 U C-6 V
ENGINE THROTTLE DECREASE 16 13 N B-7 R 10 B-5 10
ENGINE THROTTLE INCREASE 23 14 P B-6 P 9 B-4 9
CONCRETE PUMP REVERSE STROKE 17 19 V B-8 S 13 12 C-2 C-3
CONCRETE PUMP FORWARD STROKE 24 20 W C-1 T 12 13 C-3 C-4
VOLTAGE OUTPUT TO EMERGENCY DUMP VALVE RELAY 39 23 Y C-9 U 15 C-5
S0063.eps
* Per this chart, designations of the boom slewing speed functions for KVM 32XL and KVM 32XL with Flyaway Boom are NOT applicable. Refer to the repective electrical print for wiring information.
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683
Remote Control Cable/Radio
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SERVICE TRAINING
684 Service Manual

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SERVICE TRAINING
Radio Control FW 18 • Only specialists are allowed to repair the radio

controls.
• In case of any failure, notify the SCHWING
Table of Contents after-sales service.
• Only persons authorized by Messrs.
SCHWING are allowed to open leaded housings.
Black-and-white control / proportional control
• Unauthorized manipulations may result in
(as from series 1987)
great damages and render all warranty claims void.
See also section 4.1.
1. SAFETY AND ACCIDENT PREVENTION
REGULATIONS ATTENTION! Before welding the machine, make
2. SHORT INSTRUCTIONS absolutely sure that the plugs of the connection
3. PREFACE cables are detached from sockets 7, 8, and 9 of the
4. EXTRACT FROM THE TERMS OF receiver. Protect the socket by means of a sealing
WARRANTY cap. Non-observance would result in damage to
5. MODEL PLATES the electronic control system (see also customer
6. TECHNICAL DATA information K 29).
7. SHORT DESCRIPTION
8. CONTROL AND MONITORING EQUIPMENT
9. COMMISSIONING
10. OPERATING THE RADIO CONTROL 4
11. PUTTING OUT OF OPERATION -
CHANGEOVER 5
12. SAFETY DEVICES AND TROUBLESHOOTING
13. MAINTENANCE WORKS AND CHECKS,
14. CHANGING AND CHARGING OF BATTERY
7 9 8
1. Safety and Accident
Prevention Regulations
The safety and accident prevention regulations
stipulated in the operating instructions for the
truck-mounted concrete pump are applicable and
binding for the operation with the remote control
too.
• To avoid any unintended working movement of
the machine and before changing from one control
system to another:
!SET ALL CONTROL ELEMENTS IN THE

DRIVER’S CAB AND ON THE REMOTE
CONTROL PANEL TO ZERO POSITION.
STOP DRIVING ENGINE.
Service Manual 685

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SERVICE TRAINING
Safety Regulations - Concrete Pumps with Traveling
placing booms • Drive on bridges, decks, etc. only if the bearing
READ OPERATION MANUAL FOR THE & height capacity is adequate.
MACHINE. It describes the safe, proper, and most • The vehicle must not travel with an unfolded
efficient way to operate. KNOW YOUR boom.
MACHINE! • When traveling, the shut-off valves of the out-
rigger cylinders must be shut, and the outrigger
When operating the concrete pumps must be locked by means of the transport safety
and placing booms, the safety regula- devices.
tions of the responsible employers’ lia-
bility insurance company have to be Jacking
observed. The observation of these reg- • Prior to jacking, check soil conditions. If nec-
ulations shall be the responsibility of essary, increase the support foot area by placing
the contractor and operator. square timbers underneath.
• Keep sufficient distance from excavations;
The following are some supplementary recom- slopes could break away because of support pres-
sures.
mendations:
• All safety devices and provisions against acci- • On inclines, place chocks behind the wheels,
release the break, let the vehicle run against the
dents, such as warning labels and information
chocks, and apply the brake again; then jack.
signs, coverings, etc., must be in place. Do not
• After jacking, close the shut-off valves of the
remove or tamper with them. If they are miss-
outrigger cylinders, otherwise the cylinders will
ing, replace them.
lose oil, and the machine could sink to one side.
See the following drawings for location of labels:
Concrete Pump
KVM 23 - 309903 KVM 32 - 309779 • In order to avoid concrete splashes due to suc-
KVM 25 - 309918 KVM 36 - 309780 tion of air, the agitator hopper must always be filled
KVM 28 - 309778 KVM 42 - 309855 with concrete up to the mixing shaft.
KVM 31 - 309878 KVM 52 - 309930 • DO NOT OPERATE THE CONCRETE
• Check the operational reliability of the PUMPS WITHOUT THE HOPPER GRILL
machine each time before it is put into operation. FIRMLY BOLTED DOWN.
Any defects found must be repaired immediately. • NEVER ALLOW HANDS NEAR THE
• Allow the machine to be operated and main- GATE, VALVE, OR AGITATOR HOPPER
tained by qualified personnel only. WHILE THE MACHINE IS RUNNING.
• Make use of handles and steps when ascending • Before the gate or valve housing is opened,
or descending. stop the driving motor. If this is not possible (e.g.
• Keep steps, platforms, control and monitoring in the case of cleaning work), the remote control
devices, etc. free of dirt, oil, snow, and ice. cable has to be disconnected to avoid unintentional
• Before leaving the machine, protect it from movement of the valve. The concrete pump opera-
unauthorized use and unintentional movements. tor must make sure that no unauthorized person is
• Unauthorized presence in the immediate area present in the area of the open gate or valve hous-
of the concrete pump and placing boom is not ing or starts the concrete pump accidently.
allowed. Warn persons who are in the immediate
area. Stop work if persons do not leave the area Placing Boom
after having been warned. • The placing boom may be operated only up to
• Wear personal protective equipment when a maximum wind speed of 48 m.p.h. (77 km/h =
operating the machine. wind force 8).
686 Service Manual

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SERVICE TRAINING
• Under all circumstances, keep the boom suffi- enough to permit easy discharge of the con-
ciently away from obstacles such as boom cranes, crete.
scaffolds, buildings, etc. f. The pipe cleaning head must be equipped with
• The placing boom must never be used as a a working gauge and a properly sized air regu-
crane for lifting materials. lator hand valve.
• The length of the end hose must not exceed 4 g. The plug must be long enough to ensure air
meters (13 feet) in length. The end hose should not tight sealing of the pipeline at the catch basket
be kinked during pumping operations. The safety after the pipeline has been blown out.
cable between the boom pipeline and the end hose h. The plug must be tight-fitting to prevent com-
must be in place and attached. pressed air from flowing around the plug and
• If end hose is replaced with a combination of into the concrete.
reducers and hoses (for example, a 5-4 reducer and i. Work at the pipeline is allowed only after the
4” hose), then all hoses, reducers, etc. must be fas- pipeline has been relieved of compressed air.
tened with safety cables and may not exceed the Ensure that the air pressure has been com-
weight of the recommended end hose. Any of the pletely relieved.
above mentioned items should be capable of han- j. Single pipe sections and short pipes up to a
dling the pumping pressures of the specific equip- length of 40 feet must not be blown out. Great
ment. danger of accidents exists because of rapid
• Perform regular maintenance and lubrication expulsion due to too little mass!
of boom at 1 year prescribed intervals and do a • When laying pipeline, use as few bends as pos-
complete check of the boom and tower annually sible. Horizontal pipelines must be adequately sup-
using Schwing America’s “Regular Check-Up ported. When installing a vertical pipeline, the best
Concrete Placing Booms” form, SAE-510. This method is to use upright struts supporting the low-
form is supplied with all units and is available from est vertical pipe. Each succeeding pipe should then
Schwing America. be anchored to the building.
• It is preferable to install pipelines within build-
Pipelines
ings whenever possible. See operator’s manual and
• PIPELINE AND CLAMPS MUST BE SUFFI- “Pumping Concrete” booklets for more informa-
CIENT FOR PUMP CAPABILITY. tion on pipeline installation.
• The pipeline connections must not be opened
under working pressure. Before the pipeline is Remote Controls
opened, pressure must be relieved by sucking back • To avoid unintended operating movements of
the concrete. Secure couplings after assembly of the machine, set all control levers or switches in the
the pipeline. operator’s cabin and on the remote control panel to
• Because of the increased danger of accidents, the neutral position prior to any switch-over to
the following important points must be adhered to local or remote control and prior to disconnection
when blowing out the pipeline with compressed of the remote control line.
air:
a. Blowing-out should be performed under the Electrical Connections on the site-
supervision of an expert. Hydraulic Power Packs, etc.
b. No pipe bends or hoses should be connected to • The power supply connection for electrically
the end of the pipeline during the blow-out driven stationary concrete pumps or the electric
process. power packs for pumps or booms has to be
c. No person is allowed to be next to the concrete arranged by the contractor.
discharge end. • The power supply on construction sites,
d. A catch basket must be fitted to the concrete according to VDE 0100 paragraph 55, may be
outlet. taken only from a special feed point, e. g. an elec-
e. The concrete outlet should be positioned high trical distribution box with current-operated
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ground protection. The connection of the power trol command is indicated on the transmitter and
supply cable to the feed point may be carried out receiver by the green LEDs flashing.
only by a qualified electrician. • If no command is sent within a period of 20
• Fuse protection and conductor size are the seconds, the transmitter reverts to “idle state.” The
responsibility of the electrician and must comply LED of the receiver indicates permanently GREEN
with the National Electrical Code and any local = READY. The “idle state” is cancelled by operat-
codes. ing any switch.
2. Short Instructions IMPORTANT:

• Comply with safety and accident prevention
NOTE: These short instructions are to be regarded
regulations.
as a memory aid only and do not dispense from the
• Consider maximum range of transmitter.
full knowledge of the complete operating instruc-
tions. • Avoid radio shadows.
• Switch the transmitter off by turning the selec-
tor switch to “OFF.” All machine functions are
Preparing the Commissioning immediately interrupted when the EMERGENCY
OFF button is pressed.
• Switch all controls on the machine and on the
transmitter to “0” and “off.”
Reasons for Automatic Switch-off
• Switch truck engine off when warm.
• Interference by external transmitters
• Check whether the cables are connected to the
• Insufficient range due to radio shadows
antenna, power supply, receiver control, and
machine control panel. • Empty battery
• Transmitter controls are not switched to “0” or
Making Ready for Operation “OFF” when switching on the receiver.
• Switch ignition “on.”
• Place charged rechargeable battery into the 3. Preface
transmitter and the spare battery into the charger. The operating instructions contain important infor-
NOTE! Place battery into charger with poles in the mation concerning the operation and maintenance
correct position. of your
• Set selector switch on machine control panel to SCHWING MACHINE.
“Remote Control.”
• Unlock all EMERGENCY OFF buttons on the A copy thereof should always be within easy reach
machine. of the machine operator and the members of the
• Switch on receiver. LED indicates: RED. maintenance crew. Any handling of the machine
• Unlock EMERGENCY OFF button of trans- implies knowledge and close observation of the
mitter. operating instructions. It is advisable, therefore,
• Switch on transmitter power supply (selector especially prior to commissioning, to read the
switch to “ON”). LED on receiver lights up instructions carefully several times and to become
GREEN. familiar with the machine.
• If there is no reason for a fault, every further
control command will be passed on by receiver to NOTE: Perfect operation and maintenance ensure
the machine pilot control. lasting operational reliability.
Operating Mode
Downtimes as the result of avoidable maintenance
• Start truck engine.
work can largely be avoided if particular attention
• The transmission and reception of a valid con- is given to the following points:
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• Always operate the machine gently and with- 4. Extract from the Terms of
out force!
• Never change of your own values set or speci-
Warranty
fied by the manufacturer, such as hydraulic oil The following extract from the terms of warranty
pressures, tightening torques, etc.! deals with those damages which may result from
• Carry out all the prescribed maintenance and incorrect operation and maintenance:
inspection work completely and punctually!
• Use only lubricants and operating supplies The warranty does not extend
according to our recommendations!
• During operation, regularly read all the built-in a. to defects arising in consequences of natural
monitoring instruments and note any unusual reac- wear and tear, inadequate installation and erec-
tions (noises, lack of power, etc.)! tion work by third parties, inadequate commis-
• Install only ORIGINAL SCHWING SPARES! sioning, inadequate or negligent handling,
subjection to unsuitable stresses and loadings;
During operation and maintenance work, the rele- b. to defects caused by modifications or repair
vant safety regulations must be strictly observed. work carried out by the purchaser or by third
parties without our prior approval.
(Note the extract from the terms of warranty.) c. to defects arising due to the installation of
spare parts which are not genuine SCHWING
parts.
In the event of failure, possible queries, and for
ordering spare parts, please contact:
If a defective machine continues to be used in spite
Schwing America, Inc. of the defect, the warranty shall be confined only
5900 Centerville Road to the original defect.
White Bear, MN 55110
**Complete terms of warranty, see section 7 of the
(651) 429-0999
General Trading Terms.
TWX: 910-563-3539
Subsidiary of: Friedrich Wilh. Schwing GmbH
When exporting our machines, special regulations
possibly in force in the destination country must
or the authorized representative for your area.
be complied with.
Always quote the machine model, the serial num-
*Any export of SCHWING machines without
ber, and the information on the model plates.
authorization from SCHWING is not allowed.
Carry out operation and maintenance of the chas- Appropriate Applications
sis and the engine installed according to the The machine is assigned exclusively to the appli-
maker’s instructions. cation purposes mentioned in these operating
instructions.
The company of Schwing will not be liable for

damages, if
• the machine is used for operations which are
not the normal practice.
• the operation instructions, the safety regula-
tions, and the accident prevention regulations are
not observed.
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5. Model Plates Transmission of the

A model plate is attached to both the transmitter control functions : digital
and the receiver.
Charging unit for
Radio remote control can only be performed with transmitter battery : installed in the
equipment which have identical characteristics on receiver
their model plates.
Receiver:
Operation of the radio remote control is without
charge in the FRG according to PTT approval Operating frequency : in the 70 cm band
AGB-242. (27.55 inches)
Please note here: Telegram evaluation : by microcomputer
Model: ______________________ Operating voltage : 11.5 to 14.5 V or

23 to 28 V, 200 mA
Equipment Number: ______________________
Relay outputs : 18
Frequency: _____________________
of your remote control equipment, and always Analogous outputs : 8 in sequence + 6,
quote them in case of queries, etc. 12, 18, V for 24 V
or : 8 in sequence = 3,
6, 9 V for 12 V
6. Technical Data
Proportional control
Transmitter:
7. Brief Description
The new generation of SCHWING RADIO
Operating Frequency : in the 70 cm band REMOTE CONTROLS are an advanced develop-
(27.55 inches) ment of the systems first introduced in 1983.
Radio remote controls can be retrofitted or fitted at
RF output power : 4 mW the factory.
Control channels : 18 black-and-white Dependent on the machine model, black-and-

and 8 proportional white or proportional controls are available.
Operating voltage and

Transmitter
power requirements : 9,6 V DC 70 mA
The transmitter is powered by a rechargeable
nickel-cadmium battery. An inbuilt “idle state cir-
Type of operation : portable hand
cuit” ensures optimized utilization of the battery
transmitter
charge. The “idle state circuit” switches the power
supply off when no switch is operated within a
Transmission range : approximately 50
period greater than 20 seconds. The power supply
m (164.5 feet)
switches on again when a switch is operated. The
operating voltage is permanently monitored.
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An LED indicates to the machine operator that the The “radio telegram” emitted by the transmitter is
battery needs to be changed. If the battery is not detected and monitored by the receiver. If the
changed in approximately 30 minutes, the moni- receiver electronics recognizes the “radio tele-
toring circuit blocks the transmitter. gram” as correct and complete, the signal is sent to
the connected machine pilot control.
The “coding electronics” converts every switch
operation into an unmistakable transmit signal The transmitter and receiver are precisely tuned to
which is combined with a special identification each other. An external transmitter cannot affect
code before being sent by the transmitter. operation because different information (e.g.
equipment no.) belongs to the contents of each
As is known from the cable remote control system, radio telegram, and this is checked by the receiver.
the boom speed with PROPORTIONAL CON-
TROL is dependent on the excursion of the control In the event of an electronic fault or loss of tele-
lever: gram, the previous functions initiated are stopped.
The two-colour LED indicates the state of the
Short excursion = low speed receiver electronics: “FAULT”, “READY”,
Long excursion = high speed “OPERATING.” A storage rack incorporating the
recharge electronics for one transmitter battery is
By a precise graduation of the ranges of adjust- mounted in the receiver housing.
ment, the speed is almost continuously variable.
With the respective actuation of the control levers,
several movements can be made simultaneously.
Receiver
The receiver is mounted in the driver’s cabin and is
powered by the truck voltage. The hydraulic com-
ponent (pilot control) is connected by cable to the
machine control panel via the socket provided.
NOTE: ONLY connect the receiver of the PRO-

PORTIONAL CONTROL to 24 V on-board volt-
ages with negative pole connected to the chassis
(negative to ground). The BLACK-AND-WHITE
CONTROL receiver can be connected to 24 V on-
board voltages with negative to ground or, AFTER
SPECIFIC READJUSTMENTS, to 12 V systems,
or AT ZERO POTENTIAL to systems with posi-
tive to ground.
NOTE! INCORRECT VOLTAGE, SHORT-CIR-

CUIT, AND OVERLOAD destroy the electronics.
For warranty reasons, we advise against installing
the system by yourself.
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8. Control and Monitoring 6*- Selector switch: vibrator on/off

7*- Button: horn on truck
Equipment 8 - LED: EMERGENCY OFF button operated
9 - Selector switch: truck engine speed adjustment
Radio Remote
10*- Selector switch: engine on/off
Figure 1 = Black-and-white transmitter
11- Selector switch: concrete pump (pumping - off
Figure 2 = Proportional transmitter
- reverse)
12- LED: battery charge monitor
1 - Control lever with spring-centered 0-position
13- LED: radio signal output monitor
for placing boom functions
14- Selector switch: transmitter power supply ON/
2 - see 1
OFF
3 - EMERGENCY OFF button
4 - Potentiometer: output adjustment of concrete
* = Optional extra
pump
5 - Antenna socket with removable antenna
1 1 5 2
8 12 13 8
12 13 4
3
11
4
14 6 4 11
10 9 10 14
9
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Receiver RED = battery INCORRECTLY inserted
(pole), replace correctly (turn) immediately
1 - Toggle Switch: receiver ON/OFF OFF = no battery inserted
2*- 0.4 A fuse (receiver power supply) 6 - Plug-in module: transmitter battery charger
3*- 1.6 A fuse (charger power supply) 7 - Socket for connecting cable to machine control
4 - Two -colour LED: receiver state panel
GREEN = receiver READY 8 - Antenna socket
GREEN, flashing = receiver OPERATING 9 - Socket: power supply for receiver and charger
RED = receiver FAULT
5 - Two-colour LED: Battery charge control * = Not included in the new radio remote control
GREEN = battery CORRECTLY inserted series
(pole), charging
3 2 4
1
6
5
4
7 9 8
5
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SERVICE TRAINING
9. Commissioning
Preparations
3 2
1. Switch all controls on the machine and on the 1
transmitter to “0” or “OFF.”
2. Switch truck engine off when warm and with PTO
switched on.
NOTE: After a “remote start”, the engine should
run smoothly immediately. The remote control can 4
give no cold start assistance. 5
3. Disconnect remote control cable from control
panel and replace with cable: receiver - control 6. Unlock EMERGENCY OFF button of transmitter
panel. by turning to the right.
4. Check whether power supply cable, antenna cable,
and connecting cable are connected to the receiver. 2
5. Check whether antennas for transmitter and
receiver are mounted. If not, install. 1
8
Ready for operation 12 13
3
1. Switch on “ignition”.
2. Insert charged battery into the transmitter and spare 11
battery into charger. 4
14
NOTE! Make sure that the charger is inserted with 10
the correct polarity 9
3. Set selector switch on machine control panel to
“remote control”.
WARNING
Do not operate at
pressures exceeding
the rating of the
7. Set selection switch to “ON”. This causes the
entire material
delivery system.
1 following:
1 a) The power supply of the transmitter is
4 5 switched on. The red LED lights up for a short
time and extinguishes if the battery volt-
15 20
DO
IN
NO
10 U/minx100 25
RED
T OPERATE
ZONE
40 60 5 30
80
20 100
!
8 age is correct. The rhythmical flashing of the LED

¡C
0 35
6 O I O I
7 9 indicates that a radio telegram is being
M
ERGENC
O I O I HAND AUTOMATIK
transmitted.
E
b) The receiver is switched to “READY”.

STOP
10 13 14 15 The display of the two-colour LED changes to
GREEN.
4. Unlock all EMERGENCY OFF buttons on the If the two-colour LED continues to indi-
machine by turning them to the right. cate “RED”, the receiver is at FAULT.
5. Switch on the receiver using the toggle switch.
NOTE: The fault may be caused by an
LED lights up: RED. The receiver is waiting for a external transmitter in the immediate vicinity.
control signal.
The equipment is ready for operation.
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10. Operating the Radio Remote Transmitter mode

Control 1. When the receiver is ON, unlock the
EMERGENCY OFF button of the transmitter by
NOTE! In order to avoid undesired movements of turning to the right, and set the selector which to
the machine, ALWAYS switch off the power sup- “ON”.
ply of the transmitter (selector switch to “OFF”)
when the machine is not in use.
2
If the engine is not fitted with an engine ON/OFF
switch, start the engine with the “ignition key”. 1
8
Putting on the transmitter
12 13
1. Insert the spring hooks of the upper belts into the 3
carrying frame.
2. Place the belts over the shoulders. 11
3. Insert the spring hooks of the lower belts into the 4
14
carrying frame. 10
4. Adjust the length of the upper belts as required by 9
means of the buckles.
*If desired, the carrying belt can be completely
removed from the transmitter.
1 5 2
12 13 8
9 10 14 6 4 11
2. If an engine ON/OFF switch is fitted, start the truck

engine using the selector switch.
3. If no control switch is operated when the
transmitter power supply is switched on, the
transmitter first sends “address telegrams” without
a control command. The LEDs flash “GREEN”.
After 20 seconds the “idle state circuit” switches
the transmitter power supply off. The LED
extinguishes. The receiver remains in the
“READY” state and the LED remains permanently
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“GREEN”. After operating any switch, the power Transmitter range
supply of the transmitter returns. Work may then For safety reasons, the transmitter range is limited
proceed. but is sufficient for all conceivable construction
site situations. If the transmitter is taken out of this
broadcast range, all of the machine’s functions
will be stopped automatically.
3 2
1 Radio shadows
The machine operator must select his location in
such a way that he has unrestricted visibility into
the machine’s working area and that there is no
hindrance to the radio traffic.
4
5 The following may be taken as a rule of thumb:
The location has been chosen correctly if, at a
maximum distance of 50 meters (164.5 feet), the
Operation of the machine by wireless remote con- machine and the receiver’s antenna can be seen
trol is identical to that for cable remote control. without restrictions.
Please observe the following instructions for safe, Breaks in the work
uninterrupted operation: In order to prevent unauthorized operation of the
Capacity of the transmitter battery machine, the operator should not set down the
The capacity of each battery is dependent upon: transmitter once it has been switched on.
• the age of the battery,
• the charge level, and
• the ambient temperature. 2
Under extreme conditions, the capacity of the 1

transmitter battery may be exhausted after about 8 8
hours of service. (System will be shut down by the 12 13
undervoltage.) 3
In order to ensure uninterrupted operation, we rec- 11

ommend always having a charged battery on hand 4
14
while charging another battery. 10
9
The integrated charge electronics prevents an over-
load.
NOTE: In order to prevent unnecessary reduction

IMPORTANT! Before removing the transmitter,
of NiCd battery lifetime, we recommend that the
switch off the truck engine and press the EMER-
batteries be regularly changed after every 3-4
GENCY OFF button. Set the selector switch to
operating hours BEFORE the voltage monitor
“OFF” and lock the transmitter into the driver’s
indicates a battery change by flashing.
cabin. Secure the machine against unauthorized
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SERVICE TRAINING
use (see operating instructions of truck-mounted 4. Switch off the receiver by means of the toggle
concrete pump). switch.
Turn the receiver off by means of the toggle

switch. 2
3
1
3 2
1 4
5
4
5. **The LED extinguishes.
5 6. Switch the truck engine off and remove the
“ignition key”.
7. Lock the transmitter in the driver’s cabin and
secure the machine against unauthorized use.
Putting out of Operation
1. Set all controls on the transmitter to “0” or “OFF” Changeover to Cable Remote Control
position. 1. Put out of operation as described above.
2. Set the selector switch to “OFF”. 2. Remove the connecting cable: between receiver
and control panel from machine control panel.
3. Connect standard remote control cable to the
2 machine control panel.
4. Perform commissioning as normal for cable
1 remote control.
8
12 13
3
11
4
14
10
9
3. Press the EMERGENCY OFF button.
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12. Safety Facilities switch off the transmitter power supply.

In addition to manual switch-off (EMERGENCY • Set all controls of the transmitter to “0” or
“OFF” position.
OFF button), the radio remote control is provided
with automatic facilities to immediately interrupt • Change location (the transmitter may be in a
radio shadow).
or inhibit work operations in the event of a radio
fault. • Unlock the EMERGENCY OFF buttons by
turning them to the right, and switch on the
• ransmitter power supply.
1. SAFETY TEST DURING COMMISSIONING
The equipment is ready for operation again.
After switch-on, the receiver first tests whether its
radio channels are free and undisturbed.
If a signal is received, the receiver immediately Fuses
returns to the state: FAULT. (not included in new series)
NOTE: After reception of a VALID signal, the
receiver reverts to the state: READY. Sockets to receive two fuses are built into the
2. SAFETY CHECK DURING OPERATION upper part of the receiver.
The operational status will be suspended by: 0.4 A = receiver
• switching the system off manually. 1.6 A = charger
• actuating one of the EMERGENCY OFF but-
tons.
• undervoltage of the transmitter battery.
The undervoltage monitor will shut down the

transmitter if battery voltage falls below the
safety threshold. Work may proceed after exchang-
ing the battery.
• receipt of an invalid “telegram”
Transmission of the control commands from the

transmitter to the receiver is effected
using “telegrams”. These telegrams consist of a
so-called basic code (“address telegram”)
in addition to the actual control command. It is on
the basis of this basic code that the
receiver recognizes the “voice of its transmitter”.
Invalid telegrams may be caused, for example, by:
• interference due to external transmitters
• radio shadows
• contradictory control commands
IMPORTANT! Should you note during operation

that the machine does not execute any control
commands:
• press the EMERGENCY OFF button and
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13. Maintenance Works and

Checks
The radio control is virtually maintenance-free. To
insure uninterrupted operation, observe the follow-
ing instructions:
IMPORTANT!
1. The entire system is resistant to splashed water, but
it is not waterproof.
2. Keep all components clean and dry and use the
cover caps to close off immediately any connection
plugs which are not being used.
Changing the transmitter battery NOTE: Check that the cover is correctly mounted.
If mounted upside down, there is a visible gap
1. Switch off the transmitter and press the
through which humidity can penetrate into the bat-
EMERGENCY OFF button.
tery compartment.
2. Undo the locking screws by rotating through 90
degrees.
Charging the transmitter battery
The battery in the charger is exchanged in the
same way as described above, but:
CAUTION! The charger is not equipped with an
automatic polarity switch-over circuit. If the LED
lights up RED, IMMEDIATELY remove the bat-
tery and change over the contact position (turn the
battery around). The LED will indicate GREEN if
the polarity is correct.
NOTE! The time it takes to charge a battery com-
pletely is approximately 14 hours or less, if the
battery is exchanged in good time.
3. Remove battery. NOTE! DO NOT USE any other chargers: RISK

4. Insert charged battery with its contacts first into the OF EXPLOSION.
battery compartment. The position of the positive
and negative poles is not important due to the NOTE! Only use ORIGINAL SCHWING NiCd
automatic polarity switch-over circuit. rechargeable batteries: There is a RISK OF DAM-
5. Replace cover. Turn the locking screws 90 degrees AGE to the equipment if incorrect rechargeable
and clip in by applying a slight pressure. DO NOT batteries are used.
screw in.
NOTE! Do not open the batteries (fumes hazard-
ous to health).
NOTE! Do not throw away batteries that are dead

or defective. Instead, dispose of them at an
approved collection point, which is equipped to
deal with special wastes.
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700 Service Manual

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Radio Control FW 20
Table of Contents
1. TABLE OF CONENTS
2. SHORT OPERATING INSTRUCTIONS
3. FOREWORD
4. DESIGNATED USE, WARRANTY
5. SAFETY REGULATIONS AND ACCIDENT
PREVENTION REGULATIONS
6. CERTIFICATE OF APPROVAL
7. SHORT DESCRIPTION
8. TECHINCAL DATA, RATING PLATES
9. MONITORING-, WARNING-, AND CONTROL
ELEMENTS
10. PRE-OPERATING INSTRUCTIONS
11. OPERATION
12. EMERGENCY SHUT-OFF
13. INTERRUPTIONS OF WORK, END OF
OPERATION
14. REPLACING OF BATTERY
15. MALFUNCTIONS
16. MAINTENANCE, REPLACING OF FUSES
17. REPAIR
Copyrighted. These operating instructions must not be

duplicated, used improperly, or communicated to third
parties without our consent - not even by way of
excerpts.
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2. Short Operating Instructions • Pull EMERGENCY SHUT-OFF 1; LEDs 2 and 4

are extinguished; LED 3 is permanently lit: empty
The short operating instructions are to be used as a messages are being transmitted.
short reference only. They are by no means a • Actuate control element; LED 3 is flashing: instruc-
replacement for the detailed operating instructions. tion messages are being transmitted.
Please observe also the operating instructions of the
machine! Emergency Shut-Off
Pushing in the EMERGENCY SHUT-OFF BUTTON
Preparations interrupts the main functions of the machine.
• Set up the machine.
• Set all control elements on the machine and the Automatic Shut-Off
transmitter to their “0” position. for example, in case of:
• Shut off the vehicle engine as long as it is still • low battery voltage
warm, and leave the ignition on. • message errors
• Plug in the receiver cable. • electronic module failure
• Set the operating mode selector switch on the • no command instruction messages received
machine to “REMOTE”. (for more than 30 minutes).
• Set the power supply switch of the electric
control to “ON”. Interruptions of Work
• Unlock all EMERGENCY SHUT-OFF buttons • Bring placing boom into transport position.
of the machine. • Set control elements to “0”-position.
• Shut-off power supply of transmitter
Ready-for-Operation State
• Set power supply switch of the electric control
• Switch on power supply of transmitter; LED 4
to “OFF”.
is flashing.
• Lock away transmitter.
• Push EMERGENCY SHUT-OFF 1; LED 4 is
flashing faster.
2 3 4 5 6
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3. Foreward or the authorized representative for your area, quoting

always the machine model, the serial number, and the
The present operating instructions are addressed to all information on the model plates.
persons in charge of operating and servicing the
SCHWING RADIO REMOTE-CONTROL UNIT
Carrying out operation and maintenance of the chassis
and the engine installed according to the maker’s
described overleaf and to owners or users of the instructions.
equipment.
4. Designated Use
The operating instructions are to help you familiarize The equipment is exclusively designed for the control
yourself with the equipment in order to of certain types of SCHWING machines.
• use it for the purposes for which it has been
designed,
• operate the equipment safely in order to avoid Any other use is considered as contrary to its
dangers, and designated use. The equipment must be used in
accordance with the operating instructions.
• use it properly and efficiently in order to save
costs.
In addition to these, the operating instructions of the
machine must also be observed.
The equipment has been built in accordance with state-
of-the-art standards and the recognized safety rules.
Nevertheless, the equipment may constitute a risk to The equipment may only be installed by persons
persons and property if it is incorrectly used, operated, entrusted with such work by SCHWING.
serviced, or repaired. The designated use also includes the observance of the
operating, servicing, and repair instructions prescribed
Using the equipment presupposes the perfect by the manufacturer:
knowledge and strict observance of the operating • SCHWING radio remote control units must be
instructions. Therefore, you should read the operating installed, removed, operated, and repaired only by
instructions carefully and repeatedly in order to specially trained and qualified personnel. Unautho-
familiarize yourself with the equipment before putting rized additions and modifications are not permit-
it into operation for the first time. Reading the ted.
instructions after the work has begun is too late! • For servicing purposes only, ORIGINAL
SCHWING SPARE PARTS are to be used.
In addition to the operating instructions, the generally • Before export, the equipment must be adapted
applicable legal and other mandatory accident by the manufacturer to the regulations in force in
prevention rules in the country of use are to be the country of use.
observed.
Non Designated Use
In the event of failures, possible queries, and for The manufacturer cannot be held liable for damage of
ordering spare parts, please contact: the equipment resulting from use outside its designated
Schwing America, Inc. use and from incorrect and inappropriate operation and
maintenance.
5900 Centerville Road
White Bear, MN 55127
(651) 429-0999
TWX: 910-563-3539
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Extract from Terms of Warranty

The conditions mentioned below are an extract from
the terms of warranty relating particularly to damage
which may be caused by incorrect operation and
maintenance.
The warranty does not include:

a) defects due to natural wear, inappropriate
installation and fitting by third parties, incorrect
commissioning, incorrect or negligent treatment and
inappropriate use;
b) defects caused by modifications or repair work
performed by the customer or by third parties without
our previous approval;
c) defects caused by the installation of non-original
SCHWING spare parts.
If defective machinery/equipment is kept in use in spite

of defects, the warranty only includes the original
defect.
For the complete terms of warranty, please refer to our

“General Conditions of Sale”.
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5. Safety Rules and Accident after-sales service.

• Electric welding procedures always bear the
Prevention Regulations risk of damaging electronic components.
The safety rules and accident prevention regulations
contained in the machine’s operating instructions are
These components must be properly protected by an
also applicable to the operation of the machine with the
expert in electronics before such work is carried out.
radio remote control unit.
If the vehicle is to be retrofitted with a mobile car

Some additional information is given below:
telephone, the safe distance between the two antennas
• During the operation, the operator must have a must be at least 2 meters.
clear view of the machine and the concrete placing
site.
• Do not place aside the transmitter as long as it If this distance is not respected, telephone calls may
is ready for operation. cause control signal transmission interference.
• Always carry the transmitter in such a way that
any intentional contact with the control elements is
avoided.
• Cut off the transmitter’s power supply during
interruptions of the work.
• Always protect the transmitter against unau-
thorized use (by locking it away).
• Before changing the control mode, set all con-
trol elements of the direct-, cable-, and radio-
remote units to the “0” position.
• The transmitter is splash-proof (only when the
cover is closed), but not watertight.
The equipment may only be put into operation when
the cover of the receiver is properly closed.
Keep all parts clean and dry.
Close all unused connectors immediately with the

corresponding caps.
Keep the receiver cover closed when the machine is

being cleaned.
Avoid any contact of the equipment with steam jets and

aggressive detergents.
• In case of trouble, never carry out repairs on

the equipment beyond those indicated in the trou-
bleshooting measures of the present operating
instructions, but rather inform the SCHWING
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7. Short Description A power-saving feature automatically switches the

transmitter off during work interruptions in order to
The equipment consists of a portable transmitter, a save battery power.
receiver built into the machine, and a charger device for
the rechargeable transmitter battery.
The equipment bears the type-approval mark of the
Deutsche Bundespost (German Telecommunications
Depending on the type of machine, the equipment can Authority), is approved for use by the general public,
be supplied either in the proportional control version or and is not subject to registration or to licence fees.
in the pulse control version (black-and-white control).
All the control commands transmitted are safety-coated

in the transmitter so that only the pertaining receiver
responds to the signals.
The safety code is an individual code which does not

repeat itself.
Other transmitters, and also those of a different design,

will not cause the receiver to accept command signals.
The receiver checks the input signal, passing it on to

the machine control unit only if it is correct and
complete.
The channel switching of the radio equipment supplied

permits the simultaneous and interference-free
operation of several FW-20 units.
The transmitting and receiving frequencies of the unit

are selected in such a way that interference from other
radio services is virtually excluded. Moreover, the
transmitter is designed for operation with two different
transmitting frequencies.
Frequency switching in the receiver is fully automatic.
In case of interference in spite of these features, the

equipment automatically switches over to the safe
EMERGENCY SHUT-OFF state.
The transmitting range is limited to an area from which

the machine can be clearly seen.
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8. Technical Data:
Transmitter
General
Operating temperature range: . . . . . . . . . . . . . . . . . . . . . . . . . . : -10 to +50 C
Type of protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : IP 65
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 280 x 140 x 135
Transmitter-rechargeable battery set . . . . . . . . . . . . . . . . . . . . . : 9.6 V / 1000 mAh
Battery replacement at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : < 9.0 V
Automatic transmitter shut-off at . . . . . . . . . . . . . . . . . . . . . . . . : < 8.7 V
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 3 kg
Transmitter
Frequency range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 430 to 470 MHz, 2 RF channels, switch-selected
Transmitter output power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 5 mW
Transmitting range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : > 100 m
Digital System
CMOS microcontroller
PCM data transmission
Transmission time of radio commands
-pulse control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 110 msec
-proportional control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 155 msec
Operating time with fully charged battery. . . . . . . . . . . . . . . . . . : approximately 12 hours
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Receiver
General
Operating temperature range: . . . . . . . . . . . . . . . . . . . . . . . . . . : -10 to +50 C
Type of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : IP 00 (casing = IP 55)
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 19 cassette 3HE/28FE resp. 42 TE
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : approximately 2 kg (without casing)
Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 20 to 28 V
Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : max. 0.5 A
Receiver
Frequency range : 430 to 470 MHz, automatic transmitting frequency
scan
Sensitivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 1 uV
Digital System
CMOS microcontroller
PCM data telegramme decoding
Active EMERGENCY SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . . : by EMERGENCY SHUT-OFF message

from transmitter or in case of component
failure in EMERGENCY SHUT-OFF circuit
Passive EMERGENCY SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . : by data message interference of > 1 sec. or

failure of one EMERGENCY SHUT-OFF
channel
Control channel output depending on
type of unit
FW 20 - K28 - V 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 32 switching - 6 proportional channels
FW 20 - K42 - IMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 20 switching - 1 proportional channel
FW 20 - K42 - PROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 20 switching - 8 proportional channels
FW 20 - K42 - SANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 32 switching - 1 proportional channel
The transmitter and the receiver are equipped with a

rating plate. The unit serial number and the frequency Please note here:
must be the same for both units.
Type of equipment: ________________________
Transmission and reception of radio signals is only

possible with units having the same rating data. Serial number:____________________________
Frequency: ______________________________
of your equipment and indicate these whenever you

have any questions.
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9. Monitoring-, Warning-, and

Control Elements
TRANSMITTER (fig. 1)
2 3 4 5 6
1- EMERGENCY SHUT-OFF button
2- LED: battery voltage monitoring
3-LED: Transmitter signal output monitoring
4-LED: EMERGENCY SHUT-OFF
5- Selector switch: transmitter power supply

ON/OFF 1
6-Selector switch: transmitter channel selection fig. 1

HF1/HF2
The other monitoring-, warning- and control

elements correspond to those of the cable control
units of the coresponding machine.
BATTERY CHARGER (fig. 2)
1-LED: battery charger power supply ON
2- Bi-coloured LED
green LED = battery is being charged
red LED = battery not correctly

inserted - change polarity
3-Socket outlet: power supply
4-Battery compartment
fig. 2
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SERVICE TRAINING
RECEIVER POWER SUPPLY (fig. 1)
1- Key switch in driver’s cab: power supply ON
2- Pilot lamp: power supply ON
fig. 1
INSTALLATION OF RECEIVER (fig. 2)
1-Cover lock
2-Pilot lamp: power supply ON
fig. 2
RECEIVER (fig. 3)
T1-Connector for diagnostic unit
T2-Connector for diagnostic unit
fig. 3
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SERVICE TRAINING
Fig. 1 = proportional control receiver
Fig 2. = black and white control receiver
LEDs
NG = power supply
UF = vehicle system voltage
UE 1 = controller 1 supply
UCC 1 = controller 1 supply (+5V)
UE 2 = controller 2 supply
UCC 2 = controller 2 supply (+5V)
NOT 1 = failure in EMERGENCY SHUT-OFF

circuit of controller 1
fig. 1
HF = receiver
K1 = RF-channel 1 selected
K2 = RF-channel 1 selected
MC 2 = controller 2 data message reception
MC 1 = controller 1
ST 1 = controller 1 failure
ST 2 = controller 2 failure
REL = relay output defective fig. 2
PROP = proportional control output defective
TEL = data message reception
TST3 = data message error 3
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10. Pre-Operational Instructions • During “cable-controlled” operation, the radio

receiver connector is in the unwired socket.
• Position the vehicle as described in the
• Lock the cable-connector.
machine operating instructions.
• Set selector switch on the machine to
• Set all control elements of the cable control
“REMOTE”.
unit (if connected) and the control elements of the
machine to “0” position. • Release all EMERGENCY SHUT-OFF but-
tons of the machine (cf. machine operating instruc-
• Shut off drive engine when it is warm. Remote
tions).
control cannot be used to activate any existing
cold-starting aid. Leave the ignition on. • Switch on receiver power supply with key
switch in the driver’s cab.
• If required, remove the cable control unit con-
nector and insert the radio receiver connector into • The ON state is indicated by lamps on the
the socket outlet. receiver.
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After the switching on of the power supply, the LEDs
of the receiver must indicate the following state of
operation:
MODULE LED DISPLAY
NG all LEDs on
alternating in 1-second-intervals
HF K1 + K2
(transmitter-scanning)
MC 2 MC 2 flickering irregularly
flickering irregularly
TEL
MC1 on
TST 2
all others off
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• Put the transmitter into operation:
2 3 4 5 6
ACTION LED EFFECT
Set all control elements of putting into operation oth-

all LEDs off
transmitter to “0” position erwise not possible
request to test the EMER-
Switch on power supply
LED 4 flashing GENCY SHUT-OFF but-
with selector-switch 5
ton
Push EMERGENCY EMERGENCY SHUT-
LED 4 flashing faster
SHUT-OFF button OFF O.K.
transmitter ready for opera-
Unlock EMERGENCY LEDs 2+4 off; 3 perma-
tion, empty messages are
SHUT-OFF button nently lit
being transmitted
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The following operating state must now be dis-
played at the receiver:
MODULE LED DISPLAY
off (EMERGENCY SHUT-OFF circuit

NG NOT1 + NOT2
closed)
permanently lit (depending on transmitter
HF K1 or K2
channel selection)
flashing regularly (data message transmis-
MC 2 MC 2
sion rate)
MC 1 TEL flashing regularly, all others off
flashing regularly (only for black-and-
REL REL
white control)
The unit is now ready for operation.
In case of trouble, cf. section 15.
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SERVICE TRAINING
11. Operation The LEDs of the REL module on the black-and-white

control unit receiver indicate that the relay is activated.
IMPORTANT! Depressing the EMERGENCY SHUT-
OFF button in case of danger immediately interrupts
the main functions of the machine. Cf. section 12.
2 3 4 5 6
1
An energy-saving feature prevents the transmitter
battery from deep discharge. The energy-saving feature
is reset after activation of any switch.
Choose your location in such a way that the concrete
placing site and the receiver antenna can be clearly
seen from a distance of not more than 50 meters. If all control elements of the transmitter are in their
“0”-position, the transmitter power supply is cut off
after 30 minutes.
In case of radio signal interruption, the receiver

switches the machine into the EMERGENCY OFF
state. Cf. section 12.
To reactivate the radio control system (and to close the

EMERGENCY OFF valve), short activation of one of
the control elements of the transmitter is sufficient.
In order to readjust the support outriggers, it is also

sufficient to switch the mode-selector on the machine
to the “DIRECT CONTROL” position.
Battery Capacity
The capacity of the battery depends on
The operations required to control the machine with the • the age of the battery
radio transmitter are the same as with the cable control • the charge condition
unit. • the ambient temperature
Flashing of LED 3 indicates that “active messages” are Under normal conditions, the operating time of a new
being transmitted. and fully charged battery is approximately 12 hours.
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SERVICE TRAINING
It is recommended always to have a charged battery 12. Emergency Shut-Off
available, to charge another battery in the charger, and
to change the batteries about every eight hours or The control unit is equipped with 2 separate
before each new working shift. EMERGENCY SHUT-OFF modules.
Disturbances If a fault is detected by at least one of the modules, the

If, during the operation, the machine does not respond machine control system passes over to the
to control commands: EMERGENCY SHUT-OFF state.
• change the transmit frequency. If this is unsuc-
cessful:
The EMERGENCY SHUT-OFF valve in the hydraulic
• push the EMERGENCY SHUT-OFF button system opens.
• change your location
• put the control unit into operation
The hydraulic system is now working in the
• check LEDs on transmitter:
pressureless circulation mode and the main functions
2 + 4 = off are stopped.
3 = permanently lit or flashing
The EMERGENCY SHUT-OFF condition is triggered,
If the control unit cannot be put into operation, see for instance, by pressing an EMERGENCY SHUT-
section 15 OFF button or by low battery voltage.
In addition, the receiver carries out constant checks:

2 3 4 5 6
• of the transmitted data messages
• whether the control commands are executed
(double reading)
• the electric components of the receiver and
output circuits.
If faults are detected, the unit passes over to

1 EMERGENCY SHUT-OFF.
Cf. section 15.

Frequency Change
Changing the transmit frequency with selector switch 6 The unit can be restarted only after the fault has
makes sense only if another transmitter with the same been rectified.
frequency is being operated in the vicinity, or if
irregularities in the transmission are suspected.
Cf. section 10.
During a change of the frequency, the operation will be

interrupted for about 3 seconds, as the EMERGENCY
SHUT-OFF circuit of the receiver will be interrupted.
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SERVICE TRAINING
13. Interruptions of Work/End of

Operation Never use an EMERGENCY SHUT-OFF button for
ordinary shut-off.
• Fold placing boom back to its transport posi-
tion.
• Set all control elements of the transmitter to If the power supply remains on, the unit continues to
“0”-position. transmit the EMERGENCY SHUT-OFF signal. This
leads to unnecessary discharging of the battery.
• Switch off the transmitter power supply with
selector switch 5.
• Switch off the power supply of the receiver
with the key switch in the driver’s cab.
2 3 4 5 6 • Protect the transmitter against unauthorized
use (lock it away!).
• If required, remove the receiver cable from
socket 1 and plug connector into unwired socket 2.
718 Service Manual

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SERVICE TRAINING
14. Replacing the Battery • Put the machine out of operation.

• Set all control elements of the transmitter to
A flashing LED 2 indicates that the rechargeable “0”-position.
battery must be replaced.
• Switch off transmitter with selector switch 5.
• Turn the locking screws of the battery com-
2 3 4 5 6 partment counter-clockwise by 90 degrees and take
off the lid.
• Withdraw the battery.
• Insert a charged battery with the contacts
ahead into the battery compartments.
Observe battery polarity.
In case of wrong polarity, the transmitter cannot be put It is recommended to interrupt the power-supply of the
into operation. battery charger if longer operating breaks are to be
• Put on compartment lid. expected (e.g. weekends).
Turn locking screws clockwise by 90 degrees, and To do so, withdraw cable from socket 3.
engage under slight pressure without further turning. • Replace the battery as described on the front
side.
Take care that the lid fits correctly. Turning the lid 180
degrees during fitting leaves a visible air gap. In this The polarity is correct if LED 2 displays green, and it is
position, moisture can penetrate into the battery wrong if it displays red.
compartment.
• If the LED shows a red light, remove the bat-
Recharging of Battery
tery immediately and change polarity by turning
The battery charger is permanently connected to the the battery.
power-supply.
Charging of the battery is completed after 14 hours
max.
The ready-for-operation state is indicated by LED 1. The battery cannot be overcharged. If the battery is full,
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SERVICE TRAINING
the charger automatically switches over to “trickle 15. Malfunctions
charge”.
Malfunctions are mainly caused by radio signal
interference, leading to an EMERGENCY SHUT-OFF.
Radio signal interference may have different causes:
TRANSMITTER OUT OF RANGE

The transmitter range is limited for safety reasons but
is, nevertheless, sufficient for normal use on
construction sites.
RADIO SHADOW
Choose your location in such a way that the working
range of the machine can be clearly seen and that
ATTENTION - DANGER!
undisturbed radio communications are ensured.
RISK OF EXPLOSION OF THE BATTERY:
• Never use chargers from other manufacturers.
Use the following rule of thumb:
RISK OF DAMAGE if the unit is used with the wrong

batteries: The location has been correctly chosen if the concrete
placing site and the receiver antenna can be clearly
• Use only ORIGINAL SCHWING BATTER-
seen from a distance of not more than 50 meters max.
IES.
LOW VOLTAGE OF TRANSMITTER BATTERY

NOXIOUS FUMES:
• Never open rechargeable batteries. LED 2 gives a warning signal if the low voltage limit of
the battery is exceeded.
ATTENTION - PROTECTION OF THE

ENVIRONMENT! If the battery is not replaced within 30 minutes, the
• Always bring unusable batteries to special col- transmitter shuts off automatically.
lection points for disposal.
2 3 4 5 6
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Message Interference
Messages may be disturbed, for instance, by
interference from other transmitters.
An interference of up to 1 second does not affect the

functions of the machine.
The interference is, nevertheless, indicated by LEDs

TST 1, 2, 3, of the MC 1 module on the receiver.
• Switch over to another transmit frequency with

selector switch 6 if you suppose message interfer-
ence.
2 3 4 5 6
• If the vehicle is retrofitted with a mobile car

telephone, take care that the distance between the
antennas is not less than two meters.
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SERVICE TRAINING
Trouble Shooting
Never attempt repairs beyond those recommended in
For function checking and fault detection, the
the troubleshooting section.
transmitter and the receiver are both equipped with
LEDs.
SCHWING assumes no responsibility for inappropriate
repairs.
In case of proper function, only the green LEDs may be
lit. Red LEDs indicate fault.
[TROUBLESHOOTING TABLE (needs to be made)]
For troubleshooting, use the fault detection tables on
Troubleshooting: Receiver LEDs
the following pages and state the last fault message
recorded if you contact us for help. Troubleshooting Table: Transmitter LED s
= LED on / = LED flashing / X = LED flashing faster / = LED off
+
STOP
LED LED LED DESCRIPTION ACTION
Battery empty, battery wrongly
Charge Battery; Turn Power On
inserted, power OFF
Valid empty messages, energy-
Begin machine control
saving timer ON
Valid control commands Control O.K.
Low battery voltage, approx. 30 Replace battery
minutes operating time left
Transmittter shut-off due to low
Replace battery
battery voltage
EMERGENCY SHUT-OFF See receiver
EMERGENCY SHUT-OFF test Push EMERGENCY SHUT-OFF
request button
Unlock EMERGENCY SHUT-
X EMERGENCY SHUT-OFF O.K.
OFF
Not all control elements in 0 -
Control elements in 0 -
position before the transmitter was position, restart.
switched on.
Only if check is carried out by
Fault detection mode quailified personnel
Module failure Call after-sale service
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Table 1: Power Supply (NG)
MESSAGE/ POSSIBLE REMEDIAL

LED DISPLAY
CAUSE OF TROUBLE ACTION
UF, UE1, UCC1, UE2, Switch in, check

none lit Machine power failure
UCC2 power supply
UF
on Power supply failure, short Call after-sales
UE1, UCC1, UE2,
one off circuit in receiver service
UCC2
EMERGENCY SHUT- Rectify fault, unlock
OFF activated EMERGENCY
NOT1, NOT2 ON
Fault detected by electronic SHUT-OFF
system see MC1
off, but no Replace fuse, cf. sec-
NOT1, NOT2 Fuse defective
function tion 16
MESSAGE/POSSIBLE
LED DISPLAY REMEDIAL ACTION
CAUSE OF TROUBLE
Transmitter scan, no radio Switch on transmitter, choose

alternately contact better transmitter location, check
K1, K2
flashing antenna
Message format error see MC1
MESSAGE/POSSIBLE
LED DISPLAY REMEDIAL ACTION
CAUSE OF TROUBLE
Transmitter off, no radio

not flashing Switch on transmitter, choose
contact
at message better transmitter location, check
TEL
transmission antenna
Transmitter defective, RF
rate Call after-sales service
section defective
Service Manual 723

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SERVICE TRAINING
Troubleshooting Controller (MC1)
MESSAGE/ POSSIBLE CAUSE OF REMEDIAL

LED DISPLAY
TROUBLE ACTION
Failure in MC 1 or in periphery module, Call after-sales

ST1 on
e.g. REL, NG, PROP service
Call after-sales
ST2 on Failure in MC2, no exchange of data
service
REL on Failure in REL See relay output
Call after-sales
Failure in PROP, analogue outputs out of
service
tolerance, adjuster deregulated
PROP on Check vehicle
Vehicle power supply voltage <20V
power supply volt-
resp. >28V
age
TEL not flashing No radio reception Check transmitter
at the Transmitter off or defective and antenna
rhythm of
transmitted
msg. Call after-sales
TST2 on Antenna not installed or defective service
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SERVICE TRAINING
Troubleshooting Table: Transmitter LED’s
MESSAGE/POSSIBLE CAUSE
TST3 TST2 TST1 OF TROUBLE REMEDIAL ACTION
No empty message after switch-on Set control element to 0 -pos.
EMERGENCY SHUT-OFF act. Unlock EMERGENCY SHUT-OFF
Contact jamming Call Service Department
Format error in pulse-coded
Call Service Department
message
Format error in proportional
message
Another transmitter with same
frequency nearby, message affected Call Service Department
by address error
Message affected by mode error;
encoder switch in wrong position
Message affected by cyclic
redundancy check error
EMERGENCY SHUT-OFF Rectify fault, unlock EMERGENCY
message SHUT-OFF
MESSAGE/POSSIBLE CAUSE OF REMEDIAL

LED DISPLAY
TROUBLE ACTION
Call after-sales
REL not flashing Relay outputs defective or not connected
service
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SERVICE TRAINING
16. Maintenance Replacing of Fuses

The control unit is largely maintenance-free. The circuit board of the black-and-white control
Nevertheless, a check should be carried out every 4 receiver and the circuit board of the proportional
years by SCHWING. control receiver are equipped with one fuse each.
Use only miniature fuses 5 x 20 mm, 3.15 A. • Open lid of mounting rack with special key.
• Swing back lid of mounting rack and replace
fuse.
Fuses can be replaced as follows:
• Close mounting rack and put on cover.
• Switch off the unit.
• Open lock 1 and swing back cover.
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SERVICE TRAINING
17. Repair
REMOVAL OF RECEIVER
For repairs or for regular checks, the receiver must be
removed from the vehicle and sent to the factory for • Push EMERGENCY SHUT-OFF button.
repair complete with the transmitter. • Open cover, as described in section 16
• Withdraw the (blue) multipole connector from
the circuit board.
For repairs outside Germany, please address to your
• Pull off the antenna cable.
local agent.
• Loosen the four fastening screws at the front
side.
Take care that the equipment is packed shock-proof.
Depress the screws slightly and turn counter-clockwise

by 90 degrees without further turning.
Withdraw the receiver unit carefully an d smoothly

from its compartment in the vehicle.
INSTALLATION OF THE RECEIVER

• Push EMERGENCY SHUT-OFF button.
• Insert receiver carefully and smoothly into its
compartment.
• Turn the fastening screws clockwise by 90
degrees, and engage under slight pressure without
further turning.
• Plug in antenna and multipole connector.
• Close the cover.
Service Manual 727

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Operating Instructions - Radio Remote Control FW 20

Dual Fr equency
- Reference Chart -
FREQUENCY COORDINATOR
456.7525 1P-(PFCC)
456.8125 1S-(ITA)
456.8625 1S-(ITA)
456.9625 1S-(ITA)
457.0125 1S-(ITA)
457.5125 1S-(ITA)
457.525 1B-(NABER)
457.5625 1B-(NABER)
456.575 1B-(NABER)
457.6125 1B-(NABER)
457.6625 LM (ATA)
457.6875 LM (ATA)
457.7125 LM (ATA)
457.7625 LM (ATA)
(IS) ITASPECIAL INDUSTRIAL RADIO SERVICE INDUSTRIAL

TELECOMMUNICATIONS ASSOCIATION
ATTN. FREQUENCY COORDINATION DEPARTMENT
1110 NORTH GLEBE ROAD, SUITE 500
ARLINGTON, VA 22201
703-528-5115
(IB) NABER NATIONAL ASSOCIATION OF BUSINESS AND EDUCATIONAL
RADIO, INC.
ATTN. FREQUENCY COORDINATION DEPARTMENT
1501 DUKE STREET, SUITE 200
ALEXANDRIA, VA 22314
800-759-0300
703-739-0300
(LM) ATA AMERICAN TRUCKING ASSOCIATION, INC.
ATTN. GUS GYLLENHOFF
2200 MILL ROAD
ALEXANDRIA, VA 22314
703-838-1730
(IP) PFCC PETROLEUM FREQUENCY COORDINATING COMMITTEE
ATTN. MARIE HAWKINS
1110 NORTH GLEBE ROAD, SUITE 500
ARLINGTON, VA 22201
703-528-5115
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Radio Control FW 24
Table of Contents
1. Safety Instructions
2. Scope of Application
3. Start-up
4. Operation
5. Charging the Battery
6. Maintenance
7. Operation
8. Fault Indicators
Service Manual 729

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SERVICE TRAINING
Safety Instructions
SAFETY INSTRUCTIONS
Please read these operating instructions If your remote-control is a "COMFORT-

completely before putting your TELETEC Control" unit, the radio receiver must not be
remote-control into operation. disconnected. Cable operation may
otherwise be impossible.
Observe also the corresponding working
safety and accident prevention regulations. Repair work on the remote-control unit may
only be performed by TELETEC or by
The instructions relating to the operation of qualified personnel duly authorized by
the machine itself are contained in the TELETEC.
machine manual.
Non-observance of the safety instructions
Remote-control units may be used by duly will discharge TELETEC from any and all of
authorized persons after they have been their warranty and liability obligations.
instructed by a specialist.
Do not put the operational transmitter aside,

but always protect it against unauthorized
use by locking it away.
The remote-control may only be used for

purposes complying with its designated use
i.e. only for controlling the machine or plant
for which it is designated.
Any other use is forbidden.
Using the device for purposes other than its

designated use, faulty operation, insufficient
maintenance and unauthorized repairs of
the remote-control unit may cause severe
material damage and injury to persons.
In the event of malfunction or defects of the

remote-control unit depress immediately the
red EMERGENCY SHUT-OFF button,
switch the transmitter off and keep it in a
safe place.
Disconnect all cables from the receiver if

your remote-control is a "MULTI-Control"
unit.
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SERVICE TRAINING
Scope of Application
SCOPE OF APPLICATION
1 2 3
The present operating instructions are
applicable to FW 24 radio remote-control FW24-ID.eps
Stop POWER
units in proportional and digital design

HF1
4
suitable for SCHWING truck-mounted HF2
concrete pumps equipped with control

systems of the "MULTI-Control" and
FW24rmbx.eps
"COMFORT-Control" type. 6 5
The operator panels of the radio
transmitters are the same (with the
exception of switch 6, Fig.1) for both control Fig.1
systems. For detailed description please
refer to chapter 3.
The present manual does not contain Switch 6:

instructions relating to a particular type of
machine.
For machine-specific instructions please

refer to the corresponding machine manual. 0 MULTI-Control
MANUFACTURER
FW 24 remote-control units are

manufactured for SCHWING by:
TELETEC GmbH COMFORT-Control

Paul-Lincke-Ufer 39/40
10999 Berlin
Tel. 030-612 40 45
FAX 030 - 611 50 39
Service Manual 731

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SERVICE TRAINING
Start-Up
START-UP
Remote-control system 1 2 3
FW24-ID.eps
Transmitter and receiver are each equipped Stop POWER

HF1
4
with an identification plate.
HF2
To permit communication between
transmitter and receiver it is necessary that
FW24rmbx.eps
6 5
both devices have the same serial number
and frequency.
Proceed as follows to put the system into

operation: Fig.1
3. Switch on the transmitter with "Power"
1. Switch on the receiver: switch 4 by setting the switch to "HF 1" or
"HF 2" (frequency selection).
- Switch on the ignition and the power take-
off of the truck. POWER
HF1
- Apply the parking brake.
- Switch on the machine control unit with the

key-switch in the driver’s cab.
- Set the selector switch on the local control HF2

panel to "Remote".
- Insert charged battery pack into the The red light-emitting diode (LED 3) now
transmitter housing and lock the battery starts flashing at a slow rate.
case.
Stop
2. Make sure all switches are in their basic
(or neural) position before switching on the
transmitter (Fig. 1)
Fig. 1 shows only those control and 4. Perform the emergency shut-off test:
monitoring elements as a are typical of
radio remote-control unit. -Depress the emergency shut-off test,
All other elements correspond to those of -The red LED 3 now flashes at a fast rate.
the standard cable remote-control.
- Release the emergency shut-off button
Refer to the machine operating instructions. (unlock).
Unlock the EMERGENCY SHUT-OFF
button. Without unlocking, starting of the
system is inhibited for reasons of safety.
732 Service Manual

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SERVICE TRAINING
Stop To switch off the transmitter, e.g. after the

work has ended, set the "Power" switch 5 to
1 2 3 neutral position ("0").
POWER
HF1
"MULTI-Control" system"
The green LED 2 (antenna) is lit up

continuously and the red LED 3 is flashing. 0
Enable the control system by setting switch HF2
6 briefly to Do not depress the EMERGENCY SHUT-

OFF button for normal shut-off to prevent
the emergency shut-off signal from being
0 transmitted permanently and the
rechargeable battery from being emptied.
Special transmitter operation features

Only then will the red diode (LED 3) go out 1. Selecting the boom speed
and the green one will flash.
The boom control functions must be
The transmitter is now ready for operation activated with switch 6.
and the commands given with the control
elements are executed by the concrete
pump.

"COMFORT-Control" system:
The red diode (LED 3) goes out and the In the center position ("0") of this switch all
green one (LED 2) is lit up. functions of the boom are deactivated.
The transmitter is now ready for operation Moving the joysticks causes the red diode
and the commands given with the control (LED 3) to light up to indicate that boom
elements are executed by the concrete operation is disabled.
pump.
The switch must be set to the "Snail" or
Note: "Hare" symbol.
The "COMFORT-Control" system does not "Snail" = slow is the preferred speed for
provide an enabling function for switch 6. normal working operation and
Switch 6 is needed for a fault- "Hare" = fast is the speed used for setting
acknowledging function labeled "quitt" up of the placing boom.
[acknowledge].
See also the abbreviated "COMFORT-

Control" operating instructions, i.d. no.
10167123.
Service Manual 733

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SERVICE TRAINING
Depending on the type of control, the After switching over to another channel, the
selection of either "Snail" or "Hare" has a transmitter must be re-activated as
different effect: described on page 3.1 (EMERGENCY
Control digital proportional SHUT-OFF test etc.).
reduced slewing- 0-50% speed for
gear speed all boom func- The receiver will be switched over
tions automatically to the new transmission
channel.
full slewing-gear 0-100% speed In the event of persisting radio transmission

speed for all boom func- disturbances or other defects, the system
tions shuts itself off automatically and passes into
the protected EMERGENCY SHUT-OFF
state.
Note:
In the neutral position of switch (6) all

functions are available except the placing
boom functions.
This is important when the placing boom is

connected to a stationary delivery line (by a
hose bridge) and must therefore be
prevented from being moved by accident.
2. Changing the transmit channel
If the radio channel in use is disturbed

(transmission of control commands
interrupted or no transmission at all) you
can use the "Power" switch (5) to select
between "HF 1" and "HF 2".
POWER
HF1
HF2
This switch selects the transmission

channel.
734 Service Manual

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SERVICE TRAINING
Operation
OPERATION
When the remote-control is ready for

operation and after all EMERGENCY
.
SHUT-OFF buttons on the machine have
.
ig
og
C
Pr
Fr
M
been unlocked, all functions of the concrete
pump can be operated with the remote-
control unit (see the machine operating
2
1
2
T
T
C
O
M
M
N
N
instructions.) 4 5 6 7 11
n
de
tt
n
po
Indicator lamps on receiver
tla
de
r
En
Ve
La
8 9 10
Figs. 1 and 2 show the layout of the
receiver front panels:
Fig. 1 = "MULTI-Control" + -
Fig. 2 = "COMFORT-Control"
The red light-emitting diodes 5 and 7 Fig.1

("NOT/EMERGENCY" 1 + 2) monitoring the
emergency shut-off circuits go out if the
2
1
2
T
T
C
O
M
M
N
N
signals from the correctly activated
transmitter are being received. 4 5 6 7 11
n
de
tt
n
po
tla
de
r
En
Ve
La
They are lit up if no valid radio data 8 9 10
telegrams are being received or when the
emergency shut-off button on the
transmitter has been depressed.
+ -
In this case, the receiver in in the
EMERGENCY SHUT-OFF state, i.e.
deactivated.
Fig.2
The green light-emitting diodes 4 and 6 "Multi-Control" only
("MC 1 + 2") indicate by fast flashing that
valid radio data telegrams are being In this system, the green LED 1 ("MC 3")
recieved. and the green LED 2
("Freigabe/Enable") are lit up in addition.
These two LEDs indicate that the built-in

control module is activated, too.
LED 3 ("Prog.") remains off and is not

relevant for working operations.
The diode is used for servicing only.
Service Manual 735

HOME PRINT
SERVICE TRAINING
Charging the Battery

CHARGE THE BATTERY
When the red LED 1 (battery) of the To maintain the full charging capacity of the
transmitter starts to blink during normal battery over a long time, it should be
operation, the battery is almost empty. completely discharged once a week before
Stop recharging.
For this purpose, your charger is equipped

with an automatic discharge function:
Ca. 10 to 20 minutes later the transmitter
will be shut off automatically. For discharging keep the yellow button 11
depressed, insert the battery into the
During this time, the empty battery must be charger and lock.
replaced with a new one.
The yellow LED 10 ("Entladen/Discharge")
After replacing, restart the transmitter as will now light up.
described in chapter 3.
When the battery is completely discharged
Insert the empty battery for recharging into the charger switches automatically to normal
the charging case of the receiver and lock. charge and later on to trickle charge (green
Make sure the battery is inserted into the LED 9 flashing).
case with the correct polarity.
The green LED 9 ("Laden/Charge") on the

g.
3
.
og
ei
C
Pr
Fr
M
receiver panel (fig. 1 or 2) lights up.

1
When the battery is charged (after 3 hours

1
2
T
T
C
O
M
M
N
maximum), this LED begins to flash. 4 5 6 7 11

n
de
tt
n
po
tla
de
r
En
Ve
La
The battery can now either be removed

8 9 10
from the or left in the charger case.
In both ways, the battery will retain its full

charge. + -
if you insert the battery by mistake (+ and _
terminals marked on the housing) with Fig.1
wrong polarity into the charging case (the
battery can be wrongly inserted into the
1
2
1
2
T
T
C
O
M
M
N
case only with force), the red LED 8 4 5 6 7 11

("Verpolt/Wrong polarity") lights up
n
de
tt
n
po
tla
de
r
En
Ve
La
In this case, withdraw the battery and re- 8 9 10
insert correctly.
Note: On compact units, LED 8 is not available. In + -
these units, the green LED 9 ("Laden/Charge") does
not light up when the battery is inserted with wrong
polarity. Fig.2
736 Service Manual

HOME PRINT
SERVICE TRAINING
Maintenance
MAINTENANCE
The FW 24 radio remote-control unit is

largely maintenance-free.
You should nevertheless make sure that
- damaged rubber bellows at the switches

are immediately replaced.
- the transmitter is never exposed to the jet

of a high-pressure cleaner or to caustic
liquids.
- proper functioning of all control elements

is checked at regular intervals.
- all cables are disconnected from the

receiver when electric welding is performed
at the machine (concrete pump).
There is otherwise a risk of damage to

electronic components.
Service Manual 737

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SERVICE TRAINING
Operation Fault Indicators

OPERATION AND FAULT INDICATORS
The light-emitting diodes indicate different operational states and malfunctions.
= ON = OFF = FLASHING
1. TRANSMITTER
START-UP/OPERATION
LED MESSAGE ACTION
Stop transmitter activated, EMERGENCY depress EMERGENCY SHUT-OFF

SHUT-OFF test required. button (LED flashing faster) and release
Stop "Multi-Control" only:

enable required depress enable button
Stop enable accepted, transmitter ready start working

for operation, no function activated
(basic position)
Stop enable not accepted, restart protection set all switches to "0" position
active
Stop one or more functions activated, machine executes control commands

transmitter sending data
MALFUNCTIONS
Stop boom functions de-actived, "STOP"

lamp lights up when joystick is moved.
select or
Stop EMERGENCY SHUT-OFF button set all switches to "0" position, unlock
actuated EMERGENCY SHUT-OFF
Stop battery empty, remaining time for replace battery

operation = 10 to 20 min.
Stop transmitter defective repair by authorized personnel only
738 Service Manual

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SERVICE TRAINING
OPERATION AND FAULT INDICATORS (Cont.)
2. RECEIVER
MC 1 EM 1 wrong charge dis- MESSAGE ACTION

MC 2 EM 2 pol. charge
valid radio data signals machine executes control
are being received commands
no reception change frequency,

choose other location
EMERGENCY SHUT- set all switches on trans-

OFF actuated mitter to "0", unlock EMER-
GENCY SHUT-OFF button.
battery being charged
battery being finished remove battery from or

leave in charger (trickle
charge)
battery inserted with insert battery correctly

wrong polarity
battery being discharged charger switches auto-

matically to normal charge
when the battery is dis-
charged
"MULTI-Control" receiver only
MC 1 EM 1 wrong MESSAGE ACTION

MC 2 EM 2 pol.
built-in control module active
required for servicing purpose only
Service Manual 739

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SERVICE TRAINING
740 Service Manual

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SERVICE TRAINING
C32/CPC Radio The license-free spread spectrum band goes from

902 to 928 MHz, a 26 MHz wide spectrum using
Remote the full band width. Compare that to a conven-
tional radio that uses a band only 0.03 MHz wide.
Spread Spectrum Technology Where traditional radios tune to one frequency, a

Spread Spectrum radio uses 63 different frequen-
The Schwing T45 Remote Control systems cies. It stays 20 milliseconds on any one fre-
employ frequency hopping spread spectrum tech- quency and then moves on to the next (i.e. it uses
nology to provide the optimum performance 50 different frequencies every second).
allowable under present FCC and ISC regula-
tions. This technology provides a unique perfor- On each frequency the Spread Spectrum transmit-
mance advantage compared to conventional fixed ter sends all the information it reads from the
frequency systems. The major benefits are listed switches and joysticks (both on/off and propor-
below: tional). It adds a unique transmitter address (ID)
plus an error checking code (CRC-16) to make the
Interference Free: It cannot be jammed by other link safe and secure. The Spread Spectrum
RF transmitters or extraneous noise sources. receiver thus gets 50 switch readings from the
transmitter each second, all sent on a different fre-
Coordination Free: All Schwing-spread spec- quencies.
trum transmitters are factory coded. The user does
not need to worry about which frequency the unit If you work in a radio spectrum that is 'clean', the
is operating on. It operates as if there is a unique SSP radio will function just like a traditional nar-
frequency for each unit in existence. Any number row band radio. But if someone else is operating
of these units can be operated in the same location in the same area on the same frequency, you could
at the same time. get blocked or jammed by the other radio signal
making the radio useless at that site. This will not
License Free: These radios are certified by the happen with a Spread Spectrum radio.
U.S. and Canadian governments to meet their cri-
teria for license-free operation. With Spread Spec- If interference causes trouble for the Spread Spec-
trum Technology, these radios are allowed to trum at one frequency, the Spread Spectrum radio
transmit as much power and sometimes more than quickly moves onto another frequency where the
conventional licensed products. This makes for information is likely to get through. It would take
very high performance reliable RF links through hundreds of ordinary radios at a site to block the
many types of material and over very great dis- 26MHz wide spectrum used by the SSP.
tances should the application require it.
Security: Combine the Spread Spectrum robust-

ness with the added 16-bit address space and
CRC16 error-detection code built into the data
protocol, and these units provide extremely reli-
able, error-free control.
SPREAD SPECTRUM OPERATION -

(How does a frequency hopper work?)
Service Manual 741

HOME PRINT
SERVICE TRAINING
Mounting the Receiver where. The mounting bracket may be bolted to the
vehicle frame, but do not allow the antenna whip
Antenna: to contact metal parts! After mounting, insert the
The receiver antenna assembly (Figure 1) consists connector end of the cable into the mating receiver
of a mounting bracket with attached coaxial cable connector and secure the cable with tie-wraps if
and a removable whip antenna. For most close required to prevent damage.
range applications (< 300') the location of the
antenna is not too critical since the receiver is sen- Figure 1. Receiver Antenna Assembly
sitive enough to pick up the signal almost any-
742 Service Manual

HOME PRINT
SERVICE TRAINING
Transmitter Operation To ensure the utmost safety, the Emergency Stop

The transmitter has been designed for the utmost switch is monitored each time during power up. In
in durability and light weight. For ease of mainte- addition, the power off switch provides an addi-
nance, it uses a readily available rechargeable tional level of safety. These switches activate dif-
MAKITA battery unit (Figure 2). In addition, a ferent mechanisms and different relays on the
number of diagnostic features have been built into receiver to ensure that a system can be shut down.
it.
Figure 2. MAKITA battery
Service Manual 743

HOME PRINT
SERVICE TRAINING
1. RADIO TRANSMITTER ON/OFF SWITCH
If you have depressed and released the E-
To ensure safe operation, the E-Stop switch on the Stop button and both the stop light and
transmitter is checked each time the unit is pow- power light are flashing, you have a
ered up (Figure 3). In addition, all functions must function turned on.
be off or the unit will not power up.
You must honk the horn to clear the E-
(ON) The ON or start up sequence is as follows: Stops and power the E-Stop solenoids.
Ensure all functions are turned OFF.
(OFF) Turning off the Transmitter will cause the
Turn Power switch ON, the Stop light will receiver to go into an E-Stop mode and all
flash slowly until the E-Stop is depressed functions will stop.
and released. If the E-Stop is depressed
on power up, the light will flash rapidly Figure 3. T45 Radio Remote
until it is released.
Radio Transmitter On/Off

#2 Boom Motor Stop/Start Power LED Communication (Not on cable remotes) Boom Control
Speed Control LED
E-Stop LED On/Off
Left Joystick
Right Joystick
Throttle Up/Down Agitator Vibrator

Horn/Reset
Forward/Off/Reverse Off/Automatic
Emergency Stop Concrete Pump Stroke Limiter
Forward/Off/Reverse
744 Service Manual

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SERVICE TRAINING
2. POWER LED
The power LED indicates the status of the battery.
(OFF) Battery OK (with communication LED on

or flashing or battery dead with
all LED s off.
(FLAHSING)
Battery low.
3. COMMUNICATION LED
The Power light indicates the status of the trans-

mitter.
(ON) Transmitter on and ready to function
(OFF) Transmitter turned off or no battery

installed
(FLASHING)
Function turned on.
4. E-STOP LED
Depressing the E-Stop will remove power to all

outputs from controller and open the dump valves
located on the E-Stop manifold
(ON) If this light is on, it indicates the E-Stop

button is depressed.
(OFF) Unit is operational, E-Stop clear.
(FLASHING)
E-Stop still active due to power up
sequence or function On.
5. EMERGENCY STOP PUSH BUTTON
All outputs are disabled, E-Stop manifold sole-

noids are de-energized.
Service Manual 745

HOME PRINT
SERVICE TRAINING
Remote Radio Controller have the numbers 1 & 8 printed above it. The
second row SW2 will have 9 & 16 printed above
DIP SWITCH SETTINGS it. In order for the radio to operate, the switches
must be set the same as the decal. EXAMPLE: if
Each T45 transmitter is supplied with a unique ID the punched hole in the decal for SW1-1 is a 1
code (Figure 4). This code is marked on the label (Figure 7), then the corresponding dip switch must
located on the handle mounting plate, along with be set to ON. If the punched hole in the decal for
the radio serial number. The receiver must be set SW1-1 is a 0, then the corresponding dip switch
to match this code. To match the settings, the must be set to OFF. After all switches are set, re-
power to the receiver must be off. power the receiver.
On the cover of the HOPLINK (located in the

receiver) (Figure 5), you will see the dip switches
(Figure 6). In the box marked ID, there are two
rows of switches. The first row is SW1, it will Figure 4. ID Code
746 Service Manual

HOME PRINT
SERVICE TRAINING
Please note that the HOPLINK units recalculate its *** Make sure that switch #5 of the MODE dip
spread spectrum sequence every time the ID is switch (SW3) is on, all others must be off. SW3
changed -- be patient, it may take up to 5 seconds will also have 1 & 8 printed below it, SW3 is
on the first power up after an ID change before the located closest to the ribbon cable connection.
receiver goes operational.
Figure 5. Hoplink
Figure 6. Dip Switches, Radio Transmitter, and

Receiver
Service Manual 747

HOME PRINT
SERVICE TRAINING
WARNING
Do not operatre this
machine without
ASSY-326-08
SERIAL NUMBER 70136 ISSUE 2
ID CODE 1 1
SW 1: SW 2:
L1393-01 0 0
Figure 7. Dip Switch
0 = Off
ID
1 8
1 = On
SW1
1 2 3 4 5 6 7 8
9 16
SW2
SW3 1 2 3 4 5 6 7 8
Set all switches
to 00001000
1 2 3 4 5 6 7 8
1 8
MODE
748 Service Manual

HOME PRINT
SERVICE TRAINING
Troubleshooting Table: Transmitter LED s
l = LED on / = LED flashing / X = LED flashing faster / = LED off
+
STOP
Battery Dead; Power Off Charge Battery; Turn Power
On
E-Stop Test Press E-STOP button
X E-Stop Test Part Two Release E-STOP Button

Not all functions off on E-Stop Set all functions off
release
/ l Valid Data, all functions OK, continue as required
/ Valid Data, 1 + functions on OK, continue as required
/ / l Emergency Stop E-STOP Button Pressed
/ Low Battery Replace/Recharge Battery

X Module failure: Joystick Cycle Power - if not
remedied, call service
X Module failure: Radio Cycle Power - if not
remedied, call service
Service Manual 749

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SERVICE TRAINING
750 Service Manual

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SERVICE TRAINING
Omnex Radio Con-

trol System
1. Introduction
The Comfort Concrete Pump Remote Control Sys-
tem consists of a T47 cable, a T45 radio transmit-
ter, and a custom receiver (grey box). The cable
control has a North American standard 10 pin Sine
connector, and the receiver has a European stan-
dard 12 pin Burndy connector. Both the cable unit
and the receiver communicate to the Comfort Con-
trol system via its standard CAN-Bus interface for
remote control.
This manual describes considerations that should

be taken during installation and documents the
information displayed by the lights and the set-
tings available.
This issue of the manual describes the operation

for the cable unit with Issue 2 of the AFRM-1525-
02 software, the radio transmitter with Issue 3 of
the AFRM-1236-06 software, and the receiver
interface board with Issue 3 of the AFRM-1530-01
software.
Service Manual 751

HOME PRINT
SERVICE TRAINING
2. Physical Mounting
The receiver should be mounted with the connec-
tors down and in a location that allows the enclo-
sure door to be opened conveniently for access to
the inside.
Shock mounts must be used to mount the enclo-

sure! Under no circumstance should the enclosure
be directly bolted to the machine. The picture
below illustrates how the shock mounts should be
installed:
3. Considerations for
Electrowelding
The high currents and voltages employed by elec-
trowelding can damage the electronics in the Com-
fort Concrete Pump Remote Control System. If
electrowelding must be performed after the Con-
trol System has been installed, observe the follow-
ing precautions to reduce the risk of damage:
• Unplug the connectors to the receiver and
The enclosure is sealed and has a NEMA-4 rating. cable units.
When installing, ensure that nothing is done to • Do not strike an arc close to the enclosure.
compromise the watertightness of the enclosure.
When performing maintenance, it may be neces-
sary to gain access to the inside of the enclosure;
take care to close the door securely when you are
done.
The antenna should be mounted pointing upward

and should be as high as possible, preferably with
a large metal surface below it but without metal
above or to the side. The antenna must be mounted
on the outside of the machine; do not mount it
inside the cab or in a tool box. Assemble the
antenna as shown below, and turn (finger-tight
only) the connector onto the matching receptacle
on the receiver until it locks.
752 Service Manual

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SERVICE TRAINING
4. Receiver Connector table specifies the assignment of each pin, with

corresponding connectors on the TPCB-1527-01
Assignments circuit board for reference.
The receiver has a 12-pin Burndy connector for
power and all output functions. The following
TPCB-1527-01
Function Burndy Conn. Pin
Conn.
Receiver Power (24V Bat.) C J7-6

Receiver Ground D J7-5
E-Stop Contact 1A E J7-4
E-Stop Contact 1B F J7-2
E-Stop Contact 2A G J7-3
E-Stop Contact 2B H J7-1
Hydraulic Enable Valve Output (drives
J J6-3
power out when boom function on)
CAN-Bus High K J6-1
CAN-Bus Low L J6-2
The Receiver Power Input (C) supplies the elec-

tronics, the E-Stop Relays, and the Hydraulic
Enable Output. The total power required is 0.1A +
0.1A + 1.0A = 1.2A. The Ground pin (D) should
go to a low-impedance ground point either on the
vehicle chassis or at the battery or fuse box.
Service Manual 753

HOME PRINT
SERVICE TRAINING
5. Cable Unit Connector

Assignments
The Cable Unit has a 10-pin Sine connector for
power and all output functions. The following
table specifies the assignment of each pin, with
corresponding internal connectors for reference.
Internal
Function Sine Conn. Pin
Connection
Cable Unit Ground A TPCB-1605-01 J1-4

Cable Unit Power (24V Bat.) B TPCB-1605-01 J1-2
E-Stop Contact 1A C Contact Block 1
E-Stop Contact 2A D Contact Block 2
Hydraulic Enable Valve Output (drives
E PCB-I24-MC DB15-4
power out when boom function on)
CAN-Bus High G PCB-I24-MC DB15-6
CAN-Bus Low H PCB-I24-MC DB15-7
E-Stop Contact 1B J Contact Block 1
E-Stop Contact 2B K Contact Block 2
The Cable Unit Power Input (B) supplies the elec-

tronics and the Hydraulic Enable Output. The total
power required is 0.1A + 1.0A = 1.1A. The
Ground pin (A) should go to a low-impedance
ground point either on the vehicle chassis or at the
battery or fuse box.
6. Fuses
There is one replaceable fuse on the receiver
TPCB-1527-01 circuit board. It is an American
automotive cartridge (ATO) style fuse; F2 should
be 5A (brown color code). It provides power to
the E-Stop relays. The other fuses used are self-
resetting. They need the input power removed in
order to reset after a fault is corrected. The
Hydraulic Enable Output Supply has no internal
protection in either the receiver or the cable unit.
754 Service Manual

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SERVICE TRAINING
7. Operations section).
This section describes how the Comfort Concrete
Pump Remote Control System operates. It details 6. BOOM ENABLE
the operation of the lights and special consider- -on =boom function on - hydraulic enable out-
ations. put active
-off=boom functions off - hydraulic enable
7.1 Receiver output off
The receiver is operational when power is applied.
The receiver is designed to be a plug in replace- 7. E-STOP
ment of the German unit. The Hydraulic Enable -on=Receiver in E-Stop mode, E-Stop contacts
Output is capable of supplying 1 Amp. and is open.
short-circuit protected. It has a one-second hold -off=Receiver in operating mode, E-Stop con-
over after all boom functions are released. tacts closed.
-flashing (with RECEIVER MICRO STATUS
on) = restart blocking
7.1.1 Receiver Lights - General Function -other=error condition - see next section
The receiver lights are defined according to the
list below. 7.1.2 Receiver Lights - Error Conditions
The receiver lights also indicate error condi-
1. POWER-on=normal tions as defined according to the list below.
-off=no power, input power fuse blown or power
supply fault on TPCB-1527-01. 1. RECEIVER MICRO STATUS flashing con-
tinuously on first time power up of micro.
2. RECEIVER MICRO STATUS (only will occur if new micro. installed).
-on=normal Cause: CONFIG register programmed.
-off=micro. on TPCB-1527-01 failed Resolution: Cycle power to continue.
-other =error condition - see next section
2. RECEIVER MICRO STATUS flashing once
3. COM LINK -on=radio communications link per second on power up
with transmitter Cause: Software initialization failed.
-off=no link with transmitter Resolution: Cycle power. If not cleared, CPU
or EPROM circuitry is faulty.
4. SIGNAL STRENGTH 3. RECEIVER MICRO STATUS and E-STOP
-on or mostly on =good link with transmitter flashing continuously together.
-mostly off =poor link with transmitter Cause: E-Stop Drive circuitry fault detected.
-off= no data from transmitter Resolution: If COM LINK is on, HopLink
module is faulty. Otherwise, cycle power. It if
5. CAN-BUS MICRO STATUS recurs, TPCB-1527-01 board is faulty.
-blinking continuously=normal when receiv-
ing data 4. RECEIVER MICRO STATUS blinks off
-blink every 2 seconds=no CANBUS link to three times with a 2-second interval.
Comfort but receiver Cause: HopLink failure detected.
interface OK Resolution: Check ribbon cable to HopLink.
-off=normal when E-Stop is on. When E-Stop Check that HopLink ON light is on. Check
is off or blinking: CANBUS micro. failed or power to HopLink. If ON light off and power
interface failed (check error conditions in next is good, then HopLink is faulty. In all other
Service Manual 755

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SERVICE TRAINING
cases, the problem could be the HopLink, rib- 7. RECEIVER MICRO STATUS blinks off
bon cable, or interface board. four times with a 2-second interval.
Cause: Communications fault detected to
5. RECEIVER MICRO STATUS blinks off CANBUS board.
two times with a 2-second interval. Resolution: Check wiring between boards.
Cause: Interface to CANBUS board has no Otherwise fault could be on either board.
response.
7.1.3 Operator Adjustments:
Resolution: Check wiring between boards.
The ramping for the Boom (2) functions on the
Otherwise fault could be on either board.
transmitter can be dynamically adjusted using the
DIP switches in the receiver from 0.1 second to
6. RECEIVER MICRO STATUS blinks off
2.3 seconds in several steps. The ramp up time is
one time with a 2-second interval.
the time for the signal to go from OFF to the full
Cause: CANBUS error detected by CANBUS
ON setting (100%). The ramp down time is the
board.
time for the signal to from the full ON setting
Resolution: Check CANBUS interface wiring
(100%) to OFF. If the Boom (2) switches have
(external and internal). Internal connections
been set to a lower ON value, the ramp times to
are from the CANBUS board through the 4 pin
that value will be proportionately less. The follow-
headers on the TPCB-1527-01 board to the
ing charts outline the settings available.
output connector on the box.
Time (sec.) DIP Switch #1 DIP Switch #2 DIP Switch #3
0.1 off off off

0.25 off off on
0.5 off on off
0.65 off on on
0.9 on off off
1.1 on off on
1.5 on on off
2.3 on on on
0.1 off off off

0.25 off off on
0.5 off on off
0.65 off on on
756 Service Manual

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SERVICE TRAINING
0.9 on off off

1.1 on off on
1.5 on on off
2.3 on on on
7.2 Transmitter
7.2.1 Transmitter Lights
The transmitter lights are similar to all the other
transmitter products supplied to SAI. The following Troubleshooting Table: Transmitter LED s
chart details their operation.
+
STOP
Charge Battery; Turn Power
Battery Dead; Power Off On
E-Stop Test Press E-STOP button
X E-Stop Test Part Two Release E-STOP Button
N/A X E-Stop Failed Set all functions off
Not all functions off on E-Stop
N/A OK, continue as required
release
N/A Valid Data, all functions OK, continue as required
N/A Valid Data, 1 + functions on E-STOP Button Pressed
N/A Emergency Stop Replace/Recharge Battery
Boom Function on when Boom Cycle Power - if not
N/A
disabled remedied, call service
Cycle Power - if not
Low Battery
NORMAL NORMAL remedied, call service
X Module failure: Joystick remedied, call service
X Module failure: Radio remedied, call service
Module failure: Micro remedied, call service
Service Manual 757

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SERVICE TRAINING
7.2.2 Operator Controls: (rabbit) setting. The Boom (2) speed switch selects
The position of the operator controls is as per three Boom (2) speeds in each of the Boom Enable
Schwing America and is the same as the units sup- settings. The speed switch settings are as per the
plied out of Germany. The Boom Enabled Slow table below.
(snail) setting cuts all boom control outputs in half
(max.=50%) compared to the Boom Enabled Fast
Boom 2 Speed Switch Boom Enable Fast Boom Enable Slow
I 25% 13%
II 50% 25%
II 100% 50%
7.3 Cable Unit tions since the Comfort System does not supply E-
Stop status information to the cable unit. The fol-
7.3.1 Cable Unit Lights
lowing chart details the operation of the lights.
The cable unit lights are unique. That is, they do
not act the same as other cable units supplied to
SAI. The STOP light is used only for error condi- Troubleshooting Table: Transmitter LED s
+
STOP
No Power Connect Cable, check fuse
Valid Data, all function off OK, continue as required
Valid Data, 1 + functions on OK, continue as required
Boom Function on with Boom Enable Boom to activate
Disabled Boom Function.
Function on after E-Stop release Reset all function to neutral
Internal Interface Failure remedied internal wiring or
board faulty
Check cable/truck wiring -
CAN-Bus Interface Failure otherwise - internal I24-MC
board or wiring faulty*
Cycle Power-if not
remedied joystick faulty
Joystick Failure
(LED on faulty joystick ON
when powered)
758 Service Manual

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SERVICE TRAINING
7.3.2 Operator Controls: (rabbit) setting. The Boom (2) speed switch selects
The position of the operator controls is as per three Boom (2) speeds in each of the Boom Enable
Schwing America and is the same as the units sup- settings. The speed switch settings are as per the
plied out of Germany. The Boom Enabled Slow table below.
(snail) setting cuts all boom control outputs in half
(max.=50%) compared to the Boom Enabled Fast
Boom 2 Speed Switch Boom Enable Fast Boom Enable Slow

I 25% 13%
II 50% 25%
II 100% 50%
The Boom (2) Ramp speed is fixed at 1.0-second 8.2 Receiver TPCB-1527-01 Board
ramp up to 100% and 0.25-second ramp down The TPCB-1527-01 board is used in the receiver to
from 100%. provide the interface between the I24-MC board
and the HopLink module. The MAIN BYPASS
8. Troubleshooting Information jumper (JPI) must have a shorting block on pins 2
to 3 (position nearest the edge of the board) in
This section includes information on the circuit
order for the E-stop Relays to work. The on-board
boards in the receiver and cable units, including a
LED’s are defined as follows:
description of on-board LED’s.
CR3 (MICRO PWR) = 5V Power to micropro-
8.1 I24-MC Board cessor.
The I24-MC board is used in both the receiver and CR4 = Relay Drive Power through 5A fuse -
the cable units to provide the CAN-Bus interface F2.
and the Hydraulic Enable Output to the Comfort D6 (Top Red LED) = HopLink E-Stop Relay
Control System. The on-board LED’s are defined Drive OFF.
as follows: D4 (Bottom Red LED) = TPCB-1527-01 E-
LED 1 = CAN-BUS MICRO STATUS Stop Relay Drive OFF.
LED 2 = BOOM ENABLE
LED 3 = CAN-Bus Link Failure
LED 4 = Internal Error (Hydraulic Enable Out-
put shorted to supply)
LED 5 = Internal Diagnostic Mode
Service Manual 759

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SERVICE TRAINING
760 Service Manual

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SERVICE TRAINING
Conversion Charts
METRIC TO AMERICAN AND VICE-VERSA
Abbreviation TO CONVERT MULTIPLY BY TO OBTAIN Abbreviation
A atmospheres 1.0132739 bars b
A atmospheres 1.0333 kilograms/sq. centimeter kgs./cm2
A atmospheres 14.7 pounds/sq. inch PSI
b bars 0.9869 atmospheres A
b bars 1 deka newtons daN
b bars 0.98069 kilograms/sq. centimeter kgs/cm2
b bars 14.5 pounds/sq. inch PSI
btu british thermal units 778.16 foot-pounds ft-lbs
btu/min british thermal units/min. .000393 horsepower hp
btu/min british thermal units/min. 0.01757 kilowatts kw
cm centimeters .03281 feet ft
cm centimeters 0.3937 inches in
cm centimeters 10. millimeters mm
cm centimeters 0.01 meters m
cc or cm3 cubic centimeters 0.001 liters l
cc or cm3 cubic centimeters 0.000001 cubic meters m3
cc or cm3 cubic centimeters 0.00003531 cubic feet ft3
cc or cm3 cubic centimeters 0.061 cubic inches in3
ft3 cubic feet 28,320. cubic centimeters cc or cm3
ft3 cubic feet 1,728. cubic inches in3
ft3 cubic feet 0.03704 cubic yards yd3
ft3 cubic feet 7.48052 gallons (U.S. liquid) G
in3 cubic inches 16.39 cubic centimeters cc or cm3
in3 cubic inches 0.0005787 cubic feet ft3
in3 cubic inches 0.00002143 cubic yards yd3
in3 cubic inches 0.004329 gallons (U.S. liquid) G
in3 cubic inches 0.01639 liters l
m3 cubic meters 1,000,000. cubic centimeters cc or cm3
m3 cubic meters 35.31 cubic feet ft3
m3 cubic meters 1.308 cubic yards yd3
m3 cubic meters 1,000. liters l
m3 cubic meters 264.2 gallons (U.S. liquid) G
m3/hr cubic meters/hour 1.308 cubic yards/hour yd3/hr
yd3 cubic yards 764,600 cubic centimeters cc or cm3
yd3 cubic yards 27. cubic feet ft3
yd3 cubic yards 46,656. cubic inches in3
yd3 cubic yards 764.526 liters l
yd3 cubic yards 202. gallons (U.S. liquid) G
3
yd /hr cubic yards/hour 0.764526 cubic meters/hour m3/hr
daN dekanewtons 1. bars b
daN dekanewtons 14.50377 pounds/sq. inch PSI
ft feet 30.48 centimeters cm
ft feet 0.0003048 kilometers km
ft feet 0.3048 meters m
ft feet 304.8 millimeters mm
ft-lb foot-pounds 0.001286 british thermal units btu
ft-lb foot-pounds 0.1383 kilogram.-meters kg-m
ft-lb foot-pounds 1.356 newton-meters Nm
Metric Conversion01.eps
Service Manual 761

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SERVICE TRAINING

ft-lb/sec foot-pounds/second 0.001818 horsepower hp
ft-lb/sec foot-pounds/second 0.001356 kilowatts kw
G gallons 3,785. cubic centimeters cc or cm3
G gallons 0.1337 cubic feet ft3
G gallons 231. cubic inches in3
G gallons 0.003785 cubic meters m3
G gallons 0.004951 cubic yards yd3
G gallons 3.785 liters l
N/A gallons (imp.) 1.20095 U.S. gallons G
G gallons (U.S.) 0.83267 imperial gallons N/A
N/A gallons of water 8.337 pounds of water N/A
g grams 0.001 kilograms kg
g grams 0.03527 ounces (avdp.) oz
hp horsepower 42.44 british thermal units/min. btu/min
hp horsepower 33,000. foot-pounds/min. ft-lbs/min
ps horsepower (metric) 0.9863 horsepower hp
hp horsepower 1.014 horsepower (metric) ps
hp horsepower 0.7457 kilowatts kw
in inches 2.540 centimeters cm
in inches 25.4 millimeters mm
kg kilograms 2.2046 pounds lb
kg kilograms 0.001 metric tons N/A
kg/cm2 kilograms/square centimeter 0.9678 atmospheres A
kg/cm2 kilograms/square centimeter 0.9807 bars b
kg/cm2 kilograms/square centimeter 14.22 pounds/square inch PSI
kg/m2 kilograms/square meter 0.00009807 bars b
kw kilowatts 56.92 brit. thermal units/min. btu/min
kw kilowatts 1.341 horsepower hp
l liters 1000 cubic centimeters cc or cm3
l liters 61.02 cubic inches in3
l liters 0.001 cubic meters m3
l liters 0.001308 cubic yards yd3
l liters 0.2642 gallons (U.S. liquid) G
m meters 3.281 feet ft
m meters 39.37 inches in
m meters 1.094 yards yd
µm microns 0.000001 meters m
mm millimeters 0.003281 feet ft
mm millimeters 0.03937 inches in
mm millimeters 0.001 meters m
N newtons 0.2248 pounds lb
Nm newton meters 8.850252 inch-pounds in-lbs
Nm newton meters 0.7375621 foot-pounds ft-lbs
oz ounces 28.3 grams g
oz ounces 0.0625 pounds lb
lb pounds 453.597 grams g
lb pounds 4.4484552 newtons N
lb pounds .4536 kilograms kg
lb pounds 16 ounces oz
lb-ft pound-feet 0.1383 meter-kilograms m-kg
PSI pounds/square inch 0.06804 atmospheres A
PSI pounds/square inch 0.06895 bars b
Metric_Conversion02.eps
762 Service Manual

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PSI pounds/square inch 0.0703 kilograms/sq. centimeter kg/cm2

cm2 square centimeters 0.155 square inches in2
in2 square inches 6.4516 square centimeters cm2
in2 square inches 645.163 square millimeters mm2
in2 square inches 0.0007716 square yards yd2
m2 square meters 10.7639 square feet ft2
mm2 square millimeters 0.00155 square inches in2
N/A tons (metric) 1000 kilograms kg
N/A tons (metric) 2204.6 pounds lb
N/A tons (metric) 1.1023 tons (short) (U.S.) T
T tons (short) (U.S.) 0.907194 tons (metric) N/A
w watts 0.05688 british thermal units/min. btu/min
w watts 44.27 foot-pounds/min. ft-lb/min
w watts 0.0013405 horsepower hp
w watts 0.001 kilowatts kw
yd yards 0.9144 meters m
Metric_Conversion03.eps
Service Manual 763

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SERVICE TRAINING
CONVERSION FORMULAS - TO MILLIMETERS FROM INCHES: MULTIPLY INCHES BY 25.4

- TO INCHES FROM MILLIMETERS: MULTIPLY mm BY 0.03937
MILLIMETERS 0 10 20 30 40 50 60 70 80 90 100 mm
INCHES 0 1/2" 1" 2" 3" 4"
INCHES INCHES
FRACTIONS DECIMALS
mm FRACTIONS DECIMALS
mm
0.00004 0.0010 0.13780 03.5000
0.00039 0.0100 9/64 0.14063 03.5719
0.00079 0.0200 0.15000 03.8100
0.00100 0.0250 5/32 0.15625 03.9688
0.00118 0.0300 0.15748 04.0000
0.00157 0.0400 11/64 0.17188 04.3656
0.00197 0.0500 0.17500 04.4450
0.00200 0.0510 0.17717 04.5000
0.00236 0.0600 3/16 0.18750 04.7625
0.00276 0.0700 0.19685 05.0000
0.00300 0.0762 0.20000 05.0800
0.00315 0.0800 13/64 0.20313 05.1594
0.00354 0.0900 0.21654 05.5000
0.00394 0.1000 7/32 0.21875 05.5562
0.00400 0.1016 0.22500 05.7150
0.00500 0.1270 15/64 0.23438 05.9531
0.00600 0.1524 0.23622 06.0000
0.00700 0.1778 1/4 0.25000 06.3500
0.00787 0.2000 0.25591 06.5000
0.00800 0.2032 17/64 0.26563 06.7469
0.00900 0.2286 0.27500 06.9850
0.00984 0.2500 0.27559 07.0000
0.01000 0.2540 9/32 0.28125 07.1438
0.01181 0.3000 0.29528 07.5000
1/64 0.01563 0.3969 19/64 0.29688 07.5406
0.01575 0.4000 0.30000 07.6200
0.01969 0.5000 5/16 0.31250 07.9375
0.02000 0.5080 0.31496 08.0000
0.02362 0.6000 21/64 0.32813 08.3344
0.02500 0.6350 0.33465 08.5000
0.02756 0.7000 11/32 0.34375 08.7312
0.02950 0.7500 0.35000 08.8900
0.03000 0.7620 0.35433 09.0000
1/32 0.03125 0.7938 23/64 0.35938 09.1281
0.03150 0.8000 0.37402 09.5000
0.03543 0.9000 3/8 0.37500 09.5250
0.03937 1.0000 25/64 0.39063 09.9219
0.04000 1.0160 0.39370 10.0000
3/64 0.04687 1.1910 0.40000 10.1600
0.04724 1.2000 13/32 0.40625 10.3188
0.05000 1.2700 0.41339 10.5000
0.05512 1.4000 27/64 0.42188 10.7156
0.05906 1.5000 0.43307 11.0000
0.06000 1.5240 7/16 0.43750 11.1125
1/16 0.06250 1.5875 0.45000 11.4300
0.06299 1.6000 0.45276 11.5000
0.06693 1.7000 29/64 0.45313 11.5094
0.07000 1.7780 15/32 0.46875 11.9062
0.07087 1.8000 0.47244 12.0000
0.07500 1.9050 31/64 0.48438 12.3031
5/64 0.07813 1.9844 0.49213 12.5000
0.07874 2.0000 1/2 0.50000 12.7000
0.08000 2.0320 0.51181 13.0000
0.08661 2.2000 33/64 0.51563 13.0969
0.09000 2.2860 17/32 0.53125 13.4938
0.09055 2.3000 0.53150 13.5000
3/32 0.09375 2.3812 35/64 0.54688 13.8906
0.09843 2.5000 0.55000 13.9700
0.10000 2.5400 0.55118 14.0000
0.10236 2.6000 9/16 0.56250 14.2875
7/64 0.10937 2.7781 0.57087 14.5000
0.11811 3.0000 37/64 0.57813 14.6844
1/8 0.12500 3.1750 0.59055 15.0000
Conversion_Formulas01.eps
764 Service Manual

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CONVERSION FORMULAS - TO MILLIMETERS FROM INCHES: MULTIPLY INCHES BY 25.4

- TO INCHES FROM MILLIMETERS: MULTIPLY mm BY 0.03937
MILLIMETERS 0 10 20 30 40 50 60 70 80 90 100 mm
INCHES 0 1/2" 1" 2" 3" 4"
INCHES INCHES
FRACTIONS DECIMALS
mm FRACTIONS DECIMALS
mm
19/32 0.59375 15.0812 1.57480 040.00
0.60000 15.2400 1.65354 042.00
39/64 0.60938 15.4781 1 3/4 1.75000 044.45
0.61024 15.5000 1.77170 045.00
5/8 0.62500 15.8750 1.88976 048.00
0.62992 16.0000 1.96850 050.00
41/64 0.64063 16.2719 2 2.00000 050.80
0.64961 16.5000 2.04724 052.00
0.65000 16.5100 2.16540 055.00
21/32 0.65625 16.6688 2.20472 056.00
0.66929 17.0000 2 1/4 2.25000 057.15
43/64 0.67188 17.0656 2.36220 060.00
11/16 0.68750 17.4625 2 1/2 2.50000 063.50
0.68898 17.5000 2.51968 064.00
0.70000 17.7800 2 3/4 2.75000 069.85
45/64 0.70313 17.8594 2.83464 072.00
0.70866 18.0000 2.95280 075.00
23/32 0.71875 18.2562 3 3.00000 076.20
0.72835 18.5000 3.14960 080.00
47/64 0.73438 18.6531 3 1/2 3.50000 088.90
0.74803 19.0000 3.54330 090.00
3/4 0.75000 19.0500 3.93700 100.00
49/64 0.76563 19.4469 4 4.00000 101.60
0.76772 19.5000 4.33070 110.00
25/32 0.78125 19.8438 4 1/2 4.50000 114.30
0.78740 20.0000 4.72440 120.00
51/64 0.79688 20.2406 5 5.00000 127.00
0.80000 20.3200 5.51180 140.00
0.80709 20.5000 5.90550 150.00
13/16 0.81250 20.6375 6 6.00000 152.40
0.82677 21.0000 6.29920 160.00
53/64 0.82813 21.0344 7.08660 180.00
27/32 0.84375 21.4312 7.87400 200.00
0.84646 21.5000 8 8.00000 203.20
0.85000 21.5900 8.66140 220.00
55/64 0.85938 21.8281 9.44880 240.00
0.86614 22.0000 9.84250 250.00
7/8 0.87500 22.2250 10 10.00000 254.00
0.88583 22.6219 10.23620 260.00
57/64 0.89063 22.8600 11.02360 280.00
0.90000 23.0000 11.81100 300.00
0.90551 23.0188 12 12.00000 304.80
29/32 0.90625 23.0188 12.59840 320.00
59/64 0.92188 23.4156 13.38580 340.00
0.92520 23.5000 13.77950 350.00
15/16 0.93750 23.8125 14.17320 360.00
0.94488 24.0000 14.96060 380.00
0.95000 24.1300 15.74800 400.00
61/64 0.95313 24.2094 16 16.00000 406.40
0.96457 24.5000 17.71650 450.00
31/32 0.96875 24.6062 19.68500 500.00
0.98425 25.0000 20 20.00000 508.00
63/64 0.98438 25.0031 23.62200 600.00
1 1.00000 25.4000 24 24.00000 609.60
1.06299 27.0000 36 36.00000 914.40
1.10240 28.0000 39.37000 1000.00
1.18110 30.0000 48 48.00000 1219.20
1 1/4 1.25000 31.7500 60 60.00000 1524.00
1.29921 33.0000 72 72.00000 1828.80
1.37800 35.0000 78.74000 2000.00
1.41732 36.0000 96 96.00000 2438.40
1 1/2 1.50000 38.1000 118.11000 3000.00
1.53543 39.0000 196.85000 5000.00
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Service Manual 765

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Fluid Power Formulas

The following represent some of the formulas commonly used when working with concrete pumps
and related equipment. No attempt has been made to list all possible applications for these formulas.
*The diagram below relates 3 formulas regarding force, pressure, and area:
U.S.
F = FORCE (in pounds) (lb)
P = PRESSURE (in pounds per square inch) (P.S.I.)
F F=PxA
A = AREA (in square inches) (in2)
P = F/A
P A METRIC
A = F/P
F = FORCE (in kilograms) (Kg)
P = PRESSURE (in kilograms per square centimeter) (Kg/cm2)
A = AREA (in square centimeters) (cm2)
*The following relates to power required by a hydraulic system
GENERAL
QxP Q = FLOW RATE (unit of volume per time period)
POWER =
CONSTANT P = PRESSURE (unit of force per unit of area)
U.S.
HP = HORSEPOWER
GPM x PSI
HP = GPM = GALLONS PER MINUTE
1714
PSI = POUNDS PER SQUARE INCH
1714 = KNOWN CONSTANT
METRIC
KW = KILOWATTS
LPM x BAR LPM = LITERS PER MINUTE
KW =
600
BAR = METRIC UNIT OF PRESSURE
600 = KNOWN CONSTANT
The above state only the power drawn by the system, and make no allowance for the efficiency of the components.
To determine the power needed to drive a specific system, the answer to the formula must be divided by the efficiency factor.
QxP
REQUIRED POWER = E = EFFICIENCY FACTOR
CONSTANT
E
The rule of thumb for figuring efficiencies is: E = 0.7 for internal combustion engines, or E = 0.85 for electric motors.
It would be the same in Metric as in U.S. calculations.
*The following relates to theoretical flow rates by a hydraulic pump

RPM x PUMP DISPLACEMENT GENERAL
Q=
CONVERSION FACTOR
RPM x CUBIC INCHES/REV. U.S. 231 = number of cubic inches in 1 gallon

Q (in GPM) =
231
RPM x CUBIC CENTIMETERS/REV. METRIC 1000 = number of cubic centimeterss in 1 liter

Q (in liters/min.) =
1000
FluidPowerFormulas01.eps
766 Service Manual

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SERVICE TRAINING
Torque and Horsepower relations:
T=
P x CONSTANT GENERAL
RPM T = TORQUE
T x RPM P = POWER
P=
CONSTANT RPM = REVOLUTIONS PER MINUTE
P x CONSTANT
RPM =
T
HP x 5252 U.S.
T=
RPM T = TORQUE (in foot-pounds) (ft-lb)
T x RPM HP = HORSEPOWER
HP =
5252 5252 = K NOWN CONSTANT
HP x 5252
RPM =
T
KW x 9543 METRIC
T=
RPM T = TORQUE (in newton-meters) (Nm)
T x RPM KW = KILOWATTS
KW =
9543 9543 = K NOWN CONSTANT
KW x 9543
RPM =
T
Torque and Displacement relations:

U.S.
T = TORQUE (in foot-pounds) (ft-lb)
T=
DxP D = DISPLACEMENT (in cubic inches per revolution) (in3/rev.)
24 π P = PRESSURE (in pounds per square inch) (PSI)
π = Pi (3.1415927)
Finding pressure on concrete

U.S.
Rubber
Ram PC = PRESSURE ON THE CONCRETE (In PSI)
Piston
Rod PA = PISTON AREA (In square inches) (in2)
(PA) (RRA)
RA = ROD AREA (In square inches) (in2)
(RSA) (RA) RSA = ROD SIDE AREA (In square inches) (in2)
RRA = RUBBER RAM AREA (In square inches) (in2)
PA x MAX. P MAX. P = MAXIMUM HYDRAULIC OIL PRESSURE (In PSI)
(on piston side) PC =
RRA (relief valve setting)
EXAMPLE: Piston diameter 4.72 inches (120mm), Rod diameter 3.15

RSA x MAX. P inches (80mm), Rubber ram diameter 9.05 inches (230mm), relief valve
(on rod side) PC =
RRA set at 4,350 PSI (300 bar).
Area of the piston = 17.5 in2. Area of the rod = 7.79 in2.
Area of the rubber ram = 64.33 in2.
RSA = PA - RA
(17.5 - 7.79) x 4350
(on rod side) PC = (on rod side) PC = 656.6 PSI
64.33
FluidPowerFormulas02.eps
Service Manual 767

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SERVICE TRAINING
Torque Specifications must be torqued to within 6% of the requirement. For

example, a bolt to be torqued to a 200-lb requirement
The following charts show the tightening torques must be within the range of 208–192 ft-lb for a dial
specified for the bolts used on Schwing equipment. The scale torque wrench. Schwing equipment uses two
charts are to be followed unless a different torque different types of bolts, one black finish and one
specification is indicated for a particular procedure. dychromate finish.
A torque wrench must be calibrated to within 1% of its Torque specifications are very important for proper
indicated value throughout its range. Bolts must be machine function. For more information on this
torqued to within 4% of the requirement if the wrench subject, refer to the section on “torque specifications”
has a dial scale. If no dial scale is present, the bolts in the Maintenance section of this manual.
Black Screw and Nuts Torque Specifications

Wrench size For Metric NORMAL Thread
= 13 mm
8.8 10.9 12.9
Wrench Hardness Hardness Hardness
Bolt Size Size (mm) ft-lb (N-m) ft-lb (N-m) ft-lb (N-m)
M6x1 10 7 (10.5) 11 (15.5) 12 (18)
Example M 8 x 1.25 13 17 (23) 24 (32) 29 (39)
M 10 x 1.5 17 33 (44) 48 (65) 56 (76)
M 12 x 1.75 19 56 (77) 83 (113) 96 (131)
M 14 x 2 22 90 (122) 133 (180) 156 (212)
Dia =
8 mm M 16 x 2 24 139 (189) 206 (279) 242 (329)
M 18 x 2.5 27 199 (270) 286 (387) 332 (450)
M 20 x 2.5 30 282 (383) 405 (549) 472 (639)
M 22 x 2.5 32 385 (522) 551 (747) 644 (873)
Pitch =
1.25 mm M 24 x 3 36 485 (657) 697 (945) 810 (1098)
M 27 x 3 41 731 (990) 1030 (1395) 1196 (1620)
M 30 x 3.5 46 963 (1305) 1395 (1890) 1627 (2205)
M 33 x 3.5 50 1328 (1800) 1860 (2520) 2192 (2970)
M 36 x 4 55 1660 (2250) 2391 (3240) 2790 (3780)
M 39 x 4 60 2192 (2970) 3122 (4230) 3653 (4950)
S0008.eps
Note: This chart does not apply to slewing cylinders or hydraulic cylinders.
Conversion: 1 N-m = 0.738 ft-lb; 1 ft-lb = 1.355 N-m. Revised 11/96
768 Service Manual

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Black Screw and Nuts Torque Specifications

For Metric FINE Thread
8.8 10.9 12.9
Bolt Size Size (mm) ft-lb (N-m) ft-lb (N-m) ft-lb (N-m)
M8x1 13 18 (24) 26 (35) 31 (41)

M 10 x 1.5 17 37 (50) 54 (73) 63 (86)
M 10 x 1.25 17 36 (49) 50 (68) 60 (81)
M 12 x 1.25 19 62 (84) 90 (122) 106 (144)
M 12 x 1.5 19 59 (80) 86 (117) 103 (140)
M 14 x 1.5 22 96 (131) 143 (194) 169 (230)
M 16 x 1.5 24 149 (203) 219 (297) 259 (351)
M 18 x 1.5 27 226 (306) 322 (437) 379 (513)
M 20 x 1.5 30 315 (428) 452 (612) 525 (711)
M 22 x 1.5 32 432 (585) 611 (828) 697 (945)
M 24 x 2 36 531 (720) 764 (1035) 897 (1215)
M 27 x 2 41 764 (1035) 1096 (1485) 1295 (1755)
M 30 x 2 46 1096 (1485) 1561 (2115) 1827 (2475)
M 33 x 2 50 1461 (1980) 2059 (2790) 2391 (3240)
M 36 x 3 55 1793 (2430) 2524 (3420) 2989 (4050)
M 39 x 3 60 2325 (3150) 3321 (4500) 3852 (5220)
S0008.eps
Note: This chart does not apply to slewing bearings or hydraulic cylinders.
Conversion: 1 N-m = 0.738 ft-lb; 1 ft-lb = 1.355 N-m. Revised 11/96
Service Manual 769

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SERVICE TRAINING
Wrench Size
= 13 mm
DYCHROMATE 500a Torque Specifications
For Metric NORMAL Thread
8.8 10.9 12.9
Bolt Size Size (mm) ft-lb (N-m)b ft-lb (N-m) ft-lb (N-m)
Example M 8 x 1.25 13 13 (18) 20 (27) 23 (32)
M 10 x 1.5 17 27 (36) 39 (53) 46 (62)
M 12 x 1.75 19 46 (62) 66 (90) 80 (108)
M 14 x 2 22 73 (99) 106 (144) 126 (171)
Dia =
8 mm M 16 x 2 24 113 (153) 166 (225) 193 (261)
M 18 x 2.5 27 163 (221) 229 (311) 269 (365)
M 20 x 2.5 30 227 (308) 325 (441) 379 (513)
M 22 x 2.5 32 312 (423) 438 (594) 518 (702)
Pitch =
1.25 mm M 24 x 3 36 392 (531) 559 (758) 651 (882)
M 27 x 3 41 578 (783) 830 (1125) 963 (1305)
M 30 x 3.5 46 797 (1080) 1129 (1530) 1295 (1755)
S0010.eps
a. Dychromate 500 means coated with Teflon or silver colored.
b. Conversion: 1 Nm = .738 ft-lb.
770 Service Manual

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DYCHROMATE 500a Torque Specifications

For Metric FINE Thread
8.8 8.8 12.9
Bolt Size Size (mm ft-lb (N-m)b ft-lb (N-m) ft-lb (N-m)
M8x1 13 15 (20) 21 (29) 25 (33)
M 10 x 1.00 17 29 (40) 43 (58) 50 (68)
M 10 x 1.25 17 28 (38) 41 (56) 48 (65)
M 12 x 1.25 19 50 (68) 73 (99) 86 (117)
M 12 x 1.5 19 48 (65) 70 (95) 83 (113)
M 14 x 1.5 22 80 (108) 116 (158) 133 (180)
M 16 x 1.5 24 120 (162) 176 (239) 206 (279)
M 18 x 1.5 27 179 (243) 256 (347) 299 (405)
M 20 x 1.5 30 249 (338) 352 (477) 412 (558)
M 22 x 1.5 32 339 (459) 478 (648) 559 (758)
M 24 x 2 36 443 (587) 598 (810) 697 (945)
M 27 x 2 41 611 (828) 863 (1170) 1030 (1395)
M 30 x 2 46 863 (1170) 1244 (1685) 1428 (1935)
S0011.eps
a. Dychromate 500 means coated with Teflon or silver colored.
b. Conversion: 1 Nm = .739 ft lb.
Service Manual 771

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Torque Specification: Slewing

Roller Bearing Bolts
Torque - Ft-Lbs
Part (Newton-meters)
Unit Size Grade DIN
Number
Black Silver
Bolt 10030718 M24 x 130 10.9 931 694 (855 Nm) 550 (746 Nm)
31 HT
Washer 10141125 M24
KVM 32XL Bolt 10072024 M20 X 2.5 X 110 10.9 6914 405 (550 Nm) 330 (447 Nm)
and
KVM 36L Washer 10001509 M21
Bolt 10030718 M24 x 130 10.9 931 694 (855 Nm) 550 (746 Nm)
KVM 34X
Washer 10141125 M24
Bolt 10120666 M20 X 2.5 X 140 12.9 6914 480 (650 Nm) 376 (510 Nm)
KVM 36X
Washer 10001509 M21
Bolt 10009258 M20 X 2 X 150 12.9 960 509 (690 Nm) 400 (548 Nm)
KVM 36 Washer 10001509 M21
Nut 10007993 M20
Bolt 10120666 M20 X 2.5 X 140 12.9 960 480 (650 Nm) 376 (510 Nm)
KVM 39
Washer 10001509 M21
Bolt 10207022 M20 X 2.5 X 140 12.9 960 480 (650 Nm) 376 (510 Nm)
42 SX
Washer 10141124 M20
Bolt 10012926 M22 X 2.5 X 180 10.9 931 515 (700 Nm) 440 (592 Nm)
KVM 42 Washer 10012937 M23
Nut 10029928 M23
Bolt 10117168 M24 X 150 10.9 931 694 (855 Nm) 553 (750 Nm)
45/47 SX
Washer 10141125 M24
KVM 52 Bolt 10044746 M24 X 3 X 140 10.9 6914 664 (900 Nm) 550 (746 Nm)
KVM 55 Washer 10001504 M25
Bolt 10188613 M24 X 3 X160 10.9 6914 664 (900 Nm) 550 (746 Nm)
58 SX
Washer 10001504 M25
772 Service Manual

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Torque for Boom Cylinder Bolts
Torque
Cyl. Part
Unit Piston Cylinder End
No. Number
Nm Ft-Lb Nm Ft-Lb
#1 10004728 128 94 313 231
KVM 23 #2 10000661 128 94 313 231
#3 10004747 36 27 128 94
#1 10025228 627 463 190 140
#2 10032825 627 463 269 199

KVM 24x-4
#3 10025223 627 463 190 140
#4 10079930 626 462 322 238
#1 10004738 128 94 313 231
KVM 25 #2 10004738 128 94 313 231
#3 10004721 73 54 313 231
#1 10082091 1075 793 627 463
#2 10111663 627 463 269 199

KVM 26X-4
#3 10111514 626 462 322 238
#4 10110660 441 325 132 97
#1 10004740 128 94 428 316
KVM 28M #2 10004738 128 94 313 231
#3 10004722 128 94 313 231
#1 10082091 1075 793 627 463
KVM 28X #2 10110776 626 462 322 238
#3 10110660 441 325 132 97
#1 10004724 128 94 313 231
KVM 31 #2 10004734 128 94 313 231
#3 10004722 128 94 313 231
Service Manual 773

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SERVICE TRAINING
Torque
Cyl. Part Piston Cylinder End
Unit
No. Number
Nm Ft-Lb Nm Ft-Lb
#1 10024056 1075 793 440 325
#2 10023914 1075 793 269 199

KVM 32M
#3 10023699 627 463 269 199
#4 10023615 441 325 269 199
#1 10110190 1075 793 627 463
#2 10023914 1075 793 269 199

KVM 32XL
#3 10062795 627 463 269 199
#4 10023615 441 325 269 199
#1 10158046 960 710 - -
#2 10158047 960 710 - -

KVM 34X
#3 10158049 - - - -
#4 10158050 - - - -
#1 10000655 128 94 428 316
#2 10000651 128 94 428 316

KVM 36 STD
#3 10004738 128 94 313 231
#4 10004721 73 54 313 231
#1 10111029 1075 793 627 463
#2 10110461 1075 793 627 463

KVM 36X
#3 10110776 626 462 322 238
#4 10110660 441 325 132 97
#1 10111029 1075 793 627 463
#2 10110461 1075 793 627 463

KVM 39X
#3 10110776 626 462 322 238
#4 10110660 441 325 132 97
774 Service Manual

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SERVICE TRAINING
Torque
Cyl. Part Piston Cylinder End
Unit
No. Number
Nm Ft-Lb Nm Ft-Lb
#1 10023914 1075 793 269 199
#2 10080103 1075 793 627 463

KVM 42M
#3 10025228 627 463 190 140
#4 10037135 441 325 269 199
#1 10201085 950 700 -- --
#2 10110461 1075 793 627 463

KVM 42 SX
#3 10110776 626 462 322 238
#4 10110660 441 325 132 97
#1 10167681 - - 1950 1450

KVM 45SX #2 10146611 1220 900 960 700
and
KVM 47SX #3 10146612 1350 1000 - -
#4 10146613 441 325 132 100
10049567 -- -- 2350 1734

#1
10142494 -- -- 2100 1550
KVM 52
and #2 10049568 -- -- 820 605
KVM 55 #3 10049569 -- -- -- --
#4 10049570 -- -- -- --
#1 10185967 -- -- -- --
KVM 58SX #2 10185968 1150 850
and
KVM 61SX #3 10185969 -- -- -- --
#4 10185970 -- -- -- --
Service Manual 775

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WP Number Codes
EXPLANATION OF NOMENCLATURE
WP 1000 XE
World Pump Frame (Concrete Pump)

Pump Model
Twin Circuit (X) or Single Circuit (blank) Switching
Electric (E) or Diesel (blank)
WP 750 - 15XE

Pump Model
15 cm Diameter Material Cylinder Bore
WP 750 - 18XE

Pump Model
18 cm Diameter Material Cylinder Bore
In practical usage, it would be common to refer to these units as a 1000, 750-15, and a 750-18.
The pumpkit has its own complete model number. You will nd this used on the output char ts and nomographs for
speci c machines . An example:
Pumpkit: 80 / 50 X 1000 : 180
Differential Cylinder Bore Diameter (in mm)

Differential Cylinder Rod Diameter (in mm)
Stroke Length (in mm)
Material Cylinder Bore Diameter (in mm)
S0014.eps
776 Service Manual

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BP Model Number Codes

EXPLANATION OF NOMENCLATURE
The model numbers of other Schwing concrete pumps are explained by these code examples:
EXAMPLE BPL 1200 HDR - 23 KVM 32/28 XL - 125

The code for the truck pump
is broken down as follows: BP L 1200 HD R 23
Beton Pumpe (Concrete Pump)

Lastkraftwagen (Truck mounted)
Pumpkit Model#
Heavy - Duty
Rock Valve ("omit" if gate valve)
Diameter of Material Cylinders (in centimeters)
The code for the placing boom
is broken down as follows: K VM 32/28 **** - 125
Knickbarrer Verteiler Mast (Integrated placing boom)
or Derrick Verteiler Mast (Counter-jib placing boom)
Boom’s Vertical Reach (in meters)
Boom’s Horizontal reach (in meters)
* Special Dseignations: ("LW" - LightWeight) ("X"-outrigger configuration)
("L"-longer boom reach)
Diameter of Boom Pipeline (in millimeters)
EXAMPLE BPA 3001 HDD - 18R

The code for the trailer pump
is broken down as follows: BP A 3001 HD D 18 HP R
Beton Pumpe (Concrete Pump)

Highway Axle ("omit" if jobsite axle)
Pumpkit Model#
Heavy - Duty
Diesel Engine ("E" if Electric Motor)
Diameter of Material Cylinders (in centimeters)
High Pressure
Rock Valve ("omit" if gate valve)
The pumpkit has its own complete model number. You will find this used 125 / 80 x 2000 - 230
on the output charts and nomographs for specific units. An example:
Differential Cylinder Bore Diameter (in millimeters)

Differential Piston Rod Diameter (in millimeters)
Differential Stroke Length (in millimeters)
Material Cylinder Bore Diameter (in millimeters)
S0015.eps
Service Manual 777

778
All Dimension And Weights Are Approximate
FRONT OUTRIGGER REAR OUTRIGGER FRONT TO REAR MAX. FRONT MAX. REAR MAX. OUTRIGGER MAX. OUTRIGGER
TYPE BOOM SPREAD IN SPREAD IN OUTRIGGER LENGTH OUTRIGGER LOAD OUTRIGGER LOAD SOIL PSI SOIL PSI
FT. - IN. FT. - IN. FT. - IN. LBS. LBS. FRONT/REAR w/2’ x 2’ dunnage
FRONT/REAR
KVM 17 11- 9 7-2 14 - 5 16,860 11,240 109/73 109/73
KVM 23 19 - 8 7-2 18 - 6 20,947 14,332 104/94 104/94
KVM 23-4H 18 - 9 11 - 2 19 - 10 22,050 15,250 126/113 39/27
KVM 24-4H 19 - 7 11 - 10 22 - 4 27,000 20,500 195/148 47/36
KVM 25 18 - 9 11 - 2 20 - 4 23,200 14,300 134/92 41/25
KVM 26-4 19 - 7 11 - 10 22 - 4 29,000 23,500 210/170 50/40
KVM 28 20 - 5 15 - 0 22 - 7 27,560 17,420 111/130 48/31
KVM 28X 19 - 7 11 - 10 22 - 4 28,500 22,800 206/165 50/40
Outrigger Spreads and Loads
KVM 31 20 - 5 18 - 8 24 - 5 39,700 30,900 203/158 69/54

31 HT 20 - 4 20 - 4 20 - 8 24,255 28,665 79/93 42/50
KVM 32 23 - 2 16 - 0 22 - 7 30,430 22,930 120/90 53/40
KVM 32XL 19 - 8 17 - 2 24 - 4 32,600 27,000 166/138 57/47
KVM 34X 20 - 5 18 - 8 24 - 5 39,500 31,500 202/161 57/47
Service Manual
KVM 36 22 - 10 24 - 6 23 - 6 32,630 36,380 106/118 57/63
KVM 36X 24 - 4 19 - 4 29 - 5 37,800 33,300 170/150 66/58
KVM 39 25 - 7 21 - 0 29 - 11 45,500 35,000 194/159 79/60
KVM 42HW 29 - 6 29 - 6 30 - 3 49,600 52,900 162/172 86/92
SERVICE TRAINING
KVM 42 LW 27 - 11 27 - 7 27 - 9 43,400 45,400 140/146 76/79

*KVM 42 LW 27 - 11 27 - 7 27 - 9 43,400 45,400 140/146 76/79
(NEW STYLE)
KVM 41 SX 26 21 29 - 4 40,464 40,464 304/304 70/70

KVM 42 SX 27 - 3 27 - 3 29 - 0 50,700 52,900 313/327 88/92
KVM 45/47 SX 27 - 3 27 - 3 29 - 0 60,000 60,000 370/370 105/105
KVM 52 32 - 2 32 - 2 33 - 6 60,000 60,000 220/220 105/105
KVM 55 32 - 2 32 - 2 33 - 6 60,000 60,000 220/220 105/105
S 58/61 SX 29 - 2 41 - 1 37 - 9 78,680 83,176 157/166 NA
* 240ß #4 boom rotation S0016.eps
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Issue: 01/31/05
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8
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6
(B1)
(B0) 2
Mehl
1 D 7
(B4) (C3) (D4)
(C2) 12 (D0)
4 E 9
3 (D3)
Boom Pin Clearances
(D1)
(B2) 10
C 11
(B3) (D2)
B
(A0) (A3)
HP
A
(A2)
Upper
Subject: Maximum Pin-Bushing-Bore Clearances
Lower 5115-1.eps
Service Manual
HP NA A NA B NA 1 2 3 3.1 C 4 5 6 7 7.1 D 8 9 10 11 11.1 E 12
SAIE STANDARD
Approved by: Jason

KVM LWR UPR A0 A1 A2 A2.1 A3 A4 B0 B1 B2 B2.1 B3 B4 C0 C1 C2 C2.1 C3 C4 D0 D1 D2 D2.1 D3 D4
23M .099 .150 .045 ----- .041 ----- .041 ----- .045 .041 .041 ----- .041 .041 .035 .030 .030 ----- .030 .030 ----- ----- ----- ----- ----- -----
25M .108 .138 .045 ----- .045 ----- .045 ----- .045 .045 .045 ----- .045 .045 .035 .030 .030 ----- .030 .030 ----- ----- ----- ----- ----- -----
SERVICE TRAINING
Mehl
28M .108 .138 .045 ----- .045 ----- .045 ----- .045 .045 .045 ----- .045 .045 .035 .030 .035 ----- .035 .030 ----- ----- ----- ----- ----- -----
31M .108 .158 .045 ----- .041 ----- .041 ----- .045 .045 .045 ----- .045 .045 .045 .035 .035 ----- .035 .035 ----- ----- ----- ----- ----- -----
32M .108 .158 .045 ----- .045 ----- .045 ----- .045 .041 .045 ----- .045 .045 .045 .035 .041 ----- .041 .041 .035 .030 .035 ----- .035 .035
32XL ----- ----- .045 ----- .045 ----- .045 ----- .045 .041 .045 ----- .045 .045 .045 .035 .041 ----- .041 .041 .035 .030 .035 ----- .035 .035
36M ----- ----- .045 ----- .045 ----- .045 ----- .045 .045 .045 ----- .045 .045 .045 .041 .045 ----- .045 .041 .035 .030 .030 ----- .030 .030
NOTES:
1. REFERENCE SAIE 5114 FOR SLEWING BEARING INSPECTION.
Page: 1 of 9
2. ALL MEASUREMENTS ARE IN INCHES AND REPRESENT MAXIMUM ALLOWABLE CLEARANCES.

3. CONTACT THE SAI SERVICE DEPARTMENT AT (651) 429-0999 IF YOU HAVE QUESTIONS.
Standard: 5115
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(C0)
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(B1)
(B0) 2
1 D 7.1
Mehl
(C3) (D4)
(B4) 7 (C2.1) 12 (D0)
4 3.1 (C2) E 9
(B2.1) (D3)
(D1)
3 10
(B2) 11 11.1
C (D2) (D2.1)
(B3)
B
(A0) (A3)
HP
A
(A2)
Upper
Lower 5115-2.eps
Service Manual
BEARING CLEARANCES
SAIE STANDARD
Approved by: Jason

HP NA A NA B NA 1 2 3 3.1 C 4 5 6 7 7.1 D 8 9 10 11 11.1 E 12
SERVICE TRAINING
26-4 .108 .138 .045 ----- .045 ----- .045 ----- .041 .041 .041 .045 .041 .045 .045 .035 .035 .041 .035 .041 .027 .027 .024 .032 .024 .032
Mehl
28X ----- ----- .045 ----- .045 ----- .045 ----- .041 .041 .032 .045 .032 .045 .027 .027 .024 .032 .024 .032 ----- ----- ----- ----- ----- -----
34X ----- ----- .045 ----- .045 ----- .045 ----- .045 .045 .045 .045 .045 .045 .045 .038 .038 .045 .038 .045 .032 .032 .032 .032 .032 .032
36LW ----- ----- .045 ----- .045 ----- .045 ----- .045 .045 .045 .045 .045 .045 .038 .038 .032 .045 .032 .045 .024 .024 .024 .032 .024 .032
36X ----- ----- .045 ----- .045 ----- .045 ----- .045 .045 .045 .045 .045 .045 .045 .041 .032 .045 .032 .045 .027 .027 .024 .032 .024 .032
39X ----- ----- .045 ----- .045 ----- .045 ----- .045 .045 .045 .045 .045 .045 .041 .041 .032 .045 .032 .045 .030 .027 .027 .035 .027 .035
NOTES:
1. REFERENCESAIE5114 FORSLEWING BEARING INSPECTION.
Page: 2 of 9
2. ALL MEASUREMENTSAREIN INCHESAND REPRESENT MAXIMUM ALLOWABLECLEARANCES.

Standard: 5115
3. CONTACT THESAI SERVICEDEPARTMENT AT (651) 429-0999 IF YOU HAVEQUESTIONS.

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8 (C1)
Issue: 01/31/05
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(B1)
(B0) 2
1 D
Mehl
7
3.1 (C3) (C2) (D4)
(B4) (B2.1)
4 12 (D0)
E 9
(D4) (D3)
3 E
(B2)
12 (D0) (D1)
(D3) 9 10
11
C (D1) (D2)
(B3) 10
B 11 11.1
(A3) KVM 42M L.W. & H.W.
(A0) (D2) (D2.1)
HP
A KVM 42M CURRENT PRODUCTION
(A2)
5115-3.eps
Service Manual
SAIE STANDARD
Approved by: Jason

SERVICE TRAINING
Mehl
HP NA A NA B NA 1 2 3 3.1 C 4 5 6 7 7.1 D 8 9 10 11 11.1 E 12
KVM A0 A1 A2 A2.1 A3 A4 B0 B1 B2 B2.1 B3 B4 C0 C1 C2 C2.1 C3 C4 D0 D1 D2 D2.1 D3 D4
42M .045 ----- .045 ----- .045 ----- .045 .045 .045 .045 .045 .045 .045 .045 .045 ----- .045 .045 .035 .030 .035 .035 .035 .035
42LW .045 ----- .045 ----- .045 ----- .045 .045 .045 .045 .045 .045 .045 .045 .045 ----- .045 .045 .035 .030 .035 ----- .035 .035
42HW .045 ----- .045 ----- .045 ----- .045 .045 .045 .045 .045 .045 .045 .045 .045 ----- .045 .045 .035 .030 .035 ----- .035 .035
NOTES:
Page: 3 of 9

Standard: 5115
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782
(C0)
5
(C4) (C1)
8 6
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7.1
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(C2.1) E
7 (D3) (D4)
(C2) 12
Mehl
D (D0)
(B1) (C3) 9
2 (B2.1) 11
(D2) 11.1 (D1)
3.1 10
(B0) (D2.1)
1 (B2)
3
(B4)
4
(A3)
B
(B3)
(A4)
13
A (A0)
(A2) HP
Service Manual
15
(A2.1)
14
(A1)
SAIE STANDARD
5115-4.eps
Approved by: Jason

SERVICE TRAINING
Mehl
HP NA A NA B NA 1 2 3 3.1 C 4 5 6 7 7.1 D 8 9 10 11 11.1 E 12
45SX .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .032 .027 .035 .027 .035
47SX .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .032 .027 .035 .027 .035
52M .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .035 .035 .035 .035 .035
52EX .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .035 .035 .035 .035 .035
55M .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .035 .035 .035 .035 .035
58SX .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .035 .032 .044 .032 .044
Page: 4 of 9
61SX .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .045 .035 .032 .044 .032 .044
Standard: 5115
NOTES:
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(C0)
(C4) 5 (C1)
8 6
Mehl
(B1)
(B0) 2
1 D
(C3) 7 7.1 (D4)
(B4) 12
4 (C2) (C2.1) (D0)
E
(D3) 9
3
(B2) 11 (D1)
(D2) 10
C
11.1
B (B3) (D2.1)
(A3)
(A0)
HP
A
(A2)
Upper
Lower 5115-5.eps
Service Manual
SAIE STANDARD
Approved by: Jason

SERVICE TRAINING
Mehl
HP NA A NA B NA 1 2 3 3.1 C 4 5 6 7 7.1 D 8 9 10 11 11.1 E 12
23-4H .108 .138 .045 ----- .045 ----- .045 ----- .045 .041 .041 ----- .041 .041 .035 .030 .045 .030 .045 .041 .045 .030 .035 .030 .035 .035
24-4H .108 .138 .045 ----- .045 ----- .045 ----- .045 .041 .041 ----- .041 .041 .035 .030 .045 .030 .045 .041 .045 .030 .035 .030 .035 .035
NOTES:
Page: 5 of 9
Standard: 5115
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(C4) 5 (C1)
8
6
Mehl
(B1)
(B0) 2
1 D 7
(B4) 3.1 (C3) (C2)
4 (B2.1)
3
(B2)
C
(B3)
B
(A3)
(A0)
HP
A
(A2)
Upper
Lower 5115-6.eps
Service Manual
SAIE STANDARD
Approved by: Jason

SERVICE TRAINING
Mehl
HP NA A NA B NA 1 2 3 3.1 C 4 5 6 7 7.1 D 8 9 10 11 11.1 E 12
17-270 .108 .138 .045 ----- .035 ----- .035 ----- .030 .030 .035 .035 .035 .035 .030 .024 .030 ----- .030 .024 ----- ----- ----- ----- ----- -----
NOTES:
Page: 6 of 9
Standard: 5115
HOME
PRINT
(D2) (D2.1)
11 11.1
Issue: 01/31/05
Prepared by: Jason
10
(D1)
(D3) 9
Mehl
(C2) E 12 (D0)
7 (C2.1) (D4)
7.1
(C3) 6
D
(B4) 5 (C1)
(B0) 8 (C0)
4 (C4)
1
(B1) C
2 (B3)
3.1 3
(B2.1) (B2)
B
(A3)
(A0)
HP
Service Manual
A
(A2)
SAIE STANDARD
Approved by: Jason

5115-7.eps
SERVICE TRAINING
Mehl
HP NA A NA B NA 1 2 3 3.1 C 4 5 6 7 7.1 D 8 9 10 11 11.1 E 12
Page: 7 of 9
31-5HT .045 ----- .045 ----- .045 ----- .041 .035 .032 .045 .032 .045 .035 .035 .035 .041 .035 .041 .027 .027 .027 .030 .027 .030
Standard: 5115
NOTES:
HOME
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SERVICE TRAINING
Standard: 5115
SAIE STANDARD Page: 8 of 9
NOTE:
1. CLEARANCE OF SOLID PINS AND HOLLOW PINS TO BORE WITH KEEPER
CAN NOT EXCEED THE FOLLOWING.
2. CLEARANCE BETWEEN INDIVIDUAL PINS AND BUSHINGS ARE PER CHARTS
FROM PREVIOUS PAGES.
PER CHART
0.005 MAX. CLEARANCE

BOOM
BOOM
HYDRAULIC CYLINDER
or GUIDE LEVER
BOOM
PER CHART
0.015 MAX. CLEARANCE TYP.
GUIDE LEVER
BOOM
PER CHART

Prepared by: Jason Mehl Approved by: Jason Mehl
Issue: 01/31/05
786 Service Manual

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SERVICE TRAINING
Standard: 5115
SAIE STANDARD Page: 9 of 9
HOLLOW PINS
MAIN COLUMN
BOOM #1 PER CHART

HOLLOW PIN
TURRET 42M
BOOM #1 HOLLOW PIN PER CHART
BOOM #3 PER CHART
BOOM #2

HOLLOW PIN
Prepared by: Jason Mehl Approved by: Jason Mehl

Issue: 01/31/05
Service Manual 787

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SERVICE TRAINING
Nozzle Chart
ID NUMBER ORIFICE LETTER EY NUMBER THREADS & FITTING SIZES

SIZE (MM) CODE
10067689 1.2 F N.O.F. R1/4" x 12 mm
10010117 0.7 A EV 302 003 R1/2" x 12 mm
10078594 0.8 G EV 302 003 R1/2" x 12 mm
10010119 1.0 B EV 302 003 R1/2" x 12 mm
10139911 1.1 H EV 302 003 R1/2" x 12 mm
10077812 1.2 F EV 302 003 R1/2" x 12 mm
10010120 1.3 C EV 302 003 R1/2" x 12 mm
10139112 1.4 P EV 302 003 R1/2" x 12 mm
10014925 1.5 I EV 302 003 R1/2" x 12 mm
MALE to MALE 10010122 1.7 D EV 302 003 R1/2" x 12 mm
AR TYPE 10010276 2.0 E EV 302 003 R1/2" x 12 mm
10012077 1.2 F EV 302 001 R1/2" x 16 mm
10012080 1.3 C EV 302 001 R1/2" x 16 mm
10033578 1.5 I EV 302 001 R1/2" x 16 mm
10012079 1.7 D EV 302 001 R1/2" x 16 mm
10012078 2.0 E EV 302 001 R1/2" x 16 mm

SIZE (MM) CODE
10077553 0.4 M EV 302 000 R3/8" x R3/8"
10077555 0.55 N EV 302 000 R3/8" x R3/8"
10012075 0.7 A EV 302 000 R3/8" x R3/8"
10012083 0.8 G EV 302 000 R3/8" x R3/8"
10012086 1.0 B EV 302 000 R3/8" x R3/8"
10012259 1.1 H EV 302 000 R3/8" x R3/8"
10012084 1.2 F EV 302 000 R3/8" x R3/8"
10012087 1.3 C EV 302 000 R3/8" x R3/8"
MALE to FEMALE
REDS TYPE 10041326 1.4 P EV 302 000 R3/8" x R3/8"
10041325 1.5 I EV 302 000 R3/8" x R3/8"
10012088 1.7 D EV 302 000 R3/8" x R3/8"
10100230 2.5 S EV 302 000 R3/8" x R3/8"

SIZE (MM) CODE
10013886 0.7 A EV 302 004 R3/8" x R3/8"
10033540 0.8 G EV 302 004 R3/8" x R3/8"
10037858 0.9 K EV 302 004 R3/8" x R3/8"
10034181 1.0 B EV 302 004 R3/8" x R3/8"
10033541 1.1 H EV 302 004 R3/8" x R3/8"
FEMALE to FEMALE
10033543 1.3 C EV 302 004 R3/8" x R3/8"
10037859 1.8 L EV 302 004 R3/8" x R3/8"

SIZE (MM) CODE
NOZZLE
SCREW 10077811 1.2 F N.O.F. HD 44 X 12
10077806 1.5 I N.O.F. HD 44 X 12
S0017.eps
788 Service Manual

ALL TIMES ARE IN SECONDS TOLERANCE 10 SECONDS ±
BOOM #1 BOOM #2 BOOM #3 BOOM #4 SLEWING FRONT REAR OUTRIGGER
TYPE BOOM Up / Down Up / Down Up / Down Up / Down Right & Left OUTRIGGER OUTRIGGER SLEWING
90 Degrees (Degrees) *180 Degrees *180 Degrees 90 Degrees Extension In/Out Extension In/Out In/Out
17 METER 58 / 52 30 / 22 *(90¡) 37 / 25 *(180¡) N/A 35 N/A N/A N/A
23 METER 52 / 72 60 / 74 (180¡) 43 / 46 N/A 23 N/A N/A N/A
23-4H 54 / 65 43 / 40 (90¡) 27 / 30 *(90¡) 26 / 34 *(90¡) 27 9 / 14 N/A N/A
24-4 50 / 59 36 / 35 (90¡) 26 / 36 *(90¡) 24 / 33 *(90¡) 29 9 / 14 N/A N/A
24-4 Prop. (Apitech) 53 / 60 48 / 43 (90¡) 27 / 33 *(90¡) 22 / 31 *(90¡) 35 14 / 27 N/A N/A
26-4 54 / 65 43 / 40 (90¡) 27 / 36 *(90¡) 26 / 34 *(90¡) 27 9 / 14 N/A N/A

Boom Times/Without Weights
26-4 Prop. (Apitech) 50 / 64 45 / 43 (90¡) 53/68 45/61 33 12 / 20 N/A N/A
26 METER 55 / 70 69 / 77 (180¡) 45 / 60 N/A 27 9 / 14 N/A N/A
28 METER 65 / 62 62 / 67 (180¡) 40 / 48 N/A 28 N/A N/A N/A
28X 65 / 58 43 / 42 (90¡) 41 / 51 N/A 28 13 / 22 N/A N/A
Service Manual
28X (Apitech) 53 / 60 74 / 78 (180¡) 44 / 46 N/A 34 13 / 22 N/A N/A
31 METER 81 / 79 75 / 85 (180¡) 47 / 51 N/A 28 N/A N/A N/A

40 / 50*
31 HT 70 / 70 33 / 33 (90¡) 40 / 45 22 / 25 40 / 45 15 / 12 9/6 N/A
32 METER 94 / 90 63 / 54 (90¡) 75 / 70 40 / 46 30 7 / 12 7 / 12 8 / 14
SERVICE TRAINING
32XL (B&W or Proportional) 76 / 73 63 / 54 (90¡) 75 / 70 40 / 46 43 13 / 21 8 / 10 N/A
34X (Standard Outrigger) 63 / 63 46 / 46 (90¡) 62 / 62 31 / 31 35 12 / 23 8 / 12 N/A
S0018.eps
34X (Regenerative Outrigger) 63 / 63 46 / 46 (90¡) 62 / 62 31 / 31 35 12 / 13 6/6 N/A
09/28/99
Oil must be at 40ß - 50ß Celsius before testing. Times are without weights.. MRB
*Telescope In/Out
HOME
789
PRINT
790
ALL TIMES ARE IN SECONDS TOLERANCE 10 SECONDS ±
BOOM #1 BOOM #2 BOOM #3 BOOM #4 SLEWING FRONT REAR OUTRIGGER
TYPE BOOM Up / Down Up / Down Up / Down Up / Down Right & Left OUTRIGGER OUTRIGGER SLEWING
90 Degrees (Degrees) *180 Degrees *180 Degrees 90 Degrees Extension In/Out Extension In/Out In/Out
1 2 3
36 M w/3 SPD. 65 / 92 50 / 61 (90¡) 70 / 105 31 / 75 90 60 48 6/6 6/6 22 / 15
36 M PROP. 73 / 75 48 / 47 (90¡) 55 / 63 39 / 44 45 8 / 10 8 / 10 17 / 25
36X Prop. (Rexroth) 80 / 78 49 / 47 (90¡) 59 / 63 47 / 52 49 8 / 10 8 / 10 N/A
36X Prop. (Apitech) 80 / 95 49 / 47 (90¡) 59 / 65 47 / 52 60 8 / 10 8 / 10 N/A
39X 80 / 80 60 / 60 (90¡) 75 / 75 50 / 50 60 15 / 12 7/6 N/A

42 METER 75 / 80 68 / 70 (90¡) 76 / 79 51 / 53 70 11 / 19 11 / 19 17 / 30
1 2
42 M w/2 SPD. 75 / 80 68 / 70 (90¡) 76 / 79 51 / 53 108 68 10 / 18 10 / 18 16 / 28
42 M Prop. (Rexroth) 76 / 80 52 / 61 (90¡) 71 / 76 60 / 61 60 10 / 18 10 / 18 16 / 28
Service Manual
42 M Prop. (Apitech) 80 / 90 60 / 60 (90¡) 80 / 83 55 / 64 65 10 / 18 10 / 18 16 / 28
45 SX 90 / 95 70 / 70 (90¡) 90 / 90 60 / 60 70 12 / 12 N/A 8/7

Front Slewing Rear Slewing
SERVICE TRAINING
52 METER 76 / 90 60 / 67 (90¡) 66 / 76 81 / 75 82 17 / 26 23 / 37 6 / 10
Front Slewing Rear Slewing
55 METER 110 / 110 90 / 90 (90¡) 120 / 120 70 / 70 95 17 / 26 23 / 37 6 / 10
S0019.eps
Rear Slewing
58 METER 120 / 120 95 / 95 (90¡) 120 / 120 65 / 65 90 25 / 25 17 / 17 17 / 17
Rear Slewing
61 METER 130 / 130 105 / 105 (90¡) 135 / 135 70 / 70 100 25 / 25 N/A 17 / 17
09/28/99
Oil must be at 40ß - 50ß Celsius before testing. Times are without weights.. MRB
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SERVICE TRAINING
Boom Pressures & Nozzle

Chart Size
Hydraulic Valve Pressure Settings (BAR)
BOOM SIZE 32XL 32XL

(proportional)
(B&W)
32M 31M 28X
(proportional)
28X
(B&W)
28M 26M (proportional)
26-4 26-4 (B&W)
24-4 23-4H 23M 17M
(proportional)
FUNCTION
DumpValve/E-Stop 320 320 250 250 320 350
Boom Regulator 290 290 290 290
Handvalve Relief 300 310 280 350 350 280 290 330 290 350 280 260 280
Downside Relief 140 140 140 140 140 140 140 140 140 140 140 140 170
OUTRIGGER 280 320 200 280 280 300 290 280 280 280 280 260 280
PRETENSION 6 (air) 5.5 5.5 15 15 5.5 5.5 15 5-7 15 5-7 5.5 5-7
Pretension Relief 30 30 30 30 30
Piston Side Relief
Boom Holding Valve Relief Settings (BAR)

FUNCTION
Sec. 1 Piston Side 320 400 400 400 320 320 320 320 270 300 300 320
Sec. 1 Rod Side 320 320 300 300 320 320 300 320 270 300 300 320
Sec. 2 Piston Side 320 320 300 300 320 320 270 320 320 270 300 300 270 320
Sec. 2 Rod Side 320 320 300 300 320 320 270 300 320 270 300 300 270 320
Sec. 3 Piston Side 320 320 300 300 320 320 270 300 320 270 300 300 270 320
Sec. 3 Rod Side 320 320 300 300 320 320 270 300 320 270 300 300 270 320
Sec. 4 Piston Side 320 320 300 320 320 320 270 300 300 320
Sec. 4 Rod Side 320 320 300 320 320 320 270 300 300 320
Boom Circuit Nozzle Sizes are in mm / "T" after size denotes a Throttle Check
FUNCTION
Sec. 1 Piston Side 1.9T 1.9T 2.0T 1.9T 1.9T 1.8T 1.1 1.9T 1.5T 1.1
Sec. 1 Rod Side 1.5 1.5 1.7 1.5 1.7 1.4 0.8 1.5 1.3 0.9
Sec. 2 Piston Side 1.7 1.7 1.7 1.1 1.7 1.4 1.0 1.0 1.3 1.1
Sec. 2 Rod Side 1.3 1.3 1.3 1.5 1.3 1.1 1.2 1.3 1.0 0.9
Sec. 3 Piston Side 1.4 1.4 1.3 0.8 1.3 1.1 1.1 1.2 1.0 0.9
Sec. 3 Rod Side 1.1 1.1 1.0 1.1 1.0 0.9 1.5 1.7 0.7 0.5
Sec. 4 Piston Side 1.1 1.1 1.2
Sec. 4 Rod Side 0.8 0.8 1.0
Tower Slewing 1.3 1.2 1.3 1.3 1.2 1.3 1.0 0.7
S0020.eps
Service Manual 791

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Boom Pressures & Nozzle

Chart Size
Hydraulic Valve Pressure Settings (BAR)
BOOM SIZE 58SX 52M

55M
45SX 42M 42M
47SX (proportional) (B&W) 39X 36X 36LW 36M 34X 31HT
FUNCTION
DumpValve/E-Stop 350 360 330 320 320 330 330 330 300 330 350
Boom Regulator 310 320 310 290 310 300 310 310 300 310
Handvalve Relief 360 350 350 330 330 350 340 330 280 350 350
Downside Relief 80 80 140 80 80 140 140
OUTRIGGER 350 150 300 280 280 280 280 160 200 280 280
PRETENSION 20 35 35 25 25 15 25 25 5.5 15 15
Pretension Relief 50 40 34 34 30 40 40 30 30
Piston Side Relief 230
Boom Holding Valve Relief Settings (BAR)

FUNCTION
Extend Piston Side 150
Extend Rod Side 240
Sec. 1 Piston Side 250 320 330 400 400 330 350 350 400 320 320
Sec. 1 Rod Side 310 350 330 300 320 320 320 320 300 180 180
Sec. 2 Piston Side 330 320 310 300 320 320 320 320 300 320 270
Sec. 2 Rod Side 320 320 310 300 320 330 320 320 300 310 290
Sec. 3 Piston Side 260 320 320 300 320 310 320 320 300 280 230
Sec. 3 Rod Side 320 350 320 300 320 330 320 320 300 320 320
Sec. 4 Piston Side 240 260 260 300 320 320 320 320 300 290 220
Sec. 4 Rod Side 320 350 300 300 320 330 320 320 300 320 300
Boom Circuit Nozzle Sizes are in mm / "T" after size denotes a Throttle Check
FUNCTION
Sec. 1 Piston Side 1.4T
Sec. 1 Rod Side 1.4T
Sec. 2 Rod Side 1.3
Sec. 3 Rod Side 1.2
Sec. 4 Rod Side 0.8
Tower Slewing
S0131.eps
792 Service Manual

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SERVICE TRAINING
Rotek Bearing Clearance

Instructions - SAIE - 5114
Service Manual 793

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SERVICE TRAINING
794 Service Manual

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SERVICE TRAINING
Service Manual 795

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796 Service Manual

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Service Manual 797

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SERVICE TRAINING
798 Service Manual

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SERVICE TRAINING
Service Manual 799

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SERVICE TRAINING
800 Service Manual

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SERVICE TRAINING
Special Tools
Special Tools Schroeder Filter Cart

The Schroeder Portable Filtration Cart is a compact,
self contained unit equipped with high efficiency, high
Hydraulic Trouble Shooting Kits capacity elements capable of removing particulate
These kits contain a 0-600 Bar pressure gauge, a 0-40 contaminants and/or water quickly and convieniently.
Bar pressure gauge, plus all the necessary fittings, Typical applications are: Filtering the fluid in a
locking plugs, manitrol valves, and hoses to plumb the hydraulic reservoir periodically as a supplement to the
gauges into any hydraulic circuit on the unit. These filtration by the system filters. Providing clean fluid
kits include the heavy duty foam lied carrying case when re-filling and adding oil to the reservoir of the
system.
S0038.eps
Trouble Shooting Kit for BPA 750s

• Part # .......................................................30308552
S0040.eps
Trouble Shooting Kit for All BPA and BPL Models
except BPA 750
• Part # .......................................................30308553 Features:
1. Dirt alarm indicates when element needs servicing.
2. Heavy duty gear pump with high vacuum
Trouble Shooting Kit for All BPA and BPL and Sludge
capabilities.
pumps
• Part# ........................................................30403182 3. Quick disconnects to facilitate hookup at inlet and
outlet ports.
4. 1,3,10,25,60 micron elements for contamination
removal.
5. Elements for water removal.
H.P. Portable Filtration Cart

• Schwing Part# .......................................303359101
Service Manual 801

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SERVICE TRAINING
Special Tools
Flow Meters and Accesories Accessories:

AC/DC Power Supply
Flow Meter Y223 Model HT200 • Part # .......................................................30314788
Blow-Out Disc
• Schwing Part#..........................................30314789
Adapter Flange (SAE to BSP)
• Schwing Part#..........................................30303384
Calibrator
• Schwing Part#..........................................30328467
Schwing America offers the flow meter with or without
the calibrator. Please contact our Spare Parts
Department for current pricing.
S0039.eps
Flow Meter (only)

• Part #........................................................30314787
Specifications:
Maximum Flow (G.P.M.).........................................200
Flow Ranges-High Scale:
U.S.G.P.M .......................................................... 25-200
t/min. ................................................................ 100-750
Flow Ranges-Low Scale:
U.S.G.P.M .............................................................. 5-40
t/min ................................................................... 20-150
Maximum Operating Pressure ........345 Bar (5000 psi)

Temperature Scale Range ... 100°-250° F (40°-120° C)
Port Sizes ................................. 11/2" SAE (split flange)
Weight ................................................. 30 lbs. (13.6kg)
Dimensions:
Length ............................................ 15 7/8" (403.47mm)
Width.............................................. 13 1/4" (336.55mm)
Height............................................... 6 3/4" (171.45mm)
802 Service Manual

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SERVICE TRAINING
Special Tools
Material Cylinder Alignment machine requires, measure the O.D. of your differential
rod and the I.D. of the material cylinders installed. To
Tool order one of those tools, find the proper tool from the
Schwing America offers a tool which aligns the following chart, and contact our Spare Parts
material cylinders after rotation or replacement has Department.
been completed. To determine whick tool your
Rod Diameter
Material Cylinder Diameter
Ordering Chart
Rod Cylinder Item
Diameter Diameter Number Pumpkit Model Number
50 mm 150 mm 30379547 450, 500, BP 750-15

50 mm 180 mm 30339165 WP 750-18, WP 1000-18, BP 1000-18
55 mm 150 mm 30379532 250-15
55 mm 180 mm 30379533 350-18, 500-18, 650-18
63 mm 150 mm 30379534 650-15
63 mm 180 mm 30379535 580-18, 600-18, 650-18, 601-18, 900-18, 901D-18
63 mm 200 mm 30379536 800-20, 801-20, 901-20
80 mm 150 mm 30379541 3000-15, 3001-15, 5000-15
80 mm 150 mm 30379544 5000-15
80 mm 180 mm 30379548 900-18, 2000-18, 3000-18, 3001-18, 4000-18, 5000-18,
80 mm 200 mm 30379542 900-20, 1200-20, 1201-20, 2000-20, 3000-20, 3001-20, 4000-20,
5000-20, 8000-20, 2020
80 mm 230 mm 30379543 1200-23, 1201-23,2000-23, 4000-23, 5000-23, 8000-23, 2023
85 mm 180 mm 30379538 4000-18
90 mm 180 mm 30379549 8000-18HPR, 4000-18
85 mm 200 mm 30379540 1001-20
90 mm 200 mm 30379550 4000-20
85 mm 230 mm 30379539 1001-23, 4000-23
85 mm 250 mm 30364756 2525 S0044.eps
Service Manual 803

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SERVICE TRAINING
Special Tools
Piston Installation Tools for completely installed. Attempting to install the piston
without this tool can cause damage to the piston rings.
Differential Cylinders
Because the differential cylinders are designed with a To obtain any of these tools, find the proper sized tool
counter bore, it is extremely difficult to install the for your application from the chart below, and contact
differential piston while compressing the piston rings our Spare Parts Department to place your order.
at the same time. These piston intalling tools have a
taper at the mouth of tool to help compress the piston
rings and keep them compressed untill the piston is
Ordering Chart
Piston Item
Diameter Number Description
70 mm 10061734 PISTON INSTALLING TOOL 70MM

S0045.eps
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Special Tools
Gland Packing Installation Tools pushed into the mouth of the guide bushing and then
pushed completely into position by using the packing
for Differential Cylinders tool as a slide-hammer.
Important! Reference SAIE 5221 regarding proper To do this, first * lightly lubricate the inside radius of
shimming, in "Rock Valve" section in this Service the packing tool to avoid scratching the rod surface.
Manual. Then gently slide the packing tool along the rod
The gland packing tools are designed to aid in surface, drawing away from the seal and then back to
installing the gland packing seal kit (chevrons) into the the seal; again and again tapping it a little further in
guide bushing of the diff cylinder. The packing tool with each slide until the packing section is completely
has a "V" groove machined into one end to fit the shape home.
of the individual seals of the packing set. The guide NOTE: do not attempt to insert all seal sections at the
tool is beveled on one end forcing the hard edge of the same time. Rather, remove both tools from the rod and
seal section to compress thus providing easy check the seal section you just installed to be sure it did
installation into the bushing. not catch on the mouth of the guide bushing and roll
To properly use these tools together, first * lightly inside-out. If seal appears correctly installed, repeat
lubricate the inside radius of the guide tool and also the this exact procedure with the remaining seal sections,
rod surface. Then insert the guide tool onto the rod * but do not reapply any more lubricant.
with beveled edge facing outward. Now take one * To avoid trapping air or lubricant between the
section of the packing set and slide it onto the piston packing sections, we recommend using a silicone spray
rod all the way to the beveled edge of the guide tool. lubricant, if oil is used, be careful not to over-lubricate
Slide the packing tool onto the rod, with "V" groove any surfaces or seal sections.
inward mating the "V" groove with the curvature of the
seal section. Using a rubber mallet, softly strike the flat
end of the packing tool to start the seal section into the To obtain any of these tools, find the proper sized tool
guide tool. for your application from the following chart, and
contact our Spare Parts Department to place your order.
With this seal section inside the guide tool, check to
be sure the guide tool is resting flush with the guide
bushing of the diff cylinder. Now the section can be
PACKING TOOL GUIDE TOOL
Ordering Chart
Bushing Diameter of Rod Diameter of Item Number Item Number
Differential Cylinder Differential Cylinder Guide Tool Packing Tool
90 mm 50 mm 30378922 30378926
125 mm 80 mm 30378923 30378927
120 mm 80 mm 30378924 30378927
150 mm 90 mm 30378925 30378929
S0046.eps
Service Manual 805

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SERVICE TRAINING
Special Tools
Seal Replacement Tools Bushing Installation Tool

Piston Seal Guide Tool Rock Shaft Bushing Installation Tool
This tool is designed to aid in installing the piston seal This 4 piece tool aids in removal and installation of the
onto the piston rod of the Rock Valve Shifting brass bushings that are pressed into the rock valve
Cylinder. The tool allows the piston seal to stretch housing and housing cover. This tool works for both
uniformly to the diameter size of the piston and then be the short rock and long rock models. This tool prevents
easily slid into the groove of the piston rod. damage to the bushings by eliminating any need to
pound the bushings into place. With the rock housing
cover bolted into place, a bushing is placed between
one of the tool’s plates and the rock housing. The
tool’s other plate is placed onto the tool’s threaded rod
between the opposite end of the rock housing and the
tool’s threaded nut. The threaded nut is then slowly
wrenched onto the rod, drawing the brass bushing into
its place in the rock housing.
S0054.eps
Piston Seal Guide Tool

• Schwing Part#..........................................30313746
• Schwing Part# (150mm)..........................30356740
Piston Seal Form Tool

This tool, much like the piston installation tool for
differential cylinders, has a taper at the mouth to
compress (form) the piston seal and keep it formed
until the piston is completely installed into the rock
shifting cylinder barrel. The tool prevents the piston
seal from damage due to rolling.
S0056.eps
S0055.eps
Tool, Installation, 95 mm Rock Shaft Bushing
Piston Seal Form Tool • Schwing Part#..........................................10013417
• Schwing Part#..........................................30313745
• Schwing Part# (150mm)..........................30356741
806 Service Manual

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SERVICE TRAINING
Special Tools
Accumulator Charging Kit Technition Support Kit
100
50 1
50
150
100 0 20
0 00
50 25
0 00
30
00
0 35 20
00 0
25
0
S0163.eps
S0164.eps
O-Ring O-Ring O-Ring O-Ring

13 X 2 25.12 X 1.78 37.69 X 3.53 21 X 26
10061730 10000442 10166320 10004056
O-Ring - 48 X 55
O-Ring O-Ring O-Ring 10004053
12 X 5 22 X 2.5 34 X 2.5
10000205 10061728 10077601 O-Ring - 56.74 X 3.53
Accumulator Charging Kit 10118767
O-Ring Flat Ring O-Ring O-Ring

• Schwing Part# .........................................30338635 10.77 X 2.62 19.5 X 24 X 1 32.93 X 3.53 52 X 4
10000175 10002827 10000497 10000721
Adjustment Meters for Analog 9.19 X 2.62

10000155
18.72 X 2.62
10000361
32.92 X 3.53
10068689
47.2 X 3.53
10015089
Proportional Cards O-Ring

9X2
10016731
O-Ring
17 X 2.5
10061729
O-Ring
32 X 2.5
10000489
O-Ring
44 X 3
10000677

Analog Adjustment Meter 8.73 X 1.78
10000151
15.54 X 2.62
10067850
27 X 2.5
10077249
38 X 4
10000652
Drawer 1
Toggle Switch ON/OFF/ON Toggle Switch ON/ON Corrosion Inhibitor Press Out Tool - Harting
1TL 1-8 2TL 1-3 30346014 10083751
30315771 30341455
Crimp Pin - 0.5 MM

10022656
Toggle Switch ON/ON Toggle Switch ON/OFF/ON
1TL 1-3 2TL 1-7
30315770 30333041 Crimp Pin - 1.5 MM
10013423
Toggle Switch ON/OFF/ON Toggle Switch ON/OFF/ON Crimp Pin - 0.5 MM

1TL 1-1 1TL 1-7 10013422
30314009 30324217
Press Out Tool - Burndy
10028823
Toggle Switch OFF/ON Toggle Switch ON/ON Crimp Bushing - 0.5 MM

1TL 1-2 4TL 1-3 10013421
30333040 30324215
Fuse, 80 AMP E-stop Contact Crimp Bushing - 1.5 MM

30348131 303038211 10013420
S0052.eps Drawer 2
Adjusting Device Technition Support Cabinet
• Schwing Part# .........................................30321192 • Schwing Part#..........................................30366963
Service Manual 807

HOME PRINT
SERVICE TRAINING
Special Tools
Electrical Tools and connectors. The kit includes an ejection tool for
removing and inserting the contacts into the
Accessories connectors. The kit also includes a crimping pliers
Schwing America Inc. is offering an Electrical Service with interchangeable jaw inserts that adapt to both
Kit for the repair of electrical connections in cables and styles of connector contacts. All the following pieces
connectors. This kit enables a wide range of repairs to of this kit are contained in a painted metal box with a
Schwing electrical equipment. The kit includes crimp plastic divider tray and may be ordered separately or as
style pin and bushing contacts for the BURNDY brand a complete kit.
electrical connectors as well as the HARTING brand
Part Description Item Number

Service-Kit (complete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10083745
Item # Qty Part Description Item Number

1 1 Crimping tool w/exchangeable inserts . . . . . . . . . . . . . . . . . . . . 10083746
2 1 Insert for "Burndy" contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10083747
3 1 Insert for "Harting" contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10083748
4 1 Insert for insulated pin and socket connections . . . . . . . . . . . . . 10083749
5 1 Insert for un-insulated pin and socket connections. . . . . . . . . . . 10083750
6 1 Ejection tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10083751
7 25 Contact (crimp style pin), 0.32-0.52 qmm. . . . . . . . . . . . . . . . . . 10030557
8 25 Contact (crimp style bushing), 0.32-0.52 qmm . . . . . . . . . . . . . . 10030558
9 5 Contact (crimp style pin), 0.52-1.5 qmm. . . . . . . . . . . . . . . . . . . 10027381
10 5 Contact (crimp style bushing), 0.5-1.52 qmm . . . . . . . . . . . . . . . 10027382
11 25 Contact (crimp style pin), 0.5 qmm . . . . . . . . . . . . . . . . . . . . . . . 10013422
12 25 Contact (crimp style bushing), 0.5 qmm . . . . . . . . . . . . . . . . . . . 10013421
13 5 Contact (crimp style pin), 1.5 qmm . . . . . . . . . . . . . . . . . . . . . . . 10013423
14 5 Contact (crimp style bushing), 1.5 qmm . . . . . . . . . . . . . . . . . . . 10013420
15 2 Connector guide pin, M3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10013424
16 2 Connector guide bushing), M3 . . . . . . . . . . . . . . . . . . . . . . . . . . 10013425
17 10 Blade terminal, female (RED), 6.3 x 1.0 qmm . . . . . . . . . . . . . . 10007591
18 10 Blade terminal, female (BLUE), 6.3 x 2.5 qmm . . . . . . . . . . . . . 10007297
19 10 Blade terminal, female (RED), 2.8 x 0.5 qmm . . . . . . . . . . . . . . 1000772
20 10 Butt connector (RED), 0.5-1.0 qmm . . . . . . . . . . . . . . . . . . . . . . 10013447
21 10 Butt connector (BLUE), 1.0-2.5 qmm. . . . . . . . . . . . . . . . . . . . . 10012176
22 10 Ring terminal (RED) M4, 0.5-1.0 qmm . . . . . . . . . . . . . . . . . . . . 10007299
23 10 Ring terminal (RED) M6, 0.5-1.0 qmm . . . . . . . . . . . . . . . . . . . . 10022491
24 10 Ring terminal (BLUE) M4, 1.0-2.5 qmm . . . . . . . . . . . . . . . . . . . 10007301
25 10 Ring terminal (BLUE) M6, 1.0-2.5 qmm . . . . . . . . . . . . . . . . . . . 10007295
26 100 Conductor end sleeve (WHITE), 0.75 qmm . . . . . . . . . . . . . . . . 10012648
27 100 Conductor end sleeve (YELLOW), 1.0 qmm . . . . . . . . . . . . . . . 10012917
28 100 Conductor end sleeve (RED), 1.5 qmm . . . . . . . . . . . . . . . . . . . 10012649
29 100 Conductor end sleeve (BLUE), 2.5 qmm . . . . . . . . . . . . . . . . . . 10012650
30 10 Blade terminal, female, 6.3 x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 10014953
31 10 Blade terminal, male, 6.3 x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10009698
32 10 Blade terminal, male, 6.3 x 2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . 10009701
33 10 Blade terminal, male, 2.8 x 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . Not on File
34 1 Steel box with higged cover and divider tray. . . . . . . . . . . . . . . . 10083752
808 Service Manual

HOME PRINT
SERVICE TRAINING
Special Tools
Spanner Socket Tools for Boom life of the boom pin nuts by preventing the need to
hammer the nuts on and off with a drift. To order these
Pins tools, find the sizes for your machine from the chart
The spanner socket tools are designed to remove and below, and contact the Schwing America Spare Parts
install the round, notched nuts which thread onto Department with the corresponding part number:
certain boom pins. These handy sockets prolong the
Ordering Chart
Boom Item
Pin Nut Number Tool Description
66 mm/2.596" 30331885 FOUR LUG NUT SOCKET (3/4" Drive)

99 mm/3.879" 30331886 FOUR LUG NUT SOCKET (3/4" Drive)
69 mm/2.702" 30331887 SIX LUG NUT SOCKET (3/4" Drive)
S0059.eps
Service Manual 809

HOME PRINT
SERVICE TRAINING
Special Tools
Truck Engine Tools Micellaneous Tools

Pro-Link 9000 Whip Hose and Fittings
The Pro-Link 9000 is a microprocessor-based test
instrument designed to tap into the vehicle’s on-board 1 or 2
computer. It’s programmed to communicate with the
engine and/or transmission and ABS(Anti-lock Brake
System) and provide readouts you can use for
diagnostics. You have instant access to any of the 3
vehicle’s operating data as long as the Pro-Link 9000 is
5
connected to the vehicle.
4
The Pro-Link 9000 can be used on V-MacII/E-tech,
Detroit Diesel, Navistar and Cummins engines, as well
as CEEMAT and Allison transmissions.
POS. DESCRIPTION PART #

1 GAUGE (0-40 Bar) 10012414
2 GAUGE (0-400 Bar) 10004662
3 GAUGE CONNECTOR 10018990
4 WHIP HOSE 10018991
5 GAUGE PORT 10020459
S0053.eps
Rock Valve Cover Alignment

+
9 _
8 6 +
7 5 3
4 2
1
O
S0062.eps
• Schwing Part# (BPA 750-1000) ..............30320066

• Schwing Part# (BPA 900-1200) ..............30320066
For ordering information contact:
Kent-Moore
Heavy Duty Division
29784 Little Mack
Roseville, MI 48066-2298
1-800-328-6657
MPSI
Micro Processor System, Inc.
6405 Nineteen Mile Road
Sterling Heights, MI 48314
1-810-731-6410
810 Service Manual

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HOME PRINT

SERVICE MANUAL CONCRETE PUMPS

SCHWING SERVICE DEPARTMENT

FAX (651) 429-2112

SCHWING PARTS DEPARTMENT

FAX (651) 429-2112

24 Hour Service Hotline

Table of Contents Product Data .........................................................................23

Table 1. Scheduled Maintenance

Change main hydraulic oil filter √

Change high pressure oil filter √

Change water system inline filter √

Check truck fluid levels √

Bleed moisture from air tank √

Check hydraulic oil √

Bleed moisture from hydraulic tank √

Check differential cylinder rod packings √

Inspect bolts on Rock Valve and rams √

Grease Rock Valve and agitator bearings √

Grease Rollix bearing and hollow pin √

Check optional auto greaser reservoir √

Fill optional auto greaser reservoir √

Inspect for damage and leaks √

Check if maintenance is due √

Grease boom zerks √

Check pipe wall thickness √

Check oil in optional air compressor √

Check Rock Valve tension nut √

Inspect cutting ring/rotate if needed √

Lubricate mechanical moving parts √

Check tapered bend wedge bolt √

Check boom slewing gearcase oil level √

Clean slewing gearcase breather cap √

Check function of mech. boom brake √

Clean and repack the Rollix gear √

Inspect the turret bolts for tightness √

Check fluid in distribution gearcase √

Check unit mounting hardware √

Check hydraulic pressures √

Clean hydraulic oil cooler fins √

Check drive pinion mounting screw √

Change oil in optional compressor √

Change hydraulic oil for temp. reasons √

Change oil in distribution gearcase √

Change oil in boom slewing gearcase √

Test dirty filter lamp circuit √

Change hydraulic oil for age reasons √

Clean optional compressor √

Change corrosion inhibitors √

Periodic - structural inspection √

Operators Check list for Weekly

Operator’s Check List for Unit # Week Ending

( E ) Hydraulic Oil Level - TANKS

( E ) Water Box Level & TANKS

( E ) Flush Grease Lines

( E ) Hoses & Pipes

( E ) Clamps & Rubbers

( E ) All Tools & SAFETY Gear

( E ) Grease Agitator Bearings

( 2 ) Agitator Gearbox Oil Level-90W

( 2 ) Transfer Case Oil Level

( 2 ) Transmission Oil Level

( 2 ) Hyd. Pump Gear Oil Level