Operation Manual For Model SP 305

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Operation Manual for

Model SP 305
Operation Manual
Version 5.0.1
Part Number 30362000
Copyright © 2011, Schwing America, Inc.

All rights reserved
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Table of Contents
INTRODUCTION
Manufacturer’s Statement........................................................................... 6
Safety alert symbol and signal word explanation ................................. 6
How to reach us .................................................................................... 7
How to order parts ................................................................................ 7
Model Number ............................................................................................ 7
Serial Number ............................................................................................. 7
Orientation ............................................................................................ 7
Model Number Nomenclature .................................................................... 8
SP 305 ................................................................................................... 8
ID Tags ....................................................................................................... 8
Main ID tag ........................................................................................... 9
If your ID tag is missing ....................................................................... 9
SPECIFICATIONS
SP 305 ....................................................................................................... 12
Functional Description of the Main Control Block .................................. 13
SAFETY
How to Order Additional Safety Manuals ................................................ 16
Warning Labels (Decals) .......................................................................... 19
OPERATION
Preparing for the Job................................................................................. 22
Towing the unit ................................................................................... 22
Setting Up ................................................................................................. 23
Arrival at the job ................................................................................. 23
Laying pipe ......................................................................................... 23
Starting the engine .............................................................................. 24
Controlling the pump .......................................................................... 25
The control panel ................................................................................ 25
The remote control box....................................................................... 27
Note about the electric system ............................................................ 27
The volume control knob .................................................................... 27
Throttle control ................................................................................... 27
The pressure gauge ............................................................................. 27
Starting the Pour ....................................................................................... 27
Concrete mixes ................................................................................... 27
Preparing for concrete......................................................................... 27
Ready the pump .................................................................................. 28
Mix your slurry ................................................................................... 28
Beginning to pump.............................................................................. 28
Cleanout .................................................................................................... 31
Clean the delivery system ................................................................... 31
Clean the pump ................................................................................... 32
Special Pumping Situations ...................................................................... 34
ii Operation Manual - SP 305 revDate

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Table of Contents
Plugs.................................................................................................... 34
Cold weather pumping........................................................................ 35
Hot weather pumping.......................................................................... 36
Emergency procedures........................................................................ 36
Other Things You Need to Know ....................................................... 37
MAINTENANCE
Filtration.................................................................................................... 40
General information ............................................................................ 40
Specific information............................................................................ 40
To change the element ........................................................................ 41
Hydraulic Oils........................................................................................... 41
Specific information............................................................................ 42
When to change your hydraulic oil..................................................... 42
Pressure, Hoses and Fittings ..................................................................... 42
General Information............................................................................ 42
Specific Information ........................................................................... 43
General Maintenance Tips ........................................................................ 44
Torque specifications .......................................................................... 44
Adjusting relief valves ........................................................................ 44
Removal of safety devices .................................................................. 44
Preventative Maintenance......................................................................... 45
Daily maintenance .............................................................................. 45
Monthly maintenance.......................................................................... 47
Semiannual maintenance (every 6 months) ........................................ 48
Annual maintenance............................................................................ 49
Scheduled maintenance checklist ....................................................... 57
Unscheduled Maintenance ........................................................................ 58
Wear parts ........................................................................................... 58
Changing rams .................................................................................... 58
APPENDIX
Hydraulic Oil Viscosity Chart .................................................................. 62
Torque Specifications for SAE Bolts........................................................ 63
Recommended Emergency Hose Kit ........................................................ 64
Fitting Wrench Sizes................................................................................. 64
Maintenance Checklist.............................................................................. 66
Weld-on Ends / Coupling Comparison ..................................................... 67
Output Charts ............................................................................................ 68
Using the chart .................................................................................... 68
Using a Nomograph .................................................................................. 74
The quadrants...................................................................................... 76
Minimum Pipe Wall Thickness ................................................................ 82
Pictograms................................................................................................. 83
Decal Location Guide ............................................................................... 84
Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:maverick

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Table of Contents
Glossary of Terms..................................................................................... 86
Additional Reading Material .............................................................. 90
List of Lubricants and Nitrogen................................................................ 91
Hydraulic Schematic—Concrete Pump SP305 - Schematic..................... 95
Electrical Schematic SP305 - 2004 Electric ............................................. 96
Electric Schematic CE/Tier III SP305 ...................................................... 97
Nomograph SP 305 ................................................................................... 98
Output Chart available upon request ........................................................ 99
INDEX
Alphabetical Index .................................................................................. 102
iv Operation Manual - SP 305 revDate

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SP 305 OPERATION MANUAL
INTRODUCTION
Manufacturer’s Statement........................................................................ 6
Model Number ......................................................................................... 7
Serial Number.......................................................................................... 7
Model Number Nomenclature.................................................................. 8
ID Tags..................................................................................................... 8
Introduction 5
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Introduction
INTRODUCTION Safety alert symbol and signal word

explanation
This operation manual contains unit specifications, The triangle with the exclamation point inside is used
product overview information, the Safety Manual, to alert you to an important safety point and is called a
operation information, and maintenance information safety alert symbol. One of the following signal words
for your concrete pump unit. will appear after the safety alert symbol:
Manufacturer’s Statement
WARNING Danger
Improper setup / operation creates
hazards. Do not operate this machine Warning
without training. Understand the
warnings in safety manuals and on
Caution
000099.eps
decals.
The information contained in the operation manual is

absolutely necessary for the safety, proper setup,
operation, maintenance, and servicing of your concrete
pump. By learning this information and practicing it • If the safety alert symbol is followed by the signal
every day, you can expect that your concrete pump unit word DANGER, it indicates a hazardous situation
will give you efficient and reliable service year after which, if not avoided, WILL lead to death or
year. serious injury.
For your own benefit and safety, read the information in • If the safety alert symbol is followed by the signal
this manual, and follow the instructions to the letter. word WARNING, it indicates a potentially
hazardous situation which, if not avoided, COULD
Before you operate your concrete pump for the first result in death or serious injury.
time, you should read the operating instructions several
• If the safety alert symbol is followed by the signal
times through. We recommend that you keep a copy
word CAUTION, it indicates a potentially
with the concrete pump for quick reference while on
hazardous situation which, if not avoided, MAY
the job site. The general knowledge must be in place
result in minor to moderate injury.
before you arrive on the job site. Any and all persons
who operate a concrete pump must be familiar with the • The signal word CAUTION used without the
operating instructions. Even a temporary operator (for safety alert symbol means the point addresses a
example, if the normal operator is ill or on vacation) hazard which COULD cause damage to
must be familiar with the operation instructions. It equipment or property.
stands to reason that a person who has not operated a
particular concrete pump before will not know how to Warnings have been placed in the text where needed.
safely operate that concrete pump. The machine is built Additional information used with the signal words is
to the latest technology and safety regulations, but it printed in decal format, as shown below, to explain the
may still be dangerous to people and property if it is specific hazard. Occasionally bold text is used in
operated, maintained, repaired, or used incorrectly. addition to the decal for emphasis.
The illustrations contained in this manual are intended All persons working near the concrete pump unit must
to clarify text passages. They may look slightly be able to recognize hazardous situations. They must
different from your unit, but this has only been allowed know how to avoid these situations and how to react
if it does not fundamentally change the factual quickly and appropriately whenever hazardous
information. situations arise.
Technical modifications that are made to units will be Heed the warnings shown on the decals!
documented in each new edition of the operation
manual.
6 Operation Manual - SP 305 8/4/11

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Introduction
;;;;;;;;;; Whenever you call the factory for spare parts or
;;;;;;;;;;
service, always have the model number handy. You can
DANGER find the model and serial number on the ID tag that is
Hazard and consequence will be shown
mounted to the subframe of the unit (Figure 2).
in this space. For future reference, the model number and serial
000054.eps
number of your machine has been placed in the spaces
provided below
WARNING Orientation
Hazard and consequence will be shown Throughout this manual, we will refer to locations on
the unit as driver side and passenger side. We use these
000057.eps
in this space.
terms instead of right or left to avoid confusion
regarding which way you must be facing to have a left
or right orientation (Figure 1).
CAUTION
Hazard and consequence will be shown
in this space. 000036.eps
Passenger Side
How to reach us
If you encounter a circumstance that is not covered by
this manual, Schwing America’s Service Department
psds.eps
will be more than happy to assist you with all of your Driver Side
parts and service needs. Call us at either of these #’s:
• Minnesota (main office) (651) 429 - 0999 Figure 1
Driver Side / Passenger Side
• Call Center 1- 888-Schwing (724-9464)
orientation
How to order parts
To place an order for spare parts, you can order on line
at schwingparts.com, or you can call our toll free parts
line from anywhere in the continental United States,
except Minnesota. Parts department hours are Monday
through Friday, 6:00 AM to 6:00 PM (central time).
Orders will also be accepted via fax, 24 hours/day.
• Spare Parts 1- 888-Schwing (724-9464)
• Spare Parts (fax) (651) 429 - 2112
Model Number
Serial Number

(P305):pHseriesINTRO.fm Operation Manuall - SP 305 7
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Introduction
Model Number Nomenclature The pumpkit has its own complete model number
which will tell you about the differential cylinder bore
The complete model number of Schwing America’s diameter, rod diameter, and stroke length, as well as the
concrete pumps is designated by codes like the material cylinder diameter. You will find this used on
following: the output charts and nomographs for specific
machines. For example:
SP 305
The code is broken down as follows:
305pknomen.eps
2.5 / 1.75 x 30 : 5
S P 30 5
305nomen.eps
Diff. cyl. bore dia. (in inches)

Diff. cyl. rod dia. (in inches)
Schwing Diff. cyl. stroke length (in inches)
Pumpkit Material cyl. diameter (in inches)
Pumpkit yards per hour
Diameter of material cylinder (5 inches)
The bore diameter of the differential cylinders in this
The “P”, as the illustration shows, stands for pumpkit. example is 2.5 inches, while the rod diameter is 1.75
The 305, in this example, designates 30 yards per hour inches. The stroke length of the differential cylinders is
and the 5 inch diameter of the material cylinders. 30 inches, and the diameter of the material cylinders is
5 inches.
Other pumpkits are available for this machine style,
and using any of them would change the model number
of the unit. For example, if you ordered this unit with a ID Tags
204 pumpkit, the model number of the same unit would There is an identification tag on the unit, called the
become: main ID tag. The main ID tag is attached on the
passenger side of the subframe (Figure 2).
P 305
SN stamping
mavIDtag.eps
ID tag
Figure 2
Main ID tag and stamped serial number locations

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Introduction
NOTE!
The information represented on the tag is
for illustration only. Check the tag on your
unit to obtain the specific numbers which
apply to your unit.
Main ID tag
The main ID tag contains model information, the serial
number, the year of manufacture, the weight of the
unit, the strokes per minute and material pressure, and
the hydraulic systems. The unit serial number is
stamped into the subframe immediately above or below
the ID tag (Figure 3).
If your ID tag is missing

If the tag has been removed from the unit and you must
have some information about it, read the main serial
number that is stamped into the steel subframe. The
serial number is located at the base of the tongue on the
right-hand side, as shown in Figure 2. When you find
the number, call Schwing America’s Service
Department for the information. The unit files are
arranged by this serial number, and we can find out
anything about the unit from the file that corresponds
to this number. New ID tags are available once we have
the unit serial number.
1 7 1 5 3 0 0 0 1
SUBSIDIARY OF
AMERICA INC. GmbH.
5900 Centerville Rd Herne / Germany
White Bear, MN 55127 Phone: (02325) 7871
Phone: 651-429-0999 www.schwing.de
www.schwing.com
This product is covered by one or more U.S. patents - see patent decal
MODEL SP 305 SERIAL NO. 171530001 YEAR 2009
MATERIAL
WEIGHT 3350 LBS. STROKES PER MINUTE 40 MAX.
PRESSURE
625
30301733F
Max. hyd. System System System System System

pressure: 2500 1 n/a 2 n/a 3 n/a 4 n/a 5
mavmainID.eps
Figure 3
Main ID Tag (for reference only)

(P305):pHseriesINTRO.fm Operation Manuall - SP 305 9
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Introduction
NOTES

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SPECIFICATIONS
SP 305 ................................................................................................... 12
Functional Description of the Main Control Block .................................. 13
Specifications
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Specifications
SPECIFICATIONS
Note! All specifications are subject to change without notice.
Model SP 305
Pump Kit 2.5/1.75 x 30:5
Orientation Piston Side
Strokes/minute (max.) 40
Material Output (max.) 30 yd3/hr (23 m3/hr)
Material Pressure (max.) 625 PSI (43 bar)
CAT C2.2NA (Tier 4 interim)
Power (Diesel Engine)
50 HP (37 Kw)
Power (Electric Motor) 40 HP (30 Kw)
Power (hyd. pumps) 30 Kw
Output (hyd. pumps) 27 GPM (102 lpm)
Speed (hyd. pumps) (diesel) 2700 RPM**
(elect. motor) 1800 RPM
Pressure (max. hyd.) 2500 PSI (172 bar)
Max. horizontal distance 800 feet (244 m)
Max. vertical distance 200 feet (61 m)
Max. aggregate size 1” (25 mm)
Minimum Slump 0”
Material Cylinder Diameter 5” (125 mm)
Stoke Length 30” (762 mm)
Differential Cyl. Diameter 2.5 (63.5 mm)
Concrete Valve Type S
Hopper Height 42” (1065 mm)
Fuel Tank Capacity 15 gal. (58 l)
Gross Weight 3400 lb. (1525 Kg)
Length 149” (3785 mm)
Width 64” (1625 mm)
Height 66” (1675 mm)
Remote Cable Length 100 ft. (30.5 m)
Electric Motor (optional)*
*Contact Schwing America for specs
*
** Max RPM of the hydraulic pumps is calculated while the pump is under a full load. Depending on the unit it is acceptable for
the max RPM to vary slightly from the published estimate.

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Specifications
Functional Description of the

Main Control Block
When the spool of the NG06 solenoid valve is in the
neutral position (no electrical signal to the solenoids of
the NG06), the S-port of the load sensing pump is
vented to tank so that the pump is in “stand-by” mode.
When the NG06 solenoid valve is switched to an
activated position (forward or reverse), the S-port of
the load sensing pump is closed, the pump will create a
pressure, and at 3.5 bar the S1 spool starts to open the
internal connections to the S2 spools. At 5 bar the S1
spool is totally switched over into the activated
position, so the pump kit starts to work. (The 5 bar
pressure is always necessary to hold the S1 spool in the
activated position, just like the NG 20 control block).
The signal of the shifting cylinder pilots the S2 spool
and the signal of the switching valve pilots the S3
spool.
The needle valve cartridge DVE 16 of the manifold at
the pump regulates the flow of the pump, and the direct
acting SUN pressure relief cartridge limits the max.
pressure if the regulator of the pump fails. (The SUN
pressure relief cartridge is good for a flow of 200 l/
min.)
The small accumulator damps the pressure spikes.
To stop pumping, the NG06 solenoid valve has to be
deactivated; the spring centers the NG06 spool in the
neutral position. The S1 pilot system, the S-port of the
load sensing pump, and the accumulator are vented to
tank, the S1 spool switches into the neutral position,
and the pump kit stops working. The nozzle in the P-
line restricts the flow so that the accumulator is vented
softly. During “stand-by” mode, the pump creates the
stand-by pressure, so there is a flow through the nozzle
back to tank. If the stand-by pressure of the pump is
adjusted to 15 bar (218 PSI), there would be a flow
through the 1.5mm orifice of 4.3 l/min. In this
operating status we would create a lost energy of 0.1
KW.
Even a bigger orifice (quicker reaction) should not
cause a heat problem.

(P305):pHseriesSPECS.fm Operation Manual - SP 305 13
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Specifications
NOTES

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SAFETY
How to Order Additional Safety Manuals ............................................... 16
Warning Labels (Decals)........................................................................ 19
Safety
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Safety
SAFETY Schwing phone numbers

Spare Parts (Small line)(800) 237 - 8960
The information contained in this section of the Spare Parts(800) 328 - 9635
operation manual is absolutely necessary for the safe
Spare Parts (fax)(651) 429 - 2112
setup, operation, maintenance, and servicing of your
concrete pump and placing boom. Spare Parts (toll free fax)(877) 554 - 5119
The Safety Manual is a separate document from the In Minnesota,
rest of this manual. Because it is a separate document, or outside of continental U.S.(651) 429 - 0999
the page numbering and formatting will be different
NOTE!
than the rest of your manual. This was done to allow
the Safety Manual to be inserted in many different To order manuals, copy the order form
shown on page 18, and Fax it to Schwing at
publications while appearing exactly the same in all one of the above numbers, or mail it to:
places. The Safety Manual has its own alphabetical
index, which is found at the end of the Safety Manual.
Schwing Spare Parts Department
5900 Centerville Rd
How to Order Additional Safety St. Paul, MN, 55127
Manuals
To place an order for additional Safety Manuals (or any
other manual), you can call our toll free parts line from
anywhere in the continental United States except
Minnesota, where you must use the main Schwing
office number. Schwing Spare Parts Department hours
are Monday through Friday, 6:00 AM - 9:00 PM
(Central Time). Orders will also be accepted via fax, 24
hours/day.
We will ship one set of each of the following manuals
free of charge for each unit that is listed with its serial
number and current location:
Safety Manual, English: 30327535
Safety Manual, Spanish: 30381024
Co-worker Safety Rules, laminated, English: 30381022
Co-worker Safety Rules, laminated, Spanish:
30381027
Co-worker Safety Rules, paper, English: 30381023
Co-worker Safety Rules, paper, Spanish: 30381028
Small line Safety Manual, English: 30381680
Small line Safety Manual, Spanish: 30381841

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Safety
October 27, 2008
Safety/Service Bulletin 1023-08

Subject: Release of Safety Manual version 6.x.1
Dear Schwing Customer,

The Safety Manual has been updated to version 6.0.1 and has several changes most of which
pertain to the more common incidents currently being reported in the concrete pumping industry
(hose whipping, tip overs and electrocution). One notable pagination change occurred. The
pipewall thickness chart, which has always appeared on page 73 of the Safety Manual, has been
pushed back to page 75. In the past, releases such as this would include the complete paperback
manual and a non-laminated version of the updated Co-worker Safety Rules. In an effort to “Go
Green” we have decided to ship a CD containing six PDF files: Version 6.0.1 of Safety Manual
(English & Spanish); version 6.0.1 of the Co-worker Safety Manual (English & Spanish); and
version 6.0.1 of the Line Pump Safety Manual (English & Spanish). This package, as in the past,
also includes an order form for hard copies of any of those documents. Just fill out the attached
form(s) and fax it to us at the number listed. We will ship one of each manual ordered free of
charge for each unit that is listed with its serial number (including line pump units if you want that
manual) and current location. Additional manuals are available at a nominal fee. The Co-worker
Safety Rules are available as laminated books intended to be kept on the pump for easy reference.
Please instruct your operators to make the co-worker information available to the placing crew
and laborers and to read the information to the workers if they believe the workers would not
understand the printed text. If you are planning any safety training for your customers, the Co-
worker Safety Rules booklet is also available in a non-laminated version at a fraction of the cost. If
you choose to order the un-laminated version, the part numbers are 30381023 for English and
30381028 for Spanish. You could also print them yourself from the file on the enclosed disc. Of
course, the non-laminated version is not intended to be kept on the pump. It is our objective to get
a copy of each of these publications into the hands of every operator and the workers around the
pump. Please help us make the Safety Manual effective for jobsite safety by obtaining a copy for
each of your operators and encourage them to read and understand the rules. Older versions of the
manual should be discarded when the new version is in hand.
Thank you in advance for your consideration in this matter.
Best Regards,
Danny L. Mace
Manager, Product Safety Department
Schwing America, Inc.
safemanbulletinletter.fm

(P305):pHseriesSAFETY.fm
Operation Manual - SP 305 17
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Safety
Safety Manual v 6.0.1 Order Form

Please complete this form and mail to: 5900 Centerville Road
White Bear, Mn. 55127
Or send via fax to: Fax # (651) 429 - 8261 Telephone (651) 429-0999
(publications dept.) Attention: Publications
Company:
Street Address:
We cannot ship manuals to a P.O. box
City, State, Zip:
Phone ( )
Attention:
Manual part number:____________________ Model number:
Manual part number:____________________ Serial number:
Safety Manual, Bound, English v 6.0.1 .................................................................................. Part #30327535

Safety Manual, Bound, Spanish v 6.1.1 .................................................................................. Part #30381024
Co-worker, Bound & Laminated, English v 6.0.1 .................................................................... Part #30352799
Co-worker, Bound & Laminated, Spanish v 6.1.1 .................................................................. Part #30381027
Line Pump, Bound, English v 6.0.1 ......................................................................................... Part #30381680
Line Pump, Bound, Spanish v 6.1.1 ....................................................................................... Part #30381841
Feel free to copy or otherwise reproduce this form if more copies are needed. internal250:servicebulletins:601order form.ai
page 2 of 2 safemanbulletinletter.fm

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Safety
Warning Labels (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 this 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 the
Schwing America Call Center at 888- Schwing (724-
9464). 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.

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Safety
NOTES

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OPERATION
Preparing for the Job ............................................................................. 22
Setting Up .............................................................................................. 23
Starting the Pour.................................................................................... 27
Cleanout ................................................................................................ 31
Special Pumping Situations ................................................................... 34
Operation
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Operation
OPERATION •
•
a shovel
any paperwork required for the job, such as
directions and contact person, fuel permit card, cab
Preparing for the Job card, insurance certificate
• any safety devices required for travel in your
Find out what kind of concrete you will be pumping. location, such as flares, caution signs, first aid kit,
You should use a pipe and/or hose system that is three fire extinguisher
to four times bigger than the largest rock in the mix.
Be sure that lights and brakes on the towing vehicle
You can use the chart in Figure 1 to select the correct
and on the trailer are in good working order before
pipe diameter for the job.
leaving the yard.
Check all fluid levels on both the trailer and the towing
vehicle before leaving the yard (Figure 5).
Recommended minimum
Largest stone size pipe/hose diameter
OilLEV.eps
3" 1"
8 (Peagravel) 12
1"
2 2"
3"
4 3"
min_pipe_dia.eps
1" 4"
Figure 4
A guide for sizing pipeline on a SP305 Oil Level
Indicator
Be sure that there is a water source on the job. You will
not be able to clean out without water.
Be sure that you have all items required for the pour. Figure 5
You will need: Oil level indicator
• a 5-gallon bucket
• a tool box with tools
• enough hoses, pipes and clamps to do the job
(Never join two different sizes of pipes or hoses Check the tires on both the trailer and the towing
without a reducer. The longer the reducer, the less vehicle before leaving the yard.
pressure it will take to make the reduction. Never Don’t overload the trailer by using it as a cargo trailer.
join two different pipe styles (for example, a metric The chassis was designed to carry only the weight of
coupling with a heavy-duty coupling). There is no the trailer. Don’t travel with concrete in the hopper.
clamp made that will be able to keep the two sizes
together. If you have to change pipe styles, an Towing the unit
adapter pipe must be used. Any pipe or hose that
You will need more stopping distance when pulling a
you use must be able to withstand the maximum
trailer than when you are not. Do not tailgate.
pressure of the concrete pump. The SP 305 can put
out significant pressure on the material. Use only Be extremely careful when backing up with a trailer. If
pipe and hoses that are in good shape. Do not use you are not experienced with trailer backing, you
pipe that has dents or thin spots. Do not use hose should practice before getting on a public roadway.
that is frayed, has loose ends, or has loose rubber
on the inside.)

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Operation
The SP 305 has electric brakes as standard equipment. (Example: If the pump cannot be moved at
Be sure that the electrical connections from the towing all, you must start laying pipe at the pump.)
vehicle are secure and working, and always use the Lay out the pipe in such a fashion that you
will not have to add pipe or hose during the
breakaway switch (Figure 6.) pour, only remove it.
Breakaway switch and cable
Figure 7
Proper cribbing and chocking
brkaway.eps
Be sure that all clamps are pinned and tight.
Figure 6 Never join two different sizes of pipes or hoses without
The breakaway switch a reducer. The longer the reducer, the less pressure it
will take to make the reduction.
Never join two different pipe styles (for example, a
Setting Up metric coupling with a heavy-duty coupling). There is
no clamp made that will be able to keep that spot
Arrival at the job together. If you have to change pipe styles, you must
use an adapter pipe.
When you arrive on the job, first check with the job
supervisor to determine where you should set up. If Any and all pipes, hoses, clamps, adapters, or reducers
possible, choose a spot that allows hopper access for that you use must be able to withstand the maximum
two ready-mix trucks. A flat, firm, and dry location is pressure of the concrete pump. The maximum concrete
ideal. Find your source of water for the waterbox and pressure that your pump can create is stamped into the
cleanout. main ID tag, as described in the Introduction section of
this operation manual. Know this pressure number for
If the weather is above freezing, fill your waterbox as your unit, and be sure all pipe and hose components
soon as you can. If it is below freezing, wait until just you use can withstand this pressure.
before you being pumping to fill the water box.
Use only pipe and hoses that are in good shape. Do not
Laying pipe use pipe that has dents or thin spots. Do not use hose
that is frayed, has loose ends, or has loose rubber on
Generally, it is best to set up the outlet pipe and/or hose the inside.
from the required point of discharge backwards
towards the pump. When the pipe is in place, move the Lay out the remote control cable so that you will be
pump to meet the pipe, then chock the wheels and set able to see the point of discharge when pumping
the manual outriggers (Figure 7). begins. Be careful not to leave the unit alone while it is
pumping, however, because children are attracted to
NOTE! construction machines. An ideal spot for the remote
In some circumstances, you must start gives you visual access to both the point of placement
setting the delivery system from the pump and the pump. If that is not possible, you must have a
and work towards the point of discharge.
spotter for either the point of placement or the pump.

(P305):pHseriesOPERATION.fm
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Operation
Before you start the engine, fill the waterbox with If it’s cold outside, start the engine and run it at an idle
water, and grease the pivot yoke grease zerks and shaft while you are waiting for the concrete to show up. This
bushings. will cycle the hydraulic oil and warm it up a bit. This
step is not necessary if it’s warm outside. (See the
WARNING items in the following section for engine starting tips.)
Do not grease the pivot yoke while the Starting the engine
machine is stroking. Stop engine and
Either the remote control cable or the dummy plug
W026.eps
verify zero pressure before greasing.
must be plugged into the remote control cable
receptacle on the control panel. The hopper grate
must be in the down position. Adjust the manual
throttle to about 1/4 to start. This allows the oil pressure
to build, which lubricates the cylinders. This is
especially important in cold weather.
• Turn the Pump Switches to the OFF position.
Figure 8 Grease Zerks
Pivot yoke • Place Pump shift lever into the NEUTRAL
grease zerks position.
Grszerk.eps
• Make sure all Emergency Switches are in the RUN

Replace the waterbox cover before starting the engine, positions.
and do not remove it when the engine is running. • If using the optional radio (cordless) remote, the
Put a couple of shovelfuls of sand or dirt in the bottom engine won't start unless radio remote and receiver
of the hopper, above the cleanout door. This will keep are linked. Turn the radio on by using the following
concrete from filling up that area and setting. sequence:
Spray the back of the hopper and nearby areas with 1. Turn the ignition key to the ON position which
form oil. This will greatly speed up the cleanout supplies power to the receiver.
process when you have finished pumping. 2. Engage the E-stop on the radio remote.
Talk to the hose handler and agree on hand signals. 3. Press power button on radio remote, light will
Know the signals for starting, stopping, speeding up, flash.
slowing down, and so on. The ACPA recommended 4. Disengage E-stop on radio remote, light will be
hand signals are shown in the Safety Manual. solid.
The delivery system will have to be lubricated before • Wait 10 seconds before turning ignition key to
you can pump concrete through it. Many operators use engage the starter.
a sack of portland cement and water (mixed together in • Start the engine by turning the switch to the start
a bucket to a creamy consistency) to lubricate the position. Release key when engine starts. After the
delivery system. Other operators use specially designed engine is running, the charging system and oil
pipeline lubrication packets that are mixed with water pressure lamps should go off. If they don’t go off
to lubricate the line (sometimes referred to as pipe within 5 or 6 seconds, stop the engine and find the
snot). If you don’t know where to get these packets in cause of the problem.
your area, contact your local Schwing dealer.
Shoveling.eps
CAUTION
Figure 9
Sand in the The engine can be destroyed by lack of oil pressure.
cleanout door Don’t run the engine if the oil pressure light won’t go
opening at the out.
start of the day
helps cleanout
Get your slurry mixing items ready, but don’t actually

mix the slurry until concrete is on the job.

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Operation
Remote control
CAUTION (banded to hopper grate
when unit is delivered) Engine throttle
If the charging system lamp won’t go out, you are not
charging the battery. The engine doesn’t need
electricity to run, so you may still be able to pump for a
short time before the emergency stop valves open and
send all the oil back to tank.
Concrete pump
pressure guage
Control panel
(a.k.a. Operator's panel) Volume control
knob (stroke limiter)
cntrlocations.eps
Driver side
emergency stop switch
pressuregauge.eps
Figure 10
Pressure gauge location
Don’t run the engine at high RPM until it has warmed

up by running for a couple of minutes. DSestop.eps
You don’t need to lower the RPM of the engine to

adjust the strokes per minute output of this unit. The
following pages explain ways to control the unit. Figure 11
Locations of the control devices
Controlling the pump
These are the places on the unit that have operational
control functions:
• The control panel
• The volume control knob
• The throttle control
• The remote control box
• The driver side emergency stop switch
Figure 11 shows the location of the controls.

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Operation
The control panel

The control panel (Figure 12) contains:
Diesel Engine Engine
Emergency glow plug oil pressure coolent temp.
stop switch lamp lamp lamp Charging
system
lamp
controlpnl.eps
Vibrator Hour
-Forward- meter
-Off_
Engine RPM gauge
-Manual- 20
Hobbs
RPM 30
switch 10
QUARTZ
000000
I HOURS
X 1000 40
0
Optional electronic
throttle control
Agitator
Figure 12 On-Off_
switch
The control panel Pump
Off
Oil cooler switch
switch
Dummy Pump
Plug -Forward-
-Reverse-
switch
Pump
-Local- 98347087 Key switch
-Off-
-Remote-
switch
• Engine oil pressure indictor lamp - This lamp • Key switch - Starts and stops the diesel engine, and
illuminates only when there is no engine oil supplies power to the rest of the electrical system.
pressure, so it is normal for it to light when the key • Charging system lamp - This should illuminate if
switch is on but the engine is not running. It is not the key switch is in the on position, but the engine
normal for it to light when the engine is running; if is not running. It should also illuminate if the
that happens, you should stop the engine engine is running but the V-belt breaks or the
immediately. alternator stops working.
• Emergency stop button (also known as an E-stop • Remote control cable receptacle - This is where
switch). This is a standard, red-faced push button. you plug in the remote control box cable. The plug
Pushing it disables all the circuits on the unit, is covered with a weather proof cap which must be
including the accumulator circuit, by stopping the removed to plug in the remote cable.
diesel engine. The engine stops because the E-stop • Concrete pump local - off - remote switch - Selects
switch also disables the diesel engine fuel shutoff between local control concrete pump on, concrete
valve. The E-stop switch must be turned and pulled pump off and remote control. When remote control
to reset, and it must be out to start the engine. The is selected, the pump on - off function is
emergency stop switches on the driver side of the transferred to the remote control box. When you
pump and on the remote control have identical select the off position, the hydraulic pump
functionality and are wired in series with the maintains a standby pressure of 300 PSI.
emergency stop on the control panel.
• Concrete pump forward - off - reverse switch -
• Hour meter - This meter keeps track of the number When the local - off - remote switch is in the local
of hours on the diesel engine and hydraulic pumps. position, then the forward - off - reverse switch is
Use it to keep track of hours for maintenance active for controlling pump forward and reverse
purposes. functions. This switch does nothing when the local
• Engine temperature indicator lamp - This lamp - off - remote switch is set to remote.
illuminates whenever the engine oil becomes too • Other switches - as labeled
hot. Hot oil is a sign of a loose, worn, or broken V-
belt or of oil that is so old that the viscosity
properties have broken down.

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Operation
The remote control box Throttle control

The cable remote control box (Figure 13) transfers the Push the button on the end of the knob (Figure 15),
forward - off - reverse functions of the control panel then pull the knob and cable out to increase RPM. Push
to a handheld electrical enclosure. The remote control the button on the end of the knob, then push the knob
can be carried away from the pump to allow the and cable in to decrease RPM.
operator to select the best vantage point to see both the
Pull cable OUT to increase RPM,
point of discharge and the pump. push IN to decrease RPM.
throttle.eps
remboxonly.eps
THROTTLE
Friction ring
Figure 13
The cable
remote control 30362341
box Using your thumb,

push button on end
of knob to release
Note about the electric system

• The machine cannot be operated unless either the Figure 15
dummy plug or the remote control cable is plugged Adjusting the throttle
into the remote control cable receptacle on the
control panel. The emergency stop circuit is
completed by either device.
The pressure gauge
The volume control knob This gauge indicates pressure in the hydraulic circuit
(Also known as the stroke limiter) (Figure 14). This that pushes the concrete and includes the accumulator.
knob tells the hydraulic pump to put out more or less NOTE! Because accumulators store hydraulic energy,
oil (independent of the motor speed) to control the rate it is critical that this gauge work at all times. Do not
of concrete output. operate the unit unless this pressure gauge is
functional!
Turning the knob clockwise (CW) causes less oil and,
therefore, less strokes per minute.
Turning the knob counterclockwise (CCW) causes the Starting the Pour
pump to put out more oil and, therefore, more strokes
per minute. Concrete mixes
This machine is capable of pumping many different
mix types, up to and including one inch rock, but the
Less mix must be graded with some components in all of the
strokes
different sieve sizes. Generally speaking, any durable,
good quality concrete will pump. If you have trouble
pumping a mix, look at the mix design. Sieve sizes #4,
#8, and #16 must be present for the concrete to have
good pumping characteristics.
More
strokes Preparing for concrete
volumeknob.eps
When concrete arrives on the job, have the ready-mix
Volume control knob driver discharge a small amount of concrete onto the
(stroke limiter)
Figure 14 chute so you can look at it. The concrete should be well
The volume control knob mixed, meaning that you won’t see just large rocks or

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Operation
sand coming out. When a ready-mix truck has worn- • Plug in the remote cable; then select remote on the
out fins, the concrete does not always become well control panel switch. On - off, and forward -
mixed. The bulk of the load will be pumpable, but the reverse control is now transferred to the remote
first and last chute full will not pump. If you are box switch (Figure 17).
allowed to, have the ready-mix driver put the chute to
the side and dump the first chute full on the ground; Remote Cable Plug
then bring the chute back to your hopper when the remove dummy plug and
concrete looks good. It’s important to have good insert this plug into receptacle
concrete until the pipe is completely filled, so if the
mix doesn’t look pumpable, don’t put it into your
machine. This is something that becomes easy to see
with experience. Many times, water will have to be
added to the concrete in the truck to make the
consistency that is desired for the job. Find out from
the job supervisor if the slump is correct and who has
the authority to add water to loads as they arrive.
Ready the pump

The pump can be operated at the control panel or with
the remote control box. When operating, you must be
able to see both the pump and the point of discharge. If
you cannot see one or the other, a spotter must be used.
Use the remote control if it allows you to get a better
view of the job. If you decide to use the remote control,
you should get it ready and plug it in now.
remoteboxWreel.eps
• To use the remote control, first select “off” with the
“local/remote” switch (Figure 16).
Figure 17
The remote cable
localremote.eps
• Select a low to low-medium setting on the volume

control knob. This will make the concrete move
slowly through the line, which reduces the chance
20
10
RPM 30 Hobbs
QUARTZ
000000
of plugs or trapped air (Figure 18).
I HOURS
0 X 1000 40
Mix your slurry

When the concrete is right, mix your lubricating slurry
and pour it into the hopper or delivery system
(depending on whether you are mixing commercial
slurry or portland cement and water). If you have
poured the lubrication into the delivery system, be sure
to reconnect the system to the pump.
Beginning to pump
98347087
• Have the ready mix driver fill the hopper with
Local/remote concrete, and stop when the hopper is full.
Local (up position)
-Off- (center position) • Clear the discharge area of personnel before
Remote (down position) starting the pump for the first time of the day, after
Figure 16 you’ve moved, or anytime air has been introduced
Select OFF before plugging or into the line or the line has been taken apart.
unplugging the remote cable

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Operation
plugs, you should monitor the pressure gauge, until

concrete comes out of the discharge. If you cannot
see the point of discharge from the area around the
Less pump (near the gauge), arrange for a spotter to
strokes monitor the end of the line. The spotter should
watch that no one gets near the discharge and alert
you when concrete is flowing from the end.
concretepumpswtch.eps
More 20
30 Hobbs
strokes 10
RPM QUARTZ
000000
I HOURS
0 X 1000 40
volumeknob.eps
Volume control knob Concrete pump

(stroke limiter)
switch
Forward
(up position)
Reverse
Figure 18
(down position)
Adjust the volume control
98347087
remboxonly.eps
WARNING
Clear the discharge area before first
000359.eps
starting, restarting after moving, or anytime

air has been introduced into the line.
30362341
000518.eps
Figure 19
Activate the pump
• Pump slowly (few strokes per minute) until

concrete has come out at the discharge point.
• Adjust the engine throttle to maximum RPM. This • If you hear the engine starting to bog down, notice
will allow the engine to develop it’s rated the pressure gauge. If the pressure goes to the
horsepower. Note! You do NOT want to pump fast maximum setting of 2500 PSI, you may have a
when first starting. Be sure that the volume control plugged line. Immediately switch the forward /
knob is at a low setting (Figure 18). reverse switch to the “reverse” position and pump a
• When the placing crew signals to begin pumping, couple of strokes. Switch back to forward and
activate the switch of the control panel or the watch the pressure gauge. If the pressure rises to
remote control box (Figure 19). To get warning of the relief valve setting again, switch immediately

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Operation
back to reverse and relieve the pressure in the line.

See the information in this manual about removing
plugs from lines starting on page 34.
• Once the concrete comes out at the discharge point,
move yourself into position to see the discharge.
Remember, you must also be able to see the pump,
so arrange for a spotter if you cannot. In some
circumstances, it is allowed to have the ready mix
driver monitor the pump end of the job. If you will
be allowing it, you MUST be sure that the ready
mix driver understands how to stop the pump and
what will happen if air is allowed into the delivery
line. The ready mix driver may refuse the
responsibility of watching the pump. If this
happens, you will still need to arrange for a spotter. airhop1.eps
Because of the risk of injury to the ready mix

driver and the placing crew if air is introduced into
the delivery system, the hopper level must be
monitored at all times. If the ready mix driver will
not do it, you must still arrange that it be done
(Figure 20).
• Adjust the volume control knob as needed for
faster or slower pumping.
• Watch the hose handler closely. Be ready to stop
the pump when required. Kinking a placing hose
while pumping can be dangerous, because it causes
Svlvminlev.eps
the pump to go to maximum pressure, simulating a
blockage. If you see that the placing crew is minimum 4 inches above
kinking the hose, stop pumping and talk to them material cylinder opening
about it.
• Keep an eye on the pump. Listen for engine
bogging (a sign of plugging). Watch that no one, 000518.eps
especially children, get near the unit.

• When the ready-mix truck is empty, the driver
should signal you by voice or horn. If you have
shown the driver how to stop the pump, you could
also be signaled that way. In addition, an
experienced pump operator will be able to tell by
the sound of the rotating drum that it is almost
empty. The remaining larger aggregate in an
almost-empty drum falls from the fins, and instead
of hitting on concrete, it hits on steel, making a
distinctive sound. Be aware to listen for these
clues, so that you can stop the pump with a full
hopper. (You will need a full hopper so that you
can keep the concrete moving if you have to wait Figure 20
for the next load.) If no more concrete will be Do not allow air to enter the
coming, such as at the end of the pour, try to end pumping cylinders. Keep the
up with only about a third of a hopperful. hopper full when pumping.
WARNING! You cannot completely empty the
hopper, because air will be drawn into the concrete

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Operation
cylinders. This air will compress during the hose, it will probably cause a plug the next time the
pushing stroke and explode into the hopper when pipe or hose is used. Cleaning the delivery system can
the concrete valve switches (Figure 20). be done one of four ways:
• As discussed in the safety rules section of this 1. Pump out the delivery system using the
manual, do not let the ready-mix driver wash out concrete pump’s pressure. Fill the hopper with
his drum or chute in your hopper. This may cause water and pump until you reach the minimum
plugging because the cement and other fine hopper level. Refill the hopper with water and
particles are washed away from the course continue pumping. When the concrete has
aggregate. The same holds true if it is raining hard; disappeared from the hopper and concrete valve
try to protect the hopper from getting so much area, stop the pump, reverse it to remove any
water that the aggregates start to separate. residual pressure, and disconnect the delivery
• On many jobs, pipe or hose will be removed as the system from the concrete valve outlet. Open the
day goes on. Wash the removed pipe, hose, clamps, cleanout door and rinse the hopper. Use the rake
and gaskets so the concrete residue doesn’t harden to pull concrete from the valve through the outlet
(Figure 21). pipe, and rinse the valve. Shift the valve, and
rinse the open cylinder. Put a sponge ball in the
delivery system, and reconnect the line to the
pump outlet. Refill the hopper with water, and
pump until you reach the minimum hopper level.
Refill the hopper and, again, pump until you
reach the minimum hopper level. Continue doing
this until the sponge ball has been pumped out of
the delivery system. This is the method used by
most operators in most circumstances. It has the
advantage of getting most of the concrete out of
the hopper and material cylinders while you are
cleaning the pipeline. The disadvantage of this
method is that it takes a large water supply to get
the entire system and pump clean.
2. Manually clean the delivery system. Reverse
the pump to remove any pressure in the delivery
system. Stop the pump and the engine.
Disconnect the delivery system at all connection
000522.eps
points, manually empty the hoses and pipes, and
immediately wash them inside and out. For long
Figure 21 hoses, you can pour 5 or 10 gallons of water in
Wash system as it is removed one end of the hose, then walk the hose towards
the other end, lifting as you go, so the water will
always travel downhill towards the far end. This
method is best and quickest when there are only
Cleanout a few pipes or hoses to clean. It has the
advantage of taking the least amount of water to
Clean the delivery system finish. If you find that you must use this method
Begin the cleanout procedure as soon as the pour is for long delivery systems (if the unit is broken,
finished. Start by pumping out as much concrete from for example), get some help so that you can clean
the hopper as possible. Again, be sure that you do not out the unit before the concrete sets. If no help is
empty the hopper to the point that air can be available, you should know that if concrete sets,
sucked into the concrete cylinders! it ruins whatever is holding it. It is harder and
Clean out the delivery line. It is very important that all more expensive to replace the concrete valve and
concrete is removed from the delivery system. If even a material cylinders than to replace a delivery
small amount of concrete is allowed to set in a pipe or system, so adjust your cleanout accordingly.

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Operation
3. Pump out the delivery system with source delivery system and clean them manually
water pressure. Reverse the pump to remove anyway, so it might be just as quick to clean the
any pressure in the delivery system. Stop the entire delivery system manually.
pump and engine. Disconnect the delivery
system from the concrete valve outlet. Install a
sponge ball in the delivery system. Place a water Air discharge
blowout cap on the delivery system. Hook a hose regulator valve
between the water source and the water blowout
cap and pump water into the delivery system
Air inlet
until the sponge ball appears at the other end.
regulator valve
This method doesn’t always work, because the
source water pressure may not be high enough to
move the concrete through the delivery system.
ca
4. Blow the delivery system with compressed air. po
nly
.ep
s
por
We do not recommend this method, because cle ts sp
compressed air can be very dangerous if not ano ace
cov ut ba d so
handled correctly. Use it only as a last resort. e ll a
sim r both cann
Complete safety rules for using compressed air ulta po ot Water/air inlet
neo rts
are discussed in the Safety Manual. Never use usl
y
compressed air to clean out rubber hose
because the hose will jump around and move
through the air by the force of the pressure in the Figure 22
hose. You cannot hold or stand on the hose to Blow-out head
steady it because the forces will exceed your
weight, even if you are a huge person. You • Clean the clamps and gaskets used on the delivery
cannot have an entire crew of people holding the system. Do not leave any concrete, stones, or sand
hose because the force will exceed all of their on them, or the clamps won’t properly close the
weights combined. If you have only steel pipe to next time you use them.
clean, it is possible to use air, but it can still be
dangerous. Always control the discharge end Clean the pump
of the pipeline. Either a catch basket must be
Clean the hopper and concrete valve. If not already
used, or the discharge must be made safe in
done, stop the pump and disconnect the delivery
some other manner, such as routing it into a
system. (Note! Once the delivery system is
ready mix truck. The blowout head must have
disconnected, there is no more danger of compressing
two pressure bleed possibilities: an inlet valve
any air that gets sucked into the material cylinders).
and a bleed-off valve. There must be enough
Proceed as follows:
space between the two valves that a cleanout
ball cannot block both ports at the same time • Restart the unit and pump out the rest of the
(Figure 22). Remember, if you use this method, concrete from the hopper and concrete valve. Put
you must disconnect all rubber hose from the the pump in reverse, and give it one stroke. Stop
the pump as soon as the concrete valve switches
(this step assures that the material cylinder is
empty and the piston cup is towards the back of the
unit).
NOTE!
If you used method # 1 to clean the pipeline,
there will only be some clean, washed stones
and sand left in the material cylinders and
concrete valve; in that case, you can skip
this step.

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Operation
• Stop the unit. Open the cleanout cover on the

bottom of the concrete valve (Figure 23).
Hopper grate
interlock switch
epss
h.ep
tch.
swtc
cksw
trlck
inintrl
Svlv.eps
Cleanout door handle

Figure 24
The hopper grate interlock switch
Figure 23
Cleanout door concrete valve. Again, NEVER reach into the
concrete valve with your hands. Use the supplied
• Leave the hopper grate in place. Spray water cleanout rake to remove any material that won’t
through the grate into the hopper to clean concrete come out with the water spray. Continue stopping
out of the corners and the concrete valve. If you the unit, switching the concrete valve, and cleaning
need to rotate the hopper grate to the open position until the water flows out clean and clear.
to chip away hardened concrete or for any other
• Spray into the top of the hopper again, as some
reason, the pump must be stopped. To assure that
material will have been washed into the hopper
this is done, the electrical supply to the concrete
area by cleaning the inside of the concrete valve.
pump circuit is connected through an interlock
When it is clean, close the cleanout door on the
switch on the hopper grate. The pump will not
bottom of the concrete valve housing.
operate unless the hopper grate is shut, and the
pump will stop if you rotate the grate open while it • ALWAYS DRAIN THE WATERBOX AT THE
is running. Do NOT disable or bypass the hopper END OF EACH POUR. The reason for this to
grate interlock switch. It was installed for your prevent the oil from being contaminated by
protection (Figure 24). water. Here’s how it happens:
As the oil cools after a pour, it creates a vacuum in
• Stop the pump. Spray water through the outlet pipe
the differential cylinders. This vacuum causes the
into the concrete valve opening. One cylinder will
water in the box to be pulled past the packing seals
be exposed through the valve. Use the supplied
of the cylinder and into the oil. The result is milky
cleanout rake to dig out excess material. When you
oil.
have removed as much material as you can, switch
the concrete valve as instructed below. • With the engine stopped, remove the waterbox
cover. Find the drain plug on the bottom of the
NOTE! waterbox (Figure 25). Remove the plug by
Never put your hands into the concrete unscrewing the T-handle until the plug becomes
valve! loose. When the plug is out, the water will drain
• Make certain that no one is near the concrete valve out of the hole. Spray water into the waterbox, the
or the waterbox. Start the pump, and let it stroke in material cylinders, and around the tension rings
reverse until the concrete valve switches to the where the hydraulic cylinder rods come out of the
other material cylinder. Stop the pump again. waterbox wall. Do not allow cement particles or
• Spray water through the outlet pipe into the fine sand to build up. If you notice a layer of sand
concrete valve and the material cylinder. The or cement particles at the bottom, the rubber rams
opposite cylinder is now exposed through the need to be replaced. (For ram replacement

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Operation
procedures, see the Maintenance section of this Special Pumping Situations

manual). When the waterbox is clean, replace the
top cover and start the unit. Stroke the machine
Plugs
twice (two times), which will flush the water from
the material cylinders. Stop the unit. Replace the Many plugs can be avoided by simply pumping slowly
drain plug in the bottom of the waterbox. Make until concrete runs steadily from the end of the line.
sure that it is tight so that it doesn’t fall off on the The difference between a plug that can be rocked out of
road. the line and a plug that must be manually removed is
generally how hard the plug has been pressed. If you
pump slowly when you first begin to pump, you can
drain.eps
watch the pressure gauge and stop the pump before a
plug has a chance to become jammed with force.
Waterbox drain Is the line plugged?

Before taking the corrective action, you must first
determine whether the line is actually plugged. Other
situations can cause symptoms that appear to be plugs
but are not. Hydraulic components can stick in one
position or the other, electric valves can stick open, and
so on.
If you answer “yes” to all of the following questions,
the line is plugged:
• Is the pressure gauge going to the maximum
pressure setting?
Figure 25 • Is the pressure much lower when you stroke the
The waterbox drain unit in reverse?
• Spray off the rest of the unit to remove dust and • If the machine stops pumping, reverse it for two
cement particles. If you have time, brush off any strokes. Put it back into forward. Does the machine
concrete spatters that may have landed on the pump in forward for two strokes, and then stop
machine during the course of the day. If the pumping again?
spatters are already dry, use a putty knife to scrape If the answer to any of the above questions is “no,” the
them off. If you let the spatters stick for weeks, you line is not plugged. Look for the problem elsewhere, or
will need to sandblast the unit or give it an acid call the Schwing Service Department for help.
bath to remove them. If you are going to give the
Removing a plug from a pipeline.
unit an acid bath, please call our service
department for advice on protecting the If you determine that your delivery line is plugged, you
machine before proceeding. Acid must NOT will need to remove the plug before you can continue
touch chrome or rubber parts. with the pour. Follow these steps:
• Place all of the accessories back on the towing 1. Don’t try to force the plug! If the machine stops
vehicle. Secure all hoses, clamps, buckets, and because of a plug, trying to free it with high
other equipment to be sure that they don’t fly off pressure just makes the plug worse.
the truck while you’re driving. Take a moment to 2. Try to rock the plug free.
make a final check of the area to be sure you’re not
forgetting anything. WARNING
• Retract the outriggers. Check your brake light
connections, adjust and clean your mirrors, and Clear the discharge area before first
000359.eps
make all other necessary adjustments before starting, restarting after moving, or anytime
driving off the job site. air has been introduced into the line.
• Remember to get your paperwork signed before
you leave.

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Operation
WARNING! Release of stored energy hazard personnel, then try pumping in forward again. If
(Figure 26). If you are successful at rocking the plug the machine still stops, the plug is in the half of
loose, air will be introduced into the line at the delivery the line that is still connected to the pump. If
end. If a blockage would then form in front of the air, concrete comes out of the line where you
the air would become compressed when you switch disconnected it, then the plug is in the half of the
back to forward pumping. Clear the discharge area of line that was disconnected. Remember to
personnel before rocking the plug. relieve the pressure on the line again before
breaking the line anywhere else! You can
000518.eps
locate the plug by the process of elimination if
you keep breaking the line in different spots and
trying to push concrete to the disconnected point.
When you locate the plug, remove it.
Reassemble the line, including the clamp
gaskets. NOTE: Air is introduced into the line
when you break it apart, so remember to clear the
discharge area of personnel before starting again.
Lower the volume control to stroke slowly until
concrete is running steadily.
explode2.eps
Figure 26
Successfully rocking a plug loose
introduces air into the line
To rock the plug: When the unit stops pumping,

immediately put the pump forward - reverse switch
into the reverse position. Pump in reverse for two
strokes. Put it back in forward and pump for two more
strokes. Put it in reverse for two strokes, then to
forward, etc. Sometimes this method dislodges the
plug. It is less likely that reversing the pump will help
dislodge a blockage in a longer pipeline, because the Figure 27
suction you create at the pump doesn’t have enough Never open a pressurized delivery line
power to move a long horizontal line of concrete.
3. Remove the plug manually. If the above step Cold weather pumping
didn’t help, you will have to locate the plug and Keep these things in mind if you must pump at
remove it manually. Never open a delivery temperatures below 32° F (0° C):
system line that is pressurized! First, relieve • Water freezes below 32°F, so cleanout must be
the pressure in the line by pumping in reverse done with heated water.
for at least two strokes. Locate the plug by
• If concrete sits for too long, it freezes. When it
tapping on the line with a hammer. (NOTE! TAP
freezes, setting action stops. To prevent this, the
is the key word. If you hit the line too hard it will
engineer will probably order the concrete with
dent. A dented line wears out at the dent
calcium chloride or a similar chemical intended to
quickly.) When pressure is removed from the
make the concrete set before it can freeze. This can
line, it has a hollow sound, except for the plug,
work against you if you take too long to clean out
which sounds solid. Reducers, elbows, and
or if you have to wait during the pour. Speed up the
rubber hoses are most susceptible to plugs, so
cleanout process as much as possible without
start by checking them. If you cannot locate the
taking risks.
plug by tapping, break the line at about the
halfway point. Clear the discharge area of

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Operation
• If it is very cold—below zero, for example— NOTE!

concrete that sits will freeze in your machine Stay calm. Do not hurry so much that you
whether there are additive chemicals or not. If that ignore safe procedures. Nothing would slow
happens, you are done pumping. Pick up your down the cleanout process more than an
system, load it on the towing vehicle, and find a injury to you or a coworker.
warm place to clean out. Concrete will not set • If concrete is flashing in the system: Put the
when it is frozen, so you will be able to clean the pump in reverse for 2 strokes; then break the
system and pump as soon as it is warmed enough delivery system away from the pump. Put the
to thaw. pump in forward for 10 or 15 strokes to remove the
bulk of the concrete from the hopper, valve, and
• If it is extremely cold — below –20° F, or colder—
material cylinders. Spray just enough water
the concrete may freeze even while it is moving
through the concrete valve and hopper so that you
under pressure. Again, you will have to find a
know you will be able to chip out the rest later.
warm place to clean out.
Immediately get to work on the pipeline. Don’t
• CAUTION! When you are cleaning out in cold worry about the small pieces of concrete left in the
weather, ice will form on your hoses, pipe, clamps, valve and hopper until after the pipe is cleaned. If
gloves, boots, and other gear. Be very careful when you pumped out the bulk of the concrete and
handling iced objects, and take care about your sprayed it out a little, the rest can be removed
footing around the machine. afterwards. After the pipe is clean, go back to the
• CAUTION! Be sure to drain the waterbox when valve and hopper as soon as possible. The concrete
you are finished pumping in cold weather. If the may be too hard to pump or rinse with water, but it
water is allowed to freeze, the unit will be will still be easier to clean if you get at it sooner
damaged. rather than later. Concrete becomes much harder to
clean after several hours. If allowed to fully dry, it
Hot weather pumping can become extremely hard to remove, and will
Keep the following in mind if you are pumping in have to be chipped away with power tools.
temperatures above 85° F. Warning: Never put a body part into the concrete
• Concrete sets faster in hot weather. You have a valve or hopper. Also, do not open the hopper grate to
reduced margin of error for cleanout and while chip concrete or for any other reason, unless you have
waiting for concrete. Under certain circumstances, disabled the machine according to your company’s
concrete will go from being pumpable to setting in lock-out, tag-out program.
a very short time. This quick setting is known as
flashing. Emergency procedures
• If you must wait a long time for the balance load,
you will be in trouble. You should clean out and Disabling the machine in an emergency
start over if the load will take more than 15 If an emergency requires that the hydraulic system be
minutes to arrive. This means that you will have to disabled completely—such as if a hose or fitting
refill the hoses and pipes with concrete to finish the breaks—you must stop the prime mover (engine or
job, which means that they will need more concrete electric motor) immediately. With the SP 305, pushing
to finish than the ready-mix company thought. Use any emergency stop switch will kill the engine.
your best judgement. If you know you will have to
clean out before the load arrives, inform the
supervisor on the job, so enough concrete can be
ordered to refill the pipes and hoses and also to
finish the pour.
• If concrete is flashing, you will have to act fast to
save the system.

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Operation
Lock-Out, Tag-Out and a Spare Parts List available to the operator and
A lock-out, tag-out program should be developed by shop personnel at all times. Replacement Operation
your employer, according to current OSHA/ANSI Manuals and Spare Parts Lists are available for a
rules. The procedure to disable the machine from nominal charge. The Safety Manual, Quick Index, and
accidental starting or energy release is as follows: Co-worker Safety Rules booklets are available without
1. Stop the engine. charge if you supply a serial number when ordering,
and additional sets are available for a nominal fee. In
2. Remove the key. Carry the key with you. If there
addition, the warning labels which are supplied with
are additional keys, lock them away or otherwise
the unit must be easily readable and firmly attached to
account for them.
the unit. If the labels fade or peel, if you repaint the
3. Put a “Do Not Operate” tag over the key switch. machine, or if they become loose or unreadable for any
4. Verify zero pressure on the gauge shown in reason, duplicate sets are available. The only charge for
Figure 10. replacement labels is the cost of shipping. The labels
5. If you will be working on the accumulator or the are available as sets or individually. Each label has a
tires, be aware that the compressed gas in those part number printed on it, and a decal location guide is
items will remain a possible hazard even when available. Aluminum tags are not shipped with decal
the machine is disabled. In the case of the sets and must be purchased separately.
accumulator, contact Schwing America’s Service
Department for advice. Before working with the Charging Accumulators
tires, know the safety rules for tires. Before charging the accumulator, read and understand
all of the instructions found in the Maintenance section
Other Things You Need to Know of this manual. Charging an accumulator with
compressed air or oxygen may result in a serious
Reordering documentation or warning labels explosion.
It is our intention that each machine in the field have an
Operation Manual, a Safety Manual, a laminated Quick
Index, a laminated Co-worker Safety Rules booklet,
EXPLOSION CAUSED BY
WARNING
IMPROPER ACCUMULATOR
CHARGING CAN RESULT IN
DEATH OR SERIOUS INJURY!
* Follow the charging instructions exactly!
* Use ONLY dry nitrogen to charge the
accumulator!
* NEVER use oxygen or compressed air to
charge the accumulator! 000127.eps

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Operation

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MAINTENANCE
Filtration ................................................................................................. 40
Hydraulic Oils......................................................................................... 41
Pressure, Hoses and Fittings................................................................. 42
General Maintenance Tips..................................................................... 44
Preventative Maintenance ..................................................................... 45
Unscheduled Maintenance .................................................................... 58
Maintenance
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Maintenance
MAINTENANCE • the ratio of particles of a given size encountered

versus particles passed (referred to as the beta
Maintenance is what you do to the machine to keep it ratio). An example of a beta ratio would be β25 =
in good working condition. There are two kinds of 200 (pronounced beta twenty five equals two
maintenance: preventative and repairs. Preventative hundred). This means that for every 200 particles
maintenance is important to avoid unnecessary repairs, of 25 microns or larger that hit the filter media, one
but eventually even well maintained machine parts will makes it through. A finer filter would be, for
wear out and require repair or replacement. example, β12 = 200. A courser filter example
would be β25 = 75. For concrete pumps, medium
Some maintenance needs to be done by a time interval
to fine filtration is required.
such as daily, monthly, or annually. It is a good idea to
make a checklist that will tell you what maintenance is
Specific information
due and when it is due. A suggested checklist is
included in this section of this manual. It can be found Here are some facts regarding filtration as they relate to
on page 57. Keep accurate records of maintenance your pump:
performed and when the work was completed. In this • Your unit has a separate oil conditioning circuit,
way, you will know that all necessary work has been which includes an oil cooler and a filter. The oil is
completed on time. Complete maintenance records pumped from the reservoir, through the cooler and
could also make the machine worth more money when filter, back to the reservoir.
it comes time to sell or trade it. • As delivered from the factory, each SP 305 unit is
There are certain things you should know about the equipped with a filter that is rated at 10 micron
maintenance of your machine that will not come up on (shown as 10μ) absolute.
a timetable of things to do. • The beta ratio is β10 = 200. In our case, the beta
We begin the section with some general information ratio means that for every 200 particles of dirt that
regarding some of these items. hit the filter media that are 10 micron or larger in
size, 1 will make it through. Although we are not
happy about the one particle that is allowed
through, we do not use finer filtration because the
Filtration components don’t require it. Additionally, a finer
filter would plug up with dirt too often, resulting in
General information high maintenance costs to you. We have settled on
Filtration is the single most important method of a compromise that should afford long service life
keeping your unit’s hydraulic system operational. and minimum maintenance costs. Don’t be fooled
Particles that could damage the components are by the one particle that gets through, this is a high
introduced into the oil by the differential cylinders and quality element with very good trapping
the valves, through the reservoir breather, and by characteristics.
internal wear in the components. Additionally, when • The clean element pressure drop is about 3 PSI at
you change hydraulic oil, the new oil is not clean 22 gallons per minute (element only) + 2.5 PSI for
enough to be used in a concrete pump without being the housing, making a total of 5.5 PSI DP (drop in
pre-filtered. In fact, new hydraulic oil is only filtered at pressure) when the element is clean. The pressure
the refinery to 40μ (40 microns). The oil in your unit drop varies with the viscosity of the oil, which
needs to be filtered to a MINIMUM of 25μ, and means pressure in the filter will be high until the oil
preferably finer than that. Filters are rated by: is heated to normal operating temperatures.
• the size of particles they trap, and whether that size The filter will hold 55 grams of dirt, when
is nominal or absolute operating at a flow rate of 27 GPM (gallons per
minute). The flow rate is important, because the
• the dirt holding capacity, in grams
filter would hold more if you operated at a lower
• the clean element pressure drop for a given flow flow rate. Good filtration is not cheap, but it will
rate (in PSI and gallons per minute or bar and liters save you thousands of dollars by preventing
per minute), and component failure.

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Maintenance
• The model SP 305 is equipped with a recirculation To change the element

type of filtration system, meaning that there is a 1. Make sure the engine is shut off. Put the key in
pump that sucks oil from the reservoir, pumps it your pocket to prevent someone else from
through the filter and cooler, and back to the tank. starting the engine.
Whenever the engine is running, oil is being 2. Position a pan or bucket under the filter housing
filtered. The filtration is done with a spin-on filter to catch drips. The check valve built into the
assembly (Figure 28). It is equipped with an filter, which prevents back flow, should not allow
integral bypass check valve set at 30 PSI. The much leakage oil, but there will be some. Oil
bypass valve protects the filter element from spills contaminate the environment.
damage, as explained below. The assembly is
3. Unscrew the filter element. Use an oil filter
equipped with an anti-back-flow check valve,
wrench, if needed.
which prevents oil from draining out of the tank
while you are changing the spin-on element. There 4. Remove the spin-on element, and pour the oil out
is a dirty filter indicator to tell you when the into the catch pan. Do not reuse this oil.
element is dirty. You should replace the element 5. Remove the old element and replace with a new
whenever the indicator enters the yellow area and element. Replace the bowl and tighten according
the oil is heated above 20 degrees Celsius. Under to the installation instructions that come with the
normal circumstances, the element will need filter.
replacement about every 6 months. The element 6. Start the engine, and check for leaks.
has been designed to remove all particles large
enough to cause undue wear and jobsite
breakdowns (beta 10 = 200). You can keep the
hydraulic system running year after year by
replacing the element when replacement is due. Do
not substitute “will fit” elements in this housing.
Bypass Check valve Dirty Filter

The filter is equipped with an integral bypass check Indicator
valve with a 30 P.S.I. pressure-to-open rating. This is
what it does:
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 outlet rises. This Filter
pressure difference (commonly referred to as a Element
pressure differential) is called delta P and is shown as
ΔP. When the ΔP reaches 30 PSI, the check valve opens
and the oil returns to the tank unfiltered. If the filter did PHfilter.eps
not have the bypass check valve, it would simply break
apart when it was clogged. That could cause the filter Figure 28
to fail in one of two ways: The hydraulic oil filter
1. All of the dirt ever trapped by the filter, plus the
filter itself, could go directly into the system.
2. Worse yet, the filter could split open and leak to
Hydraulic Oils
the ground, draining the reservoir, and
contaminating the environment. General information
Both potential problems are avoided by the bypass Hydraulic oils are rated for viscosity, heat dissipation,
check valve. foaming characteristics, pour point, anti-wear
additives, anticorrosive additives, lubricating qualities,
compressibility, temperature range, temperature
stability, and other functions. Although many different
brands of oil will meet these specifications, they may

(P305):pHseriesMAINTENANCE.fm
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Maintenance
use different chemical additives packages to achieve is introduced into the oil. Both the DIN rating HLP
the end result. For this reason, you should not mix and HV qualities are approved for use in our
different brands of oil. The additive package from one machines.
brand may be incompatible with the additive package
from the other, rendering both packages useless. Specific information
• Recently a few manufacturers have introduced • All machines leave the Schwing factory filled with
biodegradable hydraulic oils into the market. These Mobil DTE 25 hydraulic oil unless otherwise
oils are based on vegetable extracts instead of requested by the customer. DTE 25 has an ISO
mineral extracts. They are considered safer for the viscosity rating of VG 46. If you want your new
environment in the event of a spill, although the machine filled with a different brand or different
additive packages are not inert. One brand, Mobil viscosity oil, you should specify when ordering.
EAL 224-H has been accepted for use in Schwing • Many other brands of oil have been approved for
pumps, and other brands are under consideration use in Schwing machines, including:
and testing now. The main thing that you have to • Texaco Rando HD and Rando HDZ
remember about these oils is that they must NOT
• Shell Tellus oil
be mixed with mineral based hydraulic oils, even
in very small amounts. If you will be pumping a • BP Energol
job in an environmentally sensitive location and • Aral Vitam
wish to use this type of hydraulic oil, please • Esso Nuto
contact our service department at (651) 429-0999 • Esso Univis
for instructions on making the change from • Total Azolla
mineral oil. • Wintershall Wiolan
• Viscosity of hydraulic oil is similar in concept to
(The order of the list doesn’t signify anything. Any oil
the different weights of motor oil. For example, in
which meets the quality and viscosity standards
the winter you may run 5W-30 in your car, while in
described above can be used).
the summer you run 10W-40. The same is true for
hydraulic systems. If you live in a climate where
When to change your hydraulic oil
the weather is changing from extremely hot
conditions to extremely cold conditions, you • You should change your hydraulic oil at least once
should consider changing the weight of the per year. If you use good filters and change them
hydraulic oil that you use by the season. The when they are dirty, the oil will be clean, even after
International Standards Organization (ISO) has a year, but the chemical additive packages that give
developed a method of grading hydraulic oils for the oil its properties will break down with time,
viscosity. For summer in northern North America, and no amount of filtration will bring them back.
we recommend ISO VG 46 weight oil, while in the
winter we would recommend ISO VG 32 or even Pressure, Hoses and Fittings
VG 22, depending on how cold it gets in your area.
For southern North America and Central America General Information
we recommend ISO VG 46 for the winter, and ISO
VG 68 or VG 100 for the summer, depending on The SP 305 concrete pump hydraulic systems run with
how hot it gets. The lower the ISO VG number, the medium-high pressures, in the 2500 PSI range. The
thinner the oil is, and the lower the pour point of maximum pressure is determined by adjustment of the
the oil is. On the other hand, the thinner the oil is, pressure compensator on the main hydraulic pump.
the lower the temperature will have to be before it The machines are designed to operate at this pressure.
breaks down the lubricating film that protects your Concrete pressure is just a ratio of the hydraulic
components. See the chart in the Appendix section pressure. The ratio of hydraulic pressure to concrete
of this manual for help in selecting the proper oil pressure is the same as the ratio of the differential
for your requirements. hydraulic system piston area to the concrete piston cup
area.
• The quality of the oil needed for use in a Schwing
machine is rated in the DIN system. The ratings
have to do with the chemical additive package that

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Maintenance
• If you lower the pressure at which the system runs,

you can defeat the power of the system. For
example, you ask the machine to develop 2400 PSI
hydraulic pressure to push the concrete where you
want it to go. You want to replace a hydraulic hose
with a less expensive, lower pressure hose, so you
lower the hydraulic pump pressure setting from
2500 PSI to 1500 PSI. What is the result? The Connects
concrete still requires 2400 PSI to get where you with Fitting
want it, but your pump can only put out oil up to Hose Size Hose I.D. & Tube Size
1500 PSI. Now the oil that should be pushing the
concrete is instead telling the hydraulic pump to 8 8 mm 12
stop putting out oil. Nothing moves, and your 13 13 mm 16
1COLPhoseFITTING.eps
concrete pump has been rendered useless by a
cheap hydraulic hose.
16 16 mm 20
• If you raise the pressure at which the system runs, 20 20 mm 25
you can harm the system. Using a new example,
the concrete requires that the machine develop Tube & Tube & Connects Tube &
2900 PSI hydraulic pressure to push it where you Fitting Fitting with Fitting
need it. Your machine is factory set to run at a Size O.D. Hose Size I.D.
maximum of 2500 PSI, so you raise the setting of
12 12 mm 8 8 mm
the pump compensator to do the job. The hydraulic
pump can’t withstand 2900 PSI for more than a 16 16 mm 13 13 mm
few minutes, and it breaks. You now have to 20 20 mm 16 16 mm
replace a pump before you can make another pour.
25 25 mm 20 20 mm
• If you leave the machine at the factory
specification, you DO NOT harm the system. It
gives you years of dependable service. This means
you should only use fittings and hoses that have a
sufficient WORKING PRESSURE to handle the
system requirements. If you take a job that needs Figure 29
more pressure than your machine has, you should Hose, fitting and tube sizes versus
buy or rent a higher pressure machine. connection sizes
Specific Information
• Schwing uses high pressure fittings and hoses on
all circuits, even if the relief valve for that circuit is
set to low or medium pressure. The fittings and
hoses are rated at a minimum of 5000 PSI working
pressure, and in the case of some fittings, up to • All block threads are metric or BSPP.
15,000 PSI. We advise against changing any circuit • Instructions for setting the relief functions are
to lower rated hoses or fittings. shown in the preventative maintenance section of
• We use metric fittings and hoses, with metric this manual.
threads on the couplings. There are four diameter
sizes of tubes and fittings used on this unit and four
diameter sizes of hoses. The chart in Figure 29 tells
you what the sizes are and what they will attach to.

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Maintenance
General Maintenance Tips Adjusting relief valves

While adjusting a relief valve is not normally a
Torque specifications dangerous procedure, you should remember that it has
When performing maintenance that requires removal the potential to cause trouble. The main thing to watch
and replacement of bolts, it is very important to adhere out for is this: Sometimes people who don’t know
to the torque specifications that apply to that bolt better will have a problem with a machine and begin
(Figure 30). troubleshooting by raising the pressure setting. When
that doesn’t help, they forget to lower it back down.
When you check the pressure by creating a hydraulic
block, the pressure is set too high. In extreme cases,
A this can cause hoses or fittings to burst or other
component failure. To be safe, you should begin the
Force
Prestress adjustment procedure by turning the adjustment device

to the lowest possible setting, then bring the device
duty cycles back up to the proper setting.
Removal of safety devices

Time Sometimes you will have to remove a safety guard or
other safety device in order to perform maintenance.
B For these situations, you must take extra care to be sure
of your own safety and that of your co-workers. If you
Prestress have to put your hands, feet or any other body part into
Force
a part of the machine that would normally be guarded,

be sure that the machine is turned off and that the key is
duty cycles
in your pocket. If there is more than one key in
existence, you should also put a “DO NOT OPERATE”
sign on the controls or over the start switch.
TorqueForce.eps
Time
Before restarting the machine after performing
maintenance, be sure to put away all tools, parts and
supplies, and clear the area of personnel. If your
Figure 30 company has a “lock-out, tag-out” policy in place,
Effects of proper prestressing of a bolt abide by it.
Concrete pumps are big enough to hide a man. Be sure
The graphs in Figure 30 demonstrate what happens to a to yell “clear” before starting the unit at any time, and
bolt if it is not properly torqued. The dashed line allow time for response before proceeding.
represents the prestress on the bolt. As the device that
uses the bolt goes through its normal functions, the bolt
in example “A” gets stretched and relaxed with every
duty cycle, because the bolt is prestressed under the
maximum force of the cycle.
In example “B”, the prestress of the bolt has been

raised to more than the maximum force of the duty
cycle, so the bolt doesn’t ever feel the cycle. In this
example, bolt “B” would last MUCH longer than bolt
“A”. The torque specifications for bolts used on
Schwing equipment are found in the Appendix section
of this manual.

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Maintenance
Preventative Maintenance 5. Bleed the water out of the bottom of the

hydraulic oil reservoir by opening the drain cock
NOTE! or faucet located at the bottom of the reservoir
There is a sample maintenance chart shown (Figure 32). Place a drain pan under the outlet
in this section of the manual, page 57. hose, open the valve, and watch the liquid as it
leaves the hose. When the liquid changes from
Daily maintenance water to oil, close the valve. Because of
1. Check the levels and condition of the lubricants condensation, which is aggravated by large
and coolant in the towing truck. Follow the heating-cooling cycles, it is normal that there
manufacturers recommendations for quantity will be a small amount of water in the tank every
and type. day, but it should settle to the bottom of the tank
2. If the towing vehicle has air brakes, bleed the overnight. The water that is drained should be
moisture out of the truck air system by opening clear, and the oil that follows it should also be
the pet cocks located on the bottom of the air clean, not milky.
tanks. This is especially important if there is a
chance that the moisture will freeze.
3. Check the condition of the tires on both the
towing truck and the trailer. Do not drive the unit
with bald, cracked or damaged tires.
4. Check the level and condition of the hydraulic oil
(Figure 31). Top up, if necessary, with the same
brand and type of oil. If you have a filter buggy
to pump oil into the tank, use it. Replace milky
looking oil, which is a sign of water
contamination. Try to determine the source of the
water, if possible. If the oil has turned milky
quickly, like from one day to the next, then just
replacing the oil will not solve your problem, and
the new oil may be milky looking the next
morning. If you need help with ideas of where to
look for the source of water contamination, call
Schwing America’s Service Department at (651)
429-0999. Drain cock
OilLEV.eps tan
kdr
ain
.ep
s
Figure 32
The drain cock used to drain water
from the reservoir
6. Check the differential cylinder rod packings for

wear by filling the waterbox with water above
Oil Level the level of the differential cylinder rods (if no
Indicator grate is installed) or above the bolt down grates
(if installed). Let it sit for a few minutes. If oil
begins to float to the top of the water, it is an
Figure 31 indication that the rod packings are worn. (Oil is
The hydraulic oil level indicator lighter than water, and will float.) Don’t forget to

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Maintenance
let the water out after the check, especially if your pocket, remove the hopper grate, and
freezing temperatures are expected. Failure to inspect with a wrench. If you find that they are
replace the rod packings when they need it will loose, tighten with a torque wrench to the torque
result in contaminates from the water box, specifications found in the Appendix section of
including water, entering the hydraulic oil at the this manual. Don’t forget to replace the hopper
packings and wearing on the rods, cylinder grate before using the machine.
tubes, guide bushings, pistons and the piston 8. Grease the pivot shaft bearing and outlet
rings. The material that gets worn off of the assembly (Figure 33). This can be done on the
above mentioned items also becomes job as described in the Operation section of this
contamination, accelerating the wear. Left manual.
unchecked, this wear will totally destroy a 9. Visually inspect the unit for damage or leaks
differential cylinder. Normally, you will be due each day. Repairs should be made before the unit
for new packings after 1 to 2 years. is operated.
7. Each day you should visually inspect the bolts on 10. Once a day you should check your maintenance
the rubber rams as well as those on the S - tube. checklist to see if any scheduled maintenance is
Notice if there is any play. If you see something due.
suspicious, shut off the engine, put the key in
Grease relief
valve
Zerk for
This is a grease relief port.
outlet assembly
98355558
Do not replace with a zerk fitting.

98355558
The Grease relief valve above is

designed to prevent over greasing Zerk for
which could prevent valve movement. pivot shaft bearing
The decal below points out that it is
indeed a relief and not a broken zerk.
If it is replaced with a grease fitting
the pressure from excess grease will
prevent the valve from moving.
INFORMATION
98355558

mavzerk.eps
Figure 33
Grease zerks for the outlet assembly and the
pivot shaft bearing to be greased each day

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Maintenance
Monthly maintenance
Grease the two fittings of the crank arm lever monthly
(Figure 34).
Grease Zerks
Grszerk.eps
Figure 34
Grease zerks on the crank arm lever
should be greased monthly
Check mounting hardware 2. When the oil is warm (40° C on the temperature
Check the mounting hardware of the subframe, the oil gauge of the operator’s panel), The pressure can
tank, the pumpkit, the differential cylinders, and the be checked and assumed to be accurate.
material cylinders. Check for bolt tightness, cracks and
Setting the concrete pump pressure
other abnormalities.
The concrete pump pressure is preset at the factory and
Check hydraulic pressures should not require adjustment. The pressure cut-off on
Check all hydraulic pressures. The specifications for the hydraulic pump is set at 2500 PSI and the
each circuit are shown below and on the hydraulic redundant relief is 2900 PSI. If you feel that your pump
schematic that applies to that circuit. The schematics has a pressure problem, contact the Schwing America
are all contained in the Appendix section of this Service Department at the Call Center (888-Schwing).
manual. Changes in pressures may indicate trouble in
Clean the oil cooler fins
one or more components and will serve as early
warning indicators IF you check them on a regular Spray out the coils of the optional oil cooler with a
basis. PRESSURE SETTINGS MUST BE MADE high velocity water nozzle or pressure washer. If you
WITH THE OIL AT NORMAL OPERATING use a pressure washer, be careful not to get so close that
TEMPERATURE (40° to 60° C). To heat the oil to you damage the electric motor or bend the cooler fins.
operating temperature:
1. When the oil is very cold (at or below the pour
point of your hydraulic oil), Bring engine RPM
to an idle and let the engine idle until the temp.
gauge on the operator’s panel reads 20°.

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Maintenance
Semiannual maintenance (every 6 months) machine. If you don’t own a filter buggy for oil
transfer, consider buying one, or at least rent one for
Change hydraulic oil for temperature reasons the occasions when you change your hydraulic oil.
Change hydraulic oil if you live in a geographical
location where the weather changes the temperature Checking the Accumulator
range drastically. If you save the oil in clean barrels The accumulator on this unit does not store energy and
and properly store the barrels, you can reinstall this oil does not require charging. The accumulator function is
when the weather changes back. You can use the oil for more to serve as a dampener than to store energy for
a maximum of 2 six month seasons. Contact your the purpose of shifting the valve as accumulators in a
hydraulic oil dealer to obtain clean barrels and the twin circuit system do. The maximum pressure on the
proper storage procedures. Caution! If you ignore accumulator for the SP 305 is 1500 PSI and should
proper storage procedures, the oil will become so function properly for years.
contaminated that reuse will become destructive to the
WARNING
EXPLOSION CAUSED BY
accumulator!
charge the accumulator! explosion warning.eps

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Maintenance
Annual maintenance 4. Once the oil is drained, clean the tank through the
inspection covers using cleaning solvent and lint
Change hydraulic oil for age reasons free rags. DO NOT USE GASOLINE! Remove all
Change hydraulic oil if you haven’t already done it of the silt from the bottom of the tank.
because of the weather. The same filling rules that 5. Close the drain, if open. Refill by pumping new oil
apply to adding hydraulic oil apply to filling the tank out of the barrels with a filter cart. If no cart is
after draining and cleaning. To change the oil: available, rent one. REMEMBER! NEW OIL IS
1. The engine must be shut off. Put the key in your NOT CLEAN ENOUGH TO INSTALL IN YOUR
pocket. UNIT. If you ignore this step, you may begin
2. The oil should be cool. This is for safety reasons. having trouble with pumps and valves immediately
Do not change oil that is above 120° F (50° C). or within the first few days. See the information at
the beginning of this chapter for specific
3. Drain the old oil into barrels or another waste oil
information about hydraulic oils that are approved
receptacle. The oil can be pumped out of the
for use in Schwing machines.
inspection cover on the top of the tank or drained
out of the bottom of the tank (Figure 35). 6. Change the main return filter before restarting the
unit (Figure 35).
Inspection cover
Filler cap
tankfill.eps
Dirty Filter Drain cock

Indicator tan
kdr
ain
.ep
s
Filter
Element
Figure 35
Change hydraulic oil
PHfilter.eps

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Maintenance
Check the pre- charge of accumulators 1. Before you begin, you will need a charging kit
Check the accumulator gas pre-charge as shown: (Figure 37). Do not attempt to charge the
• 1st check-one week after first use accumulators without one. You can order the
charge valve assembly from Schwing America
• 2nd check-three months after first use
using part number 30338635. There is also a kit
• 3rd check-one year after first use available directly from Hydac. Hydac Corporation
• 4th check and beyond-annually can be reached at (610) 264-9503. The Hydac part
If the accumulator requires charging, read all of the number is FPS 250 F 2.5 G4 K.
instructions before beginning the job. Accumulators 2. You must use a high-pressure regulator with the
must be charged only with dry nitrogen. Never use nitrogen bottle. If it was not supplied with the
compressed air or oxygen (Figure 36), as the oxygen bottle, order one before proceeding with this job.
molecules will combine with the hydraulic oil and 3. Before beginning the charging procedure, stop the
lower the flash point of the oil to below room engine, and remove the key.
temperature. You will create a major explosion by
using compressed air or oxygen to charge NOTE!
accumulators. People have died using compressed air The accumulator on the P305 does not serve
or oxygen to charge accumulators. Use dry nitrogen, to shift the Rock Valve as it would on a twin
circuit system. The only function of the
not liquid nitrogen. accumulator on this unit is to absorb shock
from pressure spikes as the valve shifts.
Charging procedure
The following steps are required for checking and
charging the accumulator.
WARNING
EXPLOSION CAUSED BY
accumulator!
Figure 36
Warning decal for accumulator charging

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Maintenance
Tank Regulated High pressure gas

pressure pressure regulator is not
included with the
kit. These are
available from the
nitrogen supplier.
Regulator adjustment
Nitrogen bottle handle
100
1500
150
50
1000 2000
500 2500
PSI
bar 200
0
Hose
30341207
Charge valve assembly
30341201
BPL
Accumulator Charging Kit
HYDAC bladder
accumulator (Includes hose and charge valve assembly)
SCHWING PART NUMBER:
30338635 chargekit PN's.eps
Figure 37
Accumulator charge kit for HYDAC
bladder accumulators

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Maintenance
4. Remove the valve protection cap and the valve seal

cap from the accumulator that you will charge first
(Figure 38).
Valve protection cap
Valve seal cap
Valve stem
O-ring
HYDAC bladder
accumulator
accum closeup
Figure 38
Detail of accumulator
gas valve area

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Maintenance
100
1500
150
50
1000 2000 Pressure
500 2500 gauge
PSI
bar 200 Valve body
0
Figure 39 T-handle
Charge valve assembly
Gas chuck
accum charge assy.eps

Swivel nut
Gas
valve stem
Bleed valve
5. On the charge valve assembly, locate the T-handle 6. On the charge valve assembly, close the bleed
of the gas chuck (Figure 39). Rotate it valve (Figure 40), and disconnect the hose from the
counterclockwise (outward) completely before gas valve stem. This step closes the charge valve
attaching the swivel nut to the accumulator gas stem to prevent the gas pressure from escaping out
valve stem. of the hose and ensures that the initial pressure
reading is accurate.
100
1500
150
50
1000 2000
500 2500
PSI
bar 200
0
Figure 40
Close bleed valve and
disconnect hoses Remove hose
charge assy/bleed/hose.eps
Bleed valve
Close valve

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Maintenance
7. Find the swivel nut (Figure 41) on the charge valve

.
assembly. Screw the swivel nut onto the

accumulator gas valve. Tighten to 10–15 in./lb.
8. After the swivel nut is attached, screw the T-handle
(Figure 39) in (clockwise) three (3) full turns. This
presses a pin into the gas valve and opens it. Read
the pressure on the charge valve assembly gauge
(Figure 42) before you attach the nitrogen bottle to
the charge valve assembly. The pressure should
read 103 bar (1500 PSI). If there is no reading on
the gauge, turn the T-handle in (clockwise) one Spec. 100 bar (1450 PSI)
more full turn.
100
NOTE! 1500
150
50
If the T-handle is turned in (clockwise) more 1000
500
2000
than 4 full turns from the full 2500
counterclockwise position, it may damage PSI

bar 200
the accumulator gas valve.
0
• If no adjustment is necessary, skip to step #16.
• If pressure is too high, skip to step #13.
• If pressure must be added, proceed to step #9.
100
1500
150
50
1000 2000
500 2500
PSI
bar 200
0
read gauge.eps
Swivel nut Figure 42

Read nitrogen pressure
on gauge
Valve stem
HYDAC bladder
accumulator
charge assy/ontoaccum.eps
Figure 41
Attach swivel nut to
accumulator gas valve

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Maintenance
High-pressure
regulator
Nitrogen supply
valve
Regulated pressure
Figure 43 adjustment handle Higher
Nitrogen bottle
Make connections Lower
between
nitrogen bottle and 100
charge kit 1500
150
50
1000 2000
500 2500
PSI
bar 200
Bleed valve
chargekithookup
9. Be sure that the nitrogen bottle supply valve is 12. Adjust the regulator handle clockwise, raising the
firmly closed. Attach the high-pressure regulator to regulated pressure. The accumulator will begin to
the nitrogen bottle; then attach the hose to the high- fill. Continue filling until the charge kit gauge
pressure regulator. Finally, attach the other end of reads the desired pressure of 1500 PSI. Close the
the hose to the valve assembly gas valve stem, as nitrogen bottle supply valve.
shown in Figure 43. Do not open the nitrogen 13. If you overcharge the nitrogen pressure, proceed as
bottle supply valve yet. follows:
10. Turn the regulated pressure adjustment handle on • Close the nitrogen bottle supply valve.
the high-pressure regulator counterclockwise to its • Slowly open the bleed valve on the charge kit.
minimum setting. Close the bleed valve when the correct
11. Crack open the nitrogen bottle supply valve pressure is reached.
(Figure 44). You will get a reading on the high-
NOTE!
pressure gauge side of the regulator. Note that if
there is not at least 1500 PSI showing on the high Never let nitrogen out of the accumulator by
pressing the gas valve pin with a foreign
pressure regulator gauge at this time, you will not object. The high pressure may rupture the
be able to charge the nitrogen to the 1500 PSI valve seat!
specification. If that is the case, you will need a
14. Let the nitrogen sit in the accumulator for 10 to 15
new bottle of nitrogen before proceeding. If there
minutes. This allows the gas temperature to
is enough pressure in the nitrogen bottle to do the
stabilize. Recheck the pressure on the charge kit
job, proceed to step #14.
gauge.

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Maintenance
MUST read at least 1500 PSI

Crack open
supply valve
Figure 44
When the supply
valve is open, bottle
pressure shows on
the high pressure
gauge
Nitrogen Bottle
mavCracksupply.eps
15. Add or release nitrogen until the pressure is •

Remove the charge kit.
correct. Be sure that the bleed valve is closed •
If you are finished with the charge kit, remove
before adding pressure and that the nitrogen bottle the hose and regulator.
supply valve is closed before releasing pressure. 17. Make a bubbly mixture from soap and water.
16. When the correct pressure is reached, proceed as Spread the mixture around the accumulator gas
follows: valve to check for gas leaks. Gas leaks will push
• Close the nitrogen bottle supply valve. the bubbles away from the area of the leak. If you
• Unscrew the T-handle on the charge kit find a leak, replace the accumulator or have it
(counterclockwise) until resistance is felt. This repaired by qualified personnel. Never repair an
will close the accumulator gas valve. accumulator yourself.
• Open the bleed valve, which releases the 18. Replace the gas valve seal cap (tighten to 22 ft./
pressure in the hose, charge valve assembly, lb.), and hand-tighten the valve protection cap.
and regulator. 19. Repeat the procedure for any other accumulators.
• While holding the gas valve on the
accumulator, unscrew the charge kit swivel
nut.
WARNING
EXPLOSION CAUSED BY
accumulator!

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Maintenance
Scheduled maintenance checklist

The following is the normal recommended
maintenance schedules (after the break-in period).
SCHEDULED MAINTENANCE
Item D W M SA A page:
Change main return filter When plugged....... .................................................40

Check tires X .............................................................................45
Check hydraulic fluid X .............................................................................45
Bleed moisture from hyd. tank X .............................................................................45
Check differential cyl. rod packings X .............................................................................45
Inspect bolts on rock valve & rams X .............................................................................46
Grease rock & agitator bearings X .............................................................................46
Fill optional auto greaser reservoir X .............................................................................46
Inspect for damage and leaks X .............................................................................46
Check if maintenance is due X .............................................................................46
Inspect cutting ring & rotate, if needed ........ X ...................................................................58
Check unit mounting hardware .................. X..........................................................47
Check hydraulic pressures .................. X..........................................................47
Change oil for temperature reasons ..............................X ...............................................48
Charging the accumulator ..............................X ...............................................48
Change oil for age reasons ..........................................X................................... 49
D = daily, W = weekly, M = monthly, SA = semi annually, A = annually

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Maintenance
Unscheduled Maintenance Changing rams

The following items will have to be maintained on your When you begin to see grout in your waterbox at the
pump. The time of service that you get from these parts end of the day, it is time to change the rams.
varies dramatically from unit to unit because of the
wide range of applications to which these machines are
subjected. Differences in concrete and pressure play a
major role in the wear of these components.
NOTE!
Wear parts
When changing rams, you will have to put
The cutting ring on this unit will wear with yards your hands in the material cylinder on
pumped. The gap between the cutting ring and several occasions. YOU MUST TAKE THE
transition tube (Figure 45, top) is designed to be 1/8th FOLLOWING PRECAUTIONS TO AVOID
AMPUTATION OF HANDS, ARMS AND
of an inch. The gap can be monitored and kept in FINGERS:
tolerance by turning the adjusting nut on the slew lever • DO NOT REACH INTO THE MATERIAL
(Figure 45, bottom) with the 3 1/4” wrench that is CYLINDER WITH THE ENGINE RUNNING.
supplied or with a channel lock pliers. After the
• DO NOT USE THE REMOTE CONTROL
adjusting nut is tightened all the way, the cutting ring
FOR THIS PROCEDURE! UNPLUG IT AND
should be changed. Failure to maintain the 1/8th inch
STORE IT.
gap will cause premature wear of the cutting ring and
spec. plate. • DO NOT ALLOW ANYONE ELSE NEAR THE
CONTROLS WHEN YOU ARE CHANGING
RAMS. The chances of accidental amputation are
greatly increased if more than one person is
around. There are also less distractions when you
are alone, so your attention will not become
divided. If someone comes up, stop working until
they leave.
• Please do not skip any of the above steps.
To remove the old rams

1. Start the engine.
2. Close the shut-off valve (also known as the ball

cock and quarter turn valve Figure 46).
Figure 45
Cutting ring gap (top)
Adjustment nut for cutting ring (bottom)

305clsd.eps
Figure 46
Concrete pump shut-off valve
3. Drain the waterbox.

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Maintenance
4. Activate the pump in reverse mode, bringing the 9. Separate the components (Figure 48), and clean all
piston cup down to the end of the material cylinder. residue from the face plate and O-ring back plate,
The pump will pressure out before the S-tube as well as the O-ring groove.
shifts, because the shutoff valve is closed; however,
you should be able to stop the pump and have
access to the piston cup before the pump pressures
out. Installation tool
5. Push the emergency stop button on the operator’s
panel and stop the engine. Put the key in your
pocket, and verify that the pressure gauge is
showing zero.
6. Remove the hopper on the SP 305 by removing all
of the hopper mount bolts.
7. Place a 1 1/8” socket on an impact wrench, and
remove the center mount bolt (Figure 47).
Back Plate
Face Plate
Piston cup
cupparts.eps
Figure 48

Piston cup components
10. Install the new O-ring on the back plate, and apply
a coat of grease to the entire O-ring.
To install the new ram

1. Start the engine and run the piston rod back down

to the end of the stroke, stop the engine, push the e-
stop button, and put the key in your pocket.
Figure 47
Piston cup mount bolt should be removed NOTE!
with an impact wrench An alignment/installation tool is supplied
for installing the new ram. If the alignment
8. Remove the piston cup assembly from the material tool is lost, it may be helpful to cut the head
cylinder. from a 3/4” bolt that is 3 to 4 inches long,
screw the alignment bolt into the end of the
NOTE! rod, and slide the components over the bolt
If the cup won’t slide out easily: start the to reinstall.
engine, release the e-stop, and activate the 2. The back side of the O-ring back plate is keyed for
pump in forward mode just long enough to the purpose of rod alignment. This keyway, or pilot
pull the rod away from the piston cup. Stop
the pump before the cylinder reaches the hole, should also be greased lightly before being
end of the stroke, push the e-stop button, placed on the alignment pin.
stop the engine, and put the key back in 3. Push the back plate into the material cylinder, and
your pocket. align the pilot with the end of the rod.
After verifying zero pressure on the gauge,
use a screwdriver or small pry tool in the 4. Grease the new piston cup, and slide it over the
center bolt hole to remove the piston cup. alignment pin with the flat side to the back plate, as
shown in Figure 48.

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Maintenance
5. Set up the face plate as follows: NOTE!

• 3/4” bolt Hydraulic hoses should be replaced every six
• Lock washer years to avoid the possibility of accidental
rupture and possible personal injury. The
• Faceplate w/chamfer opposite bolt head date of manufacture of a hydraulic hose can
• O-ring be found stamped into the hose fitting.
• Bushing w/chamfer facing back
• O-ring
6. Coat threads of center bolt with Never Sieze.
7. Remove the alignment bolt and replace it with the
3/4” center bolt and face plate.
8. Tighten the 3/4” bolt until tight.
9. Open the shutoff valve. (Note that the unit will not
cycle with this valve closed.) Repeat procedure for
the other side.
Changing the material cylinders

The material cylinders also eventually wear out. They
are considered worn out when the inside diameter has
grown 3 millimeters beyond the specification for new.
For example, a 750-18 has 180mm material cylinders.
When the inside diameter reaches 183 mm, they are
worn out. With 150’s they are worn out at 153, etc.
Normally, it is the end attached to the valve that wears
out first, because it sees the most concrete. The
waterbox end may be in brand new condition, because
that end never experiences concrete. For this reason,
the material cylinders were designed to be able to flip
them end-for-end. That way you can move the worn
out part to the waterbox and the like-new part to the
concrete valve for double the life. If you are going to
do this, you have to catch the wear on the material
cylinders before they get too thin or break through in
one or more spots. When that happens you can’t flip
them, because they would be structurally too weak to
hold the pressure forces at the waterbox end.
The actual act of changing and aligning the material
cylinders was the subject of a service bulletin in 1986.
The procedure still applies today. Contact Schwing’s
Service Department at (651) 429-0999 if you need a
copy of the bulletin.
Inspecting hydraulic hoses

Hydraulic hoses should be checked during routine
inspections. Check for damage to the outer layer or
fittings. For example; Wire reinforcement is exposed,
separation from the fitting, chafing, cuts, cracks, brittle
outer layer or any other type of deformation like layer
separation, blistering, crushing, corrosion, or kinking.
In addition check for leaking fittings or improper fit.

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APPENDIX
Hydraulic Oil Viscosity Chart ................................................................. 62
Torque Specifications for SAE Bolts ...................................................... 63
Recommended Emergency Hose Kit..................................................... 64
Fitting Wrench Sizes .............................................................................. 64
Maintenance Checklist........................................................................... 66
Weld-on Ends / Coupling Comparison................................................... 67
Output Charts ........................................................................................ 68
Using a Nomograph............................................................................... 74
Minimum Pipe Wall Thickness ............................................................... 82
Pictograms............................................................................................. 83
Decal Location Guide ............................................................................ 84
Glossary of Terms.................................................................................. 86
List of Lubricants and Nitrogen.............................................................. 91
Hydraulic Schematic—Concrete Pump SP305 - Schematic.................. 95
Hydraulic Schematic—Concrete Pump SP305 - Schematic.................. 95
Electrical Schematic SP305 - 2004 Electric .......................................... 96
Electrical Schematic SP305 - 2004 Electric .......................................... 96
Output Chart available upon request ..................................................... 99
Appendix
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Appendix
APPENDIX • The minimum permissible viscosity represents

the warmest temperature at which the oil will
This section contains the technical information for still be thick enough to provide lubrication and
your machine and its systems. This information is sealing. If it were warmer, the components
correct for your machine when it leaves the factory, but would have metal-to-metal contact (thermal
it may need to be updated from time to time. breakdown).
• The optimum operating viscosity is the range
of oil thickness at which the oil works best
Hydraulic Oil Viscosity Chart (thin enough to flow easily, yet thick enough to
The illustration below shows the relationship between protect the system components).
the oil temperature and its viscosity. As you can see, An example of how to read a chart for VG-46 oil is
the oil gets thicker when the temperature is low and given in the chart below. The chart shows the cold start
thinner as the temperature rises. limit as –8°C (18°F) and the minimum permissible
• The cold start limit represents the coldest tem- viscosity as 90°C (194°F). The optimum range is 50°–
perature at which the oil is thin enough to flow 76°C.
into the hydraulic pumps. If it were any colder,
the pumps would not be able to suck in the oil
(cavitation).
Temperature of Hydraulic Oil

(C) -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120
Cold Start Limit
(very thick oil)
Water freezes
Water boils
VG
VG 2
VG 2
VG 6
VG 8
2
3
4
6
10
0
Optimum
Operating
Viscosity
000044.eps
Minimum permissible
viscosity
(C) -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120
(F) -40 -22 -4 14 32 50 68 86 104 122 140 158 176 194 212 230 248
C = degrees Celsius
F = degrees Fahrenheit
62 Operation Manual - SP 305 revDate

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Appendix
Torque Specifications for SAE must be torqued to within 6% of the requirement. For
example, a bolt to be torqued to a 200 pound
Bolts requirement must be within the range of 208–192 foot
The following charts show the tightening torques pounds for a dial scale torque wrench.
specified for the bolts used on PH series pumps. The Schwing equipment uses two different types of bolts;
charts are to be followed unless a different torque one has a black finish and the other has a dychromate
specification is indicated for a particular procedure. finish.
A torque wrench must be calibrated to within 1% of its Torque specifications are very important for proper
indicated value throughout its range. Bolts must be machine function. For more information on this
torqued to within 4% of the requirement if the wrench subject, refer to the section on bolt tightening in the
has a dial scale. If no dial scale is present, the bolts Maintenance section of this manual.
GENERAL SAE BOLT TORQUE SPECIFICATION TABLE

Use the values listed unless special torques are specified. Values are for UNC and UNF thread fasteners.
Values do not apply if graphite, moly-disulphide or other extreme pressure lubricant is used.
Table 1
SAE Grade
5 8
Number
Bolt head identifi-
cation marks. See
Note below.
Bolt Size lb.-ft N•m lb.-ft N•m

1/4” 9-11 12-15 12-15 16-20
5/16” 17-20.5 23-28 24-29 33-39
3/8” 35-42 48-57 45-54 61-73
7/16” 54-64 73-87 70-84 95-114
1/2” 80-96 109-130 110-132 149-179
9/16” 110-132 149-179 160-192 217-260
5/8” 150-180 203-244 220-264 298-358
3/4” 270-324 366-439 380-456 515-618
7/8” 400-480 542-651 600-720 814-976
1” 580-696 787-944 900-1080 1220-1464
1-1/8” 800-880 1085-1193 1280-1440 1736-1953
1-1/4” 1120-1240 1519-1681 1820-2000 2468-2712
1-3/8” 1460-1680 1980-2278 2380-2720 3227-3688
1-1/2” 1940-2200 2631-2983 3160-3560 4285-4827
NOTE: Bolt head identification marks are shown as per grade. Manufacturer’s marks may vary.

(P305):Appendix.fm Operation Manual - SP 305 63
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Appendix
Recommended Emergency
Hose Kit
Schwing recommends that you carry one of each of the
following hoses on the unit in case you blow a hose on
the job. Each size listed represents the longest hose of
each diameter that is installed on the unit at the factory.
Keep the insides of the hoses clean until they are
needed by capping the ends and using tape to hold the
cap in place. Dirt introduced into your hydraulic
system through the installation of a hose that was not
kept clean will cause a variety of problems in the
operation of the unit.

Fitting Wrench Sizes

This chart is provided as an aid to selecting the proper
wrench to hold or tighten the hydraulic fittings on
Schwing equipment. Sizes may change, so use this
chart only as a guide.
Straight fittings
% & ' &( ) ) * & ' &( )

" "
# " ! $
! " !

! ! " $
%+, ))

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Appendix
Banjo fittings
End Cap Separate from Stem

Metric Wrench Sizes Nearest American Wrench Sizes
Fitting or Cap Nut Coupling Body End Cap Cap Nut Coupling Body End Cap
Tube Size (mm) (mm) (mm) (mm) (in.) (in.)
8 mm 17 22 19 11/16 7/8 3/4
12 / R1/4 in. 22 22 19 7/8 7/8 3/4
12 / R3/8 in. 22 27 22 7/8 1 1/16 7/8
12 / R1/2 in. 22 30 24 7/8 1 3/16 15/16
16 mm 30 32 27 1 3/16 1 1/4 1 1/16

20 mm 36 41 32 1 7/16 1 5/8 1 1/4
mavbanjo.eps
End Cap Part of Stem

12 / R3/8 in. 22 24 22 7/8 15/16 7 /8
16 mm 30 30 27 1 3/16 1 3/16 1 1/16

25 mm 46 46 41 1 13/16 1 13/16 1 5/8

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Appendix
Maintenance Checklist
The following are the normal recommended
maintenance schedules (after the specified break-in
period).
SCHEDULED MAINTENANCE
Item D W M SA A page:
Change main return filter When plugged ...... .................................................40

Check tires X .............................................................................45
Check hydraulic fluid X .............................................................................45
Bleed moisture from hyd. tank X .............................................................................45
Check differential cyl. rod packings X .............................................................................45
Inspect bolts on rock valve & rams X .............................................................................46
Grease pivot shaft and bearings X .............................................................................46
Fill optional auto greaser reservoir X .............................................................................46
Inspect for damage and leaks X .............................................................................46
Check if maintenance is due X .............................................................................46
Inspect cutting ring & rotate, if needed ........ X ...................................................................58
Check unit mounting hardware .................. X .........................................................47
Check hydraulic pressures .................. X .........................................................47
Change oil for temp. reasons ..............................X ...............................................48
Checking the accumulator ..............................X ...............................................48
Change oil for age reasons ..........................................X................................... 49
D = daily, W = weekly, M = monthly, SA = semi annually, A = annually

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Appendix
Weld-on Ends / Coupling Comparison
Shown is a comparison among commonly used

ends/couplings. No two ends shown can be joined
without the use of an adapter pipe or a special
adapter clamp. Clamps and pipe strength must also
be considered when determining proper system
requirements. The ratios shown in the text below Male / Female
represent the safety factor from burst : working O-Ring
pressures. (shown with clamp)
1. Male / female o-ring type couplings have the
highest pressure rating of the ends commonly used
for concrete pumping. They can withstand 4350 PSI
@ a 2:1 safety factor. They are self aligning and
waterproof when used with o-rings in good condi-
tion. Typically not used on booms because of their
weight. Pipes equipped with this style coupling
cannot be swapped end-for-end.
2. Heavy-Duty couplings are designed for pressures Heavy Duty

up to 2250 PSI @ 2:1. They have 20% more contact
area than metric couplings, and a tapered face that
draws the pipe sections together during assembly.
Both the ends and clamps weigh more than metric
style, and therefore should not be used on booms
without consulting the manufacturer.
3. Metric couplings are designed for pressures up to

1400 PSI @ 2:1. They have 85% more contact area Metric
than grooved couplings. The face is flat and will not
draw pipe together. Although they have a raised
edge, they are not compatible with Heavy Duty cou-
plings unless a special clamp or an adapter pipe is 0.15"
used to change from one style to the other. Metric
connections are standard equipment on booms
because of the weight savings compared with other
styles.
Grooved
4. Grooved couplings (lip height of 0.15” or less) (Victaulic)
are designed for pressures only up to 750 PSI @
2:1. The recessed groove is hard to clean when
changing pipe on a job. The weld-on end fails
before the pipe because the groove is cut into the weldends4.eps
pipe thickness, making it the weakest spot. Grooved

couplings are not recommended for concrete pump-
ing applications.
NOTE: All pressure ratings listed refer to 5 inch (125mm) diameters

in like-new condition. Other pressures would apply to other sizes.

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Appendix
Output Charts • maximum strokes per minute of your pumpkit

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

PSI Bar
2000 138 Concrete
PISTON SIDE
Performance characteristics of
ROD SIDE
the axial piston hydraulic pump 1900 131

pressure is
(bar)
(bar)
Pump Speed
1900 RPM 1800 124
PISTON SIDE
Hydraulic relief valve is set at
shown here.
350 bar max. pressure (5075 PSI). 1700 117
350 1600 1621 110
Max. pressure
Hydraulic oil 1500 103 is shown for
pressure shown 300 1400 97 both piston
here, ranging from 1300 90 and rod side
zero to the relief 250 ROD SIDE
1200 83 configurations.
1100 76
valve setting. 350 1000 1007 69
200
900 62
300
OIL PRESSURE
800 55
250 700 48
150
200
600 41
Concrete
500 34
100
150
output is
400 28
300 21
shown here,
100
The breakpoint 50
200 14
with max.
and minimum Q 50
100 7 shown for both
specification are 0 117 187 piston and rod
Breakpoint
listed here. =199 bar 20 40 60 80 100 120 140 160 180 200 cu yards/ hr side
Min Q 7 15 23 30 38 46 53 61 69 76 84 92 99 107 115 122 130 138 145 153 cu meters/ hr
@ 350 bar configurations.
=284 l/m
Hydraulic liters per CONCRETE OUTPUT
28.530 NUMBER OF STROKES
ROD 5 10 15 20 25
(stroke / min.)
minute, and the SIDE
OIL VOLUME
50 100 150 200 250 300 350 400 450 500 (liter / min.)
corresponding
17.8 Information
strokes per minute, PISTON 5 10 15 20 25 30 NUMBER OF STROKES
(stroke / min.)
SIDE
OIL VOLUME
about the
for both piston and 100 200 300 400 500 (liter / min.)
pumpkit and
rod side. Differential Hydraulic Cylinder Material Cylinders Hydraulic Pumps hydraulic
Bore dia. / Rod dia. x Stroke length Bore dia. x Stroke length Type / KW
The Schwing ISO 130 mm / 80 mm x 2000 mm 230mm x 2000 mm 2 x Voac V30D 140
pumps is
document number
2 x 92 KW shown here.
SAIE 5240-032 Slewing cylinder 80 / 45 x 185
and revision date Rev. 081997 THE PERFORMANCE CURVE INDICATES THAT THERE IS NO ALLOWANCE FOR
are listed here. Init.
FILLING EFFICIENCY OF THE CONCRETE CYLINDER.
000026.eps

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Appendix
Example 1—Checking flow at a given pressure the rod side scale (item A in the example below). Draw
Your unit is configured on the rod side (standard from a line straight across the page until you intersect with
the factory). You notice that your machine is not the horsepower curve (item B). Next, draw a straight
getting as many strokes per minute as you are used to line down from the intersection point until you pass
seeing. You count the strokes and see that you are through the rod side number of strokes scale, and read
getting about 21 1/2 per minute. You check your the strokes per minute. At 220 bar you should be
pressure gauge and see that the hydraulic oil pressure is getting a little more than 21 strokes per minute. Your
at 220 bar. To determine whether your unit is acting unit is fine.
normally, locate the 220 bar oil pressure marking on
CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
000025.eps
2000 138
PERFORMANCE CHARACTERISTICS OF
1900 131
PISTON SIDE
THE AXIAL PISTON HYDRAULIC PUMP

ROD SIDE
1800 124
(bar)
(bar)
PUMP SPEED
2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110
350 1500 103

PISTON SIDE
1400 97
300
B. Draw a line STRAIGHT 1300 1285 88.6 90
across the page until you
contact the horsepower 1200 83
A. Find 220 bar curve of the rodside. Then 1100 76
250 on the rod side oil draw a line straight down
OIL PRESSURE (BAR)
pressure scale. from the intersection point. 1000 70
350 ROD SIDE 900 62

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

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

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Appendix
Example 2—Checking your hydraulic pumps digital tachometer if one is available.

To determine whether your pumps are still in good • Know how to use your flowmeter. Read the
working condition, use the output chart and a flow instructions that came with it, and remember
meter. Test one pump at a time, multiply the readings that a flowmeter must be calibrated periodi-
by 2, and chart the result. You must multiply the cally.
readings because the chart is based on the output of • Make two copies of the output chart so you
two pumps, but we are only testing one at a time. don’t ruin your original. You need one chart for
To test your pumps: each pump tested.
• Be sure you are using the chart that applies to Read the flow at 0 bar, 100 bar, 150 or 200 bar, 250 bar,
your unit. and 300 bar. Also, document the breakpoint. The
• Select the proper gear for pumping (found on breakpoint is where the flow drops off rapidly. You will
the information plate mounted in the cab). be able to notice it on the flowmeter. If you think it
• Set the pump speed (input drive shaft) RPM. would be helpful, copy the chart below. Check which
Pump speed information is found on line 16 of reading you used (150 or 200 bar). The breakpoint will
the Delivery Inspection Report which arrived be very close to either 150 or 200 bar, so it is not
with your unit when it was new. A difference necessary to take both readings. The breakpoint
of even a few RPM will give you a bad read- specification is shown on each output chart.
ing. Check the RPM of the drive shaft with a
Breakpoint 1st Pump 2nd Pump

specification Liters/min Total Liters/min Total
(read on meter) (for plotting) (read on meter) (for plotting)
0 bar x2 x2
100 bar x2 x2
breakpoint x2 x2
breakpoint
150 or 200 bar x2 x2
250 bar x2 x2
300 bar x2 x2
000032.eps
As an example, we’ll assume that we have just taken

the following readings:

178 0 bar 199 x2 398 x2
100 bar 196 x2 392 x2

178 breakpoint 194 x2 388 x2
breakpoint
150 or 200 bar 169 x2 338 x2
250 bar 138 x2 276 x2
300 bar 117 x2 234 x2

000031.eps

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Appendix
Now plot the readings on the output chart. Take a clean • Turn the ruler vertically, and draw a light line
output chart and proceed as follows: up the page from the liters/minute reading you
• Lay a straight edge horizontally across the took at that pressure (remember to multiply the
page at the pressure point you are plotting. reading by 2). In our example, we measured
Draw a light line across the chart. In the exam- 276 liters at 250 bar.
ple below, we use the rod side scales and curve • Put a dot at the point where the two lines inter-
(you could use the piston side scale and curve sect.
instead). The ruler is shown ready to draw a • Do the same thing with each pressure reading.
line at 250 bar hydraulic pressure. You should end up with six dots.
CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
000454.eps
2000 138
PERFORMANCE CHARACTERISTICS OF
1900 131
PISTON SIDE
THE AXIAL PISTON HYDRAULIC PUMP

ROD SIDE
1800 124
(bar)
(bar)
PUMP SPEED
2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110
350 1500 103

PISTON SIDE
1400 97
300 1300 1285 88.6 90

1200 83
1100 76
250
OIL PRESSURE (BAR)
1000 70
350 ROD SIDE 900 62

200
800 55
300 758 52
700 48
150 250
600 41
1
200 2 3 4 5 6 7 8 9 10 11
500 34
100
150 400 28
300 21
100
50 200 14
50 7
100
breakpoint 0 13 26 39 52 65 105 118 131 144 157 170 183 196

78 92
178 bar 103 170.5
CONCRETE OUTPUT (cu yd / h)
26
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
15.5
PISTON 5 10 15 20 25 30 NUMBER OF STROKES
OIL VOLUME
100 200 300 400 500 (liter / min.)

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Appendix
• Connect the dots. If your plotted line reason-

ably matches the specification plot on the
chart, the pump is fine. If your line is to the
lower left of the specification plot, the pump is
getting weak. If your line is to the upper right,
you have done the test incorrectly, or you are
using the wrong chart. In our example, the
pump is okay. (See the plot that follows.)
CONCRETE CONCRETE
Piston side scales have been removed for clarity PRESSURE
(PSI)
PRESSURE
(BAR)
000317.eps
1200 83
ROD SIDE
300 bar
(bar)
1100 76
1000 70
350 ROD SIDE 250 bar 900 62

Breakpoint 800 55
300 758 52
700 48
OIL PRESSURE (BAR)
250
600 41
200 500 34
150 200 bar 400 28

300 21
100 100 bar
50
OK 0 bar
200 14
7
100
breakpoint 0 13 26 39 52 65 78 92
105 118 131 144 157 170 183 196
178 bar 170.5
26
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
(234) (276) (338) (388) (398)
(392)
Check the second pump. Hook up the flowmeter just as

when you 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.

178 0 bar 199 x2 398 195 x2 390
100 bar 196 x2 392 183 x2 366
178 breakpoint 194 x2 388 178 166 x2 332
breakpoint
150 or 200 bar 169 x2 338 137 x2 274
250 bar 138 x2 276 102 x2 204
000030.eps
300 bar 117 x2 234 69 x2 138

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Appendix
Again, plot the results 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 below).
Piston side scales have been removed for clarity CONCRETE

PRESSURE
CONCRETE
PRESSURE
(PSI) (BAR)
000318.eps
1200 83
ROD SIDE
300 bar
(bar)
1100 76
1000 70
350 ROD SIDE 250 bar 900 62

Breakpoint 800 55
300 758 52
700 48
OIL PRESSURE (BAR)
250
600 41
200 500 34
400 28
150 200 bar
300 21
100 100 bar
50
WEAK 0 bar
200
100
14
breakpoint 0 13 26 39 52 65 105 118 131 144 157 170 183 196

78 92
178 bar 170.5
26
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
(138) (204) (274) (332) (366)(390)
When you connect the dots, the line is completely There are many different possible pump kits and power
below the specifications. This pump is very weak and settings for this unit. If you accidentally destroy your
will completely stop pumping oil soon. You may notice original output chart, please have your serial number
high heat with this unit if you are pumping at high oil handy when you call to get a replacement. Also, please
pressures. Note! Never try to make up for this weak advise us if you have changed differential cylinders,
pump by increasing the speed of the engine. If the material cylinders, or hydraulic pumps, because you
pump turns faster than specification, it will not be able may need a different output chart than the one that was
to draw oil as fast as it is turning (“cavitation”), and originally shipped with the unit.
immediate failure could result.
If the plotted curve matches the specification plot for a
while but the breakpoint is too high or too low, it is
possible to make an adjustment. Contact Schwing
America’s Service Department for the procedure.

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Appendix
Using a Nomograph 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
General information
power output of the hydraulic pumps only. (All the
If you have read the original Schwing America power from the truck engine is normally not available
publication Nomographs—A Guide to Usage, you will to the concrete pump and should not be used for power
notice several changes in this document. Because not calculations.) If you know the required output for the
all of the power from the truck engine can be used for job, the nomograph will help you calculate the required
the concrete pump, the TK number of the engine has no pressure. If you know the output and pressure, you can
meaning. Therefore, this section about using calculate the power requirement.
nomographs is being adapted especially for boom The nomograph was developed by extensive trial-and-
pumps. We can still figure out the TK of the job to do, error testing and has proven to be accurate to ±10% in
but the suitability of the pump has to be determined in nearly all pumping applications. The original
a different manner. To make the pump numbers and job nomographs used “spread measure” of fresh concrete
numbers match, we will use a “Power Factor Number,” instead of slump, and the two are not directly
which takes into account the power of the hydraulic interchangeable. Some approximations are used in
pumps instead of the engine and is easy to use with translating the charts from spread measure to slump,
cubic yards per hour and PSI instead of cubic meters but the ±10% accuracy still applies. In all cases, it is
per hour and bar. assumed that you will receive fresh, high-quality
Concrete pumps are limited in what jobs they can do concrete on your job and that the concrete will be
by three factors: plastic enough to flow into the material cylinders. If
1. the amount of power available, you know that the concrete will be hard to feed into the
cylinders, you should adjust the output requirement to
2. the maximum concrete output available, and
compensate for incomplete filling. For example, if you
3. the maximum concrete pressure available. will need 50 cubic yards per hour into the form but the
To estimate the power a pump requires to complete a concrete is so stiff that it will fill the cylinders only
particular job and to determine which pump is 80%, you should multiply the required output by 1.25
appropriate, a nomograph is used. (1÷80%).
With a concrete pump that is driven by its own prime The nomograph is divided into four quadrants (Figure
mover, such as a trailer-mounted concrete pump or a 49).
truck-mounted pump with a separate drive engine, the
TK number does not apply to truck mounted units.
(72600) Pipeline diameter in inches
Curve shown is the Power Factor number (PF).
200
000029.eps
Q in yd3/hr.
For vertical placing, 180

add 1.105 PSI per foot
of level difference. 160
6" 5" 4.5"
Upper left quadrant 140

4"
120 116
Rodside
100
Upper right quadrant
80
Pistonside 67
60
40
132 KW 20
Figure 49 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800
P in PSI 1566 870
600 400 200
Quadrants 100
200
2"
300
Lower left quadrant Lower right quadrant
400
2.5"
500
600
3"
4" 5" 6" Pumpkit Model: 120/80 x 1600:200 3000 2500 2000 1800 1500 1200 1000 800
Slump of fresh concrete in inches Power: 132 KW Proportional value of pipeline in feet

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Appendix
TK number does not apply to truck mounted units.

(72600) Pipeline diameter in inches
Curve shown is the Power Factor number (PF).
200
000455.eps
Q in yd3/hr.
6" 5" 4.5"
140
4"
120 116
Rod side
100
80
Piston side 67
60
40
132 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI 1566 870
100
200
2"
300
400
2.5"
500
600
3"
4" 5" 6" Pumpkit Model: 120/80 x 1600:200 3000 2500 2000 1800 1500 1200 1000 800
Slump of fresh concrete in inches Power: 132 KW Proportional value of pipeline in feet
Figure 50
Moving around a nomograph
The upper left quadrant is the beginning and end point 2. We will use 5-in.-diameter pipeline.
of the graph, and it shows maximum output, pressure, 3. We will need the following pipeline lengths:
and power for a specific machine. The upper right
Separately laid pipeline:
quadrant accounts for the relationship between
concrete output and pipeline diameters. The lower right • 40 ft. of 5-in. rubber hose
quadrant accounts for the resistance to flow of the • 150 ft. of 5-in. horizontal steel pipe
entire pipeline system. The lower left quadrant Boom pipe, elbows, and deck system:
accounts for the pumpability of the concrete. • 13 ft. of 5-in. rubber hose
To use the nomograph, you begin at output required • 144 ft. of 5-in. steel pipe (on the boom and
and move clockwise until you encounter the lines that pump deck)
represent your job situation. Each time you meet the • 5.25 ft. of 6–to–5-in. reducer (on the pump)
line that applies, you make a 90° turn until you come to
• 4 5-in. 45° elbows, radius 250 mm
a point on the bottom of the upper left quadrant that
shows pressure required (Figure 50). • 11 5-in. 90° elbows, radius 250 mm
• 2 6-in. 90° elbows, radius 250 mm
To illustrate the use of a nomograph, we will use a
hypothetical job situation with the following 4. We will specify a slump of 5-6 in. and use the 5-in.
specifications: line on the chart.
1. We will need an average output of 75 cubic yards 5. In addition, when we add the pressure for the
per hour, but we will be pumping only 75% of the vertical run, we will have to add 1.1 times 70 ft =
time. The rest of the time will be spent moving 77 PSI.
hose, removing pipe lengths, waiting for concrete All of these criteria will be explained in detail as we go
trucks, and taking care of miscellaneous jobs. This through the individual quadrants.
means that when we are actually pumping, we will
need an output rate of 75 ÷.75 = 100 yd3/hr.

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Appendix
Power factor
number
TK number does not apply to truck mounted units. (replaces TK)
Curve shown is Power Factor number (PF). 72600
200
000028.eps
Q in yd3/hr.
140
Rod Side 120

Power curve
100
Maximum output and
80 maximum pressure of
Piston Side a specific unit
60
Kw rating
40
132 KW
20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI
Figure 51
Upper left quadrant
The quadrants efficiency factors figured in. When using an

1. The upper left quadrant describes the power Americanized nomograph (pressure in PSI and flow in
curve of a given hydraulic pump Kw rating and the cubic yards per hour), the pressure multiplied by the
maximum output and maximum pressure of a output must always be less than or equal to the PF. For
particular model of concrete pump (Figure 51). example, if you needed 50 cubic yards per hour and
determined that this will require 750 PSI, you can
Any concrete pump selected for a job must meet three multiply 50 by 750, which equals 37,500. Any pump
technical parameters: you select must have a PF of 37,500 or greater. If you
• the power factor number of the pump must be are using a nomograph that has been converted to
equal to or greater than the power factor num- metric units of measure (pressure in bar and output in
ber of the job, cubic meters per hour), you can still multiply the
• the maximum output required by the job must pressure by the output, but you must multiply the
be available from the pump, and answer by the conversion factor between metric and
• the maximum pressure required by the job English units of measure to get the PF. The conversion
must be available from the pump. factor for cubic yards to cubic meters and for bar to PSI
It is important to notice the pump maximum pressure is 18.966. For all practical purposes, you can use 19.
and maximum output, even if the power factor number For example, if you need 50 cubic meters per hour and
of the pump is larger than the job requires. These determine that your job setup will require 65 bar, you
parameters are decided during the design stage of the can multiply 50 by 65, which equals 3250. Multiply
unit and cannot be adjusted on the job. If the unit is this by 19, and you find that your PF requirement is
able to go from rod side to piston side, maximum 61,750. Again, any pump you select for the job in this
pressure and output can be exchanged—that is, you can example should have a PF of 61,750 or greater.
decrease one while increasing the other the same The maximum output (abbreviated as max Q) is
amount. determined by the size of the hydraulic pumps, the
The power factor number (PF) replaces the TK number of strokes per minute, and the size of the
number on a truck-mounted unit. It is the Kw differential and material cylinders. The unit is usually
multiplied by a constant (550) that has several designed so maximum output can be achieved only at

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Appendix
less than maximum pressure. a 6-inch pipeline has 49 percent more surface area
Maximum pressure (abbreviated as max P) is to coat than a 4-inch pipeline, the volume of
determined by the size of the differential and material concrete that can move on the layer is increased by
cylinders and the setting of the main relief valve. To be 125 percent, which results in lower velocity of the
sure that the unit will handle the job, be careful to concrete (in feet per second), lower friction, and,
notice max P and max Q. Here is an example of why therefore, lower pressure. A pump that may not be
that is important: You contract to pump a job that capable of completing a difficult job through 4- or
requires only 20 yards per hour, but you calculate that 5-inch pipe may be able to do it easily through 6-
you will need 2100 PSI pressure. The PF of this job is inch pipe. Note! Experience has taught us that 5-
42,000 (20 x 2100). The pump shown in Figure 51 has inch is the optimum pipeline size for lengthy
a TK of 72,600, so there is enough power available. vertical runs, such as those found on high-rise
However, the maximum pressure available from the buildings. It is large enough for most aggregate but
pump is only 1570 PSI. This pump would not do the small enough that you minimize the amount of
job. concrete that slides back into the hopper when the
concrete valve cycles, which we call backwash.
2. Follow the chart in a straight line from required
You must also consider the people at the point of
output into the upper right quadrant until you
placement. Very few hose handlers, if any, can
come to the size of the pipeline that you will use. A
move 6-inch hose on a slab all day. There is no
good rule of thumb for sizing pipeline is to use the
provision in the nomograph for mixing pipeline
largest diameter pipeline that you can. It takes less
sizes. For example, if you will be reducing from 5-
force to move concrete through a 6-inch pipeline
inch to 4-inch pipe, you should calculate the chart
than, for example, a 4-inch pipeline. When
as if you were using 4-inch pipe for the entire
pressure is exerted on concrete in a pipeline, a
distance. This will not be completely accurate, but
paste of water and cement fines coats the inside of
you will be safe in your pressure calculation. In our
the pipeline and forms a slippery layer on which
example, we use 5-inch pipeline (Figure 52).
the bulk of the concrete slides. While it is true that
Pipeline diameter in inches

Q in yd3/hr.
6" 5" 4.5"
4"
Make a 90˚ turn when

you intersect with the
pipeline diameter that
applies to your job.
000023.eps
Figure 52
Upper right quadrant—Pipeline diameter

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Appendix
When the output line intersects the pipeline diameter • each 90° bend with a radius of 1 meter (long
that corresponds to your job, draw a line straight down sweep) = 10 feet
into the lower right quadrant, as shown in Figure 52. • each 30° or 45° bend with a radius of 1 meter
3. The lower right quadrant refers to the or 250 mm = 3 feet
proportional value of your pipeline. It is a way of • each section of rubber hose causes three times
taking into account not only the length of the as much resistance as the same length of steel
pipeline, but also the number of bends, the pipe (e.g., 12 ft. of rubber hose has the same
increased resistance of flow in rubber hose, and resistance as 36 ft. of pipeline)
other factors. It is more a measure of the resistance • Figure all horizontal and vertical distances
to flow than a measure of length. In calculating the equally. The increased pressure required to
proportional value of your pipeline, always apply push concrete vertically is accounted for by
the following criteria: adding pressure, not distance. An example
• each 90° bend with a radius of 250 mm (boom pipeline is shown below (Figure 53).
elbow) = 3.5 feet
mavprop.eps
40 ft.
hose
400 ft. pipe
70 ft.
level
difference
elbow - 90°, r = 250 mm...3.5 feet

elbow - 90°, r = 1 meter...10 feet
elbow - 30° or 45°, r = 250mm or 1 meter...3 feet
Example: You must go 400 feet through the pipeline, then through 40 feet of rubber hose.
Calculate the proportional value as follows:
40 10-foot pipe sections = 400. feet

3.5 x 2 = 7 feet (for 90˚ elbows)
40 x 3 = 120. feet (for the rubber hose)
Total = 527.0 feet
Round down to 500 feet to make it easy to use the chart (Figure 54).
Figure 53
Calculating proportional values

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Appendix
000021.eps
100
200
300
400
Make a 90˚ turn when
500
proportional value that
applies to your job.
600
3000 2500 2000 1800 1500 1200 1000 800

Proportional value of pipeline in feet
Figure 54
Lower right quadrant—Proportional value of pipeline
When you have calculated the proportional value of of the concrete. If the concrete specifications allow
your pipeline, extend your line down from the upper a range in slump (for example 5–6 in.), always use
right quadrant until it intersects with the line that the lower end to be safe. In our example, we use 5-
represents your pipeline. When you reach the inch slump. Extend the line from the lower right
intersection, make a 90° turn clockwise into the lower quadrant until it intersects with the 5-inch slump
left quadrant. As noted previously, we are using 500 line; then make a 90° turn clockwise. This will lead
feet as our proportional value (Figure 54). you back into the upper left quadrant (Figure 55)
4. The lower left quadrant refers to the pumpability through the pressure scale.
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI
Figure 55 2"
Lower left quadrant—
Pumpability of the
concrete
2.5" Make a 90˚ turn when
slump that applies to
your job.
3" 000020.eps
4" 5" 6"
Slump of fresh concrete in inches

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Appendix
56,650
Power factor number (PF)
English to Metric Conversion Factor is PF 18.966
000019.eps
200
Q in. yd3/hr.
140
Example Job
Working power (in kW)
120
100
80
60
40
103 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI
Figure 56
Is this unit sufficient for the job?
As you can see by the chart in Figure 55, we are PF = 62,700

reentering the upper left quadrant through the pressure The unit must have a PF over 62,700, and it must be
scale at about 550 PSI. Remember, we now have to add able to pump 100 yd3/hr and 627 PSI simultaneously.
the head pressure for our vertical rise. At 1.1 PSI per Look at the pump shown in our sample nomograph
foot of level difference and our 70-foot vertical run, we (Figure 56).
must now add 1.1 x 70 = 77 PSI to the 550 PSI from
• Can the unit pump at 627 PSI? Yes
the chart.
550 PSI + 77 PSI = 627 PSI • Can the unit pump 100 yd3/hr? Yes
• Can the unit pump both simultaneously? No!
NOTE! This unit will not do the job.
When calculating the head pressure from
The engine is a little too small. The intersection of 100
vertical runs, it doesn’t matter if the
yards3/hr and 627 PSI has been plotted for visual
pipeline runs straight up and down or if it
representation, but you can see immediately that the PF
runs uphill at an angle. Only the level
of the job (62,700) is bigger than the PF of the unit
difference in feet is needed for the pressure
(56,650). The curved black line represents the PF of the
calculation. If the pipeline is running
unit. If the unit is going to be able to handle the job, the
downhill, the operator will need special
intersection of pressure and yd3/hr will be to the right
knowledge, but you don’t need to add any
and down from the curved line. Anything to the left or
head pressure to the nomograph.
above the line is beyond the power of the hydraulic
The nomograph is now complete. The PF of our job pumps. If we could order this same unit with the pumps
can be calculated like this: set to a higher Kw, the PF of the higher Kw unit would
PF = PSI x yd3/hr be 72,600, which would be sufficient.
We need a unit that is capable of 627 PSI and 100 yd3/ Plotting the intersection of our hypothetical job again,
hr. The PF of this job is: you can see that it falls within the power zone of the
PF = (627 x 100) hydraulic pumps (Figure 57).

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Appendix
Bearing in mind that the nomograph should only be • Pump the top of the building at 85 yd3/hr
considered accurate to within ±10 percent, you should
instead of 100 yd3/hr.
always calculate conservatively, and allow for the
graph tolerance. In the case of the pump in Figure 57, • Pump the top of the building at a 6-inch slump
we should still be safe even if the pressure required instead of 5-inch. (This would still be within
were 10% greater (690 PSI).What if you already own specifications.)
the pump shown in Figure 56? Is there anything that • Remove some of the rubber hose at the end of
can be done to the job specifications to make the unit the horizontal run. Normally, with job circum-
with the less powerful pumps work? You could use the stances that did not require a substantial verti-
smaller PF unit shown in Figure 56 if you can get cal run, you could also use 6-inch instead of 5-
permission to do any of the following things: inch-diameter pipeline. But in our example, the
entire vertical run was made with the boom.
The boom can never support 6-inch pipeline.
72,600
Power Factor number (PF)
English to Metric Conversion factor is PF 18.966
200
Q (in yd3/hr)
Working power (in kW)
140
120
100
Example Job 80
60
40
132 kW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
000018.eps
P (in PSI)
Figure 57
Same model pump with larger Kw hydraulic pumps

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Appendix
Minimum Pipe Wall Thickness
Minimum Pipe Wall Thickness As a Function of Pressure

11 gauge 9 gauge 7 gauge 3/16” SCHEDULE 40
(1/4 wall)
300
D
4200 290
TED
ATE
m
D
te
ATE
A
TRE
280
ys
E
4000
“s
T TR
TRE
ED
4.4
EAT
270
AT
m
A
AT
te
RE
4“ H
” HE
)
HE
3800
ys
TED
m
T
260
“s
m
AT
4.4
em
“
25
4 .9
4.0
EA
HE
(1
st
250 m
ste
TR
sy
3600
”&
m
6“
te sy
8“
AT
ys
4.8
“
4.
240 )s 5
HE
3400 ge
5“
u
230 ga m
11 ste
3200 220 , 9, “ sy
“ (7 6
210 4.9
3000
200
2800
190
2600 180
MATERIAL PRESSURE
170
2400
160
2200 150
2000 140
130
1800
120
1600 110
100
1400
pipewallvsPress2.eps
90
1200 80
1000 70
60
800
50
600 40
400 30
20
0.120”
0.150”
0.177”
0.188”
0.250”
200
10
0 0
PSI BAR
0 .050" .100" .150" .200" .250" .300" .350"
.025" .075" .125" .175" .225" .275" .325" .375"
.heat treated .standard PIPE WALL THICKNESS
1. This chart assumes a safety factor of 2:1. Higher safety factors may be required in some circumstances.
2. Wear reduces wall thickness. Thickness must be checked on a regular basis.
3. Pressures may be limited even more by clamp style or pipe end used.
4. The chart is based on 62,000 PSI tensile strength. Heat-treated calculations are based on 120,000 PSI tensile strength.
5. The chart is for pressure calculations ONLY. There is no allowance for mechanical forces other than pressure, and thicker
walls may be needed for mechanical strength because of support or restraint considerations.
6. The chart does not take into account metal fatigue caused by pressure cycles.
Note! This chart is intended as a guide for concrete pumping applications and is subject to the notes,
assumptions, and conditions listed above. Any other use of this chart is not recommended.
This chart does not apply to double-wall pipe. Double wall pipe can be checked by inspecting the inside of the pipe. If the insert is intact, the pipe is
okay. If the insert is worn through, the pipe must be replaced. Contact your pipe supplier for the pressure capacity of your double-wall pipe.

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Appendix
Pictograms
Shown below are the pictograms used on the SP 305
along with a brief description of each.
REMOTE CONTROL BOX
Concrete pump
forward on
reverse off
OPERATOR'S PANEL
Concrete pump
Local / Remote
- + forward
Pump ON Local control
Off
oil oil charging reverse
Remote control pressure temperature system
Mavpictograms.eps

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Appendix
Decal Location Guide
SAFETY LABELS (1 of 2)
30336983A
30392275 30390178
30390772 30394795 30390161
30309999C
30390771 30333268
30335000A
30336985
ENGINE
MAINTENANCE
30364521
30332668B 30390207 30301733F
30306123C
30390771 30362340 30393651
30364520A 30363822
30390178 30394795 30309999C 30390772

30333578
30390771
30336985
30390161
30364521
30390771
10/01/04 Rev 1 P 305 30364520A

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Appendix
SAFETY LABELS (2 of 2)
30337004A
30350290 30355137 30363822

30337004A
30390566
30390207
30337004A
30334976B 30324599C 30350290 HYDRAULIC 30392272 30319872D
OIL
SPECIFICATION
30312146A 30309998C 30309998C
30334976B
30309998C 30355887
30302078C
30390771 30390771
30363739 30319869C
30332962
10/01/04 Rev 1 P 305

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Appendix
Glossary of Terms foot, which is the approximate mass of hard rock

(normal) concrete.
The following list defines some terms used in this
manual. Certified Operator
An operator who has been issued a certification
Accumulator card by the American Concrete Pumping Associ-
A hydraulic device that stores fluid power energy ation. There are several classes of certification,
in much the same way that a capacitor stores each relating to a different category of pump. For
electrical energy. Because an accumulator an operator to become certified, he or she must
stores energy, it must be drained and depressur- pass tests regarding operation, setup, and
ized before work begins on an actuator or cleanout for each category of pump. They must
hydraulic system equipped with an accumulator. also pass the safety rules test common to all cer-
Agitator or Re-Mixer tification categories, meet the experience
A device set in the concrete hopper to keep con- requirements set forth for each category, and
crete moving, which prevents it from setting. It is maintain a safe and clean driving record. Certi-
typically a rotating shaft to which several paddles fied operators are considered qualified operators
have been mounted. See also: Hopper Grate in their categories. See also: Expert, Qualified
Operator
AWS D1.1
The code for structural welding with steel, as Certified Welder
defined by the American Welding Society. Sec- As it relates to concrete pumping and this safety
tions 3, 5, and paragraph 9.25 of section 9 apply. manual, a Certified Welder is a person who has
See also: Certified Welder and EN 287-1 applied for, taken, and passed the American
Welding Society (AWS) or the European Normal
Black and White (EN) test for structural steel welding. Anyone
If a boom is black and white it means that the welding on a concrete pump placing boom, out-
speed of the boom is not proportional to the rigger, tower, or other device must be certified to
movement of the joystick. Speed can only be AWS D1.1 sections 3, 5, and paragraph 9.25 of
controlled by feathering of the joystick. section 9 and/or EN287-1/PREN288-3.
Blanking Plate Concrete Pressure

Also known as a blanking plug or end cap. Its The force per square area that is exerted on the
purpose is to prevent material from falling out of concrete. The concrete pressure is always a ratio
the delivery system (typically the end hose) when in direct proportion to the hydraulic oil pressure
moving a full boom over personnel or property. on the concrete pump circuit. See also: Maximum
Pressure
Blockage
If the pump is pushing and concrete fails to come Conductors
out at the point of discharge, a blockage is the Materials that conduct electricity. Copper, silver,
cause. The causes of blockages are detailed in aluminum, gold, steel, and water are considered
section 6.18 of this manual. Blockages can cre- good conductors of electricity. Air, fiberglass, rub-
ate dangerous situations by causing high con- ber, ceramics, and glass are considered poor
crete pressure combined with the sometimes conductors. All of these conductors have a resis-
uncoordinated efforts of untrained workers to tance to the flow of electricity, which is measured
remedy the problem. in terms of ohms per linear foot. As voltage
increases, more current flows through the same
Bulk Density resistance. With high-voltage electric wires—
The mass of a substance per volume. For exam- 8000 volts, for example—even poor conductors
ple, 1 cubic foot of air weighs much less than 1 carry enough current through your body to
cubic foot of water. One cubic foot of lightweight ground to kill you. (As little as 35 milliamps can
concrete weighs less than 1 cubic foot of steel- cause cardiac arrest.) Some conductors, such as
entrained concrete. We could say that steel- air, resist electricity very well, but if the voltage
entrained concrete has a higher bulk density gets high enough, current will flow. (Lightning is a
than lightweight concrete. All calculations for the good example of this.) See also: Electrocution
operation manuals and specifications of concrete
pumps are based upon 150 pounds per cubic

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Appendix
Decibels foreign material include small animals, hammers,

A measurement of volume equal to one tenth of ready-mix truck fins, unmixed clumps of cement,
a bel, abbreviated dB. As it applies to concrete hardened concrete that breaks away from ready-
pumps, it is a measurement of the sound pres- mix truck fins, and soft drink cans. Many of these
sure level one meter away from a noise source. items can create a blockage if they are pumped
Because constant exposure to loud sound can through the system.
cause permanent hearing loss, OSHA has devel-
oped guidelines for time limits on exposure to Go Devil
sound at different volumes. The chart is in sec- A plug made from a rubber composite, usually
tion 8.14 of the Safety Manual. with several fins that expand to seal when pres-
sure is applied. Go devils are intended to be
Drive Engine inserted in a steel delivery pipeline and pushed
The primary source of power for a hydraulic sys- with water or compressed air for the purpose of
tem. Typically, the word engine denotes an inter- cleaning the pipe. Not to be used with rubber
nal combustion device, whereas the word motor hose or short sections of pipe. See also: Sponge
denotes an electrical device. See also: Prime Ball
Mover
Guide
Electrocution An assistant brought in to help with backing up a
Made by combining the words “electric” + “execu- truck or trailer or with other circumstances in
tion.” It means “death by electricity.” See also: which the driver cannot see enough to ensure
Conductors safety. See also: Spotter
EN 287-1 / PREN 288-3 High Voltage

The code for structural welding with steel as For the purposes of this manual, any current over
defined by the European Norm. See also: Certi- 120 volts AC is considered high voltage. In the
fied Welder United States, electrically driven concrete pumps
normally operate the motors at 480 volts AC
Expert (high voltage) and the controls at 24 volts DC
As used in this safety manual, an expert is (low voltage). With electric wires in residential or
defined as a person who, on the basis of special- industrial areas, the voltage is approximately
ized training and experience, has developed a 8000 volts to ground or 13,800 volts from phase
high degree of knowledge and skill in the areas to phase (distribution voltage). When dealing
of concrete pumps, concrete pumping, cleanout with electric wires that are mounted high above
procedures, generally accepted engineering the ground on steel towers, the voltage ranges
norms, and safety regulations to the extent of from 100,000 to 1,000,000 volts (transmission
being able to evaluate equipment and processes voltage).
as they relate to job safety. Experts demonstrate
their knowledge and abilities by passing the certi- Hopper Grate
fication testing and experience requirements of A meshwork typically made from steel bars and
the American Concrete Pumping Association. placed over the concrete hopper. It serves to
Other experts may include master mechanics keep human body parts away from the agitator
and after-sales service technicians of the manu- (when left in its proper position) and to keep
facturer. See also: Certified Operator large foreign objects from falling into the hopper,
which could cause blockages if they were
Fast Switch pumped. The hopper grate must be secured in
A secondary hydraulic circuit added to single-cir- position in order to be effective.
cuit machines to disable the stroke limiter during
the switch of the Rock Valve cylinder, thereby Jacking the Outriggers
making the Rock Valve switch quickly. This circuit Adjustment of the outriggers in the vertical direc-
is not needed or available on twin-circuit tion. With boom-mounted concrete pumps, you
machines. should strive to make the adjustments so that the
unit sits within 3° of level.
Foreign Material
Material that was never intended to be pumped
but ends up in the concrete hopper. Examples of

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Appendix
Licensed Electrician machinery or process in use. For safety reasons,

A qualified electrician licensed by the state, do not allow unauthorized presence in the opera-
county, or municipality where the connections tional area.
are to be made. In some locations, electricians OSHA
are not required to be licensed, but the work
Occupational Safety and Health Administration.
should still be completed by a competent profes-
A branch of the U. S. federal government that
sional. Under no circumstances should high-volt-
deals with job safety. It establishes and enforces
age connections be made by a concrete pump
safety regulations for industry and business. One
operator or related personnel.
of the areas over which it has authority is con-
Maintenance struction job sites and workshops.
All procedures for servicing, inspection, and Personal Protective Apparel
repair of concrete pumps and related equipment
Things you can wear to protect yourself from
and devices. Maintenance and inspection are
potential dangers in a concrete placing environ-
methods of maintaining the desired state of the
ment. Examples are:
equipment. Repair is the method of restoring the
• snug-fitting work clothes
desired state of the equipment.
• steel-toed work boots
Maximum Pressure • lime-resistant gloves
When talking about a hydraulic system, maxi- • safety glasses
mum pressure refers to the highest pressure that • ear muffs or ear plugs
can be achieved with the settings of the circuit • rubber boots for when you have to stand in
relief valves. When discussing concrete output, concrete
maximum pressure refers to the pressure that • hard hat
will be developed if the hydraulic system pres- Point of Discharge
sure reaches the relief valve setting. Concrete The location on the machine from which concrete
pressure is always the force at which the differ- is expelled from a delivery system. This can be
ential cylinders are moving, divided by the cross-
the point of placement (the actual form that is
sectional area of the concrete cylinder. Maximum
being filled with concrete) or the cleanout area
concrete pressure, then, is developed when the
after completion of a job.
differential cylinders are moving with maximum
force, which is determined by the hydraulic sys- Pour
tem relief valve setting. During normal pumping, Used by the concrete pumping industry and in
the resistance of moving the concrete through this manual as a noun. It is the specific job for the
the pipe or boom creates the pressure needed pump during any given time period, e.g. “We’ll
by the pump and is well under the maximum grab lunch right after the pour.”
pressure. See Also: Concrete Pressure
Prime Mover
Minimum Safety Distance The primary power source for a hydraulic sys-
In this manual, the term “minimum safety dis- tem. The term “prime mover” denotes neither an
tance” refers to the closest distance that you are internal combustion engine nor an electric motor.
allowed to approach an object or electrical wires
while leaving room for errors in human judgment
Proportional
Proportional movement means the speed that a
or machine malfunction. The distance from elec-
boom or outrigger travels is proportional to the
trical wires in the United States is 17 feet, as rec-
amount of movement on the control handle (joy-
ommended by the American Concrete Pumping
stick or outrigger handle).
Association. This distance may have other values
in different countries.
Murphy’s Law
An old adage that says: “Anything that can go
wrong, will go wrong, and at the worst possible
moment.”
Operational Area
The area around a working piece of equipment
or point of discharge where dangers can be
encountered because of the nature of the

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Appendix
PTO (Power Take Off) remove the wedge only results in forcing more of
A switchable output from the transmission or an the finest particles past the rocks, compounding
intermediate gearcase. On a concrete pump, the the problem. In some cases, the wedge can be
PTO is used to divert the power from the engine broken up by alternately pumping in forward and
and drive train to turn the hydraulic pumps. then reverse. See also: Blockage
Qualified Operator Separate Pipeline

An individual who meets all the following qualifi- A pipeline, other than the placing boom pipeline,
cations: that is laid between the concrete pump and the
• reached the age of 18 point of discharge.
• is physically and mentally capable
• has been trained in the proper operation Shutoff Valve
and maintenance of the pump and placing In hydraulics: a valve with the ability to stop the
boom, if applicable flow or pressure of hydraulic oil. Must be able to
• has demonstrated his or her capabilities to withstand the maximum pressure of the hydraulic
the hiring company with respect to the circuit that it controls. In concrete: A manually or
operation and maintenance of the pump hydraulically operated valve that prevents the
and placing boom flow of concrete in either direction. Some con-
• can be expected to perform assigned crete shutoff valves also have the ability to divert
duties in a reliable manner the flow of concrete to a different pipeline; for
example, to a discharge point for cleanout. The
Qualified Personnel shutoff valve must be able to withstand the maxi-
A generic term used to describe people who are mum pressure on the concrete of which the
qualified to do work in their area of application. pump is capable.
For example, having your boom repairs
inspected by “qualified personnel” before use Single Circuit
refers to inspection by a certified welder or certi- The plumbing method used for the pumpkit in
fied welding inspector. Having repairs to your which both the differential cylinders and the Rock
hydraulic system done by “qualified personnel” Valve cylinder are moved by the main hydraulic
would refer to repairs made by qualified work- pumps. Single-circuit machines are not equipped
shop personnel. with an accumulator.
Qualified Workshop Personnel Soft Switch

An individual who meets all of the following quali- A secondary hydraulic circuit added to twin-cir-
fications: cuit machines to account for the oil coming from
• has reached the age of 18 years the main hydraulic pumps while the Rock Valve is
• is physically and mentally capable being switched by the oil from the accumulator.
• has been trained in proper repair, mainte-
nance, and inspection procedures plus the Soil Pressure
pertinent safety rules for concrete pumps The force per square area that is exerted on the
and related equipment ground by the outrigger legs. The amount of
• has demonstrated their capabilities to their pressure that the soil will support varies with the
company with regard to the procedures composition and compaction of the soil. To deter-
and rules discussed above and mine the stability of the soil, see the chart in sec-
• can be expected to perform assigned tion 5.16 of this manual.
duties in a reliable manner
Sponge Ball
Rock Jam A medium-to-hard, spherical sponge used to
A specific type of blockage caused when the clean the inside of delivery pipelines. See Also:
cement and fines of the concrete are not present Go Devil
in sufficient quantity to fully coat the larger aggre-
gates and the walls of the delivery system. In Spotter
these cases, the rock (larger aggregates of the A spotter is a person who stands at a vantage
mix) form a wedge inside the pipe. Resistance to point where he or she can see both the point of
movement then becomes overpowering, and the discharge and the pump operator. The spotter
concrete stops. Increasing pressure to try to uses two-way radios or hand signals to direct the

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Appendix
operator to operate the unit as required by the Unauthorized

job circumstances. A spotter can be anyone who Without authority, without permission. Examples:
is familiar with the safety rules for the pump and Unauthorized operation of the boom could be
workers and is equipped with a radio or knows operation by a passing teenager. Unauthorized
the appropriate hand signals. A spotter is needed repairs to the boom could be repairs made with-
whenever the operator cannot safely see the out the manufacturer’s permission.
point of placement or the distance between the
unit and an unsafe area. See Also: Guide Unintentional Movement
Movement of the pump, boom, or related equip-
Sucking Back ment without a specific, intentional command by
The act of putting the concrete pump into the the operator. An example of an unintentional
reverse mode for any of several reasons. Some movement is if an operator fell while walking with
examples of reasons to suck back: the remote control box and accidentally hit a joy-
• To relieve pressure in the delivery system stick, which caused a boom movement. Uninten-
before opening when a blockage has tional movement can be avoided by disabling the
occurred. hydraulic system with the emergency stop
• To clean the boom with a sponge ball upon devices when the unit is not in immediate use.
completion of the pour.
• To remove concrete from the boom for the Vertical Run
purpose of folding the boom for moving. Sections of concrete delivery pipeline that run in
an up and down direction. Vertical runs have very
Thrust Block specific procedures and rules for installation,
Also known as a “dead man.” This is a large block support, cleaning, and inspection. Concrete
of poured concrete, usually with one or more pumping personnel should, therefore, have spe-
sweep elbows cast inside, placed at the bottom cific training in these procedures and rules
of a vertical run for the purpose of supporting the before attempting to use them in a job setting.
weight of the vertical run and for lateral stabiliza-
tion of the pipeline. It stabilizes and supports the Water Jet
vertical run by virtue of its enormous mass (nor- The stream of water that comes out the end of a
mally one cubic yard or larger). water hose or pressure washer. The water jet is
the only part of the water system that needs to
Towing Vehicle go into the hopper, concrete valve, or waterbox
In this manual, the term “towing vehicle” applies for cleaning.
only to trailer- mounted concrete pumps. It is the
vehicle you use to tow the trailer on the road, job- Additional Reading Material
site, or in the yard. The size and condition of the
towing vehicle are extremely important in these This is a partial list of the books that have been written
applications. See the safety rules regarding this on the subject of concrete pumping. Omission of any
subject in section 4 of this safety manual. relevant books was done so unintentionally.
• Pumping Concrete and Concrete Pumps, Karl
Transport Position Ernst v. Eckardstein. F. W. Schwing GmbH,
“Transport Position” refers to the position of the 1983.
boom during transport. For transport, the boom
is completely folded and lowered into the rests,
• Pumping Concrete—Techniques and Applica-
and the boom straps are secured. When stowing tions, Robert Allen Crepas. Aberdeen Group,
in the traveling position because of a thunder- 1991.
storm, however, the boom straps need not be • Nomographs—A Guide to Usage, Robert
secured if no travel is imminent. Edwards. Schwing America, Inc., 1992.
Twin Circuit
The plumbing method used for the pumpkit in
which the differential cylinders are moved by the
main hydraulic pumps but the Rock Valve is
moved by the oil stored in an accumulator.

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Appendix
List of Lubricants and Nitrogen

This list describes the materials that were installed in
your concrete pump unit when it left the factory. Other
brands of lubricants and their usage are described in
the following lists.
Hydraulic oil Texaco Rando 46
Gearcase oil Mobilube® HD 80w-90
Truck fluid levels See owners manual for your specific truck
Compressor oil Mobil Rarus 427 or 429
Grease for gears and

Castrol Industrial-Optimoly Paste White
spline couplers
Grease for autogreaser Mobil Grease HP or CM-S
Dry nitrogen Any brand of dry nitrogen is suitable for

recharging accumulators
Materials.eps

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Appendix
Hydraulic Oils
ISO viscosity VG 32 = Winter in northern US and Canada
ISO viscosity VG 46 = Summer in northern US and Canada
ISO viscosity VG 68 = Tropical areas, desert summers, indoor uses
Brand Viscosity / DIN quality designation

VG 32 / HLP VG 46 / HLP VG 68 / HLP
Texaco Rando HD* HD 32 HD 46 HD 68
Texaco Rando HDZ** HDZ 32 HDZ 46 HDZ 68
Mobil DTE DTE 24 DTE 25 DTE 26
Shell Tellus 32 46 68
Aral Vitam GF 32 GF 46 GF 68
BP - Energol HLP 32 HLP 46 HLP 68
Esso - Nuto H 32 H 46 H 68
Total - Azolla ZS 32 ZS 46 ZS 68
Wintershall - Wiolan HS 32 HS 46 HS 68
* Rando HD 46 is installed in new machines at the Schwing Factory - standard
** Rando HDZ is available for installation in new machines from the Schwing Factory - optional
• The following table shows the characteristics of Rando HD 46. You may use this information for
comparison with other brands.
ISO Viscosity Viscosity Flash Pour Foam, Seq II
Viscosity cST @ cST @ Viscosity Gravity point point ml foam @ 0/10
Class 40 C 100 C Index API F F minutes
VG 32 30.1 5.3 106 30.7 385 -25 20/0
VG 46 46.2 6.9 105 29.3 425 -20 20/0
VG 68 65.5 8.7 103 28.6 445 -20 20/0
• Some oil manufacturers offer vegetable-based hydraulic oils, which are considered environmentally
friendly (the additive packages are not inert, however). These vegetable-based oils must NEVER be
mixed with mineral-based oils. A complete flush of the hydraulic system must be performed when
changing to this type of fluid. See the list below for a sample of the available oils and viscosities.
Vegetable Based Hydraulic Oils

Brand Viscosity Information
Texaco Biostar Hydraulic 32 Considered equivalent to ISO VG 32 viscosity
Texaco Biostar Hydraulic 46 Considered equivalent to ISO VG 46 viscosity
Mobil EAL 224-H Considered equivalent to ISO VG 36 viscosity
Shell Naturelle HF-M Considered equivalent to ISO VG 42 viscosity OM14

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Appendix
Gearcase Oils
A) for distribution gearcases

VG 220 / CLP
Texaco Meropa 220
Mobil Mobilgear 630
Shell Omala Oil 220
Aral Degol BG 220, Degol BMB 220
BP Energol GR-XP 220
Esso Spartan - EP 220
Wintershall Wiolan - IT 220
B) for motor vehicle gearcases
Brand Viscosity / Mil-L quality designation

90 (85w-90) / 2105 B
Texaco Geartex EP-C
Mobil Mobilube HD
Shell Spirax HD, Spirax MB
Aral Gearbox Oil HYP
BP Energear Hypo 90, Hypogear 90 EP
Esso Gear Oil GX-D, Gear Oil GX
Wintershall Wiolan Hypoid Gearbox Oil 90
• The order of the list is meaningless. Any oil that meets the DIN quality designation and ISO
viscosity specification may be used.
• The lubricants listed above are suitable for continuous ambient temperatures of -10 C (14 F) to +40
C (104 F). For conditions outside of this range, contact the oil manufacturer for recommendations.
• Viscosity class 220 roughly corresponds to SAE 90.
Compressor Oils
• Use VG 100 oil when ambient temperature is 0 to 10 C (32 to 50 F).
• Use VG 150 oil when ambient temperature is above 10 C (50 F).
Brand ISO Viscosity / DIN quality designation

VG 100 / VDL VG 150 / VDL
Texaco Compressor Oil - EP 100 Compressor Oil - EP 150
Mobil Rarus 427 Rarus 429
Shell Corena - H 100 Corena - H 150
Aral Motanol - HE 100 Motanol - HE 150
BP Energol - RC 100 Energol - RC 150
Wintershall
OM15
Wiolan - CD 100 Wiolan - CD 150

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Appendix
Grease
A) For filling the automatic greasers

EP 2 / CLP
Texaco Starplex 2
Mobil Mobilgrease HP
Shell Alvania EP - 2
• Shell Alvania is installed in new machines at the Schwing factory.

• Any equivalent grease may be used.
B) For all other bearings
Brand Viscosity / Pressure rating

2 / EP
Texaco Multifak EP-2
Mobil Mobilith AW 2
Shell Alvania grease R 2
Aral HLP 2
BP Energrease LS2
Esso Multipurpose grease Beacon 2
Optimal Olitsta longtime 3 EP
• The order of the lists is meaningless. Any grease that meets the quality designation and viscosity
specification may be used.
OM19A

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TOC
HYDRAULIC SCHEMATIC
(P305):Appendix.fm
P305
Change
Agitator
SAIE 10260
(Optional)
Rev. 032508 New release
initials MB
B A
T
TOC
A2 B2
S3 1450 psi

XA1 XB1 450 bar
A1 B1
S2
XA 1.3 mm 1.3 mm XB
S1
XR XP
SP P 1800 psi
Print
124 bar
T2 T1
MP P
1.5 mm
T S MP1 Agitator
E-Stop
NG6
T MP
Operation Manual - SP 305

10u Filter
2900 psi 30 psi 35 psi
200 bar 2 bar 2.4 bar
P
M
A10V 45 DFLR Cooler
2500 psi
172 bar
X
Hydraulic Schematic—Concrete Pump SP305 - Schematic
Note:
Pressures are set to the
accuracy of the gauge as
received from the
manufacturer.
95
Appendix
96
HOPPER GRATE SWITCH E-STOP CABLE REMOTE CONTROL
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TOC
E-STOP FWD N REV

Appendix
ON,OFF,ON
2 1
30 0
3 B A C D F E
30 WHITE
DUMMY PLUG
0,1 B A C D F E
50a 15 17 19
B A C D F E
E-STOP
ORANGE ORANGE
TOC
DUMMY PLUG REMOTE

F1 ORANGE MUST BE PLUGGED IN
GREEN
15A FOR PUMP TO OPERATE
OIL OIL
CHARGING TEMP PRESSURE L O R
FAN
YELLOW
P N R
GREY
WHITE
BLACK
PURPLE
ORANGE
12G WHITE
BLACK/WHITE
WHITE/ORANGE
BLACK
RED
Print
RED
H
BLACK
87 86 87 86
K 1 87a K 2 87a

30 85 30 85
Electrical Schematic SP305 - 2004 Electric
RED
ELECTRIC BRAKES
BLACK
F2 K3 86 87
30A BREAK
87a FORWARD REVERSE AWAY
BLUE
SWITCH
WHITE
GREEN
BROWN
85 30
YELLOW
30 50a W
F3 F4 LEFT RIGHT TAIL
20A B+ D+ 10A
BRAKES
NOTE: ALL GROUND WIRES ARE GREEN 25A

+ +
STARTER M ALTERNATOR
T P
12V
--
-- 31 31 D -- GREEN
OIL HOUR ENGINE ENGINE FUEL

COOLER METER TEMP OIL SHUT
PRESSURE OFF P3 0 5 02/25/04
revDate
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Appendix
Electric Schematic CE/Tier III SP305
SP305-- CE Tier/ComIII
ELECTRICAL SCHEMATICS
SP 305 CE Tier/COM III

Revision: 071305, add 36Kw, RE By: Number: Max Q
Model: P 305
revDate
Power: 30 Kw
36 Kw
Metric to English Conversion factor is TK x 18.966 054 102 l/m

Technical identification number (TK) RE Revision date: 071305 Power: 30 Kw
36 Kw
For vertical placing, Pumpkit Model: 2.5/1.75 x 30:5
Model: P 305
(17069)
(14225)
add 1.105 PSI per foot Pipeline diameter in inches

TK 900
TK 750
of level difference.
6" 5" 4.5" 4" 3" * 2" * *estimate
Revision date: 071305
Q in yd3/hr.
60
102 l/m
Max Q
40
Number:
054
P 305 30
36 Kw 20
30 Kw
1000 800 600 400 200
P in PSI 625

2"
100
2.5"
Print
200
3"
4"
300
5"
400
Nomograph SP 305
TOC
500
6"
600
Appendix
TOC
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3000 2500 2000 1800 1500 1200 1000 800

Slump of fresh concrete in inches Proportional value of pipeline in feet
98
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Appendix
Output Chart available upon request

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Appendix
NOTES

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INDEX
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Alphabetical Index
Alphabetical Index crank arm

greasing .....................................................24
cribbing ...........................................................23
A
accumulator
charging ....................................................50
D
additional reading material list .......................90 danger ................................................................6
aggregate decal and warning labels ordering ..................19
guide for sizing pipeline ...........................22 decals
appendix location guide ............................................84
additional reading material .......................90 dummy plug
fitting/wrench sizes ...................................64 remote cable ..............................................28
glossary of terms .......................................86
hydraulic oil viscosity chart ......................62 E
minimum pipe wall thickness chart ..........82 electric brakes .................................................22
output chart ...............................................68 electrical system
pictogram list ............................................83 notes ..........................................................27
recommended emergency hose kit ............64 emergency hose kit
torque specifications .................................63 recommended ............................................64
using nomographs .....................................74 emergency procedures
disabling the unit .......................................36
B lock-out, tag-out ........................................36
boom pipeline
wall thickness chart ...................................82 F
breakaway switch ............................................23 filtration
bypass check valve bypass check valve ....................................41
oil filter .....................................................41 general information ...................................40
specific information ..................................40
C fitting/wrench size chart ..................................64
caution ...............................................................6 fitting/wrench sizes .........................................64
charging the accumulator ................................50 flashing ............................................................36
chocking ..........................................................23
concrete G
mixes .........................................................27 general information
preparation ................................................27 hoses and fittings ......................................42
control devices hydraulic oil ..............................................41
locations ....................................................25 general maintenance tips
controlling the pump adjusting relief valves ...............................44
instructions ................................................25 removal of safety devices ..........................44
coupling comparison torque specifications .................................44
weld-on ends .............................................67 glossary of terms, alphabetical ........................86
couplings greasing
grooved type .............................................67 list of lubricants ........................................91
heavy-duty type .........................................67 pivot yoke .................................................24
male/female o-ring type ............................67
metric type ................................................67 H
victaulic type .............................................67
hoses and fittings

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Alphabetical Index
general information ...................................42 boom .......................................................... 8

specific information ..................................43 explanation of ............................................. 8
hot weather pumping .......................................36 pump .......................................................... 8
hydraulic oil pumpkit ...................................................... 8
general information ...................................41
specific information ..................................42 N
nomographs .................................................... 74
I notes
id tag electrical system ....................................... 27
if missing .....................................................9
locations ......................................................8 O
instructions oil
controlling the pump .................................25 level indicator ........................................... 22
starting the engine .....................................24 oil temperature
starting the pump .......................................28 thermometer ............................................. 22
other things you should know
J charging accumulators ............................. 37
job site preparation ..........................................22 reordering documentation ........................ 37
output chart
K checking your hydraulic pumps ............... 70
key switch explanation ............................................... 68
control panel ..............................................26 overview
kit warning labels .......................................... 19
recommended emergency hoses ...............64
knob P
volume control ..........................................27 pictograms ...................................................... 83
pipeline
L procedure for laying ................................. 23
laying pipe pipeline size
procedure ...................................................23 guide ......................................................... 22
level indicator pivot yoke
oil ..............................................................22 greasing .................................................... 24
list of lubricants and nitrogen .........................91 preparing
location guide concrete .................................................... 27
decals .........................................................84 preventative maintenance
locations annual ....................................................... 49
control devices ..........................................25 daily .......................................................... 45
monthly .................................................... 47
semiannual ............................................... 48
M pumpkit
maintenance checklist .....................................66 model number ............................................ 8
manufacturer’s statement ..................................6
mixes
Q
concrete .....................................................27
quadrants
mixing
nomograph ............................................... 76
slurry .........................................................28
model number

(P305):pHseriesIOM.fm Operation Manual - SP 305 103
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Alphabetical Index
R U
remote cable unscheduled maintenance
remove dummy plug .................................28 changing material cylinders ......................60
changing rams ...........................................58
S wear parts ..................................................58
safety decals
decal location guide ..................................84 V
safety devices viscosity
warning labels ...........................................19 hydraulic oil ..............................................62
scheduled maintenance checklist ....................57
serial number W
this unit .......................................................7 warning .............................................................6
service department ............................................7 warning labels
slickline decal location guide ..................................84
minimum wall thickness chart ..................82 decal order info .........................................19
slurry weld-on ends
mixing .......................................................28 coupling comparison .................................67
spare parts
hours ............................................................7
special pumping situations Z
cold weather pumping ...............................35 zerks
emergency procedures ..............................35 crank arm lever .........................................47
hot weather pumping ................................35
plugs ..........................................................34
specific information ........................................42
hoses and fittings ......................................43
specifications
torque ........................................................63
starting the engine
instructions ................................................24
starting the pour ..............................................27
starting the pump
instructions ................................................28
stone size
guide ..........................................................22
switch
breakaway .................................................23
T
thermometer
oil temp .....................................................22
torque specifications
metric bolts ...............................................63
towing the unit ................................................22
troubleshooting
checking your hydraulic pumps ................70

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Operation Manual for

Part Number 30362000

Copyright © 2011, Schwing America, Inc.

ii Operation Manual - SP 305 revDate

Startup 250:Users:Danny:Desktop:Operation manuals:line pumps:maverick

iv Operation Manual - SP 305 revDate

SP 305 OPERATION MANUAL

INTRODUCTION Safety alert symbol and signal word

The information contained in the operation manual is

6 Operation Manual - SP 305 8/4/11

;;;;;;;;;; Whenever you call the factory for spare parts or

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Diff. cyl. bore dia. (in inches)

8 Operation Manual - SP 305 8/4/11

If your ID tag is missing

MODEL SP 305 SERIAL NO. 171530001 YEAR 2009

Max. hyd. System System System System System

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10 Operation Manual - SP 305 8/4/11

SP 305 OPERATION MANUAL

12 Operation Manual - SP 305 4/30/12

Functional Description of the

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14 Operation Manual - SP 305 8/4/11

SP 305 OPERATION MANUAL

SAFETY Schwing phone numbers

16 Operation Manual - SP 305 8/4/11

October 27, 2008

Safety/Service Bulletin 1023-08

Dear Schwing Customer,

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Safety Manual v 6.0.1 Order Form

City, State, Zip:

Manual part number:____________________ Model number:

Manual part number:____________________ Serial number:

Manual part number:____________________ Model number:

Manual part number:____________________ Serial number:

Manual part number:____________________ Model number:

Manual part number:____________________ Serial number:

Manual part number:____________________ Model number:

Manual part number:____________________ Serial number:

Manual part number:____________________ Model number:

Manual part number:____________________ Serial number:

Safety Manual, Bound, English v 6.0.1 .................................................................................. Part #30327535

18 Operation Manual - SP 305 8/4/11

Warning Labels (Decals)

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20 Operation Manual - SP 305 8/4/11

SP 305 OPERATION MANUAL

22 Operation Manual - SP 305 7/27/12

Breakaway switch and cable

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• Make sure all Emergency Switches are in the RUN

Get your slurry mixing items ready, but don’t actually

24 Operation Manual - SP 305 7/27/12

Don’t run the engine at high RPM until it has warmed

You don’t need to lower the RPM of the engine to

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