SCHWING TrainingManual

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

PTO ...............................................................................2
Continuous Duty Solenoid ............................................2
CPC/CPCII Controller ..................................................3
Hydraulic Pumps ...........................................................3
Fixed Displacement ......................................................4
Variable Displacement ..................................................4
Main Control Block Brain .........................................4
Concrete Pump Forward/Reverse Valve .......................5
Main Control Block - S1/S2 Spool ...............................5
Main Relief Valve .........................................................6
Differential Cylinders ...................................................6
Material Cylinders ........................................................7
Differential Cylinder - Bottomed Out ...........................7
MPS Valve ....................................................................8
S3/Accumulator Control Block .....................................8
Accumulator Theory .....................................................9
Rock Valve Slewing Cylinder ......................................9
Soft Switch Relief Valve ............................................10
Main Control Block - S2 Spool ..................................10
Differential Cylinder - Beginning of stroke ................11
MPS ............................................................................11
Differential Cylinder - Bottomed Out .........................12
MPS ............................................................................12
S3/Accumulator Control Block ...................................13
Rock Valve Slewing Cylinder ....................................13
Soft Switch Relief Valve ............................................14
Main Control Block - S2 Spool ..................................14
Differential Cylinders .................................................15
Boom Pump ................................................................16

E-Stop Manifold .........................................................17
Poppet Valve Theory ..................................................17
E-Stop - Override .......................................................18
Boom Handvalve - No functions activated ................18
Boom Handvalve - Outrigger enabled ........................19
Outrigger Handvalve ..................................................19
Boom Handvalve - Boom Function Activated ...........20
Pulsar Coil Theory ......................................................20
Boom Holding Valves ................................................21
Manual Controls and Overrides ..................................21
Training Manual
Table of Contents
SERVICE TRAINING
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
Air Pressure Switch

(Energized)
To:PTO
Switch pushed in, air supply blocked by

spool.
Switch pulled out , opening is created
allowing air pressure to energize the air pressure switch.
A passage way is created allowing air pressure to be sent to the PTO.
Air blocked by spool

PULL
TO APPLY
PARKING
BRAKE
PUSH TO
RELEASE
QUARTZ
00000.1
1 HOURS
From:Truck Air Supply
PTO switch
Must be pulled
Training Manual
Power to fuse
SERVICE TRAINING
PTO
Air is routed to the small cylinder mounted
in the distribution gear case (PTO).
When the cylinder is pushed in the PTO is
in the pumping position.
When the cylinder is pushed out the PTO
is in the travel position.
Air Supply Block
To:12v Controller
PTO.eps
Fork
All hydraulic pumps for the concrete pump, placing boom, agitator, etc. are mounted on a distribution gearcase. When you are driving the truck,
the power of the truck engine is transmitted
through the truck transmission, through a propeller shaft, through the bottom of the distribution
gearcase, through another propeller shaft, and
into the rear end(s) of the truck. When you are
operating the unit, the distribution
gearcase interrupts the power to the rear ends,
and transmits it to internal gears that turn the
hydraulic pumps. Changing between travel and
pumping modes is accomplished by means of an
air switch in the truck cab.
Continuous Duty Solenoid

Electric signal from Air Switch enters Continuous Duty Solenoid
CPC/CPC II Style
(Not used on Vector units)
The signal energizes the magnetic coil in the

The energized magnetic coil, pulls the
plunger down
To: Controller
A connection is established between the 12

volt power supply and CPC Controller
Plunger
Magnetic Coil
From: 12v Power Supply
Cont_Solenoid.eps
Training Manual
SERVICE TRAINING
CPC/CPCII Controller
The CPC/CPC II provides a proportional signal
to
each of the boom functions and the concrete
pump
output. It also controls all on/off functions on the
unit. The CPC/CPC II receives power via the
PTO switch through the Continuos duty solenoid
and into the Power connector.
CPC/CPC II
POWER
REAR CTR
UMB CTR
RADIO CTR
ID
LINK
ALARM
E-STOP
WHEN WELDING ANYWHERE ON UNIT

POWER CABLE MUST BE DISCONNECTED
L1357-01
Vector Controller
Power Connector
The Vector control system is a completely digital control system, which means that the function
movements are converted to numbers (0s and
1s). The numbers are sent to the controller
where they are analyzed, converted back to analog (voltage or current), and sent to the valves
and indication devices.
Vector
OK
OFF
x1000 3
0
PTO 1500 rpm
62C
Menu: [ENTER]=ON
HOME
HELP
START
CLEAR
ENTER
QUIT
X12 Connector
(Behind)
Hydraulic Pumps
Typical Gearbox
To: Main Control Block
To: Boom Control Block
Pumpkit Pumps
s
.ep
ps
um
licP
u
dra
To:
Hy
The hydraulic pumps for the concrete pump circuit are bent axis, variable displacement piston
pumps. They are horsepower controlled, which
means that as pressure rises towards maximum,
the flow can decrease, so the power consumption
remains constant. We use this type of pump so
the truck engine will not bog down under hard
pumping conditions. The pumps also accept
external signals for control of the output. At
Schwing, we route signals to the pump from the
hydraulic stroke limiter. The net effect of these
devices is to tell the pump to put out less oil per
revolution, as required by the pump operator.
To: S3 Accumulator
Agitator
To: Oil Cooler
Training Manual
SERVICE TRAINING
Fixed Displacement
Puts out a set amount of oil, that can only be
changed by increasing/decreasing the RPMs.
Fixed Dispalcement
Bent Axis
Variable Displacement
Variable or Positive displacement pumps deliver
to the system, a variable amount of oil according
to the angle for the rotary group or swash plate.
min
max
min
Bent Axis
max
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
Training Manual
SERVICE TRAINING
Concrete Pump Forward/Reverse

Valve
To: Main Control Block/MPS Valve

P2 Vent
T
Blocked pathway (Neutral)
A
B
From: Pump
In the forward position, a passage way is

created between the pressure port and the
A port, through grooves in the spool.
Oil is sent to the XP port of the Main

Hydraulic Control Block and the XB port
of the MPS valve.
To: Main Control Block (XP port)

and MPS Valve (XB port)
A
The Concrete Pump Forward/Reversing valve is

a simple control device, containing a 3 position,
6 way spool attached to a handle. The valve
receives hydraulic oil from the Accumulator
pump.
In the neutral position, the passage way for
the hydraulic oil is blocked and will return to
tank.
This valve also plugs the vent line, which

allows pressure to build in the system
Passageway created (Forward position)
Main Control Block - S1/S2 Spool

With hydraulic pressure on the XP side of
the spool and no pressure on the XR side,
the S1 spool will move into the Forward
position.
S1 - Forward Position,
pathway to S2 spool created
Passage way created for the hydraulic oil

from the Main Hydraulic Pumps to move
past the S1 spool and unto the S2 spool.
Passage way created for the hydraulic oil
moving past the S2 spool and unto the Differential Cylinder.
S1 Spool
XP
XR
From: CP Forward/Reverse Valve

From: Pump
S2 Spool
From: Pump
HiFlowBrain_S1.eps
Pathway to Differential cylinder

To: Differential Cylinder
Training Manual
SERVICE TRAINING
Main Relief Valve

The main relief valve protects the hydraulic circuit, by relieving pressure before it reaches 350
bar or greater.
Pressure exceeds 350 bar and presses against
the 350 bar main relief valve plunger.
80 bar
350 bar
The 350 bar relief valve spring will collapse,

creating a passage way for the oil to bleed to
tank. This creates a pressure drop in the poppet spring chamber.
Less than relief pressure
Over relief pressure
Pressure is greater on the piston side of the

poppet than the spring side. This will collapse the poppet spring allowing the poppet
to open.
With the poppet opened, a passage way is
created, allowing oil to escape to tank until
350 bar pressure or lower is achieved.
Poppet opens
Excess oil drained to tank
Loop Oil
To:MPS ZK2
To:MPS ZK1
High pressure oil
The term differential cylinder means that each

hydraulic cylinder that pushes the concrete has
an area difference (referred to as an area differential) between the two sides of the piston. This
area differential exists because the rod extends
only from one side of the piston. This is in contrast to the rock
valve slewing cylinder, for example, which has a
rod
extending from both ends of the piston and therefore has the same area on both sides of the piston
(it is a nondifferential cylinder).
Hydraulic oil from the Main Control Block
flows to the rod side of the left hand differential cylinder.
The pressure from the hydraulic oil extends
the rod of the left hand differential cylinder.
From: Pumps
To:MPS ZS1
To:MPS ZS2
From: Pumps
DiffCylinders.eps
Loop oil on the piston side of the left hand

differential cylinder crosses over to piston
side of the right hand differential cylinder,
causing that rod to retract.
Training Manual
SERVICE TRAINING
Material Cylinders
The material cylinders contain rubber rams that
are connected to the differential cylinder rods.
One side will push the concrete through the Rock
valve while the opposite side will suck concrete
from the hopper.
Concrete pushed through Rock Valve
Concrete sucked in from hopper
MatCylinders.e
Differential Cylinder - Bottomed Out

Left-hand differential cylinder bottoms out.
Signal lines connected to the ZK1,ZK2,
ZS1 and ZS2 ports of the MPS valve.
To:MPS ZK2
To:MPS ZK1
From: Pumps
To:MPS ZS1
To:MPS ZS2
From: Pumps
DiffCylinders_Bottom.ep
Training Manual
SERVICE TRAINING
MPS Valve
X3
To: Soft Switch

Reversing Valve
To:
S3 Spool
XB
XA
ZS1
ZS2
ZK1
ZK2
The MPS system consists of three small directional control valves. The main pressure that is
supplied to these directional control valve is supplied by the accumulator.
A high pressure signal line from the Differential Cylinder enters the MPS valve through
the ZK2 port.
This moves the NG 6 directional valve over
creating a passage way for the Accumulator
oil to flow through MPS valve and out the
A and X3 port.
From: Differential Cyl.
From:
Differential
Cylinder
SP
Passage way created

To:S3 Spool
From: Accumulator Pump

S3/Accumulator Control Block

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

to travel to the Rock valve Slewing Cylinder
and S2 spool in the Main Control Block.
From: MPS valve "A" port

To: S2 spool
Manual Bleed
S3_Block02.eps
Training Manual
SERVICE TRAINING
Accumulator Theory
Without Nitrogen
Charge
With nitrogen charged

to pressure P1
Influx of hydraulic oil

for storage
The accumulator can be considered an energy

storage device for hydraulics, similar to the function of a battery in an electrical circuit. The accumulator stores the oil flow of a small hydraulic
pump until it is time to shift the Rock Valve.
When needed all of the oil that as been stored in
the accumulator is quickly released. This has the
following benefits:
Lower power requirements for switching the
RockValve (less horsepower taken from the
engine).
Simpler switching to begin the next stroke
(the differential cylinders get the signal to
change direction as soon as the S3 spool
moves, regardless if the Rock Valve has
moved or not).
Fluid charged to
maximum working
pressure P3
Discharge of
hydraulic oil
Fluid discharged
down to minimum
working pressure P2
AccumulatorTheory.eps
Rock Valve Slewing Cylinder

From: S3/Accumulator Control Block
The rock valve slewing cylinder is a nondifferential cylinder (see Differential Cylinder). The
switching grooves are used in single-circuit
machines, but not in twin-circuit machines.
A working line from the A port of the S3/
Accumulator Control Block enters the rear
of the Rock Valve Slewing cylinder
This pushes the rod over, thus switching
the rock valve.
RockSlewingCylinder.eps
Training Manual
SERVICE TRAINING
Soft Switch Relief Valve

Signal from MPS Valve
X3
X3
80 bar
80 bar
350 bar
350 bar
When the Rock Valve is shifting, a signal line

enters the X3 port of the Main Control Block
The Soft Switch Reversing Valve is opened,
creating a passageway to the 80 bar relief
valve.
the 80 bar Soft Switch relief valve plunger.
X3
X3
80 bar
80 bar
350 bar
350 bar

to open.
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.
S1 Spool
From: Pump
From: Pump
S2 Spool
XB
XA
From: Accumulator
Control Block
HiFlowBrain_S2.eps
Pathway to Differential cylinder
10
Training Manual
SERVICE TRAINING
Differential Cylinder - Beginning of

stroke
Loop Oil

flows to the rod side of the right-hand differential cylinder.
the rod of the right-hand differential cylinder.
pressure oil
To:MPS ZK2
Loop oil on the piston side of the right-hand

side of the left hand differential cylinder,
To:MPS ZK1
From Pumps
To:MPS ZS1
To:MPS ZS2
DiffCylinders_NewStroke.eps
From Pumps
MPS
X3
A high pressure signal line from the Differential Cylinder is sent to the ZK1 port of
the MPS valve.
Pressure is greater on the ZK1 side of the

NG 6 spool than the ZK2 side.
Signal lost
The NG 6 spool will move to the right

closing the passage way for high pressure
accumulator oil.
XB
XA
ZS1
ZS2
ZK1
ZK2
SP
Passage way closed

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
X3
To: Soft Switch

Reversing Valve
B
To: S3 Spool
XB
XA
ZS1
ZS2
A high pressure signal line from the Differential Cylinder enters the MPS valve through
the ZS2 port.
This moves the NG 6 directional valve over
creating a passage way for the Accumulator
oil to flow through MPS valve and out the
B port and unto the S3 spool.
Accumulator oil also travels out the X3
port and unto the Soft Switch Reversing
Valve.
From:
Differential Cylinder
To:Soft Switch Reversing Valve
To:S3 Spool
ZK2
ZK1
From:Differential Cylinder
SP
Passage way created
From:Differential Cylinder
12
Training Manual
SERVICE TRAINING
S3/Accumulator Control Block

and Main Control Block
Hydraulic oil from the MPS valve B port

enters the XB port of the S3/Accumulator
Control Block.
The S3 spool moves to the left.
A passage way is created for accumulator oil

to travel to the Rock valve Slewing Cylinder
and S2 spool in the Main Control Block.
S3_Block.eps

Manual Bleed
To: S2 spool
Rock Valve Slewing Cylinder

A working line from the B port of the S3/
Accumulator Control Block enters the front
of the Rock Valve Slewing cylinder
This pushes the rod over, thus switching

the rock valve.
From: S3/Accumulator
Control Block
Training Manual
13
SERVICE TRAINING
Soft Switch Relief Valve

Signal from MPS Valve
X3
X3
80 bar
80 bar
350 bar
350 bar
When the Rock Valve is shifting, a signal line

enters the X3 port of the Main Control Block
The Soft Switch Reversing Valve is opened,
creating a passageway to the 80 bar relief
valve.
the 80 bar Soft Switch relief valve plunger.
X3
X3
80 bar
80 bar
350 bar
350 bar

to open.
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: Pump
From: Pump
S2 Spool
HiFlowBrain_S2.eps
From: Accumulator
Control Block
14
Training Manual
SERVICE TRAINING
flows to the rod side of the left hand differential cylinder.
the rod of the left hand differential cylinder.
Loop oil on the piston side of the left hand
side of the right hand differential cylinder,
From Pumps
From Pumps
DiffCylinders_04.eps
Training Manual
15
SERVICE TRAINING
Typical Boom Circuit

Boom Cylinder
To:Outrigger Function
Outrigger Handvalve
Boom Pump
1 PM
P1
P4
P3
P2
Boom Handvalve
Estop Manifold
Boom Pump
To: Boom Control Block
To: Main Control Block
The hydraulic pump for the placing boom is a

variable displacement, bent axis, axial piston
pump. It feeds all of the following components:
the hydraulic cylinders on the boom sections
the hydraulic cylinders on the outriggers
the hydraulic motor for the boom slewing
gear
Boom Pump
the hydraulic motor for the water pump

the hydraulic motor of the compressor
(optional equipment)
dra
Hy
s
.ep
02
s_
mp
u
P
ulic
To: S3 Accumulator
To: Agitator
To: Oil Cooler
Training Manual
16
SERVICE TRAINING
E-Stop Manifold
Hydraulic oil from the boom pump enters the
E-stop Manifold from the P1 port.
P2
T
T
P4
P3
Equal Pressure
Poppet Closed
P1
Energized Solenoid
If the solenoid is not energized, a passage

way will be created for the signal line to go
to tank.
Signal Line from P1 port
This will create a pressure drop on the spring

side of the poppet valve.
P2
T
T
P3
With the solenoid energized, a signal line

from the P1 port enters the spring side of
the poppet valve. This will equalize the pressure on both sides of the poppet. The pressure plus spring tension will hold the poppet
closed.
Greater Pressure
Poppet Opened
P4
P1
De-energized Solenoid
Pressure from the P1 port will overtake the

spring tension, allowing the poppet to open.
A passage way is created for the oil from the
P1 port to escape to tank.
Passage way to tank
Poppet Valve Theory

1
Pressure A = B
Pressure A
Pressure A
Pressure B + Spring
Pressure A > B
Pressure A > B
Pressure B + Spring
1. Pressure A and B are equal. With B

pressure, plus the spring, Pressure A is not
great enough to open the poppet.
2. If pressure A is greater than pressure B
plus the spring tension, pressure A will
collapse the spring, lower the poppet.
3. With the poppet lowered, a path for excess
pressure is created and flows back to tank.
4. When pressure B is greater or equal to
pressure A the spring will expand, closing
the pathway to tank.
Pressure A = B
Housing
Pressure A
Poppet
Pathway to Tank
(open)
Pressure B + Spring
Pathway to Tank
(closed)
Spring
Pressure B + Spring
Training Manual
17
SERVICE TRAINING
E-Stop - Override
Concrete pump,
agitator, accumulator
dump valve
Override
buttons
MP
Boom/outrigger
circuit dump
valve
T
MP
P3
P2
Agitator
system plumbing
P4
P1
Concrete pump
system plumbing
Turn the bypass key switch to Bypass

position. If control is not restored, there
probably a hydraulic problem; Proceed to the
next step.
To manually bypass each system, the inlet
plumbing to the nonworking system must be
plumbed out of the manifold.
With the engine stopped, disconnect the
plumbing for the nonworking system at the
appropriate fitting
Boom/outrigger
system plumbing
Accumulator
system plumbing
BY-PASS
NORM. BY-PASS
by-pass2.eps
Boom Handvalve - No functions activated

Oil enters the Boom Handvalve from the P
port.
Blocked passage way
C2
C1
Apitech_Side_03.eps
From: Pump
From: Boom Pump
18
Training Manual
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.
In the neutral position, the passage way for
the hydraulic oil is blocked
In the extend position, a passage way is
created between the pressure port and the
A port of the Outrigger hand valve.
To: Outrigger Function
This will send oil to whatever outrigger function has been activated. Example Outrigger
Extend.
Training Manual
19
SERVICE TRAINING
Boom Handvalve - Boom Function

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

From: Pump
Passage open
Apitech_Side_01.eps
From: Boom Pump
Pulsar Coil Theory

Coil
Control Oil to Spool
Control Disk
As the control disk pulses on and off, pretension

oil is allowed to flow from the pressure passage
to the tank passage. Since the top orifice is larger
than the bottom orifice, eventually more oil will
be in the tank passage than can leave through the
0.024 orifice. At this point, pressure will build in
the main spool control port and move the main
spool.
The longer the on time, the greater the pressure
in the control port, and the further the main spool
is moved, causing the boom to go faster.
0.040 Orifice
Pilot Pressure
20
Training Manual
SERVICE TRAINING
Boom Holding Valves

Passage way for rod side oil (to tank)
Passage way for piston side oil
Two hydraulically unlockable check valves

(H.E.R. valves, or holding valves) on each boom
cylinder prevent the boom from coming down
unintentionally
LINE B
LINE A
From:Boom Handvalve
Passage way closed. Oil trapped, cylinder held in place
LINE B
LINE A
Manual Controls and Overrides

000419.eps
10 11
AGITATOR
CONCRETE PUMP
Boom 1
Boom 2
Boom 3
Boom 4
Boom 1 Telescope
Slewing
Boom / Outrigger
Water / Compressor
10189517
DANGER
Electrocution hazard.
Stay back from high
voltage wires at least
17 feet (5 meters).
WARNING
Do not operate this
machine without
training. Understand
the warnings in safety
manuals and on decals.
WARNING
Clear area
before activating
outriggers
REAR EXTEND
REAR JACKING
FRONT JACKING
FRONT EXTEND
8 12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
E-stop
Boom #1 Control Handle
Boom Telescope Handle
Boom Slewing Control Handle
Water Pump/Air Compressor Handle
Water Pump System Change-Over Valve
Concrete Pump Handle
Agitator Handle
Two Position Boom/Outrigger Handle.
Training Manual
21
SERVICE TRAINING
22
Training Manual
SERVICE TRAINING
The Schwing Group ............................................................ 1
Schwing America, Inc. ................................................. 1
Hydraulic Training
General Principles ............................................................... 3
Mechanical Versus Hydraulic ............................................. 7
Transfer of Energy .............................................................. 7
Hydraulic Jack ..................................................................... 8
Linear & Rotary Actuators .................................................. 8
Basic Hydraulic Components .............................................. 9
Check Valve Comparison ................................................. 10
Shuttle Valve ..................................................................... 11
Throttle Check Valve ........................................................ 12
Switching Valves .............................................................. 13
Hydraulic Pumps ............................................................... 14
Placing boom hydraulic pumps .................................. 14
Concrete pump hydraulic pumps ............................... 14
Fixed Displacement Pump ................................................ 15
Rexroth A2F20 ........................................................... 15
Variable Displacement Pump ............................................ 15
Rexroth A7VO ........................................................... 15
Variable Displacement Axial Piston Pump ....................... 16
RexrothA10VO .......................................................... 16
RexrothA11VO .......................................................... 16
Rexroth A11VO Adjustments .................................... 17
Transfer Cases ................................................................... 18
Relief Valves ..................................................................... 19
Safety Relief Valves .......................................................... 20
Pressure Relief Valve Type DB ................................. 20
Pressure Relief Valves Type DBW ............................ 20
Hydraulic Symbols ............................................................ 21
Hydraulic Symbols (Cont.) ............................................... 22
Formulas ............................................................................ 28
Pumpkits
800 Gate Valve .................................................................. 30
801 Gate Valve .................................................................. 31
801 Pumpkit Schematic ............................................. 32
Concrete Pump Control Block ................................... 33
Stroke Limiter ............................................................ 34
Table of Contents
494 Block ....................................................................34

Hydraulically Unlockable CheckValve ......................35
Gate Valve ..................................................................35
900-1200 Single Circuit .....................................................37
900-1200 Single Circuit Schematic ............................38
Concrete Pump Control Block ....................................39
Stroke Limiter .............................................................40
494 Block ....................................................................40
Switching Valve .........................................................41
A7VO .........................................................................41
Rock Valve .................................................................42
Phase A .......................................................................44
Phase B .......................................................................45
Phase C .......................................................................46
Phase D .......................................................................47
Phase E .......................................................................48
Phase F ........................................................................49
Phase G .......................................................................50
Phase H .......................................................................51
Phase I ........................................................................52
Phase J ........................................................................53
Phase K .......................................................................54
Troubleshooting .................................................................55
High-Flow Single Circuit 2020/2023 ................................61
High-Flow Single Circuit Schematic ..........................62
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
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
S3 Control Block ........................................................91
MPS ............................................................................92
Accumulator Control Block/Dump Valve ..................93
Soft Switch .................................................................94
Phase A .......................................................................96
Training Manual
Table of Contents
Phase B .......................................................................98
Phase C .....................................................................100
Phase D .....................................................................102
Twin Circuit with Variable displacement
accumulator pump Schematic 104
Model Number Nomenclature .........................................105
Hi-Flow Pumpkits (2023-2525) ......................................106
Hi-Flow Pumpkits (2525H) .............................................107
Hi-Flow Pumpkits Schematic ...................................108
Concrete Pump Control Block .................................109
Main Relief/Soft Switch Block ................................110
MPS ..........................................................................111
S3 Control Block - Machined ...................................112
S3 Control Block - Cast ...........................................113
2023 Circuit diagram ................................................114
Phase A .....................................................................114
Phase B .....................................................................116
Phase C .....................................................................118
Phase D .....................................................................120
Booms
Black & White .................................................................123
Electric/Air/Oil .........................................................123
Electric/Oil/Oil .........................................................123
Proportional .....................................................................125
Boom Holding Valves .....................................................126
28X B&W Boom .............................................................127
Load Sense Hydraulic Circuits ........................................131
Overview ..................................................................131
Components ..............................................................132
Basic Principles - Simple Circuit .............................133
Basic Principles - Orifice .........................................134
Basic Principles - Without Relief Valve ..................135
Basic Principles - With Relief Valve .......................136
Basic Principles - Delta-P ........................................137
Basic Principles - Delta-P ........................................138
Basic Principles - Pressure Cut-Off .........................139
Basic Principles - Shuttle Valves .............................140
Basic Principles - Pressure Regulator ......................141
A7 Variable Displacement Hydraulic Pump Training ....142
All Functions in Neutral ...........................................142
Cylinder Extend Function Initiated ..........................144
Hydraulic Cylinder Extending .................................146
Hydraulic Cylinder Fully Extended Pump ...............148
Fixed Displacement Pump Training ................................150
All Function in Neutral ............................................150
Boom Function Activated ........................................151
Cylinder Pressurized at the End of Stroke ...............152
Output Charts ...................................................................153
Using the Chart ................................................................154
Using a Nomograph ........................................................ 159

General information ................................................. 159
The quadrants ........................................................... 161
Minimum Pipe Wall Thickness ....................................... 167
Preventative Maintenance ............................................... 168
Scheduled Maintenance ........................................... 168
Filtration .......................................................................... 170
Specific information ................................................. 170
Changing hydraulic oil filters .................................. 170
Changing high pressure water filter ......................... 171
Hydraulic Oils ................................................................. 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
Ohms 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
Controller Systems .......................................................... 199
Analog ...................................................................... 199
Digi-Prop (Microwave) ............................................ 199
Comfort Control ....................................................... 199
C32 ........................................................................... 200
CPC .......................................................................... 200
CPC II ...................................................................... 200
Vector - Current Production ..................................... 201
28X Truck and Pumpkit Circuit ...................................... 203
28X Boom Circuit ........................................................... 204
Training Manual
SERVICE TRAINING
Misc Procedures
Material Cylinder Alignment .......................................... 205
Pumping on piston side ................................................... 207
(Available on some units only) ................................ 207
Shimming the Differential Cylinders .............................. 208
Determining the proper shimm size ......................... 208
Dimension A ............................................................ 208
Dimension B ............................................................ 208
Formula .................................................................... 209
Apitech Control Chamber Air Bleed Procedure ............. 210
Hydraulic Pump Adjustments ......................................... 213
Main System Pumps A11VO ................................... 213
Setting the Flow Rate ............................................... 213
Horsepower Setting .................................................. 214
Q-min Output Flow .................................................. 214
Check all hydraulic pressures. ................................. 215
Setting pressures on Hi-flo -6 pumpkits .................. 215
Pressure setting procedure: ...................................... 216
Setting the soft switch relief pressure ...................... 217
Accumulator Bypass Retrofit .......................................... 219
Service Bulletin 1001-03 ......................................... 219
Trouble Shooting Kit ...................................................... 220
Training Manual
Table of Contents
Table of Contents
Training Manual
SERVICE TRAINING
The Schwing Group
Schwing America, Inc.
Schwing America, Inc. is a wholly owned subsidiary of

the Schwing GmbH located in Herne, Germany.
Schwing was founded in Germany in 1934, it has
always been a family owned company and is currently
managed by Gerhard Schwing.
The Schwing Group has grown steadily since its
inception over sixty years. The company is known for
its innovation and worldwide operations. The Groups
primary products are concrete pumps, ready mix trucks
and batch plants. Pumping and boom technologies are
applied to other products as opportunities arise.
Currently the Schwing Group has factories located
around the world at:
Schwing GmbH, Herne, Germany
Schwing GmbH, Memmingen, Germany
Schwing America, Inc., White Bear, USA
Schwing GmbH, St. Stefan, Austria
Schwing SIWA, Sao Paulo, Brazil
Schwing Shanghai, China
Schwing India
The Schwing group also has numerous sales and
service locations around the world.
SAI was started in 1974, located in a small office on

Pierce Butler Road. At this time SAI was primarily a
sales, service and parts facility, with the assembly and
some manufacturing subbed out to Telelect. This
arrangement continued until October 1978. Telelect
suffered a prolonged strike, which really hurt SAI. It
was at this time that the Schwing company purchased
the property here at 5900 Centerville Road. This
facility was previously a distribution center for Arctic
Cat snowmobiles, and consisted of 114,000 sq. ft.,
which included a couple pole barns on 16 acres of land.
In 1983, we added 20,000 sq. ft. of production space
and then in 1986 we added 28,000 sq. ft. to this space
introducing our paint facility and testing facility.
Then in 1989, an additional 29 acres of land was
purchased to the North, and our 20,000 sq. ft. weld
shop was constructed. We also worked over one of the
pole barns for our fab facility and trailer assembly
plant. These additions have proven to be a major break
through to make us a complete manufacturing facility.
In 1993 we started on our 28,000 sq. ft. office facility.
In 1995 we completed construction of a 62,000 sq. ft.
state of the art Weld Shop.
In addition, in 1996 we added the 15,000 sq. ft.
Training Manual
SERVICE TRAINING
machining center, which is home of the new Forrest

Line machining Center.
For the year 2000, Schwing America, Inc. has added a
75,000 sq. ft paint booth. This state-of-the-art
behemoth is the largest building in the surrounding
communities. Dubbed the Super Booth by industry
insiders. This is the largest facility for painting
concrete pumps in the world. The six-story structure
combines with retractable roof panels to accommodate
unfolded booms. Painters will use catwalks to cover
every surface with high quality acrylic urethane in an

endless array of colors and paint schemes. Climate
controlled conditions assure proper curing and drying
time. A new solvent recovery system keeps the Super
Booth environmentally friendly.
Today Schwing America has over 326,000 square feet
of manufacturing space and employs over 400 people.
E
N
S
W
Training Manual
SERVICE TRAINING
Hydraulic Training
General Principles
1. Hydraulic pressure always takes path of least
resistance.
2. Hydraulic pressure is created equal in all directions

(Pascal's Law).
Pascal's Law
2 A 10 pound force applied
to a stopper with a
surface area of one
square inch......
1 The bottle is filled

with a liquid, which
is not compressible
3 Results in 10 pounds of force on

every square inch (pressure) of
the container wall
4 If the bottom has an area of 20

square inches and each square
inch is pushed on by 10 pounds
of force, the entire bottom
recieves a 200 pound push.
3. Liquids (oil) are relatively incompressible.
OIL
AIR
1000 lbs of Force
1000 lbs of Force
Training Manual
OIL
AIR
SERVICE TRAINING
4. When hydraulic pressure and flow is not converted

into work it is converted into heat.
Open relief (Heat)
5. When oil is heated it will expand (5% or more).

Atmospheric pressure
forces water past seals
Vacuum formed as
hydraulic oil cools
Seals
Hydraulic Cylinder
Water Box
6. When oil is heated the viscosity of it changes.
6 bar
4
Training Manual
SERVICE TRAINING
7. GPM (Gallons Per Minute) only determine the

speed at which the actuator (motor or cylinder)
operates.
0 GPM
10 GPM
8. P.S.I. (Pounds Per Square Inch) determine only the

amount of force exerted upon the load by the actuator.
10,000 LBS
LOAD
10 gallon maximum
capacity cylinder
10 inch of area on
cylinder piston
1000 PSI
Training Manual
SERVICE TRAINING
9. The resistance created in a hydraulic circuit,

whether by the amount of the load on the actuator
and/or the pressure drop in a circuit, is what determines how much work is required.
U.S.
F = FORCE (in pounds) (lb)
F=PxA
F
P
P = F/A
A = F/P
P = PRESSURE
(in pounds per square inch) (P.S.I.)
A = AREA (in square inches) (in2)
METRIC
F = FORCE (in kilograms) (Kg)
P = PRESSURE
(in kilograms per square centimeter) (Kg/cm2)
A = AREA (in square centimeters) (cm2)
GENERAL
POWER =
QxP
CONSTANT
Q = FLOW RATE
(unit of volume per time period)
P = PRESSURE
(unit of force per unit of area)
U.S.
HP = HORSEPOWER
HP =
GPM x PSI
1714
GPM = GALLONS PER MINUTE

PSI = POUNDS PER SQUARE INCH
1714 = KNOWN CONSTANT
METRIC
KW = KILOWATTS
KW =
LPM x BAR
600
LPM = LITERS PER MINUTE

BAR = METRIC UNIT OF PRESSURE
600 = KNOWN CONSTANT
Training Manual
SERVICE TRAINING
Mechanical Versus Hydraulic
1. An input force of
10 lb.(44.48 N) on a
one square inch
2
(6.45 cm ) piston...
COMPARISON OF MECHANICAL FORCES

VERSUS HYDRAULIC FORCES
2. will balance 100 lb
(444.82 N) here...
1. Ten pounds (44.48 N) here...
3. This pressure will

support a 100 lb.
(444.82 N) weight if
this is a 10 sq. in.
(64.52 cm2 ) piston.
100 lb.
(444.82 N)
10 lb.
(44.48 N)
1 sq. in.
(6.45 cm2 )
10 sq. in.
(64.51 cm2 )
2. develops a pressure of
10 pounds per square inch(psi)
(.69 bar) (68.94 kilopascals)
throughout the container.
100 lb.
(444.82 N)
10 lb.
(44.48 N)
INPUT
4. this arm.
3. if this arm is 10 times

as long as...
4. The forces are proportional

to the piston areas.
OUTPUT
100 lb. (444.82 N)

10 lb. (44.48 N)
=
10 sq. in (64.52 cm2)
1 sq. in (6.45 cm2)
A. SIMPLE MECHANICAL LEVER
B. SIMPLE HYDRAULIC PRESS
Transfer of Energy
ENERGY CAN NEITHER BE CREATED NOR DESTROYED
1. Moving the small piston 10 in.
0.25 m) displaces 10 cu. in.
(163.87 cm3) of liquid.
(1 sq. in. x 10 in. =10 cu. in.)
(6.45 cm2 x 25.40 cm = 163.87 cm3)
2. 10 cu. in. (163.8 cm3) of liquid

will move the larger piston only
1 in. (2.54 cm)
(10 sq. in. x 1 in. = 10 cu. in.)
(64.52 cm x 2.54 cm = 163.87 cm )
100 lb.
(444.82 N)
10 lb.
(44.48 N)
1 sq. in.
(6.45 cm2)
10 sq. in.
(64.51 cm2)
1 in
(0.02 m)
10 in
(0.25 m)
4. The energy transfer here also is

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

10 lb. x 10 in. (44.48 N x 0.25 m)
or 100 in. lb. (11.30 Nm)
Training Manual
SERVICE TRAINING
Hydraulic Jack
HYDRAULIC
ROD
8"
PISTON
Linear & Rotary Actuators

LINEAR ACTUATOR
1.The pump pushes the

hydraulic liquid into lines.
ROTARY ACTUATOR
2. Lines carry the liquid to

actuators which are pushed
to cause a mechanical output
to move a load.
4. Rotary actuators or motors

give the system rotating output.
They can be connected to pulleys,
gears,rack-and-pinions, conveyors, etc.
MOTOR
PUMP
LOAD
PUMP
PISTON & ROD

TO RESERVOIR
3. Some actuators operate in

a straight line (linear actuators).
They are called cylinders or rams.
They are used to lift weight, exert
force, clamp, etc.
Training Manual
ROTARY
DRIVE SHAFT
SERVICE TRAINING
Basic Hydraulic Components
Check Valve
Throttle Valve
Throttle Check Valve
Switching Valve
Training Manual
SERVICE TRAINING
Check Valve Comparison
In-Line Check Valve
Cartridge Check Valve
Right Angle Check Valves
10
CHECK VALVE
COMPLETE
P/N 30333030
CHECK VALVE
COMPLETE
P/N 30333031
CARTRIDGE
W/SEALS
P/N 30333032
CARTRIDGE
W/SEALS
P/N 30333033
SEAL KIT ONLY

P/N 30333034
SEAL KIT ONLY

P/N 30333035
TORQUE
SPECIFICATION
55 ft/lbs.
TORQUE
SPECIFICATION
200 ft/lbs.
Training Manual
SERVICE TRAINING
Shuttle Valve
A shuttle valve is used where the higher of the two

pressures must be selected, while blocking the lower
pressure input.
C
B
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.
Greater pressure from "A" port
C
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).
Model MK (Throttle/Check Valve)

This valve is capable of flow control in one direction
while allowing reverse free flow in the opposite. Fluid
passes spring (6), through radial drilling and throttling
area (4). Throttling is achieved similarly to the MG
valve. In the reverse direction, pressure acts on the area
of check valve (5). When pressure exceeds spring force
(6), the poppet opens, allowing reverse free flow
through the valve. Fluid also passes through the throttle
area (4), thereby flushing contamination from the
valve.
Throttle Check Valve Model MK
Caution! Do not adjust the valve while under pressure
12
Training Manual
SERVICE TRAINING
Switching Valves
POPPET END PORT
The switching valves have a logic function in that they

sense multiple pressures simultaneously and will route
oil from the poppet end port to the output port only
when the pressure from the poppet end port exceeds the
pressure at the spring end port by more than 2:1 in
most situations
BODY
SEAT
O-RING
AND
BACK-UP
RINGS
POPPET
HOUSING
SIDE POR
(PLUGGED
SIDE PORT
POPPET
BODY
O-RING
AND
BACK-UP
RING
SPRING
SIDE PORT
SPRING
GUIDE
SPRING END POR

T
SPRING END PORT
SPRING
GUIDE
SPRING
POPPET
POPPET END PORT
Pressure equal on both sid

es
POPPET
HOUSING
High Pressure pushes poppet backallowing

oil to flow through th
e side port, sending a
signalto S3
Training Manual
Pressure greater onthe Spring End Port

forcingthe poppet to close
13
SERVICE TRAINING
Hydraulic Pumps
Concrete pump hydraulic pumps
Placing boom hydraulic pumps

Load sensing proportional
The hydraulic pump for the placing boom is a variable
displacement, bent axis, axial piston pump, with load
sensing control. It can feed all of the following
components:
the hydraulic cylinders on the boom sections
the hydraulic cylinders on the outriggers
the hydraulic motor for the boom slewing gear
the hydraulic motor for the water pump
the hydraulic motor of the compressor (optional

equipment)
The hydraulic pumps for the concrete pump circuit are

bent axis, variable displacement piston pumps. They
are horsepower controlled, which means that as
pressure rises, the flow decreases, so the power
consumption remains constant. We use this type of
pump so the truck engine will not bog down under hard
pumping conditions. The pumps also accept external
signals for control of the output. At Schwing, we route
signals to the pump from the hydraulic stroke limiter
and the dampener (with single circuit), or the
accumulator (with twin circuit). The net effect of these
devices is to tell the pump to put out less oil per
revolution, as required by the pump operator.
The directional control valves for all of the above

circuits are incorporated into control blocks and
equipped with hand levers. In addition, the control
block for the boom functions have electric over oil
piloting for operation via remote control.
PumpKit Pumps
PumpKit Pumps
Proportional Boom Pump
Boom Pump
Accumulator Pump
Oil Cooler Pump
Agitator Pump
Stiebel 4194
Stiebel 4400
PumpKit Pumps
PumpKit Pumps
Accumulator Pump
Oil Cooler Pump
Accumulator
Pump
Agitator Pump
Oil Cooler Pump
Agitator Pump
Stiebel 4194
InLine Drive
(other options are available)
14
Training Manual
SERVICE TRAINING
Fixed Displacement Pump
Variable Displacement Pump
Rexroth A2F20
Rexroth A7VO
Fixed displacement pumps discharge a set volume of

fluid regardless of the system requirements. This
volume can be changed only by changing the drive
speed of the pump. If the system requires less fluid than
the pump is discharging, the balance of the flow must
find an alternate pah which is usually over a relief valve
and back to the reservoir.
Variable pump with axial tapered piston rotary group

of bent axis design, for open circuit hydraulic drives.
This pump is suitable for mobile applications.
Comprehensive programming of control devices is
available. The robust taper roller drive shaft bearings
are designed to give long service life. Output flow is
proportional to drive speed and pump displacement is
steplessly variable between maximum and zero.
Horse Power Control
(other locations possible)
Q min
Q max
Q max
25 -
Q min
Horsepower Adjustment Screw

(other locations possible)
Training Manual
15
SERVICE TRAINING
Variable Displacement Axial

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

Q max
16
Training Manual
SERVICE TRAINING
Rexroth A11VO Adjustments

Pressure Cut-Off
Pressure Cut-Off
Delta P
Q min
Q min
Load Sense Port
Q max
Q max
A11VO Boom Pump
A11VO Accumulator Pump
Horsepower Control
*Stroke
Regulation
*Stroke Regulation
**Pressure Cut-Off
Pressure Cut-Off
Horsepower
Control
Style #1
***Pressure Cut-Off
Q min
Horsepower
Control
Q min
*Stroke Regulation
Style #2
* The beginning of stroke regulation has been increased from 5-7
bar to 8-10 bar on pumps with the following serial numbers:
**
Pressure Cut-Off / Style #1

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

Turn Counter-Clock-wise to increase the pressure
Turn Clock-wise to decrease the pressure
A11VO 130 - 21034174, dated 08/22/05

A11VO 190 - 21006318, dated 08/01/05
Pumps with serial numbers below these should also have
beginning of stroke regulation pressure set to 8-10 bar.
A11VO 190/130 Main Pumps
Training Manual
17
SERVICE TRAINING
Transfer Cases
Hydraulic pumps for the concrete pump, placing boom,
agitator, etc., are usually mounted on a distribution
gearcase. When you are driving the truck, the power of
the truck engine is transmitted through the truck
transmission, through a propeller shaft, through the
bottom of the distribution gearcase, through another
propeller shaft, and into the rear end(s) of the truck.
When you are operating the unit, the distribution

gearcase interrupts the power to the rear ends, and
transmits it to internal gears that turn the hydraulic
pumps. Changing between travel and pumping modes
is accomplished by means of an air switch in the truck
cab.
4194
4195
4400
18
Training Manual
SERVICE TRAINING
Relief Valves
This is a direct acting non adjustable relief valve.
When the oil has enough pressure to over take the
spring the relief poppet will start to move out of the
way and allow the excess pressure to be relieved to
tank. This style pressure relief is not adjustable except
by changing the internal spring.The maximum system
pressure that this style can be used for is limited
because the spring must directly act upon system
pressure and thus higher pressures would require a
larger spring. When this direct acting design relieves it
causes pulsations in the system.
Pressure
This is a pilot operated adjustable relief valve. The

relief poppet has a small orifice in it that allows the
hydraulic pressure to also be applied on the back side
of the poppet. This internal chamber is hydraulically
locked and it will hold the main poppet closed as long
as it has equal pressure on the front side and the back
side. There is also a much smaller pilot poppet, that is
operator adjustable. This smaller poppet, with a smaller
area, can have a smaller spring controlling it. Once this
pilot poppet opens we lose our hydraulic lock, the
pressure is reduced on the back side and thus the main
poppet can relieve the excess pressure to tank. With
this design we are able to control large volumes of oil
at high pressures with minimal sized springs.
Pressure
Tank
Tank
This is a direct acting adjustable relief valve. When

the oil has enough pressure to over take the spring the
relief poppet will start to move out of the way and
allow the excess pressure to be relieved to tank. This
style is adjustable though a external control which
varies the spring tension on the relief poppet.The
maximum system pressure that this style can be used
for is limited because the spring must directly act upon
system pressure and thus higher pressures would
require a larger spring.
Pressure
Tank
Pressure
Pressure
Tank
Tank
Training Manual
19
SERVICE TRAINING
Safety Relief Valves
Pressure Relief Valves Type DBW
Pressure control valve type DB/DBW are pilot

operated pressure relief valves. They are used to limit
(DB) or unload by means of solenoids (DBW) pressure
in a system. Pressure relief valves (DB) consist mainly
of a pilot valve with pressure setting element and main
valve with main spool insert.
In principle, the function of this valve is the same as

that of valve type DB. Unloading at the main spool is
achieved by means of actuating the built-on directional
control valve.
Pressure Relief Valve Type DB

Pressure in line A affects the main spool (1). At the
same time there is pressure via control passage (4) and
(5) through orifice (2), (3) and (15) to the spring loaded
side of the main spool (1) and pilot poppet (6). If
system pressure exceeds the value set at the spring (8),
pilot poppet (6) opens.
The oil on the spring loaded side of the main spool (1)
now flows through orifice (3), control passage (5) and
poppet (6), and into spring chamber (9). From here it
flows internally - type DB.-30/.through passage (10),
or externally-type DB.-20/.Y.by means of control port
(11) to tank. Orifices (2), (3) and (15) cause a pressure
drop at the main spool (1), and the connection from
line A to line B opens. The oil now flows from line A to
line B, while the set operating pressure in maintained.
The valve can be unloaded or switched to a different
pressure (second pressure rating) by means of port X
(13).
VENT
LINE
20
Training Manual
SERVICE TRAINING
Hydraulic Symbols
SHOWING DIN (DEUTSCHE INDUSTRIAL NORM) SYMBOLS USED ON SCHWING SCHEMATICS
NO ATTEMPT HAS BEEN MADE TO SHOW EVERY POSSIBLE COMBINATION.
LINE, WORKING
P = R 1/2"
T = R 1/2"
SP = R 3/4"
G = R 3/8"
AC = R 11/2"
Y = R 3/8"
Nitrogen pressure set at 55 bar

(800 PSI)
G
1.9 mm
LINE, JOINING
("T" FITTING)
S3
0.8 mm
hole drilled
through
spool
190
bar
SP
LINE, PASSING
138 bar
Y
This line MUST

return to tank by
itself.
P
NG
10
10
Filter
Agitator
LINE TO RESERVOIR (TANK)
2.0
mm
LINE, PILOT or SIGNAL
300
bar
BP 750 & 1000 TC
S1
(with twin cylinder switching and

Hartman control valves)
P 0-25 bar
2.0 mm
599010
1-95 RE
Y(T)
A
125 b
bar
LINE, PLUGGED
P
RESTRICTION, FIXED
(orifice, nozzle)
0.7 mm
100
bar
LINE, WORKING
LINE, PILOT or SIGNAL
12
Filter
A11VO
LINE, PASSING
LINE TO RESERVOIR (TANK)

(ABOVE FLUID LEVEL)
(BELOW FLUID LEVEL)
CONNECTOR
LINE, PLUGGED
LINE, JOINING
("T" FITTING)
RESTRICTION, FIXED
(orifice, nozzle)
Training Manual
1.3
1.3
OR
21
SERVICE TRAINING
Hydraulic Symbols (Cont.)
RESTRICTION, VARIABLE
(throttle valve or adjustable orifice)
PUMP, SINGLE
FIXED DISPLACEMENT
MANUAL SHUT-OFF VALVE
PUMP, SINGLE
VARIABLE DISPLACEMENT
(MANITROL VALVE)
X1
X2
A
A1
PRIME MOVER,
ELECTRIC MOTOR
PUMP, SINGLE
VARIABLE DISPLACEMENT,
SHOWING HORSEPOWER
CONTROL CIRCUITS.
D
PRIME MOVER,
INTERNAL COMBUSTION ENGINE
(Diesel shown..."G" if gas.)
MOTOR, ROTARY,
FIXED DISPLACEMENT
MOTOR, ROTARY,
FIXED DISPLACEMENT
BI - DIRECTIONAL
22
Training Manual
SERVICE TRAINING
CYLINDER, SINGLE ACTING
PRESSURE GAUGE
CYLINDER,
DIFFERENTIAL ROD
TEMPERATURE GAUGE
ACCUMULATOR,
GAS CHARGED
CYLINDER, DOUBLE
END ROD
ACCUMULATOR,
SPRING LOADED
FILTER OR STRAINER
CYLINDER, DOUBLE END ROD WITH GROOVES IN

PISTON ROD FOR SWITCHING FUNCTION
(ROCK VALVE SHIFTING CYLINDER)
FILTER WITH INTEGRAL

BYPASS CHECKVALVE
Training Manual
6 bar
23
SERVICE TRAINING

OIL COOLER WITH
ELECTRIC FAN MOTOR
HYDRAULICALLY UNLOCKABLE
CHECK VALVE.
(CLOSED)
OIL COOLER WITH

HYDRAULIC FAN MOTOR
HYDRAULICALLY UNLOCKABLE
CHECK VALVE WITH INTEGRAL
RELIEF VALVE.
(OPEN)
320 BAR
(H.E.R. BOOM HOLDING VALVE)
BASIC VALVE ENVELOPE

PRESSURE SWITCH
NORMALLY CLOSED
NORMALLY OPEN
PRESSURE RELIEF VALVE

(SAFETY VALVE OR
SAFETY CARTRIDGE)
CHECK VALVE (BASIC)
CHECK VALVE, FIXED FORCE
280 bar
A 2.0
(SPRING FORCE INDICATED)

WITH EXTERNAL DRAIN
300 bar
(SHOWN WITH A NORMALLY

OPEN SOLENOID VALVE...
MANY OTHER POSSIBILITIES
ARE AVAILABLE).
ADJUSTABLE CHECK VALVE

(PRETENSION OR PRELOAD VALVE)
(Desired spring force indicated)
6 BAR
300 bar

WITH EXTERNAL DRAIN
24
Training Manual
F NR
SERVICE TRAINING

A
P 0-55 bar
Y(T)
A
PRESSURE REDUCING VALVE
ACCUMULATOR
UNLOADING VALVE
MANUAL (STROKE LIMITER) OR

DAMPNER
P
T
70 bar
300
bar
0-50
bar
PRESSURE REDUCING VALVE

(ELECTRIC STROKE LIMITER)
ACCUMULATOR DUMP VALVE

(ELECTRIC)
A 55 bar
T
P
T
P
MY
Pressure
reducing valve
MG
G
Y
A
Electric
stroke limiter
1.5
THROTTLE
CHECK VALVE
FIXED (size shown)
ADJUSTABLE
SLEW BRAKE
VALVE
P
A
CARTRIDGE VALVE
(SWITCHING VALVE)
OLD WAY
NEW WAY
SHUTTLE VALVE
SHOWN 2 DIFFERENT WAYS
Training Manual
25
SERVICE TRAINING
X1
X2
A
A1
COMPONENT ENCLOSURE
BRAKE VALVE
(BERINGER)
(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)
B
R
BRAKE VALVE (SAUER)

(USED ON #1 SECTION
DOWN FUNCTION)
VENTED RESERVOIR
(TANK)
26
Training Manual
SERVICE TRAINING

DIRECTIONAL CONTROL VALVES
DIRECTIONAL VALVE: METHODS OF OPERATION
BASIC VALVE SYMBOL

MULTIPLE FLOW PATHS
PILOT PRESSURE
DIRECTIONAL VALVE
OR
2 POSITION, 3 WAY
SOLENOID
DIRECTIONAL VALVE
2 POSITION, 4 WAY
SPRING
DIRECTIONAL VALVE
3 POSITION, 4 WAY, CLOSED CENTER
MANUAL
(HANDLE OR PUSHBUTTON)
DIRECTIONAL VALVE
3 POSITION, 4 WAY, OPEN CENTER
DETENT
DIRECTIONAL VALVE
3 POSITION, 4 WAY
CLOSED PRESSURE CENTER
HAND LEVER
DIRECTIONAL VALVE
3 POSITION, 4 WAY, TANDEM CENTER
(REQUIRES A HOLLOW SPOOL)
EXAMPLES OF COMBINATIONS OF METHODS
3 POSITION, 6 WAY, CLOSED CENTER (10631)
SOLENOID OPERATED,
SPRING RETURN
DIRECTIONAL VALVE, 3 POSITION,

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

WITH DETENT

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

5 WAY, LOAD SENSING,
CLOSED CENTER,
INFINITE POSITIONING
(PROPORTIONAL)
PRESSURE REGULATOR
(REGULATES DELTA P)
USED ON LOAD SENSING SYSTEMS
OR
Training Manual
27
SERVICE TRAINING
Formulas
Piston Side
Rod Side
R2
R2
= 3.14
R = 1/2 of Diameter
5
= 3.14
R = 1/2 of Diameter
2.5
10,000
Pounds
3.14(2.5 x 2.5) = 19.625

3.14 x 6.25 = 19.625
3.14(1.25 x 1.25) = 4.90625

3.14 x 1.5625 = 4.90625
Piston - Rod = Rod Side Area
Area of piston = 19.625
19.625 - 4.90625 = 14.719
19.625
10,000
Pounds
10,000 = 509.55
19.625
10,000 = 679.39
14.719
To move this load it will take

about 510 psi
To move this load it will take

about 680 psi
POWER =
5100
1714
28
14.719
10,000
Pounds
10 GPM x 510
1714 (A Constant)
POWER =
6800
1714
= 2.975 HP
Training Manual
10 GPM x 680
1714 (A Constant)
= 3.967 HP
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
7
300
bar
10A
10B
D
12A
12B
11A
11C
11B
2
6 bar
2
1
39000156.eps
1. Hydraulic oil reservoir
7. Directional control valve S-2
2. Main hydraulic pumps
8. Locking Valve
3. Main pressure relief valve
9A9B. Needle valves
4. Directional control valve S-1 (forward/reverse)
10A10B. Hydraulically Unlockable Check valves
5. Gate Valve
11A11C. Check valves
12A12B. Differential Cylinders
32
Training Manual
SERVICE TRAINING
Concrete Pump Control Block
T P1
9B
9A
9B
S3
S1
1.5 mm
hole drilled
through spool
S2
300
bar
3
8
9A
S-1
S-2
7
S-3
6
39000155.eps
Training Manual
33
SERVICE TRAINING
Stroke Limiter
P
2
A
4
0-50
BAR
4
1
3
2
A
39000158.eps
494 Block
A
5
agitator
motor
P
1
2
Agitator
pressure*
H2O pump
motor
A
B
H2O
pressure*
5
1
39000157.eps
CA B
34
Training Manual
SERVICE TRAINING
Hydraulically Unlockable CheckValve
C
B
A
C
2
1
A
1
0.7
mm
39000160.eps
Gate Valve
B
D
1
C
2
D
2
C
Training Manual
39000163.eps
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
11
10B
4
10D
10C
10E
9A
8A
8B
12
9B
10F
1
8A8B. Differential hydraulic cylinders
9A9B. Switching valves
10A10F. Check valves
11. Ball cock (Shutoff valve)
5. Rock valve slewing cylinder
12. Hydraulic oil filter with bypass valve (return filter

38
Training Manual
SERVICE TRAINING
P1
X
S3
1.5 mm
hole drilled
through spool
S1
10B
P2
300 bar
S2
A
10A
Port size
limits flow
S-1
S-2
S-3
6
39000147.eps
Training Manual
39
SERVICE TRAINING
Stroke Limiter
P
2
A
4
0-50
BAR
4
1
3
2
A
39000158.eps
494 Block
A
5
agitator
motor
P
1
2
Agitator
pressure*
H2O pump
motor
A
B
H2O
pressure*
5
1
39000157.eps
CA B
40
Training Manual
SERVICE TRAINING
Switching Valve
C
C
B
B
2
2
1
39000161.eps
A7VO
Q min
1
2
B
Q max
X1
X1
X2
X2
A
A1
A1
D
2
2
To
Boom
Circuit
Training Manual
39000162.eps
41
SERVICE TRAINING
Rock Valve
1
A
2
A
1
C
D
F GH
B
F
H
G
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

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

valve (2) in the left position oil flows to the right hand
differential acting on the rod side. Oil from the piston
side of the right hand differential oil is passed to the
piston side of the left hand differential and the rod side
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
(Tank, or oil at rest)
12
18
13
3 S3
1.5 mm
hole drilled
through spool
S1
300
bar
1
10
2 S2
14
15
20
D
5
6
44
16
17
Training Manual
6 bar
SERVICE TRAINING
Phase B
(1), filter (7) and back to the hydraulic tank.
End of first working stroke
* NOTE: If the left hand differential has not fully

extended at this point due to not enough loop oil, high
pressure oil will continue to flow through check valve
(17) on the right hand differential until the left hand
differential is fully extended.
The differential cylinders have reached the end of their

stroke position*. Switching valve (5) is sending a high
pressure signal to the left hand end cap of S3 valve (3).
Oil from the right hand end cap of the S3 valve (3) is
relieved via check valve (15), the S2 valve (2), S1 valve
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
12
18
13
3 S3
1.5 mm
hole drilled
through spool
S1
300
bar
1
10
2 S2
14
15
20
D
5
6
16
17
Training Manual
6 bar
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.
Oil from the left hand side of the rock valve shift
cylinder is routed to tank via valves (3, 1) and filter (7).
Rock valve cylinder getting oil to extend
High pressure oil from switching valve (5) has now

shifted the S3 valve (3) fully to the right hand position.
At this point the pressure oil to the rock valve shift
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
12
18
13
3 S3
1.5 mm
hole drilled
through spool
S1
300
bar
1
10
2 S2
14
15
20
D
5
6
46
16
17
Training Manual
6 bar
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
valve (2) is routed to the hydraulic tank via check valve
(13), valves (3, 1) and the filter (7).
S2 valve getting signal to shift
The rock valve shift cylinder (4) has now fully

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
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
12
18
13
3 S3
1.5 mm
hole drilled
through spool
S1
300
bar
1
10
2 S2
14
15
20
D
5
6
16
17
Training Manual
6 bar
47
SERVICE TRAINING
Phase E
Left hand differential getting oil to move
With the S2 valve (2) fully shifted and held in the right
hand position, pressure oil is routed through the S1
valve (1) and the S2 valve (2) to the rod side of the left
hand differential cylinder. Please note that while the

left hand differential cylinder is starting to retract,
check valve (17) must close otherwise the right hand
differential cylinder will not extend.
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
12
18
13
3 S3
1.5 mm
hole drilled
through spool
S1
300
bar
1
10
2 S2
14
15
20
D
5
6
16
8
M
17
Note: Check Valve Must Close
48
Training Manual
6 bar
SERVICE TRAINING
Phase F
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.
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
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
12
18
13
3 S3
1.5 mm
hole drilled
through spool
S1
300
bar
1
10
2 S2
14
15
20
D
5
6
16
17
Training Manual
6 bar
49
SERVICE TRAINING
Phase G
(3) is relieved via check valve (14), the S2 valve (2), S1

valve (1), filter (7) and back to the hydraulic tank.
End of second working stroke (diagram 7)
* 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.
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
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
12
18
13
3 S3
1.5 mm
hole drilled
through spool
S1
300
bar
1
10
2 S2
14
15
20
D
5
6
50
16
17
Training Manual
6 bar
SERVICE TRAINING
Phase H
Rock valve cylinder getting oil to retract
High pressure oil from the switching valve (6) has not
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
cylinder is getting oil so that the cylinder will retract.

Oil from the right hand side of the rock valve shift
cylinder (4) is being routed to tank via valves (3, 1) and
filter (7).
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
12
18
13
3 S3
1.5 mm
hole drilled
through spool
S1
300
bar
1
10
2 S2
14
15
20
D
5
6
16
17
Training Manual
6 bar
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 (2) is routed to the hydraulic tank via check
valve (12), valves (3, 1) and filter (7).
S2 valve getting signal to shift
The rock valve shift cylinder (4) has now fully

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
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
12
18
13
3 S3
1.5 mm
hole drilled
through spool
S1
300
bar
1
10
2 S2
14
15
20
D
5
6
52
16
17
Training Manual
6 bar
SERVICE TRAINING
Phase J
differential cylinder. Please note that check valve (16)

must close otherwise the right hand differential
cylinder will not retract.
Right hand differential getting oil to move
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
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
12
18
13
3 S3
1.5 mm
hole drilled
through spool
S1
300
bar
1
10
2 S2
14
15
20
D
5
6
16
17
Training Manual
6 bar
53
SERVICE TRAINING
Phase K
First working stroke
Refer to diagram 1 for explanation of first working

stroke.
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
12
18
13
3 S3
1.5 mm
hole drilled
through spool
S1
300
bar
1
10
2 S2
14
15
20
D
5
6
54
16
17
Training Manual
6 bar
SERVICE TRAINING
Troubleshooting
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
was completely shifted to the left. This would cause

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
A
OPEN
S3
1.5 mm
hole drilled
through spool
S1
300
bar
S2
M
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 its 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
S3
1.5 mm
hole drilled
through spool
S1
300
bar
S2
M
6 bar
56
Training Manual
SERVICE TRAINING
Rock valve shifts and as soon as the

differential cylinder shifts the rock valve
shifts again (machine gunning).
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
right hand differential for the start of the next stroke.

However since 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. (See diagram 3B).
KEY
High Pressure
Rocking Oil
Low Pressure
Zero Pressure
S3
1.5 mm
hole drilled
through spool
S1
300
bar
S2
A
Note:
Stuck Open
D
M
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
S3
1.5 mm
hole drilled
through spool
S1
300
bar
S2
A
Note:
Stuck Open
D
M
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
S3
1.5 mm
hole drilled
through spool
S1
300
bar
S2
A
Note:
Stuck Open
D
M
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
Ball Cock
S3
1.5 mm
hole drilled
through spool
S1
300
bar
S2
Note:
Stuck Open
D
M
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
ZK2
1.3
ZS2
1.3
SP
ZK1
9A
ZS1
9B
XA
XB
3.5
3.5
TO STROKE LIMITER PORT "PBP"
B
X3
TO STROKE LIMITER PORT "PZ"
A2
B2
B3
A3
S3
10C
6
XB3
XA1
10D
1.5
A
B
B1
A1
S2
XA
11
XB
PR
PP
S1
XR
XP
P2
P1
MP
10E
1.8
T2
1.2
12
T1
1.4
300 bar
X1
8A
8B
10F
T
1.8
9A9B. Switching Valves
10A10F. Check valves
11. Ball cock (Shutoff valve)
12. Main flow poppet relief valve
62
Training Manual
SERVICE TRAINING

A2
B2
B3
A3
S3
XA1
X1 MP
XB3
B
B1
XB
P1
X
1
T1
PR
S2
XA
P2
XR
PP
S1
A1
P2
P
1.5
T2
XP
1
B
XP
P1
MP
T2
XB
T1
12
300 bar
1.2
1.4
3
XB
B3
B2
A2
A3
X1
2
1
Training Manual
63
SERVICE TRAINING
Switching Manifold
10A
3.5MM Orifice
10B
ZK2
SP
ZK1
1.3
9A
3.5MM Orifice
1.3MM Orifice
ZS2
ZS1
1.3
9B
9C
9C
XB
XA
A
9A
9B
3.5
3.5
10A
10B
X3
MPS_SC.eps
Stroke Limiter with Fast Switch/Dampner

MG2
Reversing Valve
(for Fast Switch)
G2
11
Dampner
0.7
20
bar
0-30
bar
X1
MX1
3.5-40
bar
12
10
4
2
3.5-40
bar
MP
MG1
0.7
7
9
12
PBP
10
PZ
5
11
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.
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Training Manual
SERVICE TRAINING
Phase
A Hi-Flow Single Circuit
KEY
High Pressure
Rocking Oil Pressure

Low Pressure
Zero Pressure
ZK2
SP
1.3
ZK1
9A
ZS2
1.3
ZS1
9B
XA
A
XB
3.5
3.5
10A
10B
X3
10C
A2
B2
B3
A3
S3
10D
6
XB3
XA1
1.5
A
A1
B1
S2
11
XA
XB
PR
PP
S1
XR
XP
P2
P1
MP
10E
1.8
T2
1.2
8A
3
300 bar
T1
12
8B
1.4
X1
T
1.8
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 bushing, it exposes a port to the end cap of the reversing
valve (9B), which becomes connected to high pressure 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 position, 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

Low Pressure
Zero Pressure
ZK2
SP
1.3
ZK1
9A
ZS2
1.3
ZS1
9B
XA
A
XB
3.5
3.5
10A
10B
X3
10C
A2
B2
B3
A3
S3
10D
6
XB3
XA1
1.5
A
A1
B1
S2
11
XA
XB
PR
PP
S1
XR
XP
P2
P1
MP
10E
1.8
T2
1.2
8A
3
300 bar
T1
12
8B
1.4
X1
T
1.8
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

Low Pressure
Zero Pressure
ZK2
SP
1.3
ZK1
9A
ZS2
1.3
ZS1
9B
XA
A
XB
3.5
3.5
10A
10B
X3
10C
A2
B2
B3
A3
S3
10D
6
XB3
XA1
1.5
A
A1
B1
S2
11
XA
XB
PR
PP
S1
XR
XP
P2
P1
MP
10E
1.8
T2
1.2
8A
3
300 bar
T1
12
8B
1.4
X1
T
1.8
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

Low Pressure
Zero Pressure
ZK2
SP
1.3
ZK1
9A
ZS2
1.3
ZS1
9B
XA
A
XB
3.5
3.5
X3
10C
A2
B2
B3
A3
S3
10D
6
XB3
XA1
1.5
A
B
B1
A1
S2
11
7
XB
XA
PR
PP
S1
XR
XP
P2
P1
MP
10E
1.8
T2
1.2
8A
3
300 bar
T1
12
8B
1.4
X1
T
1.8
1
10F
Training Manual
73
SERVICE TRAINING
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 wouldnt switch because there wasnt
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 its 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
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 doesnt slam
and it doesnt 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
S1
S2
S3
S3
74
Training Manual
SERVICE TRAINING
1200 Twin Circuit with Switching Valves
Twin Circuit with Switching Valves

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

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
S3
8A
19
15
16
8B
17
9A
18
10C
1
10D
9B
10B
10A
22
NG
10
13
23
7
1
4
S2
S1
0.7 mm
21
12
24
20
13. Accumulator unloading valve
2. Main hydraulic pump
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
9A9B. Switching valves
21. Accumulator circuit filter
10A10D. 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
P1
S1
300 bar
S2
P2
Port size
limits flow
S-1
2
S-2
39000148.eps
S3 Control Block
6
6
S3
1
39000149.eps
Training Manual
77
SERVICE TRAINING
Soft Switch
2
4
1
0.7 mm
4
80
bar
Soft switch
39000151.eps
Accumulator Unloader Valve
39000153.eps
78
Training Manual
SERVICE TRAINING
Accumulator Control Block/Dump Valve

1
2
Nitrogen pressure set
at 100 bar (1450 PSI)
Accumulator control device
300
bar
5
6
6
7
4
39000152.eps
Accumulator Pump
A11
A10
200 bar
39000154.eps
Training Manual
79
SERVICE TRAINING

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.

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).

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.
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).

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 rightside differential cylinder (8B). The cylinder
cylinder. The right-side material cylinder fills with
concrete. (This is called the suction stroke.)
80
Training Manual
SERVICE TRAINING
Phase
6.3
mm
A Twin Circuit
14
5
6.3
mm
Nitrogen pressure
set at 100 bar
(1450 PSI)
19
11
15
S3
8A
16
8B
17
9A
300
bar
18
10C
1
10D
9B
22
10B
10A
NG
10
13
T
2.5 mm
0.7
mm
2.5 mm
200
bar
Y
0.7
mm
1
4
S2
S1
320
bar
0.7 mm
21
KEY
High Pressure
12

Low Pressure
Zero Pressure
Training Manual
20
81
SERVICE TRAINING
Phase B
The right-side differential cylinder (8B) reaches

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).

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
Phase
6.3
mm
B Twin Circuit
14
5
Nitrogen pressure
set at 100 bar
(1450 PSI)
6.3
mm
11
19
15
S3
8A
16
8B
17
9A
300
bar
18
10C
1
10D
9B
P
10B
10A
NG
10
22
13
T
2.5 mm
0.7
mm
2.5 mm
200
bar
Y
0.7
mm
1
4
S2
S1
320
bar
0.7 mm
21
KEY
High Pressure
12

Low Pressure
Zero Pressure
20
28X 1200 TCphaseAoriginal
Training Manual
83
SERVICE TRAINING
Phase C

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
Phase
6.3
mm
C Twin Circuit
14
5
Nitrogen pressure
set at 100 bar
(1450 PSI)
6.3
mm
11
19
15
S3
8A
16
8B
17
9A
300
bar
18
10C
1
10D
9B
10A
10B
NG
10
22
13
T
2.5 mm
0.7
mm
2.5 mm
200
bar
Y
0.7
mm
1
4
S2
S1
320
bar
0.7 mm
21
KEY
High Pressure
12

Low Pressure
Zero Pressure
20
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

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
Phase
6.3
mm
D Twin Circuit
14
5
Nitrogen pressure
set at 100 bar
(1450 PSI)
6.3
mm
11
19
15
S3
8A
16
8B
17
9A
300
bar
18
10C
1
10D
9B
10A
10B
22
NG
10
13
T
200
bar
2.5 mm
0.7
mm
2.5 mm
0.7
mm
1
4
S2
S1
320
bar
0.7 mm
3
21
KEY
High Pressure
12

Low Pressure
Zero Pressure
Training Manual
20
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
1
19
11
S3
8A
8B
17
9A
15
16
18
10C
1
10D
9B
22
23
10B
10A
NG
10
13
25
S2
S1
0.7 mm
21
12
24
20

2. Main hydraulic pump
4. Directional control valve S1
5. Rock Valve slewing cylinder
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
90
13. Accumulator unloading valve

14. Accumulator
15. Electric accumulator dump valve
17. Accumulator shutoff valve
18. Accumulator safety relief valve
21. Accumulator circuit filter
22. Accumulator redundant relief valve
24. Soft Switch valve
25. Shuttle valve
Training Manual
SERVICE TRAINING
P1
S1
300 bar
S2
P2
Port size
limits flow
S-1
2
S-2
39000148.eps
S3 Control Block
6
6
S3
1
39000149.eps
Training Manual
91
SERVICE TRAINING
MPS
1
2
4
5
S3
1
3

92
NG
10
Training Manual

SERVICE TRAINING
Accumulator Control Block/Dump Valve

1
2
at 100 bar (1450 PSI)
300
bar
5
6
6
7
4
39000152.eps
Accumulator Pump
A11
A10
200 bar
39000154.eps
Training Manual
93
SERVICE TRAINING
Soft Switch
2
4
1
0.7 mm
4
80
bar
Soft switch
39000151.eps
94
Training Manual
SERVICE TRAINING
Training Manual
95
SERVICE TRAINING

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.

right differential cylinder (8B) flows through
cylinder (item 8A). This oil is called rocking oil
(orange).

cylinder (8A) to extend. The cylinder rod extends,

cylinder (8A) is routed back to the tank through
in green.
The oil shown as blue is at rest, or pressureless,

such as the oil in the reservoir.
Phase A
As soon as you switch the unit distribution

gearcase to the pumping position, the accumulator
pressure oil (red) to charge the accumulator circuit
(14).

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).

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

position.

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

of the S2 valve (7) into the rod side of the right
side differential cylinder (8B). The cylinder
96
Training Manual
SERVICE TRAINING
Phase
A MPS Twin Circuit

6.3
mm
14
Nitrogen pressure
set at 100 bar
(1450 PSI)
6.3
mm
19
11
15
S3
8A
16
8B
6
9A
T
1.0 mm
10C
1.0 mm
10D
17
300
bar
18
1
9B
To e-stop
manifold
23
10B
10A
NG
10
22
250 bar
13
T
2.5 mm
0.7
mm
2.5 mm
200
bar
Y
0.7
mm
1
4
S2
S1
320
bar
0.7 mm
21
KEY
High Pressure
12

Low Pressure
Zero Pressure
Training Manual
20
97
SERVICE TRAINING
Phase B
The right side differential cylinder (8B) reaches

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).

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

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

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
6.3
mm
1
19
11
15
S3
8A
16
8B
6
9A
T
17
300
bar
18
1.0
mm
1.0
mm
10C
1
10D
9B
To e-stop
manifold
23
10B
10A
NG
10
22
250 bar
13
T
2.5 mm
0.7
mm
2.5 mm
200
bar
Y
0.7
mm
1
4
S2
S1
320
bar
0.7 mm
To e-stop
manifold
21
KEY
High Pressure
12

Low Pressure
Zero Pressure
Training Manual
20
99
SERVICE TRAINING
Phase C


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,

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
into the delivery pipeline. (Pressure stroke.)

differential cylinder (8B) is routed through the S2
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
6.3
mm
1
19
11
15
S3
8A
16
8B
6
9A
T
1.0
mm
1.0
mm
17
300
bar
18
10C
1
10D
9B
To e-stop
manifold
23
10B
10A
NG
10
22
250 bar
13
T
2.5 mm
0.7
mm
200
bar
Y
0.7
mm
2.5 mm
4
S2
S1
320
bar
0.7 mm
21
KEY
High Pressure
12

Low Pressure
Zero Pressure
Training Manual
20
101
SERVICE TRAINING
Phase D
The left side differential cylinder (8A) retracts to

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

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.

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).

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
6.3
mm
1
19
11
15
S3
8A
16
8B
6
9A
T
1.0
mm
1.0
mm
17
300
bar
18
10C
1
10D
9B
To e-stop
manifold
23
10B
10A
NG
10
22
250 bar
13
T
200
bar
Y
2.5 mm
2.5 mm
0.7
mm
0.7
mm
1
4
S2
S1
320
bar
0.7 mm
21
KEY
High Pressure
12

Low Pressure
Zero Pressure
Training Manual
20
103
SERVICE TRAINING
Twin Circuit with Variable displacement

accumulator pump Schematic
6.3
mm
14
Nitrogen pressure
set at 100 bar
(1450 PSI)
5
6.3
mm
1
19
11
15
S3
8A
16
8B
17
9A
T
1.0
mm
1.0
mm
300
bar
18
10C
1
10D
9B
To e-stop
manifold
23
10B
2.5 mm
10A
2.5 mm
0.7
mm
22
250 bar
NG
10
0.7
mm
1
4
S2
S1
320
bar
3
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 Americas
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

5
S3
13
16
14
17
18
15
P
9A
9B
20
10A
10B
11
7
S2
S1 4
24
3
10C
22
12
21
1.1
8A
23
8B
10D
19
1

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
108
13. Accumulator
14. Pilot to close accumulator dump valve
16. Accumulator pressure maintenance check valve
17. Accumulator relief valve
21. Soft switch relief valve
22. Soft switch shutoff valve
23. Soft switch reversing valve
24. Main flow poppet valve
Training Manual
SERVICE TRAINING

A
B
B1
A1
3.0
mm
XA
S2
XB
3.0
mm
PP
0.7
mm
PR
0.7
mm
S1
T2
XP
P2
P1
T
X1
P1
MP
T1
T2
24
1.2
P
P
350 bar
MX
1.4
P2
R R
P X
XR
X3
XA
X1
22
80 bar
X2
21
X3
XB
1.1
T
23
7
4
24
3
23
The standard Schwing control block has used up to 560

LPM of oil. We have developed a new control block
designed for 800 LPM of oil. Called G-3 for 3rd
Generation Control Block and is also known as the HiFlow Brain.
21
for compact simpler design

The twin circuit machines with G-3 control block will
also use the condensed version accumulator (only one
larger one).
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
MX
1.4
350 bar
X1
2
6
80 bar
X2
X3
4
1.1
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
9B
10A
9A
The MPS system is an important part of the twin circuit

system incorporated in the Hi-flo pump kit. The MPS
system consists of three small directional control
valves mounted in a manifold. This replaced the two
switching valves that were located on the passenger
side differential cylinder. The main pressure that is
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.
10B
cylinders to switch with a minimum delay. The S3

block and the system accumulator are separated from
the main control block and located above the hopper
end of the material cylinders. Access to these
components is facilitated by removing the decking
between the water box and the rear boom rest.
The faster switch of the S3 valve allows the differential
Training Manual
111
SERVICE TRAINING
S3 Control Block - Machined

B
A
A1
B1
S3
XA
XB
2.0
mm
6
4
300
bar
Mp
M
P
Mp1
M
S
P
1
8.0
mm
7
Psp
T
P
PS
1
3
6
5
2
S0153.eps
112
Training Manual
SERVICE TRAINING
S3 Control Block - Cast
A3
B2
A2
B3
S3
XB1
2
bar
2.0
mm
3
M
P
MSP2
SP
P P1
T MS
MSP1
TUV
330
bar
2
4
MSP3
6.5
mm
M
S
P
3
1 A
T3
SP
M
S
P
2
XA1
MP
4
6
1
7
2
5
S0154.eps
Training Manual
113
SERVICE TRAINING
2023 Circuit diagram

of the S2 valve (7) into the rod side of the right
side differential cylinder (8A). The cylinder

right differential cylinder (8A) flows through
cylinder (item 8B). This oil is called rocking oil
(orange).

cylinder (8B) to extend. The cylinder rod extends,

cylinder (8B) is routed back to the tank through
in green.
The oil shown as blue, such as the oil in the

reservoir, is at rest, or pressureless.

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.
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
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 cutoff 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.

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

position.

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
High Pressure

Low Pressure
Soft Switch Pressure
Zero Pressure
S3
14
17
15
18
16
9A
9B
23
10A
10B
11
7
S2
S1 4
26
3
10C
25
12
24
1.1
8A
27
8B
10D
20
1
hiflo A.eps
Training Manual
115
SERVICE TRAINING
Phase B
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).

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

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
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

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
High Pressure

Low Pressure
Zero Pressure
S3
14
17
15
18
16
9A
9B
23
10A
10B
11
7
S2
S1 4
26
3
10C
25
12
24
1.1
8A
27
8B
10D
20
1
hiflo A.eps
Training Manual
117
SERVICE TRAINING
Phase C

bottom dead center position.

are charged to the pressure cut-off point of the
accumulator hydraulic pump (20). When the cutoff 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,

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
into the delivery pipeline. (Pressure stroke.)

differential cylinder (8A) is routed through the S2
to tank (1).
118
Training Manual
SERVICE TRAINING
Phase
C Hi-Flo
KEY
High Pressure

Low Pressure
Zero Pressure
S3
14
17
15
18
16
9A
9B
23
10A
10B
11
7
S2
S1 4
26
3
10C
25
12
24
1.1
8A
27
8B
10D
20
1
hiflo A.eps
Training Manual
119
SERVICE TRAINING
Phase D
The left side differential cylinder (8B) retracts to

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.

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).

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

one complete cycle, which consists of two suction
strokes and two pressure strokes.
Training Manual
SERVICE TRAINING
Phase
D Hi-Flo
KEY
High Pressure

Low Pressure
Zero Pressure
S3
14
17
15
18
16
9A
9B
23
10A
10B
11
7
S2
S1 4
26
3
10C
25
12
24
1.1
8A
27
8B
10D
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
1PM
P1
P4
P3
P2
39000165.eps
Electric/Oil/Oil - Fixed Displacement
1PM
P1
P4
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
HER - SV2 - R 1/2"

SCHEMATIC DRAWING
CYLINDER CONNECTION
UNLOCKABLE
CHECK
RETURN OIL
CONNECTION
(LEAKAGE OIL)
RELIEF (NON-ADJUSTABLE)
SAFETY VALVE
CONTROL LINE CONNECTION
(CONNECTED WITH WORKING LINE
OF THE OPPPOSITE SIDE)
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.
This auxiliary safety valve protects the cylinder from
excess pressure; therefore, this valve must not be set at
random. Precision setting for a specific placing boom
model is necessary and can only be done with the
correct equipment and certified personnel.
BLEED OFF
SCREW
PRESSURE
CONNECTION
(WORKING LINE)
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 hydraulic oil is flowing out uniformly from the

working line, this indicates that the check valve is not
sealing properly, or debris in the oil has caused the
unlocking system to hang up and not allow the check
valve ball to seat. If there are any questions concerning
holding valves or other areas of your Schwing
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
126
PORT Y
Training Manual
CYLINDER ROD
SERVICE TRAINING
28X B&W Boom
300 bar
T
Outrigger Jacking Cylinders
B A P1
KVM 28
BOOM #2
BOOM #1 (MAIN)
B3
1.3
270 BAR
A3
1.7
270 BAR
B4
1.0
A2
1.7
B2
A1
1.3
B1
1.3
SLEWING CYLINDERS
2.0
5 - 7 bar
Zero Pressure (Tank, or oil at rest)
AIR TANK
140 bar
A4
Low Pressure
1.3
Neutral
Control Pressure
270 BAR
BOOM #3 (Tip)
270 BAR
280 bar
Reduced Pressure
196101
10/91
RE
W/ MONSUN - TISON HANDVALVES
High Pressure
127
Training Manual
SERVICE TRAINING
300 bar
T
B A P1
KVM 28
196101
10/91
RE
BOOM #2
BOOM #1 (MAIN)
B3
1.3
270 BAR
A3
1.7
270 BAR
B4
1.0
A2
1.7
B2
A1
1.3
B1
1.3
SLEWING CYLINDERS
2.0
5 - 7 bar
AIR TANK
140 bar
A4
1.3
Low Pressure
#3 Extend Only
Control Pressure
270 BAR
BOOM #3 (Tip)
270 BAR
280 bar
Reduced Pressure
High Pressure
Training Manual
128
SERVICE TRAINING
300 bar
T
B A P1
KVM 28
196101
10/91
RE
BOOM #2
BOOM #1 (MAIN)
B3
1.3
270 BAR
A3
1.7
270 BAR
B4
1.0
A2
1.7
B2
A1
1.3
B1
1.3
SLEWING CYLINDERS
2.0
5 - 7 bar
AIR TANK
140 bar
A4
Low Pressure
1.3
#1 Retract
#3 Extend
Control Pressure
270 BAR
BOOM #3 (Tip)
270 BAR
280 bar
Reduced Pressure
High Pressure
129
Training Manual
SERVICE TRAINING
B A P1
PRINT # 329324
300 bar
T
A
P
35 bar
270 BAR
BOOM #3 (Tip)
270 BAR
280
bar
270 BAR
BOOM #2
1.0
B4
270 BAR
1.3
A4
1.3
B3
140 bar
BOOM #1 (MAIN)
1.7
A3
KVM 28
190321
1.7
A2
B2
1.3
B1
SLEWING CYLINDERS
2.0
1.3
A1
5-7
bar
Training Manual
130
SERVICE TRAINING
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 inline 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.
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.
1.0
1.3
A4
280 bar
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
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
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
could malfunction from contamination.
A1
X3
39000177.eps
Training Manual
131
SERVICE TRAINING
Components
Constant:A theoretical factor that is regarded as
invariant in specified circumstances. The constant for
calculating hydraulic HP is: 1714 (when psi and gpm
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
(kW). To calculate hydraulic horsepower consumption,
use the following formula; HP= Pressure multiplied by
the Volume, divided by a Constant.
HP =
GPM x PSI
1714
KW =
LPM x BAR
600
Orifice: A restriction installed in either a hydraulic or

pneumatic passageway to create a pressure drop. This
does not always reduce flow directly, but it may cause
enough pressure upstream so that some of the flow
would be diverted or reduced elsewhere.
Pressure
Drop
Orifice created between the spool and valves walls
39000182
Delta Pressure (Delta-P):The pressure differential

between two given points in a hydraulic circuit.
Q-Maximum(Q-max): The highest volumetric flow

rate possible from the hydraulic pump. Adjusted with a
mechanical stop screw. Turn screw inward to decrease
and outward to increase.
Q-Minimum(Q-min): The lowest volumetric flow rate
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
1200 PSI
82.75 bar
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
compensating valve.
X
C1
G1/2
C1
Section
Compensator
X3
39000183.eps
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
39000191a.eps
Training Manual
137
SERVICE TRAINING
Basic Principles - Delta-P

In this diagram, the cylinder will take exactly 2
minutes to extend. There will be a pressure of 1000 psi
at the cylinder and a pressure of 1200 psi at the pump.
The orifice caused a drop in pressure (Delta-P). The
regulator has been adjusted to maintain 200 psi (Delta-
P). The pump is only supplying the amount of oil

required to maintain the (Delta-P). In this case, 5 gpm.
If the size of the orifice increases, the flow rate will be
increased by the Delta-P regulator. That will increase
the speed of the cylinder.
10
1000 psi
Delta P
The pressure differential
between two given points
in a hydraulic circuit
1200 psi
X3
39000191.eps
138
Training Manual
SERVICE TRAINING
Basic Principles - Pressure Cut-Off

In this diagram, the cylinder is at the end of its stroke.
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.
The regulator has been adjusted to a pressure limit of

3000 psi. The pump is only supplying the amount of oil
required to maintain 3000 psi.
10,000 lbs
10
4350 psi
4350 psi
X3
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
3000 psi. If any one cylinder reaches the end of its
stroke, the main pressure will be 3000 psi.
In this diagram, the cylinder with the highest load

(2500 psi) will be monitored at the regulator. The
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
10,000 lbs
10
2500 psi
10
2000 psi
1000 psi
X3
39000193.eps
140
Training Manual
SERVICE TRAINING
Basic Principles - Pressure Regulator
P regulator
P regulator
X
20
bar P
300
bar
Pressure
Regulator
300 bar
P
Regulator
20 bar
0 bar
ORIFICE
0.8 mm
KVM 36X . . . . 1.6 mm
0-15 Bar
KVM 36 LW . . 1.6 mm
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
Pressure Regulator
(300 bar)
P Regulator
(20 bar)
P
T
39000219.eps
Training Manual
141
SERVICE TRAINING
A7 Variable Displacement Hydraulic Pump Training

All Functions in Neutral
The directional valve is in the neutral position.
Hydraulic oil is blocked at the handvalve.
Pressure below 20 bar

Pressure below 20 bar
X
20
bar P
C2
300
bar
C1
39000197.eps
A
C1
C2
20 bar spring
P
20 bar spring
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
Passageway opened to tank
39000195.eps
The pumps rotary group is at reduced displacement,

and is only putting out enough oil to maintain 20 bar
(Delta-P)
Passageway opened to tank
X
20
bar P
+20 bar pressure pushing on spool

Compressed Spring
39000199.eps
A
300
bar
T
A
X
20
bar P
This will create a pressure drop on the piston side of

the Control Piston Chamber, allowing the spring on rod
side of the chamber to decompress. As the spring
decompresses the angle of the rotary group will
increase. The pump will displace more oil, until 20 bar
(Delta-P) reached.
A1
300
bar
X3
39000194.eps
Not enough pressure to hold back the spring

A
+20 bar pressure pushing on spool
X
20
bar P
Compressed Spring
A1
300
bar
X3
T
P
39000200.eps
X3
Pressure on the A port drops below 20 bar, the force

of the spring is greater than the pressure exerted on the
spool. The spring will decompress, moving the spool to
the left.
P
X3
The rotary group angle will increase/decrease as

necessary to maintain 20 bar (Delta-P).
142
Training Manual
SERVICE TRAINING
KEY
High Pressure
330 bar
320 bar
Low Pressure
310 bar
Control Pressure
320 bar
1.0 mm
Reduced Pressure
Zero Pressure
1.0 mm
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.
P regulator
A7 VO Pump
X
20
bar P
A1
300
bar
X3
A7 VO Pump
P regulator
A1
Q-MIN
Pressure
Regulator
300 bar
P
Regulator
20 bar
0 bar
ORIFICE
0.8 mm
KVM 36X . . . . 1.6 mm
0-15 Bar
KVM 36 LW . . 1.6 mm
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
Q-MAX
X3
HT001.ai
Training Manual
143
SERVICE TRAINING
Cylinder Extend Function Initiated

The directional valve has been moved to the "cylinder
extend" position. Oil travels through the handvalve and
to the boom holding valve. A signal is also sent from
the handvalve to the Delta P regulator, via the X port.
This will create a pressure drop allowing the spring on

rod side to decompress, thus changing the angle of the
rotary group to displace enough oil to extend the
hydraulic cylinder.
Decompressed Spring
The pressure from the X port plus the 20 bar spring

is greater than the pressure on the A port side of the
spool. This will move the spool to the left, creating a
passage way for the oil in the Control Piston Chamber
of the hydraulic pump to tank.
A
X
A1
20 + Load
bar P T
300
bar
X3
1
A
Pressure + 20 bar
spring signal from
handvalve pushing
on spool
39000202.eps
Rotary Group
A
X
A1
X3
20 + Load
bar P T
300
bar
Oil enters the holding valve. The hydraulically

unlockable check valve opens allowing oil to enter
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.
X3
A
Control Piston Chamber
Pressure + 20 bar spring signal

from handvalve pushing on spool
C1
C2
Open Relief
320 bar
X
A
310 bar
330 bar
320 bar
1.0 mm
Control Piston Chamber
1.0 mm
X3
39000201.eps
Open Checkvalve
39000203.eps
144
Training Manual
SERVICE TRAINING
KEY
High Pressure
330 bar
320 bar
Low Pressure
310 bar
Control Pressure
320 bar
1.0 mm
Reduced Pressure
Zero Pressure
1.0 mm

P regulator
A7 VO Pump
X
A1
20 + Load
bar P T
300
bar
X3
A7 VO Pump
P regulator
A1
Q-MIN
Pressure
Regulator
300 bar
P
Regulator
20 bar
0 bar
ORIFICE
0.8 mm
KVM 36X . . . . 1.6 mm
0-15 Bar
KVM 36 LW . . 1.6 mm
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
Q-MAX
X3
HT002.ai
Training Manual
145
SERVICE TRAINING
Hydraulic Cylinder Extending

The hydraulic pump is only putting out enough oil to
extend the hydraulic cylinder. Depending upon the load
requirements, the signal line pressure will increase or
decrease accordingly. If the signal line pressure
increases, the 20 bar Delta P spool will open, allowing
allowing a larger passageway for the Control Piston
Chamber oil to escape to tank. This will decrease the
pressure on the piston side of the Control Piston
Chamber, allowing the spring on the rod side to
decompress and the angle of the rotary group to
increase, creating more flow to meet the load
requirements.
Example:
Load requirements for a particular function increse.
Increased Load
X port pressure on the spring side of the 20 bar spool

is greater than the A port pressure. The spool will
move to the left, creating a larger passageway for the
Control Piston Chamber oil to escape to tank.
The farther left the spool moves,
the larger the opening back to tank
X
A
A
20 + Load
bar P
39000206.eps
With a larger passageway to tank, pressure decreases in

the Control Piston Chamber.
Increased Load
X
1.0 mm
320 bar
A1
310 bar
330 bar
320 bar
T
1.0 mm
39000204.eps
As the load requirements increase, the signal line

pressure from the handvalve to the X port increases.
Increased Load
X3
39000207.eps
With a larger opening created to tank, the pressure

on the piston side of the chamber will decrease.
Increased Load
C2
C1
Spring decompresses, rotary group angle increases,

more flow created.
C1
C2
More oil displaced

A1
Load increases, signal

line pressure increases
X
A
20
bar P
39000205.eps
146
Training Manual
X3
39000208.eps
SERVICE TRAINING
KEY
High Pressure
330 bar
320 bar
Low Pressure
310 bar
Control Pressure
320 bar
1.0 mm
Reduced Pressure
Zero Pressure
1.0 mm

P regulator
A7 VO Pump
X
20
bar P
A1
300
bar
X3
System when equipped with Rexroth hydraulic pump
A7 VO Pump
P regulator
A1
Q-MIN
Pressure
Regulator
300 bar
P
Regulator
20 bar
0 bar
ORIFICE
0.8 mm
KVM 36X . . . . 1.6 mm
0-15 Bar
KVM 36 LW . . 1.6 mm
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
Q-MAX
X3
HT002.ai
Training Manual
147
SERVICE TRAINING
Hydraulic Cylinder Fully Extended Pump

The cylinder has fully extended.
If pressure reaches over 300 bar. The spring on the 300

bar spool will compress. Creating a passageway for oil
from the A port to pass through the spool and flow to
the piston side of the Piston Control Chamber.
300+ pressure
X
T
300
bar
310 bar
320 bar
320 bar
1.0 mm
330 bar
A
A1
X3
1.0 mm
39000211.eps
39000209.eps
Pressure has been equalized on both ends of the 20 bar

(Delta P) spool.
P
X3
C2
C1
C1
C2
Pressure on the piston side of the chamber is greater

than the rod side pressure, plus spring. The spring will
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
X
A
X
20
bar P
A1
300
bar
X3
X3
300
bar
A1
39000212.eps
P
X3
P
X3
39000210.eps
148
The rotary group angle will increase/decrease putting

out more/less oil to maintain 300 bar.
Training Manual
SERVICE TRAINING
KEY
High Pressure
330 bar
320 bar
Low Pressure
310 bar
Control Pressure
320 bar
1.0 mm
Reduced Pressure
Zero Pressure
1.0 mm

P regulator
A7 VO Pump
X
20
bar P
A1
300
bar
X3
A7 VO Pump
P regulator
A1
Q-MIN
Pressure
Regulator
300 bar
P
Regulator
20 bar
0 bar
ORIFICE
0.8 mm
KVM 36X . . . . 1.6 mm
0-15 Bar
KVM 36 LW . . 1.6 mm
KVM 42 . . . . . .1.6 mm
KVM 52 . . . . . .not used
Q-MAX
X3
HT003.ai
Training Manual
149
SERVICE TRAINING
Fixed Displacement Pump Training

All Function in Neutral
EB
1.0
B1
290 bar
320 bar
B2
330 bar
T
300 bar
A2
A1
1.0
EA
C1
C2
G1/2
C1
C2
PP
G1/2
15
bar
0.2
mm
300
bar
P
.061 mm
LS
KEY
High Pressure
Reduced Pressure
Pretension Pressure
High pressure filter
Low Pressure
Zero Pressure
2.0
atmospheres
150
Training Manual
SERVICE TRAINING
Boom Function Activated
EB
1.0
B1
290 bar
320 bar
B2
330 bar
T
300 bar
A2
A1
1.0
EA
C1
C2
G1/2
C1
C2
PP
G1/2
15
bar
0.2
mm
300
bar
P
.061 mm
LS
KEY
High Pressure
Reduced Pressure
Pretension Pressure
Low Pressure
Zero Pressure
2.0
atmospheres
Training Manual
151
SERVICE TRAINING
Cylinder Pressurized at the End of Stroke
EB
1.0
B1
290 bar
320 bar
B2
330 bar
T
300 bar
A2
A1
1.0
EA
C1
C2
G1/2
C1
C2
PP
G1/2
15
bar
0.2
mm
300
bar
P
.061 mm
LS
KEY
High Pressure
Reduced Pressure
Pretension Pressure
Low Pressure
Zero Pressure
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

horsepower controlled. That means that when pressure
rises past a certain point (known as the breakpoint), the
pumps change their displacement per revolution,
resulting in less flow and fewer strokes per minute. The
reason for this is so the pumps will not stall your
engine by drawing too much horsepower. Output charts
show the horsepower curve (in kilowatts, or Kw) of the
concrete pump hydraulic circuit. From them, you can
determine the:
maximum concrete pressure of the pumpkit model.
maximum output (in cubic yards per hour) of the
pumpkit model.
maximum output (in liters per minute, L/min) of

your hydraulic pumps.
expected output at various pumping pressures.
condition of your hydraulic pumps when used in

conjunction with a flowmeter.
breakpoint of your hydraulic system.
BPL 1200 HDR-23
Pumpkit model
PERFORMANCE CHARACTERISTICS OF
THE AXIAL PISTON HYDRAULIC PUMP
ROD SIDE
(bar)
PISTON SIDE
(bar)
An explanation of an output chart is shown on the

following pages, followed by some examples of chart
usage. The output chart of the pumpkit shipped with
this manual is shown later.
PUMP SPEED
2100 RPM
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI).
350
PISTON SIDE
Piston
side
breakpoint
200
ROD SIDE
131
1800
124
1700
117
1600
110
1500
103
83
1100
76
1000
70
900
62
800
The
breakpoint
specification
is
listed here.
52
48
41
200
500
34
150
400
28
300
21
200
14
100
100
50
breakpoint 0
178 bar
13
26
39
52
65
78
92
105 118 131 144

103
CONCRETE OUTPUT (cu yd / h)
157 170 183 196

170.5
26
5
50
PISTON
SIDE
10
100
150
5
100
15
200
10
200
300
20
250
300
15.5
15
20
400
500
25
350
400
25
OIL VOLUME
(liter / min.)
30 NUMBER OF STROKES
(stroke / min.)
OIL VOLUME
(liter / min.)
Material Cylinders
Bore dia. x Stroke length
Hydraulic Pumps
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
Training Manual
Concrete output is shown

here, with max
shown for both
piston and rod
side configurations.
(stroke / min.)
Differential Hydraulic Cylinder

Bore dia. / Rod dia. x Stroke length
output chart explain.eps
Concrete pressure is shown

here.
Max.
pressure
is
shown
for
both
piston
and rod side
configurations
55
600
250
ROD
SIDE
Hydraulic liters per

minute and the corresponding strokes
per minute for both
piston and rod side.
758
700
100
50
97
88.6 90
1200
Rod side
breakpoint
300
150
1900
1300 1285
250
350
CONCRETE
PRESSURE
(BAR)
138
1400
300
OIL PRESSURE (BAR)
Hydraulic oil pressure shown here,

ranging from zero to
the relief valve setting.
CONCRETE
PRESSURE
(PSI)
2000
Information
about
the
pumpkit and
hydraulic
pumps
is
shown here.
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
straight across the page until you intersect with the
horsepower curve (Item B). Next, draw a straight line
down from the intersection point until you pass through
the rod side number of strokes scale, and read the
strokes per minute. At 220 bar you should be getting a
little more than 21 strokes per minute. Your unit is fine.
Example 1Checking flow at a given pressure

Your unit is configured on the rod side (standard from
the factory). You notice that your machine is not getting
as many strokes per minute as you are used to seeing.
You count the strokes and see that you are getting
about 21 1/2 per minute. You check your pressure gauge
and see that the hydraulic oil pressure is at 220 bar. To
determine whether your unit is acting normally, locate
ROD SIDE
(bar)
PISTON SIDE
(bar)
output chart use.eps
PUMP SPEED
2100 RPM
350
PISTON SIDE
B. Draw a line STRAIGHT

across the page until you
contact the horsepower
curve of the rodside. Then
draw a line straight down
from the intersection point.
OIL PRESSURE (BAR)
300
A. Find 220 bar

on the rod side oil
pressure scale.
250
200
ROD SIDE
350
250
200
EXAMPLE 1
100
150
50
50
131
1800
124
1700
117
1600
110
1500
103
1400
97
1300 1285
88.6 90
1200
83
1100
76
1000
70
900
62
758
52
55
700
48
600
41
500
34
400
28
13
graph tells
you how 14
many
200
yards/hour you can expect
(in this100case, about 7138).
Where the line crosses the
number
26 39 52 65 78 92 105 118 131 144 157 170 183
196 of strokes scale tells
103
170.5 you how many strokes per
minute you can expect (in
this case, a little over 21).
26
ROD
SIDE
5
50
PISTON
SIDE
10
100
150
5
100
15
200
10
200
300
20
250
300
15.5
15
20
400
500
Example 2Checking your hydraulic pumps

To determine whether your pumps are still in good
working condition, use the output chart and a flow
meter. Test one pump at a time, multiply the readings
154
1900
21 the
300 the line leaves
C. Where
100
breakpoint 0
178 bar
CONCRETE
PRESSURE
(BAR)
138
800
300
150
CONCRETE
PRESSURE
(PSI)
2000
25
350
400
25
(stroke / min.)
OIL VOLUME
(liter / min.)
(stroke / min.)
OIL VOLUME
(liter / min.)
by 2, and chart the result. You multiply the readings

because the chart is based on the output of two pumps,
but we are only testing one at a time.
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. Dont 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.
1st Pump
breakpoint
specification
150 or
liters/min
(read on meter)
2nd Pump
Total
(for plotting)
liters/min
(read on meter)
Total
(for plotting)
0 bar
x2
x2
100 bar
x2
x2
breakpoint
x2
200 bar
x2
x2
250 bar
x2
x2
300 bar
x2
x2
breakpoint
x2
checking output form
As an example, well assume that we have just taken

the following readings.
Training Manual
155
SERVICE TRAINING
Plot the readings on the output chart. Take a clean

output chart and proceed as follows:
Lay a straight edge horizontally across the page at

the pressure point you are plotting. Draw a light
line across the chart. In the example below, we use
the rod side scales and curve (you could use the
piston side scale and curve instead). The ruler is
shown ready to draw a line at 250 bar hydraulic
pressure.
Turn the ruler sideways and draw a light line up

the page from the liters/minute reading you took
at that pressure. (Remember to multiply the
reading by 2.) In our example, we measured 276
liters at 250 bar.
Put a dot at the point where the two lines intersect.
Do the same thing with each pressure reading. You

should end up with six dots.
ROD SIDE
(bar)
PISTON SIDE
(bar)
1checking output.eps
PUMP SPEED
2100 RPM
350
PISTON SIDE
OIL PRESSURE (BAR)
CONCRETE
PRESSURE
(BAR)
138
1900
131
1800
124
1700
117
1600
110
1500
103
1400
97
1300 1285
300
250
200
CONCRETE
PRESSURE
(PSI)
2000
1200
83
1100
76
1000
70
900
62
ROD SIDE
350
800
300
150
250
1
200
10
100
150
50
50
13
26
39
52
65
78
92
105 118 131 144

103
5
50
PISTON
SIDE
100
150
5
100
156
10
15
200
10
200
300
20
250
300
15.5
15
20
400
500
Training Manual
52
55
48
600
41
11
500
34
400
28
300
21
200
14
100
157 170 183 196

170.5
26
ROD
SIDE
758
700
100
breakpoint 0
178 bar
88.6 90
25
350
400
25
(stroke / min.)
OIL VOLUME
(liter / min.)
(stroke / min.)
OIL VOLUME
(liter / min.)
SERVICE TRAINING
the upper right of the spec, you have done the test
incorrectly, or you are using the wrong chart. In
our example, the pump is okay. (See the plot
which follows.)
Connect the dots. If your plotted line reasonably

matches the specification plot on the chart, the
pump is fine. If your line is to the lower left of the
spec, the pump is getting weak. If your line is to
ROD SIDE
(bar)
CONCRETE
PRESSURE
(PSI)
2checking output.eps
300 bar
350
83
1100
76
1000
70
900
62
Breakpoint 800
300
OIL PRESSURE (BAR)
1200
250 bar
ROD SIDE
250
200
200 bar
150
100
50
breakpoint 0
178 bar
100 bar
OK
13
26
0 bar
39
52
65
78
92
105 118 131 144
CONCRETE
PRESSURE
(BAR)
758
52
55
700
48
600
41
500
34
400
28
300
21
200
14
100
157 170 183 196

170.5

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

below the specifications. This pump is very weak and
will completely stop pumping oil soon. You may notice
high heat with this unit, if you are pumping at high oil
pressures.
handy when you call to get a replacement. Also, please

advise us if you have changed differential cylinders,
material cylinders, or hydraulic pumps, because you
may need a different output chart than the one that was
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 America publication, NomographsA 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 concrete 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 figure out the TK of the job to do, but the suitability of the pump has to be determined in
a different manner. To make the pump numbers 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.
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-anderror 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
(180%).
The nomograph is divided into four quadrants
.
Upper left quadrant
Upper right quadrant
Figure 1
Quadrants
Lower left quadrant
Training Manual
Lower right quadrant
159
SERVICE TRAINING
To use the nomograph, you begin at output required

and move clockwise until you encounter the lines that
represent your job situation. Each time you meet the
line that applies, you make a 90 turn until you come to
a point on the bottom of the upper left quadrant that
shows pressure required (Figure 2).
The upper left quadrant is the beginning and end point

of the graph and shows maximum output, pressure, and
power for a specific machine. The upper right quadrant
accounts for the relationship between concrete output
and pipeline diameters. The lower right quadrant
accounts for the resistance to flow of the entire pipeline
system. The lower left quadrant accounts for the
pumpability of the concrete.
Pipeline diameter in inches
(72600)
200
For vertical placing,

add 1.105 PSI per foot
of level difference.
180
160
Q in yd3/hr.
boom-small-no blocks-eps
TK number does not apply to truck mounted units.

Curve shown is the Power Factor number (PF).
6"
5"
4.5"
140
4"
120 116
Rod side
100
80
Piston side
60
67
40
132 KW
20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800
1566
870
P in PSI
600
400
200
100
200
2"
300
400
2.5"
500
600
3"
4"
5"
6"
Slump of fresh concrete in inches
Pumpkit Model: 120/80 x 1600:200

Power: 132 KW
3000 2500 2000 1800 1500
1200
1000
800
Proportional value of pipeline in feet
Figure 2
Moving around a nomograph
To illustrate the use of a nomograph, we will use a
hypothetical job situation with the following
specifications.
1. We will need an average output of 75 cubic yards
per hour, but we will be pumping only 75% of the
time. The rest of the time will be spent moving
hose, removing pipe lengths, waiting for concrete
trucks, and taking care of miscellaneous jobs. This
means that when we are actually pumping, we will
need an output rate of 75 .75 = 100 yd3/hr.
2. We will use 5-in.-diameter pipeline.
3. We will need the following pipeline lengths:
Separately laid pipeline.
40 ft of 5-in. rubber hose
150 ft of 5-in. horizontal steel pipe
160
Boom pipe, elbows, and deck system.
13 ft of 5-in. rubber hose
144 ft of 5-in. steel pipe (on the boom and pump

deck)
5.25 ft of 6to5-in. reducer (on the pump)
4 5-in. 45 elbows, radius 250 mm

4. We will specify a slump of 5-6 in. and use the 5-in.
line on the chart.
5. In addition, when we add the pressure for the vertical run, we will have to add 1.1 times 70 ft = 77
PSI.
All of these criteria will be explained in detail as we go
through the individual quadrants.
Training Manual
SERVICE TRAINING
The quadrants

Kw rating
180
160
Example Job
Working power (in kW)
Power curve
200
Power factor
number
(replaces TK)
Q in. yd3/hr.
upper left quad-eps
Power factor number (PF)

English to Metric Conversion Factor is PF 18.966
56,650
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 particular model of concrete pump (Figure 3).
140
120
100
Maximum output and
80maximum pressure
of a specific unit
60
40
20
103 KW
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 exchangedthat 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 pressure 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 completing 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 optimum 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 placement. Very few hose handlers, if any, can move
6-inch hose on a slab all day. There is no provision 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.
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 quadrantPipeline 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 proportional 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).
150 ft. pipe
40 ft.
hose
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
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).
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

Make a 90 turn when

proportional value that
applies to your job.

Figure 6
Lower right quadrant - proportional value of pipeline
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).
8. The lower left quadrant refers to the pumpability

of the concrete. If the concrete specifications allow
a range in slump (for example 56 in.), always use
the lower end to be safe. In our example, we use 5inch slump. You extend the line from the lower

Figure 7
Lower left quadrant
pumpability of the
concrete

Make a 90 turn when

slump that applies to
your job.

164

Training Manual

!
SERVICE TRAINING
NOTE!
When calculating the head pressure from
vertical runs, it doesnt matter if the pipeline runs straight up and down, or if it runs
uphill at an angle. Only the level difference
in feet is needed for the pressure calculation.
If the pipeline is running downhill, the operator will need special knowledge, but you
dont need to add any head pressure to the
nomograph.
upper left quad-eps
We need a unit that is capable of 627 PSI, and 100 yd3/

hr. The PF of this job is:
PF = (627 x 100)
PF = 62,700
The unit must have a PF over 62,700 and it must be
able to pump 100 yd3/hr and 627 PSI simultaneously.
Look at the pump shown in our sample nomograph
(Figure 8).
Can the unit pump at 627 PSI? Yes
Can the unit pump 100 yd3/hr? Yes
Can the unit pump both simultaneously? No! This

unit will not do the job.
Power factor number (PF)

English to Metric Conversion Factor is PF 18.966

180
160
Example Job
200
Q in. yd3/hr.
550 PSI + 77 PSI = 627 PSI
The nomograph is now complete. The PF of our job

can be calculated like this:
PF = PSI x yd3/hr
56,650
As you can see by the chart in Figure 7, we are

reentering the upper left quadrant through the pressure
scale at about 550 PSI. Remember, we now have to add
the head pressure for our vertical rise. At 1.1 PSI per
foot of level difference, and our 70-foot vertical run,
we must now add 1.1 x 70 = 77 PSI to the 550 PSI
from the chart.
140
120
100
80
60
40
20
103 KW
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
yards3/hr and 627 PSI has been plotted for visual
representation, but you will see immediately that the
PF of the job (62,700) is bigger than the PF of the unit
(56,650). The curved black line represents the PF of the
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
pumps set to a higher Kw? The PF of the higher Kw

unit is 72,600. This should work. Plotting the
intersection of our hypothetical job again, you will see
that it falls within the power zone of the hydraulic
pumps (Figure 9)
Training Manual
165
SERVICE TRAINING
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.
Power Factor number (PF)

English to Metric Conversion factor is PF
18.966
200

180
160
140
120
100
Example Job
80
60
40
20
132 kW
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800
P (in PSI)
600
400
Figure 9
Same model pump with larger Kw hydraulic pumps
166
Training Manual
200
up1ft 132Kw Quad 2000R.eps
Q (in yd3/hr)
72,600
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:
SERVICE TRAINING
Minimum Pipe Wall Thickness
Training Manual
167
SERVICE TRAINING
Preventative Maintenance
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.
This is only a generic sample of a maintenance chart.

Please refer to your O/M manual for your specific
units break-in period.
As Indicated
Annually
Semi-annually
Quarterly
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
168
Monthly
Task
Weekly
Daily
Scheduled Maintenance
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
Training Manual
SERVICE TRAINING
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 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
As Indicated
Annually
Change hydraulic oil for temp. reasons

Check the accumulator pre-charge
Semi-annually
Quarterly
Monthly
Task
Weekly
Daily
Scheduled Maintenance (Continued)
= Breakin period
Training Manual
169
SERVICE TRAINING
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 25 = 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 12 = 200. A courser filter
example would be 25 = 75. Concrete pumps
require medium to fine filtration.
because A) the components dont 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.
Dont 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 P 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 P. When the P
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.
Specific information
Changing hydraulic oil filters
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 12) absolute.
The beta ratio is 12 = 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
Your concrete pump is equipped with a P sensing

switch in the filter housing that turns on a light on the
operators 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 P. When the oil
reaches operating temperature, the light should go off.
If it doesnt, 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
170
Training Manual
SERVICE TRAINING
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 P switch, so you should change it whenever
the return filter light comes on. The rating on the
filter is 25 = 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.
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.
Training Manual
171
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.
172
Training Manual
SERVICE TRAINING
Electrical
Introduction
This guide will help you learn how to service current
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
Ohms law, identify series, parallel and series-parallel
circuits, and troubleshoot circuits using various testers.
Its a fairly complete journey from concepts to
applications.
Electrons (13)
-
What is Electricity?
Nucleus
(w/13 Protons)
Figure 1. Aluminum atom (Neutral state)
One Electron Is
Forced From
The Atom Leaving
Only 12
-
Electricity is the flow or displacement of electrons.

Normally, the atoms in a substance are balanced in an
electrically neutral state. Theyre made up of equal
numbers of positively-charged protons and negativelycharged electrons.
However, it is possible to strip electrons from atoms.
This creates areas of positive and negative charge in a
substance: positive charge where there are atoms
without the normal number of electrons, and negative
charge where there are excess electrons. As you might
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
Training Manual
173
SERVICE TRAINING
Static electricity is electricity that does not move. Its

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.
Figure 3. Opposite charges attract
The attractive and repulsive forces created by static

electricity work like magnets. This principle is used in
copy machines, CRTs 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 components circuitry can
destroy it.
Figure 4. Like charges repel
Figure 5. Typical static discharge
174
Training Manual
SERVICE TRAINING
Dynamic electricity is moving electricity thats

created when electrons flow from atom to atom through
a substance. Its the type that flows through power lines
to homes or that lights the headlights on a truck.
Electrons (13)
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
an electron from its neighbor and so on down the line.
Figure 6. Electron Flow=Current Flow
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
reverses direction
AC and DC. Two types of electric currents exist; AC,

for Alternating Current, and DC, for Direct Current.
In DC currents, the electrons flow in one direction only.
So, in all the diagrams youll 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
Training Manual
175
SERVICE TRAINING
Amperage
Seconds
0
3
Amperage describes the rate of current flow. It is

measured in amps, using an ammeter. The higher the
amperage, the greater the number of electrons flowing
past a single point in one second.
1
2
6.28 Billion
Billion Electrons
Per Second
1 Amp
Figure 9. Amperage is the rate of current flow

Low Current Flow
Low Heat
High Current Flow

High Heat
Figure 10. Relationship of current flow and

heat
CURRENT CAPACITY INCREASES
WIRE RESISTENCE DECREASES
Figure 11. Relationship of current capacity

and resistance to wire thickness
176
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
second. Similarly, one amp is equal to 6.28 billion
electrons passing a single point in one second.
Current flow and heat are related. As amperage

increases, more electrons flow and more heat is
generated. Any electrical component that carries
current, generates heat. For this reason, the wires in a
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
(AWG) and metric. In the AWG system, as the wires
get thicker, the number designation decreases. For
example, a 20 AWG wire is very thin, while a 4 AWG
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
thin, and a 19 metric gauge wire is much thicker.
Because insulation sizes vary, never try to judge the

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.
Training Manual
SERVICE TRAINING
Electron Flow
Wire Conductor
Figure 12. Voltage is the push, or pressure, on electrons
Voltage
Allows Less
Flow (Amps)
Voltage is the force that moves electrons through a

circuit. Its also known as electromotive force, or
EMF. Technically, it is the potential difference in
electron pressure between any two points. Voltage is
measured in volts, using a voltmeter.
Allows More
Flow (Amps)
The higher the voltage, the more force is available to

cause electrons to flow. The lower the voltage, the less
available force.
1000
10
Figure 13. A resistence is a restriction
Allows Less
Flow (Amps)
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
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)
0
Figure 14. The two extremes of resistence
Resistance descries how much a component or circuit

resists, or restricts, current flow. Think of it as a kind of
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
ohmmeter.
Training Manual
177
SERVICE TRAINING
Copper Wire
POWER
1000
500
200
200
BATT
9V
20
200u
2000
m
Conductors. Some materials have very low resistance

to current flow because they have many electrons,
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
steel of the trucks engine and chassis are typical
conductors in a Schwing electrical circuit.
20m
200m
200m
200
2000k
200k
20k
2000
Besides the thickness of a wire, several other factors

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
partially cut wire operates in a circuit as if its entire
length were of the reduced diameter at the point of the
cut.
200 mA FUSED
500V max
500V
COM
V mA
Figure 15. Copper conductor
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.
Long Wire Offers

More Resistence
Figure 16. Resistence of short vs. long wires
RESISTANCE
Why does temperature affect a conductor? At lower

temperatures, the atoms in a conductor remain rigidly
aligned and dont move around much. Resistance and
heat are low because electrons flow relatively smoothly
from atom to atom.
.05
.04
70F
170F
TEMPERATURE
Figure 17. Resistence to temperature
relationship in 10ft. long wire
178
Heating a conductor increases its resistance: The

higher the temperature, the greater the resistance. In
addition, conductors themselves generate heat as
current flows through them. This heat also causes the
resistance of a conductor to increase as it is warms up
and decrease as it cools down. As long as a conductor
is properly sized, the amount of resistance it offers in a
circuit is so low that it can usually be disregarded, and
the amount of heat it generates wont damage the
circuit.
At higher temperatures, however, the atoms in a

conductor are less well aligned and move around a lot
more. Many electrons collide with electrically
balanced atoms before reaching positively charged
atoms. The increased frequency of these collisions
increase resistance and generates excess heat.
Training Manual
SERVICE TRAINING
Insulation
POWER
1000
500
200
200
BATT
9V
20
200u
2000
m
Insulators. Materials with a very high resistance to

current flow are called insulators. Insulators have no
free electrons that can conduct a current. Theyre 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
with another conductor. Glass, rubber, and ceramic are
other examples of typical insulators.
20m
200m
200m
200
2000k
200k
20k
2000
200 mA FUSED
500V max
500V
COM
Figure 18. Wire insulation
Circuit Breaker
V mA
Basic Circuits
A typical Schwing concrete pump circuit is made of a
voltage source, a circuit protection device, a load, a
control and a ground.
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 circuits 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.
Training Manual
179
SERVICE TRAINING
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
faulty in some way. Typical faults include cut wires and
loose or corroded connections. If the voltage drop
across a wire or connection is sever enough, the circuit
will not operate, or will operate improperly the light
dim, cranking slows, or the battery discharges
frequently.
POWER
1000
500
200
200
BATT
9V
20
200u
2000
m
20m
200m
200m
200
2000k
200k
20k
2000
200 mA FUSED
500V max
500V
COM
V mA
Figure 20. Measuring voltage drop
Potentiometer
POWER
+12V
1000
-0V
500
200
200
BATT
9V
20
200u
2000
m
20m
200m
200m
200
2000k
200k
20k
2000
200 mA FUSED
500V max
500V
COM
Figure 21. Rheostat
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
current flow and creating a closed circuit.
V mA
Other types of controls vary the function of a load by

increasing or decreasing current flow. Variable
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.
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.
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Training Manual
SERVICE TRAINING
Schematics
Circuit Types
Electrical diagrams, also called schematics represent

the different components of a circuit using various
symbols. Most of the symbols shown on page 138-140
are standard; be sure to familiarize yourself with them.
However, be aware that some components may be
represented differently on other schematics. If a
symbol is unfamiliar, refer to the legend for the
schematic.
When two or more loads are use in a circuit, they can

be connected to form any one of three different types of
circuits: series, parallel, and series-parallel.
Schwing America produces a variety of Electrical

System Manuals for different electrical control
systems. The schematics they contain are great
troubleshooting aids that allow you to examine a circuit
on paper and figure how it should work. You can locate
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.
Series. A series circuit exists when the loads are

connected end-to-end in one continuous path. In this
type of circuit, one of the loads is disconnected or
develops an open, all of them stop functioning.
Parallel. A parallel circuit exists when the loads are

connected side-by-side so that there are a number of
paths for current flow. In this arrangement, if one load
is disconnected or open, the others continue to
function.
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 deenergized position, youll 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
Normally closed
N.C. =ON
Normally open
USED
A.N.S.I.
SYMBOLS
AS SHOWN
SCHWING SCHEMATICS
: N.O. =
KEY
PUSHBUTTO
N
(EMERGENCY STOP)
Relays
SWITCHES
KEY: N.O. = Normally open
Solid line = position of
LINE
operational
Position ofCONNECTOR
functions (detented "ON",
shown)
spring returned "OFF"
Method of
operation:
(double throw
switch shown)
Control
s)
MAGNET
COIL
(DIN drawing
DIN
ANSI
shown)
FOR HYDRAULIC VALVE
Contacts
(Bosch brand
(higher current rating)
1 N.O. and
1N.C. contact
PUSHBUTTON
shown
as
ON O OFF
In this example,
contact is made
between terminals
1 and 2 in the
"ON" position
OFF
BATTERY
shown
Pivot point of the switch
line indicates
below the activation
would be
that the contact lever
#2 in the
drawn towards contact
FUNCTION WHEN
ACTIVATED "ON"
"ON" position
CHASSIS GROUND
"OFF" position activated,
indicated by solid line
d during
Spring is compresse
that it will
activation, indicating
return to "O" when released
as
ON O OFF
In this example,
contact is made
STARTER between terminals
OR
B+
86
DIN
DIN
TACHOMETER SENDING UNIT

(PROXIMITY SWITCH,
DIN - ANALOG CONVERTER)
ANSI
DIGITAL
87a 87
(L.E.D.)
N.C. contacts
50a N.O. contact
wire
N.C. contact
are underlined
OVER-CURR
ENT SWITCH
30
numbers
SHIELDED
CABLE
(Always normally closed)
N.C.
CR 3
14 (Show all conductors
1
9
5
inside shield)
8
STARTER
DIN
OL
CR 3
FLOAT
SWITCH
1
1
9
Level)
common
hot
15
CR 2
2
16
ANSI
MISC. DEVICES
ANSI
RESISTOR
(VALUE INDICATED IN OHMS)
(K = 1000)
POTENTIOMETER
(Value indicated)
OR
T
2.5 K
POT
1K
1K
DIN
CURRENT FLOWS
IN THIS DIRECTION
Primary
120V
60 HZ
ANSI
120V
60 HZ
TRANSFORMER
Secondary
12V
12V
DIN
ANSI
BRIDGE RECTIFIER
(A.C. to D.C. converter)
ANSI
FS
TERMINAL CONNECTORS
31
9 (Oil
shown ELECTRIC MOTOR

Pivot point of the switch
line indicates
below the activation
would be
FUNCTION WHEN
that the contact lever
#3 in the
ACTIVATED "OFF"
pushed towards contact
"OFF" position
plug
TGS.
which relay
these numbers denote
coil will operate the contact
DIN
receptacle
D.P.D.T.
ALTERNATOR
OL
ANSI
TGS.
on one part
If the relay coil is drawn
contacts
K3
MECHANICA
andLthe
SWITCH
schematic,
of the31
D30
part, the relay
(V-BELT
on another
SWITCH)
are drawn
NONE
K3) will be listed
number (in this example,
as shown here. OIL TEMPERATURE AVAILABLE
in both places
+
TRANSMITTER
DIN
ANSI
(both DIN)
these numbers
Control Relays
) show the location
TAS
(ANSI "ladder" drawing
(line number)
contacts
of the
N.O.
Relay coil
Relay terminal
C that the relay coil
DIODE
numbers
TEMPERATU
will operateBLOCKED
RE SWITCH
CURRENT
TAS
IN THIS DIRECTION
line numbers
N.C.
OR
CR 2
C 2
CR 1
3
8, 9
13
9LIGHT EMITTING DIODE
1
5
1
DIN
9
CR
7
ANSI
OFF
20A
20A
MOTOR OVERLOAD
RELAY
S.P.S.T.
0 1 2
D+
lens color)
ANSI
0,1,2
1 and 3 in the
"OFF" position
ON
DIN
ANSI
PLUG AND RECEPTACLE
OR
85
PS.
PS.
FUSE
87 RATING INDICATED)
87a(AMP
K3
ON
ANSI
K3
TOGGLE SWITCH
G
30
85
ALTERNATOR
switch
In the "ON" position,
detent
is held in place by the
line)
(indicated by the vertical
ANSI
CB / DISC
CIRCUIT BREAKER /
DISCONNECT
SWITCH (Letter
R
indicates
N.O.
Component N.C.
enclosure
DIN
86
AS DRAWN
("O" POSITION)
"ON" position activated,

DIN
OR
Contacts (2 N.O.
contacts shown).
Dashed lines =
available positions
of switch
DIN
PRESSURE SWITCH
LINES,3 PASSING
DIN
DISC.
If the contact operator is shown

extending beyond the last contact,
it indicates that this operator will
also
work a contact shown elsewhere
on
the schematic.
ANSI
N.C.
LAMP
85WITH BULB
30
ON OFF
86
87
87a
Terminals
(Numbers shown if
they are presesnt
on the switch)
Relay coil
(very small current
N.O.
draw)
MOMENTARY CONTACT
HORN
LINES, JOINING
ON O OFF
Component
enclosure
DISCONNECT
SWITCH
N.C. = Normally closed
switch as drawn
21
21
22
DIN
22
ANSI
N.O.
CAPACITOR
FS
Q
DIN
common
N.C.
neutral
(VALUE INDICATED
POSITIVE
NEGATIVE
TERMINALS
TERMINALS
FARADS)
IN
( = micro or 1 millionth)
ANSI
Figure 22. Typical electrical symbols
2 F
DIN
2 F
ANSI
Figure 24. Typical parallel circuit
Training Manual
181
SERVICE TRAINING
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.
Figure 25. Typical series - Parallel circuit

12V
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,
two 12 volt/85 amp batteries in series yield 24 volts/85
amps of output.
+
POWER
12V
1000
500
BATT
200
200
9V
20
200u
2000
m
20m
200m
200m
200
2000k
200k
2000
20k
200 mA FUSED
500V max
500V
COM
V mA
Figure 26. Batteries in parallel
12V
POWER
1000
500
200
200
BATT
9V
20
12V
200u
2000
m
20m
200m
200m
200
2000k
200k
20k
2000
200 mA FUSED
500V max
500V
COM
V mA
Figure 27. Batteries in series
182
Training Manual
SERVICE TRAINING
I=
Ohms Law
E
R
Amperage, voltage, and resistance are related in a

circuit. Ohms 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. I is the current in amps, E is the voltage, and R is the
resistance in ohms.
R= E
I
Figure 28. The different forms of Ohms Law
E
I R
You should memorize the different forms of Ohms law

because youll need them when troubleshooting
circuits.
Figure 29. Memory aid for Ohms Law
Heres a quick way to remember Ohms 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 Ohms law to solve for

amperage, voltage, resistance and voltage drop follow:
12 ohm load
Figure 30. Typical amperage calculation
12V = 4A x 3
To solve for voltage, the equation can be rearranged

like this: E=I x R. And to solve for resistance, the
equation is R equals E/I.
Amperage. Whats the current flow in a closed circuit

having a 12 ohm load connected to a 12 volt battery?
The answer is 1 amp. (12volts/12ohms=1 amp)
Voltage. Now, whats the voltage in a circuit with 4

amps of current flowing through a 3 ohm load? Its 12
volts. (4 amps x 3 ohms = 12 volts.)
Figure 31. Typical voltage calculation
Training Manual
183
SERVICE TRAINING
Resistance. Whats the resistance in a circuit with a 12

volt battery and 12 amps of current flow? Its 1 ohm.
(12 volts/12amps = 1 ohm.)
= 12V
12A
Figure 32. Typical resistance calculation
Voltage Drop. Now, what should be the voltage drop

across the 12 ohm load in that first circuit? (Figure 32)
Its 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, youd know the circuit had
a poor connection or damaged conductor that was
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
doesnt operate and cant use up any voltage.
12V=1 Amp x 12
12 ohm load
POWER
500
1000
BATT
200
200
9V
20
200u
2000
m
20m
200m
200m
200
2000k
200k
20k
2000
200 mA FUSED
500V max
500V
COM
V mA
Figure 33. Typical voltage drop calculation
0V=0 Amp x 12
12 ohm load
POWER
1000
500
200
200
BATT
9V
20
200u
2000
m
20m
200m
200m
200
2000k
200k
20k
2000
200 mA FUSED
500V max
500V
COM
V mA
Figure 34. Voltage drop in open circuit
184
Training Manual
SERVICE TRAINING
Series Circuit Laws
When there is more than one load in a circuit,

determining the values to plug into Ohms law requires
a little more effort. Thats because series and parallel
circuits obey different rules. For series circuits, those
rules are:
Figure 35. Series circuit
4
+4
4
12
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

the circuit.
Third, the sum of the individual voltage drops

across the loads equals the source voltage.
Total Resistance. For example, whats the total

resistance in a circuit with a 12 volt battery connected
to three 4 ohm loads wire in series? Its 12 ohms; you
just add up the resistance.
(4 ohms + 4 ohms + 4 ohms = 12 ohms.)
POWER
1000
500
200
200
BATT
9V
20
200u
2000
m
Amperage. Whats the amperage in this circuit. Since

its the same throughout the circuit, you can use Ohms
law:
20m
200m
200m
200
2000k
200k
20k
2000
200 mA FUSED
500V max
500V
COM
V mA
Figure 36. Total resistence in series circuit
12 volts/12 ohms = 1 amp.
1Amp= 12V
12
Figure 37. Amperage in series circuit
Training Manual
185
SERVICE TRAINING
Voltage Drop. Now, whats the voltage drop across one

of the loads. To figure that, you use Ohms law and
plug in the total circuit current and the resistance of one
load. 1 amp x 4 ohms = 4 volts.
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 Ohms law, you get
the same current value: 4 volts/4 ohms = 1 amp of
current flow.
4V=1 Amp x 4
POWER
500
1000
200
200
BATT
9V
20
200u
2000
m
20m
The third rule also proves out. Each 4 ohm load causes
a 4 volt drop, and 4 volts + 4 volts + 4 volts = 12 volts
the source voltage.
200m
200m
200
2000k
200k
2000
20k
200 mA FUSED
500V max
500V
COM
V mA
Figure 38. Voltage drop of one load in series

circuit
Parallel Circuit Laws

The rules that parallel circuits follow are:
12 Volts
POWER
1000
500
200
200
BATT
First, the voltage drop across each branch of the

circuit is the same as the source voltage.
Second, the total amperage in a parallel circuit is

equal to the total of the individual branch
amperages. This means you can treat each
individual branch of the circuit as a series circuit,
and add up their individual amperages to find the
total flowing through the parallel circuit.
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.
9V
20
200u
2000
m
20m
200m
200m
200
2000k
200k
20k
2000
200 mA FUSED
500V max
500V
COM
V mA
Figure 39. Sum of voltage drops equals

source voltage
RT =
1
1 + 1 + 1
R1 R2 R3 etc.
Now, lets apply these rules:
Figure 40. Parallel circuit
186
Training Manual
SERVICE TRAINING
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 thats 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
1000
500
200
200
BATT
9V
20
200u
2000
m
20m
200m
200m
200
2000k
200k
2000
20k
200 mA FUSED
500V max
Figure 41. Measuring total amperage in a

parallel circuit
Total
Resistance
1
= 1
1 + 1 + 1
3
12 12 12
12
Add Fractions
Find a Common
Denominator, If
Necessary
1 = 1x 4 = 4
1
1
4
Simplify
Fraction
Invert
Fraction and
Multiply
Figure 42. Calculating total resistance in a

parallel circuit
Total Resistance. To find the total resistance of this

circuit, you plug numbers into the total resistance
equation. See Figure 42 for an illustration of how to
solve the equation for this example. The total resistance
in this circuit is 4 ohms. This number also agrees with
the 3 amps of total current: Using Ohms law, 12 volts/
4 ohms = 3 amps.
An important difference between parallel and series

circuits is that as you add more branches to a parallel
circuit, its total resistance decreases instead of
increases. And this, of course, increases the current in
the circuit. For instance, add another 12 ohm load in
parallel with the previous circuit, and the total
resistance goes down to 3 ohms, while the amperage
increases to 4 amps.
+
-
POWER
1000
500
200
200
BATT
9V
20
POWER
1000
500
200
200
BATT
200u
2000
m
20m
9V
20
200u
2000
m
20m
200m
200m
200
2000k
200k
200m
200m
200k
20k
20k
200 mA FUSED
500V max
500V
200
2000k
2000
2000
COM
V mA
200 mA FUSED
500V max
500V
Figure 43. Measuring total resistance in a

parallel circuit
Figure 44. Total total resistance in a parallel

circuit
Training Manual
187
SERVICE TRAINING
Series Parallel Circuits

12 V
-
That brings us to series-parallel circuits. When youre

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, youll find the
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.
Figure 45. Series - Parallel circuit
1
= 1
1 + 1
2
12 12
12
1 = 1x 6 =
1
1
6
Figure 46. Equivalent resistance for parallel

part of previous series - parallel
circuit
12 V
-
Figure 47. Previous series - parallel circuit

simplified
188
Training Manual
SERVICE TRAINING
Circuit Faults
Opens. An open puts unwanted infinite resistance into

the circuit. Because theres a break, however, no
current flows, the components in the circuit do not
operate and no heat is generated. As a result, an
ammeter will not give a reading, but a voltmeter,
depending on where it is placed, may or may not show
a voltage reading.
POWER
1000
500
200
200
BATT
9V
20
200u
2000
m
20m
200m
200m
200
2000k
200k
2000
20k
Electrical circuits fail when they are open or shorted.

An open circuit occurs when theres an unwanted break
in the circuit resulting in no current flow. The break
may be in the wiring or a component.
200 mA FUSED
500V max
500V
Figure 48. Voltage reading before opne
These unwanted resistances allow current to flow, but

at a reduced amount. This causes components either to
stop operating or to operate at a reduced level. The
starter motor turns too slowly or the lights dim, for
instance.
POWER
1000
500
200
200
BATT
9V
20
200u
2000
m
20m
200m
200m
200
2000k
200k
20k
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.
2000
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
Training Manual
189
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
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 cant be
controlled by its switch. These are called shorts to
voltage.
Figure 51. Short to ground
Using Test Equipment
To diagnose circuit faults, youll 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 dont
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
tools, but can cause other problems if not used
correctly.
Jumper Wire
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)
meters can give misleading readings. Use only a high
impedance (10 mega-ohms or more) digital mulitmeter
for testing circuits containing solid-state components.
Unpowered
Test Light
Self - Powered
Test Light
Figure 53. Other useful troubleshooting tools
190
Jumper Wire. A jumper wire is simply a length of

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
exists in the part of the circuit youve bypassed.
Training Manual
SERVICE TRAINING
Fused jumper wires are recommended to protect the

circuit youre testing. A 5 amp fuse in the wire will
adequately protect most circuits. Of course, you can
use a larger fuse if the circuit youre 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.
Figure 54. Jumper wire bypassing an opening
Test Light "On"
CAUTION
Unpowered Test Light. An unpowered
testlight is simply a bulb with leads attached
to the bulbs terminals. A 12 volt light is
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 current 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 voltage is present. To find out how much, you
must use a voltmeter.
Figure 55. Voltage check with a unpowered

test light
Test Light "Off"
You can test continuity of parts of a circuit

by connecting the light into the circuit. Continuity, 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
Training Manual
191
SERVICE TRAINING
Test Light
"On"
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.
Short to Ground
Figure 57. Checking for a short to ground with
an unpowered test light
Test Light "On"
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
the bulb lights with the circuit on, you know theres a
short to ground in the circuit.
If touch the probes to different ends of a conductor

(wire, switch, connector, etc.) and the bulb lights, you
know theres continuity through the conductor. If the
bulb is dim or does not light, there is an added
resistance or an open exists in the conductor. To find
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.
Test Light "On"
Figure 58. Test light indicating continuity
Test Light "Off"
+
+
Figure 59. Test light indicating an opening
192
Figure 60. Checking for a short to ground with

a self-powered test light
Training Manual
SERVICE TRAINING
POWER
1000
500
BATT
200
200
9V
20
200u
2000
m
20m
200m
200m
200
2000k
Red Lead
200k
20k
2000
200 mA FUSED
500V max
500V
Black Lead
COM
V mA
Figure 61. Proper Fluke multimeter lead

connections for measuring
amperage
POWER
1000
500
200
200
BATT
9V
20
200u
2000
m
20m
200m
200m
the meter on its proper care and use. In particular, note

how the test leads should be connected to the
instrument for different tests. And make sure the meter
will not be damaged when used to measure amperage
in the ranges you expect.
Always observe the proper polarity when connecting

the meter leads. Properly connect the leads to the
meter. Then, always connect the negative battery
terminal and the positive, or red, lead to the conductor
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.
Units of Measurement. One of the things youll 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
stand for 20,000 and 200, stands for.200 (200
thousandths).
200
2000k
200k
20k
2000
200 mA FUSED
500V max
500V
COM
V mA
Figure 62. Observing proper polarity when

making a connections
To change a given measurement from one unit to

another, find both units on this chart. Then move
the decimal point the (total) number of places
indicated, in the direction that matches the
direction of your desired change.
Digital Multimeters are preferred over other types of

meters because they are more accurate and will not
damage most electronic circuits.
MEGA (M)
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
KILO (K)
BASE UNITS
VOLTS
OHMS
AMPS
3
MILLI (m)
MICRO (u)
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
clamp. However, the reading on the meter still
indicated amperage.
Figure 64. Measuring amperage
Voltage. When measuring voltage or voltage drop,

always connect the meter in parallel so that its 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.
Conductors should have almost no voltage drop. A

drop greater than 0.1 volt in a low-current conductor, or
0.3 volts in a high-current conductor (such as a battery
cable) indicates a damaged conductor or a poor
connection.
POWER
1000
500
200
200
BATT
9V
20
200u
2000
m
20m
200m
200m
200
2000k
200k
20k
2000
200 mA FUSED
500V max
500V
COM
V mA
Figure 65. Measuring resisitance of a load

Youll 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, youre 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
194
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.
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 dont 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 cant
find it, dont 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,
its 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, youll solve the problem. If necessary, record your
test results so you can analyze them more carefully.
Training Manual
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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
LAMP WITH BULB
(Letter
indicates
lens color)
R
DIN
ANSI
LINES, PASSING
20A
20A
FUSE
(AMP RATING INDICATED)
DIN
ANSI
G
receptacle
ALTERNATOR
PLUG AND RECEPTACLE
OR
plug
B+
DIN
ANSI
D+
ALTERNATOR
31
TACHOMETER SENDING UNIT

(PROXIMITY SWITCH,
DIGITAL - ANALOG CONVERTER)
DOIL TEMPERATURE
TRANSMITTER
(both DIN)
+
BATTERY
OR
CURRENT FLOWS
IN THIS DIRECTION
DIODE
CURRENT BLOCKED
IN THIS DIRECTION
OR
CHASSIS GROUND
LIGHT EMITTING DIODE

(L.E.D.)
50a
30
STARTER
STARTER
31
ELECTRIC MOTOR
196
SHIELDED CABLE
(Show all conductors
inside shield)
TERMINAL CONNECTORS
21
21
POSITIVE
TERMINALS
Training Manual
22
22
NEGATIVE
TERMINALS
SERVICE TRAINING
Electrical Symbols
SWITCHES
RELAYS
KEY: N.O. = Normally open N.C. = Normally closed
KEY: N.O. = Normally open N.C. = Normally closed

Control Relays
(DIN drawings)
(Bosch brand shown)
Solid line = position of switch as drawn

Position of operational
functions (detented "ON",
spring returned "OFF" shown)
Method of
operation:
(double throw
switch shown)
ON O OFF
Contacts
(higher current rating)
1 N.O. and
1N.C. contact
shown
Terminals
(Numbers shown if
they are presesnt
on the switch)
Relay coil
(very small current
draw)
87a
86
87
85
30
ON OFF
OR
Component
enclosure
Component
enclosure
Contacts (2 N.O.
contacts shown).
Dashed lines =
available positions
of switch
86
AS DRAWN
("O" POSITION)
87a 87
K3
85
In the "ON" position, switch
is held in place by the detent
(indicated by the vertical line)
"ON" position activated, as

OR
86
K3
ON O OFF
ON
30
85
In this example,
contact is made
between terminals
1 and 2 in the
"ON" position
OFF
Pivot point of the switch shown

below the activation line indicates
that the contact lever would be
drawn towards contact #2 in the
"ON" position
87a 87
If the relay coil is drawn on one part

of the schematic, and the contacts
are drawn on another part, the relay
number (in this example, K3) will be listed
in both places as shown here.
K3
Control Relays
(ANSI "ladder" drawing)
FUNCTION WHEN
ACTIVATED "ON"
Relay terminal
numbers
Relay coil
line numbers
Spring is compressed during
activation, indicating that it will
return to "O" when released
"OFF" position activated, as

ON O OFF
ON
Pivot point of the switch shown

below the activation line indicates
that the contact lever would be
pushed towards contact #3 in the
"OFF" position
13
N.C. contact
1
In this example,
contact is made
between terminals
1 and 3 in the
"OFF" position
3
CR
N.O. contact
CR 3
these numbers
show the location
(line number)
of the contacts
that the relay coil
will operate
8, 9
N.C. contacts
are underlined
wire
numbers
14
these numbers denote which relay

coil will operate the contact
OFF
CR 2
CR 1
7
30
3
9
FUNCTION WHEN
ACTIVATED "OFF"
common
hot
Training Manual
CR 3
9
15
CR 2
2
16
common
neutral
197
SERVICE TRAINING
Electrical Symbols
SWITCHES: Methods of operation
PUSHBUTTON
(EMERGENCY STOP)
DIN
If the contact operator is shown

extending beyond the last contact,
it indicates that this operator will also
work a contact shown elsewhere on
the schematic.
ANSI
DISC.
DISCONNECT
SWITCH
DIN
ANSI
N.O.
PUSHBUTTON
MOMENTARY CONTACT
CB / DISC
Q
N.C.
DIN
CIRCUIT BREAKER /
DISCONNECT
SWITCH
ANSI
PS.
N.O.
PRESSURE SWITCH
PS.
N.C.
DIN
MOTOR OVERLOAD
RELAY
ANSI
TOGGLE SWITCH
TGS.
OL
DIN
S.P.S.T.
ANSI
MISC. DEVICES
TGS.
0 1 2
RESISTOR
(VALUE INDICATED IN OHMS)
(K = 1000)
D.P.D.T.
0,1,2
DIN
2.5 K
ANSI
POT
MECHANICAL SWITCH
(Hopper Grate Switch)
NONE
AVAILABLE
DIN
1K
POTENTIOMETER
(Value indicated)
1K
ANSI
DIN
ANSI
Primary
120V
60 HZ
120V
60 HZ
Secondary
12V
12V
DIN
ANSI
DIN
ANSI
TAS
N.O.
C
TEMPERATURE SWITCH
TRANSFORMER
TAS
N.C.
DIN
OVER-CURRENT SWITCH
(Always normally closed)
ANSI
OL
N.C.
DIN
BRIDGE RECTIFIER
(A.C. to D.C. converter)
ANSI
FS
N.O.
Q
FLOAT SWITCH
(Oil Level)
FS
Q
DIN
198
N.C.
CAPACITOR
(VALUE INDICATED IN
FARADS)
( = micro or 1 millionth)
ANSI
Training Manual
2 F
DIN
2 F
ANSI
SERVICE TRAINING
Controller Systems
Analog
39000170.eps
Digi-Prop (Microwave)
40
60
20
0 0 0 0 0
80
1
10
100
C
HOURS
VDO
Filter
in Bypass
15
10
MAT
20
U/minx100
25
30
35
OIL
COOLER
ON
OFF
3034
1803
30339533
4
9
10
39000171.eps
Comfort Control
3034
1221
30339533
4
9
10
39000172.eps
Training Manual
199
SERVICE TRAINING
C32
OUTPUT
PARAM VALUE
THRESHOLD
20
2_
25
O
T O P E R AT E
D Z O N E!
RE
NO
U/minx100 I
POWER
START PWM
3_
30
REAR CTR
KEY
MAX
1_
15
10
4_
MAX PWM
35
5_
UMB CTR
RAMP UP
6_
RADIO CTR
ID
RAMP DOWN
MIN
LINK
40
ALARM
60
20
80
100
E-STOP
STORE
VDO

3034
4
1803
30339533
9
4
10
7
L1357-01
9
10
39000173.eps
30339530
CPC
OUTPUT
PARAM VALUE
KEY
MAX
1_
THRESHOLD
2_
START PWM
3_
RPM
POWER
4_
MAX PWM
REAR CTR
5_
UMB CTR
RAMP UP
6_
RADIO CTR
ID
LINK
C
NORMAL
RAMP DOWN
MIN
BYPASS
ALARM
E-STOP
STORE

3034
Reset
30345602
L1357-01
9
10
39000174.eps
30351405A
CPC II
OUTPUT
PARAM VALUE
MAX
1_
KEY
THRESHOLD
2_
START PWM
3_
RPM
POWER
4_
MAX PWM
REAR CTR
5_
UMB CTR
RAMP UP
6_
RADIO CTR
ID
LINK
C
NORMAL
RAMP DOWN
MIN
BYPASS
ALARM
E-STOP
STORE

Reset
L1357-01
200
Training Manual
30357944
39000175.eps
10
CPC 2
8540
SERVICE TRAINING
Vector - Current Production
OK
OFF
x1000 3
0
PTO 1500 rpm
62C
Menu: [ENTER]=ON
HOME
HELP
START
30356534 C
3
HP
QUIT
ENTER
10
CLEAR
30362348
39000176.eps
Training Manual
201
202
X2 Terminal Block
3 - TB #3
1 - TB #1
Training Manual
Non-joining lines
2
1.5 - 1.5 SQ. MILS

all 3 wires
Relay coil location

11 - page 11
2 - reference 2
Joining lines
K12 Relay contact ".1" - reference 1 same page
K12 relay location

same page
.2 - reference 2
6 - 6 SQ. MILS
(wire size)
(Reference #s)
X11 - Plug connector X11

B2 - pin on X11
SERVICE TRAINING
SERVICE TRAINING
28X Truck and Pumpkit Circuit
JunctionBox
(see boom
schematic)
orange
Trouble Light
Receptacle at
Operators
Panel
Panel
Light
to Pin 2/5
brown
G
G
brown
brown
brown
from Pin 1/11
Emergency
stop button
10 gauge
12 gauge
red
orange
red
brown
=
=
=
Remote
thermometer for
Pass. Side oil tank
grey
brown
brown
G
Small
On-Off
switch
All fuses
20 amp
(AGC size)
Remote thermometer
for Drivers side oil tank
orange
red
16 gauge
brown
Tachometer
Panel
Light
brown
brown
orange
red
black
purple
purple
white
white
USA 28M
1/94 GRP
white with
black stripe
electric oil
cooler only
green
yellow
Continuous
duty
solenoid
Switch
on
pump
air
shift
lever
blue
brown
yellow
purple
Oil cooler
light (red)
cooler
M Oil
motor 12V
purple
red
purple
red
white & black stripe
H
Hour
meter
Oil cooler
On/Off switch
white
Warning
lamp
white
black
In line
fuse
25 A
25 A
red
purple
Dirty oil
filter light
(red)
brown
Key switch
terminal - Hot
when in "On"
brown
position
blue
black
12 volt
+
Tachometer
sending unit
(proximity switch)
Trouble Light
Receptacle
at Center of
Unit
Dirty hyd. oil

filter pressure
switch 35 PSID
(2.4 bar)
Training Manual
Passenger side
hyd. oil
temperature
sending unit
Drivers side
hyd. oil
temperature
sending unit
203
SERVICE TRAINING
28X Boom Circuit
U.S.A. 28 METER AS WIRED...1989 and LATER

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

(See truck/pump schematic)
STOP
white
A2
A2
A3
A3
A4
A4
A5
A5
B1
B1
B2
B2
B3
B3
C5
C5
B4
B4
B5
B5
15
10
15
15
15
1/1
1/2
1/3
1/4
1/5
1/6
1/7
1/8
1/12
C2
C2
C4
C4
C3
C3
C1
C1
16
14
12
13
11
10
16
14
12
13
11
10
16
14
12
13
11
10
16
14
12
13
11
2/4
2/11
2/5
2/2
2/1
10
d1
11
1/9
1/10
10
d2
11
4
5
6
2
d1
d2
2/7
2/3
2/12
A1
A1
1/9
1/10
1/11
2/6
2/7
2/8
2/9
10 12
9 11
9
10
11
12
204
10
11
Training Manual
12
13
P2
14
15
16
17
CONCRETE PUMP
REVERSE
+ 2
CONCRETE PUMP
FORWARD
CONCRETE PUMP
REVERSE RELAY
CONCRETE PUMP
FORWARD RELAY
G2
THROTTLE DOWN
F2
THROTTLE UP
E2
Components 2 thru 5
BYPASS VALVE
C2 D 2
#2 BOOM RETRACT
#2 BOOM EXTEND
B2
#3 BOOM RETRACT
A2
#3 BOOM EXTEND
SLEWING CW
SLEWING CCW
#1 BOOM DOWN
#1 BOOM UP
12 Volt
18
19
2/90 RE
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
Placing a spot light in the waterbox
2. Select the forward mode of the S1 valve, AT
THE SLOWEST POSSIBLE SPEED! Look into
the material cylinder from the valve end. The gap
between the alignment tool (See Figure 67) and the
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.
Figure 68
Light rays in material cylinder
If the alignment tool should contact the cylinder wall at any time, return the pump to
neutral immediately! Damage may occur to
cylinder wall.
Training Manual
205
SERVICE TRAINING
3. If, for example, the alignment tool contacts the cylinder 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.
9.
10.
11.
12.
13.
NOTE!
If a squeaking sound indicates the alignment tool is dragging on the material cylinder, turn off the pump IMMEDIATELY!
If there is no dragging, you may proceed to step 11.
If dragging does happen, repeat the visual checks.
Loosen the bolts on the material cylinders and
valve housing, and at the machine frame, and
repeat the alignment procedure.
Check the mounting of the pump kit and its mounting to the pump kit frame.
Tighten all bolts.
Complete the reassembly of valves, and install the
rubber rams.
NOTE!
If proper alignment cannot be achieved otherwise, 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 slowest 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 likenew 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
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
.
Loosen for
rotation
Add dead
plugs
(1200s only)
This hose
1200s only
Add hose
and fittings
to each side
Loosen for
rotation
rod/piston change.eps
Loosen for
rotation
Loosen for
rotation
Rod Side
Configuration
Changes
Training Manual
Piston Side
Configuration
207
SERVICE TRAINING
Shimming the Differential

Cylinders
Tension Ring
Determining the proper shimm size

When ever you rebuild differential cylinders, it may be
necessary to add shimms to the tension ring. Adding
shimms protects the cylinder rod from the cheveron
seals in the event the cheveron seals expand. Use the
following procedure to determine the proper amount of
shimming necessary.
Cheveron Seal Set
Dimension A
Tape
Using a caliper measure the distance from the top of

the bushing down to the bushing seal recess. See Figure
70.
Figure 71
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
bushing seal recess.
Dimension B = 57.4 mm
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
SERVICE TRAINING
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.
If the valve is mounted in its 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.
Spool
Spool
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 several 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 exiting 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.
Figure 74
Typical Apitech Handvalve
Solenoid
Solenoid
O-ring
Spool Plug with

Flow Limiter
PC2 Control
Chamber
Solenoid
Figure 77
Bleeding the PC2 control chamber
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
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
Training Manual
SERVICE TRAINING
exiting from around the threads of the port plug,

turn in the port plug into the valve housing until the
seal contacts the valve housing surface. Then
remove the pilot signal and any other positive pressure from the valve. Tighten the port plug into the
valve housing to 25 35 in. lbs. of torque.
Spool Plug with

Flow Limiter
O-ring
PC2 Control
Chamber
Port Plug
PC2 Control
Chamber
Figure 78
If the valve is mounted with the main spool horizontal
and the solenoids are to the left or the right of the main
spool in the same horizontal plane (Figure 79), then the
following must be done:
Figure 80
The PC1 control chamber (handle side) is bled
torque.
NOTE!
Solenoid
Solenoid
Spool
Figure 79
Spool Horizontal - Solenoids to the left and
right of main spool
Due to the internal core of the casting, it

may be necessary to slightly tilt either the
valve or the equipment in which the valve is
mounted on, so that the end plug is the highest point of the valve section, in order to
remove all the air from the control chamber.
The PC2 control chamber (spring side) is bled

torque.
Training Manual
211
SERVICE TRAINING
Spool Plug with

Flow Limiter
O-ring
PC2 Control
Chamber
signal. Once there is no more air exiting 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

Flow Limiter
Figure 81
O-ring
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
Chamber
Figure 82
Vertically mounted handvalve
Only the upper control chamber needs to be
bled since the air in the lower control chamber will
rise and the air will purge out of the control chamber through the clearance around the main spool
(Figure 83 or Figure 84 depending upon the orientation 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 supply a pilot signal to the end chamber by energizing
the solenoid closest to the plug with 100% input
212
Figure 84
Air bleeding the upper control chamber using
the port plug
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,
the following steps must be done in order that they are
listed;
T
P
T
MG
P
MY
G
Y
Setting the Flow Rate

Before flow metering the pumps, ensure that the
maximum engine Rpms 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 Rpms 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
PRESSURE
ROD SIDE
4500
350
300
4000
3500
3000
2500
2000
1500
1000
250
200
131
117

1600
110
1500
103
1400
97
MY
1300
90
1200
83
1100
76
200 Kw
150
100
Break Point
180 Kw = 182 bar
200 KW = 202 bar
At 350 bar
180 Kw = 278 l/m
200 Kw = 309 l/m
10
20
7.5 15
30 40
50 60
70 80
900
62
800
55
700
48
600
41
500
34
400
27
300
21
200
14
100
208
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
CONCRETE OUTPUT
5
10
100
15
200
20
300
25
400
30
500
32
535
P
T
MG
G
Y
1000 1007 69
50
500
124
1700
SA
OIL PRESSURE
5000
Bar
138
1900
1800
180 Kw
5500
PSI
2000
PUMP SPEED
2100 RPM
M
PL
E
Piston Side
Bar
Piston Side
PSI
BPL 2023-5
350 or 400 HP truck
Number of strokes
(stroke / min.)
Oil volume
(liter / min.)
Break Points
Figure 86
Sample output chart
Setting Stroke Limitation

Now that the maximum flow rate and horsepower
settings have been made, the beginning of stroke
limitation can be set. Adjust the supplement system
pressure to the maximum pressure of 50 bar.
1. Make sure the stroke limit potentiometer at the rear
operation panel or remote box is at the maximum
material output setting.
Adjustment Knob
Adjustment Knob
Figure 88
Stroke Limiters (two generations)
3. Increase the engine Rpm's to the maximum setting
and while watching the flow meter scale, slowly
turn the stroke limit potentiometer to the minimum
material output until the maximum flow rate begins
to drop.
4. When the flow rate begins to drop, stop turning the
potentiometer and read the pressure on the 0 to 40
bar gauge. The reading that is seen is the
beginning of stroke limitation. The reading should
be between 5 to 7 bar. If it is not, then adjust the
beginning of stroke limitation screw accordingly to
achieve the proper pressure reading.
a. If the pressure is too high, then turn the screw
counter-clockwise (out) to reduce the pressure.
b. If the pressure is too low, then turn the screw
clockwise (in) to increase the pressure.
Q-min Output Flow
Figure 87
Stroke Limiter Potentiometer
2. Install a 0 to 40 bar gauge in the electric stroke
limit line going to the Y port of the hydraulic
pumps, at this time the reading on the gauge should
be 0.
214
Once the beginning of stroke limitation is set, the next

step is to check the Q min output flow.
1. With the 0 to 40 bar gauge still in the electric
stroke limit line going to the Y port of the hydraulic
pumps.
Increase the engine Rpm's to the
maximum setting and while watching the flow
meter scale, turn the stroke limit potentiometer to
the minimum material output. The 0 to 40 bar
gauge should be reading approximately 25 bar
more than the beginning of stroke limitation setting
to ensure the hydraulic pumps are all the way to the
minimum against the Q min stop. The Q min
reading should be between 15 to 25 liters per
minute. If it is too high, turn the Q min screw out
Training Manual
SERVICE TRAINING
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
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 Department 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 agitator will not be able to turn and the oil will be
forced over the relief valve. At an idle (about 600
RPM), 4.5 horsepower is being converted to heat.
Q min Screw
Q min Screw
Figure 89
Q-min screw locations
agitoff.eps
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
reliefs 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.
Figure 90
Agitator shutoff valve
15. When the oil temperature gauge shows 50C, open
the shutoff valve.
Setting pressures on Hi-flo -6 pumpkits

a. To set the pressure of the main relief valve on Hiflo 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!
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:
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.
Training Manual
215
SERVICE TRAINING
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
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 concrete pump main system pressure gauge, near the estop manifold, from a safe distance.
NOTE!
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 concrete 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 pumpkit 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.
26.
18. If you have not already closed the soft switch shutoff valve and the concrete pump shutoff valve (Figure 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
27.
28.
29.
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 pressure gauge reads lower than the specified
target.
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 increments. 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.
Stop the truck engine, put the key in your pocket.
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.
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
Training Manual
SERVICE TRAINING
bottom of the two hydraulic pumps (Figure 92).

You must be able to read both gauges simultaneously to ensure that one pump is not more dominant than the other.
NOTE!
The gauges in the M1 ports will read considerably less than the cutoff pressure of the
pump. On a -6 (190/130 pump combination)
the 190 will usually read 85 to 90 bar while
the 130 reads about 110 bar. They could
read the same however, at approximately
110 bar, but the 190 must never read higher
than the 130. The actual cutoff pressure will
be read on the concrete pump main system
pressure gauge near the e-stop manifold.

130ajst.eps
Figure 92
Adjustment screw locations
Soft switch
shutoff valve
30. Activate concrete pump forward to pressure out the

pump and read the pressure on the two gauges in
the M1 ports.
32. When you have achieved the same pressure on the

M1 port gauges, you can begin to adjust the pressure cutoff screws in or out simultaneously until
you achieve the desired pressure setting of 350 bar
(again, confirm the pressure specification with the
hydraulic schematic).
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.
Concrete pump
shutoff valve
Closed
hif
lob
rn
.e
ps
Open

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
higher than the other, that pump will be more dominant. The pressure gauge in the M1 port of the
dominant pump will however, read lower than the
other. To equalize the two pumps you must either
adjust the cutoff screw in (clockwise) to increase
the pressure of the pump showing the higher reading or adjust the cutoff screw of the dominant
pump showing the lower reading out (counterclockwise) to reduce the pressure. These adjustments must be made until the two gauges in the M1
ports are reading approximately the same.
Main Pressure
Gauge port

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).
Training Manual
217
SERVICE TRAINING
When you put the pump in forward now, the main concrete pump pressure gauge should read the pressure
shown on the schematic for soft switch. If adjustment
is needed, loosen soft switch relief valve jam nut (Figure 93) with a 9/16 open end wrench, and use a 5/32
allen wrench to adjust the pressure. Turn the adjustment screw in (clockwise) to raise the pressure or out
(counter clockwise), to lower the pressure. When you
attain the required pressure, tighten the jam nut while
holding the allen wrench to keep the pressure from rising. Be sure to open the concrete pump shutoff valve
on the side of the brain (Figure 93) when you are finished. 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
to operating temperature (60c 80 c), and check all
work for leaks.
Service Bulletin 1001-03

Reference page 4 for schematic.
Before installing this kit make sure that the engine is
off, the key is removed, and the accumulator system is
de-energized by confirming that the accumulator
pressure gauge is at zero and the manual dump valve
on the accumulator manifold is opened.
Install check valve and fittings, items 8, 9, and 10 in the
pressure line from the outlet of the hydraulic pump.
Make sure that the check valve is installed in the
correct orientation (free flow from the pump) as shown
in Figure 1. These items must be installed between the
outlet of the pump and where the line is Teed for the
e-stop manifold so that the accumulator system will be
de-energized when an e-stop button is depressed or the
machine is taken out of PTO mode. Reconnect all
lines.
ACCUMULATOR
SYSTEM
11
To test the bypass operation you need to disconnect the

pressure line from the accumulator hydraulic pump.
Plug the hose and pump using items #12, 13, and 14 as
in Figure 2.
ACCUMULATOR
SYSTEM
AGITATOR
VALVE
9
10
E-STOP
AGITATOR
VALVE
9
10
14
13
B
CLOSED FOR
BYPASS
A
2.0 bar
39000215.eps
12
13
ACCUMULATOR
PUMP
Figure 2
Plugging the hose and pump
B
CLOSED FOR
BYPASS
A
2.0 bar
E-STOP
11
39000214.eps
ACCUMULATOR
PUMP
Figure 1
Installing Checkvalves and Fittings
Confirm the 1/4 turn valve shutoff on the agitator
system is installed in the B line of the agitator system
as shown in Figure 1. If your machine is not equipped
with a 1/4 turn shutoff, p/n 10004680, one must be
installed. Disconnect the 1/4 turn valve from the tube
or hose going to the agitator hydraulic motor. Install
items 5, 4, 3, 1, 2, and hose 11. Make sure that the
check valve is installed in the correct orientation (free
flow from agitator to accumulator system). Reconnect
the tube or hose going to the agitator motor.
Route hose 11 under the deck and T it into the P port
of the accumulator manifold using items 6 and 7.
Close the 1/4 turn valve on the accumulator system and

stroke the machine with water in the hopper. The
accumulator gauge should respond very similar as it
does with the accumulator pump. Also, you must
confirm that the e-stop manifold does de-energize the
accumulator system.
Retrofit Assembly Kit# 30364723
SEQ QTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
2.00
2.00
1.00
PART#
10102204
10008108
10020109
10019122
10018848
10018849
10008033
10019728
10008110
10003861
10049909
10016789
10001741
10008093
DESCRIPTION
VALVE CHECK S10A 0.0
FITTING STR GES-16-SR 1/2
FITTING STR EGESD-16-SR 1/2 WD
FITTING EL EWSD-16-S
FITTING TEE ELSD-16-S
FITTING STR REDSD 20/16S
FITTING TEE ELSD-20-S
FITTING STR EGESD 20 SR 3/4 WD
FITTING STR GES 20-SR 3/4
VALVE CHECK S 15 A 2/0
HOSE H.P. DN 13/4 X 1700 DKO-S
FITTING PLUG VS 20 S
CAP NUT M 20 S
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 BPAs
Part # 30308552
Trouble Shooting Kit BPAs and BPLs
Part # 30308553 (shown)
220
Training Manual
SERVICE TRAINING
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
Table of Contents
Table of Contents
SERVICE TRAINING
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,
boom, and outrigger assembly should be performed by
a qualified boom inspector, at the following intervals:
The first five years - at least once per year.
Five to ten years - every 6 months
Ten years and older - every 500 working hours,
or at least once per year, whichever occurs
first.
Figure 2
Visible rust, indicating a possible crack.
If paint is found to have split and rust is coming
through, remove the paint and do a close visual
inspection. If a crack is found a Schwing approved
boom inspector must be called in for analysis. Please
contact SAI Engineering if you have any questions.
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 arent likely to show cracks (paint
covers them up). Cracks typically wont 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
of the unit available when you call Spare Parts.
Figure 3
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
Paint crack - may indicate a crack in the metal.
Figure 4
Dented corners, indicating damage.
Training Manual
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
CAUTION
TION
SO
C IA
E
CONCRET
BOOM UP
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.
2.
Only the operator may authorize access to the unit or surrounding area.
3.
Safety devices and guards must NOT be altered or removed.
4.
Stop the operation if any malfunctions, failures or structural faults occur. DO NOT restart
until repaired.
5.
NEVER try to finish the operation with the emergency stop dump valves bypassed.
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
operator and point of discharge for the purpose of giving instructions to the
operator.
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.
9.
DO NOT unfold the boom unless the outriggers are fully extended and properly jacked.
Shortrigging is NEVER allowed on the side of the pour.
P/N 30345427
10.
Maintain a safe distance from excavations or cliffs. Stay as far back from the edge as the
depth of the excavation or cliff. (This is the one to one rule).
11.
Never retract the outriggers until the boom is folded into the transport position.
Factory-filled with
Rando HD
P/N 30345426
TEXACO
1. TO RELEASE, PULL
SLIDE-PLATE DOWN AND
PIVOT HANDLE OUT AND UP
COMPLETELY.
TIE-DOWN
STRAP AND
RATCHET
4.
5.
6.
BOOM RIGHT
OPEN OR
CLOSE OR
EXTEND BOOM RETRACT BOOM
1.
Rando HDZ
TEXACO
S
MP ING A
2.
3.
BOOM DOWN BOOM LEFT
Stand clear of
outriggers when
activating.
5
Factory-filled with
SAFETY INSTRUCTIONS
1. Release tie-down strap before lifting boom.
2. Lower boom into cradle and reattach tie down strap
before transport.
SLIDE-PLATE
1.
SAFETY INSTRUCTIONS
WARNING
Do not use the

boom as a crane
or hoist.
ERICAN
AM
PU
WARNING
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
illuminated. Normal operating temperature is
needed because, on some machines, when the oil
is cold the "dirty filter" lamp may illuminate even if
the filter is clean.
Stay back from
high voltage wires
at least 17 feet
(5 meters).
When light is on, hydraulic pumps are

engaged. Do not put transmission in
reverse. Do not drive unit.
IMPORTANT
DANGER
Falling hazard.
Not a work
platform.
IMPORTANT
30355887
Use
A MOBIL PRODUCT
HANDLE
Change all filter elements if the dirty filter lamp illuminates when oil is
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.
11
Mobil DTE 25
10
DATE OF LAST CHANGE
DATE OF LAST CHANGE
DATE OF LAST CHANGE
12.
Be sure outriggers are retracted and pinned before driving the unit.
13.
NEVER drive the unit with extended outriggers or an unfolded placing boom! Not even a
few feet.
14.
The supplied safety cable MUST be used to secure the discharge hose or reducer to the
tip section.
15.
DO NOT overload the boom. The maximum allowable weight from hose or reducer/hose
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
boom.
16.
In the event of a thunderstorm or high winds (over 48 MPH), the boom must be folded into
the transport position.
WARNING
7.
8.
9.
10.
11.
STOP BOOM START PUMP SLOW PUMP STOP PUMP
LITTLE BIT
SPEED UP
DOWN
12.
ADD WATER
4-GALLONS
13.
ALL DONE
CLEAN UP
2. TO REATTACH, PULL 2"

OF STRAP THRU RATCHET
PUMP THE HANDLE

TO TIGHTEN.
PUSH HANDLE
DOWN TO LOCK.
Do not operate at
pressures exceeding
the rating of the
entire material
delivery system.
12
DANGER
ROCK VALVE
TM
16
3,409,334
3,580,696
3,640,303
3,685,543
3,741,691
3,829,251
4,019,839
4,057,373
4,178,142
4,191,513
4,260,338
4,343,598
4,373,225
4,373,875
4,392,510
4,437,817
4,465,441
4,472,118
4,556,370
4,621,375
4,681,022
4,708,288
4,852,467
4,978,073
5,066,203
5,106,225
5,106,272
5,224,654
5,257,912
5,263,828
5,281,113
5,332,366
5,346,368
5,401,140
Re. 32,041
Re. 32,657
Re. 32,719
30308020 C
WARNING
WARNING
22
CAUTION
You can order additional operation manuals, spare

parts books, safety manuals and decal sets by
contacting us at:
Schwing America, Inc.
1-(800)-328-9635
6:00 AM to 9:00 PM Central Time
Monday through Friday
27
26
Keep hands out of

waterbox.
Stop engine/motor if
access is required.
Keep covers closed.
WARNING
Keep hands out
of hopper and
valve assembly.
See operation
manual if access
is required.
Keep hands out of

waterbox.
if
Stop engine/motor
access is required.
Keep covers closed.
Do not operate this

machine without
SAFETY
23
MANUAL
29
Electric Motors
1. Stop the electric motor.
2. Remove the key, place it

in your pocket, and put
a "DO NOT OPERATE"
tag on the switch.
2. Lock out the power

source according to an
approved
lockout-tagout program.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
32
2.
25
35
34
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
This unit will NOT operate unless one of these

plugs is connected to the control receptacle.
USE OF THE TOWING EYES

You MUST pull within 15 of straight when
attached to these towing eyes, or unit damage
may result.
1. The radio remote control receiver (if so

equipped).
2. The cable remote.
3. The shorting plug (supplied).
WARNING
40
Put all remote

control functions
in OFF position
BEFORE
connecting cable.
36
37
WARNING
EXTEND OUTRIGGER TO HERE BEFORE UNFOLDING BOOM
44
WARNING
(shown on dummy receptacle)
24 Volts
Here
Do not touch
hydraulic oil leaks.
Get immediate
medical attention if
oil penetrates skin.
radio or cable remote plug

(shown on control receptacle)
47
2. For a hydraulic problem, the inlet plumbing to the nonworking system must be plumbed
out of the manifold. With the engine stopped, disconnect the plumbing for the nonworking system at the fitting
pointed
out
BY-PASS
Boom/outrigger
below.
Plug both
NORM. BY-PASS
circuit dump
open fittings that
valve
result, using hydraulic
blocking plugs. Be
Accumulator
sure to tighten the
circuit dump
plug/fitting connecvalve
tion before restarting
Concrete pump
the engine.
dump valve
Boom/outrigger
3. The emergency stop
system plumbing
manifold is now plumAccumulator
bed out of the system.
Concrete pump
system plumbing
Make repairs before
system plumbing
reusing the machine.
40A
49
WARNING
30353078
EMERGENCY POWER SOURCE
30350982 A
46
45
Total weight of all hanging

hoses, reducers and clamps
must NOT exceed 215
pounds including concrete.
Do NOT hang 5 inch (125mm)
system from this boom.
Emergency stop
switches do NOT
function when
manual bypass is
depressed.
24 Volts Here
1. Remove nuts from battery connections

on outside left battery.
2. Bend cables out of the way as shown
3. Install jumper cable as shown
4. 24 volts now available as shown
NORMAL POWER SOURCE
WARNING
WARNING
48
30A
30343571
SAFETY INSTRUCTIONS
1. Turn the bypass key switch to "BY-PASS" position. If control is restored, there is an electrical problem in the control circuits. You can clean out and fold up with the key switch
override. If control is not restored, there is a hydraulic problem; proceed to step 2.
IGN 12V GND
24V
SAFETY INSTRUCTIONS
Extend outriggers until striped
decals are visible, as shown in
illustrations.
43
42
OVERRIDE OF EMERGENCY STOP MANIFOLD
Use ONLY for emergency foldup and cleaning.
Emergency stop buttons DO NOT WORK when procedure is used.
SAFETY INSTRUCTIONS
Unit will tip if

outriggers are not
fully extended.
shorting plug
30343260 A
41
Stand clear of
outriggers when
activating.
Use retaining
pins in all
delivery system
clamps.
WARNING
Clear area
before activating
outriggers
15
15
EMERGENCY STOP
PARO DE EMERGENCIA
ARRT D'URGENCE
39
38
MANUAL
1.
30
Total weight of all

hanging hoses, reducers
and clamps must NOT
exceed 376 pounds
including concrete.
Do not operate this

machine without
SAFETY
33
WARNING
31
WARNING
WARNING
WARNING
Boom strap
MUST be used
during travel.
1. Raise #2 boom.
CUIDADO WARNING
WARNING
WARNING
Safety guard
is missing.
BEFORE REMOVING HOPPER GRATE OR

PERFORMING ANY SERVICE:
PROCEDURE FOR RAISING THE BOOM

Unfold the boom in this order to avoid damage to the truck cab.
24
Stay back from high
17 feet (5 meters).
28
SAFETY INSTRUCTIONS
Gasoline or Diesel Engines
1. Stop the engine.
SAFETY INSTRUCTIONS
WARNING
2. Raise #1 boom.
Keep hands out

of hopper and
valve assembly.
See operation
manual if access
is required.
IMPORTANT
Do not stand on
hopper grates.
20
Boom may float down without warning if tip is brought into hazard zone.
Before opening a
blocked pipeline,
relieve pressure
by making 2
reverse strokes.
21
WHEN PERFORMING ANY WELDING

ON THIS UNIT IT IS NECESSARY TO
DISCONNECT ALL THE WIRING FROM
THE DUVAC II SYSTEM. FAILURE TO DO
THIS MAY DAMAGE THE COMPONENT.
HAZARD ZONE
(During operation, tip
hose must never
enter this zone)
19
WARNING
WARNING
HAZARD ZONE
SAFE ZONE
(During operation, tip
hose must always
be in this zone)
18
This machine is
remote controlled
and may start at any
time. Stop engine
before servicing unit.
WARNING
SAFE ZONE
Stay clear.
Contact will result in
death or serious injury
if the unit becomes
electrically charged.
This product is covered by one or more of the following U.S. patents:
15
WARNING
DANGER
Stay back from high
17 feet (5 meters).
14
13
ADVENTENCIA
WARNING
WARNING
NO!
IMPORTANT!
Los interruptores de
emergencia de paro no
funcionan cuando se
activa el sobre paso
manual
WARNING
Emergency stop
switches do NOT
function when manual
override is activated.
WATER ONLY
58
DIESEL ONLY
59
57
WARNING
SAFETY INSTRUCTIONS
Clear discharge area when

first starting the pump,
restarting after moving, or
whenever air is present in
the delivery system. See
Safety Manual.
OVERRIDE OF EMERGENCY STOP MANIFOLD

Use ONLY for emergency foldup and cleaning.
Emergency stop buttons DO NOT WORK when procedure is used.
1.
2.
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
restored, there is a
hydraulic
problem;
Accumulator
proceed to step 2.
system plumbing
Boom/outrigger
F o r
a system plumbing
hydraulic problem, the
inlet plumbing to the
nonworking
system
must be plumbed out of
the manifold. With the
engine
stopped,
disconnect
the
plumbing
for
the
nonworking system at
the fitting pointed out at
right. Plug both open
fittings that result, using
51
SAFETY INSTRUCTIONS
Explosion / fire
hazard. Stop engine
before refueling.
Boom/outrigger
circuit override
handle
Shutoff valve - closed to preheat hydraulic

oil by creating high pressure.
NEVER PARTIALLY EXTEND OUTRIGGERS
2.
3.
Outriggers must NEVER be partially extended when the boom will be used,
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.
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
NO!
Serial #:
Was built according to these drawings.
Agitator shutoff valve
52
SAFETY INSTRUCTIONS
WARNING
ATTENTION!
hydraulic:
hyd. boom:
60
output chart:
30357363
61
Do not partially
extend outriggers.
See Safety
Instructions.
30358147
Outrigger
Outer Box
Reinforcements
62
Figure 5
Sample decal location guide. See your Operation Manual
for your specific unit.
Training Manual
WARNING
OK
Outrigger
Inner Box
Reinforcements
electric:
Shutoff valve - open for normal operation.
30354564
55
54
Open
Concrete pump,
accumulator
override handle
56
Do not insert solid

objects into waterbox
cleanout holes.
1.
Fire extinguisher
inside.
30354741
53
Closed
Concrete pump
system plumbing
50
Stop agitator before

putting any solid
object in hopper.
Tipping hazard.
Additional cribbing
needed for many soil
types, including
asphalt. See manual.
Outrigger
Reinforcements
Aligned
30358148
30359230
63
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
Figure 11
Check the hopper grate for damage. Make
sure the hopper grate switch works properly.
Correct
Figure 12
Make sure the water box covers and safety
grates are in place.
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.
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
percent of original wall thickness.
Figure 17
Check for cracks on outrigger tube, pay special
attention to all welded seams
Training Manual
Do not partially extend outriggers

Structural damage could result.
NO!
.ep
58
04
00
Force
Fulcrum
Outrigger
Inner Box
Reinforcements
1. Outrigger fully retracted.
Outrigger
Outer Box
Reinforcements
No lever action.
Force absorbed by reinforcements.
Force must be low, or unit will tip.
Figure 18
Transparent outrigger shows reinforcement
areas (curved outriggers have the same
limitations)
Fulcrum
Force
CAUTION
Force
Fulcrum
000467.eps
Structural damage to outriggers is

possible. Do not jack outriggers unless
they are either fully extended or fully
retracted.
2. Outrigger fully extended.
Partial extension of telescoping outriggers is not

acceptable at any time. Jacking the outriggers while
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).
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.
Lever action present, but

force absorbed by reinforcements.
Fulcrum
Force
Force
NO!
Fulcrum
3. Outrigger partially extended.

Lever action present, but force transmitted to
areas with no reinforcements.
Outrigger bends, bottom plate dents, or both.
000459.eps
Training Manual
Tower
Items to check:

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
Figure 24
Check for damaged or worn hydraulic lines.
Figure 26
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:

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:

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:

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 36
Crack on bottom plate
Figure 39
Check for cracks and damage on the guide
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
Page: 1 of 5
SAIE STANDARD
Subject: Procedures for Setting Boom Rests
The following procedures are for Schwing America personal to follow and adhere to in regards to the setting 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

Issue: 11/11/99
Mielke/Mark Berggren
Approved by: Jason
Mehl
05/29/06
Training Manual
17
Standard: 5158
Page: 2 of 5
SAIE STANDARD
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

Issue: 11/11/99
18
Approved by: Jason
05/29/06
Training Manual
Mehl
Standard: 5158
Page: 3 of 5
SAIE STANDARD
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

Issue: 11/11/99
Approved by: Jason
Mehl
05/29/06
Training Manual
19
Standard: 5158
Page: 4 of 5
SAIE STANDARD
Prepared by: Jim

Issue: 11/11/99
20
Approved by: Jason
05/29/06
Training Manual
Mehl
Standard: 5158
Page: 5 of 5
SAIE STANDARD
Prepared by: Jim

Issue: 11/11/99
Approved by: Jason
Mehl
05/29/06
Training Manual
21
22
Training Manual
SERVICE TRAINING
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
Table of Contents
Training Manual
Output Chart - Sample
CONCRETE
PRESSURE
(PSI)
2000
CONCRETE
PRESSURE
(BAR)
138
1900
131
1800
124
1700
117
1600
110
1500
103
1400
97
ROD SIDE
(bar)
PISTON SIDE
(bar)
BPL 1200 HDR-23
PUMP SPEED
2100 RPM
350
PISTON SIDE
1300 1285
OIL PRESSURE (BAR)
300
250
200
1200
83
1100
76
1000
70
900
62
ROD SIDE
350
800
300
150
758
52
55
700
48
600
41
200
500
34
150
400
28
300
21
200
14
100
250
100
50
88.6 90
100
50
Breakpoint
=178 bar
@ 300 bar
=238 l/m
13
26
39
52
65
78
92
105 118 131 144

103
157 170 183 196

170.5
26
5
ROD
SIDE
50
PISTON
SIDE
10
100
150
5
100
15
200
10
200
300
20
250
300
15.5
15
20
400
500
25
350
(stroke / min.)
OIL VOLUME
(liter / min.)
400
25
(stroke / min.)
OIL VOLUME
(liter / min.)
Differential Hydraulic Cylinder

Bore dia. / Rod dia. x Stroke length
Material Cylinders
Bore dia. x Stroke length
Hydraulic Pumps
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
Nomograph - Sample
Model: BPL 900

320 l/m
Revision date: 042298 Power: 132 Kw
By: Number:
Pumpkit Model:
TK number does not apply to truck mounted units.

Curve shown is the Power Factor number (PF).
(72600)

180
160
Q in yd3/hr.

Max Q
120/80 x 1600:200
200
012
Number:
Max Q
Model: BPL 900

320 l/m
Revision date: 042298 Power: 132 Kw
012
6"
5"
4.5"
140
4"
120 116
Rodside
100
80
67
Pistonside
60
40
132 KW
20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800
1566
870
P in PSI
600
400
200
100
200
2"
300
400
2.5"
500
600
3"
4"
5"
6"
3000 2500 2000 1800 1500
1200
1000
800
Proportional value of pipeline in feet
Slump of fresh concrete in inches
Training Manual
Accumulator Bypass Retrofit - Reference

Service Bulletin Number:
* Normal Mode
Bypass Mode
Valve Open
Valve Closed
1001-03
WHITE BEAR, MINN. 55127

Name: Accumulator Bypass Retrofit
Assembly: N/A
Product: Twin Circuit Models

Drawn By: MB
P
A1
1.5 mm
S3
11
6.0 mm
Psp
9
T
Agitator
This line must return

to tank by itself
Mp
Truck air supply
A
5-7 bar
10 bar
T(A)
P(B)
CLOSED FOR
BYPASS
Emergency stop
manifold
SP
2.0 bar
MP2
MP3
P2
0.9
ZK1
P3
ACCUMULATOR
PUMP
1.3
mm
Shut-Off*
Valve
2nd agitator with

long rock and
sloped side units
ZK2
AGITATOR
VALVE
10
2.0 mm
1.3
mm
XB
Mp1
300
bar
E-STOP
Approved
200 bar
ACCUMULATOR
XA
SYSTEM
Nitrogen pressure set at
100 bar (1450 PSI)
Checked
FOR REFERENCE ONLY

SERVICE BULLETIN 1001-03
B1
Date 08/14/03
2 1.6
Note:
Pressures are set to the
accuracy of the gauge as
received from the
manufacturer.
FOR REFERENCE ONLY

SERVICE BULLETIN 1001-03
ZS1
Figure 1
XB
0.9
XA
3.5
mm
3.5
mm
Concrete Pump
Forward/Off/Reverse
MP1
P1
2 1.6
X3
See boom schematic
ZS2
MG 7-105 bar
ACCUMULATOR
SYSTEMA
A1
3.0
mm
B1
7 S2
XA
11
3.0
mm
XB
XP
AGITATOR
VALVE
MP
9
T2
T1
1.2
2.0 bar
350 bar
12
13
80
13
bar
1.3
X3
1.8
mm
4
X1
A1
B
2.0 bar
P1
10
1.1
T
S1
E-STOP P2
1.8
mm
MY
Y3
PP
14
PR
XR
0-35 bar
1.4
See boom
schematic
CLOSED FOR
BYPASS
MX
X1
X1
Y3
X2
10 bar
ACCUMULATOR
PUMP
A1
Rexroth
A7VO-LRDH
Hydraulic pumps
50 psi
P
Figure 2
200 bar
M
Hyd. oil cooler
w/elec fan
Training Manual
800
Training Manual
801
A
agitator
motor
Pipe Gate
BPL 601, 801, 1001, 1201 HDD

KVM 28, 31, 36
P
Agitator
pressure*
Hopper Gate
H2O pump
motor
A
B
M
Hydraulic stroke limiter
added 1982 and later
P
H2O
pressure*
P
0-50
BAR
Position 1 =
Spring Return
S3
S1
Position 2 =
Detent
A
CA B
1.5 mm
hole drilled
through spool
5.5 bar
300
bar
*Agitator pressure =
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
A
A
A1
A1
D
0.7
mm
To
Boom
Circuit
6 bar
1.0 mm orifice on 1001 and 1201

S
Training Manual
900
PRINT # 329325
BPL 900 HDR

KVM 23, 28, 32
Equipped with
OF - 494 control block
P
200 bar
A
B
M
0-50
BAR
210 bar
Position 1 =
Spring Return
S3
Position 2 =
Detent
S1
T1
1.5 mm
hole drilled
through spool
CA B
T
5.5 bar
300
bar
S2
X1
X1
X2
X2
A
A
A1
A1
D
M
To
Boom
Circuit
6 bar
S
Training Manual
900 w/o FAST SWITCH
BPL 900 HDR

KVM 32XL,
24-4, 26-4
with
Single circuit switching,
7 place boom manifold,
&
10167892 (12v) or 10167893 (24v)
emergency stop manifold
0-55 bar
Y(T)
STROKE
LIMITER
T
A
B
Agitator
Note:
received from the
manufacturer.
200 bar
Hydraulic style
remote throttle
actuation
AIR TANK
only needed with
5 - 7 bar
hydraulic style
remote throttle
actuation
S3
S1
See boom
schematic
P4
MP4
To boom
circuit
300
bar
Concrete Pump
For. / Neut. / Rev.
X1
MP1
P1
260 bar
350 bar
MP2-4
1.5
1.5
1.6
Emergency
stop
manifold
1.6
2
A
A1
Change
X1
Y3
Y3
A1
D
To
Boom
Circuit
35 PSI P
Training Manual
SAIE 10057
initials
Port size
limits flow
P2
Swap P3 and P4 on e-stop manifold.
P3
Rev.061198
1.5 mm
hole drilled
through spool
S2
6
bar
900 WITH FAST SWITCH
Remote controlled
stroke limiter
T
A
Remote Throttle
Actuation (hyd. version)
Agitator
70
bar
Change
A
NG 6
AIR TANK
200 bar
P
Gauge Port
0-400 bar
Water
pump
5 - 7 bar
0.7 mm
T B
Note:
received from the
manufacturer.
S3
1.5 mm
hole drilled
through spool
S1
initials
FAST
SWITCH P
X
with Single
Circuit Switching,
fast switch,
and 344780 (12v) or
344781 (24v) E-stop manifold
Release
6
bar
Rev.032697
STROKE
LIMITER
SAIE 10038
BPL 900 HDR

KVM 28X
KVM 26-4
Compressor
(Optional)
0-55 bar
Y(T)
T
210 bar
P
300 bar
S2
B
T
Concrete Pump
For. / Neut. / Rev.
See boom
schematic
D
X1
Port size
limits flow
X1
Y3
Y3
A1
250
bar
A1
Emergency stop manifold
M
To
Boom
Circuit
3.5 bar
A7VO-80 LR
Training Manual
A7VO-80 LR
900 WITH FAST SWITCH and DAMPNER
Remote controlled
stroke limiter
(Hartman style)
Remote controlled
stroke limiter
(Rexroth style)
Agitator
T
A
P
B
T
0-55 bar
Y(T)
70
bar
A
P
DAMPENER
FAST
SWITCH P
X
with Single Circuit Switching,

4 or 5 place b & w boom manifold,
30344780 (12v) or
30344781 (24v) E-stop manifold
NG 6
Compressor
(Optional)
Water
pump
initials
BPL 1200 HDR

KVM 28X / 26-4 / 32 XL
Release
200 bar
Gauge Port
0-400 bar
Rev.082797
SAIE 10055
STROKE
LIMITER
Change
T
P
T B
0.7 mm
0-55
bar
Y(T)
A
0.7 mm
AIR TANK
S3
C
1.5 mm
hole drilled
through spool
210 bar
6 bar
S1
See boom
schematic
B
300 bar
S2
250
bar
Concrete Pump
For. / Neut. / Rev.
E
X1
Port size
limits flow
X1
Y3
Y3
A1
M
3.5 bar
Note:
received from the
manufacturer.
A1
D
To
Boom
Circuit
5.5 bar
A7VO-107 LR
Training Manual
A7VO-107 LR
10
1200 TC WITH SWITCHING VALVES
Remote controlled
stroke limiter
Nitrogen pressure set at 100 bar

(650 PSI)
Rev.112596
0-55
bar
Release
initials
P
P
Change
SAIE 10026
70
bar
BPL 900-1200 KVM 36X
TWIN CIRCUIT
with electric over air pilot
Y(T)
A
300
bar
S3
Note:
received from the
manufacturer.
Manual stroke
limiter
P
This line must
return to tank
by itself.
Accumulator pump
unloading valve
Concrete Pump
Forward/Neutral/Reverse
T
200
bar
AIR TANK
NG
10
6 bar
250 bar
0.7
mm
0.7
mm
2.5 mm
Agitator
2.5 mm
S2
B
200
bar
S1
320
bar
Port size
limits flow
0.7 mm
X1
X1
A2F-23
A2F-10
Y3
120
bar
Hyd. oil cooler

w/elec fan
Soft switch
Remote Throttle
Y3
A
A
A1
A1
P
T
35 psi
P
6
bar
1200 = A7VO-107 LR
900 = A7VO-80 LR
See boom schematic
1200 = A7VO-107 LR
900 = A7VO-80 LR
Training Manual
11
1200 TC WITH MPS
Change
SAIE 10025
Rev.071797
6.3 mm
Remote controlled
stroke limiter
,,
,,
,,
,,

at 100 bar (1450 PSI)
initials
BPL 900-1200 KVM 36X
MPS - TWIN CIRCUIT
P
P
6.3 mm
0-55
bar
add c.p. checkvalve to e-stop circuit
with electric over air pilot,

emergency stop manifold
70
bar
Note:
received from the
manufacturer.
A
Y(T)
A
300
bar
S3
Manual stroke
limiter

T
1.0 mm
1.0 mm
P
This line must
return to tank
by itself.
A
A
Accumulator pump
unloading valve
Concrete Pump
Forward/Neutral/Reverse
200
bar
AIR TANK
NG
10
6 bar
T
0.7
mm
2.5 mm
0.7
mm
Agitator
2.5 mm
S2
B
200
bar
S1
320
bar
Port size
limits flow
0.7 mm
X1
A2F-10
Y3
80
bar
Hyd. oil cooler

w/elec fan
Soft switch
Remote Throttle
X1
A2F-23
Y3
A
See boom
schematic
A
A1
A1
C
250 bar
P
T
35 psi
P
1200 = A7VO-107 LR
900 = A7VO-80 LR
See boom schematic
1200 = A7VO-107 LR
900 = A7VO-80 LR
Training Manual
Emergency stop
manifold
6
bar
12
HI-FLOW - SINGLE CIRCUIT

Change
SAIE 10207
Rev. 102901
T
Truck air supply
initials
200 bar
330
bar
3
1.6
2
5-7 bar
P1
2020-4, 2023-4
KVM 32 XG
HI-FLOW - SINGLE CIRCUIT
0.9
See boom schematic
MP1
with Rexroth A7VO hydraulic pumps

and cartridge type MPS manifold
B
Agitator
P(B)
T(A)
Release.
1.6
P3
P2
0.9
Emergency stop
manifold
T
MP3
MP2
A
T
SP
B
ZK2
1.3
ZK1
ZS2
1.3
ZS1
Concrete Pump
Forward/Off/Reverse
MP
MG2
20
bar
XA
A
XB
3.5
3.5
G2
PBP
3.5-40
bar
X3
PZ
0.7
3.5-40
bar
0.7
A2
B2
0-30
bar
B3
A3
S3
XA1
MG1
XB3
MX1
X1
1.5
A
X1
A1
B1
Y3
S2
XA
XB
A1
PR
PP
S1
XR
XP
P2
P1
S
MP
T2
1200 or 2020/2023 = A7VO-107 LR

900 = A7VO-80 LR
T1
1.2
See boom schematic
X1
300 bar
1.4
Y3
X1
1.8
A
A1
10 bar
1.8
Training Manual
1200 or 2020/2023 = A7VO-107 LR

900 = A7VO-80 LR
13
P
Truck air supply
5-7 bar
A1
Agitator
B1
S3
1.5
mm
XA
XB
2nd agitator with

long rock and
sloped side units
Concrete Pump
Forward/Off/Reverse
2020-4, 2023-4
KVM 34 X
MPS - TWIN CIRCUIT

100 bar (1450 PSI)
6.0 mm
Psp
Mp1
2.0
mm
300
bar
Mp

to tank by itself
200 bar
P
with Rexroth A7VO hydraulic pumps

and cartridge type MPS manifold
Note:
received from the
manufacturer.
initials
Change
Correct max. pressure for 2020 versions.
SAIE 10115
Rev. 120798
2023-4
G2
MG2
T
SP
MP5
ZK2
Remote Throttle
Actuation (hyd. version
used when engine not
electronically controlled)
ZK1
P4
Emergency stop
manifold
0-30
bar
P3
0.9
1
X1
P2
2 1.6
MX1
ZS2
MP2
3.5-55
bar
260
bar
ZS1
MG1
MP1
P
0.9
XB
T
1
5.5 bar
X3
XA
P1
MP
PBP
PZ
A1
3.0
mm
2 1.6
See boom schematic
XA
B1
S2
XB
3.0
mm
X1
Y3
PR
0.7
mm
PP
XR
S1
0.7
mm
A
A1
XP
P2
See boom
schematic
P1
MP
T2
T1
1.2
2023 = 350 bar
2020 = 328 bar
1.4
1200 = A7VO-107 LR
900 = A7VO-80 LR
MX
X1
X1
1.8
80
bar
Y3
A
X2
Hyd. oil cooler

w/elec fan
A1
A7VO-LRDH
Hydraulic pumps are
used only on -4 machines
X3
1.1
1.8
35 psi
P
200 bar
Training Manual
1200 = A7VO-107 LR
900 = A7VO-80 LR
14
B1
S3
XA
XB
T

100 bar (1450 PSI)
6.0
mm
Psp
200 bar
to tank by itself
Agitator
Mp1
2.0
mm
300
bar
Acumulator control device
Truck air supply
2nd agitator with

long rock and
sloped side units
Mp
T
5-7 bar
initials
Change
3.5 mm and 1.3 mm nozzles adde to A, B,

ZS2, and ZK2 ports on MPS manifold.
P
A1
SAIE 10139
10 bar
Rev. 110499
Note:
received from the
manufacturer.
2023-5
T(A)
P(B)
Emergency stop
manifold
T
SP
MP5
2023-5
KVM 39X, 34X
MPS - TWIN CIRCUIT
MP2
P4
ZK2
P3
0.9
ZK1
1.3
mm
1
3
ZS2
260
bar
ZS1
1.3
mm
e-stop manifold
10167892 (12v) or 10167893 (24v)
P2
2 1.6
A
B
MP1
Concrete Pump
Forward/Off/Reverse
XA
1
3.5
mm
3.5
mm
P1
2 1.6
X3
See boom schematic
0.9
XB
P1
P
A
A1
3.0
mm
XA
S2
XB
PR
0.7
mm
PP
XR
B1
3.0
mm
Pressure
reducing
valve 55 bar
0.7
mm
P
T
A
S1
XP
P2
P1
T2
T1
Y T2
T1
A
Electric
stroke limiter
MP
T2
see
note
T1
see
note
1.2
360 bar
1.4
MX
See boom
schematic
X1
1.8
mm
80
bar
X2
Hyd. oil cooler

w/elec fan
X3
M1
1.1
1.8
mm
35 psi
P
Training Manual
M1
M
Note: A11VO-LRDH
Hydraulic pumps are
limited to 350 bar
by pressure cutoff.
200 bar
15
2525H
KVM 52
MPS - TWIN CIRCUIT
Agitator
B
2nd agitator with

long rock and
sloped side units
A1
B1
S3
XA
XB
T

100 bar (1450 PSI)
6.0
mm
Psp
With switching signal

from waterbox end

to tank by itself
Note:
received from the
manufacturer.
200 bar
P
Mp1
2.0
mm
Acumulator control device
300
bar
Mp
T
initials
Change
3.5 mm and 1.3 mm nozzle added to A, B,

ZS2, and ZK2 ports on MPS manifold.
SAIE 10143
Rev. 110399
2525H
P
MP5
MP2
P4
Remote Throttle
Actuation (hyd. version
used when engine not
electronically controlled)
T
1.1
P3
0.9
P2
2 1.6
260
bar
MP1
Truck air supply
X3
1
80
bar
X2
P1
2 1.6
350
bar
X1
See boom schematic
0.9
B
Concrete Pump
Forward/Off/Reverse
5-7 bar
T
360 bar
1.4
MX

1.2
T1
T2
MP
P1
P2
0.7 mm XP
XR
T
A
S1
55 bar
PP
PR 0.7 mm
3.0 mm
XB
Pressure
reducing valve
XA 3.0 mm
S2
A1
B1
B
P
T
M
X3
T1
T2
Y M
T1
T2
2.0 mm
3.5
mm
3.5
mm
see
note
XA
XB
ZS1
ZS2
see
note
5.5 bar
Electric
stroke limiter
See boom
schematic
Hyd. oil cooler

w/elec fan
1.3
mm
ZK1
M
ZK2
1.3
mm
SP
35 psi
P
M1
M1
A11VO-LRDH
Hydraulic pumps are
limited to noted pressure
by pressure cutoff.
Training Manual
200 bar
16
KVM 31 EZ Boom
BOOM #2
150/90 x 1195
BOOM #1 (MAIN)
260/160 x 11 80
BOOM #4 (TIP)
120/70 x 805
BOOM #3
170/90 x 1200
BOOM #1 (Extend)
130/80 x 4645
SLEWING (LEFT - RIGHT)

125/100 x 550
Rear
Front
Outrigger Extension
Cylinder Rear
60/40 x 1520
A1
A2
A1
10
14
160 bar
150 bar
250 bar
240 bar
A1
1.0 mm
EA
A2
310 bar
B1
300 bar
330 bar
A1
1.0 mm
EA
10
10188569
EA
1.0 mm
B2
A2
1.0 mm
EB
B1
320 bar
290 bar
A2
B1
1.0 mm
B2
10189483
EB
220 bar
190 bar
270 bar
320 bar
180 bar
B2
B1
280 bar
B2
10189484
1.0 mm
230 bar
A1
300 bar
A2
EB
1.0 mm
210 bar
10189485
EB
1.0 mm
240 bar
10160891
EA
1.0 mm
300 bar
HOME
Outrigger Extension
Cylinder Front
70/50 x 2300
B2
T
A1
B1
0 - 16
bar
1.0 mm
125
bar
B1
125
bar
125
bar
C
125
bar
EB
EA
150 bar
150 bar
13
150 bar
T1
14 bar
21
T
A
Front of Unit
Water
pump
Optional HP
water pump
Optional
air compressor
or
280
bar
T1
35 l/m
180 bar
C2
C1
C2
G1/2
C1
C2
C1
G1/2
G1/2
C2
C1
G1/2
C2
C1
G1/2
C2
C2
C1
C2
C1
G1/2
G1/2
C1
22
14
C1
125
bar
MPS
125
bar
125
bar
125
bar
G1/2
10
10
140 bar
30
bar
1
15
bar
MP
Outrigger Extension
Cylinder Front
70/50 x 2300
18
P2
350
bar

125/100 x 550
Rear
Front
Outrigger Extension
Cylinder Rear
60/40 x 1520
0.55
P
T
LS
14
HYDRAULIC SCHEMATIC
KVM 31 EZ boom
from GmbH 10200675
11
X
T2
T1
See concrete pump

schematic
MP3
P2
Note:
received from the
manufacturer.
GD# 10200675
Rev. 112904
initials
T1
R T2
17
MP1
MP2
2.0
bar
Z To concrete pump circuit
0.3
bar
hydraulic pump, port Z.
310 bar
Change
SAIE 10235

P1
330
bar
P3
20 bar P
1.5
bar
20
M
Not used without 3-circuit

control.
Emergency stop
manifold
0.9
1.6
0.9
12
1.6
g maxV
g minV
Release.
M1
2.5
bar
A11 VO DRS
Training Manual
M1
A11 VO DRSP
17
KVM 32XL
Driver Side
BOOM #1 (MAIN)
200/125 x 1030
10151785
320
bar
BOOM #2
180/110 x 1300
10151785
320
bar
310
bar
P1
E
320
bar
P2
X
P1
P2
10151785
310
bar
P1
P2
X
BOOM #3
150/90 x 800
P2
BOOM #4 (TIP)
110/70 x 670
10151785
310
bar
320
bar
P1
E
P1
HOME

90/60 x 650
Outrigger Extension Cylinders

Rear
Front
60/40 x 1520
70/50 x 2300
P2
X
P1
P2
Water
pump
310
bar
P1
P2
X
Optional air
compressor
P2
P1
320
bar
320
bar
310
bar
10151785
310
bar
10151785
320
bar
T
310
bar
10151785
320
bar
T
310
bar
A1
10151785
B1
0 - 16
bar
200 bar
200 bar
P
14 bar
140
bar
T
A
80
bar
140
bar
80
bar
80
bar
140
bar
80
bar
140
bar
P
280
bar
P1
T
140 bar
C2
C1
C2
G1/2
C1
C2
G1/2
C1
C2
C1
G1/2
C2
G1/2
C1
C2
G1/2
C1
C2
G1/2
C1
MPS
G1/2
30
bar
15
bar
Outrigger Extension Cylinders

Rear
60/40 x 1520
Front
70/50 x 2300
90/60 x 650
MP
350
bar
P2
P
T
LS
HYDRAULIC SCHEMATIC
KVM 32XL
St
w/meter out spools

applies to proportional units only
and E-stop manifold number 10181606 (12v)
or 10181607 (24v)
0
See concrete
pump schematic
P3
MP2
initials
P1
P regulator
330 bar
A
A1
MP5
20
bar
0.9
A
3
To LS port
of Apitech
X3
1.6
2
300
bar
0.9
1.6
Emergency
stop
manifold
X
P
Rev. 061900 Release
Change
MP1
SAIE 10188
P2
Note:
received from the
manufacturer.
2.0
atmospheres
Training Manual
System when equipped with Voac hydraulic pump
18
32XLG
BOOM #2
180/110 x 1300
BOOM #1 (MAIN)
200/125 x 1030
BOOM #4 (TIP)
110/70 x 670
BOOM #3
150/90 x 800
HOME
10151785
10151785
1.0 mm
10151785
1.0 mm
310 bar
10151785
1.0 mm
310 bar
1.0 mm
310 bar
Water
Tank
310 bar
320 bar
320 bar
320 bar
320 bar
320 bar
320 bar
320 bar
320 bar
SR
SR1
310 bar
310 bar
1.0 mm
1.0 mm
A1
1.0 mm
1.0 mm
10151785
10151785
Water
pressure
310 bar
310 bar
B1
0 - 16
bar
10151785
10151785
High pressure
water (optional)
200 bar
200 bar
Driver Side
14 bar
Outrigger Extension Cylinder

Rear
70/50 x 2300
T
A

125/100 x 550

Front
60/40 x 1520
140
bar
140 bar
C2
C1
G1/2
C2
C1
C2
G1/2
C1
G1/2
C2
C1
C2
G1/2
C1
C2
G1/2
C1
G1/2
C2
C1
140
bar
80
bar
80
bar
MPS
G1/2
15
bar
80
bar
0.76
mm
140
bar
80
bar
140
bar
P
280
bar
0.61
mm
0.2 mm
P1
300
bar
T
P
LS
See pump schematic
HYDRAULIC SCHEMATIC
32XLG
MP2
w/fixed displacement boom pump and

proportional Inlet control valve
XLG units SN170522735 and higher
MP3
P3
P2
Change
P1
Note:
received from the
manufacturer.

Rear
70/50 x 2300
Emergency
stop
manifold

125/100 x 550

Front
60/40 x 1520
Passenger Side
T
0.9
SAIE 10229
MP1
0.9
1.6
2
1
1.6
2
3
Rev. 120403 Release
2.0
atmospheres
initials
Training Manual
19
34 XG
BOOM #2
180/125 x 151 0
EB
1.0
B1
1.0
B2
A2
EB
B2
1.0
320 bar
B1
A2
EA
290 bar
A1
1.0
1.0
A1
1.0
B2
330 bar
330 bar
EB
320 bar
310 bar
B1
320 bar
190 bar
B2
180 bar
A2
320 bar
330 bar
EB
280 bar
1.0
A1
HOME
BOOM #4 (TIP)
110/60 x 805
A2
EA
Grayed components represent

optional equipment
140 bar
B1
320 bar
EA
BOOM #3
150/100 x 1173
290 bar
BOOM #1 (MAIN)
225/125 x 880
Water
Tank
330 bar
A
300 bar
Water pump
A1
1.0
HP water pump
Water
pressure
EA
A1
B1
High pressure
water
0 - 16
bar
150 bar
150 bar
Driver Side
Outrigger Extension
Cylinder
14 bar

125/100 x 550
Outrigger Extension
Cylinder
T
A
Front
60/40 x 1520
Rear
70/50 x 2300
Compressor
P
140 bar
140
bar
C1
C2
G1/2
C1
C2
C1
G1/2
C2
G1/2
C1
C2
G1/2
C1
C2
G1/2
C1
C2
G1/2
C1
C2
140
bar
80
bar
80
bar
PP
G1/2
15
bar
80
bar
140
bar
80
bar
140
bar
P
280
bar
0.2
mm
300
bar
P
.061 mm
LS
HYDRAULIC SCHEMATIC
34 XG
w/fixed displacement boom pump and
proportional control valve
330 bar
Note:
received from the
manufacturer.
SAIE 10187
GD#
Rev. 070803
Outrigger Extension
Cylinder
Rear
70/50 x 2300

125/100 x 550
Outrigger Extension
Cylinder
Front
60/40 x 1520
Passenger Side
Change
Compressor circuit, outrigger cyl. sizes,
brake valve pressures corrected.
2.0
atmospheres
initials
Training Manual
20
KVM 39X
Driver Side
BOOM #2
200/140 x 1620
BOOM #1 (MAIN)
240/180 x 1080
BOOM #4 (TIP)
120/70 x 805
BOOM #3
150/80 x 1173
Optional air
compressor
Water
pump
HOM
10151786

Rear
70/50 x 2075
1.0 mm
1.0 mm
330 bar
320 bar
1.0 mm
1.0 mm
1.0 mm
1.0 mm
10180550
320 bar
320 bar
330 bar
310 bar
310 bar
310 bar
330 bar
320bar
300 bar
320 bar
310bar
330 bar

Front
95/82 + 58/44 X 3561
1.0 mm
1.0 mm
320 bar
320 bar

100/65 x 650
10180549
10180551
A1
B1
10151785
0 - 16
bar
200 bar
200 bar
P
14 bar
140
bar
T
A
140
bar
80
bar
80
bar
80
bar
140
bar
80
bar
140
bar
P
280
bar
P1
200 bar
C2
C1
G1/2
C2
C1
G1/2
C2
C1
C2
G1/2
C1
C2
G1/2
C1
G1/2
C2
C1
C2
G1/2
C1
MPS
G1/2
30
bar
15
bar

Rear
70/50 x 2075
MP
350
bar

100/65 x 650

Front
95/82 + 58/44 X 3561
P2
P
T
LS
HYDRAULIC SCHEMATIC
KVM 39X
See concrete pump
schematic
MP3
P3
P2
P1
2.0
atmospheres
Emergency stop
manifold
w/slewing motor manifold,

Apitech control block, and emergency stop manifold
10181606 (12 volt) or 10181607 (24 volt)
Note:
received from the
manufacturer.
MP1
330
bar
P regulator
A
X
MP2
T
20
bar P
A1
300
bar
SAIE 10162
X3
Rev. 120299
Change
E-stop manifold symbol corrected.
initials
Training Manual
21
S 39/41 SX
14.03.2006
HOME
Training Manual
22
S 42 SX
HOME
Driver Side
Outrigger Extension Cable

110/80 x 750
Outrigger Slewing Cylinder

100/40 x 327
Front
Front
Rear
Rear
A1
B1
A2
B2
B3
A3
B4
A4
P
200
bar
T2
350
bar
300
bar
200
bar
To/From Boom System (10233-2)
T1
350
bar
P1
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:
received from the
manufacturer.
Rear
100/40 x 327
Front
Rear
110/80 x 750
Front
Passenger Side
Change
SAIE 10233-1/2
Rev. 090904
Release
initials
Training Manual
23
S 42 SX
BOOM #4 (TIP)
110/70 x 1000
HOME
10151788
320
bar
Grayed components represent

optional equipment
A1
Water
Tank
B1
200 bar
320
bar
320
bar
320
bar
10039659
400 bar
400 bar
P2
X
E
P2
320
bar
300
bar
10151788
10039659
P2
BOOM #1 (MAIN)
180/110 x 1300
300
bar
P2
300
bar
10151788
10151788
P2
320
bar
BOOM #2
225/140 x 1600
300
bar
P2
X
P1
200 bar
10151788
300
bar
P1
0 - 16
bar
BOOM #3
160/110 x 1200
300
bar
10151788
320 bar
320 bar
10049891
10049891
14 bar
Water pump
#1 Down - brake valve
HP water pump
To/From Outrigger System (10233-1)
Water
pressure
High pressure
water
0.35
T1
0.35
T2
P1
PP
C2
MP
C1
C2
C1
C2
C1
C2
C1
C2
C1
C2
C1
C2
C1
90 bar
190 bar
15
bar
30bar
P2
350
bar
P
T
see concrete
pump schematic
P3
P2
MP3
LS
MP1
HYDRAULIC SCHEMATIC
KVM 42 SX
P1
W/ Apitech boom control valves,

and e-stop manifold 10181607
320 bar
MP2
P regulator
X
0.9
20
bar P
0.9
1.6
1.6
2
A1
300
bar
Change
SAIE 10233-2/2
Rev. 090904
P
Boom hydraulic pump
Training Manual
initials
Release
2.0
atmospheres
X3
1
Note:
received from the
manufacturer.
24
S 45 SX
HOME
Driver Side
110/80 x 750
Rear

100/40 x 327
Rear
Front
Front
A1
B1
A2
B2
A3
B3
A4
B4
P
T1
350
bar
200
bar
T2
200
bar
300
bar
350
bar
P1
A4
B4
A3
B3
A2
B2
A1
B1
HYDRAULIC SCHEMATIC
KVM 45 SX
applies to unit SN 70526011, 170526002 and later
Note:
received from the
manufacturer.
Front
Rear

100/40 x 327
Rear
Front
110/80 x 750
Passenger Side
SAIE 10047-1/2
Rev. 040898
initials
Change
Correct p.s. outrigger slewing/350 bar
secondary relief connection
Training Manual
25
S 45 SX
HOME
Water
pump
Optional air
compressor
BOOM #4 (TIP)
115/70 x 995
HYDRAULIC SCHEMATIC
KVM 45 SX
10151788
320
bar
applies to unit SN 70526011, 170526002 and later
BOOM #3
200/110 x 1200
10151786
300
bar
330
bar
A1
Note:
received from the
manufacturer.
B1
200 bar
P1
P1
200 bar
320
bar
P1
Change
Rev. 040898
Change adjustable checkvalve to fixed

spring checkvalve, change pilot valve to 35
bar, assign flow to outrigger supply valve.
initials
14 bar
280
bar
330
bar
T
350
bar
330
bar
P2
P1
P1
P2
P1
P1
P2
320
bar
320
bar
T
10151786
10151784
P2
260
bar
10151787
BOOM #1 (MAIN)
340/115 x 2290
310
bar
P2
P1
P2
SAIE 10047-2/2
10151785
320
bar
P2
0 - 16
bar
BOOM #2
260/160 x 1990
P2
310
bar
10151785
350
bar
T
330
bar
10151784
T
A
A4
A3
B3
A2
B2
A1
B1
Pv
Ls
160 - 200
B4
P
X
Y
Ls
T1
Dr2-a'
P1
35
bar
b'
230 bar
a'
Dr1-b'
T2
350
bar
40
bar
30 l
max.
a2
b1
a1
A-G 4-a1
b2
A-G 2-b1
a3
B-G 1-a2
b3
B-G 3-b2
a4
C-G 4-a3
b4
C-G 2-b3
Y
D-G 1-b4
D-G 3-a4
200
bar
LS
see concrete
pump schematic
MP2
PST
P
P2
C-G 4-a3
C-G 2-b3
D-G 3-a4
D-G 1-b4
A-G 4-a1
A-G 2-b1
B-G 3-b2
B-G 1-a2
Dr 1-a'
Dr 1-b'
P regulator
20
bar
A1
P3
MP1
310
bar
P
P1
X3
T
A
330
bar
P
Boom hydraulic pump
Training Manual
MP3
2.0
atmospheres
26
52 M
HOME
Driver Side
Rear
180/150 x 900
Front
180/150 x 900
Rear
140/90 x 300
A1
B1
A2
Extension Cylinder
Front
140/90 x 1145
B2
Front
90/70 x 1870
A3
B3
A4
B4
350
bar
350
bar
50
bar
T1
T2
See SAIE 10079

page 2 of 2
P1
150
bar
350
bar
350
bar
50
bar
A1
B1
A2
B2
A3
B3
A4
B4
HYDRAULIC SCHEMATIC
KVM 52
1 of 2 (outrigger circuit)
Note:
received from the
manufacturer.
SAIE 10079-1/2
Rev. 102298
Change
Rear
180/150 x 900
Front
180/150 x 900

Rear
140/90 x 300
Front
140/90 x 1145
Extension Cylinder
Front
90/70 x 1870
change main outrigger relief to 150 bar
Passenger Side
initials
Training Manual
27
52 M
HYDRAULIC SCHEMATIC
KVM 52
BOOM #2
280/160 x 2100
BOOM #3
210/110 x 1173
BOOM #4 (TIP)
130/80 x 1069
2 of 2 (boom circuit)
w/10167892 (12v) or
10167893 (24v) Estop manifold
all changes on page 1 of 2
0 - 16
bar
Note:
received from the
manufacturer.
10065681
320 bar
10065681
320 bar
10065680
350 bar
10065681
320 bar
A1
B1
10065680
350 bar
10047783
350 bar
10065681
320 bar
10047784
260 bar
280
bar
200 bar
200 bar
initials
14 bar
See SAIE 10079

page 1 of 2
A
A
A
A
1.5
P1
adjusted to 20 bar
dynamic pressure
T1
adjusted to 20 bar
dynamic pressure
T2
adjusted to 20 bar
dynamic pressure
Pst
Pst
L
50
bar
adjusted
to 20 bar
dynamic
pressure
30
bar
a4
b1
b1 a1
a1 b2
b2 a2
a2 b3
b3 a3
b4
a3
b4 a4
a4 b5
b5 a5
a5
b6
b6
a6
A4
B4
a5
A5
B5
a6
a6
A6
B6
a1
A1
B1
a2
A2
B2
a3
A3
B3
190
bar
350 bar
L(T)
10146289
190
bar
10146290
X (LS)
X (LS)
P
b4
b5
b6
b1
b2
b3
See concrete pump schematic
P3
P4
P2
MP1
P1
a6
b6
a5
b5
a4
b4
a3
b3
a2
b2
MP2
a1
b1
Rev. 102298
SAIE 10079-2/2
Change
HOME
BOOM #1 (MAIN)
350/160 x 2730
Water
pump
330 bar
P regulator
High
pressure
filter
High
pressure
filter
20 bar
P
A1
A
MP5
0.9
1.6
T
Emergency
stop
manifold
310
bar
0.9
1.6
2
1
2
1
X3
5.5
bar
Boom hydraulic pump
Training Manual
28
S 58 SX
BOOM #4 (TIP)
160/80 x 1110
BOOM #3
240/120 x 1500
BOOM #2
320/200 x 2200
BOOM #1 (MAIN)
400/180 x 3450
Water pump
HP water pump
HOME
EB
260 bar
A1
250 bar
330 bar
A2
A1
320 bar
310 bar
320 bar
A1
1.0 mm
EA
250 bar
330 bar
A2
A2
B1
330 bar
260 bar
A1
1.0 mm
B2
270 bar
320 bar
A2
0 - 16
bar
B1
250 bar
240 bar
A1
EA
1.0 mm
1.0 mm
B2
330 bar
B1
320 bar
B2
B1
EB
1.0 mm
340 bar
EB
1.0 mm
B2
B1
1.0 mm
1.0 mm
EA
water tank
EB
EA
250 bar
water
output
HP
water
output
14 bar
T
B
240 bar
P1
T1
0.55 mm
LS T
T2
300 bar
300 bar
R1
360 bar
A
A
280 bar
20
bar
B
180 bar
230 bar
HYDRAULIC SCHEMATIC
S 58, 61 SX boom
page 1 0f 2
T2
20 bar
initials
Change
Update to match GmbH rev. Add "61."
MP3 P2
P3
Emergency stop
manifold
MP1
P1
350
bar
1.5
bar
Note:
received from the
manufacturer.
Rev. 102502
See concrete pump

schematic
w/estop manifold 10181606 (12V) or 10181607 (24V)

from Gmbh print #10185941
SAIE 10197-1/2
T1
MP2
T
310 bar
M
A11VO
170 l/m
5 bar
M1
Training Manual
29
S 58 SX
Driver Side
HOME

130/60 x 445

130/70 x 800
Rear
Rear
A1
B1
Front
A2
B2
Outrigger Roller
22 x 33
Front
A3
B3
A4
B4
P
P1
350
bar
210
bar
210
bar
200
bar
T1
200
bar
T2
200
bar
350
bar
210
bar
200
bar
310
bar
210
bar
C
T
A4
B4
A3
B3
A2
Rear
B1
HYDRAULIC SCHEMATIC
S 58, 61 SX
page 2 of 2

130/60 x 445
A1
B2
Rear
Front

130/70 x 800
Note:
received from the
manufacturer.
Front
Outrigger Roller
22 x 33
SAIE 10197-2/2
Rev. 102502
Change
Update to match GmbH rev. Add "61."
initials
Passenger Side
Training Manual
30

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SERVICE TRAINING

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SCHWING SERVICE DEPARTMENT

FAX (651) 429-2112

SCHWING PARTS DEPARTMENT

FAX (651) 429-2112

24 Hour Service Hotline

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

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

PTO Switch/Air Valve ..................................................1

Boom Pump ................................................................16

Typical Twin Circuit

PTO Switch/Air Valve

Air Pressure Switch

Switch pushed in, air supply blocked by

Air blocked by spool

From:Truck Air Supply

Continuous Duty Solenoid

The signal energizes the magnetic coil in the

A connection is established between the 12

From: 12v Power Supply

WHEN WELDING ANYWHERE ON UNIT

To: Boom Control Block

Main Control Block Brain

Hydraulic oil will flow through the Main

S1 - Neutral Position, pathway block

Concrete Pump Forward/Reverse

To: Main Control Block/MPS Valve

Blocked pathway (Neutral)

In the forward position, a passage way is

Oil is sent to the XP port of the Main

To: Main Control Block (XP port)

The Concrete Pump Forward/Reversing valve is

This valve also plugs the vent line, which

Passageway created (Forward position)

Main Control Block - S1/S2 Spool

Passage way created for the hydraulic oil

From: CP Forward/Reverse Valve

Pathway to Differential cylinder

Main Relief Valve

The 350 bar relief valve spring will collapse,

Over relief pressure

Pressure is greater on the piston side of the

Excess oil drained to tank

The term differential cylinder means that each

Loop oil on the piston side of the left hand

Concrete sucked in from hopper

Differential Cylinder - Bottomed Out

To: Soft Switch

Passage way created

From: Differential Cyl.

S3/Accumulator Control Block

The S3 spool moves to the left.

From: MPS valve "B" port

A passage way is created for accumulator oil

From: MPS valve "A" port

With nitrogen charged

Influx of hydraulic oil

The accumulator can be considered an energy

Rock Valve Slewing Cylinder

From: S3/Accumulator Control Block

Soft Switch Relief Valve

When the Rock Valve is shifting, a signal line

Pressure is greater on the piston side of the