SERVICE TRAINING

TRAINING MANUAL

Copyright All rights reserved.

The information and drawings contained herein must not be duplicated, used improperly, or
communicated to third parties without the consent of Schwing America Inc.
All Information is subject to revision

5900 Centerville Road White Bear, MN 55127 TEL 651-429-0999 FAX 651-429-2112 www.schwing.com
 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
 SERVICE TRAINING
Table of Contents
Typical Twin Circuit ........................ 1 Typical Boom Circuit .................... 16
PTO Switch/Air Valve ..................................................1 Boom Pump ................................................................16
PTO ...............................................................................2 E-Stop Manifold .........................................................17
Continuous Duty Solenoid ............................................2 Poppet Valve Theory ..................................................17
CPC/CPCII Controller ..................................................3 E-Stop - Override .......................................................18
Hydraulic Pumps ...........................................................3 Boom Handvalve - No functions activated ................18
Fixed Displacement ......................................................4 Boom Handvalve - Outrigger enabled ........................19
Variable Displacement ..................................................4 Outrigger Handvalve ..................................................19
Main Control Block “Brain” .........................................4 Boom Handvalve - Boom Function Activated ...........20
Concrete Pump Forward/Reverse Valve .......................5 Pulsar Coil Theory ......................................................20
Main Control Block - S1/S2 Spool ...............................5 Boom Holding Valves ................................................21
Main Relief Valve .........................................................6 Manual Controls and Overrides ..................................21
Differential Cylinders ...................................................6
Material Cylinders ........................................................7
Differential Cylinder - Bottomed Out ...........................7
MPS Valve ....................................................................8
S3/Accumulator Control Block .....................................8
Accumulator Theory .....................................................9
Rock Valve Slewing Cylinder ......................................9
Soft Switch Relief Valve ............................................10
Main Control Block - S2 Spool ..................................10
Differential Cylinder - Beginning of stroke ................11
MPS ............................................................................11
Differential Cylinder - Bottomed Out .........................12
MPS ............................................................................12
S3/Accumulator Control Block ...................................13
Rock Valve Slewing Cylinder ....................................13
Soft Switch Relief Valve ............................................14
Main Control Block - S2 Spool ..................................14
Differential Cylinders .................................................15

Training Manual
 SERVICE TRAINING
Table of Contents

Service Manual
 SERVICE TRAINING

Typical Twin Circuit

Main Control Block
Main Relief/Soft Switch

MPS Valve

Differential Cylinders

S3/Accumulator Valve

Rock Valve
Slewing Cylinder Accumulator Pump

Boom Pump

Rock Valve

PTO
Material Cylinders Hydraulic Pumps

PTO Switch/Air Valve

Air Pressure Switch
• Switch pushed “in”, air supply blocked by
Air Pressure Switch
(Energized) spool.
• Switch pulled “out” , opening is created
To:PTO
allowing air pressure to energize the air pres-
sure switch.
• A passage way is created allowing air pres-
sure to be sent to the PTO.

Air blocked by spool

PULL
TO APPLY
PARKING
QUARTZ
BRAKE
00000.1
PUSH TO
RELEASE 1 HOURS

From:Truck Air Supply

PTO switch
Power to fuse
Must be pulled

Training Manual 1
 SERVICE TRAINING

PTO
• Air is routed to the small cylinder mounted
in the distribution gear case (PTO).
• When the cylinder is pushed “in” the PTO is
in the pumping position.
• When the cylinder is pushed “out” the PTO
is in the travel position.

Air Supply Block All hydraulic pumps for the concrete pump, plac-
ing boom, agitator, etc. are mounted on a distri-
bution gearcase. When you are driving the truck,
the power of the truck engine is transmitted
through the truck transmission, through a propel-
ler shaft, through the bottom of the distribution
To:12v Controller
gearcase, through another propeller shaft, and
into the rear end(s) of the truck. When you are
operating the unit, the distribution
gearcase interrupts the power to the rear ends,
and transmits it to internal gears that turn the
hydraulic pumps. Changing between travel and
PTO.eps Fork pumping modes is accomplished by means of an
air switch in the truck cab.

Continuous Duty Solenoid

CPC/CPC II Style • Electric signal from Air Switch enters Con-
(Not used on Vector units) tinuous Duty Solenoid
• The signal energizes the magnetic coil in the
Continuous Duty Solenoid
• The energized magnetic coil, pulls the
plunger “down”
• A connection is established between the 12
To: Controller volt power supply and CPC Controller
Plunger

From: 12v Power Supply

Magnetic Coil

Cont_Solenoid.eps

2 Training Manual
 SERVICE TRAINING

CPC/CPCII Controller
The CPC/CPC II provides a proportional signal
CPC/CPC II
to
POWER

REAR CTR

UMB CTR
each of the boom functions and the concrete
RADIO CTR

ID

LINK
pump
ALARM

E-STOP
output. It also controls all on/off functions on the
unit. The CPC/CPC II receives power via the
WHEN WELDING ANYWHERE ON UNIT
POWER CABLE MUST BE DISCONNECTED
PTO switch through the Continuos duty solenoid
and into the “Power” connector.
L1357-01

“Power” Connector
Vector Controller
The Vector control system is a completely digi-
tal control system, which means that the function
movements are converted to numbers (0’s and
Vector 1’s). The numbers are sent to the controller
where they are analyzed, converted back to ana-
log (voltage or current), and sent to the valves
and indication devices.
1 2
OK OFF

0 x1000 3
PTO 1500 rpm 62˚C

Menu: [ENTER]=ON

X12 Connector
HOME + HELP START (Behind)
CLEAR - ENTER QUIT

Hydraulic Pumps
The hydraulic pumps for the concrete pump cir-
Typical Gearbox
cuit are bent axis, variable displacement piston
To: Boom Control Block To: Main Control Block pumps. They are horsepower controlled, which
means that as pressure rises towards maximum,
Pumpkit Pumps
the flow can decrease, so the power consumption
remains constant. We use this type of pump so
the truck engine will not bog down under hard
pumping conditions. The pumps also accept
external signals for control of the output. At
Schwing, we route signals to the pump from the
hydraulic stroke limiter. The net effect of these
devices is to tell the pump to put out less oil per
revolution, as required by the pump operator.

s
ps
.ep To: S3 Accumulator
um
ulicP
dra To: Agitator
Hy

To: Oil Cooler

Training Manual 3
 SERVICE TRAINING

Fixed Displacement
Puts out a set amount of oil, that can only be
changed by increasing/decreasing the RPMs.
Fixed Dispalcement Variable Displacement
Bent Axis
Variable or Positive displacement pumps deliver
to the system, a variable amount of oil according
to the angle for the rotary group or swash plate.
min

max Variable Displacement

Bent Axis

min max

Variable Displacement
Swash Plate

PumpCutaways.eps

Main Control Block “Brain”

• Oil from hydraulic pumps enter the “P1” and
“P2” ports of the Main Control Block.
• S1 spool is in the neutral position
From: Pumps
• Hydraulic oil will flow through the Main
Control Block and go back to the hydraulic
tank.
To: Tank To: Tank

S1 Spool

From: Pump

From: Pump
S2 Spool

HiFlowBrain.eps

S1 - Neutral Position, pathway block

4 Training Manual
 SERVICE TRAINING

Concrete Pump Forward/Reverse

Valve
The Concrete Pump Forward/Reversing valve is
a simple control device, containing a 3 position,
A B 6 way spool attached to a handle. The valve
To: Main Control Block/MPS Valve
receives hydraulic oil from the Accumulator
“P2” Vent pump.
T
• In the neutral position, the passage way for
the hydraulic oil is blocked and will return to
Blocked pathway (Neutral) A
tank.
B
From: Pump • In the “forward” position, a passage way is
created between the pressure port and the
P
“A” port, through grooves in the spool.
• Oil is sent to the “XP” port of the Main
To: Main Control Block (XP port)
and MPS Valve (XB port) Hydraulic Control Block and the “XB” port
of the MPS valve.
A B • This valve also plugs the vent line, which
allows pressure to build in the system

Passageway created (Forward position)

Main Control Block - S1/S2 Spool

• With hydraulic pressure on the “XP” side of
the spool and no pressure on the “XR” side,
the S1 spool will move into the “Forward”
S1 - Forward Position, position.
pathway to S2 spool created
• Passage way created for the hydraulic oil
from the Main Hydraulic Pumps to move
past the S1 spool and unto the S2 spool.
• Passage way created for the hydraulic oil
moving past the S2 spool and unto the Dif-
S1 Spool
ferential Cylinder.
“XP” “XR” From: CP Forward/Reverse Valve
From: Pump
S2 Spool

From: Pump

HiFlowBrain_S1.eps

Pathway to Differential cylinder

To: Differential Cylinder

Training Manual 5
 SERVICE TRAINING

Main Relief Valve

The main relief valve protects the hydraulic cir-
cuit, by relieving pressure before it reaches 350
80 bar bar or greater.
350 bar
• Pressure exceeds 350 bar and presses against
the 350 bar main relief valve plunger.
• The 350 bar relief valve spring will collapse,
creating a passage way for the oil to bleed to
tank. This creates a pressure drop in the pop-
pet spring chamber.
Less than relief pressure Over relief pressure • Pressure is greater on the piston side of the
poppet than the spring side. This will col-
lapse the poppet spring allowing the poppet
to open.
• With the poppet opened, a passage way is
created, allowing oil to escape to tank until
350 bar pressure or lower is achieved.

Poppet opens Excess oil drained to tank

Differential Cylinders
The term differential cylinder means that each
hydraulic cylinder that pushes the concrete has
an area difference (referred to as an “area differ-
ential”) between the two sides of the piston. This
Loop Oil area differential exists because the rod extends
only from one side of the piston. This is in con-
trast to the rock
valve slewing cylinder, for example, which has a
rod
extending from both ends of the piston and there-
fore has the same area on both sides of the piston
To:MPS ZK2 (it is a nondifferential cylinder).
To:MPS ZK1 • Hydraulic oil from the Main Control Block
flows to the rod side of the left hand differen-
High pressure oil
tial cylinder.
• The pressure from the hydraulic oil extends
the rod of the left hand differential cylinder.
From: Pumps • Loop oil on the piston side of the left hand
To:MPS ZS1 differential cylinder crosses over to piston
To:MPS ZS2 side of the right hand differential cylinder,
From: Pumps DiffCylinders.eps
causing that rod to retract.

6 Training Manual
 SERVICE TRAINING

Material Cylinders
The material cylinders contain rubber rams that
are connected to the differential cylinder rods.
One side will push the concrete through the Rock
valve while the opposite side will suck concrete
from the hopper.

Concrete “pushed” through Rock Valve

Concrete “sucked in” from hopper

MatCylinders.e

Differential Cylinder - Bottomed Out

• Left-hand differential cylinder bottoms out.
• Signal lines connected to the “ZK1”,“ZK2”,
“ZS1” and “ZS2” ports of the MPS valve.

To:MPS ZK2

To:MPS ZK1

From: Pumps
To:MPS ZS1
To:MPS ZS2
DiffCylinders_Bottom.ep
From: Pumps

Training Manual 7
 SERVICE TRAINING

MPS Valve
The MPS system consists of three small direc-
tional control valves. The main pressure that is
X3 supplied to these directional control valve is sup-
To: Soft Switch
Reversing Valve
plied by the accumulator.
A B • A high pressure signal line from the Differ-
To:
S3 Spool ential Cylinder enters the MPS valve through
the “ZK2” port.
XB XA • This moves the NG 6 directional valve over
creating a passage way for the Accumulator
oil to flow through MPS valve and out the
ZS1 ZS2
“A” and “X3” port.

From: Differential Cyl.

ZK1 ZK2
From:
Differential
Cylinder

SP T
Passage way created
To:S3 Spool

From: Accumulator Pump

From: Differential Cyl.
From: Accumulator Pump

S3/Accumulator Control Block

• Hydraulic oil from the MPS valve “A” port
enters the “XA” port of the S3/Accumulator
Control Block.
To: Rock valve slewing cylinder • The S3 spool moves to the “left”.
and S2 spool
From: MPS valve "B" port • A passage way is created for accumulator oil
to travel to the Rock valve Slewing Cylinder
and S2 spool in the Main Control Block.

From: MPS valve "A" port

To: Rock valve slewing cylinder

To: S2 spool

Manual Bleed

S3_Block02.eps

From: Accumulator Pump

From: Accumulator Pump

8 Training Manual
 SERVICE TRAINING

Accumulator Theory
The accumulator can be considered an energy
storage device for hydraulics, similar to the func-
tion of a battery in an electrical circuit. The accu-
mulator stores the oil flow of a small hydraulic
pump until it is time to shift the Rock Valve.
When needed all of the oil that as been stored in
the accumulator is quickly released. This has the
Without Nitrogen With nitrogen charged Influx of hydraulic oil following benefits:
Charge to pressure P1 for storage
• Lower power requirements for switching the
RockValve (less horsepower taken from the
engine).
• Simpler switching to begin the next stroke
(the differential cylinders get the signal to
change direction as soon as the S3 spool
moves, regardless if the Rock Valve has
moved or not).
Fluid charged to Discharge of Fluid discharged
maximum working hydraulic oil down to minimum
pressure P3 working pressure P2

AccumulatorTheory.eps

Rock Valve Slewing Cylinder

From: S3/Accumulator Control Block The rock valve slewing cylinder is a nondifferen-
tial cylinder (see Differential Cylinder). The
switching grooves are used in single-circuit
machines, but not in twin-circuit machines.
• A working line from the “A” port of the S3/
Accumulator Control Block enters the rear
From: S3/Accumulator Control Block of the Rock Valve Slewing cylinder
• This pushes the rod over, thus “switching”
the rock valve.

RockSlewingCylinder.eps

Training Manual 9
 SERVICE TRAINING

Soft Switch Relief Valve

Signal from MPS Valve When the Rock Valve is shifting, a signal line
X3 X3 enters the “X3” port of the Main Control Block
• The Soft Switch Reversing Valve is opened,
80 bar 80 bar creating a passageway to the 80 bar relief
350 bar 350 bar valve.
• Pressure exceeds 80 bar and presses against
the 80 bar Soft Switch relief valve plunger.
• The 80 bar relief valve spring will collapse,
creating a passage way for the oil to bleed to
tank. This creates a pressure drop in the pop-
pet spring chamber.
X3 X3 • Pressure is greater on the piston side of the
poppet than the spring side. This will col-
80 bar 80 bar lapse the poppet spring allowing the poppet
350 bar 350 bar to open.
• With the poppet opened, a passage way is
created, allowing oil to escape to tank until
80 bar pressure or lower is achieved.

Path open to tank

Main Control Block - S2 Spool

• Signal line from the MPS valve enters the
“XB” port of the Main Control Block
• S2 spool moves to the ‘right”
• A passage way is created for oil to travel to
the Differential Cylinder.

From: CP Forward/Reverse Valve

S1 Spool From: Pump

From: Pump

S2 Spool

“XB” “XA”

HiFlowBrain_S2.eps From: Accumulator

Control Block
Pathway to Differential cylinder To: Differential Cylinder

10 Training Manual
 SERVICE TRAINING

Differential Cylinder - Beginning of

stroke
Loop Oil • Hydraulic oil from the Main Control Block
flows to the rod side of the right-hand differ-
ential cylinder.
• The pressure from the hydraulic oil extends
the rod of the right-hand differential cylin-
der.
• Loop oil on the piston side of the right-hand
differential cylinder crosses over to piston
side of the left hand differential cylinder,
pressure oil To:MPS ZK2 causing that rod to retract.
To:MPS ZK1

From Pumps
To:MPS ZS1
To:MPS ZS2
DiffCylinders_NewStroke.eps
From Pumps

MPS
Signal lost • A high pressure signal line from the Differ-
ential Cylinder is sent to the “ZK1” port of
X3 the MPS valve.
• Pressure is greater on the “ZK1” side of the
A B
NG 6 spool than the “ZK2” side.
• The NG 6 spool will move to the “right”
closing the passage way for high pressure
XB XA accumulator oil.

ZS1 ZS2
From: Differential Cyl.

ZK1 ZK2

SP T
Passage way closed
From: Differential Cyl.

From: Accumulator Pump From: Accumulator Pump

Training Manual 11
 SERVICE TRAINING

Differential Cylinder - Bottomed Out

• The Differential cylinder has reached the
bottom of the last stroke.
• High pressure signal line are sent to the
“ZK1”, “ZK2”, “ZS1” and “ZS2” ports of
the MPS valve.

To:MPS ZK2

To:MPS ZK1

From Pumps
To:MPS ZS1
To:MPS ZS2
DiffCylinders_03.eps
From Pumps

MPS
• A high pressure signal line from the Differ-
ential Cylinder enters the MPS valve through
X3
To: Soft Switch
the “ZS2” port.
Reversing Valve • This moves the NG 6 directional valve over
A B
creating a passage way for the Accumulator
To: S3 Spool
oil to flow through MPS valve and out the
“B” port and unto the S3 spool.
XB XA
• Accumulator oil also travels out the “X3”
port and unto the Soft Switch Reversing
ZS1 ZS2 Valve.
From:
Differential Cylinder
To:Soft Switch Reversing Valve
ZK1 ZK2 To:S3 Spool
From:Differential Cylinder

SP T

Passage way created

From: Accumulator Pump

From:Differential Cylinder
From: Accumulator Pump

12 Training Manual
 SERVICE TRAINING

S3/Accumulator Control Block

To: Rock valve slewing cylinder • Hydraulic oil from the MPS valve “B” port
and Main Control Block enters the “XB” port of the S3/Accumulator
From: MPS valve "A" port Control Block.
• The S3 spool moves to the “left”.
• A passage way is created for accumulator oil
A B to travel to the Rock valve Slewing Cylinder
and S2 spool in the Main Control Block.

S3_Block.eps
To: Rock valve slewing cylinder
To: S2 spool Manual Bleed

From: MPS valve "A" port

From: Accumulator Pump

From: Accumulator Pump

Rock Valve Slewing Cylinder

From: S3/Accumulator Control Block
From: S3/Accumulator
Control Block
• A working line from the “B” port of the S3/
Accumulator Control Block enters the front
of the Rock Valve Slewing cylinder
• This pushes the rod over, thus “switching”
the rock valve.

Training Manual 13
 SERVICE TRAINING

Soft Switch Relief Valve

Signal from MPS Valve When the Rock Valve is shifting, a signal line
X3 X3 enters the “X3” port of the Main Control Block
• The Soft Switch Reversing Valve is opened,
80 bar 80 bar creating a passageway to the 80 bar relief
350 bar 350 bar valve.
• Pressure exceeds 80 bar and presses against
the 80 bar Soft Switch relief valve plunger.
• The 80 bar relief valve spring will collapse,
creating a passage way for the oil to bleed to
tank. This creates a pressure drop in the pop-
pet spring chamber.
X3 X3
• Pressure is greater on the piston side of the
poppet than the spring side. This will col-
80 bar 80 bar
lapse the poppet spring allowing the poppet
350 bar 350 bar to open.
• With the poppet opened, a passage way is
created, allowing oil to escape to tank until
80 bar pressure or lower is achieved.

Path open to tank

Main Control Block - S2 Spool

• Signal line from the MPS valve enters the
“XA” port of the Main Control Block
• S2 spool moves to the “left”
• A passage way is created for oil to travel to
the Differential Cylinder.

S1 Spool From: CP Forward/Reverse Valve

From: Pump

From: Pump
S2 Spool

HiFlowBrain_S2.eps To: Differential Cylinder

From: Accumulator
Control Block

14 Training Manual
 SERVICE TRAINING

Differential Cylinders
• Hydraulic oil from the Main Control Block
flows to the rod side of the left hand differen-
tial cylinder.
• The pressure from the hydraulic oil extends
the rod of the left hand differential cylinder.
• Loop oil on the piston side of the left hand
differential cylinder crosses over to piston
side of the right hand differential cylinder,
causing that rod to retract.

From Pumps

From Pumps DiffCylinders_04.eps

Training Manual 15
 SERVICE TRAINING

Typical Boom Circuit

Boom Cylinder

To:Outrigger Function

Outrigger Handvalve

Boom Pump

P1
1 PM

M P4
T
T

P3

P2

Boom Handvalve
Estop Manifold

Boom Pump
To: Boom Control Block To: Main Control Block The hydraulic pump for the placing boom is a
variable displacement, bent axis, axial piston
pump. It feeds all of the following components:
• the hydraulic cylinders on the boom sections
• the hydraulic cylinders on the outriggers
• the hydraulic motor for the boom slewing
Boom Pump
gear
• the hydraulic motor for the water pump
• the hydraulic motor of the compressor
(optional equipment)

s
.ep To: S3 Accumulator
02
s_
ump
P
ulic To: Agitator
dra
Hy

To: Oil Cooler

Training Manual 16
 SERVICE TRAINING

E-Stop Manifold
• Hydraulic oil from the boom pump enters the
P2 E-stop Manifold from the “P1” port.
T T • With the solenoid energized, a signal line
P3
P4
Equal Pressure
from the “P1” port enters the spring side of
P1 the poppet valve. This will equalize the pres-
Poppet Closed
sure on both sides of the poppet. The pres-
sure plus spring tension will hold the poppet
Energized Solenoid closed.
• If the solenoid is not energized, a passage
Signal Line from P1 port way will be created for the signal line to go
to tank.
P2 • This will create a pressure drop on the spring
T T side of the poppet valve.
P4 Greater Pressure
P3 Poppet Opened • Pressure from the P1 port will overtake the
P1 spring tension, allowing the poppet to open.
• A passage way is created for the oil from the
De-energized Solenoid “P1” port to escape to tank.

Passage way to tank

Poppet Valve Theory

1 Pressure “A” = “B”
Pressure “A”
Pressure “B” + Spring
3 Pressure “A” > “B”
2 Pressure “A” > “B”
Pressure “A”
Pressure “B” + Spring
4 Pressure “A” = “B”
Pressure “A”
1. Pressure “A” and “B” are equal. With ‘B”
pressure, plus the spring, Pressure “A” is not
great enough to open the poppet.
2. If pressure “A” is greater than pressure “B”
plus the spring tension, pressure “A” will
collapse the spring, lower the poppet.
3. With the poppet lowered, a path for excess
pressure is created and flows back to tank.
4. When pressure ‘B” is greater or equal to
pressure “A” the spring will expand, closing
the pathway to tank.
Housing
Poppet

Pathway to Tank Pathway to Tank

Spring
(open) (closed)

Pressure “B” + Spring Pressure “B” + Spring

Training Manual 17
 SERVICE TRAINING

E-Stop - Override
• Turn the bypass key switch to “Bypass”
Override
Concrete pump, position. If control is not restored, there
agitator, accumulator probably a hydraulic problem; Proceed to the
buttons dump valve
MP
S next step.
Boom/outrigger
T circuit dump • To manually bypass each system, the inlet
valve plumbing to the nonworking system must be
S
MP

plumbed out of the manifold.

P3
• With the engine stopped, disconnect the
P2 P4 P1
Concrete pump plumbing for the nonworking system at the
Agitator system plumbing
system plumbing
appropriate fitting
Boom/outrigger
Accumulator system plumbing
system plumbing BY-PASS
NORM. BY-PASS

by-pass2.eps

Boom Handvalve - No functions acti-

vated
• Oil enters the Boom Handvalve from the “P”
port.

Blocked passage way

C2 C1

Apitech_Side_03.eps

From: Pump

From: Boom Pump

18 Training Manual
 SERVICE TRAINING

Boom Handvalve - Outrigger enabled

• Outrigger push button is depressed
• Pulsar coil is activated
• Spool moves, creating a passage way for the
oil to exit out of the “C2” port and unto the
outrigger hand valve.

To: Outrigger Handvalve

To: Outrigger Handvalve

Apitech_Side_02.eps
Solenoid Energized
Passage open
From: Boom Pump

Outrigger Handvalve
The Outrigger hand valve is a simple control
device, containing four - 3 position, 6 way spools
attached to handles. The valve receives hydraulic
oil from the Boom Handvalve.
A B • In the neutral position, the passage way for
the hydraulic oil is blocked
• In the “extend” position, a passage way is
created between the pressure port and the
“A” port of the Outrigger hand valve.
• This will send oil to whatever outrigger func-
tion has been activated. Example “Outrigger
To: Outrigger Function Extend”.

A B

Training Manual 19
 SERVICE TRAINING

Boom Handvalve - Boom Function

Activated
• Either the pulsar coil or handle are activated
Blocked passage way • A passage way is created for the oil to be
sent to whatever boom function has been
activated.

To: Boom Function

From: Pump

Passage open

Apitech_Side_01.eps
From: Boom Pump

Pulsar Coil Theory

Coil As the control disk pulses “on” and “off”, pre-
Control Oil to Spool
tension
oil is allowed to flow from the pressure passage
to the tank passage. Since the top orifice is larger
than the bottom orifice, eventually more oil will
be in the tank passage than can leave through the
0.024 orifice. At this point, pressure will build in
the main spool control port and move the main
spool.
The longer the “on” time, the greater the pressure
in the control port, and the further the main spool
is moved, causing the boom to go faster.

Control Disk
0.040 Orifice
Pilot Pressure

20 Training Manual
 SERVICE TRAINING

Boom Holding Valves

Passage way for rod side oil (to tank)
Two hydraulically unlockable check valves
Passage way for piston side oil
(H.E.R. valves, or holding valves) on each boom
cylinder prevent the boom from coming down
unintentionally

LINE B

LINE A

From:Boom Handvalve

Passage way closed. Oil trapped, cylinder held in place

LINE B

LINE A

Manual Controls and Overrides

000419.eps 1. E-stop
1 2 3 4 5 6 7
2. Boom #1 Control Handle
3. Boom #2 Control Handle
4. Boom #3 Control Handle
10 11 5. Boom #4 Control Handle
6. Boom Telescope Handle
7. Boom Slewing Control Handle
AGITATOR

8. Water Pump/Air Compressor Handle

CONCRETE PUMP

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

DANGER WARNING
10189517

9. Water Pump System Change-Over Valve

8 12
Electrocution hazard.
4

10. Concrete Pump Handle

Do not operate this
Stay back from high machine without
voltage wires at least training. Understand
17 feet (5 meters). the warnings in safety
3

manuals and on decals.

WARNING
11. Agitator Handle
12. Two Position Boom/Outrigger Handle.
Clear area
before activating
outriggers

9
REAR EXTEND REAR JACKING FRONT JACKING FRONT EXTEND

Training Manual 21
 SERVICE TRAINING

22 Training Manual

The Schwing Group ............................................................ 1
Schwing America, Inc. ................................................. 1
Hydraulic Training
General Principles ............................................................... 3
Mechanical Versus Hydraulic ............................................. 7
Transfer of Energy .............................................................. 7
Hydraulic Jack ..................................................................... 8
Linear & Rotary Actuators .................................................. 8
Basic Hydraulic Components .............................................. 9
Check Valve Comparison ................................................. 10
Shuttle Valve ..................................................................... 11
Throttle Check Valve ........................................................ 12
Switching Valves .............................................................. 13
Hydraulic Pumps ............................................................... 14
Placing boom hydraulic pumps .................................. 14
Concrete pump hydraulic pumps ............................... 14
Fixed Displacement Pump ................................................ 15
Rexroth A2F20 ........................................................... 15
Variable Displacement Pump ............................................ 15
Rexroth A7VO ........................................................... 15
Variable Displacement Axial Piston Pump ....................... 16
RexrothA10VO .......................................................... 16
RexrothA11VO .......................................................... 16
Rexroth A11VO Adjustments .................................... 17
Transfer Cases ................................................................... 18
Relief Valves ..................................................................... 19
Safety Relief Valves .......................................................... 20
Pressure Relief Valve Type DB ................................. 20
Pressure Relief Valves Type DBW ............................ 20
Hydraulic Symbols ............................................................ 21
Hydraulic Symbols (Cont.) ............................................... 22
Hydraulic Symbols (Cont.) ............................................... 23
Hydraulic Symbols (Cont.) ............................................... 24
Hydraulic Symbols (Cont.) ............................................... 25
Hydraulic Symbols (Cont.) ............................................... 26
Hydraulic Symbols (Cont.) ............................................... 27
Formulas ............................................................................ 28
Pumpkits
800 Gate Valve .................................................................. 30
801 Gate Valve .................................................................. 31
801 Pumpkit Schematic ............................................. 32
Concrete Pump Control Block ................................... 33
Stroke Limiter ............................................................ 34
Training Manual
SERVICE TRAINING
Table of Contents
494 Block ....................................................................34
Hydraulically Unlockable CheckValve ......................35
Gate Valve ..................................................................35
900-1200 Single Circuit .....................................................37
900-1200 Single Circuit Schematic ............................38
Concrete Pump Control Block ....................................39
Stroke Limiter .............................................................40
494 Block ....................................................................40
Switching Valve .........................................................41
A7VO .........................................................................41
Rock Valve .................................................................42
Phase A .......................................................................44
Phase B .......................................................................45
Phase C .......................................................................46
Phase D .......................................................................47
Phase E .......................................................................48
Phase F ........................................................................49
Phase G .......................................................................50
Phase H .......................................................................51
Phase I ........................................................................52
Phase J ........................................................................53
Phase K .......................................................................54
Troubleshooting .................................................................55
High-Flow Single Circuit 2020/2023 ................................61
High-Flow Single Circuit Schematic ..........................62
Concrete Pump Control Block ....................................63
Switching Manifold ....................................................64
Stroke Limiter with Fast Switch/Dampner .................64
Phase A .......................................................................66
Phase B .......................................................................68
Phase C .......................................................................70
Phase D .......................................................................72
Twin Circuits .....................................................................74
1200 Twin Circuit with Switching Valves ........................75
Twin Circuit Schematic w/Soft Switch ......................76
Concrete Pump Control Block ....................................77
S3 Control Block ........................................................77
Soft Switch .................................................................78
Accumulator Unloader Valve .....................................78
Accumulator Control Block/Dump Valve ..................79
Phase A .......................................................................80
Phase B .......................................................................82
Phase C .......................................................................84
Phase D .......................................................................86
1200 Twin Circuit with MPS .............................................89
Twin Circuit with MPS/Soft Switch ...........................90
Concrete Pump Control Block ....................................91
S3 Control Block ........................................................91
MPS ............................................................................92
Accumulator Control Block/Dump Valve ..................93
Soft Switch .................................................................94
Phase A .......................................................................96
Table of Contents
Phase B .......................................................................98
Phase C .....................................................................100
Phase D .....................................................................102
Twin Circuit with Variable displacement
accumulator pump Schematic 104
Model Number Nomenclature .........................................105
Hi-Flow Pumpkits (2023-2525) ......................................106
Hi-Flow Pumpkits (2525H) .............................................107
Hi-Flow Pumpkits Schematic ...................................108
Concrete Pump Control Block .................................109
Main Relief/Soft Switch Block ................................110
MPS ..........................................................................111
S3 Control Block - Machined ...................................112
S3 Control Block - Cast ...........................................113
2023 Circuit diagram ................................................114
Phase A .....................................................................114
Phase B .....................................................................116
Phase C .....................................................................118
Phase D .....................................................................120
Booms
Black & White .................................................................123
Electric/Air/Oil .........................................................123
Electric/Oil/Oil .........................................................123
Proportional .....................................................................125
Boom Holding Valves .....................................................126
28X B&W Boom .............................................................127
Load Sense Hydraulic Circuits ........................................131
Overview ..................................................................131
Components ..............................................................132
Basic Principles - Simple Circuit .............................133
Basic Principles - Orifice .........................................134
Basic Principles - Without Relief Valve ..................135
Basic Principles - With Relief Valve .......................136
Basic Principles - Delta-P ........................................137
Basic Principles - Delta-P ........................................138
Basic Principles - Pressure Cut-Off .........................139
Basic Principles - Shuttle Valves .............................140
Basic Principles - Pressure Regulator ......................141
A7 Variable Displacement Hydraulic Pump Training ....142
All Functions in Neutral ...........................................142
Cylinder Extend Function Initiated ..........................144
Hydraulic Cylinder Extending .................................146
Hydraulic Cylinder Fully Extended Pump ...............148
Fixed Displacement Pump Training ................................150
All Function in Neutral ............................................150
Boom Function Activated ........................................151
Cylinder Pressurized at the End of Stroke ...............152
Output Charts ...................................................................153
Using the Chart ................................................................154
Training Manual
Using a Nomograph ........................................................ 159
General information ................................................. 159
The quadrants ........................................................... 161
Minimum Pipe Wall Thickness ....................................... 167
Preventative Maintenance ............................................... 168
Scheduled Maintenance ........................................... 168
Filtration .......................................................................... 170
General information ................................................. 170
Specific information ................................................. 170
Changing hydraulic oil filters .................................. 170
Changing high pressure water filter ......................... 171
Hydraulic Oils ................................................................. 171
General information ................................................. 171
Specific information ................................................. 172
When to change your hydraulic oil .......................... 172
Electrical
Introduction ..................................................................... 173
What is Electricity? ......................................................... 173
Amperage ........................................................................ 176
Voltage ............................................................................ 177
Resistance ........................................................................ 177
Basic Circuits .................................................................. 179
Schematics ...................................................................... 181
Circuit Types ................................................................... 181
Ohm’s Law ...................................................................... 183
Series Circuit Laws ......................................................... 185
Parallel Circuit Laws ....................................................... 186
Series – Parallel Circuits ................................................. 188
Circuit Faults ................................................................... 189
Using Test Equipment ..................................................... 190
The Troubleshooting Process ................................... 195
Electrical Symbols .......................................................... 196
Electrical Symbols .......................................................... 197
Electrical Symbols .......................................................... 198
Controller Systems .......................................................... 199
Analog ...................................................................... 199
Digi-Prop (Microwave) ............................................ 199
Comfort Control ....................................................... 199
C32 ........................................................................... 200
CPC .......................................................................... 200
CPC II ...................................................................... 200
Vector - Current Production ..................................... 201
28X Truck and Pumpkit Circuit ...................................... 203
28X Boom Circuit ........................................................... 204
 SERVICE TRAINING
Table of Contents
Misc Procedures
Material Cylinder Alignment .......................................... 205
Pumping on piston side ................................................... 207
(Available on some units only) ................................ 207
Shimming the Differential Cylinders .............................. 208
Determining the proper shimm size ......................... 208
Dimension A ............................................................ 208
Dimension B ............................................................ 208
Formula .................................................................... 209
Apitech Control Chamber Air Bleed Procedure ............. 210
Hydraulic Pump Adjustments ......................................... 213
Main System Pumps A11VO ................................... 213
Setting the Flow Rate ............................................... 213
Horsepower Setting .................................................. 214
Q-min Output Flow .................................................. 214
Check all hydraulic pressures. ................................. 215
Setting pressures on Hi-flo -6 pumpkits .................. 215
Pressure setting procedure: ...................................... 216
Setting the soft switch relief pressure ...................... 217
Accumulator Bypass Retrofit .......................................... 219
Service Bulletin 1001-03 ......................................... 219
Trouble Shooting Kit ...................................................... 220

Training Manual
Table of Contents

Training Manual

The Schwing Group
Schwing America, Inc. is a wholly owned subsidiary of
the Schwing GmbH located in Herne, Germany.
Schwing was founded in Germany in 1934, it has
always been a family owned company and is currently
managed by Gerhard Schwing.
The Schwing Group has grown steadily since its
inception over sixty years. The company is known for
its innovation and worldwide operations. The Groups
primary products are concrete pumps, ready mix trucks
and batch plants. Pumping and boom technologies are
applied to other products as opportunities arise.
Currently the Schwing Group has factories located
around the world at:
• Schwing GmbH, Herne, Germany
• Schwing GmbH, Memmingen, Germany
• Schwing America, Inc., White Bear, USA
• Schwing GmbH, St. Stefan, Austria
• Schwing SIWA, Sao Paulo, Brazil
• Schwing Shanghai, China
• Schwing India
The Schwing group also has numerous sales and
service locations around the world.
Training Manual
SERVICE TRAINING
Schwing America, Inc.
SAI was started in 1974, located in a small office on
Pierce Butler Road. At this time SAI was primarily a
sales, service and parts facility, with the assembly and
some manufacturing subbed out to Telelect. This
arrangement continued until October 1978. Telelect
suffered a prolonged strike, which really hurt SAI. It
was at this time that the Schwing company purchased
the property here at 5900 Centerville Road. This
facility was previously a distribution center for Arctic
Cat snowmobiles, and consisted of 114,000 sq. ft.,
which included a couple pole barns on 16 acres of land.
In 1983, we added 20,000 sq. ft. of production space
and then in 1986 we added 28,000 sq. ft. to this space
introducing our paint facility and testing facility.
Then in 1989, an additional 29 acres of land was
purchased to the North, and our 20,000 sq. ft. weld
shop was constructed. We also worked over one of the
pole barns for our fab facility and trailer assembly
plant. These additions have proven to be a major break
through to make us a complete manufacturing facility.
In 1993 we started on our 28,000 sq. ft. office facility.
In 1995 we completed construction of a 62,000 sq. ft.
state of the art Weld Shop.
In addition, in 1996 we added the 15,000 sq. ft.
1

machining center, which is home of the new Forrest
Line machining Center.
For the year 2000, Schwing America, Inc. has added a
75,000 sq. ft paint booth. This state-of-the-art
behemoth is the largest building in the surrounding
communities. Dubbed the “Super Booth” by industry
insiders. This is the largest facility for painting
concrete pumps in the world. The six-story structure
combines with retractable roof panels to accommodate
unfolded booms. Painters will use catwalks to cover
N S
2 Training Manual
SERVICE TRAINING
every surface with high quality acrylic urethane in an
endless array of colors and paint schemes. Climate
controlled conditions assure proper curing and drying
time. A new solvent recovery system keeps the Super
Booth environmentally friendly.
Today Schwing America has over 326,000 square feet
of manufacturing space and employs over 400 people.
 SERVICE TRAINING

Hydraulic Training
General Principles
1. Hydraulic pressure always takes path of least
resistance.

2. Hydraulic pressure is created equal in all directions

(Pascal's Law).

Pascal's Law

2 A 10 pound force applied

to a stopper with a
1 The bottle is filled
with a liquid, which surface area of one
is not compressible square inch......
3 Results in 10 pounds of force on
every square inch (pressure) of
the container wall

4 If the bottom has an area of 20

square inches and each square
inch is pushed on by 10 pounds
of force, the entire bottom
recieves a 200 pound push.

3. Liquids (oil) are relatively incompressible.

OIL 1000 lbs of Force OIL

AIR 1000 lbs of Force AIR

Training Manual 3
 SERVICE TRAINING

4. When hydraulic pressure and flow is not converted

into work it is converted into heat.

Open relief (Heat)

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

Vacuum formed as Atmospheric pressure

hydraulic oil cools forces water past seals

Seals

Hydraulic Cylinder

Water Box

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

6 bar

4 Training Manual
 SERVICE TRAINING

7. GPM (Gallons Per Minute) only determine the

speed at which the actuator (motor or cylinder)
operates.

0 GPM 10 GPM

8. P.S.I. (Pounds Per Square Inch) determine only the

amount of force exerted upon the load by the actua-
tor.
10,000 LBS
LOAD

10 gallon maximum
capacity cylinder

10 inch of area on
cylinder piston

1000 PSI

Training Manual 5
 SERVICE TRAINING

9. The resistance created in a hydraulic circuit,

whether by the amount of the load on the actuator
and/or the pressure drop in a circuit, is what deter-
mines how much work is required.

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)

GENERAL
Q = FLOW RATE
QxP (unit of volume per time period)
POWER = P = PRESSURE
CONSTANT
(unit of force per unit of area)
U.S.
HP = HORSEPOWER
GPM x PSI GPM = GALLONS PER MINUTE
HP =
1714
PSI = POUNDS PER SQUARE INCH
1714 = KNOWN CONSTANT

METRIC
KW = KILOWATTS
LPM x BAR
KW = LPM = LITERS PER MINUTE
600
BAR = METRIC UNIT OF PRESSURE
600 = KNOWN CONSTANT

6 Training Manual
 SERVICE TRAINING

Mechanical Versus Hydraulic

1. An input force of 3. This pressure will

10 lb.(44.48 N) on a support a 100 lb.
one square inch (444.82 N) weight if
2 this is a 10 sq. in.
(6.45 cm ) piston...
COMPARISON OF MECHANICAL FORCES (64.52 cm2 ) piston.
VERSUS HYDRAULIC FORCES
100 lb.
10 lb. (444.82 N)
2. will balance 100 lb (44.48 N)
1. Ten pounds (44.48 N) here... (444.82 N) here... 1 sq. in.
10 sq. in.
(6.45 cm2 )
(64.51 cm2 )

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

100 lb.
(444.82 N)

10 lb.
(44.48 N)

4. The forces are proportional

INPUT OUTPUT
to the piston areas.

3. if this arm is 10 times 4. this arm.

10 lb. (44.48 N) 100 lb. (444.82 N)
as long as... =
1 sq. in (6.45 cm2) 10 sq. in (64.52 cm2)

A. SIMPLE MECHANICAL LEVER B. SIMPLE HYDRAULIC PRESS

Transfer of Energy
ENERGY CAN NEITHER BE CREATED NOR DESTROYED

1. Moving the small piston 10 in.
0.25 m) displaces 10 cu. in.
(163.87 cm3) of liquid.
(1 sq. in. x 10 in. =10 cu. in.)
(6.45 cm2 x 25.40 cm = 163.87 cm3)
2. 10 cu. in. (163.8 cm3) of liquid
will move the larger piston only
1 in. (2.54 cm)
(10 sq. in. x 1 in. = 10 cu. in.)
(64.52 cm x 2.54 cm = 163.87 cm )

100 lb.
10 lb. (444.82 N)
(44.48 N)
1 sq. in.
(6.45 cm2) 10 sq. in.
(64.51 cm2)
1 in
(0.02 m)

10 in
(0.25 m)

4. The energy transfer here also is

3. The energy transfer here equals 100 in. lb. (11.30 Nm)
10 lb. x 10 in. (44.48 N x 0.25 m) (1 in. x 100 lb. = 100 in. lb.)
or 100 in. lb. (11.30 Nm) (.02 m x 444.82 N = 11.30 Nm)

Training Manual 7
 SERVICE TRAINING

Hydraulic Jack

HYDRAULIC
8"

ROD

PISTON

Linear & Rotary Actuators

LINEAR ACTUATOR ROTARY ACTUATOR

1.The pump pushes the
hydraulic liquid into lines.
4. Rotary actuators or motors
give the system rotating output.
2. Lines carry the liquid to
They can be connected to pulleys,
actuators which are pushed
gears,rack-and-pinions, conveyors, etc.
to cause a mechanical output
to move a load.

MOTOR

PUMP

LOAD
PUMP

PISTON & ROD

TO RESERVOIR ROTARY
DRIVE SHAFT

3. Some actuators operate in

a straight line (linear actuators).
They are called cylinders or rams.
They are used to lift weight, exert
force, clamp, etc.

8 Training Manual
 SERVICE TRAINING

Basic Hydraulic Components

Check Valve

Throttle Valve

Throttle Check Valve

Switching Valve

Training Manual 9
 SERVICE TRAINING

Check Valve Comparison

In-Line Check Valve

Cartridge Check Valve

Right Angle Check Valves

CHECK VALVE CHECK VALVE
COMPLETE COMPLETE
P/N 30333030 P/N 30333031

CARTRIDGE CARTRIDGE
W/SEALS W/SEALS
P/N 30333032 P/N 30333033

SEAL KIT ONLY SEAL KIT ONLY

P/N 30333034 P/N 30333035

TORQUE TORQUE
SPECIFICATION SPECIFICATION
55 ft/lbs. 200 ft/lbs.

10 Training Manual
 SERVICE TRAINING

Shuttle Valve
B
A shuttle valve is used where the higher of the two
pressures must be selected, while blocking the lower
pressure input. A C

A C
The valve has two inlet, ports “A” and “C”, and one
output port “B”. When either port A or C is
pressurized, a ball automatically seals the other inlet
and allows the higher pressure fluid to flow to port “B”.

B B

A C A C

Greater pressure from "A" port Greater pressure from "C" port
39000145.ai

Training Manual 11
 SERVICE TRAINING

Throttle Check Valve

Flow control valve Model MK is pressure, temperature
and viscosity dependent throttle/check valves, used to
restrict flow. It consists of adjustment sleeve (1) and
inner housing (2).

5 4 3 1 6 2

Model MK (Throttle/Check Valve)

This valve is capable of flow control in one direction
while allowing reverse free flow in the opposite. Fluid
passes spring (6), through radial drilling and throttling
area (4). Throttling is achieved similarly to the MG
valve. In the reverse direction, pressure acts on the area
of check valve (5). When pressure exceeds spring force Throttle Check Valve Model MK
(6), the poppet opens, allowing reverse free flow
through the valve. Fluid also passes through the throttle
area (4), thereby flushing contamination from the
valve.
Caution! Do not adjust the valve while under pressure

5 4 6 5 4 6

12 Training Manual
 SERVICE TRAINING

Switching Valves POPPET END PORT

The switching valves have a logic function in that they BODY

sense multiple pressures simultaneously and will route SEAT

O-RING POPPET
oil from the poppet end port to the output port only AND HOUSING
BACK-UP
when the pressure from the poppet end port exceeds the RINGS
pressure at the spring end port by more than 2:1 in
SIDE PORT SIDE POR
most situations (PLUGGED
POPPET
BODY O-RING
SPRING AND
SIDE PORT BACK-UP
RING

SPRING
GUIDE

SPRING END POR

T

SPRING END PORT

SPRING
GUIDE

SPRING

POPPET

POPPET END PORT POPPET

HOUSING

Pressure equal on both sid

es High Pressure pushes poppet backallowing Pressure greater onthe Spring End Port
oil to flow through th
e side port, sending a forcingthe poppet to close
signalto S3

Training Manual 13
 SERVICE TRAINING

Hydraulic Pumps Concrete pump hydraulic pumps

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

PumpKit Pumps

PumpKit Pumps Proportional Boom Pump

Boom Pump
Accumulator Pump

Oil Cooler Pump

Agitator Pump
Stiebel 4194 Stiebel 4400

PumpKit Pumps
Proportional Boom Pump PumpKit Pumps

Proportional Boom Pump

Accumulator Pump

Oil Cooler Pump

Accumulator
Pump

Agitator Pump Agitator Pump

Oil Cooler Pump
Stiebel 4194 InLine Drive
(other options are available)

14 Training Manual
 SERVICE TRAINING

Fixed Displacement Pump Variable Displacement Pump

Rexroth A2F20
Fixed displacement pumps discharge a set volume of
fluid regardless of the system requirements. This
volume can be changed only by changing the drive
speed of the pump. If the system requires less fluid than
the pump is discharging, the balance of the flow must
find an alternate pah which is usually over a relief valve
and back to the reservoir.
Rexroth A7VO
Variable pump with axial tapered piston rotary group
of bent axis design, for open circuit hydraulic drives.
This pump is suitable for mobile applications.
Comprehensive programming of control devices is
available. The robust taper roller drive shaft bearings
are designed to give long service life. Output flow is
proportional to drive speed and pump displacement is
steplessly variable between maximum and zero.

Horse Power Control

(other locations possible)

Q min

Q max

Q min

0ß
25ß -

Q max

Horsepower Adjustment Screw

(other locations possible)

Training Manual 15
 SERVICE TRAINING

Variable Displacement Axial RexrothA11VO

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

Q min

Pressure Cut-off Screw

Q max

16 Training Manual
 SERVICE TRAINING

Rexroth A11VO Adjustments

Pressure Cut-Off
Pressure Cut-Off
Delta P
Q min Q min
Load Sense Port

Q max
Q max

A11VO Accumulator Pump A11VO Boom Pump

Horsepower Control
*Stroke *Stroke Regulation
Regulation **Pressure Cut-Off
Pressure Cut-Off
Horsepower
Control

Style #1

***Pressure Cut-Off

Q min
Horsepower
Q min Control

*Stroke Regulation

* The beginning of stroke regulation has been increased from 5-7 **
bar to 8-10 bar on pumps with the following serial numbers:
A11VO 130 - 21034174, dated 08/22/05
A11VO 190 - 21006318, dated 08/01/05
***
Pumps with serial numbers below these should also have
beginning of stroke regulation pressure set to 8-10 bar.
Style #2
Pressure Cut-Off / Style #1
Turn Clock-wise to increase the pressure
Turn Counter-Clock-wise to decrease the pressure
Pressure Cut-Off / Style #2
Turn Counter-Clock-wise to increase the pressure
Turn Clock-wise to decrease the pressure

A11VO 190/130 Main Pumps

Training Manual 17

Transfer Cases
Hydraulic pumps for the concrete pump, placing boom,
agitator, etc., are usually mounted on a distribution
gearcase. When you are driving the truck, the power of
the truck engine is transmitted through the truck
transmission, through a propeller shaft, through the
bottom of the distribution gearcase, through another
propeller shaft, and into the rear end(s) of the truck.
4194
4400
18 Training Manual
SERVICE TRAINING
When you are operating the unit, the distribution
gearcase interrupts the power to the rear ends, and
transmits it to internal gears that turn the hydraulic
pumps. Changing between travel and pumping modes
is accomplished by means of an air switch in the truck
cab.
4195

Relief Valves
This is a direct acting non adjustable relief valve.
When the oil has enough pressure to over take the
spring the relief poppet will start to move out of the
way and allow the excess pressure to be relieved to
tank. This style pressure relief is not adjustable except
by changing the internal spring.The maximum system
pressure that this style can be used for is limited
because the spring must directly act upon system
pressure and thus higher pressures would require a
larger spring. When this direct acting design relieves it
causes pulsations in the system.
Pressure
Tank
This is a direct acting adjustable relief valve. When
the oil has enough pressure to over take the spring the
relief poppet will start to move out of the way and
allow the excess pressure to be relieved to tank. This
style is adjustable though a external control which
varies the spring tension on the relief poppet.The
maximum system pressure that this style can be used
for is limited because the spring must directly act upon
system pressure and thus higher pressures would
require a larger spring.
Pressure
Tank
Training Manual
SERVICE TRAINING
This is a pilot operated adjustable relief valve. The
relief poppet has a small orifice in it that allows the
hydraulic pressure to also be applied on the back side
of the poppet. This internal chamber is hydraulically
locked and it will hold the main poppet closed as long
as it has equal pressure on the front side and the back
side. There is also a much smaller pilot poppet, that is
operator adjustable. This smaller poppet, with a smaller
area, can have a smaller spring controlling it. Once this
pilot poppet opens we lose our hydraulic lock, the
pressure is reduced on the back side and thus the main
poppet can relieve the excess pressure to tank. With
this design we are able to control large volumes of oil
at high pressures with minimal sized springs.
Pressure
Tank
Pressure
Tank
Pressure
Tank
19
 SERVICE TRAINING

Safety Relief Valves Pressure Relief Valves Type DBW

In principle, the function of this valve is the same as
Pressure control valve type DB/DBW are pilot that of valve type DB. Unloading at the main spool is
operated pressure relief valves. They are used to limit achieved by means of actuating the built-on directional
(DB) or unload by means of solenoids (DBW) pressure control valve.
in a system. Pressure relief valves (DB) consist mainly
of a pilot valve with pressure setting element and main
valve with main spool insert.

Pressure Relief Valve Type DB

Pressure in line A affects the main spool (1). At the

same time there is pressure via control passage (4) and
(5) through orifice (2), (3) and (15) to the spring loaded
side of the main spool (1) and pilot poppet (6). If
system pressure exceeds the value set at the spring (8),
pilot poppet (6) opens.
The oil on the spring loaded side of the main spool (1)
now flows through orifice (3), control passage (5) and
poppet (6), and into spring chamber (9). From here it
flows internally - type DB.-30/.through passage (10),
or externally-type DB.-20/.Y.by means of control port
(11) to tank. Orifices (2), (3) and (15) cause a pressure
drop at the main spool (1), and the connection from
line A to line B opens. The oil now flows from line A to
line B, while the set operating pressure in maintained.
The valve can be unloaded or switched to a different
pressure (second pressure rating) by means of port “X”
(13).

VENT
LINE

20 Training Manual
 SERVICE TRAINING

Hydraulic Symbols

SHOWING DIN (DEUTSCHE INDUSTRIAL NORM) SYMBOLS USED ON SCHWING SCHEMATICS

NO ATTEMPT HAS BEEN MADE TO SHOW EVERY POSSIBLE COMBINATION.

LINE, WORKING
P = R 1/2"
T = R 1/2"
SP = R 3/4"
Nitrogen pressure set at 55 bar G = R 3/8"
(800 PSI) AC = R 11/2"
Y = R 3/8"
G
1.9 mm

LINE, JOINING
S3 ("T" FITTING)

0.8 mm LINE, PASSING

hole drilled SP 190
through bar 138 bar
spool
This line MUST Y
return to tank by
itself.

P T

NG
10 10 Filter
Agitator

2.0 LINE TO RESERVOIR (TANK)

mm
A B
LINE, PILOT or SIGNAL
300
bar

BP 750 & 1000 TC

(with twin cylinder switching and S1 X
P 0-25 bar
Hartman control valves) 2.0 mm
599010
1-95 RE
125 b
bar
Y(T)

A LINE, PLUGGED
P R
RESTRICTION, FIXED
(orifice, nozzle)
100 G Y
bar
0.7 mm
12 Filter
A11VO

LINE, WORKING
LINE, PASSING

LINE, PILOT or SIGNAL LINE TO RESERVOIR (TANK)

(ABOVE FLUID LEVEL)

(BELOW FLUID LEVEL)

CONNECTOR

LINE, PLUGGED

LINE, JOINING
("T" FITTING)
1.3 1.3
RESTRICTION, FIXED
(orifice, nozzle) OR

Training Manual 21
 SERVICE TRAINING

Hydraulic Symbols (Cont.)

RESTRICTION, VARIABLE PUMP, SINGLE

(throttle valve or adjustable orifice) FIXED DISPLACEMENT

MANUAL SHUT-OFF VALVE PUMP, SINGLE

(MANITROL VALVE) VARIABLE DISPLACEMENT

X1
M X2
A
A1
PRIME MOVER,
ELECTRIC MOTOR
PUMP, SINGLE
VARIABLE DISPLACEMENT,
SHOWING HORSEPOWER S
CONTROL CIRCUITS.

PRIME MOVER,
INTERNAL COMBUSTION ENGINE
(Diesel shown..."G" if gas.) MOTOR, ROTARY,
FIXED DISPLACEMENT

MOTOR, ROTARY,
FIXED DISPLACEMENT
BI - DIRECTIONAL

22 Training Manual
 SERVICE TRAINING

Hydraulic Symbols (Cont.)

CYLINDER, SINGLE ACTING PRESSURE GAUGE

CYLINDER, TEMPERATURE GAUGE

DIFFERENTIAL ROD

ACCUMULATOR,
GAS CHARGED

CYLINDER, DOUBLE ACCUMULATOR,

END ROD SPRING LOADED

FILTER OR STRAINER

CYLINDER, DOUBLE END ROD WITH GROOVES IN

PISTON ROD FOR SWITCHING FUNCTION
(ROCK VALVE SHIFTING CYLINDER)

FILTER WITH INTEGRAL 6 bar

BYPASS CHECKVALVE

Training Manual 23
 SERVICE TRAINING

Hydraulic Symbols (Cont.)

OIL COOLER WITH M

ELECTRIC FAN MOTOR HYDRAULICALLY UNLOCKABLE
CHECK VALVE.

OIL COOLER WITH (CLOSED) (OPEN)

HYDRAULIC FAN MOTOR

320 BAR
HYDRAULICALLY UNLOCKABLE
CHECK VALVE WITH INTEGRAL
RELIEF VALVE.
(H.E.R. BOOM HOLDING VALVE)

BASIC VALVE ENVELOPE

PRESSURE SWITCH
NORMALLY CLOSED

NORMALLY OPEN

PRESSURE RELIEF VALVE

(SAFETY VALVE OR
CHECK VALVE (BASIC) SAFETY CARTRIDGE) 280 bar

A 2.0
CHECK VALVE, FIXED FORCE
(SPRING FORCE INDICATED) 300 bar
PRESSURE RELIEF VALVE
WITH EXTERNAL DRAIN
(SHOWN WITH A NORMALLY
OPEN SOLENOID VALVE...
MANY OTHER POSSIBILITIES
ARE AVAILABLE).

ADJUSTABLE CHECK VALVE

(PRETENSION OR PRELOAD VALVE) 6 BAR
(Desired spring force indicated) 300 bar F NR
PRESSURE RELIEF VALVE
WITH EXTERNAL DRAIN

24 Training Manual
 SERVICE TRAINING

Hydraulic Symbols (Cont.)

P 0-55 bar A

Y(T)

A
PRESSURE REDUCING VALVE ACCUMULATOR P Y T
MANUAL (STROKE LIMITER) OR UNLOADING VALVE
DAMPNER

B 70 bar 300
0-50 bar
bar
A
PRESSURE REDUCING VALVE
(ELECTRIC STROKE LIMITER) P
ACCUMULATOR DUMP VALVE
P
(ELECTRIC)
T T

A 55 bar
T

P
T
MG Pressure
P
G
reducing valve A
MY Y
Electric
stroke limiter

1.5

THROTTLE SLEW BRAKE

CHECK VALVE FIXED (size shown) ADJUSTABLE VALVE

P P
A

OLD WAY NEW WAY

CARTRIDGE VALVE
(SWITCHING VALVE) SHUTTLE VALVE
SHOWN 2 DIFFERENT WAYS
P

A
P

Training Manual 25
 SERVICE TRAINING

Hydraulic Symbols (Cont.)

X1
X2
A
A1

COMPONENT ENCLOSURE

BRAKE VALVE
(BERINGER) X A
(USED ON #1 SECTION
DOWN FUNCTION)

BALL COCK
(SHUT OFF VALVE,
QUARTER TURN VALVE)
B

BRAKE VALVE
(COUNTERBALANCE VALVE)
(USED ON ALL SECTIONS KVM 52 & 55)
X A
B
R Z

X A Y
BRAKE VALVE (SAUER)
(USED ON #1 SECTION
DOWN FUNCTION)

Z VENTED RESERVOIR
(TANK)

26 Training Manual
 SERVICE TRAINING

Hydraulic Symbols (Cont.)

DIRECTIONAL CONTROL VALVES

DIRECTIONAL VALVE: METHODS OF OPERATION
BASIC VALVE SYMBOL
MULTIPLE FLOW PATHS
PILOT PRESSURE OR
DIRECTIONAL VALVE
2 POSITION, 3 WAY

DIRECTIONAL VALVE SOLENOID

2 POSITION, 4 WAY

SPRING
DIRECTIONAL VALVE
3 POSITION, 4 WAY, CLOSED CENTER
MANUAL
DIRECTIONAL VALVE (HANDLE OR PUSHBUTTON)
3 POSITION, 4 WAY, OPEN CENTER

DETENT
DIRECTIONAL VALVE
3 POSITION, 4 WAY
CLOSED PRESSURE CENTER

HAND LEVER
DIRECTIONAL VALVE
3 POSITION, 4 WAY, TANDEM CENTER
(REQUIRES A HOLLOW SPOOL) EXAMPLES OF COMBINATIONS OF METHODS

DIRECTIONAL VALVE SOLENOID OPERATED,

3 POSITION, 6 WAY, CLOSED CENTER (10631) SPRING RETURN

DIRECTIONAL VALVE, 3 POSITION,

6 WAY, CLOSED PRESSURE CENTER, HAND LEVER OPERATED
ORIFICED A & B PORTS IN CENTER (10632F) WITH DETENT

DIRECTIONAL VALVE, 3 POSITION,

5 WAY, LOAD SENSING, HAND LEVER OR
CLOSED PRESSURE CENTER, SOLENOID OPERATED,
INFINITE POSITIONING SPRING CENTERED
(PROPORTIONAL)

DIRECTIONAL VALVE, 3 POSITION, SOLENOID CONTROLLED,

5 WAY, LOAD SENSING, PILOT PRESSURE OPERATED,
CLOSED CENTER, SPRING CENTERED,
INFINITE POSITIONING WITH HAND LEVER
(PROPORTIONAL)

X OR

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

Training Manual 27
 SERVICE TRAINING

Formulas

Piston Side Rod Side

R2 R2
= 3.14 = 3.14
R = 1/2 of Diameter R = 1/2 of Diameter

5 2.5
10,000
Pounds

3.14(2.5 x 2.5) = 19.625 3.14(1.25 x 1.25) = 4.90625

3.14 x 6.25 = 19.625 3.14 x 1.5625 = 4.90625

Piston - Rod = Rod Side Area

Area of piston = 19.625
19.625 - 4.90625 = 14.719
19.625
10,000 14.719
Pounds
10,000
Pounds

10,000 = 509.55 10,000 = 679.39

19.625 14.719

To move this load it will take To move this load it will take
about 510 psi about 680 psi

10 GPM x 510 10 GPM x 680

POWER = POWER =
1714 (A Constant) 1714 (A Constant)

5100 6800
= 2.975 HP = 3.967 HP
1714 1714

28 Training Manual
 SERVICE TRAINING

Pumpkits
Single Circuit Pumpkits Twin Circuit Pumpkits

800 1200 w/Switching Valves

801 1200 w/MPS

900/1200 2023 Hi-Flow

Hi-Flow 2525 Hi-Flow

PumpkitCompare.eps

Training Manual 29
 SERVICE TRAINING

800 Gate Valve

30 Training Manual
 SERVICE TRAINING

801 Gate Valve

Training Manual 31
 SERVICE TRAINING

801 Pumpkit Schematic

5
Pipe Gate

Hopper Gate

9B
9A 6

4 3
7

300
bar

10A 10B

D
12A 12B 11C 2 2

11A 11B 6 bar

1 39000156.eps

1. Hydraulic oil reservoir 7. Directional control valve S-2

2. Main hydraulic pumps 8. Locking Valve
3. Main pressure relief valve 9A–9B. Needle valves
4. Directional control valve S-1 (forward/reverse) 10A–10B. Hydraulically Unlockable Check valves
5. Gate Valve 11A–11C. Check valves
6. Directional control valve S-3 12A–12B. Differential Cylinders

32 Training Manual
 SERVICE TRAINING

Concrete Pump Control Block

9B T P1
9A
9B
T
6
S3
S1 4
1.5 mm
hole drilled
through spool 300 B
7
bar
A
S2
3

8 9A

S-1

S-2

S-3

39000155.eps

Training Manual 33
 SERVICE TRAINING

Stroke Limiter

1
P

2 A
4 T

P
3
4 0-50
BAR
1
3

2 T

A
39000158.eps

494 Block

A
agitator
5 motor
3 B
6

P
1 Agitator H2O pump
pressure* motor
2

3 6 A

2 B

H2O
pressure*

1
4
2 1
4

39000157.eps
CA B

34 Training Manual
 SERVICE TRAINING

Hydraulically Unlockable CheckValve

C
B

A
B
C
B 2
1
A
1
C

0.7 2
mm
39000160.eps

Gate Valve

A 1 B D
1

A C
2
D

2
C 39000163.eps

Training Manual 35
 SERVICE TRAINING

36 Training Manual
 SERVICE TRAINING

900-1200 Single Circuit

Single Circuit

Training Manual 37
 SERVICE TRAINING

900-1200 Single Circuit Schematic

900 Pumpkit - eps

10A 10B 11

7 3
4

10D
10C

10E D
9A
2 2
8A 8B

9B 12
10F

1. Hydraulic oil reservoir 8A–8B. Differential hydraulic cylinders

2. Main hydraulic pumps 9A–9B. Switching valves
3. Main pressure relief valve 10A–10F. Check valves
4. Directional control valve S-1 (forward/reverse) 11. Ball cock (Shutoff valve)
5. Rock valve slewing cylinder 12. Hydraulic oil filter with bypass valve (return filter
6. Directional control valve S-3
7. Directional control valve S-2

38 Training Manual
 SERVICE TRAINING

Concrete Pump Control Block

P1
S3 P2

X
10B

P
1.5 mm
T
hole drilled
through spool
6
S1 4

X
R
B
7
300 bar
3 A
S2

10A

Port size
limits flow

S-1

S-2

S-3

39000147.eps

Training Manual 39
 SERVICE TRAINING

Stroke Limiter

1
P

2 A
4 T

P
3
4 0-50
BAR
1
3

2 T

A
39000158.eps

494 Block

A
agitator
5 motor
3 B
6

P
1 Agitator H2O pump
pressure* motor
2

3 6 A

2 B

H2O
pressure*

1
4
2 1
4

39000157.eps
CA B

40 Training Manual
 SERVICE TRAINING

Switching Valve

C
C
B B
2

1
A

2
1

39000161.eps

A7VO

1
A
2 Q min
1
2
B

Q max

X1 A B X1

X2 X2

A A
1 1
A1 A1

D
2 2
To
Boom
Circuit

S S 39000162.eps

Training Manual 41
 SERVICE TRAINING

Rock Valve

1
2
D
A B C
2
A
1
E F GH
B
C
D
F
G
H E

39000164.eps

42 Training Manual
 SERVICE TRAINING

Training Manual 43
 SERVICE TRAINING

Phase A oil of the left hand differential is directed back to tank

First working stroke
With S1 valve (1) in the forward position, and the S2
valve (2) in the left position oil flows to the right hand
differential acting on the rod side. Oil from the piston
side of the right hand differential oil is passed to the
piston side of the left hand differential and the rod side
via valves S2 and S1 and through the filter (7). Oil
directed through the S3 has the rock valve shift
cylinder held in the retracted (right) position so that
concrete from the left hand material cylinder is being
pushed into the delivery pipe line. Concrete from the
hopper is being sucked into the right hand material
cylinder.

KEY
4
High Pressure
Rocking Oil
Low Pressure

Zero Pressure
(Tank, or oil at rest)

12 13 18

3 S3

1.5 mm
hole drilled
through spool S1
300
1 bar

2 S2 10

15
14

20

16
7
5 8
M
6
17 6 bar

44 Training Manual
 SERVICE TRAINING

Phase B (1), filter (7) and back to the hydraulic tank.

End of first working stroke * NOTE: If the left hand differential has not fully
extended at this point due to not enough loop oil, high
The differential cylinders have reached the end of their
pressure oil will continue to flow through check valve
stroke position*. Switching valve (5) is sending a high
(17) on the right hand differential until the left hand
pressure signal to the left hand end cap of S3 valve (3).
differential is fully extended.
Oil from the right hand end cap of the S3 valve (3) is
relieved via check valve (15), the S2 valve (2), S1 valve

KEY
4
High Pressure
Rocking Oil
Low Pressure

Zero Pressure
(Tank, or oil at rest)

12 13 18

3 S3

1.5 mm
hole drilled
through spool S1
300
1 bar

2 S2 10

15
14

20

16
7
5 8
M
6
17 6 bar

Training Manual 45
 SERVICE TRAINING

Phase C cylinder (4) is changed and the right hand side of the
cylinder is getting oil so that the cylinder will extend.
Rock valve cylinder getting oil to extend
Oil from the left hand side of the rock valve shift
High pressure oil from switching valve (5) has now cylinder is routed to tank via valves (3, 1) and filter (7).
shifted the S3 valve (3) fully to the right hand position.
At this point the pressure oil to the rock valve shift

KEY
4
High Pressure
Rocking Oil
Low Pressure

Zero Pressure
(Tank, or oil at rest)

12 13 18

3 S3

1.5 mm
hole drilled
through spool S1
300
1 bar

2 S2 10

15
14

20

16
7
5 8
M
6
17 6 bar

46 Training Manual
 SERVICE TRAINING

Phase D rock valve shift cylinder (4). As the S2 valve (2) shifts
to the right oil from the right hand end cap of the S2
S2 valve getting signal to shift
valve (2) is routed to the hydraulic tank via check valve
The rock valve shift cylinder (4) has now fully (13), valves (3, 1) and the filter (7).
extended. At this point a signal is sent to the left hand
end cap of the S2 valve (2) from a signal port on the

KEY
4
High Pressure
Rocking Oil
Low Pressure

Zero Pressure
(Tank, or oil at rest)

12 13 18

3 S3

1.5 mm
hole drilled
through spool S1
300
1 bar

2 S2 10

15
14

20

16
7
5 8
M
6
17 6 bar

Training Manual 47
 SERVICE TRAINING

Phase E hand differential cylinder. Please note that while the

left hand differential cylinder is starting to retract,
Left hand differential getting oil to move
check valve (17) must close otherwise the right hand
With the S2 valve (2) fully shifted and held in the right differential cylinder will not extend.
hand position, pressure oil is routed through the S1
valve (1) and the S2 valve (2) to the rod side of the left

KEY
4
High Pressure
Rocking Oil
Low Pressure

Zero Pressure
(Tank, or oil at rest)

12 13 18

3 S3

1.5 mm
hole drilled
through spool S1
300
1 bar

2 S2 10

15
14

20

16
7
5 8
M
6
17 6 bar

Note: Check Valve Must Close

48 Training Manual
 SERVICE TRAINING

Phase F
Middle of the second working stroke (diagram 6)
Pressure oil is being routed through the S1 valve (1)
and S2 valve (2) to the rod side of the left hand
differential cylinder causing it to retract. Oil from the
piston side of the left hand differential cylinder is
passed to the piston side of the right hand differential
via the loop hose. The oil on the rod side of the right
hand differential is going through valves (2 and 1),
filter (7) and back to the tank. Oil directed through the
S3 valve has the rock valve shift cylinder held in the
extended position so that concrete from the right hand
material cylinder is being pushed into the delivery pipe
line and concrete from the hopper is being sucked into
the left hand material cylinder.

KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)

12 13 18

3 S3

1.5 mm
hole drilled
through spool S1
300
1 bar

2 S2 10

15
14

20

16
7
5 8
M
6
17 6 bar

Training Manual 49
 SERVICE TRAINING

Phase G
End of second working stroke (diagram 7)
The left hand differential cylinder has now fully
retracted*. Switching valve (6) is sending a high
pressure signal to the right hand end cap of the S3
valve (3). Oil from the left hand end cap of the S3 valve
(3) is relieved via check valve (14), the S2 valve (2), S1
valve (1), filter (7) and back to the hydraulic tank.
* NOTE: If the left hand differential cylinder has not
fully retracted at this point because of to much loop oil,
high pressure oil will continue to flow through check
valve (16) and back to the hydraulic tank until the left
hand differential cylinder is fully retracted.

KEY
4
High Pressure
Rocking Oil
Low Pressure

Zero Pressure
(Tank, or oil at rest)

12 13 18

3 S3

1.5 mm
hole drilled
through spool S1
300
1 bar

2 S2 10

15
14

20

16
7
5 8
M
6
17 6 bar

50 Training Manual
 SERVICE TRAINING

Phase H cylinder is getting oil so that the cylinder will retract.

Oil from the right hand side of the rock valve shift
Rock valve cylinder getting oil to retract cylinder (4) is being routed to tank via valves (3, 1) and
High pressure oil from the switching valve (6) has not filter (7).
shifted the S3 valve (3) fully to the left hand position.
At this point the pressure oil to the rock valve shift
cylinder (4) is changed and the left hand side of the

KEY
4
High Pressure
Rocking Oil

Low Pressure
Zero Pressure
(Tank, or oil at rest)

12 13 18

3 S3

1.5 mm
hole drilled
through spool S1
300
1 bar

2 S2 10

15
14

20

16
7
5 8
M
6
17 6 bar

Training Manual 51
 SERVICE TRAINING

Phase I the rock valve shift cylinder (4). As the S2 valve (2)
shifts to the left oil from the right hand end cap of the
S2 valve getting signal to shift
S2 valve (2) is routed to the hydraulic tank via check
The rock valve shift cylinder (4) has now fully valve (12), valves (3, 1) and filter (7).
retracted. At this point a signal is sent to the right hand
end cap of the S2 valve (2) from a signal port on the on

KEY
4
High Pressure
Rocking Oil

Low Pressure
Zero Pressure
(Tank, or oil at rest)

12 13 18

3 S3

1.5 mm
hole drilled
through spool S1
300
1 bar

2 S2 10

15
14

20

16
7
5 8
M
6
17 6 bar

52 Training Manual
 SERVICE TRAINING

Phase J differential cylinder. Please note that check valve (16)

must close otherwise the right hand differential
Right hand differential getting oil to move cylinder will not retract.
With the S2 valve (2) fully shifted and held in the left
position, pressure oil is routed through the S1 valve (1)
and the S2 valve (2) to the rod side of the right hand

KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)

12 13 18

3 S3

1.5 mm
hole drilled
through spool S1
300
1 bar

2 S2 10

15
14

20

16
7
5 8
M
6
17 6 bar

Training Manual 53
 SERVICE TRAINING

Phase K
First working stroke
Refer to diagram 1 for explanation of first working
stroke.

KEY
4
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)

12 13 18

3 S3

1.5 mm
hole drilled
through spool S1
300
1 bar

2 S2 10

15
14

20

16
7
5 8
M
6
17 6 bar

54 Training Manual
 SERVICE TRAINING

Troubleshooting was completely shifted to the left. This would cause

Differentials start to move before the rock
valve has completely shifted.
If check valve (A) is stuck open, the left hand
differential would start to retract and the right hand
differential would start to extend before the rock valve
some of the concrete from the right hand material
cylinder to be pumped back into the hopper. If the
problem occurred while the right cylinder was
extended and the left cylinder was retracted, check
valve (B) has failed.

KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)

A
OPEN B

S3

1.5 mm
hole drilled
through spool S1
300
bar

S2

6 bar

Training Manual 55
 SERVICE TRAINING

Before rock valve shifts to the right the
unit builds high pressure, left differential
continues to move, right differential has
stopped.
The unit has too much rocking oil and the right hand
differential has reached it’s stop. The left hand
differential continues to get pressure oil to the rod side
so that the excess rocking oil can be exhausted through
check valve (A). As soon as the left hand differential
has fully retracted a signal will be sent out of the
switching valve to S3 valve.

KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)

S3

1.5 mm
hole drilled
through spool S1
300
bar

S2

6 bar

56 Training Manual
 SERVICE TRAINING

Rock valve shifts and as soon as the right hand differential for the start of the next stroke.
differential cylinder shifts the rock valve However since check valve (A) is stuck open and the
shifts again (machine gunning). pressure oil shifts the S3 valve to the right causing the
rock valve to shift to the left. (See diagram 3B).
The rock valve has shifted to the right and a signal
from the rock valve has shifted the S valve to the left.
The pressure oil is supposed to go to the rod side of the

KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)

S3

1.5 mm
hole drilled
through spool S1
300
bar

S2

B
A

Note:
Stuck Open

6 bar

Training Manual 57
 SERVICE TRAINING

Check valve (A) is stuck open and the

pressure oil shifts the S3 valve to the right
causing the rock valve to shift to the left.
After the rock valve shifts to the left a signal is sent to
the S2 valve to shift the direction of the differentials.

KEY
High Pressure
Rocking Oil
Low Pressure

Zero Pressure
(Tank, or oil at rest)

S3

1.5 mm
hole drilled
through spool S1
300
bar

S2

B
A

Note:
Stuck Open

6 bar

58 Training Manual
 SERVICE TRAINING

The differentials are already in the end

position for this mode so a signal is sent
to the S3 valve and the rock valve will shift
again to the right.
Thus we get the machine gun sound and no concrete
output.

KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)

S3

1.5 mm
hole drilled
through spool S1
300
bar

S2

B
A

Note:
Stuck Open

6 bar

Training Manual 59
 SERVICE TRAINING

Rock valve shifts to the right and then the
machine builds high pressure.
After the rock valve is done shifting to the right a
signal is supposed to be sent to the right hand end cap
of the S2 to shift it to the left, however the signal will
not reach the S2 end cap because the ball cock is
closed.
NOTE: If the ball cock was partially closed the
machine would continue to stroke, however there
would be a pressure spike between the time the rock
valve is done shifting and the differential cylinders start
moving.

KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)

Ball Cock

S3

1.5 mm
hole drilled
through spool S1
300
bar

S2

Note:
Stuck Open

6 bar

60 Training Manual
 SERVICE TRAINING

High-Flow Single Circuit 2020/2023

Single Circuit
S3 shifting by signal from Switching valve

Training Manual 61
 SERVICE TRAINING

High-Flow Single Circuit Schematic

5 1

T SP

ZK2 1.3 ZK1

9A

ZS2 1.3 ZS1

9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B

X3

TO STROKE LIMITER PORT "PZ"

A2 B2
A3 B3

10C S3 6 10D
XA1 XB3

1.5
A B

A1 B1

S2 7
XA XB

11 PR

PP

S1 4
XR XP

P2 P1

MP

10E
1.8 T2 T1
1.2
12
3 1.4
300 bar

8A X1
8B 10F
T
1.8
2 2
1

1. Hydraulic oil reservoir 7. Directional control valve S-2

2. Main hydraulic pumps 8A–8B. Differential hydraulic cylinders
3. Main pressure relief valve 9A–9B. Switching Valves
4. Directional control valve S-1 (forward/reverse) 10A–10F. Check valves
5. Rock valve slewing cylinder 11. Ball cock (Shutoff valve)
6. Directional control valve S-3 12. Main flow poppet relief valve

62 Training Manual
 SERVICE TRAINING

Concrete Pump Control Block

A2 B2
A3 B3

6
XA1 S3 XB3 X1 MP P2
T2

P
1.5

R
A B
T

X
R
A1 B1

X
7

A
S2
XA XB
P1
T1

X
A
PR

1
PP

P
P
S1 4
XR XP

P2 P1
XP

X
B
A3

1
MP

T2 T1
XB A2
12 1.2 4
3 B2
5
XB B3
1.4
300 bar
X1
3
T

5 6

Training Manual 63
 SERVICE TRAINING

Switching Manifold

10A 3.5MM Orifice

10B T SP

ZK2 1.3 ZK1

9A
3.5MM Orifice 1.3MM Orifice
ZS2 1.3 ZS1

9C 9B
9C
XA XB

A 3.5 3.5 B
10A 10B
9A
9B X3

MPS_SC.eps

Stroke Limiter with Fast Switch/Dampner

MG2 G2 6
4
Reversing Valve 11
(for Fast Switch) Dampner 3
6 7 20 0.7
bar

0-30
bar
1 9 X1

8 MX1
3.5-40 8
12 bar

2 10 MG1 5
4
2 0.7
MP 3.5-40
bar

9
12
PBP PZ T
10
5

11
1
3

SC_FastSwitchDampner.eps

64 Training Manual
 SERVICE TRAINING

Training Manual 65
 SERVICE TRAINING

The following diagrams A through D show the

switching functions of the concrete pumpkit plumbed
on the ROD SIDE with simplified schematics. The
agitator, boom, and S-1 control circuits are not shown.

Phase A
• Pressure oil (red) flows through the S3 valve (6)
(cross-over position) into the retract side oil port
of the rock slewing cylinder (5).

• The rod of the rock slewing cylinder (5) retracts

(shown in the new position).

• When the slewing cylinder has completely

retracted, the switching groove lines up with the
switching port and routes pressure oil to the right
side end cap of the S2 valve (7).

• The S2 valve (7) moves into the parallel position

(shown in the new position).

• The oil in the left side end cap of the S2 escapes to

tank through thecheck valve (10C.)

• Pressure oil (red) flows through the cross-over

position of the S2 spool (7) into the rod side of the
right side differential cylinder (8B). The cylinder
retracts, which creates a vacuum in the material
cylinder. The right side material cylinder fills with
concrete. (This is called the suction stroke).

• The oil that is forced out of the piston side of the

right differential cylinder flows through a hose
into the piston side of the left differential cylinder
(8A). This oil is called rocking oil (orange).

• The rocking oil forces the left side differential

cylinder (8A) to extend. The concrete in that
material cylinder is pumped out of the machine.
(This is called the pressure stroke).

• The oil from the rod side of the left cylinder is

routed back to the tank. (Green).

• The blue oil, such as the oil in the reservoir, is at

rest, or pressureless.

66 Training Manual
 SERVICE TRAINING

Phase A Hi-Flow Single Circuit

KEY
High Pressure
5 1
Rocking Oil Pressure
Low Pressure
Zero Pressure
(Tank, or oil at rest)

T SP

ZK2 1.3 ZK1

9A
ZS2 1.3 ZS1

9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B
10A 10B
X3

TO STROKE LIMITER PORT "PZ"

10C A2 B2 10D
A3 B3

S3 6
XA1 XB3

1.5
A B

A1 B1

S2 7
11 XA XB

PR

PP

S1 4
XR XP

P2 P1

MP

10E
1.8 T2 T1
1.2 12
8A 8B
3 1.4
300 bar
X1
2 2
1.8
T 1
10F

Training Manual 67
 SERVICE TRAINING

Phase B
• The right side differential cylinder (8B) reaches
bottom dead center. If there is not enough rocking
oil in the loop to bring the left side cylinder to the
top dead center position, oil will be added now
through check valve 10F.

• The left side differential cylinder (8A) reaches top

dead center. As the piston reaches the guide bush-
ing, it exposes a port to the end cap of the reversing
valve (9B), which becomes connected to high pres-
sure oil (red). The left end cap of the reversing
valve (9B) is connected to low pressure oil (green),
so the reversing valve slides into the parallel posi-
tion, sending high pressure oil (red) toward the end
cap of the S3 valve (6).

• The pressure signal reaches the S3 valve (6) end

cap, pushing the valve to the right, which places it
into the cross-over position (shown in the new
position).

• The oil on the right end cap of the S3 valve flows

through the switching valve and back to tank.

• In the parallel position, the S3 valve routes oil to

the extend port of the rock valve slewing cylinder.
The cylinder begins to extend.

• The oil from the left side of the rock slewing

cylinder is routed back to tank.

68 Training Manual
 SERVICE TRAINING

Phase B Hi-Flow Single Circuit

KEY
High Pressure
5 1
Rocking Oil Pressure
Low Pressure
Zero Pressure
(Tank, or oil at rest)

T SP

ZK2 1.3 ZK1

9A
ZS2 1.3 ZS1

9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B
10A 10B
X3

TO STROKE LIMITER PORT "PZ"

10C A2 B2 10D
A3 B3

S3 6
XA1 XB3

1.5
A B

A1 B1

S2 7
11 XA XB

PR

PP

S1 4
XR XP

P2 P1

MP

10E
1.8 T2 T1
1.2 12
8A 8B
3 1.4
300 bar
X1
2 2
1.8
T 1
10F

Training Manual 69
 SERVICE TRAINING

Phase C
• The rock valve slewing cylinder (5) reaches the
top dead center position.

• When the slewing cylinder (5) has completely

extended, the switching groove lines up with the
switching port and routes pressure oil to the left
side end cap of the S2 valve (7).

• The pressure pushes the S2 spool (7) to the right,

placing it into the parallel position (shown in the
new position).

• The oil in the right end cap of the S2 escapes to

tank through the check valve(10D).

• Oil from the pump is routed through the S2 valve

to the rod side of the left hand differential cylinder
8A.

• The left side differential cylinder (8A) begins to

retract. In the material cylinder, concrete begins to
flow in to fill the void left by the retracting rubber
ram. (Suction stroke).

• The oil escaping from the left side differential

cylinder travels through the hose to the piston side
of the right hand differential cylinder (8B),
forcing it to extend. In the material cylinder, the
concrete from stage A is forced out into the
delivery pipeline. (Pressure stroke).

• The oil from the rod side of the right hand

material cylinder is routed through the S2 valve
(7), through the return filter, and back to tank.

70 Training Manual
 SERVICE TRAINING

Phase C Hi-Flow Single Circuit

KEY
High Pressure
5 1
Rocking Oil Pressure
Low Pressure
Zero Pressure
(Tank, or oil at rest)

T SP

ZK2 1.3 ZK1

9A
ZS2 1.3 ZS1

9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B
10A 10B
X3

TO STROKE LIMITER PORT "PZ"

10C A2 B2 10D
A3 B3

S3 6
XA1 XB3

1.5
A B

A1 B1

S2 7
11 XA XB

PR

PP

S1 4
XR XP

P2 P1

MP

10E
1.8 T2 T1
1.2 12
8A 8B
3 1.4
300 bar
X1
2 2
1.8
T 1
10F

Training Manual 71
 SERVICE TRAINING

Phase D
• The left side differential cylinder retracts (8A) to
bottom dead center. The right side differential
cylinder extends to top dead center (shown in their
new positions).

• Any excess rocking oil is routed to the tank across

check valve 10E.

• When the right side differential cylinder is in the

bottom dead center position, pressure is applied to
the left end cap of the reversing valve 9A. The
right end cap of the reversing valve is connected
to low pressure, so the valve slides into the
parallel position. The reversing valve routes the
pilot signal to the right side end cap of the S3
valve (6).

• The S3 valve moves to the left in response to the

pilot signal, putting it into the cross-over position
(shown in the new position). The oil in the left
side end cap of the S2 escapes to tank across
check valve (10D).

• Pressure oil is routed through the S3 valve to the

retract port of the rock slewing cylinder.

• The rock cylinder retracts (5), sending the extend

side oil back to tank through the S3 spool.

• When the rock cylinder reaches bottom dead

center, the switching groove lines up with the
switching port and oil is routed to the right end
cap of the S2 valve.

This brings us back to phase A. The machine has made

one complete cycle, which consists of 2 suction strokes
and 2 pressure stroke.

72 Training Manual
 SERVICE TRAINING

Phase D Hi-Flow Single Circuit

KEY
High Pressure
5 1
Rocking Oil Pressure
Low Pressure
Zero Pressure
(Tank, or oil at rest)

T SP

ZK2 1.3 ZK1

9A
ZS2 1.3 ZS1

9B
XA XB
TO STROKE LIMITER PORT "PBP"
A 3.5 3.5 B

X3

TO STROKE LIMITER PORT "PZ"

10C A2 B2 10D
A3 B3

S3 6
XA1 XB3

1.5
A B

A1 B1

S2 7
11 XA XB

PR

PP

S1 4
XR XP

P2 P1

MP

10E
1.8 T2 T1
1.2 12
8A 8B
3 1.4
300 bar
X1
2 2
1.8
T 1
10F

Training Manual 73

Twin Circuits
Beginning in 1995, most units became available with
optional twin circuit switching. “Twin Circuit” refers
to the fact that there is one hydraulic circuit to move
the differential cylinders, and another separate circuit
to switch the rock valve. On single circuit units, the
main hydraulic pumps move the main differential
cylinders AND the rock valve.
There are certain advantages to having a separate
hydraulic circuit to switch the rock valve. For example,
under the single circuit system, if you were pumping a
stiff, lean mix and pressure was running high, it would
also take quite a bit of pressure to switch the rock
valve. There were even a few isolated cases where the
rock valve wouldn’t switch because there wasn’t
enough pressure available, usually when pumping
straight up. The reason that it was hard to switch the
rock valve was because the valve had to try to dislocate
a column of concrete that still had pressure on it from
the stroke. The next stroke could not begin until the
rock valve had completed it’s travel.
When using twin circuit, the differential cylinders do
not have to wait for the rock valve before they change
directions and begin the next stroke. As soon as the S-3
spool changes directions, which gives the rock valve
Single Circuit
S1
S2
S3
74 Training Manual
SERVICE TRAINING
the oil to change directions, oil is also routed to the
valve that changes the direction of the differential
cylinders. If the rock valve cylinder has enough
pressure available to switch, it will do so. If not, it will
wait. As soon as the differential cylinders have changed
directions, one of the following things will happen:
If the rock valve has already switched, concrete will
immediately be drawn from the hopper, and pushed
into the pipeline, which is just a normal stroke.
If the rock valve has NOT already switched, concrete
will begin to be drawn from the pipeline and pushed
into the hopper. This reduces the pressure in the
pipeline to zero. As soon as pressure in the pipeline is
relieved, the rock valve switches across. It doesn’t slam
and it doesn’t pound, it just moves. As soon as the rock
valve has moved, concrete is accelerating out of the
unit like normal.
The concrete is not actually pumped in reverse,
because as soon as the pressure in the pipeline drops to
zero, the rock valve switches. A complete description
of the twin circuit switching sequence is found in this
chapter starting on page 56. This system has the added
benefit of reducing wear on the cutting ring, the
spectacle plate, the kidney seal and kidney plate, as
well as the rock valve slewing cylinder.
S1
S2 Twin Circuit
S3
 SERVICE TRAINING

1200 Twin Circuit with Switching Valves

Twin Circuit with Switching Valves

S3 switching by signal from switching Soft switch pressure is used to switch
valves S3

Accumulator oil switches the rock Rock may or may not shift at the
same time as the differential cylinders

Training Manual 75
 SERVICE TRAINING

Twin Circuit Schematic w/Soft Switch

14

5 1

11 19

S3 6 15
16
8A 8B 17
9A
18
10C
1
10D 1

9B

22 NG
10B 10A 10 13

23
7 1
4
S2

S1 3
0.7 mm

21

24 12

2 20
1

1. Hydraulic oil reservoir 13. Accumulator unloading valve

2. Main hydraulic pump 14. Accumulator
3. Main pressure relief valve 15. Electric accumulator dump valve
4. Directional control valve S-1 16. Manual accumulator dump valve
5. Rock valve slewing cylinder 17. Accumulator shutoff valve
6. Directional control valve S-3 18. Accumulator safety relief valve
7. Directional control valve S-2 19. Accumulator pressure gauge
8A–8B. Differential hydraulic cylinders 20. Accumulator hydraulic pump
9A–9B. Switching valves 21. Accumulator circuit filter
10A–10D. Check valves 22. NG 10 valve for forward/reverse
11. Ball cock 23. Shuttle Valve
12. Hydraulic oil filter with bypass valve (return filter) 24. Soft Switch Valve

76 Training Manual
 SERVICE TRAINING

Concrete Pump Control Block

P1
P2

X
P
S1 4
T

7 3
300 bar
B

X
S2

R
Port size
A
limits flow

S-1

2
S-2

39000148.eps

S3 Control Block

6
S3

39000149.eps

Training Manual 77
 SERVICE TRAINING

Soft Switch

2
4

3
1

0.7 mm

3 2

80
bar

Soft switch

39000151.eps

Accumulator Unloader Valve

A
2

1
1

2
P Y T

39000153.eps

78 Training Manual
 SERVICE TRAINING

Accumulator Control Block/Dump Valve

1
2
Nitrogen pressure set
7 at 100 bar (1450 PSI)

3 Accumulator control device

4 2 300 1
3 bar

5
6
6

T Y P
5
7

39000152.eps

Accumulator Pump

200 bar
A11 A10
39000154.eps
1

Training Manual 79
 SERVICE TRAINING

The following diagrams A through D show the
switching functions of the concrete pumpkit plumbed
on the ROD SIDE with simplified schematics. The
agitator, boom, and S-1 control circuits are not shown.
Phase A
• As soon as you switch the unit distribution
gearcase to the pumping position, the accumulator
hydraulic pump (20) begins pumping high
pressure oil (red) to charge the accumulator circuit
(14).
• The high pressure oil (red) from the accumulator
circuit charges the accumulator (14). When the
accumulator pressure reaches the setting of the
accumulator dump valve (13), the accumulator
dump valve opens and routes the oil from the
accumulator charge pump (20) back to the
reservoir (1).
• The oil that is forced out of the piston side of the
right differential cylinder (8B) flows through
hoses into the piston side of the left differential
cylinder (Item 8A). This oil is called rocking oil
(orange).
• The rocking oil forces the left side differential
cylinder (8A) to extend. The cylinder rod extends,
pushing concrete out of the material cylinder,
through the rock valve, and into the pipeline. (This
is called the pressure stroke.)
• The oil from the rod side of the left differential
cylinder (8A) is routed back to the tank through
the return filter (12). The low pressure oil is shown
in green.
• The oil shown in blue, such as the oil in the
reservoir, is at rest, or pressureless.

• The high pressure oil (red) from the accumulator

circuit flows through the S3 directional control
valve (6), which is in the parallel position, into the
retract side oil port of the rock slewing cylinder
(5).

• The rod of the rock slewing cylinder (5) retracts, if

it is not already retracted.

• The S1 directional control valve (4), which

controls whether the unit pumps in forward,
neutral, or reverse, is put into the forward
position.

• A pilot signal (high pressure oil) is routed from

the accumulator circuit to the right-side end cap of
the S2 directional control valve (7), which moves
into the parallel position.

• High pressure oil (red) flows from the main

hydraulic pump (2) through the parallel position
of the S2 valve (7) into the rod side of the right-
side differential cylinder (8B). The cylinder
retracts, which creates a vacuum in the material
cylinder. The right-side material cylinder fills with
concrete. (This is called the suction stroke.)

80 Training Manual
 SERVICE TRAINING

6.3
Phase A Twin Circuit
mm

14
Nitrogen pressure
5 1 set at 100 bar
6.3 (1450 PSI)
mm

19
11
S3 15
16
8A 8B 17
9A 6 300
bar
18
10C
1
10D 1
9B

22 NG
10 13
10B 10A
T
200
bar

Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2

S1 320 3
0.7 mm bar

21
KEY
High Pressure
12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1

Training Manual 81
 SERVICE TRAINING

Phase B

• The right-side differential cylinder (8B) reaches

bottom dead center. If there is not enough rocking
oil in the loop to bring the left-side differential
cylinder (8A) to the top dead center position, oil is
added now through check valve 10D.

• The left-side differential cylinder (8A) reaches top

dead center. As the piston reaches the guide
bushing, it exposes a port to the poppet end port of
the switching valve (9A), which becomes
connected to high pressure oil (red). The spring
end port of the switching valve (9A) is connected
to low pressure oil (green), so the switching valve
opens, sending high pressure oil (red) toward the
left-side end cap of the S3 valve (6).

• The pressure signal reaches the S3 valve end cap

(6), pushing the valve to the right, which places it
into the crossover position.

• The oil on the right end cap of the S3 valve (6)

flows through the check valve (Item 10B) back to
tank (1).

• In the crossover position, the S3 valve (6) routes

oil from the accumulators to the extend port of the
rock valve slewing cylinder (5). The cylinder
begins to extend.

• The oil from the left side of the rock valve slewing
cylinder (5) is routed back to tank (1).

• A pilot signal (high pressure oil) is routed from

the accumulator circuit to the left-side end cap of
the S2 directional control valve (7). The S2 valve
slides to the right, into the crossover position.

• As the rock valve slewing cylinder (5) extends,

pressure in the accumulator circuit falls. When it
drops below the set point of the accumulator
dump valve (13), the dump valve closes, and the
accumulator hydraulic pump (20) begins to
recharge the accumulator circuit.

82 Training Manual
 SERVICE TRAINING

6.3
Phase B Twin Circuit
mm

14
Nitrogen pressure
5 1 set at 100 bar
6.3 (1450 PSI)
mm

11 19

S3 15
16
8A 8B 17
9A 6 300
bar
18
10C
1
10D 1

9B
P

22 NG
10B 10A 10 13
T
200
bar

Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2

S1 320 3
0.7 mm bar

21
KEY
High Pressure
12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
28X 1200 TCphaseAoriginal

Training Manual 83
 SERVICE TRAINING

Phase C
• The rock valve slewing cylinder (5) reaches the
top dead center position.

• High pressure oil (red) continues to flow into the

accumulator circuit until the accumulators (14)
are fully charged to the pressure preset at the
accumulator dump valve (13). The accumulator
dump valve opens, sending oil from the
accumulator hydraulic pump (20) back to the tank
(1) without pressure.

• The S2 valve (7) has finished sliding to the right.

Oil is now routed from the main hydraulic pump
(2) to the rod side of the left-hand differential
cylinder (8A).

• As the left-hand differential cylinder (8A) moves,

high pressure oil (red) reaches the spring end port
of the switching valve (9A). The valve closes by
the pressure applied to the spring end port. This
removes the pilot signal to the left side of the S3
directional control valve (6).

• As the left-side differential cylinder (8A) retracts,

it creates a void in the material cylinder and
concrete begins to flow in to fill that void (suction
stroke.)

• The oil from the piston side of the left-side

differential cylinder (8A) travels through the hoses
to the piston side of the right-hand differential
cylinder (8B), forcing it to extend. In the material
cylinder, the concrete from stage A is forced out
into the delivery pipeline (pressure stroke).

• The oil from the rod side of the right-hand

differential cylinder (8B) is routed through the S2
valve (7), through the return filter (12), and back
to tank (1).

84 Training Manual
 SERVICE TRAINING

6.3
Phase C Twin Circuit
mm

14
Nitrogen pressure
5 1 set at 100 bar
6.3 (1450 PSI)
mm

11 19

S3 15
16
8A 8B 17
9A 6 300
bar
18
10C
1
10D 1
9B

22 NG
10B 10A 10 13
T
200
bar

Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2

S1 320 3
0.7 mm bar

21
KEY
High Pressure
12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1
28X 1200 TCphaseAoriginal

Training Manual 85
 SERVICE TRAINING

Phase D

• The left-side differential cylinder (8A) retracts to

bottom dead center. The right- side differential
cylinder (8B) extends to top dead center.

• Any excess rocking oil (orange) is routed to the

tank (1) across check valve 10C.

• When the left-side differential cylinder is in the

bottom dead center position, pressure is applied to
the poppet end port of the switching valve 9B. The
switching valve opens and sends a pilot signal to
the right-side end cap of the S3 valve (6).

• The S3 valve (6) moves to the left in response to

the pilot signal, putting it into the parallel
position. The oil in the left-side end cap of the S3
valve (6) escapes to tank (1) across check valve
10A.

• High pressure oil (red) is routed from the

accumulator circuit through the S3 valve (6) to the
retract port of the rock valve slewing cylinder (5).

• The rock valve slewing cylinder (5) retracts,

sending the extend side oil back to tank (1)
through the S3 valve (6) and the return filter (12).

• When the rock valve slewing cylinder (5) reaches

bottom dead center, the switching groove lines up
with the switching port and oil is routed to the
right end cap of the S2 valve (7).

• As the rock slewing cylinder (5) extends, pressure

in the accumulator circuit falls. When it drops
below the set point of the accumulator dump valve
(13), the dump valve closes and the accumulator
hydraulic pump (20) begins pumping pressure oil
(red) to charge the accumulator circuit (14).

• This brings us back to Phase A. The machine has

made one complete cycle, which consists of two
suction strokes and two pressure strokes.

86 Training Manual
 SERVICE TRAINING

6.3
Phase D Twin Circuit
mm

14
Nitrogen pressure
5 1 set at 100 bar
6.3 (1450 PSI)
mm

11 19

S3 15
16
8A 8B 17
9A 6 300
bar
18
10C
1
10D 1
9B

22 NG
10B 10A 10 13
T
200
bar
Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2

S1 320 3
0.7 mm bar

21
KEY
High Pressure
12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1

Training Manual 87
 SERVICE TRAINING

88 Training Manual
 SERVICE TRAINING

1200 Twin Circuit with MPS

Twin Circuit with MPS

Soft Switch

Training Manual 89
 SERVICE TRAINING

Twin Circuit with MPS/Soft Switch

14

5 1

19
11
S3 15
16
8A 8B 17
6
9A
18
10C
1
10D 1

9B

22

23 NG
10 13
10B 10A

25
7 4 1

S2

S1
0.7 mm 3
21

12
24

2 20
1

1. Hydraulic oil reservoir 13. Accumulator unloading valve

2. Main hydraulic pump
3. Main pressure relief valve
4. Directional control valve S1
5. Rock Valve slewing cylinder
6. Directional control valve S3
7. Directional control valve S2
8A - 8B. Differential hydraulic cylinders
9A - 9B. Reversing valves (MPS)
10A - 10D. Check valves
11. Main shutoff valve (Ball cock)
12. Hydraulic return filter with bypass valve
14. Accumulator
15. Electric accumulator dump valve
16. Manual accumulator dump valve
17. Accumulator shutoff valve
18. Accumulator safety relief valve
19. Accumulator pressure gauge
20. Accumulator hydraulic pump
21. Accumulator circuit filter
22. Accumulator redundant relief valve
23. NG 10 valve for forward/reverse
24. Soft Switch valve
25. Shuttle valve

90 Training Manual
 SERVICE TRAINING

Concrete Pump Control Block

P1
P2

X
P
S1 4
T

7 3
300 bar
B

X
S2

R
Port size
A
limits flow

S-1

2
S-2

39000148.eps

S3 Control Block

6
S3

39000149.eps

Training Manual 91
 SERVICE TRAINING

MPS

1 5
3
2 4

S3
1
3


   

    
 
  
  
 

 
3

2 4 NG
10



5 5 




92 Training Manual
 SERVICE TRAINING

Accumulator Control Block/Dump Valve

1
2
Nitrogen pressure set
7 at 100 bar (1450 PSI)

3 Accumulator control device

4 2 300 1
3 bar

5
6
6

T Y P
5
7

39000152.eps

Accumulator Pump

200 bar
A11 A10
39000154.eps
1

Training Manual 93
 SERVICE TRAINING

Soft Switch

2
4

3
1

0.7 mm

3 2

80
bar

Soft switch

39000151.eps

94 Training Manual
 SERVICE TRAINING

Training Manual 95
 SERVICE TRAINING

The following diagrams A through D show the
switching functions of the concrete pump kit plumbed
on ROD SIDE with simplified schematics. The agitator,
boom, and S-1 control circuits are not shown.
Phase A
• As soon as you switch the unit distribution
gearcase to the pumping position, the accumulator
hydraulic pump (20) begins pumping high
pressure oil (red) to charge the accumulator circuit
(14).
• The high pressure oil (red) from the accumulator
circuit charges the accumulator (14). When the
accumulator pressure reaches the setting of the
accumulator dump valve (13), the accumulator
dump valve opens and routes the oil from the
accumulator charge pump (20) back to the
reservoir (1).
• The oil that is forced out of the piston side of the
right differential cylinder (8B) flows through
hoses into the piston side of the left differential
cylinder (item 8A). This oil is called rocking oil
(orange).
• The rocking oil forces the left side differential
cylinder (8A) to extend. The cylinder rod extends,
pushing concrete out of the material cylinder,
through the rock valve, and into the pipeline. (This
is called the pressure stroke.)
• The oil from the rod side of the left differential
cylinder (8A) is routed back to the tank through
the return filter (12). The low pressure oil is shown
in green.
• The oil shown as blue is at rest, or pressureless,
such as the oil in the reservoir.

• The high pressure oil (red) from the accumulator

circuit flows through the S3 directional control
valve (6), which is in the parallel position, into the
retract side oil port of the rock slewing cylinder
(5).

• The rod of the rock slewing cylinder (5) retracts, if

not already retracted.

• The S-1 directional control valve (4), which

controls whether the unit pumps in forward,
neutral, or reverse, is put into the forward
position.

• A pilot signal (high pressure oil) is routed from

the accumulator circuit to the right side end cap of
the S2 directional control valve (7), which moves
into the parallel position.

• High pressure oil (red) flows from the main

hydraulic pump (2) through the parallel position
of the S2 valve (7) into the rod side of the right
side differential cylinder (8B). The cylinder
retracts, which creates a vacuum in the material
cylinder. The right side material cylinder fills with
concrete. (This is called the suction stroke.)

96 Training Manual
 SERVICE TRAINING

Phase A MPS Twin Circuit

6.3
mm 14
Nitrogen pressure
set at 100 bar
(1450 PSI)
5 1
6.3
mm
19
11
S3 15
16
8A 8B 17
6 300
9A bar
T P
18
B A 1.0 mm 10C
1
T P 1.0 mm 10D 1
B A

9B
To e-stop
manifold
22 P

NG 250 bar
23
10 13
10B 10A
T
200
bar

Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2

320
bar
3
S1
0.7 mm

21
KEY
High Pressure 12
Rocking Oil Pressure
Low Pressure 20
2
Zero Pressure
(Tank, or oil at rest) 1

Training Manual 97
 SERVICE TRAINING

Phase B
• The right side differential cylinder (8B) reaches
bottom dead center. If there is not enough rocking
oil in the loop to bring the left side differential
cylinder (8A) to the top dead center position, oil is
added now through check valve 10D.

• The left side differential cylinder (8A) reaches top

dead center. As the piston reaches the guide
bushing, it exposes a port to the poppet end port of
the switching valve (9A), which becomes
connected to high pressure oil (red). The spring
end port of the switching valve (9A) is connected
to low pressure oil (green), so the switching valve
opens, sending high pressure oil (red) toward the
left side end cap of the S3 valve (6).

• The pressure signal reaches the S3 valve end cap

(6), pushing the valve to the right, which places it
into the cross-over position.

• The oil on the right end cap of the S3 valve (6)

flows through the check-valve (item 10B) back to
tank (1).

• In the cross-over position, the S3 valve (6) routes

oil from the accumulators to the extend port of the
rock valve slewing cylinder (5). The cylinder
begins to extend.

• The oil from the left side of the rock valve slewing
cylinder (5) is routed back to tank (1).

• A pilot signal (high pressure oil) is routed from

the accumulator circuit to the left side end cap of
the S2 directional control valve (7). The S2 valve
slides to the right, into the cross-over position.

• As the rock valve slewing cylinder (5) extends,

pressure in the accumulator circuit falls. When it
drops below the set point of the accumulator
dump valve (13), the dump valve closes, and the
accumulator hydraulic pump (20) begins to
recharge the accumulator circuit.

98 Training Manual
 SERVICE TRAINING

Phase B MPS Twin Circuit

6.3
mm 14
Nitrogen pressure
set at 100 bar
(1450 PSI)
5 1
6.3
mm
19
11
S3 15
16
8A 8B 17
6 300
9A bar
T P
18
B A 1.0
mm
10C
1.0 1
T P mm 10D 1
B A

9B
To e-stop
manifold
22 P

NG 250 bar
23
10 13
10B 10A
T
200
bar

Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2

320
bar
3
S1
0.7 mm
To e-stop
manifold
21
KEY
High Pressure 12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1

Training Manual 99
 SERVICE TRAINING

Phase C
• The rock valve slewing cylinder (5) reaches the
top dead center position.

• High pressure oil (red) continues to flow into the

accumulator circuit until the accumulators (14)
are fully charged to the pressure preset at the
accumulator dump valve (13). The accumulator
dump valve opens, sending oil from the
accumulator hydraulic pump (20) back to the tank
(1) without pressure.

• The S2 valve (7) has finished sliding to the right.

Oil is now routed from the main hydraulic pump
(2) to the rod side of the left hand differential
cylinder (8A).

• As the left hand differential cylinder (8A) moves,

high pressure oil (red) reaches the spring end port
of the switching valve (9A). The valve closes by
the pressure applied to the spring end port. This
removes the pilot signal to the left side of the S3
directional control valve (6).

• As the left side differential cylinder (8A) retracts,

it creates a void in the material cylinder and
concrete begins to flow in to fill that void.
(Suction stroke.)

• The oil from the piston side of the left side

differential cylinder (8A) travels through the hoses
to the piston side of the right hand differential
cylinder (8B), forcing it to extend. In the material
cylinder, the concrete from stage A is forced out
into the delivery pipeline. (Pressure stroke.)

• The oil from the rod side of the right hand

differential cylinder (8B) is routed through the S2
valve (7), through the return filter (12), and back
to tank (1).

100 Training Manual

 SERVICE TRAINING

Phase C MPS Twin Circuit

6.3
mm 14
Nitrogen pressure
set at 100 bar
(1450 PSI)
5 1
6.3
mm
19
11
S3 15
16
8A 8B 17
6 300
9A bar
T P
18
B A 1.0
mm
10C
1.0 1
T P mm 10D 1
B A

9B
To e-stop
manifold
22 P

NG 250 bar
23
10 13
10B 10A
T
200
bar

Y P
0.7 0.7
mm mm
2.5 mm
7 2.5 mm 1
4
S2

320
bar
3
S1
0.7 mm

21
KEY
High Pressure 12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1

Training Manual 101

 SERVICE TRAINING

Phase D

• The left side differential cylinder (8A) retracts to

bottom dead center. The right side differential
cylinder (8B) extends to top dead center.

• Any excess rocking oil (orange) is routed to the

tank (1) across check valve 10C.

• When the left side differential cylinder is in the

bottom dead center position, pressure is applied to
the poppet end port of the switching valve 9B. The
switching valve opens and sends a pilot signal to
the right side end cap of the S3 valve (6).

• The S3 valve (6) moves to the left in response to

the pilot signal, putting it into the parallel
position. The oil in the left side end cap of the S3
valve (6) escapes to tank (1) across check valve
10A.

• High pressure oil (red) is routed from the

accumulator circuit through the S3 valve (6) to the
retract port of the rock valve slewing cylinder (5).

• The rock valve slewing cylinder (5) retracts,

sending the extend side oil back to tank (1)
through the S3 valve (6) and the return filter (12).

• When the rock valve slewing cylinder (5) reaches

bottom dead center, the switching groove lines up
with the switching port and oil is routed to the
right end cap of the S2 valve (7).

• As the rock slewing cylinder (5) extends, pressure

in the accumulator circuit falls. When it drops
below the set point of the accumulator dump valve
(13), the dump valve closes and the accumulator
hydraulic pump (20) begins pumping pressure oil
(red) to charge the accumulator circuit (14).

• This brings us back to phase A. The machine has

made one complete cycle, which consists of two
suction strokes and two 0pressure strokes.

102 Training Manual

 SERVICE TRAINING

Phase D MPS Twin Circuit

6.3
mm 14
Nitrogen pressure
set at 100 bar
(1450 PSI)
5 1
6.3
mm
19
11
S3 15
16
8A 8B 17
6 300
9A bar
T P
18
B A 1.0
mm
10C
1.0 1
T P mm 10D 1
B A

9B
To e-stop
manifold
22 P

NG 250 bar
23
10 13
10B 10A
T
200
bar

Y P
0.7 0.7
2.5 mm
7 2.5 mm
mm mm
1
4
S2

320
bar
3
S1
0.7 mm

21
KEY
High Pressure 12
Rocking Oil Pressure
Low Pressure
2 20
Zero Pressure
(Tank, or oil at rest) 1

Training Manual 103

 SERVICE TRAINING

Twin Circuit with Variable displacement

accumulator pump Schematic

6.3
mm 14
Nitrogen pressure
set at 100 bar
(1450 PSI)
5 1
6.3
mm
19
11
S3 15
16
8A 8B 17
6 300
9A bar
T P
18
B A 1.0
mm
10C
1.0 1
T P mm 10D 1
B A

9B
To e-stop
manifold
22
NG 250 bar
23
10
10B 10A

0.7 0.7
2.5 mm
7 2.5 mm
mm mm
1
4
S2

S1 320 3
bar

To e-stop
manifold
21

12

2 20
1
TCVariable.ai

104 Training Manual

 SERVICE TRAINING

Model Number Nomenclature

The complete model number of Schwing America’s
concrete pumps is designated by codes like the
following: S 58 SX -125 BPL 2525H-5 120/85MPS
The code is broken down as follows:

S 58 SX - 125 BPL 2525H-5 120/85MPS

The break down is as follows:

S 58 SX- 125
Boom pipe diameter in millimeters
Outrigger design Super X
Vertical Boom reach in meters
Manufacture Schwing

BPL 2525H-5 120/85MPS

Truck mounted concrete pump (Beton Pumpe Lastkraftwagen)

Pump stroke length in meters 2.5 m
Material cylinder diameter millimeters 250 mm
Factory set up to run on the piston side
Liters of hydraulic oil per minute 500 +
Hydraulic piston diameter 120 mm
Diameter of the piston rod 85 mm
Twin circuit pumpkit

Training Manual 105

 SERVICE TRAINING

Hi-Flow Pumpkits (2023-2525)

106 Training Manual

 SERVICE TRAINING

Hi-Flow Pumpkits (2525H)

Piston Side Operation

Optional Waterbox Switching

Training Manual 107

 SERVICE TRAINING

Hi-Flow Pumpkits Schematic

S3 6

13
16 14 17
15 18
P

9A

9B

20
10A 10B

11

S2 7

S1 4

24

3
10C
22 12
21
1.1 23 10D 2
8A 8B
T
19
1

1. Hydraulic oil reservoir 13. Accumulator

2. Main hydraulic pumps 14. Pilot to close accumulator dump valve
3. Main pressure relief valve 15. Manual accumulator dump valve
4. Directional control valve S1 16. Accumulator pressure maintenance check valve
5. Rock valve slewing cylinder 17. Accumulator relief valve
6. Directional control valve S3 18. Accumulator pressure gauge
7. Directional control valve S2 19. Accumulator hydraulic pump
8A - 8B. Differential hydraulic cylinders 20. NG 10 valve for forward/reverse
9A - 9B. Reversing valves (MPS) 21. Soft switch relief valve
10A - 10D. Check valves 22. Soft switch shutoff valve
11. Main shutoff valve (Ball cock) 23. Soft switch reversing valve
12. Hydraulic return filter with bypass valve 24. Main flow poppet valve

108 Training Manual

 SERVICE TRAINING

Concrete Pump Control Block

A B

A1 B1
3.0 3.0
mm
XA S2 XB mm

PR
7 PP
0.7
mm
X3 P2
T2
0.7 4
mm
XR
S1 XP

P X
R R
P2 P1

MP T
X1
T2

24
1.2
T1
P1

P
A 1.4 MX

P
350 bar

3 22
X1

X2
XA
80 bar

A
X3
21
B
1.1

23
XB
T

24

A 3

23
21

The standard Schwing control block has used up to 560 for compact simpler design
LPM of oil. We have developed a new control block The twin circuit machines with G-3 control block will
designed for 800 LPM of oil. Called G-3 for 3rd also use the condensed version accumulator (only one
Generation Control Block and is also known as the Hi- larger one).
Flow Brain.
This block incorporates the soft switch into the relief
valve and the accumulator manifold valve into the S-3,

Training Manual 109

 SERVICE TRAINING

Main Relief/Soft Switch Block

1 1.4 MX
350 bar

X1
2
6 X2
80 bar

X3
4 1.1
5

6
4

5
1

39000213.eps

110 Training Manual

 SERVICE TRAINING

MPS

10A 3.5MM Orifice

10B

3.5MM Orifice 1.3MM Orifice

9A

9C
9B
9C

9A 10A 10B
9B

The MPS system is an important part of the twin circuit cylinders to switch with a minimum delay. The S3
system incorporated in the Hi-flo pump kit. The MPS block and the system accumulator are separated from
system consists of three small directional control the main control block and located above the hopper
valves mounted in a manifold. This replaced the two end of the material cylinders. Access to these
switching valves that were located on the passenger components is facilitated by removing the decking
side differential cylinder. The main pressure that is between the water box and the rear boom rest.
supplied to these directional control valves is supplied
by the accumulator. This means we are using
accumulator pressure to switch the S3 valve. The end
result is a faster, more consistent switch.
The faster switch of the S3 valve allows the differential

Training Manual 111

 SERVICE TRAINING

S3 Control Block - Machined

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
Psp

M
Mp1

X
2.0 T
mm 6 300 Mp
bar
T
P
3 4 5
P
PS
2

3
6

2 4

S0153.eps

112 Training Manual

 SERVICE TRAINING

S3 Control Block - Cast

1
B
X
3
B
A3 A2 B2 B3
B
XA1
1
S3 A
XB1

2
P
1 A

S
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

5
S0154.eps

Training Manual 113

 SERVICE TRAINING

2023 Circuit diagram
The following diagrams A through D show the
switching functions of the fully hydraulic pump control
system plumbed on ROD SIDE with simplified
schematics. The agitator, boom, and S-1 control
circuits are not shown.
• High pressure oil (red) flows from the main
hydraulic pump (2) through the parallel position
of the S2 valve (7) into the rod side of the right
side differential cylinder (8A). The cylinder
retracts, which creates a vacuum in the material
cylinder. The right side material cylinder fills with
concrete. (This is called the suction stroke.)

Phase A
Please note that right and left refer to the orientation
you would have if you stood on the unit by the rock
valve, looking towards the cab of the truck.
• As soon as you switch the unit distribution gear
case to the pumping position, the accumulator
hydraulic pump (20) begins pumping high
pressure oil (red) to charge the accumulators.(14).
• Shown in the beginning position in phase A
schematic. High pressure oil (red) continues to
flow into the accumulator circuit until the
accumulators (14) are charged to the pressure cut-
off point of the accumulator hydraulic pump (20).
When the cut-off point is reached, the
accumulator pump reduces the hydraulic oil flow
until there is just enough to maintain the cut-off
pressure.
• The oil that is forced out of the piston side of the
right differential cylinder (8A) flows through
hoses into the piston side of the left differential
cylinder (item 8B). This oil is called rocking oil
(orange).
• The rocking oil forces the left side differential
cylinder (8B) to extend. The cylinder rod extends,
pushing concrete out of the material cylinder,
through the rock valve, and into the pipeline. (This
is called the pressure stroke.)
• The oil from the rod side of the left differential
cylinder (8B) is routed back to the tank through
the return filter (12). The low pressure oil is shown
in green.
• The oil shown as blue, such as the oil in the
reservoir, is at rest, or pressureless.

• The high pressure oil (red) from the accumulator

circuit flows through the S3 directional control
valve (6), which is in the parallel position, into the
extend side oil port of the rock slewing cylinder
(5).

• The rod of the rock slewing cylinder (5) extends,

if not already extended.

• The S1 directional control valve (4), which

controls whether the unit pumps in forward,
neutral, or reverse, is put into the forward
position.

• A pilot signal (high pressure oil) is routed from

the accumulator circuit to the end cap of the S2
directional control valve (7), which moves into the
parallel position.

114 Training Manual

 SERVICE TRAINING

Phase A Hi-Flo
KEY
5 High Pressure
Rocking Oil Pressure
Low Pressure
Soft Switch Pressure
Zero Pressure
6 S3
(Tank, or oil at rest)

14
17 15 18
16
P

9A

9B

23
10A 10B

11

S2 7

S1 4

26

3
10C
25 12
24
1.1 27 10D 2
8A 8B
T
20
1
hiflo A.eps

Training Manual 115

 SERVICE TRAINING

Phase B
Please note that right and left refer to the orientation
you would have if you stood on the unit by the rock
valve, looking towards the cab of the truck.
• The left side differential cylinder (8B) reaches top
dead center. If there is so much rocking oil in the
loop that the right side differential cylinder (8A)
cannot retract to the bottom dead center position,
then oil is removed now through check valve 10C.

• The right side differential cylinder (8A) reaches

bottom dead center. As the piston reaches the
guide bushing, it exposes a port to the end cap of
the reversing valve (9A), which becomes
connected to high pressure oil (red). The left end
cap of the reversing valve (9A) is connected to
low pressure oil (green), so the reversing valve
slides into the parallel position, sending high
pressure oil (red) toward the end cap of the S3
valve (6).

• The pressure signal reaches the S3 valve end cap

(6), pushing the valve into the cross-over position.

• The oil on the right end cap of the S3 valve (6)

flows back to tank (1).

• In the cross-over position, the S3 valve (6) routes

oil from the accumulators to the retract port of the
rock valve slewing cylinder (5). The cylinder
begins to retract.

• The oil from the extend side of the rock valve

slewing cylinder (5) is routed back to tank (1).

• Shown in beginning position in phase B

schematic. A pilot signal (high pressure oil) is
routed from the accumulator circuit to the left side
end cap of the S2 directional control valve (7).
The S2 valve slides into the cross-over position.

• As the rock slewing cylinder (5) retracts, pressure

in the accumulator circuit falls. When it drops
below the set point of the accumulator hydraulic
pump cut-off pressure, the accumulator hydraulic
pump (20) increases the flow of hydraulic oil to
charge the accumulator circuit (14).

116 Training Manual

 SERVICE TRAINING

Phase B Hi-Flo
KEY
5 High Pressure
Rocking Oil Pressure
Low Pressure
Soft Switch Pressure
Zero Pressure
6 S3
(Tank, or oil at rest)

14
17 15 18
16
P

9A

9B

23
10A 10B

11

S2 7

S1 4

26

3
10C
25 12
24
10D 2
1.1
27
8A 8B
T
20
1
hiflo A.eps

Training Manual 117

 SERVICE TRAINING

Phase C

Please note that right and left refer to the orientation

you would have if you stood on the unit by the rock
valve, looking towards the cab of the truck.
• The rock valve slewing cylinder (5) reaches the
bottom dead center position.

• High pressure oil (red) continues to flow into the

accumulator circuit until the accumulators (14)
are charged to the pressure cut-off point of the
accumulator hydraulic pump (20). When the cut-
off point is reached, the accumulator pump
reduces the hydraulic oil flow until there is just
enough to maintain the cut-off pressure.

• The S2 valve (7) has finished sliding. Oil is now

routed from the main hydraulic pump (2) to the
rod side of the left hand differential cylinder (8B).

• As the left hand differential cylinder (8A) moves,

rocking oil (gold) reaches the left end cap of the
reversing valve (9A). The valve closes by the
pressure applied and the force of the return spring.
This removes the pilot signal to the left side of the
S3 directional control valve (6).

• As the left side differential cylinder (8B) retracts,

it creates a void in the material cylinder and
concrete begins to flow in to fill that void.
(Suction stroke.)

• The oil from the piston side of the left side

differential cylinder (8B) travels through the hoses
to the piston side of the right hand differential
cylinder (8A), forcing it to extend. In the material
cylinder, the concrete from stage A is forced out
into the delivery pipeline. (Pressure stroke.)

• The oil from the rod side of the right hand

differential cylinder (8A) is routed through the S2
valve (7), through the return filter (12), and back
to tank (1).

118 Training Manual

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Phase C Hi-Flo
KEY
5 High Pressure
Rocking Oil Pressure
Low Pressure
Soft Switch Pressure
Zero Pressure
6 S3
(Tank, or oil at rest)

14
17 15 18
16
P

9A

9B

23
10A 10B

11

S2 7

S1 4

26

3
10C
25 12
24
10D 2
1.1
27
8A 8B
T
20
1
hiflo A.eps

Training Manual 119

 SERVICE TRAINING

Phase D This brings us back to phase A. The machine has made

one complete cycle, which consists of two suction
Please note that right and left refer to the orientation strokes and two pressure strokes.
you would have if you stood on the unit by the rock
valve, looking towards the cab of the truck.
• The left side differential cylinder (8B) retracts to
bottom dead center. The right side differential
cylinder (8A) approaches top dead center.

• If there is not enough rocking oil to completely

extend cylinder 8A, rocking oil will now be added
through check valve 10D.

• When the left side differential cylinder is in the

top dead center position, pressure is applied to the
right end cap of the reversing valve 9B. The left
end cap of the reversing valve is connected to low
pressure, so the valve slides into the parallel
position. The reversing valve routes the pilot
signal to the right side end cap of the S3 valve (6).

• The S3 valve (6) moves to the parallel position in

response to the pilot signal. The oil in the left side
end cap of the S3 valve (6) escapes to tank.

• High pressure oil (red) is routed from the

accumulator circuit through the S3 valve (6) to the
extend port of the rock valve slewing cylinder (5).

• The rock valve slewing cylinder (5) extends,

sending the retract side oil back to tank (1)
through the S3 valve (6).

• As the rock slewing cylinder (5) extends, pressure

in the accumulator circuit falls. When it drops
below the set point of the accumulator hydraulic
pump cut-off pressure, the accumulator hydraulic
pump (20) increases the flow of hydraulic oil to
charge the accumulator circuit (14).

• At the same time that the rock valve cylinder is

extending, a high pressure pilot signal is sent to
the right end port of the S2 spool. It slides into the
parallel position. When it has completed the
travel, oil is routed from the main pump (2) to the
rod side of the right hand differential cylinder
(8A).

120 Training Manual

 SERVICE TRAINING

Phase D Hi-Flo
KEY
5 High Pressure
Rocking Oil Pressure
Low Pressure
Soft Switch Pressure
Zero Pressure
6 S3
(Tank, or oil at rest)

14
17 15 18
16
P

9A

9B

23
10A 10B

11

S2 7

S1 4

26

3
10C
25 12
24
10D 2
1.1
27
8A 8B
T
20
1
hiflo D.eps

Training Manual 121

 SERVICE TRAINING

Booms
Black & White Proportional

Electric/Air/Oil - Non Load Sensing Electric/Oil/Oil - Varable Displacement Pump

Electric/Oil/Oil - Non Load Sensing Electric/Oil/Oil - Fixed Displacement Pump

Electric/Oil/Oil - Load Sensing

BoomCompare.eps

122 Training Manual

 SERVICE TRAINING

Black & White

Electric/Air/Oil

39000168.eps

Electric/Oil/Oil

39000167.eps

Training Manual 123

 SERVICE TRAINING

Electric/Oil/Oil - Load Sensing

39000169.eps

124 Training Manual

 SERVICE TRAINING

Proportional
Electric/Oil/Oil - Variable

To:Outrigger Function

P1
1PM

M P4
T
T

P3

P2

39000165.eps

Electric/Oil/Oil - Fixed Displacement

To:Outrigger Function

P1
1PM

M P4
T
T

P3

P2

39000166.eps

Training Manual 125

 SERVICE TRAINING

Boom Holding Valves
Schwing uses a specially-designed hydraulically
unlockable check valve on all hydraulic cylinders
which operate placing boom sections. These valves
seal the hydraulic cylinder to prevent it from creeping
or moving until pressure is applied to it. A holding
valve is installed at both ends of the hydraulic cylinder
to prevent movement and limit pressure in either
direction.
TRUCK-MOUNTED AND SEPARATE
PLACING BOOM HYDRAULIC CYLINDER HOLDING VALVES
If you should have a problem with a boom section
creeping, position the boom in an area which still
produces pressure in the corresponding cylinder but
leaves the holding valve in an accessible area. Loosen
the fitting of the pressure connection of the working
line and the leakage oil connection. With the hydraulic
pump not turning, you will be able to see which portion
of the valve is leaking.
If oil flowing out uniformly from the leakage oil
connection, this indicates that the auxiliary safety valve
is not properly sealing. If this holding valve is on boom
section 1 cylinder, holding valve replacement is
necessary.

HER - SV2 - R 1/2" CYLINDER CONNECTION

SCHEMATIC DRAWING This auxiliary safety valve protects the cylinder from
BLEED OFF
excess pressure; therefore, this valve must not be set at
PRESSURE
CONNECTION
SCREW random. Precision setting for a specific placing boom
(WORKING LINE) model is necessary and can only be done with the
correct equipment and certified personnel.

UNLOCKABLE
CHECK RETURN OIL If hydraulic oil is flowing out uniformly from the
CONNECTION
(LEAKAGE OIL) working line, this indicates that the check valve is not
sealing properly, or debris in the oil has caused the
RELIEF (NON-ADJUSTABLE) unlocking system to hang up and not allow the check
SAFETY VALVE
valve ball to seat. If there are any questions concerning
CONTROL LINE CONNECTION holding valves or other areas of your Schwing
(CONNECTED WITH WORKING LINE
OF THE OPPPOSITE SIDE) equipment that you need answered, contact your local
Schwing dealer or Schwing America, Inc. for more
information.

HER VALVE INSTALLATION

DRIP-TANK

PORT X

BLOCK A BLOCK B

LINE B
CYLINDER
LINE A PORT Y
CYLINDER ROD

126 Training Manual

 127
BOOM #3 (Tip) BOOM #2 BOOM #1 (MAIN) SLEWING CYLINDERS
Outrigger Jacking Cylinders 270 BAR 270 BAR
270 BAR 270 BAR
SERVICE TRAINING

140 bar
1.7 2.0

Training Manual
1.3 1.0 1.7 1.3 1.3 1.3
A4 B4 A3 B3 A2 B2 A1 B1
P T
B A P1
280 bar
T T
300 bar
AIR TANK
28X B&W Boom

T P
KVM 28 Neutral
W/ MONSUN - TISON HANDVALVES 5 - 7 bar
196101
10/91
RE
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure (Tank, or oil at rest)
 BOOM #3 (Tip) BOOM #2 BOOM #1 (MAIN) SLEWING CYLINDERS
Outrigger Jacking Cylinders 270 BAR 270 BAR
SERVICE TRAINING

270 BAR 270 BAR

140 bar
1.7 2.0

Training Manual
1.3 1.0 1.7 1.3 1.3 1.3
A4 B4 A3 B3 A2 B2 A1 B1
B A P1 T
P
280 bar
300 bar T T
T P
KVM 28 AIR TANK
W/ MONSUN - TISON HANDVALVES
196101 #3 Extend Only
10/91
RE 5 - 7 bar
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure (Tank, or oil at rest)

128
 129
BOOM #3 (Tip) BOOM #2 BOOM #1 (MAIN) SLEWING CYLINDERS
Outrigger Jacking Cylinders 270 BAR 270 BAR
270 BAR 270 BAR
SERVICE TRAINING

140 bar
1.7 2.0

Training Manual
1.3 1.0 1.7 1.3 1.3 1.3
A4 B4 A3 B3 A2 B2 A1 B1
B A P1 T
P
280 bar
300 bar T T
T P
KVM 28 AIR TANK
W/ MONSUN - TISON HANDVALVES
196101 #1 Retract
10/91
RE #3 Extend 5 - 7 bar
High Pressure Reduced Pressure Control Pressure Low Pressure Zero Pressure (Tank, or oil at rest)
 PRINT # 329324
BOOM #3 (Tip) BOOM #2 BOOM #1 (MAIN) SLEWING CYLINDERS
Outrigger Jacking Cylinders
270 BAR 270 BAR
SERVICE TRAINING

270 BAR 270 BAR

140 bar
1.7 2.0

Training Manual
35 bar
1.3 1.0 1.7 1.3 1.3 1.3
B A P1
A4 B4 A3 B3 A2 B2 A1 B1
T
P
300 bar
T P 280
bar
T T
A 5-7
bar
T P
KVM 28
W/ MONSUN - TISON HANDVALVES
190321

130

Load Sense Hydraulic Circuits
Overview
Load sense hydraulic circuits offer advantages over
conventional fixed flow circuits. One advantage is
improved efficiency. With the conventional system, a
fixed displacement hydraulic pump is used to run the
boom. This hydraulic pump must have the capability of
displacing enough oil volume to run the largest
cylinder on the boom. However, because the smaller
cylinders on the boom require less oil volume, an in-
line orifice is used to divert the excess oil to tank via
the relief valve. When no boom function is activated,
this fixed volume of oil is routed through the handvalve
and back to the tank. All of the excess oil is converted
to wasted horsepower and heat.
39000178.eps
With the original load sense hydraulic circuit, a
variable displacement hydraulic pump was used. This
hydraulic pump puts out only the required volume of
oil needed to run any particular function or
combination of functions. This pump also de-strokes to
a minimum output when no functions are activated;
thus conserving energy and fuel.
A7 VO Pump A could malfunction from contamination.
A1
X3
39000177.eps
Training Manual
SERVICE TRAINING
When activating a function by remote on a “black &
white” system, the handvalve spool is fully activated
and a signal is sent to the hydraulic pump to send the
required amount of oil to run that function.
1.3 1.0
A4
P
280 bar
T
39000180.eps
When activating a function on a proportional system,
electronics are used to vary the position of the
handvalve spool, which in turn varies the speed of the
function. The proportional system allows the operator
to move the boom as slow and as fast as desired; thus
increasing controllability for smoother boom
movement, and reducing operator effort.
C2 C1
G1/2
39000181.eps
NOTE!
The complete hydraulic system on a load
sense hydraulic circuit must be kept as clean
as possible due to many of the components
used in these circuits contain precision
machined metering passages and spools that
131
 SERVICE TRAINING

Components Orifice: A restriction installed in either a hydraulic or

pneumatic passageway to create a pressure drop. This
Constant:A theoretical factor that is regarded as does not always reduce flow directly, but it may cause
invariant in specified circumstances. The constant for enough pressure upstream so that some of the flow
calculating hydraulic HP is: 1714 (when psi and gpm would be diverted or reduced elsewhere.
are used). The constant for calculating kW is: 600
(when bar and lpm are used).
Horsepower (HP):A unit of power in the United
States Customary System, equal to 0.7457 kilowatts Pressure
(kW). To calculate hydraulic horsepower consumption, Drop
use the following formula; HP= Pressure multiplied by
the Volume, divided by a Constant.

GPM x PSI Orifice created between the spool and valves walls
HP =
1714
Q-Maximum(Q-max): The highest volumetric flow
LPM x BAR
KW = rate possible from the hydraulic pump. Adjusted with a
600
39000182
mechanical stop screw. Turn screw inward to decrease
and outward to increase.
Delta Pressure (Delta-P):The pressure differential Q-Minimum(Q-min): The lowest volumetric flow rate
between two given points in a hydraulic circuit. possible from the hydraulic pump. Adjusted with a
mechanical stop screw. Turn screw inward to increase
and outward to decrease.

Q-Min Screw

Delta P = 13.8 bar

(200 psi)

1000 PSI
68.95 bar Q-Max Screw
Q-Max Q-Min

Section Compensator: A component in the directional

control valves that self-adjusts for supply pressure
changes. Also described as a pilot operated pressure
1200 PSI
82.75 bar compensating valve.
X
C1
G1/2

Section
Compensator
C1
X3

P 39000183.eps
T
C2
Section
Compensator
39000186.eps

132 Training Manual

 SERVICE TRAINING

Basic Principles - Simple Circuit

In this diagram, the cylinder will take exactly 1 minute
to extend with a pressure of 1000 psi. When the
cylinder reaches the end of the stroke, something will
have to break because there is no relief valve and the
hydraulic pump is fixed displacement, meaning the .
pump will continue to put out oil until it is shut off.

10,000 lbs

10”

1000 psi

10 GPM

39000187.eps

Training Manual 133

 SERVICE TRAINING

Basic Principles - Orifice

In this diagram, we have a 10 gpm fixed displacement
pump, an orifice creating a pressure drop of 200 psi,
and free-flowing back to tank.

0 psi

200 psi

10 GPM

39000188.eps

134 Training Manual

 SERVICE TRAINING

Basic Principles - Without Relief Valve

In this diagram, the cylinder will take exactly 1 minute
to extend with a pressure of 1000 psi at the cylinder
and a pressure of 1200 psi at the pump due to the
orifice that caused a pressure drop. The orifice did NOT
change the flow rate nor the cylinder speed. When the
cylinder reaches the end of the stroke, something will
have to break because there is no relief valve.

10,000 lbs

10”

1000 psi

1200 psi

10 GPM

39000189.eps

Training Manual 135

 SERVICE TRAINING

Basic Principles - With Relief Valve

In this diagram, A relief valve has been added. When
the cylinder has bottomed out, the relief valve vents the
excess pressure to tank. The pressure vented to tank
becomes wasted horsepower and generates heat.

10,000 lbs

10,000 lbs

10”

10”

1000 psi 2000 psi

1200 psi 2000 psi

2000 psi

10 GPM 10 GPM

39000190.eps

136 Training Manual

 SERVICE TRAINING

Basic Principles - Delta-P

In this diagram, the handvalve is in the neutral position.
The pump is only putting out enough oil to maintain
Delta -P.

10”

0 psi

Delta P
The pressure differential
between two given points
in a hydraulic circuit

200 psi
2000 psi
X

X3

P
A T

39000191a.eps

Training Manual 137

 SERVICE TRAINING

Basic Principles - Delta-P P). The pump is only supplying the amount of oil
required to maintain the (Delta-P). In this case, 5 gpm.
In this diagram, the cylinder will take exactly 2
If the size of the orifice increases, the flow rate will be
minutes to extend. There will be a pressure of 1000 psi
increased by the Delta-P regulator. That will increase
at the cylinder and a pressure of 1200 psi at the pump.
the speed of the cylinder.
The orifice caused a drop in pressure (Delta-P). The
regulator has been adjusted to maintain 200 psi (Delta-

10”

1000 psi

Delta P
The pressure differential
between two given points
in a hydraulic circuit

1200 psi

X3

P
A T

39000191.eps

138 Training Manual

 SERVICE TRAINING

Basic Principles - Pressure Cut-Off The regulator has been adjusted to a pressure limit of
3000 psi. The pump is only supplying the amount of oil
In this diagram, the cylinder is at the end of it’s stroke.
required to maintain 3000 psi.
There will be a pressure of 3000 psi at the cylinder and
a pressure of 3000 psi at the pump. The orifice does
NOT cause a drop in pressure because there is no flow.

10,000 lbs

10”

4350 psi

4350 psi

X3

P
A T

39000192.eps

Training Manual 139

 SERVICE TRAINING

Basic Principles - Shuttle Valves have been replaced by the proportional handvalves.
The regulator has been adjusted to a pressure limit of
In this diagram, the cylinder with the highest load
3000 psi. If any one cylinder reaches the end of it’s
(2500 psi) will be monitored at the regulator. The
stroke, the main pressure will be 3000 psi.
regulator will maintain the 200 psi delta-P above that
load. The orifices, needed to cause a drop in pressure,

25,000 lbs 20,000 lbs 10,000 lbs

10” 10” 10”

2500 psi 2000 psi 1000 psi

X3

P
A T

39000193.eps

140 Training Manual

 SERVICE TRAINING

Basic Principles - Pressure Regulator

Δ P regulator Δ P regulator
X
20 Pressure
Regulator
bar Δ P 300 bar

ΔP
Regulator
20 bar
300
X
bar A T
0 bar

ORIFICE
KVM 36X . . . . 1.6 mm
P 0.8 mm
0-15 Bar
KVM 36 LW . . 1.6 mm
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
P
A T

Pressure Regulator
(300 bar)

ΔP Regulator
(20 bar)

39000219.eps

Training Manual 141

 SERVICE TRAINING

A7 Variable Displacement Hydraulic Pump Training

All Functions in Neutral

Pressure below 20 bar
The directional valve is in the neutral position.
Hydraulic oil is blocked at the handvalve. Pressure below 20 bar X
20
bar Δ P

X 300
bar
C2 C1

39000197.eps
A T
20 bar spring
P
20 bar spring
C2

C1

A T

Moving the spool to the left will create a passage way

from the Control Piston Chamber of the hydraulic
pump to tank.
Oil blocked by spool
39000195.eps
Passageway opened to tank

The pumps rotary group is at reduced displacement, Passageway opened to tank

X
and is only putting out enough oil to maintain 20 bar 20
bar Δ P
(Delta-P)
X 300
bar
+20 bar pressure pushing on spool
Compressed Spring 39000199.eps
A T
A P

X
A1 This will create a pressure drop on the piston side of
20
bar Δ P
the Control Piston Chamber, allowing the spring on rod
T
side of the chamber to decompress. As the spring
300
bar decompresses the angle of the rotary group will
X3
increase. The pump will displace more oil, until 20 bar
A T
P 39000194.eps (Delta-P) reached.
Not enough pressure to hold back the spring
A
A1
+20 bar pressure pushing on spool X
20
bar Δ P
Compressed Spring T

300
bar
X3

P 39000200.eps
A
P
T
A T

X3

Pressure on the “A” port drops below 20 bar, the force X

of the spring is greater than the pressure exerted on the A T

P
spool. The spring will decompress, moving the spool to X3
the left.
Not enough pressure to hold back the spring

The rotary group angle will increase/decrease as

necessary to maintain 20 bar (Delta-P).

142 Training Manual

 SERVICE TRAINING

KEY
High Pressure
1.0 mm

Reduced Pressure

320 bar
Control Pressure 330 bar

320 bar

310 bar
Low Pressure

Zero Pressure 1.0 mm

(Tank, or oil at rest)

NOTE: On the schematic, the 20 bar

Delta P spool and spring is shown
above the 300 bar spool and spring.
On the Pressure Regulator cut-out,
you can see that in reality the 300 bar
spool and spring is located above the
20 bar Delta P spool and spring.

Δ P regulator A7 VO Pump A
A1
3 X
20
bar Δ P T

300
bar
X3

P
A T

Δ P regulator A7 VO Pump
A1
Q-MIN
Pressure
Regulator
300 bar

ΔP
Regulator A
20 bar

X 0 bar
A T

ORIFICE
KVM 36X . . . . 1.6 mm
P 0.8 mm
KVM 36 LW . . 1.6 mm
0-15 Bar Q-MAX
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
X3

HT001.ai

Training Manual 143

 SERVICE TRAINING

Cylinder Extend Function Initiated This will create a pressure drop allowing the spring on
rod side to decompress, thus changing the angle of the
The directional valve has been moved to the "cylinder
rotary group to displace enough oil to extend the
extend" position. Oil travels through the handvalve and
hydraulic cylinder.
to the boom holding valve. A signal is also sent from
the handvalve to the Delta P regulator, via the “X” port.
Decompressed Spring
The pressure from the “X” port plus the 20 bar spring A
is greater than the pressure on the “A” port side of the X
A1

spool. This will move the spool to the left, creating a 20 + Load
bar Δ P T
passage way for the oil in the Control Piston Chamber
of the hydraulic pump to tank. 300
bar
X3
1 P
A T 39000202.eps
Pressure + 20 bar
spring signal from Rotary Group
handvalve pushing
on spool

A A T

A1 P
X
X3
20 + Load
bar Δ P T
Not enough pressure to hold back the spring
300
bar
X3 Oil enters the holding valve. The hydraulically
A T
unlockable check valve “opens” allowing oil to enter
P

Control Piston Chamber

Pressure + 20 bar spring signal
from handvalve pushing on spool
C2
the piston side chamber of the hydraulic cylinder. A
signal is also sent to the rod side hydraulically
unlockable checkvalve. This will open the relief valve
and create a passageway for the oil on the rod side
chamber to escape to tank.

C1

Open Relief

1.0 mm
320 bar

330 bar

320 bar
310 bar

X
A T
P

1.0 mm
Control Piston Chamber X3
39000201.eps
Open Checkvalve
39000203.eps

144 Training Manual

 SERVICE TRAINING

KEY
High Pressure
1.0 mm

Reduced Pressure

320 bar
Control Pressure 330 bar

320 bar

310 bar
Low Pressure

Zero Pressure 1.0 mm

(Tank, or oil at rest)

NOTE: On the schematic, the 20 bar

Delta P spool and spring is shown
above the 300 bar spool and spring.
On the Pressure Regulator cut-out,
you can see that in reality the 300 bar
spool and spring is located above the
20 bar Delta P spool and spring.

Δ P regulator A7 VO Pump A
A1
X
20 + Load
bar Δ P T

300
bar
X3

P
A T

Δ P regulator A7 VO Pump
A1
Q-MIN
Pressure
Regulator
300 bar

ΔP
Regulator A
20 bar

X 0 bar
A T

ORIFICE
KVM 36X . . . . 1.6 mm
P 0.8 mm
KVM 36 LW . . 1.6 mm
0-15 Bar Q-MAX
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
X3

HT002.ai

Training Manual 145

 SERVICE TRAINING

Hydraulic Cylinder Extending ‘X” port pressure on the spring side of the 20 bar spool
is greater than the “A” port pressure. The spool will
The hydraulic pump is only putting out enough oil to
move to the left, creating a larger passageway for the
extend the hydraulic cylinder. Depending upon the load
Control Piston Chamber oil to escape to tank.
requirements, the signal line pressure will increase or
decrease accordingly. If the signal line pressure The farther left the spool moves,
increases, the 20 bar Delta P spool will open, allowing the larger the opening back to tank
allowing a larger passageway for the Control Piston
Chamber oil to escape to tank. This will decrease the X
pressure on the piston side of the Control Piston A
20 + Load
Chamber, allowing the spring on the rod side to A T
bar Δ P
decompress and the angle of the rotary group to 39000206.eps
increase, creating more flow to meet the load
requirements.
Example: With a larger passageway to tank, pressure decreases in
Load requirements for a particular function increse. the Control Piston Chamber.

Increased Load Increased Load

X

1.0 mm
A T
320 bar

330 bar
A1
320 bar
310 bar

T
1.0 mm

39000204.eps
X3

As the load requirements increase, the signal line 39000207.eps

pressure from the handvalve to the “X” port increases.

With a larger opening created to tank, the pressure
on the piston side of the chamber will decrease.
Increased Load Increased Load

C2 C1
Spring decompresses, rotary group angle increases,
more flow created.
C2

C1

More oil displaced

A1

Load increases, signal X3

line pressure increases 39000208.eps

X
X A
20
A T
bar Δ P
39000205.eps

146 Training Manual

 SERVICE TRAINING

KEY
High Pressure
1.0 mm

Reduced Pressure

320 bar
Control Pressure 330 bar

320 bar

310 bar
Low Pressure

Zero Pressure 1.0 mm

(Tank, or oil at rest)

NOTE: On the schematic, the 20 bar

Delta P spool and spring is shown
above the 300 bar spool and spring.
On the Pressure Regulator cut-out,
you can see that in reality the 300 bar
spool and spring is located above the
20 bar Delta P spool and spring.

Δ P regulator A7 VO Pump A
A1
X
20
bar Δ P T

300
bar
X3

P
A T

System when equipped with Rexroth hydraulic pump

Δ P regulator A7 VO Pump
A1
Q-MIN
Pressure
Regulator
300 bar

ΔP
Regulator A
20 bar

X 0 bar
A T

ORIFICE
KVM 36X . . . . 1.6 mm
P 0.8 mm
KVM 36 LW . . 1.6 mm
0-15 Bar Q-MAX
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
X3

HT002.ai

Training Manual 147

 SERVICE TRAINING

Hydraulic Cylinder Fully Extended Pump If pressure reaches over 300 bar. The spring on the 300
bar spool will compress. Creating a passageway for oil
The cylinder has fully extended.
from the “A” port to pass through the spool and flow to
the piston side of the Piston Control Chamber.

300+ pressure
A
A1
1.0 mm
X

320 bar
T
330 bar
300
320 bar
bar
310 bar X3
1.0 mm
P
39000211.eps
39000209.eps

Pressure has been equalized on both ends of the 20 bar

X

(Delta P) spool.
A T

P
X3
C2 C1

Pressure on the piston side of the chamber is greater

than the rod side pressure, plus spring. The spring will
C2

C1

compress, decreasing the angle of the rotary group,

resulting in less flow. The pump will only put out
enough flow to maintain 300 bar.

Equal pressure A
A1
X
A
A1 20
X bar Δ P T

300
T
bar
300 X3
bar
P
X3 39000212.eps

P
A T

A T

P
X
X3

A T

P The rotary group angle will increase/decrease putting

X3
39000210.eps
out more/less oil to maintain 300 bar.

148 Training Manual

 SERVICE TRAINING

KEY
High Pressure
1.0 mm

Reduced Pressure

320 bar
Control Pressure 330 bar

320 bar

310 bar
Low Pressure

Zero Pressure 1.0 mm

(Tank, or oil at rest)

NOTE: On the schematic, the 20 bar

Delta P spool and spring is shown
above the 300 bar spool and spring.
On the Pressure Regulator cut-out,
you can see that in reality the 300 bar
spool and spring is located above the
20 bar Delta P spool and spring.

Δ P regulator A7 VO Pump A
A1
X
20
bar Δ P T

300
bar
X3

P
A T

System when equipped with Rexroth hydraulic pump

Δ P regulator A7 VO Pump
A1
Q-MIN
Pressure
Regulator
300 bar

ΔP
Regulator A
20 bar

X 0 bar
A T

ORIFICE
KVM 36X . . . . 1.6 mm
P 0.8 mm
KVM 36 LW . . 1.6 mm
0-15 Bar Q-MAX
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
X3

HT003.ai

Training Manual 149

 SERVICE TRAINING

Fixed Displacement Pump Training

All Function in Neutral

EB

∅1.0
B2 B1

320 bar
330 bar

290 bar
300 bar

A2 A1
∅1.0
EA

C1 C2 C1 C2 PP
G1/2 G1/2
15
bar

0.2
mm
300
bar

.061 mm P

T
LS

KEY
High Pressure

Reduced Pressure
Pretension Pressure
High pressure filter
Low Pressure

Zero Pressure
(Tank, or oil at rest)

2.0
atmospheres

150 Training Manual

 SERVICE TRAINING

Boom Function Activated

EB

∅1.0
B2 B1

320 bar
330 bar

290 bar
300 bar

A2 A1
∅1.0
EA

C1 C2 C1 C2 PP
G1/2 G1/2
15
bar

0.2
mm 300
bar

.061 mm
P

T
LS

KEY
High Pressure

Reduced Pressure
Pretension Pressure
Low Pressure High pressure filter

Zero Pressure
(Tank, or oil at rest)

2.0
atmospheres

Training Manual 151

 SERVICE TRAINING

Cylinder Pressurized at the End of Stroke

EB

∅1.0
B2 B1

320 bar
330 bar

290 bar
300 bar

A2 A1
∅1.0
EA

C1 C2 C1 C2 PP
G1/2 G1/2
15
bar

0.2
mm 300
bar

.061 mm
P

T
LS

KEY
High Pressure

Reduced Pressure
Pretension Pressure
Low Pressure High pressure filter

Zero Pressure
(Tank, or oil at rest)

2.0
atmospheres

152 Training Manual

 SERVICE TRAINING

Output Charts • maximum strokes per minute of your pumpkit

model.
The hydraulic pumps that drive your concrete pump are • maximum output (in liters per minute, L/min) of
horsepower controlled. That means that when pressure your hydraulic pumps.
rises past a certain point (known as the breakpoint), the
pumps change their displacement per revolution, • expected output at various pumping pressures.
resulting in less flow and fewer strokes per minute. The • condition of your hydraulic pumps when used in
reason for this is so the pumps will not stall your conjunction with a flowmeter.
engine by drawing too much horsepower. Output charts • breakpoint of your hydraulic system.
show the horsepower curve (in kilowatts, or Kw) of the
concrete pump hydraulic circuit. From them, you can An explanation of an output chart is shown on the
determine the: following pages, followed by some examples of chart
• maximum concrete pressure of the pumpkit model. usage. The output chart of the pumpkit shipped with
this manual is shown later.
• maximum output (in cubic yards per hour) of the
pumpkit model.
CONCRETE CONCRETE
Pumpkit model BPL 1200 HDR-23 PRESSURE
(PSI)
PRESSURE
(BAR)
Concrete pres-
2000 138
PERFORMANCE CHARACTERISTICS OF
sure is shown
1900 131
PISTON SIDE

THE AXIAL PISTON HYDRAULIC PUMP

here. Max.
ROD SIDE

PUMP SPEED 1800 124

(bar)

(bar)

2100 RPM
1700 117 pressure is
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110 shown for
350
PISTON SIDE
1500 103 both piston
1400 97
Hydraulic oil pres- and rod side
300 Piston side 1300 1285 88.6 90
sure shown here, 1200 83
configurations
breakpoint
ranging from zero to 250
1100 76
OIL PRESSURE (BAR)

1000 70
the relief valve set-
ROD SIDE 900 62
ting. 200 350 Rod side
800 55
300 breakpoint 700
758 52
48
150 250
Concrete out-
600 41
200 500 34
put is shown
100
150 400 28 here, with max
100
300 21 shown for both
50 200 14
piston and rod
50 7
100
The breakpoint side configura-
breakpoint 0 13 26 39 52 65 78 92
105 118 131 144 157 170 183 196
specification is 178 bar
103 170.5
tions.
listed here. CONCRETE OUTPUT (cu yd / h)

26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
Hydraulic liters per 15.5
PISTON 5 10 15 20 25 30 NUMBER OF STROKES
minute and the cor- SIDE (stroke / min.) Information
OIL VOLUME
responding strokes 100 200 300 400 500 (liter / min.) about the
per minute for both Differential Hydraulic Cylinder Material Cylinders Hydraulic Pumps
pumpkit and
piston and rod side. Bore dia. / Rod dia. x Stroke length Bore dia. x Stroke length Type / KW
hydraulic
125 mm / 80 mm x 2000 mm 230mm x 2000 mm 2 x A7VO-107
output chart explain.eps
2 x 66KW pumps is
Slewing cylinder 80 / 45 x 185 shown here.

Training Manual 153

 SERVICE TRAINING

Using the Chart the 220 bar oil pressure marking on the rod side scale
(item A in the example below). Then draw a line
Example 1—Checking flow at a given pressure straight across the page until you intersect with the
Your unit is configured on the rod side (standard from horsepower curve (Item B). Next, draw a straight line
the factory). You notice that your machine is not getting down from the intersection point until you pass through
as many strokes per minute as you are used to seeing. the rod side number of strokes scale, and read the
You count the strokes and see that you are getting strokes per minute. At 220 bar you should be getting a
about 21 1/2 per minute. You check your pressure gauge little more than 21 strokes per minute. Your unit is fine.
and see that the hydraulic oil pressure is at 220 bar. To
determine whether your unit is acting normally, locate
CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
output chart use.eps
2000 138
PERFORMANCE CHARACTERISTICS OF
1900 131
PISTON SIDE

THE AXIAL PISTON HYDRAULIC PUMP

ROD SIDE

PUMP SPEED 1800 124

(bar)

(bar)

2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110

350 1500 103

PISTON SIDE
1400 97
B. Draw a line STRAIGHT 1300 1285
300 88.6 90
across the page until you
contact the horsepower 1200 83
A. Find 220 bar curve of the rodside. Then 1100 76
250 on the rod side oil draw a line straight down
OIL PRESSURE (BAR)

pressure scale. from the intersection point. 1000 70

350 ROD SIDE 900 62

200
800 55
300 758 52
700 48
150 250
600 41
200
EXAMPLE 1 500 34
100
150 400 28

300 the line leaves

C. Where 21 the
100 graph tells you how 14 many
50 200
yards/hour you can expect
50
(in this100case, about 7138).
Where the line crosses the
breakpoint 0 13 number
26 39 52 65 78 92 105 118 131 144 157 170 183 196 of strokes scale tells
178 bar 103 170.5 you how many strokes per
minute you can expect (in
CONCRETE OUTPUT (cu yd / h)
this case, a little over 21).
26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
15.5
PISTON 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
100 200 300 400 500 (liter / min.)

Example 2—Checking your hydraulic pumps by 2, and chart the result. You multiply the readings
To determine whether your pumps are still in good because the chart is based on the output of two pumps,
working condition, use the output chart and a flow but we are only testing one at a time.
meter. Test one pump at a time, multiply the readings

154 Training Manual

 SERVICE TRAINING

To test your pumps:
• Use use the chart that applies to your unit (see
Output Chart in the Appendix of your Operation
Manual).
• Select the proper truck transmission gear for
pumping (found on the information plate mounted
in the truck cab).
• Set the pump speed (input drive shaft) RPM.
Pump speed information is found on line 16 of the
Delivery Inspection Report which arrived with
your unit when it was new. A difference of even a
few RPM will give you a bad reading. Check the
RPM with a digital tachometer if one is available.
• Know how to use your flowmeter. Read the
instructions that came with it. A flowmeter must
be calibrated periodically.
• Make two copies (one for each pump tested) of
the Output Chart located in the Appendix of the
Operation Manual. Don’t use the original copy,
you will need additional copies of the original for
future tests.
Read the flow at 0 bar, 100 bar, 150 or 200 bar, 250 bar,
and 300 bar. Also document the breakpoint. The
breakpoint is where the flow drops off rapidly. You will
be able to notice it on the flowmeter. If you think it
would be helpful, copy the chart below. Check which
reading you used (150 or 200 bar). The breakpoint will
be very close to either 150 or 200 bar, so it is not
necessary to take both readings. The breakpoint
specification is shown on each output chart.

breakpoint 1st Pump 2nd Pump

specification liters/min Total liters/min Total
(read on meter) (for plotting) (read on meter) (for plotting)
0 bar x2 x2

100 bar x2 x2

breakpoint x2 x2
breakpoint
150 or 200 bar x2 x2

250 bar x2 x2

300 bar x2 x2
checking output form

As an example, we’ll assume that we have just taken

the following readings.

Training Manual 155

 SERVICE TRAINING

Plot the readings on the output chart. Take a clean • Turn the ruler sideways and draw a light line up
output chart and proceed as follows: the page from the liters/minute reading you took
• Lay a straight edge horizontally across the page at at that pressure. (Remember to multiply the
the pressure point you are plotting. Draw a light reading by 2.) In our example, we measured 276
line across the chart. In the example below, we use liters at 250 bar.
the rod side scales and curve (you could use the • Put a dot at the point where the two lines intersect.
piston side scale and curve instead). The ruler is
shown ready to draw a line at 250 bar hydraulic • Do the same thing with each pressure reading. You
pressure. should end up with six dots.

CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
1checking output.eps
2000 138
PERFORMANCE CHARACTERISTICS OF
1900 131
PISTON SIDE

THE AXIAL PISTON HYDRAULIC PUMP

ROD SIDE

PUMP SPEED 1800 124

(bar)

(bar)

2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110

350 1500 103

PISTON SIDE
1400 97

300 1300 1285 88.6 90

1200 83
1100 76
250
OIL PRESSURE (BAR)

1000 70

350 ROD SIDE 900 62

200
800 55
300 758 52
700 48
150 250
600 41
1
200 2 3 4 5 6 7 8 9 10 11
500 34
100
150 400 28

300 21
100
50 200 14
50 7
100

breakpoint 0 13 26 39 52 65 78 92
105 118 131 144 157 170 183 196
178 bar 103 170.5
CONCRETE OUTPUT (cu yd / h)

26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
15.5
PISTON 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
100 200 300 400 500 (liter / min.)

156 Training Manual

 SERVICE TRAINING

• Connect the dots. If your plotted line reasonably the upper right of the spec, you have done the test
matches the specification plot on the chart, the incorrectly, or you are using the wrong chart. In
pump is fine. If your line is to the lower left of the our example, the pump is okay. (See the plot
spec, the pump is getting weak. If your line is to which follows.)

CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
2checking output.eps
1200 83
ROD SIDE

300 bar
(bar)

1100 76

1000 70

350 ROD SIDE 250 bar 900 62

Breakpoint 800 55
300 758 52
700 48
OIL PRESSURE (BAR)

250
600 41
200 500 34

150 200 bar 400 28

300 21
100 100 bar
50
OK 0 bar
200 14

7
100

breakpoint 0 13 26 39 52 65 78 92 105 118 131 144 157 170 183 196

178 bar 170.5
CONCRETE OUTPUT (cu yd / h)

26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
(234) (276) (338) (388) (398)
(392)

Check the second pump. We hook up the flowmeter

just as when we checked the first pump. Again, be sure
that you have the correct speed, gear, chart, and so on.
This time our example will have worse results.

Training Manual 157

 SERVICE TRAINING

Plot the results again on a clean copy of the flowchart.

As we plot this pump, we can see that the dots are
moving quite a bit to the inside of the flow
specification. (See next chart.)

When you connect the dots, the line is completely handy when you call to get a replacement. Also, please
below the specifications. This pump is very weak and advise us if you have changed differential cylinders,
will completely stop pumping oil soon. You may notice material cylinders, or hydraulic pumps, because you
high heat with this unit, if you are pumping at high oil may need a different output chart than the one that was
pressures. originally shipped with the unit.
NOTE!
Never try to make up for this weak pump by
increasing the speed of the engine. As the
pump turns faster than specifications, it will
not be able to suck oil as fast as it is turning
(it is called “cavitation” if this happens),
and immediate failure could results.
If the plotted curve matches the spec for a while, but
the breakpoint is too high or too low, it is possible to
make an adjustment. Contact the Schwing America
Service Department for the procedure.
There are many different possible pumpkits and power
settings for this unit. If you accidentally destroy your
original output chart, please have your serial number

158 Training Manual

 SERVICE TRAINING
Using a Nomograph
General information
NOTE!
If you have read the original Schwing Amer-
ica publication, Nomographs—A Guide to
Usage, you will notice several changes in this
document. Because not all of the power
from the truck engine is used for the con-
crete pump, the TK number of the engine
has no meaning. Therefore, this section
about using nomographs has been adapted
especially for boom pumps. You can still fig-
ure out the TK of the job to do, but the suit-
ability of the pump has to be determined in
a different manner. To make the pump num-
bers and job numbers match, we will use a
“Power Factor number,” which takes into
account the power of the hydraulic pumps
instead of the engine and is easy to use with
cubic yards per hour and PSI instead of
cubic meters per hour and bar.
Concrete pumps are limited in what jobs they can do
by three factors:
1. The amount of power available.
2. The maximum concrete output available.
3. The maximum concrete pressure available.
To estimate the power a pump requires to complete a
particular job and to determine which pump is
appropriate, a nomograph is used.
Upper left quadrant
Figure 1
Quadrants
Lower left quadrant
Training Manual
With a concrete pump that is driven by its own prime
mover, such as a trailer-mounted concrete pump or a
truck-mounted pump with a separate drive engine, the
power rating (in Kw) is shown for the engine or electric
motor. With a truck-mounted pump that uses a PTO
from the truck engine, the power rating reflects the
power output of the hydraulic pumps only. (All the
power from the truck engine is normally not available
to the concrete pump and should not be used for power
calculations.) If you know the required output for the
job, the nomograph will help you calculate the required
pressure. If you know the output and pressure, you can
calculate the power requirement.
The nomograph was developed by extensive trial-and-
error testing and has proven to be accurate to ±10% in
nearly all pumping applications. The original
nomographs used “spread measure” of fresh concrete
instead of slump, and the two are not directly
interchangeable. Some approximations are used in
translating the charts from spread measure to slump,
but the ±10% accuracy still applies. In all cases, it is
assumed that you will receive fresh, high-quality
concrete on your job and that the concrete will be
plastic enough to flow into the material cylinders. If
you know that the concrete will be hard to feed into the
cylinders, you should adjust the output requirement to
compensate for incomplete filling. For example, if you
will need 50 cubic yards per hour into the form but the
concrete is so stiff that it will fill the cylinders only
80%, you should multiply the required output by 1.25
(1÷80%).
The nomograph is divided into four quadrants
.
Upper right quadrant
Lower right quadrant
159
 SERVICE TRAINING

The upper left quadrant is the beginning and end point To use the nomograph, you begin at output required
of the graph and shows maximum output, pressure, and and move clockwise until you encounter the lines that
power for a specific machine. The upper right quadrant represent your job situation. Each time you meet the
accounts for the relationship between concrete output line that applies, you make a 90° turn until you come to
and pipeline diameters. The lower right quadrant
a point on the bottom of the upper left quadrant that
accounts for the resistance to flow of the entire pipeline
system. The lower left quadrant accounts for the shows pressure required (Figure 2).
pumpability of the concrete.

TK number does not apply to truck mounted units.

Curve shown is the Power Factor number (PF).
(72600) Pipeline diameter in inches
200
boom-small-no blocks-eps

Q in yd3/hr.
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
6" 5" 4.5"
140
4"
120 116
Rod side
100

80
Piston side 67
60

40

132 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI 1566 870

100

200

2"
300

400
2.5"

500

600

3"
4" 5" 6" Pumpkit Model: 120/80 x 1600:200 3000 2500 2000 1800 1500 1200 1000 800
Slump of fresh concrete in inches Power: 132 KW Proportional value of pipeline in feet

Figure 2
Moving around a nomograph

To illustrate the use of a nomograph, we will use a Boom pipe, elbows, and deck system.
hypothetical job situation with the following • 13 ft of 5-in. rubber hose
specifications. • 144 ft of 5-in. steel pipe (on the boom and pump
1. We will need an average output of 75 cubic yards deck)
per hour, but we will be pumping only 75% of the • 5.25 ft of 6–to–5-in. reducer (on the pump)
time. The rest of the time will be spent moving • 4 5-in. 45° elbows, radius 250 mm
hose, removing pipe lengths, waiting for concrete
• 11 5-in. 90° elbows, radius 250 mm
trucks, and taking care of miscellaneous jobs. This
means that when we are actually pumping, we will • 2 6-in. 90° elbows, radius 250 mm
need an output rate of 75 ÷.75 = 100 yd3/hr. 4. We will specify a slump of 5-6 in. and use the 5-in.
line on the chart.
2. We will use 5-in.-diameter pipeline.
5. In addition, when we add the pressure for the verti-
3. We will need the following pipeline lengths: cal run, we will have to add 1.1 times 70 ft = 77
Separately laid pipeline. PSI.
• 40 ft of 5-in. rubber hose All of these criteria will be explained in detail as we go
• 150 ft of 5-in. horizontal steel pipe through the individual quadrants.

160 Training Manual

 SERVICE TRAINING

The quadrants
1. The upper left quadrant describes the power
curve of a given hydraulic pump Kw rating and the
maximum output and maximum pressure of a par-
ticular model of concrete pump (Figure 3).

Power factor

56,650
Power factor number (PF) number
upper left quad-eps
English to Metric Conversion Factor is PF Ö 18.966 (replaces TK)
200

Q in. yd3/hr.
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
140
Example Job
Working power (in kW)

120
Power curve 100
Maximum output and
80maximum pressure
of a specific unit
60
Kw rating
40

103 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI

Figure 3
Upper left quadrant

Any concrete pump selected for a job must meet three
technical parameters:
• The power factor number of the pump must be
equal to or greater than the power factor number
of the job.
• The maximum output required by the job must be
available from the pump.
• The maximum pressure required by the job must
be available from the pump.
It is important to notice the pump maximum pressure
and maximum output, even if the power factor number
of the pump is larger than the job requires. These
parameters are decided during the design stage of the
unit and cannot be adjusted on the job. If the unit is
able to go from rod side to piston side, maximum
pressure and output can be exchanged—that is, you can
decrease one while increasing the other the same
amount.
The power factor number (PF) replaces the TK
number on a truck-mounted unit. It is the Kw
multiplied by a constant (550) that has several
efficiency factors figured in. When using an
Americanized nomograph (pressure in PSI and flow in
cubic yards per hour), the pressure multiplied by the
output must always be less than or equal to the PF of
the pump. For example, if you needed 50 cubic yards
per hour and determined that this will require 750 PSI,
you can multiply 50 by 750, which equals 37,500. Any
pump you select must have a PF of 37,500 or greater. If
you are using a nomograph that has been converted to
metric units of measure (pressure in bar and output in
cubic meters per hour), you can still multiply the
pressure by the output, but you must multiply the
answer by the conversion factor between metric and
English units of measure to get the PF. The conversion
factor for cubic yards to cubic meters and bar to PSI is
18.966. For all practical purposes, you can use 19. For
example, if you need 50 cubic meters per hour and
determine that your job setup will require 65 bar, you
can multiply 50 by 65, which equals 3250. Multiply
this by 19, and you find that your PF requirement is
61,750. Again, any pump you select for the job in this
example should have a PF of 61,750 or greater.

Training Manual 161

 SERVICE TRAINING

The maximum output (abbreviated as max Q) is
determined by the size of the hydraulic pumps, the
number of strokes per minute, and the size of the
differential and material cylinders. The unit is usually
designed so maximum output can be achieved only at
less than maximum pressure.
Maximum pressure (abbreviated as max P) is
determined by the size of the differential and material
cylinders and the setting of the main relief valve. To be
sure that the unit will handle the job, be careful to
notice max P and max Q. Here is an example of why
that is important: You contract to pump a job that
requires only 20 yards per hour, but you calculate that
you will need 2100 PSI pressure. The PF of this job is
42,000 (20 x 2100). The pump shown in Figure 3 has a
TK of 72,600, so there is enough power available.
However, the maximum pressure available from the
pump is only 1570 PSI. This pump would not do the
job.
6. Follow the chart in a straight line from required
output into the upper right quadrant until you
come to the size of the pipeline that you will use. A
good rule of thumb for sizing pipeline is to use the
largest-diameter pipeline that you can. It takes less
force to move concrete through a 6-inch pipeline
than, for example, a 4-inch pipeline. When pres-
sure is exerted on concrete in a pipeline, a paste of
water and cement fines coats the inside of the pipe-
line and forms a slippery layer on which the bulk of
the concrete slides. While it is true that a 6-inch
pipeline has 49 percent more surface area to coat
than a 4-inch pipeline, the volume of concrete that
can move on the layer is increased by 12 percent,
which results in lower velocity of the concrete (in
feet per second), lower friction, and therefore lower
pressure. A pump that may not be capable of com-
pleting a difficult job through 4- or 5-inch pipe may
be able to do it easily through 6-inch pipe. Note!
Experience has taught us that 5-inch is the opti-
mum pipeline size for lengthy vertical runs such
as those found on high-rise buildings. It is large
enough for most aggregate, but small enough
that you minimize the amount of concrete that
slides back into the hopper when the concrete
valve cycles, which we call backwash. You must
also consider the people at the point of place-
ment. Very few hose handlers, if any, can move
6-inch hose on a slab all day. There is no provi-
sion in the nomograph for mixing pipeline sizes.
For example, if you will be reducing from 5-inch to
4-inch, pipe, you should calculate the chart as if
you were using 4-inch pipe for the entire distance.
This will not be completely accurate, but you will
be safe in your pressure calculation. In our example
(Figure 4) we use 5-inch pipeline.

Pipeline diameter in inches

Q in yd3/hr.

6" 5" 4.5"

4"

Make a 90° turn when

you intersect with the
pipeline diameter that
applies to your job.

uppr rght quad-eps

Figure 4
Upper right quadrant—Pipeline diameter

162 Training Manual

 SERVICE TRAINING

When the output line intersects the pipeline diameter
that corresponds to your job, draw a line straight down
into the lower right quadrant, as shown in Figure 4.
7. The lower right quadrant refers to the propor-
tional value of your pipeline. It is a way of taking
into account not only the length of the pipeline, but
also the number of bends, the increased resistance
of flow in rubber hose, and other factors. It is more
a measure of the resistance to flow than a measure
of length. In calculating the proportional value of
your pipeline, always apply the following criteria:
• Each 90° bend with a radius of 250 mm (boom
elbow) = 3.5 feet.
boom 4 nomo.eps
• Each 90° bend with a radius of 1 meter (long
sweep) = 10. feet.
• Each 30° or 45° bend with a radius of 1 meter or
250 mm = 3 feet.
• Each section of rubber hose causes three times as
much resistance as the same length of steel pipe
(e.g., 12 feet of rubber hose has the same
resistance as 36 feet of pipeline).
• Figure all horizontal and vertical distances
equally. The increased pressure required to push
concrete vertically is accounted for by adding
pressure, not distance.
• An example pipeline is shown below (Figure 5).

40 ft.
hose
150 ft. pipe

70 ft.
level
difference

elbow - 90°, r = 250 mm...3.5 feet

elbow - 90°, r = 1 meter...10 feet
elbow - 30° or 45°, r = 250mm or 1 meter...3 feet

Note!
Proportional value of the 39X boom and deck pipe system is 261 feet.
This value includes elbows, reducer, and tip hose.

Example: You must go 150 feet out through the deck and boom pipe, including the tip hose, then
through 40 feet of rubber hose. Calculate the proportional value as follows:
all boom system = 261. feet (includes a 12-ft long, 5-in. tip hose)
15 10-foot pipe sections = 150. feet
40 x 3 = 120. feet (for the rubber hose)
Total = 531. feet.
Round the total to 500 feet to make it easy to use the following chart (Figure 6).

Figure 5
Calculating proportional values

Training Manual 163


Once you have calculated the proportional value of
your pipeline, extend your line down from the upper
right quadrant until it intersects with the line that
represents your pipeline. When you reach the

SERVICE TRAINING
intersection, make a 90° turn clockwise, into the lower
left quadrant. As noted above, we are using 500 feet as
our proportional value (Figure 6).









Make a 90° turn when 

you intersect with the
proportional value that 
applies to your job.


       



     
Lower right quadrant - proportional value of pipeline
8. The lower left quadrant refers to the pumpability
of the concrete. If the concrete specifications allow
a range in slump (for example 5–6 in.), always use
the lower end to be safe. In our example, we use 5-
inch slump. You extend the line from the lower
   

Figure 6
right quadrant until it intersects with the 5-inch
slump line, then make a 90° turn clockwise. This
will lead you back into the upper left quadrant
through the pressure scale (Figure 7).
           
 

Figure 7
Lower left quadrant—
pumpability of the
concrete 

 Make a 90° turn when

you intersect with the
slump that applies to
your job.

    !

  
   



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As you can see by the chart in Figure 7, we are The nomograph is now complete. The PF of our job
reentering the upper left quadrant through the pressure can be calculated like this:
scale at about 550 PSI. Remember, we now have to add PF = PSI x yd3/hr
the head pressure for our vertical rise. At 1.1 PSI per
We need a unit that is capable of 627 PSI, and 100 yd3/
foot of level difference, and our 70-foot vertical run,
hr. The PF of this job is:
we must now add 1.1 x 70 = 77 PSI to the 550 PSI
from the chart. PF = (627 x 100)
PF = 62,700
550 PSI + 77 PSI = 627 PSI
The unit must have a PF over 62,700 and it must be
NOTE! able to pump 100 yd3/hr and 627 PSI simultaneously.
When calculating the head pressure from Look at the pump shown in our sample nomograph
vertical runs, it doesn’t matter if the pipe- (Figure 8).
line runs straight up and down, or if it runs
uphill at an angle. Only the level difference • Can the unit pump at 627 PSI? Yes
in feet is needed for the pressure calculation. • Can the unit pump 100 yd3/hr? Yes
If the pipeline is running downhill, the oper- • Can the unit pump both simultaneously? No! This
ator will need special knowledge, but you unit will not do the job.
don’t need to add any head pressure to the
nomograph.

56,650
Power factor number (PF)
upper left quad-eps
English to Metric Conversion Factor is PF Ö 18.966
200

Q in. yd3/hr.
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
140
Example Job
Working power (in kW)

120
100
80
60
40

103 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI
Figure 8
Is this unit sufficient for the job?

The engine is a little too small. The intersection of 100 pumps set to a higher Kw? The PF of the higher Kw
yards3/hr and 627 PSI has been plotted for visual unit is 72,600. This should work. Plotting the
representation, but you will see immediately that the intersection of our hypothetical job again, you will see
PF of the job (62,700) is bigger than the PF of the unit that it falls within the power zone of the hydraulic
(56,650). The curved black line represents the PF of the pumps (Figure 9)
unit. If the unit is going to be able to handle the job, the
intersection of pressure and yd3/hr will be to the right
and down from the curved line. Anything to the left or
above the line is beyond the power of the hydraulic
pumps. What if we could order this same unit with the

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 SERVICE TRAINING

The nomograph should only be considered accurate to
within ±10 percent. You should always calculate
conservatively, and allow for the graph tolerance. In the
case of the pump in Figure 9, we should still be safe
even if the pressure required were 10 percent greater
(690 PSI).What if you already own the pump shown in
Figure 8? Is there anything that can be done to the job
specifications to make the unit with the less powerful
pumps work? You could use the smaller PF unit shown
in Figure 8 if you can get permission to do any of the
following things:
• Pump the top of the building at 85 yd3/hr instead
of 100 yd3/hr.
• Pump the top of the building at a 6-inch slump
instead of 5-inch. (This would still be within
specifications.)
• Remove some of the rubber hose at the end of the
horizontal run. Normally, with job circumstances
that did not require a substantial vertical run, you
could also use 6-inch instead of 5-inch-diameter
pipeline, but in our example, the entire vertical run
was made with the boom. The boom can never
support 6-inch pipeline.

72,600
Power Factor number (PF)
English to Metric Conversion factor is PF 18.966
200

Q (in yd3/hr)
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
Working power (in kW)

140

120

100

Example Job 80

60

40

132 kW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
up1ft 132Kw Quad 2000R.eps
P (in PSI)

Figure 9
Same model pump with larger Kw hydraulic pumps

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Minimum Pipe Wall Thickness

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Preventative Maintenance This is only a generic sample of a maintenance chart.

Please refer to your O/M manual for your specific
unit’s break-in period.
The table below lists the normal recommended
maintenance schedules (after the break-in period). A
description of each maintenance task is on the pages of
this manual listed in the page number column.

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 √

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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 √
Check the accumulator pre-charge Δ Δ √
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 √

Δ = Breakin period

Training Manual 169


Filtration
General information relates to all concrete pumps.
Specific information contains information the relates to
your Schwing concrete pump.
General information
Filtration is the single most important method of
keeping the concrete pump hydraulic system
operational. Particles that could damage the
components are introduced into the oil by the
differential cylinders and the valves through the
reservoir breather tube and by internal wear in the
components themselves. Additionally, when you
change hydraulic oil the new oil is not clean enough to
be used in a concrete pump without being filtered. In
fact, new hydraulic oil is only filtered at the refinery to
40m (40 microns). The oil in a Schwing concrete
pumps must be filtered to a minimum of 25m, and
preferably finer than that. Filters are rated by:
• the size of particles they trap and whether that size
is nominal, or absolute,
• the dirt holding capacity in grams, and
• the clean element pressure drop for a given flow
rate as well as the ratio of particles of a given size
encountered versus particles passed through the
filter (referred to as the beta ratio). (The flow rate
can be in PSI and gallons per minute or bar and
liters per minute.) An example of a beta ratio
would be β25 = 200 (pronounced “beta twenty
five equals two hundred”). This means that for
every 200 particles of 25 microns or larger that hit
the filter media, one makes it through. A finer
filter example would be β12 = 200. A courser filter
example would be β25 = 75. Concrete pumps
require medium to fine filtration.
Specific information
Here are some facts regarding filtration as they relate to
your pump.
• As delivered from the factory, each Schwing
concrete pump is equipped with a return filter that
is rated at 12 micron (shown as 12μ) absolute.
• The beta ratio is β12 = 200. This means that for
every 200 particles of 12 microns or larger that hit
the filter media, one makes it through. Although
we are not happy about the one particle that is
allowed through, we do not use finer filtration
170 Training Manual
SERVICE TRAINING
because A) the components don’t require it, and
B) a finer filter would plug up with dirt too often,
resulting in high maintenance costs to you. We
have settled on a compromise that should afford
long service life and minimum maintenance costs.
Don’t be fooled by the one particle that gets
through, this is an extremely high quality element
with very good trapping characteristics.
• The clean element pressure drop is about 6 PSI at
400 liters per minute (element only) + 2 PSI for
the housing, for a total of 8 PSI ΔP when the
element is clean. The pressure drop varies with the
viscosity of the oil, that is why you can ignore the
dirty filter light until the oil is heated to normal
operating temperatures.
The filter holds between 65 and 80 grams of dirt
when operating at a flow rate of 400 L/m. The
flow rate is important because the filter would
hold more if you operated at a lower flow rate.
Good filtration is not cheap, but it will save you
thousands of dollars by preventing component
failure.
• The return filter is equipped with an integral
bypass check valve with a spring force of 50
pounds. That means that when the filter is clogged
with dirt and oil is having a hard time making it
through, the pressure difference between the filter
inlet and the tank rises. This pressure difference
(commonly referred to as a pressure differential)
is called delta P and is shown as ΔP. When the ΔP
reaches 50 PSI, the check valve opens, and the oil
returns to the tank unfiltered. If the filter did not
have the bypass check valve, it would simply
break apart when it was clogged. That would put
all of the dirt that it ever trapped directly into the
system, and the element itself would become a
contaminant.
Changing hydraulic oil filters
Your concrete pump is equipped with a ΔP sensing
switch in the filter housing that turns on a light on the
operator’s panel when the filter is in bypass. While the
light is on, the oil is not being filtered. When the oil is
cold, the filter may go into bypass simply because the
oil is stiff enough to create 50 PSI ΔP. When the oil
reaches operating temperature, the light should go off.
If it doesn’t, the filter is plugged with dirt. If you have a
filter with you, install it at the first opportunity. If you
do not have a spare filter, change it as soon as you get

back to the shop, or order the filter so it can be replaced
soon. Remember, unfiltered oil wears out every
hydraulic component on the concrete pump.
Your concrete pump may be equipped with a main
return oil filter mounted on top of the hydraulic oil
reservoir or an inline filter located on the passenger
side just above the hydraulic oil cooler. (Both types of
filter are shown in.
t
The boom/outrigger circuit is equipped with an in-line
high-pressure filter. This filter is in a canisters rated to
handle the pressure that is felt by this circuit. There is
no integral bypass in this filter. The filter is not fitted
with a ΔP switch, so you should change it whenever
the return filter light comes on. The rating on the
filter is β25 = 200. We install this filter to catch large
particles that may cause a boom valve or holding valve
to stick in an open position. Because the boom circuit
gets its oil from the same tank as the return filter, the
oil should be clean anyway.
The oil tank breather filter is mounted on top of the
hydraulic oil tank. This filter should be changed when
the main return oil filter is changed.
The high pressure oil filter is located on the passenger
side of the unit.
The type of filters installed on your unit are the result
of years of experience and testing. We recommend that
you do not change the housing or element to some
other type. You may learn that in the long run, cheaper
is more expensive.
Changing high pressure water filter
The optional high pressure water pump has an inline
filter between the water tank and the optional high
pressure water pump. This filter needs to be inspected,
cleaned, or replaced at the same time hydraulic oil
filters are changed. This filter will also need inspection
and cleaning if water is not flowing through the high
pressure water system. The part number for the filter
element is in the Parts List manual supplied with your
concrete pump.
Hydraulic Oils
General information relates to all hydraulic oils.
Specific information contains hydraulic oil
recommendations for Schwing concrete pumps.
Training Manual
SERVICE TRAINING
General information
Hydraulic oils are rated for viscosity, heat dissipation,
foaming characteristics, pour point, antiwear additives,
anticorrosive additives, lubricating qualities,
compressibility, temperature range, temperature
stability, and other functions. Although many different
brands of oil meet these specifications, they may use
different chemical additive packages to achieve the end
result. For this reason, you should not mix two
different brands of oil. The additive package from one
brand may be incompatible with the additive package
from the other, rendering both packages useless.
Recently a few manufacturers have introduced
biodegradable hydraulic oils onto the market. These
oils are based on vegetable extracts instead of mineral
extracts. They are considered safer for the environment
in the event of a spill, although the additive packages
are not inert. One brand, Mobil EAL 224-H, has been
accepted for use in Schwing pumps, and other brands
are under consideration and testing. These oils must
not be mixed with mineral-based hydraulic oils, even in
very small amounts. If you will be pumping a job in an
environmentally sensitive location and want to use this
type of hydraulic oil, please contact the Schwing
Service Department at (651) 429-0999 for instructions
on making the change from mineral oil.
Viscosity of hydraulic oil is similar in concept to the
different weights of motor oil. For example, in the
winter you may run 5W-30 in your car, while in the
summer you run 10W-40. The same is true for
hydraulic systems. If you live in a climate where the
weather is changing from extremely hot conditions to
extremely cold conditions, you should consider
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
gets. The lower the ISO VG number the thinner the oil
and the lower the pour point of the oil. On the other
hand, the thinner the oil, the lower the temperature will
have to be before it breaks down the lubricating film
that protects your components.
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 SERVICE TRAINING

The quality of the oil needed for use in a Schwing

concrete pump is rated in the DIN system. The ratings
have to do with the chemical additive package that is
introduced into the oil. Both the DIN rating HLP and
HV qualities are approved for use in our concrete
pumps.

Specific information

Most concrete pumps leave the Schwing factory filled

with Texaco Rando HD 46 hydraulic oil, which has an
ISO viscosity rating of VG 46. Rando HDZ 46, an
extended-viscosity oil designed for use under severe
conditions, is available on request. If you want your
new concrete pump filled with a different brand or
different viscosity oil, you should specify it when
ordering.

Many other brands of oil have been approved for use in

Schwing concrete pumps, including:

• Mobil DTE

• Shell Tellus oil

• BP Energol

• Aral Vitam

• Esso Nuto

• Esso Univis

• Total Azolla

• Wintershall Wiolan

The order of the brands listed is not significant. Any oil

that meets the quality and viscosity standards described
above can be used.

When to change your hydraulic oil

Change your hydraulic oil at least once a year. If you

use good filters, and change them when they are dirty,
the oil will be clean even after a year. The chemical
additive packages that give the oil its properties will
break down with time, however and no amount of
filtration will bring them back.

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Electrical Introduction
This guide will help you learn how to service current
Electrons (13) and future Schwing electrical systems. Even if you
- have little or no experience with electrical repairs, this
-
guide will help. It begins with the basic definition of
electricity and continues all the way through the
- -
troubleshooting process. It will show you how to use
Ohm’s law, identify series, parallel and series-parallel
- - - - circuits, and troubleshoot circuits using various testers.
It’s a fairly complete journey from concepts to
applications.
- - - -
-

Nucleus
What is Electricity?
(w/13 Protons) Electricity is the flow or displacement of electrons.
Normally, the atoms in a substance are balanced in an
electrically neutral state. They’re made up of equal
Figure 1. Aluminum atom (Neutral state) numbers of positively-charged protons and negatively-
charged electrons.

-
However, it is possible to strip electrons from atoms.
This creates areas of positive and negative charge in a
-
One Electron Is substance: positive charge where there are atoms
- - Forced From without the normal number of electrons, and negative
The Atom Leaving charge where there are excess electrons. As you might
Only 12
- - - - have guessed, these two oppositely charged areas
attract each other. Why? Because the unbalanced atoms
and stray electrons always want to return to the
- - - - balanced, or electrically neutral, state. On the other
- hand, areas with the same charge repel.

The Atom is Unbalanced

With 13 Protons Resulting
In A Positively Charged Atom

Figure 2. How a positively charged aluminum

atom is created

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Static electricity is electricity that does not move. It’s

created when electrons are rubbed off one material by
friction and deposited on another. A common example
of this is when a balloon is rubbed against some fabric.
The fabric gives up some electrons to the balloon. This
makes the balloon negatively charged and the fabric
positively charged.

Since opposite charges attract each other, this causes

the balloon and fabric to stick together. And since like
charges repel, two of these negatively-charged balloons
will push each other apart.

The attractive and repulsive forces created by static

electricity work like magnets. This principle is used in
Figure 3. Opposite charges attract copy machines, CRT’s and electrostatic painting
processes.

Unfortunately, static electricity has its bad side too.

Unwanted discharges, like the zap you get when you
touch a metal doorknob, can be dangerous. For
example, truck drivers who transport flammable
materials such as gasoline have to make sure that no
sparks caused by ESD are created when gasoline is
being loaded or unloaded. In addition, even a small
discharge packs a high-voltage punch that may damage
sensitive electronic parts and modules. Be careful not
to touch the terminals of an electronic module. A static
discharge through the component’s circuitry can
destroy it.

Figure 4. Like charges repel

Figure 5. Typical static discharge

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Dynamic electricity is moving electricity that’s

created when electrons flow from atom to atom through
a substance. It’s the type that flows through power lines
Electrons (13)
to homes or that lights the headlights on a truck.

The flow of electrons is called an electric current. To

- - - - understand how it works, picture a row of atoms: An
electric current starts when an electron is stripped from
an atom at the end of the row. This now positively
charged atom then attracts a negatively charged
electron from its neighbor, leaving its neighbor
positively charged. The neighboring atom then attracts
Figure 6. Electron Flow=Current Flow an electron from its neighbor and so on down the line.

For current to flow then, there must be a complete path

of atoms (called a closed circuit) and an electron
“pump”, that can trip electrons from atoms on one side
using a strong positive charge and push them through
the circuit on the other side using a strong negative
charge.

In a typical Schwing concrete pump circuit, wires

provide the path of atoms, and the battery is the pump
that forces the electrons to flow from atom to atom.

Figure 7. AC current flow periodically AC and DC. Two types of electric currents exist; AC,
reverses direction for Alternating Current, and DC, for Direct Current.

In DC currents, the electrons flow in one direction only.

So, in all the diagrams you’ll be looking at, DC current
flows from the positive battery terminal to the negative.

DC current is used to power the electrical systems of

all Schwing concrete pump. It has important properties
you must understand to properly repair electrical
circuits. Those properties are amperage, voltage, and

+ resistance.

Figure 8. DC current flow constantly in one

direction only

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Amperage
Seconds
0 Amperage describes the rate of current flow. It is
measured in amps, using an ammeter. The higher the
3 1 amperage, the greater the number of electrons flowing
past a single point in one second.
2

It helps to think to current as water, and amperage as

the rate of water flow through a pipe. You can measure
the rate of water flowing in a pipe in gallons per
6.28 Billion second. Similarly, one amp is equal to 6.28 billion
Billion Electrons electrons passing a single point in one second.
Per Second

1 Amp
Current flow and heat are related. As amperage
Figure 9. Amperage is the rate of current flow increases, more electrons flow and more heat is
generated. Any electrical component that carries
Low Current Flow current, generates heat. For this reason, the wires in a
Low Heat Schwing concrete pump are sized according to the
amount of current they must carry. Thick wires carry
large currents, while thin wires are used for small
currents. Thick wires can handle a large current
without burning up because they are made up of more
atoms with more available electrons. They therefore
resist the flow of current less than thin wires.

Wire gauge sizes describe the thickness or thinness of a

wire. Gauge size refers to the wire core, not the
insulation covering it. Two numbering systems are
used to designate wire sizes: American Wire Gauge
High Current Flow
High Heat (AWG) and metric. In the AWG system, as the wires
get thicker, the number designation decreases. For
Figure 10. Relationship of current flow and example, a 20 AWG wire is very thin, while a 4 AWG
heat wire is much thicker. The metric system works in the
opposite way. As the wires get thicker, the number
designation increases. So, a.5 metric gauge wire is very
CURRENT CAPACITY INCREASES thin, and a 19 metric gauge wire is much thicker.

Because insulation sizes vary, never try to judge the

WIRE RESISTENCE DECREASES
Figure 11. Relationship of current capacity
and resistance to wire thickness
thickness of a wire core by looking at the size of the
insulation. Always refer to the code or measure the
thickness with an appropriate tool. And always replace
a wire with new one of the same gauge or thicker. A
wire that is too thin poses a fire hazard because it may
overheat and burn.

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Electron Flow Wire Conductor

Figure 12. Voltage is the push, or pressure, on electrons

Voltage
Allows Less Voltage is the force that moves electrons through a
Flow (Amps) circuit. It’s also known as “electromotive force,” or
“EMF”. Technically, it is the potential difference in
1000 electron pressure between any two points. Voltage is
measured in volts, using a voltmeter.

Allows More The higher the voltage, the more force is available to
Flow (Amps) cause electrons to flow. The lower the voltage, the less
available force.
10

Figure 13. A resistence is a restriction Voltage is like the water pressure in a pipe. At 10 psi of
pressure, water flows through a pipe at a certain rate. At
20 psi, the water will flow almost twice as fast. The
relationship is similar in an electrical circuit. For
example, at 12 volts, current flows through a particular
Allows Less
Flow (Amps) circuit at a rate of 12 amps. At 24 volts, however,
current flow through that same circuit at a rate of 24
amps.
Infinite

Resistance
Allows More
Flow (Amps) Resistance descries how much a component or circuit
resists, or restricts, current flow. Think of it as a kind of
0 electrical friction. The greater the resistance, the less
current flows. The less the resistance, the greater the
current flow. Resistance is measured in ohms, using an
Figure 14. The two extremes of resistence ohmmeter.

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Conductors. Some materials have very low resistance

to current flow because they have many electrons,
Copper Wire called “free” electrons, that can be made to move
easily. These are called “conductors.” Most metals are
good conductors. Copper and aluminum wires,
switches, and connector terminals and the iron and
POWER
1000
500 200 BATT steel of the truck’s engine and chassis are typical
200 9V

20
2000
200u conductors in a Schwing electrical circuit.
m 20m

200m
200m

2000k 200

200k 2000
20k

200 mA FUSED
500V max
500V Besides the thickness of a wire, several other factors
COM V mA
affect the resistance of a conductor. They include
condition, length and temperature. For instance, a wire
in poor condition with a partially cut core, has
increased resistance because the narrower width at the
cut restricts the movement of electrons. In fact, the
Figure 15. Copper conductor partially cut wire operates in a circuit as if its entire
length were of the reduced diameter at the point of the
cut.
Short Wire Offers
Less Resistence
The length of the conductor also affects its resistance.
A longer wire offers more resistance than a shorter
wire (of the same diameter) because the voltage has to
move the electrons through it farther.

Heating a conductor increases its resistance: The

higher the temperature, the greater the resistance. In
addition, conductors themselves generate heat as
Long Wire Offers current flows through them. This heat also causes the
More Resistence resistance of a conductor to increase as it is warms up
and decrease as it cools down. As long as a conductor
Figure 16. Resistence of short vs. long wires is properly sized, the amount of resistance it offers in a
circuit is so low that it can usually be disregarded, and
RESISTANCE the amount of heat it generates won’t damage the
circuit.

.05Ω Why does temperature affect a conductor? At lower

temperatures, the atoms in a conductor remain rigidly
aligned and don’t move around much. Resistance and
heat are low because electrons flow relatively smoothly
.04Ω from atom to atom.
At higher temperatures, however, the atoms in a
70˚F 170˚F conductor are less well aligned and move around a lot
TEMPERATURE more. Many electrons collide with electrically
balanced atoms before reaching positively charged
Figure 17. Resistence to temperature atoms. The increased frequency of these collisions
relationship in 10ft. long wire increase resistance and generates excess heat.

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Insulators. Materials with a very high resistance to

Insulation current flow are called “insulators.” Insulators have no
free electrons that can conduct a current. They’re used
to keep current flowing in a particular circuit and
covers a wire to keep current flowing through its
copper conductor and prevent any unwanted contact
POWER

200
1000
500 200 BATT

9V
with another conductor. Glass, rubber, and ceramic are
20
2000
m
200u

20m
other examples of typical insulators.
200m
200m

2000k 200

200k 2000
20k

200 mA FUSED
500V max
500V

COM V mA

Basic Circuits

A typical Schwing concrete pump circuit is made of a

voltage source, a circuit protection device, a load, a
Figure 18. Wire insulation
control and a ground.

Circuit Breaker The voltage source is the pressure source or electron

pump that creates the force necessary to make current
flow. The battery is ultimately the voltage source for all
circuits in a truck. However, the alternator is the
voltage source for most circuits when the engine is
running.

Batteries convert chemical energy to electrical energy

using the reaction of two different conductive metals in
an acid solution. Alternators convert the mechanical
energy of the rotating crankshaft into electrical energy.

Figure 19. Circuit breakers Circuit protection devices such as fuses and circuit
breakers are designed to protect a circuit’s wiring and
components by cutting off current flow when it
becomes too high. They do this by switching off or
melting. This opens, or breaks, the circuit.

Loads are electrical devices designed to perform

various useful functions. They convert electrical energy
into other forms of energy. For instance, a light bulb
converts electrical energy into light energy, a starter
motor converts it into mechanical energy, and a resistor
converts it into heat energy. AC compressor clutches,
relay coils, horns, and gauges are other examples of
loads.

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A load has resistance and draws a certain amount of

current in a circuit. It also uses up voltage as current
passes through it. This is called “voltage drop”; it is
measured by connecting a voltmeter across a load. A
circuit will operate properly as long as the resistance
+ and voltage drop of its load remain normal.
-
A good conductor, however, has a small resistance and
causes very little or no (measurable) voltage drop. A
conductor with high resistance and high voltage drop is
POWER
1000
500 200 BATT faulty in some way. Typical faults include cut wires and
200 9V

20
2000
m
200u

20m
loose or corroded connections. If the voltage drop
200m

2000k
2000
200m

200
across a wire or connection is sever enough, the circuit
200k

will not operate, or will operate improperly – the light

20k

200 mA FUSED
500V max
500V

COM V mA
dim, cranking slows, or the battery discharges
frequently.
Figure 20. Measuring voltage drop

Potentiometer Controls are used to turn circuits on and off. The

simplest type of control is the on-off switch. Opening a
switch turns off the circuit by breaking the path of
current flow and creating an open circuit. Closing a
switch turns on a circuit by completing the path of
POWER
1000
500 200 BATT
current flow and creating a closed circuit.
+12V -0V 20
200 9V

200u
2000
m 20m

200m
200m

2000k
2000
200 Other types of controls vary the function of a load by
200k
20k

200 mA FUSED
500V max
500V
increasing or decreasing current flow. Variable
COM V mA
resistors, do this by allowing you to vary the amount of
resistance in the circuit. So, in a light dimming circuit,
for example, the higher the resistance, the dimmer the
lights, and the less resistance, the brighter the lights.

Figure 21. Rheostat A ground is a return for current flow to the voltage
source. Ultimately, the negative battery terminal serves
as the ground for all the circuits in Schwing concrete
pumps. However, since the frame and engine are also
connected to this terminal and are conductors, most
ground connections are made to them, not the battery
terminal.

When working on a Schwing concrete pump, always

be sure to note the proper ground polarity. Reversing
battery or jumper cable connections can instantly
destroy solid-state parts and modules.

180 Training Manual

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Schematics Circuit Types

Electrical diagrams, also called “schematics” represent When two or more loads are use in a circuit, they can
the different components of a circuit using various be connected to form any one of three different types of
symbols. Most of the symbols shown on page 138-140 circuits: series, parallel, and series-parallel.
are standard; be sure to familiarize yourself with them.
However, be aware that some components may be
represented differently on other schematics. If a Series. A series circuit exists when the loads are
symbol is unfamiliar, refer to the legend for the connected end-to-end in one continuous path. In this
schematic. type of circuit, one of the loads is disconnected or
develops an open, all of them stop functioning.

Schwing America produces a variety of Electrical

Parallel. A parallel circuit exists when the loads are
System Manuals for different electrical control
connected side-by-side so that there are a number of
systems. The schematics they contain are great
paths for current flow. In this arrangement, if one load
troubleshooting aids that allow you to examine a circuit
is disconnected or open, the others continue to
on paper and figure how it should work. You can locate
function.
the likely causes of a problem on the schematic and go
directly to those places on the truck. This can save you
a great deal of time by reducing the number of
components you have to remove and the number of
wires you have to trace.
+

To read a schematic, follow the current flow from the

-
positive battery terminal to the negative. Since switches
and relay contacts are usually shown in the off or de-
energized position, you’ll have to determine how a
circuit operates by following current flow as if these
components were on or energized.
Figure 23. Typical series circuit
SWITCHE
RELAYS S: Methods of operation
SHOWING DIN (DEUTSCHE INDUSTRIAL NORM) SYMBOLS, PLUS COMMONLY
SWITCHES Normally open
Normally closed
N.C. =ON DISCONNECT Q
DISC.
USED
KEY : N.O. =
A.N.S.I. SYMBOLS AS SHOWN
PUSHBUTTO SCHWING SCHEMATICS
SWITCH
N.C. = Normally closed N
KEY: N.O. = Normally open (EMERGENCY STOP)
Relays
LINE Control If the contact operator is shown
(DIN drawing s)
MAGNET COIL extending beyond the last contact,
switch as drawn DIN it indicates that this operator will
Solid line = position of shown) ANSI also
operational
Position ofCONNECTOR
Contacts
(higher current rating)
(Bosch brand FOR HYDRAULIC VALVE
Relay coil
work a contact shown elsewhere
on
DIN the schematic.
ANSI
functions (detented "ON", 1 N.O. and (very small current
N.O.
DIN ANSI
shown)
spring returned "OFF" 1N.C. contact PUSHBUTTON draw)
shown
MOMENTARY CONTACT
HORN 86 Q
CB / DISC
Method of LINES, JOINING N.C.
operation: ON O OFF 1 Terminals
(Numbers shown if
87a 87 DIN ANSI
CIRCUIT BREAKER /
DISCONNECT
(double throw
switch shown) they are presesnt SWITCH (Letter
on the switch) PS.
LAMP
85WITH BULB R indicates
30 N.O. lens color)
ON OFF DIN ANSI
PRESSURE SWITCH
2 LINES,3 PASSING PS.
OR Component N.C.
enclosure
FUSE DIN 20A 20A
Contacts (2 N.O. ANSI MOTOR OVERLOAD
Component 86 87 RATING INDICATED)
87a(AMP
Dashed lines = contacts shown). RELAY OL
enclosure available positions DIN ANSI
of switch K3
TOGGLE SWITCH
G
AS DRAWN
+
85 30 TGS.
S.P.S.T.
("O" POSITION) receptacle
DIN ANSI

ALTERNATOR OR PLUG AND RECEPTACLE plug

as In the "ON" position,
switch
B+ OR MISC. DEVICES
"ON" position activated, is held in place by the
detent 0 1 2 TGS. DIN ANSI
indicated by solid line (indicated by the vertical
line) 86 D+
D.P.D.T. RESISTOR
K3 TACHOMETER SENDING UNIT
0,1,2
(VALUE INDICATED IN OHMS) 2.5 K
85 (PROXIMITY SWITCH, (K = 1000)
ON O OFF 1 ALTERNATOR
In this example, DIN - ANALOG CONVERTER)
DIGITAL 87a 87 ANSI
contact is made
between terminals on one part
If the relay coil is drawn
1 and 2 in the MECHANICA
of the31schematic, andLthe contacts
SWITCH K3
D- part, the relay 30
"ON" position (V-BELT
are drawn on another
SWITCH) POT
K3) will be listed NONE POTENTIOMETER 1K
ON OFF number (in this example,
in both places as shown here. OIL TEMPERATURE AVAILABLE (Value indicated)

-
2 3 +
TRANSMITTER
DIN ANSI
OR T 1K
(both DIN)
BATTERY Control Relays these numbers DIN ANSI
) show the location
shown (ANSI "ladder" drawing (line number)
TAS
Pivot point of the switch - contacts
CURRENT FLOWS
line indicates of the
N.O. IN THIS DIRECTION
below the activation Relay terminal Relay coil
°C that the relay coil
120V 120V
would be DIODE Primary
that the contact lever FUNCTION WHEN TEMPERATU numbers
60 HZ 60 HZ
drawn towards contact
#2 in the RE SWITCH will operateBLOCKED
CURRENT
"ON" position
ACTIVATED "ON" IN THIS DIRECTION
TAS
TRANSFORMER
line numbers
CHASSIS GROUND OR N.C.
CR 1 CR 2 °C 2
3 Secondary
d during 13 8, 9 12V
as Spring is compresse 1 5 9LIGHT EMITTING DIODE 12V
"OFF" position activated, activation, indicating
that it will 7 9 1 CR
DIN ANSI
indicated by solid line (L.E.D.) DIN
return to "O" when released ANSI
50a N.O. contact N.C. contacts
N.C. contact
OVER-CURR wire are underlined
30 ENT SWITCH numbers
(Always normally closed) SHIELDED CABLE
ON O OFF 1 CR 3 N.C. OL
BRIDGE RECTIFIER
In this example, 14 (Show all conductors
contact is made
1
5 9 (A.C. to D.C. converter)
STARTER between terminals 8 STARTER inside shield)
DIN ANSI
1 and 3 in the which relay
these numbers denote
"OFF" position
coil will operate the contact FS 21 21 22 22 DIN ANSI
ON OFF
31 TERMINAL CONNECTORS
N.O.
2 3 Q
CR 3 CR 2 2
FLOAT SWITCH 15
16
G CAPACITOR
1
1 2 8
9 (Oil 9
Level) FS (VALUE INDICATED
POSITIVE NEGATIVE IN
common TERMINALS
FARADS)TERMINALS
shown ELECTRIC MOTOR M N.C.
2 μF
Pivot point of the switch common Q neutral
(μ = micro or 1 millionth) 2 μF
line indicates hot
below the activation DIN
that the contact lever
would be FUNCTION WHEN DIN ANSI ANSI
#3 in the
pushed towards contact ACTIVATED "OFF"
"OFF" position

Figure 22. Typical electrical symbols Figure 24. Typical parallel circuit

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Series-Parallel. Any circuit that combines series and

parallel connections is called a series-parallel circuit.

On Schwing concrete pumps, batteries may be

+ connected in parallel or series. When batteries are
connected in parallel, the available current of each
battery adds to the first, but the voltage output remains
- the same. So, if you connect two 12 volt/85 amp
batteries in parallel, the output from both will be 12
volts/170 amps.

The opposite effect occurs when you connect batteries

in series. The voltage output of each battery adds to the
first, but the available current remains the same. Thus,
Figure 25. Typical series - Parallel circuit
two 12 volt/85 amp batteries in series yield 24 volts/85
amps of output.
12V

- +
POWER
500 200 BATT

12V
1000
200 9V

20 200u
2000
m 20m

200m

- +
200m

2000k 200

200k 2000
20k

200 mA FUSED
500V max
500V

COM V mA

Figure 26. Batteries in parallel

12V

- + POWER
1000
500 200 BATT

200 9V

20 200u

12V 2000
m

200m
200m
20m

2000k 200

200k 2000

-
20k

+ 200 mA FUSED
500V max
500V

COM V mA

Figure 27. Batteries in series

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Ohm’s Law
I= E Amperage, voltage, and resistance are related in a
R circuit. Ohm’s law describes this relationship and can
be used to find a missing value when the other two are
known.
E=IxR
The basic equation of the law is I equals E divided by
R= E R. I is the current in amps, E is the voltage, and R is the
I resistance in ohms.

Figure 28. The different forms of Ohm’s Law

To solve for voltage, the equation can be rearranged
like this: E=I x R. And to solve for resistance, the

E equation is R equals E/I.

I R
You should memorize the different forms of Ohm’s law
because you’ll need them when troubleshooting
Figure 29. Memory aid for Ohm’s Law circuits.

Here’s a quick way to remember Ohm’s law: Arrange

the letters of the law as shown in Figure 29. Then cover
the letter of the value you want to solve. The positions
of the other two letters will show you how to solve for
+ the one you covered.
- 1Amp= 12V
12

Examples of how to use Ohm’s law to solve for

12 ohm load amperage, voltage, resistance and voltage drop follow:

Amperage. What’s the current flow in a closed circuit

having a 12 ohm load connected to a 12 volt battery?
Figure 30. Typical amperage calculation
The answer is 1 amp. (12volts/12ohms=1 amp)

12V = 4A x 3 Voltage. Now, what’s the voltage in a circuit with 4

amps of current flowing through a 3 ohm load? It’s 12
volts. (4 amps x 3 ohms = 12 volts.)

Figure 31. Typical voltage calculation

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Resistance. What’s the resistance in a circuit with a 12

volt battery and 12 amps of current flow? It’s 1 ohm.
(12 volts/12amps = 1 ohm.)

1 = 12V Voltage Drop. Now, what should be the voltage drop

12A across the 12 ohm load in that first circuit? (Figure 32)
It’s 12 volts. (1 amp x 12 ohms =12 volts.) The load
uses up all the voltage in order to operate. If you get a
significantly lower reading, you’d know the circuit had
a poor connection or damaged conductor that was
Figure 32. Typical resistance calculation adding unwanted resistance to (and stealing voltage
from) the circuit.

What should be the voltage drop across the 12 ohm

load if the circuit is opened? Zero volts. (0 amps x 12
ohms = 0 volts.) With no current flowing, the load
doesn’t operate and can’t use up any voltage.
+ 12V=1 Amp x 12
-

12 ohm load
POWER
500 200 BATT
1000
200 9V

20 200u
2000
m 20m

200m
200m

2000k 200

200k 2000
20k

200 mA FUSED
500V max
500V

COM V mA

Figure 33. Typical voltage drop calculation

+
- 0V=0 Amp x 12

12 ohm load
POWER
500 200 BATT
1000
200 9V

20 200u
2000
m 20m

200m
200m

2000k 200

200k 2000
20k

200 mA FUSED
500V max
500V

COM V mA

Figure 34. Voltage drop in open circuit

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Series Circuit Laws

When there is more than one load in a circuit,

determining the values to plug into Ohm’s law requires
+ a little more effort. That’s because series and parallel
- circuits obey different rules. For series circuits, those
rules are:

4 4 4 • First, the sum of the individual resistances in a

series circuit equals the total circuit resistance.

• Second, current has the same value at any point in

Figure 35. Series circuit
the circuit.

• Third, the sum of the individual voltage drops

across the loads equals the source voltage.

+ 4 Total Resistance. For example, what’s the total

- +4 resistance in a circuit with a 12 volt battery connected
4 to three 4 ohm loads wire in series? It’s 12 ohms; you
12 just add up the resistance.
(4 ohms + 4 ohms + 4 ohms = 12 ohms.)
POWER
500 200 BATT
1000
200 9V

20 200u
2000

Amperage. What’s the amperage in this circuit. Since

m 20m

200m
200m

2000k 200

200k
20k
2000

200 mA FUSED
500V max
500V
it’s the same throughout the circuit, you can use Ohm’s
COM V mA law:
12 volts/12 ohms = 1 amp.
Figure 36. Total resistence in series circuit

+
- 1Amp= 12V
12

Figure 37. Amperage in series circuit

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 SERVICE TRAINING

Voltage Drop. Now, what’s the voltage drop across one

of the loads. To figure that, you use Ohm’s law and
plug in the total circuit current and the resistance of one
load. 1 amp x 4 ohms = 4 volts.

+
- 4V=1 Amp x 4 This result also agrees with the rule that current is the
same throughout the circuit. If you plug the voltage
drop and resistance of one load into Ohm’s law, you get
the same current value: 4 volts/4 ohms = 1 amp of
current flow.
POWER
500 200 BATT
1000
200 9V

20 200u
2000
m 20m

200m

2000k
200k 2000
200m

200 The third rule also proves out. Each 4 ohm load causes
20k

200 mA FUSED
500V max
500V a 4 volt drop, and 4 volts + 4 volts + 4 volts = 12 volts –
COM V mA
the source voltage.
Figure 38. Voltage drop of one load in series
circuit

Parallel Circuit Laws

The rules that parallel circuits follow are:

+
- 12 Volts
• First, the voltage drop across each branch of the
circuit is the same as the source voltage.

POWER
1000
500 200 BATT
• Second, the total amperage in a parallel circuit is
20
2000
200 9V

200u equal to the total of the individual branch

m 20m

200m

2000k
200m

200
amperages. This means you can treat each
individual branch of the circuit as a series circuit,
200k 2000
20k

200 mA FUSED
500V max
500V

COM V mA and add up their individual amperages to find the

Figure 39. Sum of voltage drops equals total flowing through the parallel circuit.
source voltage
• Third, the total resistance in a parallel circuit is
less than the value of the smallest branch
resistance. Another formula must be used to
calculate this total resistance value.
+
- RT = 1
1 + 1 + 1
R1 R2 R3 etc.
Now, let’s apply these rules:

Figure 40. Parallel circuit

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Total Amperage. What is the total amperage in a

circuit with a 12 volt battery connected to three 12
ohms loads wired in parallel? You know from the first
rule that the voltage drop across each of the loads is 12
volts, since that’s what the source voltage is. If each
+
-
load is 12 ohms, the amperage through each branch is 1
amp. (12 volts/12ohms = 1 amp.) The total current then
is 3 amps.

(1 amp + 1 amp + 1 amp = 3 amps.)

POWER
500 200 BATT
1000
200 9V

20 200u
2000
m 20m

200m

2000k
2000
200
200m

Total Resistance. To find the total resistance of this

200k
20k

200 mA FUSED
500V max circuit, you plug numbers into the total resistance
Figure 41. Measuring total amperage in a equation. See Figure 42 for an illustration of how to
parallel circuit solve the equation for this example. The total resistance
in this circuit is 4 ohms. This number also agrees with
Total the 3 amps of total current: Using Ohm’s law, 12 volts/
Resistance
4 ohms = 3 amps.

1 = 1 1 = 1x 4 = 4
1 + 1 + 1 3 1 1 An important difference between parallel and series
12 12 12 12 4 circuits is that as you add more branches to a parallel
circuit, its total resistance decreases instead of
Add Fractions increases. And this, of course, increases the current in
Find a Common Invert
Denominator, If Simplify Fraction and the circuit. For instance, add another 12 ohm load in
Necessary Fraction Multiply parallel with the previous circuit, and the total
resistance goes down to 3 ohms, while the amperage
Figure 42. Calculating total resistance in a increases to 4 amps.
parallel circuit

+
+ -
-

POWER
500 200 BATT
1000
200 9V

POWER 20 200u

500 200 BATT 2000

1000 m 20m
200 9V
200m
200m
20 200u
2000 2000k 200
m 20m 2000
200k
20k
200m
200m 200 mA FUSED
500V max
500V
2000k 200

200k 2000
20k
COM V mA
200 mA FUSED
500V max
500V

Figure 43. Measuring total resistance in a Figure 44. Total total resistance in a parallel
parallel circuit circuit

Training Manual 187

 SERVICE TRAINING

Series – Parallel Circuits

12 V
That brings us to series-parallel circuits. When you’re
- + trying to calculate values in these circuits, you have to
simplify parts of the circuit. That usually means
substituting an equivalent resistance for the parallel
part of the circuit, and then applying the series laws to
determine values for the overall circuit.

For instance, suppose you had a circuit like the one

shown in Figure 45. What is the total resistance of this
circuit? To figure that out, first find an equivalent
resistance for the two 12 ohm loads in parallel. Using
the parallel resistance equation, you’ll find the
Figure 45. Series - Parallel circuit equivalent resistance is 6 ohms. Now, to find the total
resistance, treat the circuit as if it were a simple series
circuit: 6 ohms + 6 ohms = 12 ohms. You can find the
amperage and voltage drops easily now: The amperage
is 1 amp, and 6 volts are dropped across each load.
1 = 1 1 = 1x 6 =
1 + 1 2 1 1
12 12 12 6

Figure 46. Equivalent resistance for parallel

part of previous series - parallel
circuit

12 V
- +

Figure 47. Previous series - parallel circuit

simplified

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Circuit Faults

Electrical circuits fail when they are open or shorted.

An open circuit occurs when there’s an unwanted break
+ in the circuit resulting in no current flow. The break
- may be in the wiring or a component.
Opens. An open puts unwanted infinite resistance into
the circuit. Because there’s a break, however, no
current flows, the components in the circuit do not
POWER

200
1000
500 200 BATT

9V
operate and no heat is generated. As a result, an
20
2000
m
200u

20m
ammeter will not give a reading, but a voltmeter,
depending on where it is placed, may or may not show
200m
200m

2000k 200

200k 2000
20k

200 mA FUSED
500V max
500V a voltage reading.
Figure 48. Voltage reading before opne
Unwanted Resistances. Opens are one extreme of
unwanted added resistance. But problems also occur
when any unwanted, but less then infinite, resistance is
added in series to a circuit. This may be caused by a
wire of incorrect size or material, a damaged wire,
+ loose or dirty connectors, or corroded connections or
- terminals.

These unwanted resistances allow current to flow, but

at a reduced amount. This causes components either to
POWER
1000
500 200 BATT stop operating or to operate at a reduced level. The
200 9V

20
2000
m
200u

20m
starter motor turns too slowly or the lights dim, for
200m

2000k
2000
200m

200
instance.
200k
20k

200 mA FUSED
500V max
500V

Figure 49. Voltage reading after open
Shorts. A short circuit occurs when previously
unconnected conductors touch one another allowing
current to bypass a part of a circuit. Shorts may occur
within a component, such as a starter motor or relay
coil, or across conductors in one or more circuits.

+
-

Figure 50. Short across conductors in

separate circuits

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 SERVICE TRAINING

Shorts often provide current with an alternate path of

lower resistance. A common example of this is a short
to ground. This makes bypassed components
inoperative and increases current flow. The increased
flow creates heat which usually causes a fuse or circuit
+ breaker to blow, adding an open to the short condition.
-
However, if the short bypasses the circuit protection,
components and wiring may burn up from the
increased heat.

A short may also bypass current so that the controls of

Figure 51. Short to ground
one circuit operate the components in another. For
example, lights that were previously controlled by one
switch may now go on whenever another set of lights is
switched on. Or a short may bypass the controls of a
circuit so that it operates continuously and can’t be
controlled by it’s switch. These are called “shorts to
voltage.”

+ Using Test Equipment

-
To diagnose circuit faults, you’ll have to use test
equipment. One very useful test instrument is the
digital multimeter. This device combines the functions
of an ammeter, voltmeter, and ohmmeter, so you don’t
separate pieces of equipment to measure these values.

Figure 52. Short voltage across switch However, jumper wires and self-powered and
unpowered test lights are also useful troubleshooting
Jumper Wire tools, but can cause other problems if not used
correctly.

CAUTION: Never begin to test a circuit without

knowing whether it contains any solid-state
components. Jumper wires and self-powered test lights
can damage circuits containing solid-state components,
and low-impedance analog (needle reading type)
Unpowered meters can give misleading readings. Use only a high
Test Light impedance (10 mega-ohms or more) digital mulitmeter
for testing circuits containing solid-state components.

Jumper Wire. A jumper wire is simply a length of

Self - Powered
Test Light insulated wire with clips or probes on each end. You
use a jumper wire to bypass a suspected fault and see
whether the circuit operates correctly. If it does, a fault
Figure 53. Other useful troubleshooting tools exists in the part of the circuit you’ve bypassed.

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Fused jumper wires are recommended to protect the

circuit you’re testing. A 5 amp fuse in the wire will
adequately protect most circuits. Of course, you can
use a larger fuse if the circuit you’re testing normally
+ draws more than 5 amps of current.
-
Be cautious when using a jumper wire: Never bypass a
load of any kind. The lower resistance of the wire will
increase current flow and may cause the wiring or
components to overheat or burn.

CAUTION
Unpowered Test Light. An unpowered
Figure 54. Jumper wire bypassing an opening testlight is simply a bulb with leads attached
to the bulb’s terminals. A 12 volt light is
Test Light "On" used on 12 volt systems, a 6 volt light on 6
volt systems. This type of test light must be
used in a powered, or active, circuit, since
the only way the bulb will light is when cur-
rent flows from the circuit and through the
+ light to ground.
-
You can check for voltage in a circuit by
touching one lead to ground and probing
the circuit with the other lead. This type of
testing, however, only tells you where volt-
age is present. To find out how much, you
must use a voltmeter.

You can test continuity of parts of a circuit

Figure 55. Voltage check with a unpowered
test light
+ Test Light "Off"
-
by connecting the light into the circuit. Con-
tinuity, or a complete current path, exists
when the bulb lights fully. A dim light
means there is an additional resistance in
the circuit before or after the points where
the light was connected. No light means
there is an open.

Figure 56. Continuity check with an

unpowered test light

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Connecting the light in series allows you to check for a

short to ground. Just disconnect the loads in the circuit,
and put the light in series where the fuse should be. If
Test Light the bulb lights with the circuit on, you know there’s a
"On"
short to ground in the circuit.

+
- Self-Powered Test Light. A self-powered test light has
its own battery, so it must be used in an unpowered
circuit. You use it to check for continuity.

If touch the probes to different ends of a conductor

Short to Ground
(wire, switch, connector, etc.) and the bulb lights, you
Figure 57. Checking for a short to ground with know there’s continuity through the conductor. If the
an unpowered test light bulb is dim or does not light, there is an added
resistance or an open exists in the conductor. To find
Test Light "On" out just how much resistance there is, you must use a
ohmmeter.

+ Check for a short to ground by disconnecting the

- normal ground connection of the circuit (including any
redundant grounds) and connecting the light between a
part of the circuit and ground. If the bulb lights, a short
to ground exits.

Figure 58. Test light indicating continuity Test Light "On"

Test Light "Off"

+
-
+
-

Figure 60. Checking for a short to ground with

Figure 59. Test light indicating an opening a self-powered test light

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the meter on its proper care and use. In particular, note

how the test leads should be connected to the
POWER
BATT
instrument for different tests. And make sure the meter
500 200
1000
200 9V
will not be damaged when used to measure amperage
20 200u in the ranges you expect.
2000
m 20m

200m
200m

2000k 200 Always observe the proper polarity when connecting

200k 2000
Red Lead 20k
the meter leads. Properly connect the leads to the
200 mA FUSED
500V max
500V meter. Then, always connect the negative battery
terminal and the positive, or red, lead to the conductor
COM V mA
Black Lead connected to the positive battery terminal. With a
digital meter, but it will indicate a negative reading on
the display when it should be positive.
Figure 61. Proper Fluke multimeter lead
connections for measuring
amperage Units of Measurement. One of the things you’ll have
to get used to when using a multimeter is
understanding the different units of measure. The
symbols for these units mean the following: Capital K,
for kilo, is 1,000. Capital M, for mega, is 1,000,000.
Small m, for milli, is one-thousandth and small u, for
+
- micro, means one-millionth. A number without one of
these symbols behind it stands for a basic amps, volts
or ohms measurement. A number with one of these
symbols behind it means the basic value is multiplied
of dividend by 1,000 or 1,000,000. For instance, 20K
POWER

stand for 20,000 and 200, stands for.200 (200

500 200 BATT
1000
200 9V

20 200u

thousandths).
2000
m 20m

200m
200m

2000k 200

200k 2000
20k

200 mA FUSED
500V max
500V

COM V mA

To change a given measurement from one unit to

another, find both units on this chart. Then move
Figure 62. Observing proper polarity when the decimal point the (total) number of places
making a connections indicated, in the direction that matches the
direction of your desired change.
Digital Multimeters are preferred over other types of
3
meters because they are more accurate and will not
damage most electronic circuits. BASE UNITS
VOLTS
MEGA (M) KILO (K) MILLI (m) MICRO (u)
OHMS
AMPS

3 3 3 3
It is important to remember how to connect a
mulitmeter to obtain the proper reading and prevent
damage to the meter or sensitive electronic circuit.

First, read and follow the instructions that come with Figure 63. Converting units of measure

Training Manual 193

 SERVICE TRAINING

connected on the instrument.

When measuring the amperage, always connect the
meter in series with the circuit so that current flows
through it. Initially, make your connections with the
+ circuit unpowered. Then turn the meter to the correct
- range and turn on the circuit.

Current clamps are also available for use with a digital

multimeter. These allow you to measure amperage
without wiring the meter into the circuit. You just close
the clamp around the conductor and the meter reads the
current flow in amps. Usually, the mulitmeter must be
set to a mV (millivolts) scale for use with current
Figure 64. Measuring amperage clamp. However, the reading on the meter still
indicated amperage.

Voltage. When measuring voltage or voltage drop,

always connect the meter in parallel so that it’s across a
+ device or a part of the circuit. This is an advantage over
- amperage and resistance measurements, because you
can often leave the device or circuit connected. Take
your measurements with the circuit device powered.

POWER
500 200 BATT
Conductors should have almost no voltage drop. A
1000

20
2000
200 9V

200u
drop greater than 0.1 volt in a low-current conductor, or
0.3 volts in a high-current conductor (such as a battery
m 20m

200m
200m

2000k 200

200k
20k
2000

200 mA FUSED
500V max
500V
cable) indicates a damaged conductor or a poor
COM V mA connection.

Figure 65. Measuring resisitance of a load

You’ll sometimes find it necessary to convert between
the different units of measure. This is simply a matter
of moving decimal point and adding or subtracting
zeros. (Actually, you’re multiplying or dividing by the
number of thousands between units.) For instance, 1M
ohm equals, 1,000K ohms, and 2.2m amps equals.0022
amps. See Figure 65 for how to make conversions.
Amperage. Before measuring amperage, make sure
the meter is capable of handling the amount of current
flow you want to measure. Many digital meters will
only handle 2 amps of current, some even less. Others
with different connections, can handle up to 10 or 20
amps. Also make sure you have the leads properly
Resistance measurements must be made with the
circuit unpowered and the components under test
isolated. This always means turning off the power and
sometimes means disconnecting the components or
wiring you want to test from the rest of the circuit.
Remember, zero ohms of resistance indicates a
complete circuit with no resistance. Conductors should
have zero or very close to zero ohms of resistance. A
resistance greater than 0.1 ohm indicates a damaged
conductor or a poor connection. On the other hand, an
infinite resistance reading, usually a “1-” or “OL”
reading on the meter, indicates an open.

194 Training Manual

 SERVICE TRAINING

The Troubleshooting Process

A logical, step-by-step approach to troubleshooting is

absolutely necessary. A good general approach is to
observe all symptoms. Perform a visual inspection, test
the circuit, make repairs, then test the repair.

Observe and Verify. When observing symptoms, first

make sure that there really is a problem, and the
operator is not merely mistaking the normal operation
of a system for a malfunction. If you don’t notice a
problem, it may be intermittent. In this case, you need
to recreate the conditions that caused the malfunction
in order to find it. This means operating the unit under
the same conditions it failed under. If you still can’t
find it, don’t give up yet. There are still some things
you can do during testing that may reveal it.

Next, perform a visual check of the problem circuit.

Look for broken, loose, or corroded connections or
wires, burned –out bulbs, blown fuses, misadjusted
switches, etc. The problem may be nothing more then a
disconnected connector. Looking for the simple things
now can help you solve the problem quickly.

Test. If the cause of the malfunction is still a mystery,

it’s time to test the circuit. To do this properly, refer to
the wiring diagram for the unit. Note the path that
current must take in order for the circuit to operate
correctly. Check the operation of those components
which share sources of power or ground with problem
circuit. If such components operate correctly, you can
eliminate part of the circuit, up to the point where it
connects with a working component, as a source of the
problem. On the other hand, if you find that a couple of
circuits are operating incorrectly, you can begin testing
at the points these circuits have in common, if any.

Refer to the proper Service Manuals or Service

Bulletins for recommended tests. If non, apply, start
testing near the middle of the circuit where the wires or
components can be easily reached, unless your initial
observations lead you to a specific part of circuit. What
tests you choose are up to you. As long as you progress
in an orderly manner and understand the readings you
get, you’ll solve the problem. If necessary, record your
test results so you can analyze them more carefully.

Training Manual 195

 SERVICE TRAINING

Electrical Symbols

SHOWING DIN (DEUTSCHE INDUSTRIAL NORM) SYMBOLS, PLUS COMMONLY

USED A.N.S.I. SYMBOLS AS SHOWN ON SCHWING SCHEMATICS

LINE
MAGNET COIL
FOR HYDRAULIC VALVE
CONNECTOR DIN ANSI

HORN
LINES, JOINING

(Letter
LAMP WITH BULB R indicates
lens color)
DIN ANSI
LINES, PASSING

FUSE 20A 20A

(AMP RATING INDICATED)
DIN ANSI
G
receptacle
ALTERNATOR OR PLUG AND RECEPTACLE plug
B+ DIN ANSI
D+
TACHOMETER SENDING UNIT
ALTERNATOR (PROXIMITY SWITCH,
DIGITAL - ANALOG CONVERTER)

31 D-

+ OIL TEMPERATURE
TRANSMITTER OR T
(both DIN)
BATTERY

- CURRENT FLOWS
IN THIS DIRECTION
DIODE
CURRENT BLOCKED
IN THIS DIRECTION
CHASSIS GROUND OR
LIGHT EMITTING DIODE
(L.E.D.)
50a
30
SHIELDED CABLE
(Show all conductors
STARTER STARTER inside shield)

21 21 22 22
31 TERMINAL CONNECTORS

POSITIVE NEGATIVE
TERMINALS TERMINALS
ELECTRIC MOTOR M

196 Training Manual

 SERVICE TRAINING

Electrical Symbols

SWITCHES RELAYS
KEY: N.O. = Normally open N.C. = Normally closed KEY: N.O. = Normally open N.C. = Normally closed

Solid line = position of switch as drawn Control Relays

Contacts
(DIN drawings)
Position of operational
functions (detented "ON", (higher current rating) (Bosch brand shown)
spring returned "OFF" shown) 1 N.O. and Relay coil
1N.C. contact (very small current
Method of shown draw)
operation:
(double throw
ON O OFF 1 Terminals 86
switch shown) (Numbers shown if 87a 87
they are presesnt
on the switch)

ON OFF
30 85
2 3

OR
Component
Component Contacts (2 N.O.
Dashed lines = enclosure
enclosure contacts shown).
available positions
of switch
86 87a 87
AS DRAWN
("O" POSITION) K3
85 30

"ON" position activated, as In the "ON" position, switch

indicated by solid line is held in place by the detent
(indicated by the vertical line)
OR
86
K3
ON O OFF 1
In this example, 85
contact is made
between terminals 87a 87
1 and 2 in the If the relay coil is drawn on one part
"ON" position of the schematic, and the contacts K3
ON OFF are drawn on another part, the relay 30
number (in this example, K3) will be listed
2 3
in both places as shown here.

Pivot point of the switch shown

Control Relays these numbers
below the activation line indicates (ANSI "ladder" drawing) show the location
that the contact lever would be (line number)
drawn towards contact #2 in the FUNCTION WHEN Relay terminal of the contacts
Relay coil
"ON" position ACTIVATED "ON" numbers that the relay coil
line numbers will operate

"OFF" position activated, as Spring is compressed during CR 1 CR 2

indicated by solid line activation, indicating that it will 1 13 3 2
7 9 1 5 9 8, 9
return to "O" when released CR
N.C. contact N.O. contact N.C. contacts
ON O OFF 1
In this example,
wire
numbers
are underlined

contact is made CR 3
1 14
between terminals 8 5 9
1 and 3 in the
"OFF" position these numbers denote which relay
ON OFF
coil will operate the contact
2 3

CR 3 CR 2
1 15 16 2
Pivot point of the switch shown
9 9 1 2 8 G
below the activation line indicates
common common
that the contact lever would be hot neutral
pushed towards contact #3 in the
FUNCTION WHEN
"OFF" position ACTIVATED "OFF"

Training Manual 197

 SERVICE TRAINING

Electrical Symbols

SWITCHES: Methods of operation DISC.

Q
DISCONNECT
SWITCH
PUSHBUTTON
(EMERGENCY STOP) If the contact operator is shown
extending beyond the last contact,
DIN ANSI it indicates that this operator will also
work a contact shown elsewhere on
DIN ANSI
the schematic.
N.O.
PUSHBUTTON Q
CB / DISC

MOMENTARY CONTACT
N.C.
CIRCUIT BREAKER /
DIN ANSI DISCONNECT
SWITCH
PS.

N.O.

PRESSURE SWITCH PS.

N.C.

DIN ANSI MOTOR OVERLOAD OL

RELAY

TOGGLE SWITCH TGS.

DIN ANSI
S.P.S.T.

MISC. DEVICES
TGS.
0 1 2
D.P.D.T. RESISTOR
2.5 K
0,1,2 (VALUE INDICATED IN OHMS)
(K = 1000)
DIN ANSI

POT
MECHANICAL SWITCH 1K
(Hopper Grate Switch) NONE POTENTIOMETER
AVAILABLE (Value indicated)
1K
DIN ANSI DIN ANSI

TAS
120V 120V
N.O. Primary 60 HZ 60 HZ
¡C
TEMPERATURE SWITCH TRANSFORMER
TAS

N.C. Secondary
¡C 12V 12V

DIN ANSI DIN ANSI

OVER-CURRENT SWITCH OL
(Always normally closed) N.C. BRIDGE RECTIFIER
(A.C. to D.C. converter)
DIN ANSI

DIN ANSI
FS

N.O.
Q CAPACITOR
FLOAT SWITCH FS
(VALUE INDICATED IN
(Oil Level) N.C.
FARADS) 2 F 2 F
Q ( = micro or 1 millionth) DIN ANSI
DIN ANSI

198 Training Manual

 SERVICE TRAINING

Controller Systems
Analog

39000170.eps

Digi-Prop (Microwave)

40 60 0 0 0 0 0 1
10
80
20 100
C
HOURS

VDO
P

Filter
C
in Bypass

15 20 MAT
10 U/minx100 25

5 30

0 35
OIL
COOLER
ON

OFF

3034
1803

30339533
5 6
4

7
3

8
2

9
1

0 10

39000171.eps

Comfort Control

0
0 0

0
0

0 0

! 3034
1221

30339533
5 6
4
7
3

8
2

9
1

0 10

39000172.eps

Training Manual 199

 SERVICE TRAINING

C32

OUTPUT PARAM VALUE KEY

MAX
1_
THRESHOLD
15 20 D
2_
10 U/minx100 I 25

O
N

NO
RE
START PWM

T O P E R AT E
3_

D Z O N E!
5 30
POWER
4_
MAX PWM
REAR CTR 0 35
5_
UMB CTR
6_ RAMP UP
RADIO CTR

ID RAMP DOWN MIN

+ -
LINK

40 60
ALARM 80
20 100
E-STOP C

STORE
VDO

WHEN WELDING ANYWHERE ON UNIT

POWER CABLE MUST BE DISCONNECTED

3034
1803
5 6
4

7
3
30339533

8
2
L1357-01 5

9
1
4 6
0 10

7
3

8
2

9
1
0 10

30339530

39000173.eps

CPC

OUTPUT PARAM VALUE KEY

MAX
1_
THRESHOLD

2_

3_ START PWM

POWER RPM 4_
MAX PWM
REAR CTR
5_
UMB CTR
6_ RAMP UP
RADIO CTR

ID + - RAMP DOWN MIN

LINK
C
NORMAL BYPASS

ALARM

E-STOP
STORE

WHEN WELDING ANYWHERE ON UNIT

POWER CABLE MUST BE DISCONNECTED

3034
Reset 8540

30345602
L1357-01 4
5 6 7
3

8
2

9
1

0 10

39000174.eps
30351405A

CPC II

OUTPUT PARAM VALUE KEY

MAX
1_
THRESHOLD

2_

3_ START PWM

POWER RPM 4_
MAX PWM
REAR CTR
5_
UMB CTR
6_ RAMP UP
RADIO CTR

ID RAMP DOWN MIN

C + -

LINK NORMAL BYPASS

ALARM

E-STOP
STORE

∅ ∅
WHEN WELDING ANYWHERE ON UNIT
POWER CABLE MUST BE DISCONNECTED

Reset

5 6
4

L1357-01
7
3

8
2

9
1

0 10

CPC 2 30357944
39000175.eps

200 Training Manual

 SERVICE TRAINING

Vector - Current Production

2
1
OK OFF

0 x1000 3
PTO 1500 rpm 62˚C

Menu: [ENTER]=ON

1
HOME + HELP START 2
30356534 C

HP

30362348
CLEAR - ENTER QUIT R 4
5 6

7
3

8
2

9
1
0 10

39000176.eps

Training Manual 201

 (Reference #’s)

202
2
6 - 6 SQ. MILS
(wire size)

K12 relay location

same page Joining lines
.2 - reference 2

Relay coil location

11 - page 11
X2 Terminal Block
2 - reference 2
3 - TB #3 X11 - Plug connector X11
1 - TB #1 B2 - pin on X11

Non-joining lines

Training Manual
2
1.5 - 1.5 SQ. MILS
all 3 wires
SERVICE TRAINING

K12 Relay contact ".1" - reference 1 same page

 SERVICE TRAINING

28X Truck and Pumpkit Circuit

JunctionBox
(see boom orange
Trouble Light brown
2 1 schematic)
Receptacle at Tachometer
Operator’s Panel Panel
Panel Light Light
G
to Pin 2/5 + brown brown G
brown brown
from Pin 1/11 red red

orange
brown Remote
thermometer for Remote thermometer

Emergency
stop button
Pass. Side oil tank for Driver’s side oil tank
orange
= 10 gauge
= 12 gauge grey brown brown
= 16 gauge red G G
Small
All fuses On-Off
20 amp switch brown brown
(AGC size) orange
red
black purple
white purple
USA 28M
black stripe
white with
1/94 GRP
electric oil
white cooler only

green yellow
red white
25 A

In line
fuse
25 A

Warning Oil cooler

lamp On/Off switch

H
purple

purple

purple
yellow
white & black stripe
black

white

Hour red red

meter
Oil cooler
M Oil
cooler
motor 12V light (red)
Switch purple
Continuous on
duty pump
solenoid brown blue
air Dirty oil
shift filter light
lever (red)
brown
Key switch
terminal - Hot
when in "On"
position brown
blue black
+

Tachometer Trouble Light Dirty hyd. oil Passenger side Driver’s side
12 volt sending unit Receptacle filter pressure hyd. oil hyd. oil
+ (proximity switch) at Center of switch 35 PSID temperature temperature
Unit (2.4 bar) sending unit sending unit

Training Manual 203

 SERVICE TRAINING

28X Boom Circuit

U.S.A. 28 METER AS WIRED...1989 and LATER

yellow
1. OPERATOR’S PANEL
red
2. REMOTE CONTROL R= Remote Control
L= Local Control white
BOX-992.900.100.900
brown SEE TRUCK/PUMP
3. REMOTE CORD (red) R Off L SCHEMATIC
992.900.801.900 1 3 1 3
brown 86 87
4. CABLE DRUM/90
FEET-992.903.000.100 85 30 Off 2 4 2 4 NOT-AUS
5. JUNCTION BOX (Emergency Stop)
(12 volt) 992.900.104.800 blue red
brown
6. DISCONNECT BOX
(assembly consisting of red
303394,303393, 303395,
992.900.700.700) NORMALLY OPEN
7. CABLE TREE BYPASS VALVE 20 Amp x 5
(boom and outrigggers) white
305609 1
white

STOP

25 A
A B C D E F G H G+ G- S O P
2

(See truck/pump schematic)

Continuous Duty Solenoid
P
A1 A2 A3 A4 A5 B1 B2 B3 C5 B4 B5 C2 C4 C3 C1
A1 A2 A3 A4 A5 B1 B2 B3 C5 B4 B5 C2 C4 C3 C1
3
1 2 3 4 5 6 7 8 15 9 10 16 14 12 13 11
1 2 3 4 5 6 7 8 15 9 10 16 14 12 13 11
4
1 2 3 4 5 6 7 8 15 9 10 16 14 12 13 11
1 2 3 4 5 6 7 8 15 9 10 16 14 12 13 11 5
2/4 2/11 2/5
1/1 1/2 1/3 1/4 1/5 1/6 1/7 1/8 1/12 2/1 2/2 1/9
8 8
10 10 1/10
1/11
d1 d2 d1 d2
2/6
1/9 11 11 2/7
5 5
1/10 2/8
2/12
2/3

2/7 2/9

6 10 12
1 2 3 4 5 6 7 8 9 11
1 2 3 4 5 6 7 8 9
10
11
12
7 +
12 Volt

1 1 1 1 1 1 1 1 1 1 1 1

2 A2 B2 C2 D 2 E2 F2 G2 H 2 + 2 - 2 P2 S -
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
#1 BOOM UP

#1 BOOM DOWN

SLEWING CCW

SLEWING CW

#3 BOOM EXTEND

#3 BOOM RETRACT

#2 BOOM EXTEND

#2 BOOM RETRACT

THROTTLE UP

THROTTLE DOWN

CONCRETE PUMP
FORWARD RELAY

CONCRETE PUMP
REVERSE RELAY

CONCRETE PUMP
FORWARD

CONCRETE PUMP
REVERSE
Components 2 thru 5
BYPASS VALVE

2/90 RE

204 Training Manual

 SERVICE TRAINING

Misc Procedures
Material Cylinder Alignment
1. To visually inspect the alignment, put a trouble
light in the waterbox, at the opening to the cylinder
being aligned (See Figure 66). Be careful with
fingers and hands in the waterbox. Put the trouble
light in the waterbox, then remove your hand
BEFORE proceeding to the next step.

Figure 67
Material Cylinder Alignment Tool

LIGHT RAYS
CYLINDER WALL

ALIGNMENT TOOL

Figure 66 Figure 68
Placing a spot light in the waterbox Light rays in material cylinder
2. Select the “forward” mode of the S1 valve, AT If the alignment tool should contact the cyl-
THE SLOWEST POSSIBLE SPEED! Look into inder wall at any time, return the pump to
the material cylinder from the valve end. The gap neutral immediately! Damage may occur to
between the alignment tool (See Figure 67) and the cylinder wall.
cylinder wall should be seen as even rays of light
(See Figure 68). When the cylinder gets fully
extended, the alignment tool may drop a small
amount or even barely touch the material cylinder
wall.

Training Manual 205

 SERVICE TRAINING

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 (See Figure 69). 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 cylinder.
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 of the pump kit and its mount-
ing to the pump kit frame.
12. Tighten all bolts.
13. Complete the reassembly of valves, and install the
rubber rams.

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 69
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.

206 Training Manual

 SERVICE TRAINING

Pumping on piston side tools to install them.

(Available on some units only)
Piston side pumping changes your concrete pump from
a low-pressure, high-volume machine into a high
pressure, low-volume machine. This would be handy,
for example, to pump long distances horizontally or
vertically.
Piston side operation dramatically raises the maximum
pressure on the concrete. For this reason, it is crucial
that your entire material delivery system be rated to
handle the available pressure and be maintained in like-
new condition. Remember that pipe wall thickness
wears with each yard of concrete pumped. Inspect the
wall thickness regularly. The maximum material
pressure available on the piston side depends on which
differential and material cylinders you purchased with
your unit. The maximum material pressure is recorded
on the main ID tag.
To convert your machine to piston side operation, you
must have some additional hoses and fittings, plus the
Loosen for
rotation
This hose
1200’s only
When changing the hoses from the rod side port to the
piston side port, you must cross them. This keeps the
machine in the same sequence of events as when it is
hooked up for rod side pumping. Failure to cross the
hoses will result in pumping in reverse whenever you
select forward.
When you have finished with the need for piston side
operation, change it back to rod side immediately.
When you are configured on the piston side, the safety
rules for the following topics become even more
important:
• Opening lines under pressure
• Sucking back plugged lines before opening
• Pressure-handling capacity of pipes, hoses, and
clamps in your delivery system
• The dangers of blockages
All of these items are covered in the Safety Manual.
Understand the rules and live by them
.
Add dead
plugs
(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

Training Manual 207

 SERVICE TRAINING

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 Cheveron Seal Set
shimming necessary.

Dimension A
Tape
Using a caliper measure the distance from the top of
the bushing down to the bushing seal recess. See Figure Figure 71
70. Compacting the Cherevon seals
Use the caliper to measure the distance between the top
and the bottom of the compacted cheveron seals. See
Figure 72.

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 70
Measuring for dimension A Figure 72
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 71.

208 Training Manual

 SERVICE TRAINING

Formula

A should equal B
B - A = shims required

In this example:
57.40
- 57.12
.28 mm (.011")

Refer to SAIE 5221

Figure 73
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.
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.

Training Manual 209


Apitech Control Chamber Air
Bleed Procedure
The mounting orientation of the Apitech boom control
handvalve makes a difference in the way the air is bled
out of the control chambers. Normally, if the valve was
installed at the factory then there is no reason to bleed
the air from the control chambers. But if a spool or
solenoid is replaced, then air can enter the control
chambers and may need to be bled. The following is
a list of the potential mounting orientations of the valve
and the procedure to remove the air from the control
chambers, if ever required.
Figure 74
Typical Apitech Handvalve
If the valve is mounted in it’s normal horizontal
position with solenoids above the main spool (Figure
75), then the valve will automatically purge the air
from the control chambers, as the valve is actuated.
Solenoid Spool Solenoid
Figure 75
Normal Horizontal Position
If the valve is mounted with the main spool horizontal
and the solenoids (Figure 76) are below the main spool,
then the following must be done:
210 Training Manual
SERVICE TRAINING
Spool Solenoid
Solenoid
Figure 76
Horizontal mounted - Solenoids below the
main spool
• The PC2 control chamber (spring side) is bled
by loosening the spool plug with flow limiter sev-
eral turns in order for the O-ring to disengage with
the lead-in surface of the SAE port (Figure 77).
Then supply a pilot signal to the end chamber by
energizing the solenoid closest to the plug with
100% input signal. Once there is no more air exit-
ing from the threads of the plug, turn the plug into
the valve housing until the O-ring contacts the
lead-in surface. Then remove the pilot signal and
any other positive pressure from the valve. Tighten
the plug into the valve housing to 10 - 30 ft. lbs. of
torque.
Spool Plug with
O-ring Flow Limiter
PC2 Control
Chamber
Figure 77
Bleeding the PC2 control chamber
• The PC1 control chamber (handle side) is bled
by loosening the port plug several turns (Figure
78). Then supply a pilot signal to the end chamber
by energizing the solenoid closest to the port plug
with a 100% input signal. Once there is no more air
 SERVICE TRAINING

exiting from around the threads of the port plug,

turn in the port plug into the valve housing until the Spool Plug with
O-ring Flow Limiter
seal contacts the valve housing surface. Then
remove the pilot signal and any other positive pres- PC2 Control
sure from the valve. Tighten the port plug into the Chamber
valve housing to 25 – 35 in. lbs. of torque.

Port Plug

PC2 Control
Chamber

Figure 80
Bleeding the PC2 control chamber
• The PC1 control chamber (handle side) is bled
by loosening the spool plug with flow limiter sev-
Figure 78 eral turns in order for the O-ring to disengage with
Bleeding the PC1 control chamber the lead-in surface of the SAE port (Figure 81).
Then supply a pilot signal to the end chamber by
If the valve is mounted with the main spool horizontal
energizing the solenoid closest to the plug with
and the solenoids are to the left or the right of the main
100% input signal. Once there is no more air exit-
spool in the same horizontal plane (Figure 79), then the
ing from the threads of the plug, turn the plug into
following must be done:
the valve housing until the O-ring contacts the
lead-in surface. Then remove the pilot signal and
any other positive pressure from the valve. Tighten
the plug into the valve housing to 10 - 30 ft. lbs. of
torque.
NOTE!
Solenoid Solenoid Due to the internal core of the casting, it
may be necessary to slightly tilt either the
Spool valve or the equipment in which the valve is
mounted on, so that the end plug is the high-
Figure 79 est point of the valve section, in order to
remove all the air from the control chamber.
Spool Horizontal - Solenoids to the left and
right of main spool
• The PC2 control chamber (spring side) is bled
by loosening the spool plug with flow limiter sev-
eral turns in order for the O-ring to disengage with
the lead-in surface of the SAE port (Figure 80).
Then supply a pilot signal to the end chamber by
energizing the solenoid closest to the plug with
100% input signal. Once there is no more air exit-
ing from the threads of the plug, turn the plug into
the valve housing until the O-ring contacts the
lead-in surface. Then remove the pilot signal and
any other positive pressure from the valve. Tighten
the plug into the valve housing to 10 - 30 ft. lbs. of
torque.

Training Manual 211

 SERVICE TRAINING

signal. Once there is no more air exiting from the

O-ring threads of the plug, turn the plug into the valve
Spool Plug with
Flow Limiter housing until the O-ring contacts the lead-in sur-
PC2 Control face. Then remove the pilot signal and any other
Chamber
positive pressure from the valve. Tighten the plug
into the valve housing to 10 - 30 ft. lbs. of torque.

Spool Plug with

Flow Limiter

Figure 81
O-ring
Bleeding the PC1 control chamber
If the valve is mounted with the main spool vertical
(Figure 82), then the following must be done:
Upper Control
Chamber
Upper Chamber
Figure 83
Bleeding the upper control chamber using
spool plug with flow limiter

Spool Plug with

Flow Limiter

O-ring

Upper Control
Figure 82 Chamber
Vertically mounted handvalve
• Only the upper control chamber needs to be Figure 84
bled since the air in the lower control chamber will Air bleeding the upper control chamber using
rise and the air will purge out of the control cham- the port plug
ber through the clearance around the main spool
(Figure 83 or Figure 84 depending upon the orien-
tation of the valve).The upper control chamber is
bled by loosening the spool plug with flow limiter
several turns in order for the O-ring to disengage
with the lead-in surface of the SAE port. Then sup-
ply a pilot signal to the end chamber by energizing
the solenoid closest to the plug with 100% input

212 Training Manual

 SERVICE TRAINING

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
to the tandem A11VO main system hydraulic pumps,
T
the following steps must be done in order that they are P
T
listed; P
MG
G
MY Y

Setting the Flow Rate

Before flow metering the pumps, ensure that the
maximum engine Rpm’s are set to the proper
specifications. All Schwing units have a metal ID tag
located inside the cab displaying the specific RPM
settings for that particular unit. Set the supplement
system pressure to 0 bar by turning the adjustment
knob all the way out on the electric stroke limiter. This
will avoid false readings of the flow rate until the
maximum flow rate and horsepower break points are
set.
Adjustment Knob Adjustment Knob
Figure 85
Electric Stroke Limiters
Install the flow meter. (Consult the operation manual
for proper installation and use of the flow meter). Set
the engine Rpm’s at maximum and set the maximum
flow at the Q max screw to the proper specifications per
the output chart. (Check your operators manual for the
proper output chart for your specific unit).

A11VO130 / A11VO130

Q-max Screws

A11VO130 / A11VO190

Q-max Screws

Training Manual 213

 SERVICE TRAINING

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

T
Piston Side

Piston Side

THE AXIAL PISTON HYDRAULIC PUMP

1800 124
PSI

Bar

PUMP SPEED

E 2100 RPM
HYDRAULIC RELIEF VALVE IS SET AT
350 BAR MAX. PRESSURE (5075 PSI).
1700

1600

1500
117

110

103
T

P
G
P

MG
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 600 41
200
SA

2500

2000
150
500

400
34

27
Figure 88
1500

1000
100 300

200
21

14
Stroke Limiters (two generations)
50
500

0
100 7
3. Increase the engine Rpm's to the maximum setting
Break Point 208
180 Kw = 182 bar
200 KW = 202 bar
At 350 bar
180 Kw = 278 l/m
10 20
7.5 15
30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220
23 30.5 38 46 53.5 61 69 76.5 84 92 99 107 114 122 130 137 145 153 160 168
cu yd / h
cu meters/ h
and while watching the flow meter scale, slowly
200 Kw = 309 l/m
CONCRETE OUTPUT

32
turn the stroke limit potentiometer to the minimum
5 10 15 20 25 30 Number of strokes

100 200 300 400 500 535

(stroke / min.)
Oil volume
material output until the maximum flow rate begins
(liter / min.)

Break Points to drop.

4. When the flow rate begins to drop, stop turning the
Figure 86 potentiometer and read the pressure on the 0 to 40
Sample output chart bar gauge. The reading that is seen is the
Setting Stroke Limitation beginning of stroke limitation. The reading should
Now that the maximum flow rate and horsepower be between 5 to 7 bar. If it is not, then adjust the
settings have been made, the beginning of stroke beginning of stroke limitation screw accordingly to
limitation can be set. Adjust the supplement system achieve the proper pressure reading.
pressure to the maximum pressure of 50 bar. a. If the pressure is too high, then turn the screw
counter-clockwise (out) to reduce the pressure.
1. Make sure the stroke limit potentiometer at the rear
operation panel or remote box is at the maximum b. If the pressure is too low, then turn the screw
material output setting. clockwise (in) to increase the pressure.

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
Figure 87 gauge should be reading approximately 25 bar
Stroke Limiter Potentiometer more than the beginning of stroke limitation setting
2. Install a 0 to 40 bar gauge in the electric stroke to ensure the hydraulic pumps are all the way to the
limit line going to the Y port of the hydraulic minimum against the Q min stop. The Q min
pumps, at this time the reading on the gauge should reading should be between 15 to 25 liters per
be 0. minute. If it is too high, turn the Q min screw out

214 Training Manual


until the reading is correct or if it is to low, turn the
Q min screw in until the reading is correct. When
the Q min has been set, the flow meter can now be
removed.
A11VO190
A11VO130
Q min Screw
Q min Screw
Figure 89
Q-min screw locations
2. Repeat steps 2 through 6 on the second main
system pump before attempting to set the pressure
cut-off on both pumps.
NOTE!
All screw adjustments with the system
relief’s and pressure cut-off must be done
while the unit (pumpkit) is in the neutral
position.
Check all hydraulic pressures.
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
Appendix of this manual. The hydraulic schematics are
the only documents in this manual that have been
updated specifically for your unit, by the serial number,
so in each of the following procedures you will be told
to refer to the schematic for the pressure required.
• Preheat the hydraulic oil
Pressure settings must be made with the oil at normal
operating temperatures (40°− 60° C). In the past we
could pressure out a function in the boom or outrigger
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:
Training Manual
SERVICE TRAINING
1. Locate the agitator shutoff valve and close it.
NOTE! If your unit does not have a shutoff valve,
order one from the Schwing Spare Parts Depart-
ment using part number 10004680 (valve), and
number 30303432 (tube). Contact the Service
Department for installation instructions.
14. Activate the agitator. With the valve closed the agi-
tator 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.
0
agitoff.eps
Figure 90
Agitator shutoff valve
15. When the oil temperature gauge shows 50˚C, open
the shutoff valve.
Setting pressures 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 91) and close it by rotating
the handle 90 degrees.
b. The quarter turn shutoff valve for the concrete
pump (Figure 91) will also need to be closed
during this procedure.
NOTE!
Main system adjustments are preset at the
factory. The following procedure begins
with adjustment of the main relief cartridge
and pressure cutoff. If proper pressures can
not be obtained through these steps, refer to
the beginning of this procedure for specific
instructions on the adjustment of flow,
horsepower, beginning of stroke regulation
and Q-min.
215

Pressure setting procedure:
Soft switch
shutoff valve
Main Pressure
Gauge port
Concrete pump
shutoff valve hif
lob
rn
.e
ps
Figure 91
Concrete pump and Soft switch shutoff valves
1. Be sure that the waterbox covers and guards are in
place any time you will be working in the area
around the main control block.
16. Wear safety glasses when working around a con-
crete pump.
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 pump-
kit in the neutral position and adjustments
for pressure cutoff must be made with the
engine shut off.
17. Start the truck engine, and put the PTO in gear just
as you would to pump a job.
18. If you have not already closed the soft switch shut-
off valve and the concrete pump shutoff valve (Fig-
ure 91) do so at this time.
19. At the rear panel, select “local” control with the
“local/remote” switch and turn the electric stroke
limiter knob clockwise to maximum strokes per
minute.
20. The main system control block pressure must be
set first to properly set the pressure cutoff on both
pumps. Begin by backing off the jam nut of the
main relief cartridge (Figure 93) with a 9/16 inch
wrench.
21. Using a 5/32 inch allen wrench, turn the adjustment
screw out (counterclockwise) until you can feel no
spring tension on the adjustment screw.
22. Now, turn the screw back in (clockwise) two or
three full turns to give you a proper starting point
and tighten the jam nut.
216 Training Manual
SERVICE TRAINING
23. Stop the truck engine and put the key in your
pocket. Adjust the pressure cutoff screw (Figure
92) on each pump, by backing off the jam nut 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.
24. Adjust the engine RPM to maximum specification.
(See decal in truck cab)
25. Pressure out the system by activating the concrete
pump forward switch on the rear panel. Using the
rear panel controls will allow you to read the con-
crete pump main system pressure gauge, near the e-
stop manifold, from a safe distance.
NOTE!
Because you turned out the pressure relief
cartridge in step 21., the system pressure
should read low 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 safety, it is important to adjust
the pressure up from below the specified
target pressure rather than down from a
pressure which exceeds the target. Continue
this procedure until the main system pres-
sure gauge reads lower than the specified
target.
26. To increase the pressure put the pump in the neutral
position and adjust the relief cartridge by turning it
in (clockwise). When increasing the pressure, the
adjustments should be made in quarter turn incre-
ments. If you make adjustments to increase the
pressure but the pressure does not come up, you are
probably reading the pressure cutoff of the pumps,
if so proceed to the next step otherwise skip to step
29.Turn the relief cartridge adjustment screw back
out (counterclockwise) until you can no longer see
a pressure drop and tighten the jam nut.
27. Stop the truck engine, put the key in your pocket.
28. Go to the pressure cutoff screw on both hydraulic
pumps (Figure 92) and back off the jam nut with a
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.
29. When the proper main relief pressure is achieved,
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
 SERVICE TRAINING

bottom of the two hydraulic pumps (Figure 92).

You must be able to read both gauges simulta-   
      
neously to ensure that one pump is not more domi-      
nant 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
    
130ajst.eps
read the same however, at approximately
110 bar, but the 190 must never read higher Figure 92
than the 130. The actual cutoff pressure will Adjustment screw locations
be read on the concrete pump main system
pressure gauge near the e-stop manifold. Soft switch
shutoff valve
30. Activate concrete pump forward to pressure out the
pump and read the pressure on the two gauges in Main Pressure
the “M1” ports. Gauge port

31. Always stop the truck engine and put the key in
your pocket before making any adjustment on the
hydraulic pump. If the cutoff on one pump is set Concrete pump
higher than the other, that pump will be more dom- shutoff valve hif
lob
rn
.e
ps

inant. 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 Closed Open
adjust the cutoff screw in (clockwise) to increase
the pressure of the pump showing the higher read-   
ing or adjust the cutoff screw of the dominant
 
pump showing the lower reading out (counter-
 

clockwise) to reduce the pressure. These adjust-

ments must be made until the two gauges in the M1
ports are reading approximately the same.

  
32. When you have achieved the same pressure on the
M1 port gauges, you can begin to adjust the pres-
sure 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).
After pressure cutoff is set, return the pump to neutral,
bring engine RPM to idle, open the soft switch quarter
turn valve, and either proceed to other pressure settings
or take the transmission and PTO out of gear and shut
off the truck.
Training Manual
  
  
Figure 93
Soft switch circuit/Main relief valve
Setting the soft switch relief pressure
First, open the soft switch quarter turn valve (Figure
93) 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).
217
 SERVICE TRAINING

When you put the pump in forward now, the main con-
crete pump pressure gauge should read the pressure
shown on the schematic for soft switch. If adjustment
is needed, loosen soft switch relief valve jam nut (Fig-
ure 93) with a 9/16 open end wrench, and use a 5/32
allen wrench to adjust the pressure. Turn the adjust-
ment 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 ris-
ing. Be sure to open the concrete pump shutoff valve
on the side of the brain (Figure 93) when you are fin-
ished. The unit will not stroke with this valve closed

218 Training Manual

 SERVICE TRAINING

Accumulator Bypass Retrofit mechanical dump valve on the accumulator manifold,

start the machine and engage the PTO, bring the oil up
Service Bulletin 1001-03 to operating temperature (60c – 80 c), and check all
work for leaks.
Reference page 4 for schematic.
To test the bypass operation you need to disconnect the
Before installing this kit make sure that the engine is
pressure line from the accumulator hydraulic pump.
off, the key is removed, and the accumulator system is
Plug the hose and pump using items #12, 13, and 14 as
de-energized by confirming that the accumulator
pressure gauge is at zero and the manual dump valve in Figure 2.
on the accumulator manifold is opened.
ACCUMULATOR
Install check valve and fittings, items 8, 9, and 10 in the SYSTEM
11 1
2 3 4
pressure line from the outlet of the hydraulic pump. 7
Make sure that the check valve is installed in the 6
correct orientation (free flow from the pump) as shown 5
B B
in Figure 1. These items must be installed between the E-STOP AGITATOR
outlet of the pump and where the line is “Teed” for the VALVE CLOSED FOR
BYPASS
9 A A
e-stop manifold so that the accumulator system will be
10 2.0 bar
de-energized when an e-stop button is depressed or the 14 39000215.eps
machine is taken out of PTO mode. Reconnect all 13 12
13
lines. ACCUMULATOR
PUMP

ACCUMULATOR
SYSTEM
11 1
2 3 4
7 Figure 2
6
5
Plugging the hose and pump
B B
E-STOP AGITATOR Close the 1/4 turn valve on the accumulator system and
VALVE CLOSED FOR
BYPASS
stroke the machine with water in the hopper. The
9 A A
10 2.0 bar
accumulator gauge should respond very similar as it
8 39000214.eps does with the accumulator pump. Also, you must
ACCUMULATOR confirm that the e-stop manifold does de-energize the
PUMP
accumulator system.

Figure 1 Retrofit Assembly Kit# 30364723

Installing Checkvalves and Fittings
SEQ QTY PART# DESCRIPTION
Confirm the 1/4 turn valve shutoff on the agitator
1 1.00 10102204 VALVE CHECK S10A 0.0
system is installed in the B line of the agitator system
2 1.00 10008108 FITTING STR GES-16-SR 1/2î
as shown in Figure 1. If your machine is not equipped 3 1.00 10020109 FITTING STR EGESD-16-SR 1/2” – WD
with a 1/4 turn shutoff, p/n 10004680, one must be 4 1.00 10019122 FITTING EL EWSD-16-S
installed. Disconnect the 1/4 turn valve from the tube 5 1.00 10018848 FITTING TEE ELSD-16-S
or hose going to the agitator hydraulic motor. Install 6 1.00 10018849 FITTING STR REDSD 20/16S
items 5, 4, 3, 1, 2, and hose 11. Make sure that the 7 1.00 10008033 FITTING TEE ELSD-20-S
check valve is installed in the correct orientation (free 8 1.00 10019728 FITTING STR EGESD 20 SR 3/4” –WD
9 1.00 10008110 FITTING STR GES 20-SR 3/4”
flow from agitator to accumulator system). Reconnect
10 1.00 10003861 VALVE CHECK S 15 A 2/0
the tube or hose going to the agitator motor. 11 1.00 10049909 HOSE H.P. DN 13/4 X 1700 DKO-S
Route hose 11 under the deck and “T” it into the P port 12 2.00 10016789 FITTING PLUG VS 20 S
of the accumulator manifold using items 6 and 7. 13 2.00 10001741 CAP NUT M 20 S
14 1.00 10008093 FITTING STR GS-20-S
After the installation is complete, you need to close the

Training Manual 219

 SERVICE TRAINING

Trouble Shooting Kit

These kits contain a 0-600 Bar pressure gauge, a 0-40

Bar pressure gauge, plus all the necessary fittings,
locking plugs, manitrol valves, and hoses to plumb the
gauges into any hydraulic circuit on the unit. These kits
include the heavy duty foam lied carrying case.
Schwing Part Number:
Trouble Shooting Kit for BPA’s
• Part # 30308552
Trouble Shooting Kit BPA’s and BPL’s
• Part # 30308553 (shown)

220 Training Manual

 SERVICE TRAINING
Table of Contents
Visual Inspection

General Instructions ....................... 3

Periodic Maintenance ....................................................3
Safety Decals ................................................................4
General Items ................................................................5
Clearance at Front Boom Rest ......................................6
Outriggers .....................................................................7
Do not partially extend outriggers ................................8
Tower ............................................................................9
Turret ...........................................................................11
Slewing Gear ...............................................................12
Boom Sections ............................................................13
Concrete Delivery Pipeline .........................................15
SAIE 5158 ...................................................................17

Training Manual
 SERVICE TRAINING
Table of Contents

Service Manual
Visual Inspection
General Instructions
NOTE!
The following pages contain suggestions
about what to look for during routine visual
inspections. A complete structural
inspection must still be done according to
the manufacturers recommended schedule.

Periodic Maintenance
A complete structural inspection of the concrete pump,
Figure 2
boom, and outrigger assembly should be performed by
Visible rust, indicating a possible crack.
a qualified boom inspector, at the following intervals:
• The first five years - at least once per year. If paint is found to have split and rust is coming
through, remove the paint and do a close visual
• Five to ten years - every 6 months
inspection. If a crack is found a Schwing approved
• Ten years and older - every 500 working hours, boom inspector must be called in for analysis. Please
or at least once per year, whichever occurs contact SAI Engineering if you have any questions.
first.
At least once per week the unit should have a complete
visual inspection. The unit should be clean and dry
prior to inspection including inside the tower.
Freshly painted units aren’t likely to show cracks (paint
covers them up). Cracks typically won’t show up until
at least 150 pumping hours after painting. Visual
inspection of all components, however, must still be
done each week. Check safety decals for proper
positioning. Remember that safety decals and labels
are available, free of charge, from the SAI Spare Parts
Department. Order replacements whenever these labels
are damaged or missing. Please have the serial number Figure 3
of the unit available when you call Spare Parts. Crack on a welded joint.

All areas of discontinuity in a weldment and the weld

seams are considered critical areas to inspect. Pipeline
holders and/or supports must also be inspected.

Figure 1 Figure 4
Paint crack - may indicate a crack in the metal. Dented corners, indicating damage.

Training Manual 3
Safety Decals
Each machine is equipped with a set of warning labels
specific to the model, boom style and installed options.
Safety decals MUST be replaced if they are damaged,
faded, missing, or unreadable for any reason.
Ultraviolet radiation, rain, steam cleaning, and other
factors cause these labels to fade in time. Sets include
outrigger load labels, but they do not include metal
plates, which can be ordered separately. For installation
locations, see the decal location guide insert found in
the Appendix section of the Operation manual. To get
replacement labels, identify which label(s) you need
from the diagrams and lists, get the serial number of
the unit from the serial number plate, and call Schwing
America at (800) 328-9635. The person taking the
order will make a note of the serial number of the unit
for our files and send you the labels you need. You may
order complete sets or single labels. If the serial
number plate is missing or unreadable, the number is
stamped into the subframe just below the normal
location of the serial number plate.

SERVICE TRAINING SERVICE TRAINING

58p6.eps
WARNING IMPORTANT
WARNING SAFETY INSTRUCTIONS
WARNING
Falling hazard.
Not a work
platform.
DANGER The hydraulic oil filters on this unit are disposable.
Cleaning and re-use is not possible. It is time to
replace the filter if the oil is at normal operating
temperature and the "dirty filter" indicator light is
Do not use the
boom as a crane
1. Operation of this machine requires training. You must read all warning labels on the unit -
items covered on specific warning labels are not covered here. There are
other hazards and safety rules that are ONLY covered in the safety manual or
operation manual.

Electrocution hazard. illuminated. Normal operating temperature is

needed because, on some machines, when the oil or hoist. 2. Only the operator may authorize access to the unit or surrounding area.

is cold the "dirty filter" lamp may illuminate even if 3. Safety devices and guards must NOT be altered or removed.

Stay back from the filter is clean.

1 high voltage wires

4. Stop the operation if any malfunctions, failures or structural faults occur. DO NOT restart
until repaired.

3 4 5. NEVER try to finish the operation with the emergency stop dump valves bypassed.

at least 17 feet 6. You must always be able to see the point of discharge. If this is impossible, an assistant
(spotter) MUST be used. The spotter must be positioned to see both the
Stand clear of operator and point of discharge for the purpose of giving instructions to the
CAUTION
When light is on, hydraulic pumps are
(5 meters). outriggers when
operator.

8 engaged. Do not put transmission in

reverse. Do not drive unit.
2 5 activating.
7. Ensure the stability of the unit. Use adequate outrigger cribbing for soil conditions. Level
the unit to within 3.

8. Check for obstructions before unfolding or slewing the boom or outriggers.

Factory-filled with 9. DO NOT unfold the boom unless the outriggers are fully extended and properly jacked.
SAFETY INSTRUCTIONS Rando HDZ Shortrigging is NEVER allowed on the side of the pour.
P/N 30345427
TEXACO
ERICAN 1. Release tie-down strap before lifting boom. 10. Maintain a safe distance from excavations or cliffs. Stay as far back from the edge as the
AM
2. Lower boom into cradle and reattach tie down strap depth of the excavation or cliff. (This is the one to one rule).
CONCRET

TION

Factory-filled with
before transport.
Rando HD
C IA

SLIDE-PLATE 11. Never retract the outriggers until the boom is folded into the transport position.
SO

P/N 30345426
TEXACO
E

PU S
MP ING A
1. TO RELEASE, PULL 30355887
IMPORTANT 12. Be sure outriggers are retracted and pinned before driving the unit.
SLIDE-PLATE DOWN AND Use
TIE-DOWN Change all filter elements if the dirty filter lamp illuminates when oil is
1.
BOOM UP
2. 3.
BOOM DOWN BOOM LEFT
4.
BOOM RIGHT
5.
OPEN OR
6.
CLOSE OR
EXTEND BOOM RETRACT BOOM
STRAP AND
RATCHET
PIVOT HANDLE OUT AND UP
COMPLETELY.
Mobil DTE® 25
A MOBIL PRODUCT 11 above 20 C. If unit does not have electrical filter lamp, change the filter
elements every 13,000 yds or every 6 months, whichever occurs first.
13. NEVER drive the unit with extended outriggers or an unfolded placing boom! Not even a
few feet.

HANDLE
10
14. The supplied safety cable MUST be used to secure the discharge hose or reducer to the
DATE OF LAST CHANGE DATE OF LAST CHANGE DATE OF LAST CHANGE
tip section.

15. DO NOT overload the boom. The maximum allowable weight from hose or reducer/hose

WARNING combination is 376 pounds, which is equivalent to one 12 foot long 5 inch
hose, OR a 5 inch to 4 inch reducer and one 12 foot long 4 inch hose. NEVER
use the boom as a hoist or crane. NEVER attach a structural extension to the
Do not operate at boom.
pressures exceeding
16. In the event of a thunderstorm or high winds (over 48 MPH), the boom must be folded into
the rating of the
7. 8. 9. 10.
STOP BOOM START PUMP SLOW PUMP STOP PUMP
11.
LITTLE BIT
12.
ADD WATER
13.
ALL DONE
2. TO REATTACH, PULL 2" PUMP THE HANDLE PUSH HANDLE entire material 6 the transport position.

SPEED UP DOWN 4-GALLONS CLEAN UP

OF STRAP THRU RATCHET TO TIGHTEN. DOWN TO LOCK.
12 delivery system.
13
7 9 WARNING WARNING
DANGER
Electrocution hazard.
Stay back from high
voltage wires at least
DANGER SAFE ZONE HAZARD ZONE

14 17 feet (5 meters).
Stay clear. SAFE ZONE
(During operation, tip
hose must always
This product is covered by one or more of the following U.S. patents:
3,409,334 4,057,373 4,392,510 4,708,288 5,257,912 Re. 32,041
Contact will result in be in this zone)

HAZARD ZONE
TM
3,580,696
3,640,303
4,178,142
4,191,513
4,437,817
4,465,441
4,852,467
4,978,073
5,263,828
5,281,113
Re. 32,657
Re. 32,719
death or serious injury (During operation, tip

ROCK VALVE 3,685,543

3,741,691
3,829,251
4,260,338
4,343,598
4,373,225
4,472,118
4,556,370
4,621,375
5,066,203
5,106,225
5,106,272
5,332,366
5,346,368
5,401,140
if the unit becomes
hose must never
enter this zone)
Do not stand on
15 16 4,019,839 4,373,875 4,681,022 5,224,654
30308020 C

electrically charged. hopper grates.

20
WARNING 18 19 Boom may float down without warning if tip is brought into hazard zone.

This machine is WARNING WARNING SAFETY INSTRUCTIONS

WARNING
remote controlled Before opening a
blocked pipeline, Keep hands out of
PROCEDURE FOR RAISING THE BOOM
Unfold the boom in this order to avoid damage to the truck cab.

and may start at any relieve pressure

by making 2
waterbox. 1. Raise #2 boom.

Stop engine/motor if
time. Stop engine reverse strokes.
access is required. 1.
before servicing unit. 22 Keep covers closed.
21 24
2. Raise #1 boom.
Keep hands out
WARNING CUIDADO WARNING
of hopper and
WARNING
CAUTION IMPORTANT Electrocution hazard.

valve assembly. Stay back from high

voltage wires at least
17 feet (5 meters).
Keep hands out
2.
See operation Do not operate this
of hopper and
valve assembly.
See operation
Keep hands out of
manual if access
waterbox.
if is required.
Stop engine/motor
access is required.

You can order additional operation manuals, spare Keep covers closed.

WHEN PERFORMING ANY WELDING parts books, safety manuals and decal sets by manual if access machine without
ON THIS UNIT IT IS NECESSARY TO contacting us at: is required. training. Understand
DISCONNECT ALL THE WIRING FROM
Schwing America, Inc.
1-(800)-328-9635
SAFETY

the warnings in safety 25

THE DUVAC II SYSTEM. FAILURE TO DO
THIS MAY DAMAGE THE COMPONENT.
6:00 AM to 9:00 PM Central Time
Monday through Friday 23 MANUAL
manuals and on decals.
30
26 27 28 29 WARNING
WARNING WARNING Use retaining
SAFETY INSTRUCTIONS WARNING WARNING WARNING Total weight of all pins in all
Do not operate this hanging hoses, reducers Clear area delivery system
BEFORE REMOVING HOPPER GRATE OR Safety guard machine without and clamps must NOT before activating
PERFORMING ANY SERVICE: Boom strap clamps.
is missing. training. Understand exceed 376 pounds outriggers
Gasoline or Diesel Engines Electric Motors MUST be used SAFETY

the warnings in safety including concrete.

1. Stop the engine. 1. Stop the electric motor.
32 during travel. manuals and on decals.
MANUAL

2. Remove the key, place it

in your pocket, and put
a "DO NOT OPERATE"
2. Lock out the power
source according to an
approved
34 35 36 37
tag on the switch. lockout-tagout program. 33
3. Check accumulator 3. Check accumulator SAFETY INSTRUCTIONS
circuit pressure gauge circuit pressure gauge WARNING EXTEND OUTRIGGER TO HERE BEFORE UNFOLDING BOOM
(if so equipped) to verify (if so equipped) to verify SAFETY INSTRUCTIONS This unit will NOT operate unless one of these
zero system pressure. zero system pressure. WARNING USE OF THE TOWING EYES
plugs is connected to the control receptacle.
1. The radio remote control receiver (if so
44
31 You MUST pull within 15 of straight when
attached to these towing eyes, or unit damage
may result.
equipped).
2. The cable remote.
WARNING
15
3. The shorting plug (supplied).
SAFETY INSTRUCTIONS
EMERGENCY STOP Unit will tip if
WARNING PARO DE EMERGENCIA
15
outriggers are not
ARRÉT D'URGENCE 30343260 A shorting plug fully extended.
(shown on dummy receptacle)
24V IGN 12V GND

39 41 24 Volts
Here 30A 40A
+ - + -
Do not touch
hydraulic oil leaks. SAFETY INSTRUCTIONS
Stand clear of Get immediate
+ - + -
Extend outriggers until striped
outriggers when radio or cable remote plug medical attention if decals are visible, as shown in
24 Volts Here
activating. (shown on control receptacle)
+ - + -
Put all remote
control functions
40 oil penetrates skin.
illustrations.

EMERGENCY POWER SOURCE

1. Remove nuts from battery connections
in OFF position
BEFORE 43 + - + - on outside left battery.
2. Bend cables out of the way as shown
connecting cable.
42 30343571
NORMAL POWER SOURCE
3. Install jumper cable as shown
4. 24 volts now available as shown

38 SAFETY INSTRUCTIONS
30350982 A

OVERRIDE OF EMERGENCY STOP MANIFOLD

• Use ONLY for emergency foldup and cleaning.
WARNING WARNING
46
• Emergency stop buttons DO NOT WORK when procedure is used.
1. Turn the bypass key switch to "BY-PASS" position. If control is restored, there is an elec-
= Total weight of all hanging 45
trical problem in the control circuits. You can clean out and fold up with the key switch Emergency stop
override. If control is not restored, there is a hydraulic problem; proceed to step 2. switches do NOT hoses, reducers and clamps
2. For a hydraulic problem, the inlet plumbing to the nonworking system must be plumbed must NOT exceed 215
function when
out of the manifold. With the engine stopped, disconnect the plumbing for the nonwork-
ing system at the fit-
ting pointed out
BY-PASS Boom/outrigger
= manual bypass is
pounds including concrete.
Do NOT hang 5 inch (125mm)
ADVENTENCIA
Los interruptores de
=
WARNING
Emergency stop
WATER ONLY
below. Plug both
depressed.
58
NORM. BY-PASS

open fittings that circuit dump

valve
system from this boom. emergencia de paro no switches do NOT
result, using hydraulic
funcionan cuando se function when manual
blocking plugs. Be
sure to tighten the
plug/fitting connec-
Accumulator
circuit dump 48 49 WARNING
WARNING activa el sobre paso
manual
override is activated.
tion before restarting
valve
=
DIESEL ONLY
Concrete pump
the engine. dump valve Boom/outrigger
3. The emergency stop system plumbing
manifold is now plum-

59
bed out of the system. Accumulator

57
NO!
Make repairs before Concrete pump system plumbing WARNING
47 reusing the machine.
system plumbing
30353078 IMPORTANT!

WARNING
Do not insert solid
SAFETY INSTRUCTIONS Clear discharge area when Stop agitator before objects into waterbox SAFETY INSTRUCTIONS
OVERRIDE OF EMERGENCY STOP MANIFOLD
• Use ONLY for emergency foldup and cleaning.
• Emergency stop buttons DO NOT WORK when procedure is used.
first starting the pump,
restarting after moving, or
putting any solid
object in hopper. 56 cleanout holes.
NEVER PARTIALLY EXTEND OUTRIGGERS
whenever air is present in Explosion / fire 1. Outriggers must NEVER be partially extended when the boom will be used,
1. Pull override handle and hold. If control is
restored, there is a control system electrical problem. You can fold up and
clean out by holding the override handles. Be careful where you position
yourself when lowering the boom and closing the outriggers. If control is not
the delivery system. See
Safety Manual.
hazard. Stop engine
before refueling.
Fire extinguisher
inside.
30354741
55 WARNING
or when the truck will be raised. The forces transmitted to the outriggers must
be absorbed by the outrigger reinforcements. Partial extension defeats the
reinforcements.

53 54
restored, there is a
hydraulic problem;
proceed to step 2.
Boom/outrigger
Accumulator
system plumbing
51 SAFETY INSTRUCTIONS
2.
3.
Outriggers must be fully extended or fully retracted.
If the outrigger is fully retracted (shortrigged), different hazards are present.
See the Safety Manual, or your Operation Manual for information regarding
2. F o r a system plumbing
hydraulic problem, the
inlet plumbing to the Concrete pump
Closed WARNING
nonworking system
must be plumbed out of
system plumbing ATTENTION! NO! OK
Tipping hazard.
the manifold. With the Boom/outrigger
engine stopped, circuit override Serial #: Additional cribbing
handle Open Outrigger
disconnect the Was built according to these drawings. needed for many soil
plumbing for the
Inner Box
Agitator shutoff valve electric:
nonworking system at Concrete pump, Reinforcements
Outrigger types, including
the fitting pointed out at accumulator
override handle • Shutoff valve - open for normal operation. hydraulic: Do not partially Outrigger Reinforcements asphalt. See manual.
right. Plug both open
fittings that result, using extend outriggers. Outer Box Aligned 30359230
30354564 hyd. boom: Reinforcements
• Shutoff valve - closed to preheat hydraulic See Safety

50 52 oil by creating high pressure.

60 output chart:
30357363 61 Instructions.
30358147 62 30358148
63

Figure 5
Sample decal location guide. See your Operation Manual
for your specific unit.

4 Training Manual
General Items
Items to check:
• Boom Tie Down Straps
• Rear Steps
• Bearings and Pins Greased
• Tie Down Plates/Channels to Chassis
• Tower Tie-Down Bolts and Detach Tower Pins
• Hopper Grate
• Water Box Covers
• Clearance at Front Boom Rest (See SAIE
5158)
Figure 8
Make sure all bearings and pins are greased.

Figure 6
Check for frayed edges and a working locking
mechanism on the boom tie-down strap. Figure 9
Check for cracks on the Tie Down Plates/
Channels

Figure 7
Check for damaged or missing steps.
Figure 10
On SPB booms, make sure the detach tower
pins are in place and not damaged.

Training Manual 5
 Figure 11 Figure 12
Check the hopper grate for damage. Make Make sure the water box covers and safety
sure the hopper grate switch works properly. grates are in place.

Correct Incorrect

In the transport position, each boom rest should be in contact with the boom and
slightly compressed, (approximately 1/16 to 3/32 of an inch compression of the
rubber rest). The load of the boom should not be on the boom hook. Maintain some
clearance between the boom hook and the boom hook pin.

Clearance at Front Boom Rest

SAIE 5158 covers the proper procedure for setting the
clearance of the boom rests. Improper clearance may
result in damage to the placing boom during travel.

6 Training Manual
Outriggers
Items to check:
• Structural members and welded seams for
cracks, deformation and wear
• Operation/Functions
• Outrigger Tubes
• Outrigger Pads
• Pins, Pin Bores and Safety Devices

Figure 15
Check for cracks on the outrigger pin, also
make sure the pin is in place and functioning
properly.

Figure 13
Check for cracks on the outrigger structure.

Figure 16
Check for damage on all 4 outrigger pads.

Figure 14
Make sure the outriggers are functioning properly.
Check for proper vertical alignment. Outrigger
tubes must be replaced if wear is greater than 10 Figure 17
percent of original wall thickness. Check for cracks on outrigger tube, pay special
attention to all welded seams

Training Manual 7
Do not partially extend outriggers
Structural damage could result.

NO!
s
.ep
58
00
04
Force

Fulcrum
Outrigger
Inner Box
Reinforcements
Outrigger 1. Outrigger fully retracted.
Outer Box No lever action.
Reinforcements Force absorbed by reinforcements.
Force must be low, or unit will tip.

Figure 18
Transparent outrigger shows reinforcement Fulcrum
areas (curved outriggers have the same
limitations)
Force
CAUTION
Force
Structural damage to outriggers is Fulcrum
possible. Do not jack outriggers unless
they are either fully extended or fully
000467.eps

retracted.

2. Outrigger fully extended.

Partial extension of telescoping outriggers is not Lever action present, but
acceptable at any time. Jacking the outriggers while force absorbed by reinforcements.
they are in any position other than fully extended or
fully retracted could cause structural damage to the
outrigger outer box and/or the inner box (Figure 18). Fulcrum
The three illustrations shown on the right explain the
configurations of the outrigger in all positions.
Remember that in configuration number 1, the boom
must never be extended over a retracted outrigger. Force

Force
Fulcrum
NO!
3. Outrigger partially extended.
Lever action present, but force transmitted to
areas with no reinforcements.
Outrigger bends, bottom plate dents, or both.
000459.eps

8 Training Manual
Tower
Items to check:
• Structural members and welded seams for
cracks, deformation and wear
• Tie-Down Bolts
• Rubber Dust Cover
• Hydraulic Hoses
• Slewing Cylinders
• Tower Bolts, Bushing and Main Column

Figure 21
Crack on subframe inside bottom corner.
(view from under tower.)

Figure 19
Cracks on tower gussets

Figure 22
Check tie-down bolts and plates for damage.

Figure 20
Crack on upper tower plate

Figure 23
Check for missing or worn rubber dust cover.

Training Manual 9
 Figure 24 Figure 26
Check for damaged or worn hydraulic lines. Check for missing or damaged tower bolts. It
is recommended that the anchor bolts for the
tower be replaced every three years.

Figure 25
Make sure the cover for the slewing cylinders
is in place and not damaged.

10 Training Manual
Turret
Items to check:
• Structural members and welded seams for
cracks, deformation and wear
• Hollow Pin Mounting Bolts and Snap Ring
• Internal Structure

Figure 29
Pipeline clamp rubbing on hollow pin.

Figure 27
Damage on tower.

Figure 30
Dislodged hollow pin bushing. Damaged
retaining ring.

Figure 28
Improper hollow pin mounting bolt.

Figure 31
Cracks inside the turret

Training Manual 11
Slewing Gear
Items to check:
• Structural members and welded seams for
cracks, deformation and wear
• Bolts Tight
• Drive Gear Wear or Deterioration
• Slewing Bearing Gear Wear or Deterioration

Figure 34
Excessive Wear on slew drive

Figure 32
Check for wear or deterioration on slew drive

Figure 33
Check tightness of bolts

12 Training Manual
Boom Sections
Items to check:
• Structural members and welded seams for
cracks, deformation and wear
• Articulated Joints and Guide Levers Bearing
• Pins and Safety Devices
• Latch Hook and Assembly, Hook Support
• Hydraulic Lines
• Hydraulic Cylinder
• Threaded Pins

Figure 37
Crack on side plate

Figure 35
Damaged head section
Figure 38
Crack on the end plate

Figure 39
Figure 36 Check for cracks and damage on the guide
Crack on bottom plate levers.

Training Manual 13
 Figure 40
Bent keeper bolt Figure 43
Check for leaks and damage on boom
cylinder. Make sure the boom cylinder is
operating properly.

Figure 41
Make sure the boom hook is working properly.

Figure 44
Damage on threaded pin

Figure 42
Check for damaged hydraulic lines on boom
section

14 Training Manual
Concrete Delivery Pipeline
Items to check:
• Mounting Hardware - U-Bolts/Nuts/Saddles
• Clamps with Safety Devices
• Reducer safety cable/nylon choker
• End Hose Safety Cable

Figure 47
Check pipeline clamps for damage.

Figure 45
Make sure all U-bolts and related hardware are
in place and are not damaged.

Figure 48
Make sure nylon choker and safety cable are
in place and are not damaged.

Figure 46
Damaged U-Bolts

Figure 49
Check for broken or damaged pipe arm
clamps.

Training Manual 15
16 Training Manual
SAIE 5158

Standard: 5158
SAIE STANDARD Page: 1 of 5
Subject: Procedures for Setting Boom Rests

The following procedures are for Schwing America personal to follow and adhere to in regards to the set-
ting of the boom rests for the following units: KVM 17, KVM 23, KVM 26, KVM 28X, 31 EZ, KVM 32
XL, KVM 34X, KVM 36 X, KVM 39 X AND THE KVM 42, S 45/47 SX, KVM 52/55, S 58/61 SX and
an others.

3 Section Booms
1. The boom must be folded up unto the main rest and all four outriggers must be raised off the ground
so there is no outrigger contact with the ground

2. Raise the #1 boom section enough that the #2 boom section is off the A-Frame boom rest :A:. Then
make sure that all boom sections are folded together. Each boom rest section should be folded into the
mating boom section rest without causing the boom section to bow.

3. Then lower the #1 boom section until the #2 boom section comes in contact with the A-frame boom
rest rubber “A”. The #2 boom section should come in contact with the rubber rest enough to be
slightly compressed, approximately 1/16 to 3/32 of an inch compression of the rubber rest.

4. Position the #2 front boom rest “B” to have a 1/8 of an inch clearence with the #2 boom section. The
key to this setting must be when the #2 boom section is in the rear A-frame rest and the #2 boom is
extended (lowered) to touch the front boom rest, there is still clearence between the boom hook and
the boom hook pin. The load of the boom should never be on the boom hook while in the traveling
position.

Prepared by: Jim Mielke/Mark Berggren Approved by: Jason Mehl

Issue: 11/11/99 05/29/06

Training Manual 17
 Standard: 5158
SAIE STANDARD Page: 2 of 5
Subject: Procedures for Setting Boom Rests

4 Section Booms - Except 34X, 39X, 45 SX, 47SX and 52M

1. The boom must be folded up into the main rest and all four outriggers must be raised off the ground
so there in no outrigger contact with the ground

2. Raise the #1 boom section enough that the #2 boom section is off the A-frame boom rest “A”. Then
make sure that all boom sections are folded together. Each boom rest section should be folded into the
mating boom section rest without causing the boom to bow.

3. Then lower the #1 boom section until the #2 boom section comes in contact with the A-frame boom
rest rubber “A’. The #2 boom section should come in contact with the rubber rest enough to be slghtly
compressed, approximately 1/16 to 3/32 of an inch compression of the rubber rest.

4. Install the #4 boom rest “D” for a 1/4 to 3/8 of an inch gap between the rubber rest and the #4 boom
section.

5. After the #4 boom rest “D” is installed, lower the #4 boom section to just come in contact with the 34
boom rest “D’.

6. Then position the rear #4 boom rest “B” to touch the #4 boom section. At this time, both #4 boom
rests should be in contact with the #4 boom section.

7. Position the #2 boom rest “C” to have a 1/8 of an inch clearance with the #2 boom section. The key to
this setting must be when the #2 boom section is in the rear A-frame rest and the #2 boom is extended
(lowered) to touch “A” the front boom rest, there is still clearance between the boom hook and the
boom hook pin. The load of the boom should never be on the hook while in the traveling position.

Prepared by: Jim Mielke/Mark Berggren Approved by: Jason Mehl

Issue: 11/11/99 05/29/06

18 Training Manual
 Standard: 5158
SAIE STANDARD Page: 3 of 5
Subject: Procedures for Setting Boom Rests with preload

The boom should be completely folded so that all hydraulic cylinders are retracted to their furthermost
position. The #2 boom should be in the main rear rest. All four outriggers must be raised off the ground so
there is no outrigger contact with the ground. The front #4 boom rest dimension should be taken from the
bottom of the folded #4 boom., to the top of the tower plate on the pedestal weldment. The dimesion
should be noted and 1-1/2” added to that dimension this will be the overall length for the front boom rest
with the rubber pad bolted on. Then the #4 rear boom rest should be measured from the bottom of the
folded #4 boom, to the top of the rear pedestal boom rest. Again this dimension should be noted this time
1” should be added. This will be the overall length for the rear boom rest with the rubber pad bolted on.

Prepared by: Jim Mielke/Mark Berggren Approved by: Jason Mehl

Issue: 11/11/99 05/29/06

Training Manual 19
 Standard: 5158
SAIE STANDARD Page: 4 of 5
Subject: Procedures for Setting Boom Rests

Prepared by: Jim Mielke/Mark Berggren Approved by: Jason Mehl

Issue: 11/11/99 05/29/06

20 Training Manual
 Standard: 5158
SAIE STANDARD Page: 5 of 5
Subject: Procedures for Setting Boom Rests

Prepared by: Jim Mielke/Mark Berggren Approved by: Jason Mehl

Issue: 11/11/99 05/29/06

Training Manual 21
22 Training Manual
 SERVICE TRAINING
Table of Contents

Schematics
Output Chart - Sample .........................................................2
Nomograph - Sample ...........................................................3
Accumulator Bypass Retrofit - Reference ...........................4
800 ........................................................................................5
801 ........................................................................................6
900 ........................................................................................7
900 w/o FAST SWITCH ......................................................8
900 WITH FAST SWITCH .................................................9
900 WITH FAST SWITCH and DAMPNER ....................10
1200 TC WITH SWITCHING VALVES ..........................11
1200 TC WITH MPS .........................................................12
HI-FLOW - SINGLE CIRCUIT ........................................13
2023-4 ................................................................................14
2023-5 ................................................................................15
2525H .................................................................................16
KVM 31 EZ Boom .............................................................17
KVM 32XL ........................................................................18
32XLG ...............................................................................19
34 XG .................................................................................20
KVM 39X ..........................................................................21
S 39/41 SX .........................................................................22
S 42 SX ..............................................................................23
S 42 SX ..............................................................................24
S 45 SX ..............................................................................25
S 45 SX ..............................................................................26
52 M ...................................................................................27
52 M ...................................................................................28
S 58 SX ..............................................................................29
S 58 SX ..............................................................................30

Training Manual
Table of Contents

Training Manual
 Output Chart - Sample

CONCRETE CONCRETE
BPL 1200 HDR-23 PRESSURE PRESSURE
(PSI) (BAR)
2000 138
PERFORMANCE CHARACTERISTICS OF
1900 131

PISTON SIDE
THE AXIAL PISTON HYDRAULIC PUMP

ROD SIDE
PUMP SPEED 1800 124

(bar)

(bar)
2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110

350 1500 103

PISTON SIDE
1400 97

300 1300 1285 88.6 90

1200 83
1100 76
250

OIL PRESSURE (BAR)

1000 70

350 ROD SIDE 900 62

200
800 55
300 758 52
700 48
150 250
600 41
200 500 34
100
150 400 28
300 21
100
50 200 14
50 7
100

Breakpoint 0 13 26 39 52 65 78 92
105 118 131 144 157 170 183 196
=178 bar
@ 300 bar 103 170.5
=238 l/m
CONCRETE OUTPUT (cu yd / h)

26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
15.5
PISTON 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
100 200 300 400 500 (liter / min.)

Differential Hydraulic Cylinder Material Cylinders Hydraulic Pumps

Bore dia. / Rod dia. x Stroke length Bore dia. x Stroke length Type / KW

125 mm / 80 mm x 2000 mm 230mm x 2000 mm 2 x A7VO-107

2 x 66KW
Slewing cylinder 80 / 45 x 185
SAIE 5240-029
Rev. 100296 THE PERFORMANCE CURVE INDICATES THAT THERE IS NO ALLOWANCE FOR
FILLING EFFICIENCY OF THE CONCRETE CYLINDER.

Training Manual 2
 Nomograph - Sample

By: Number: Max Q

Revision date: 042298 Power: 132 Kw

Model: BPL 900
012 320 l/m
Revision date: 042298 Power: 132 Kw

Model: BPL 900

Pumpkit Model: 120/80 x 1600:200

TK number does not apply to truck mounted units.

(72600) Pipeline diameter in inches
Curve shown is the Power Factor number (PF).
200

Q in yd3/hr.
320 l/m
For vertical placing, 180

Max Q
add 1.105 PSI per foot
of level difference. 160
6" 5" 4.5"
Number:
012
140
4"
120 116
Rodside
100

80
Pistonside 67
60

40

132 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI 1566 870

100

200

2"
300

400
2.5"

500

600

3"
4" 5" 6" 3000 2500 2000 1800 1500 1200 1000 800
Slump of fresh concrete in inches Proportional value of pipeline in feet

Training Manual 3
 Accumulator Bypass Retrofit - Reference

Service Bulletin Number:

* Normal Mode - Valve Open 1001-03
WHITE BEAR, MINN. 55127
Bypass Mode - Valve Closed
Name: Accumulator Bypass Retrofit
Product: Twin Circuit Models Assembly: N/A
Drawn By: MB Date 08/14/03 Checked Approved
P

A1 A B B1 T
FOR REFERENCE ONLY
SERVICE BULLETIN 1001-03
200 bar
ACCUMULATOR
XA
1.5 mm
S3
SYSTEM
XB Agitator
This line must return

11 1 to tank by itself
T
2 3 4
2nd agitator with Shut-Off* Truck air supply
7
Valve
Nitrogen pressure set at Psp 6.0 mm long rock and
Mp1
100 bar (1450 PSI) sloped side units
6 2.0 mm A
300 Mp 5-7 bar
bar 5
B
Accumulator control device B T
B 10 bar
E-STOP P
AGITATOR T(A)
P(B)
VALVE CLOSED FOR
BYPASS
Emergency stop
9 A A manifold

T SP MP2 MP3
10
T
1.3
mm
2.0 bar P2

ZK2 8 ZK1
0.9
P3

1.3 ACCUMULATOR 1 2 1.6 A Note:

mm
PUMP

FOR REFERENCE ONLY

3 Pressures are set to the
ZS2 ZS1 accuracy of the gauge as
B Concrete Pump received from the
MP1 Forward/Off/Reverse manufacturer.
Figure 1 0.9

See boom schematic

XB XA
1
P1 T
2 1.6 T
B 3.5 3.5 A
3
mm mm
T T

SERVICE BULLETIN 1001-03

X3

P P

MG 7-105 bar 0-35 bar MY

ACCUMULATOR G Y
SYSTEMA B
11 1
A1 B1 2 3 4
3.0 3.0 X1
mm 7 S2
XA XB
mm

Y3
PR 6 A
PP A1
S1 5
XR XP B B
E-STOP P2 AGITATOR
P1 2.0 bar See boom
schematic

MP VALVE CLOSED FOR

BYPASS
9
T2 T1 A A S
1.2
10
2.0 bar MX
350 bar 1.4
14
X1
1.8 13 12 X1
mm
80
13 Y3
X2 10 bar A
bar
ACCUMULATOR A1

1.3 PUMP 50 psi Rexroth

ΔP A7VO-LRDH
X3 1.1 Hydraulic pumps
Figure 2 200 bar

1.8 T M
mm
S
Hyd. oil cooler
w/elec fan

Training Manual 4
 800

Training Manual 5
 801

A
agitator
motor
B
Pipe Gate

BPL 601, 801, 1001, 1201 HDD P

KVM 28, 31, 36
Agitator H2O pump
pressure* motor
Hopper Gate
A

B
M

Hydraulic stroke limiter P

added 1982 and later H2O
P pressure*

0-50
BAR Position 1 =
Spring Return
T 2 1 Position 2 =
Detent
S3
S1 A
CA B
1.5 mm
hole drilled
through spool 5.5 bar
300 *Agitator pressure =
bar with gearcase 70 bar
with direct drive 200 bar
S2 *Waterpump pressure =
with agitator gearcase 200 bar
with direct drive agitator 210 bar

A3V hydraulic pumps used

prior to 1982. A7VO shown.
X1 X1

X2 X2

M A A
A1 A1

0.7 To
mm Boom
6 bar Circuit

1.0 mm orifice on 1001 and 1201

S S

Training Manual 6
 900

PRINT # 329325 A

BPL 900 HDR B

KVM 23, 28, 32
Equipped with
OF - 494 control block P
200 bar

B
M
P
P
0-50
BAR 210 bar

T
Position 1 =
Spring Return
A 2 1 Position 2 =
Detent
S3
S1
T1 T CA B
1.5 mm
hole drilled
through spool 5.5 bar
300
bar

S2

X1 X1

X2 X2

A A
A1 A1

D
M
To
Boom
6 bar Circuit

S S

Training Manual 7
 900 w/o FAST SWITCH

BPL 900 HDR T

P KVM 32XL, A
24-4, 26-4
0-55 bar with B
Y(T) Single circuit switching,
7 place boom manifold,
STROKE A
&
Agitator
LIMITER
10167892 (12v) or 10167893 (24v)
emergency stop manifold

Note:
Pressures are set to the 200 bar
accuracy of the gauge as
received from the P Hydraulic style
manufacturer. remote throttle
actuation

AIR TANK

5 - 7 bar only needed with P

hydraulic style T
C P remote throttle
6
actuation bar
S3
S1 See boom
schematic
P4 P3 P2 MP1 P1
1.5 mm A MP4
hole drilled 260 bar 350 bar

through spool B To boom

circuit
T

T MP2-4 1.5 1.5

300 Concrete Pump
S2 bar For. / Neut. / Rev. Emergency
1.6
2
1.6
2
stop
manifold
1 3 1 3

Swap P3 and P4 on e-stop manifold.

Port size
limits flow X1 X1
Y3

Change
Y3

A A
A1 A1

D
M
To
Boom
35 PSI P

Rev.061198
Circuit

SAIE 10057

initials
S S

Training Manual 8
 900 WITH FAST SWITCH

Remote controlled
stroke limiter T
A
Remote Throttle
T Agitator Actuation (hyd. version)
B
P

Change
70
B bar
P
P
A
0-55 bar T
Y(T) BPL 900 HDR 6
bar

Release
STROKE A KVM 28X 200 bar
LIMITER P
KVM 26-4
with Single Gauge Port

Rev.032697
SAIE 10038
0-400 bar

initials
Circuit Switching,
fast switch,
FAST
SWITCH P and 344780 (12v) or
T

Compressor
344781 (24v) E-stop manifold

(Optional)
X

A B AIR TANK
Water
NG 6 pump

5 - 7 bar A T B
0.7 mm
Note:
Pressures are set to the
S3 accuracy of the gauge as
received from the
manufacturer.

1.5 mm
hole drilled
through spool S1 C P

T
210 bar
P
A

300 bar B
S2
T Concrete Pump
For. / Neut. / Rev.

See boom
schematic

D C B A

X1 X1
Port size
250
limits flow Y3 Y3 bar
A A
A1 A1

Emergency stop manifold E F

D
M
To
Boom
3.5 bar Circuit

A7VO-80 LR S S A7VO-80 LR

Training Manual 9
 900 WITH FAST SWITCH and DAMPNER

Remote controlled Remote controlled

stroke limiter stroke limiter Agitator
(Hartman style) (Rexroth style) T
A
P
T B

Change
P
T

0-55 bar 70
Y(T)
B bar

STROKE A A
LIMITER
A 200 bar

Release
P
Gauge Port
0-400 bar

Rev.082797
SAIE 10055
BPL 1200 HDR

initials
KVM 28X / 26-4 / 32 XL Compressor
(Optional)

FAST
with Single Circuit Switching, Water
pump
SWITCH P T 4 or 5 place b & w boom manifold,
DAMPENER X
NG 6
30344780 (12v) or
A B 30344781 (24v) E-stop manifold A T B

P
0.7 mm

0-55
bar
Y(T)

A
0.7 mm
AIR TANK

S3 6 bar 210 bar

C P
1.5 mm
hole drilled
through spool S1
See boom
schematic

A D C B A

B
300 bar
S2 250
bar F
T
Concrete Pump
For. / Neut. / Rev. E

Emergency stop manifold

X1 X1
Port size
limits flow Y3 Y3
A A
A1 A1

Note: D
Pressures are set to the
M accuracy of the gauge as
received from the
To
manufacturer. Boom
3.5 bar Circuit

5.5 bar

A7VO-107 LR S S A7VO-107 LR

Training Manual 10
 1200 TC WITH SWITCHING VALVES

Remote controlled
Nitrogen pressure set at 100 bar stroke limiter
(650 PSI) SAIE 10026 Change
T Rev.112596 Release

initials
P
P 70
0-55 B bar BPL 900-1200 KVM 36X
bar
TWIN CIRCUIT
A with electric over air pilot
Y(T) Note:
Pressures are set to the
300 A accuracy of the gauge as
S3 bar Manual stroke received from the
limiter manufacturer.
Accumulator control device

P
C P
This line must
return to tank Accumulator pump
by itself. unloading valve Concrete Pump
Forward/Neutral/Reverse
T
200
bar AIR TANK

Y P B
NG
10 A 6 bar

250 bar T

0.7 0.7
mm mm

2.5 mm 2.5 mm Agitator

S2
B A

200
bar
S1

320
bar
P T
Port size
0.7 mm limits flow

X1 X1 Remote Throttle
A2F-23 A2F-10 Actuation (hyd. version)
Y3 Y3
A A
120 Hyd. oil cooler
A1 A1
bar w/elec fan

Soft switch M P

35 psi T
ΔP
6
bar
1200 = A7VO-107 LR S See boom schematic S 1200 = A7VO-107 LR
900 = A7VO-80 LR 900 = A7VO-80 LR

Training Manual 11
 1200 TC WITH MPS

SAIE 10025 Change

Rev.071797 add c.p. checkvalve to e-stop circuit
6.3 mm
Remote controlled
,,
,,
stroke limiter initials

,,
Nitrogen pressure set

,, BPL 900-1200 KVM 36X

at 100 bar (1450 PSI) T

P MPS - TWIN CIRCUIT

6.3 mm P 70 with electric over air pilot,
0-55 B bar emergency stop manifold
bar

A Note:
Pressures are set to the
Y(T) accuracy of the gauge as
received from the
300 A manufacturer.
S3 bar Manual stroke
limiter
Accumulator control device

T P

B A 1.0 mm
P
C P
T P This line must
1.0 mm
return to tank Accumulator pump
by itself. unloading valve Concrete Pump
B A
Forward/Neutral/Reverse
A A T
200
bar AIR TANK

Y P B
NG
10 A 6 bar

0.7 0.7
mm mm

2.5 mm 2.5 mm Agitator

S2
B A

200
bar
S1

320
bar
P T
Port size
0.7 mm limits flow

X1 X1 Remote Throttle
A2F-23 A2F-10 See boom
Actuation (hyd. version)
schematic
Y3 Y3
A A
80 Hyd. oil cooler
A1 A1 D C B A
bar w/elec fan
250 bar
Soft switch M P

35 psi T
E
ΔP
6
Emergency stop F bar
1200 = A7VO-107 LR S See boom schematic S 1200 = A7VO-107 LR manifold
900 = A7VO-80 LR 900 = A7VO-80 LR

Training Manual 12
 HI-FLOW - SINGLE CIRCUIT
SAIE 10207 Change
P Rev. 102901 Release.
T
initials
Truck air supply 200 bar
330
bar
3
1.6
2
1
2020-4, 2023-4
5-7 bar P1
See boom schematic
0.9
KVM 32 XG
A
MP1
HI-FLOW - SINGLE CIRCUIT
B with Rexroth A7VO hydraulic pumps
1.6 3
and cartridge type MPS manifold
P(B) P3
Agitator T(A) 2
1
P2 0.9

Emergency stop
manifold
T
MP3 MP2

A
T SP Concrete Pump
Forward/Off/Reverse
B

ZK2 1.3 ZK1 T

ZS2 1.3 ZS1 MP

MG2
20
bar
XA XB G2
PBP
A 3.5 3.5 B 3.5-40
bar

X3
PZ
3.5-40 0.7
bar

0.7
T

A2 B2
0-30
A3 B3 bar

XA1 S3 XB3 MG1 MX1 X1

1.5

A B X1

A1 B1
Y3
A
XA S2 XB
A1
PR
PP
S1
XR XP

P2 P1

S 1200 or 2020/2023 = A7VO-107 LR

MP
900 = A7VO-80 LR
T2 T1
1.2
See boom schematic
X1
1.4
300 bar
Y3
X1 A
A1
1.8
T

M
10 bar

S
1200 or 2020/2023 = A7VO-107 LR
1.8 900 = A7VO-80 LR

Training Manual 13
 2023-4

Correct max. pressure for 2020 versions.

C P
Truck air supply

Change
T 5-7 bar

A
A1 A B B1 Agitator
B
2nd agitator with B Concrete Pump
XA
1.5
mm
S3
XB
long rock and
sloped side units A
Forward/Off/Reverse 2020-4, 2023-4
T
KVM 34 X

Rev. 120798
SAIE 10115
Nitrogen pressure set at
100 bar (1450 PSI)
6.0 mm
MPS - TWIN CIRCUIT
Psp Mp1
with Rexroth A7VO hydraulic pumps
Note:

initials
2.0 This line must return
mm 300 Mp to tank by itself Pressures are set to the and cartridge type MPS manifold
Accumulator control device bar 200 bar accuracy of the gauge as
T P received from the
manufacturer.
P

G2

MG2
T SP
MP5 T MP2
Remote Throttle Emergency stop P4
0-30
Actuation (hyd. version manifold bar
ZK2 ZK1 0.9 P3
used when engine not X1
electronically controlled) P2
1 2 1.6 MX1
3 3.5-55
ZS2 ZS1 260 bar
bar
MG1
MP1
P
0.9
XA XB

See boom schematic

T MP
P1
1 2 1.6
B A
3
5.5 bar
X3 PBP PZ T

A B
A1 B1
3.0 3.0 X1
mm S2 mm
XA XB
Y3
PR 0.7 A
mm
PP A1
0.7
mm S1
XR XP

P2 P1 See boom
schematic

MP

T2 T1 S 1200 = A7VO-107 LR
1.2 900 = A7VO-80 LR

2023 = 350 bar

2020 = 328 bar 1.4 MX

X1
X1
Y3
1.8 80 X2 A
bar Hyd. oil cooler A1
w/elec fan
A7VO-LRDH
X3 M
Hydraulic pumps are
1.1 used only on -4 machines
35 psi 200 bar
T ΔP
1.8
S 1200 = A7VO-107 LR
900 = A7VO-80 LR

Training Manual 14
 2023-5

3.5 mm and 1.3 mm nozzles adde to A, B,

ZS2, and ZK2 ports on MPS manifold.
accuracy of the gauge as
Pressures are set to the
10 bar

received from the

manufacturer.

Change
Note:
P

A1 A B B1
T

XA S3 XB 200 bar
This line must return
to tank by itself
T
Nitrogen pressure set at
100 bar (1450 PSI) 6.0

Rev. 110499
SAIE 10139
mm Agitator
Psp Mp1 Truck air supply
2.0
mm 300 Mp 2nd agitator with A

initials
Acumulator control device bar long rock and
T sloped side units B 5-7 bar

P
T(A)
P(B)

Emergency stop
manifold 2023-5
T SP
MP5 T MP2 KVM 39X, 34X
P4

ZK2 ZK1 0.9 P3

MPS - TWIN CIRCUIT
1.3
mm P2
e-stop manifold
1 2 1.6 10167892 (12v) or 10167893 (24v)
3
260
ZS2
1.3
ZS1 bar A
mm Concrete Pump
B Forward/Off/Reverse
MP1

0.9

See boom schematic

XB XA
P1 T
1 2 1.6 P1
B 3.5 A 3.5
mm mm 3

X3

P
A B
A1 B1 T
3.0 3.0
mm S2 mm
XA XB Pressure P
reducing
PR 0.7 valve 55 bar
PP
mm T
0.7
mm S1 A
XR XP

P2 P1 Y T2 R T1 G Z A M Y T2 R T1 G Z A M
A
MP Electric
stroke limiter
see see
T2 T1 note note
1.2

360 bar 1.4 MX

See boom
X1 schematic
1.8
mm
80 X2
bar

Hyd. oil cooler

X3
w/elec fan
1.1 M1 S M1 S

35 psi
M
T P Note: A11VO-LRDH
1.8 Hydraulic pumps are 200 bar
mm limited to 350 bar
by pressure cutoff.

Training Manual 15
 2525H

3.5 mm and 1.3 mm nozzle added to A, B,

T

ZS2, and ZK2 ports on MPS manifold.

2525H
A
Agitator KVM 52
B MPS - TWIN CIRCUIT

Change
2nd agitator with
long rock and With switching signal
sloped side units
from waterbox end
A1 A B B1
Note:
Pressures are set to the
accuracy of the gauge as
XA S3 XB received from the
This line must return
to tank by itself 200 bar manufacturer.
T
P
Nitrogen pressure set at
100 bar (1450 PSI) 6.0

Rev. 110399
SAIE 10143
Psp mm Mp1
2.0
mm 300 Mp

initials
Acumulator control device bar
T

P
MP5 T MP2
P4

0.9 P3 C P

P2
1 2 1.6
3
Remote Throttle 260
bar
T Actuation (hyd. version
used when engine not MP1
1.1
electronically controlled) Truck air supply
0.9

See boom schematic

X3
P1 B
1 2 1.6
350 Concrete Pump
5-7 bar
80 3 bar Forward/Off/Reverse
X2 bar A
P
X1
T
T
MX 1.4 360 bar
Emergency stop manifold

1.2
T1 T2

MP P

P1 P2 T

0.7 mm XP XR 55 bar
S1 A
PP
PR 0.7 mm Pressure
3.0 mm
reducing valve
XB XA 3.0 mm
S2
B1 A1
B A

T
M A Z G T1 R T2 Y M A Z G T1 R T2 Y

X3 2.0 mm

3.5 3.5 see see

note note
A mm mm B A

5.5 bar
Electric
XA XB stroke limiter

See boom
schematic
ZS1 ZS2 Hyd. oil cooler
w/elec fan
1.3
mm
M
ZK1 ZK2

1.3 35 psi S M1 S M1
mm ΔP
SP T A11VO-LRDH
Hydraulic pumps are
limited to noted pressure 200 bar
by pressure cutoff.

Training Manual 16
 KVM 31 EZ Boom

BOOM #1 (MAIN) BOOM #2 BOOM #3 BOOM #4 (TIP) BOOM #1 (Extend)

260/160 x 11 80 150/90 x 1195 170/90 x 1200 120/70 x 805 130/80 x 4645 SLEWING (LEFT - RIGHT)

Outrigger Extension Outrigger Jacking Cylinders Outrigger Extension

HOME
Cylinder Rear 125/100 x 550 Cylinder Front
60/40 x 1520 Rear Front 70/50 x 2300
4 EA 10160891
5 EB 10189485
6 EB 10189484
7 EB 10189483
8 EA 10188569 10 10
1.0 mm 1.0 mm 1.0 mm 1.0 mm 1.0 mm
A2 A1 B2 B1 B2 B1 B2 B1 A2 A1
14

300 bar

280 bar

330 bar

310 bar

160 bar
320 bar

290 bar

320 bar

300 bar

150 bar
T T T T T
180 bar

270 bar

230 bar

220 bar

240 bar
190 bar

300 bar

240 bar

210 bar

250 bar
T P B A B A B A B A C
9 A1 X B1 125 125 125 125
B2
1.0 mm
B1 A2
1.0 mm
A1 A2
1.0 mm
A1 A2
1.0 mm
A1 B2
1.0 mm
B1 0 - 16
bar bar bar bar
3
bar
EB EA EA EA EB
150 bar 150 bar

13

150 bar
14 bar
T1
21
T

A B

Front of Unit
Water Optional HP Optional
pump water pump air compressor

or
2
280
bar T1
35 l/m

180 bar
C1 22 14
125 125 125 125
C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 MPS bar bar bar bar
G1/2
1 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2
T P B A B A B A B A C
10 10
140 bar

30
bar 15
1 1 1 1 1 1 1 1 bar

0 0 0 0 0 0 0 0 Outrigger Extension Outrigger Jacking Cylinders Outrigger Extension

Cylinder Rear 125/100 x 550 Cylinder Front
2 2 2 2 2 2 2 2
60/40 x 1520 Rear Front 70/50 x 2300
MP

P2
18
350 ∅ 0.55
bar
P

T
LS
T

14 P
HYDRAULIC SCHEMATIC
1.5
KVM 31 EZ boom 11 20 bar

from GmbH 10200675 X T2 T1 G A M See concrete pump M A G X T1 R T2

schematic High pressure filter

P2 P3 P1
MP3
20 bar Δ P
330
bar 17
Note:
Pressures are set to the MP2 MP1
Z To concrete pump circuit
accuracy of the gauge as 2.0 0.3
bar bar hydraulic pump, port Z.
received from the
manufacturer. 310 bar
T Not used without 3-circuit
Emergency stop
manifold control.

SAIE 10235 Change M

12
0.9 1.6 0.9 1.6 g maxV g minV
2.5
GD# 10200675 Release. bar
Rev. 112904 M1 S
S M1
A11 VO DRS A11 VO DRSP
initials

Training Manual 17
 KVM 32XL

Driver Side
BOOM #1 (MAIN) BOOM #2 BOOM #3 BOOM #4 (TIP) Optional air Water
200/125 x 1030 180/110 x 1300 150/90 x 800 110/70 x 670 SLEWING (LEFT - RIGHT) compressor pump HOME

10151785 10151785 T 10151785 10151785

T T T
320 310 320 310 320 310
Outrigger Jacking Cylinders Outrigger Extension Cylinders
320 310
bar bar bar bar bar bar bar bar 90/60 x 650 Front Rear
70/50 x 2300 60/40 x 1520
P1 P2 P1 P2 P1 P2 P1 P2

X E X E X E X E

X E X E X E X E

P2 P1 P2 P1 P2 P1 P2
P1

320 310 320 310 320 310 320 310

bar bar bar bar bar bar bar bar
A1 X B1
T 10151785 T 10151785 T 10151785 T
10151785
0 - 16
bar

200 bar 200 bar

P
14 bar

140 80 140 80 T
T bar bar bar bar

A B

80 140 80 140
bar bar bar bar
P
P1 280
bar

T
140 bar

C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 MPS
G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2

30
bar 15
bar
Outrigger Extension Cylinders
Rear Front
60/40 x 1520 70/50 x 2300
MP Outrigger Jacking Cylinders
90/60 x 650
350 P2
bar
P

T
LS

HYDRAULIC SCHEMATIC St

KVM 32XL
w/meter out spools
0
applies to proportional units only 2.0 I
and E-stop manifold number 10181606 (12v) See concrete High pressure filter atmospheres
or 10181607 (24v) pump schematic
P3 P2 MP1 P1
MP2
Note: 330 bar P regulator A
Pressures are set to the A1

A
X X
accuracy of the gauge as MP5

P
received from the T 20

T
bar P To LS port
manufacturer. T of Apitech
300
0.9 0.9
SAIE 10188 Change bar
1.6 1.6 X3
Rev. 061900 Release
Emergency 2 2
stop P
initials manifold A T
1 3 1 3
System when equipped with Rexroth hydraulic pump System when equipped with Voac hydraulic pump

Training Manual 18
 32XLG

BOOM #1 (MAIN) BOOM #2 BOOM #3 BOOM #4 (TIP)

200/125 x 1030 180/110 x 1300 150/90 x 800 110/70 x 670 SLEWING (LEFT - RIGHT)

10151785
HOME
10151785 10151785 10151785

1.0 mm 1.0 mm 1.0 mm 1.0 mm

Water
310 bar 310 bar 310 bar 310 bar Tank
320 bar 320 bar 320 bar 320 bar SR
SR1
320 bar 320 bar 320 bar 320 bar
Water High pressure
310 bar 310 bar 310 bar 310 bar
pressure water (optional)

1.0 mm 1.0 mm 1.0 mm 1.0 mm A1 X B1

0 - 16
10151785 10151785 10151785 bar
10151785

200 bar 200 bar

Driver Side
14 bar
Outrigger Extension Cylinder Outrigger Jacking Cylinders Outrigger Extension Cylinder
T Rear 125/100 x 550 Front
70/50 x 2300 60/40 x 1520
A B

140 80 140 80 T
140 bar bar bar bar bar

C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 MPS
G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2
15
bar

80 140 80 140
0.76 bar bar
mm bar bar
P
P1 280
bar

0.2 mm
300
bar
0.61
mm T
P

T
LS

See pump schematic

P3 P2 MP1 P1
HYDRAULIC SCHEMATIC MP2 Note: Outrigger Extension Cylinder Outrigger Jacking Cylinders Outrigger Extension Cylinder
Pressures are set to the Rear Front
32XLG accuracy of the gauge as High pressure filter 70/50 x 2300
125/100 x 550
60/40 x 1520
w/fixed displacement boom pump and MP3 received from the
proportional Inlet control valve manufacturer.
XLG units SN170522735 and higher T
Passenger Side
0.9 0.9

Emergency 1.6 1.6

stop 2 2
manifold
SAIE 10229 Change
1 3 1 3
Rev. 120403 Release 2.0
atmospheres

initials

Training Manual 19
 34 XG

HOME
BOOM #1 (MAIN) BOOM #2 BOOM #3 BOOM #4 (TIP)
225/125 x 880 180/125 x 151 0 150/100 x 1173 110/60 x 805 SLEWING (LEFT - RIGHT)
Grayed components represent
EA EB EB EB
optional equipment
140 bar
M
∅1.0 ∅1.0 ∅1.0 ∅1.0
A1 A2 B2 B1 B2 B1 B2 B1
B
Water
Tank

320 bar

320 bar
320 bar

310 bar
330 bar 320 bar 330 bar 330 bar
A
T T T T

290 bar
180 bar

320 bar

280 bar
190 bar 330 bar 290 bar 300 bar
T

B1 B2 A2 A1 A2 A1 A2 A1
Water pump HP water pump
∅1.0 ∅1.0 ∅1.0 ∅1.0
EB EA EA EA Water High pressure
pressure water
A1 X B1

0 - 16
bar

150 bar 150 bar

Driver Side
Outrigger Extension Outrigger Jacking Cylinders Outrigger Extension
Cylinder 125/100 x 550 Cylinder
14 bar

A B Rear Front
Compressor 70/50 x 2300 60/40 x 1520

P
140 bar
140 80 140 80 T
bar bar bar bar
C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 PP
G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2
15
bar

80 140 80 140
bar bar bar bar
P
280
bar
0.2
mm
300
bar

.061 mm P
T
T
LS

HYDRAULIC SCHEMATIC
34 XG
w/fixed displacement boom pump and
proportional control valve
330 bar
Note: Outrigger Extension Outrigger Extension
Pressures are set to the Cylinder Cylinder
High pressure filter
accuracy of the gauge as Rear Outrigger Jacking Cylinders Front
received from the 70/50 x 2300 125/100 x 550 60/40 x 1520
manufacturer.
Passenger Side

SAIE 10187 Change

GD# Compressor circuit, outrigger cyl. sizes,
Rev. 070803 brake valve pressures corrected. 2.0
atmospheres
initials

Training Manual 20
 KVM 39X

Driver Side
BOOM #1 (MAIN) BOOM #2 BOOM #3 BOOM #4 (TIP) Optional air Water
240/180 x 1080 200/140 x 1620 150/80 x 1173 120/70 x 805 SLEWING (LEFT - RIGHT) compressor pump
HOM
10151786
Outrigger Extension Cylinder Outrigger Jacking Cylinders Outrigger Extension Cylinder
Rear 100/65 x 650 Front
1.0 mm 70/50 x 2075 95/82 + 58/44 X 3561
1.0 mm 1.0 mm 1.0 mm

320 bar

320 bar
320 bar

320 bar
330 bar
330 bar 330 bar 330 bar
320bar 310 bar 320 bar

300 bar
310bar
320 bar

310 bar
310 bar

1.0 mm 1.0 mm 1.0 mm

1.0 mm
10180550 10180549 10180551
A1 X B1
10151785
0 - 16
bar

200 bar 200 bar

P
14 bar

140 80 140 80 T
T bar bar bar bar

A B

80 140 80 140
bar bar bar bar
P
P1 280
bar

200 bar
T

C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 MPS
G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2

30
bar 15
bar
Outrigger Extension Cylinder Outrigger Extension Cylinder
Rear Front
70/50 x 2075 95/82 + 58/44 X 3561
MP Outrigger Jacking Cylinders
100/65 x 650

350 P2
bar
P

T
LS

HYDRAULIC SCHEMATIC
KVM 39X
w/slewing motor manifold,
2.0
Apitech control block, and emergency stop manifold
See concrete pump atmospheres 10181606 (12 volt) or 10181607 (24 volt)
High pressure filter
schematic Emergency stop
P1 manifold
P3 P2 MP1 Note:
MP3
330 Δ P regulator A Pressures are set to the
bar A1 accuracy of the gauge as
X received from the
MP2
T
20 manufacturer.
bar Δ P T

300
bar SAIE 10162 Change
X3
Rev. 120299 E-stop manifold symbol corrected.
P
A T initials
System when equipped with Rexroth hydraulic pump

Training Manual 21
 S 39/41 SX
14.03.2006

HOME

Training Manual 22
 S 42 SX

HOME
Driver Side
Outrigger Jacking Cylinders Outrigger Extension Cable
Outrigger Slewing Cylinder 110/80 x 750
100/40 x 327
Rear Front Front
Rear

A1 B1 A2 B2 A3 B3 A4 B4 T

P
350 T1
bar 200
bar

To/From Boom System (10233-2)

T2

300
350 bar
200
bar
bar
P1
C

T A4 B4 A3 B3 A2 B2 A1 B1

HYDRAULIC SCHEMATIC
KVM 42 SX
applies to units w/ symetrical outrigger
valves, and Apitech boom control valves.

Note: Rear Rear Front Front

Pressures are set to the Outrigger Jacking Cylinders Outrigger Extension Cable
Outrigger Slewing Cylinder
accuracy of the gauge as 110/80 x 750
100/40 x 327
received from the
manufacturer.
Passenger Side

SAIE 10233-1/2 Change

Rev. 090904 Release

initials

Training Manual 23
 S 42 SX

SLEWING (LEFT - RIGHT) BOOM #4 (TIP) BOOM #3 BOOM #2 BOOM #1 (MAIN)

110/70 x 1000 160/110 x 1200 225/140 x 1600 180/110 x 1300
HOME

10151788 10151788 10151788 10039659 10039659

T T T 400 bar 400 bar
320 300 320 300 320 300
bar bar bar bar bar bar

P1 P2 P2 P2
0 - 16
bar X E X E X E

X E X E X E
Grayed components represent A1 X B1
P1 P2 P2 P2
optional equipment

Water 320 300 320 300 320 300

200 bar 200 bar bar bar bar bar bar bar
Tank 320 bar 320 bar
T T T
10151788 10151788 10151788 10049891 10049891

14 bar

T
#1 Down - brake valve B
Water pump HP water pump
A B

Water High pressure

pressure water
To/From Outrigger System (10233-1)

0.35

T1

0.35
T2
X Y A

P1

PP C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1 C2 C1

MP 190 bar 90 bar

15
bar

30bar
P2

350
bar

T LS

see concrete
pump schematic HYDRAULIC SCHEMATIC
P3 P2 MP1 P1
MP3 High pressure filter KVM 42 SX
320 bar W/ Apitech boom control valves,
and e-stop manifold 10181607
MP2
Δ P regulator
T A
X
A1 Note:
Pressures are set to the
20 accuracy of the gauge as
0.9 0.9 bar Δ P T received from the
1.6 1.6
300
manufacturer.
2 2
bar

atmospheres
X3 Change
1 3 1 3 SAIE 10233-2/2
P Rev. 090904 Release
A T

2.0
Emergency stop manifold Boom hydraulic pump
initials

Training Manual 24
 S 45 SX

HOME
Driver Side
Outrigger Jacking Cylinders Outrigger Slewing Cylinder Outrigger Extension Cable
110/80 x 750 100/40 x 327

Rear Front Rear Front

A1 B1 A2 B2 A3 B3 A4 B4 T

P
T1
350 200
bar bar

T2

300
200 350 bar
bar bar
P1
C

T A4 B4 A3 B3 A2 B2 A1 B1

HYDRAULIC SCHEMATIC
KVM 45 SX
applies to unit SN 70526011, 170526002 and later

Note: Front Rear Rear Front

Pressures are set to the
accuracy of the gauge as
received from the
manufacturer.
Outrigger Extension Cable Outrigger Slewing Cylinder Outrigger Jacking Cylinders
100/40 x 327 110/80 x 750
Passenger Side

SAIE 10047-1/2 Change

Rev. 040898 Correct p.s. outrigger slewing/350 bar
secondary relief connection
initials

Training Manual 25
 S 45 SX

HOME Water Optional air BOOM #4 (TIP) BOOM #3 BOOM #2 BOOM #1 (MAIN)
SLEWING (LEFT - RIGHT) pump compressor 115/70 x 995 200/110 x 1200 260/160 x 1990 340/115 x 2290

HYDRAULIC SCHEMATIC
KVM 45 SX 10151788
320 300
T
10151786
330 320
T
10151785
320 310
T 10151784
350 330
T

applies to unit SN 70526011, 170526002 and later bar bar bar bar bar bar bar bar

P2 P2 P2 P2
0 - 16
P1 X E P1 X E P1 X E P1 X E
bar
Note:
Pressures are set to the
A1 X B1
accuracy of the gauge as
received from the
manufacturer.
P1 X E P1 X E P1 X E P1 X E
200 bar 200 bar P2 P2 P2 P2

SAIE 10047-2/2 Change

280 260 330 320 320 310 350 330
Rev. 040898 Change adjustable checkvalve to fixed bar bar bar bar bar bar bar bar
10151787 T 10151786 T 10151785 T 10151784 T
spring checkvalve, change pilot valve to 35
14 bar initials bar, assign flow to outrigger supply valve.
T

A B

A4 B4 A3 B3 A2 B2 A1 B1
P
P
X
Y
Ls
L Pv
Ls

160 - 200 μ
T1

T2
a' a b b' 35

230 bar
bar

Dr2-a'

Dr1-b'
P1 350
bar

40
bar

A B b a A B A B

200
bar 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
30 l
max. LS
see concrete
pump schematic
MP2
T PST P

High pressure filter P2

D-G 1-b4

D-G 3-a4

C-G 2-b3

C-G 4-a3
B-G 1-a2

B-G 3-b2

A-G 2-b1

A-G 4-a1
Dr 1-b'

Dr 1-a'

P regulator
A MP3
A1
1 2 1 3 2 4 1 3 2 4 X
20 P3
bar P T MP1

310
bar P1
X3
P T P T P T
330
bar
P
A T
Emergency stop manifold T 2.0
Boom hydraulic pump
atmospheres

Training Manual 26
 52 M

Driver Side HOME

Outrigger Jacking Cylinders Outrigger Slewing Cylinder Extension Cylinder
Rear Front Rear Front Front
180/150 x 900 180/150 x 900 140/90 x 300 140/90 x 1145 90/70 x 1870

A1 B1 A2 B2 A3 B3 A4 B4 T

350 350 50
bar bar bar

T1

T2 See SAIE 10079

page 2 of 2

P1

150
bar 350 350 50
bar bar bar
P C

A1 B1 A2 B2 A3 B3 A4 B4 T

HYDRAULIC SCHEMATIC
KVM 52
1 of 2 (outrigger circuit)

Note:
Pressures are set to the
accuracy of the gauge as
received from the
manufacturer.

Outrigger Jacking Cylinders Outrigger Slewing Cylinder Extension Cylinder

SAIE 10079-1/2 Change Rear Front Rear Front Front
180/150 x 900 180/150 x 900 140/90 x 300 140/90 x 1145 90/70 x 1870
Rev. 102298 change main outrigger relief to 150 bar

initials
Passenger Side

Training Manual 27
 52 M

HYDRAULIC SCHEMATIC
Water BOOM #1 (MAIN) BOOM #2 BOOM #3 BOOM #4 (TIP)
KVM 52 pump 350/160 x 2730 280/160 x 2100 SLEWING (LEFT - RIGHT) 210/110 x 1173 130/80 x 1069

HOME 2 of 2 (boom circuit)

w/10167892 (12v) or

all changes on page 1 of 2

10167893 (24v) Estop manifold
Change
0 - 16
bar

10065681 10065681 10065680 10047783

320 bar 320 bar A1 X B1 350 bar 350 bar
Note:
Pressures are set to the
280
accuracy of the gauge as bar
received from the 10065680 10065681
200 bar 200 bar
10065681 10047784
manufacturer. 350 bar 320 bar 320 bar 260 bar
SAIE 10079-2/2
Rev. 102298

initials

14 bar

T
M B B M M B B M
A B M B B M M B B M

A A A A
A A A A
See SAIE 10079 A X X A A X X A
A X X A A X X A
page 1 of 2
P1 1.5
adjusted to 20 bar
dynamic pressure
T1 adjusted to 20 bar
dynamic pressure
T2
adjusted to 20 bar
dynamic pressure

Pst
Pst

50 adjusted
bar to 20 bar
dynamic
30 pressure
bar
a4 A4 B4 a5 A5 B5 a6 A6 B6 a1 A1 B1 a2 A2 B2 a3 A3 B3
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
T T

190 190
bar bar

350 bar
10146289 10146290
X (LS) X (LS)
P P
b4 b5 b6 b1 b2 b3 T

See concrete pump schematic

P3 P4 P2 MP1 P1
MP2 P regulator
330 bar
High High
pressure pressure X
b1

a1

b2

a2

b3

a3

b4

a4

b5

a5

b6

a6

4 3 2 1 4 3 2 1 4 3 2 1
filter filter
20 bar
T P
A1
A
310
MP5 0.9 0.9 bar
T
P T P T P T 1.6 1.6
Emergency 2 2
stop X3 P
T A
manifold 5.5
1 3 1 3 bar
Boom hydraulic pump

Training Manual 28
 S 58 SX

BOOM #4 (TIP) BOOM #3 BOOM #2 BOOM #1 (MAIN)

SLEWING (LEFT - RIGHT) 160/80 x 1110 240/120 x 1500 320/200 x 2200 400/180 x 3450 Water pump HP water pump
HOME
EB EB EB EA
1.0 mm 1.0 mm 1.0 mm 1.0 mm
B2 B1 B2 B1 B2 B1 A2 A1

330 bar

330 bar

330 bar

260 bar
320 bar

320 bar

320 bar

250 bar
T T T T

240 bar

260 bar

330 bar

310 bar
250 bar

270 bar

340 bar

320 bar
B1 X A1

0 - 16 A2 A1 A2 A1 A2 A1 B2 B1
bar 1.0 mm 1.0 mm 1.0 mm 1.0 mm

EA EA EA EB water tank
250 bar 250 bar

water HP
output water
M output

14 bar

B A 240 bar

P1

T1
0.55 mm

A B A B A B A B A B B A B A B Z R M LS T P
T2

300 bar

300 bar

R1

a a a a a a a

360 bar
o o o o o o o

A
A
b b b b b b 280 bar b 20
bar
B
230 bar 180 bar B

HYDRAULIC SCHEMATIC
S 58, 61 SX boom T2 T1 X G A M

page 1 0f 2 See concrete pump

schematic Emergency stop
manifold
T
w/estop manifold 10181606 (12V) or 10181607 (24V) 20 bar P MP3 P2 P3 MP1 P1
P
from Gmbh print #10185941 350
bar
1.5
Note: bar MP2
Pressures are set to the T
High pressure filter
accuracy of the gauge as 310 bar
received from the
manufacturer.

SAIE 10197-1/2 Change M

A11VO 5 bar
Rev. 102502 Update to match GmbH rev. Add "61." 170 l/m
M1 S
initials

Training Manual 29
 S 58 SX

Driver Side

HOME

Outrigger Slewing Cylinder Outrigger Jacking Cylinders Outrigger Extension Cable Outrigger Roller
130/60 x 445 130/70 x 800 22 x 33
Rear Rear Front Front

A A

B B

A1 B1 A2 B2 A3 B3 A4 B4 T

P
P1
350 210 210
bar bar bar
200 200
T1 bar bar

T2

200 200
350 bar bar
bar 310
210 210 bar
bar bar

T A4 B4 A3 B3 A2 B2 A1 B1

HYDRAULIC SCHEMATIC
S 58, 61 SX
A A
page 2 of 2
B B

Note:
Pressures are set to the
accuracy of the gauge as
received from the
Rear Rear Front Front manufacturer.
Outrigger Slewing Cylinder Outrigger Jacking Cylinders Outrigger Extension Cable Outrigger Roller
130/60 x 445 130/70 x 800 22 x 33

SAIE 10197-2/2 Change

Rev. 102502 Update to match GmbH rev. Add "61."

initials
Passenger Side

Training Manual 30