Manual Operation S32-S34X

Operating Instructions
Editor: Schwing Equipamentos

Industriais Ltda.
Rod. Fernão Dias, Km 56
Mairiporã – São Paulo
S 32 X
Brasil
S 34 X
Art.-Nr.: 21980161
All rights reserved.

No part of this publication may be reproduced without prior permission in writing from the editor.
003.930.00-en
ATTENTION - BLADDER ACCUMULATOR
Depending on the equipment of the concrete For reasons of WORKING SAFETY, the follow-
pump, the machine may be equipped with a ing additional precautions must be taken be-
hydraulic bladder accumulator. fore any work (e.g.: cleaning, connection of test
gauges, repair, replacement of wear parts etc.)
Bladder accumulators are pressure vessels is being undertaken on the machine:
within the meaning of the Pressure Vessel Di-
rective 97/23EC. – shut off the machine control unit;
Before commissioning and during the operation, – shut off the drive engine and secure against
the regulations in force in the country of use inadvertent restarting (e.g. by withdrawing
must be respected. the ignition key);
The owner of the machine is responsible for the – open the manual accumulator relief valve;
observance of these regulations.
– check the hydraulic accumulator charge (the
Observe the documentation of the accumulator pressure gauge on safety block indicates "0").
manufacturer. These instructions must be kept
with the machine documentation. Any non-observance of these instructions in-
volves a RISK OF ACCIDENT (e.g.: due to un-
In Germany, an inspection by an authorized controlled switching of the Rock valve, hydraulic
testing institue is prescribed at the time of oil ejected under pressure, etc.).
commissioning and then after every 10 years at
the latest. Observe also the instructions set out in chapter
4.23 of the present operating instructions and
Within the limits of regular safety checks, the the documentation of the accumulator manufac-
bladder accumulator must be checked by a turer.
qualified person for apparent defects.
ATTENTION:
RISK OF ACCIDENT!
Depressurize the bladder accumulator
before working on the machine.
The relief valve in the accumulator block opens

automatically under certain operating conditions
so that the bladder accumulator is depressur-
ized.
002.277.04-en
PRESENTATION 1
SAFETY 2
OPERATION 3
MAINTENANCE 4
RADIO-REMOTE-
CONTROLS 5
APPENDIX 6
TI 01(GB)
0.1-1
OPERATING INSTRUCTIONS: STRUCTURE
MAIN SECTIONS TEXT LAYOUT
The operating instructions consist of 6 main Extra important text sections are printed in
sections. "bold" type.
CHAPTERS ATTENTION - DANGER!

This symbol indicates risks and
Each main section is preceded by a table of how to avoid them.
contents listing the individual chapters. The most important points for oc-
cupational safety and accident pre-
The operating instructions are complete even if vention are summarized in main
some chapters listed in the table of contents are section 2 "SAFETY".
not included.
Main section 2 is of a general na-
ture and contains no information
In such cases, the missing chapters deal with
relating to specific machines.
optional equipment not applicable to your ma-
chine.
DIRECTION SPECIFICATIONS
SINGLE PAGES
Direction specifications such as "left" or "right"
The single pages of each chapter are num- always refer to the direction of travel of the ma-
bered consecutively. The page number is cen- chine (Fig. 1).
tred at the top of the page.
Example:
1. 4 - 2
1............. = main section

4.......... = chapter
- 2..... = page
A code number for internal text processing (e.g.

002.897.00) is centred at the foot of each page.
This number is irrelevant to the reader of the
operating instructions
Fig. 1
002.897.00-en
0.1-2
IMPORTANT TERMS MODIFICATIONS
Important modifications to the series status of

Remote control the machines are covered in the respective new
edition of the operating instructions.
During normal working operation, the control

system of the machine must be operated by TECHNICAL INFORMATION LEAFLETS
remote control (cable or radio) only.
SCHWING compiles these information leaflets
(Fig. 1) to pass on important, new know-how to
our customers and agents.
Local control
The information may be machine-specific or of
general interest.
The term "local control" (for control elements)
covers all special modes of operation not be- The leaflets are distributed through our agen-
longing to normal working operations, such cies and form a supplement where necessary to
as: our operating instructions.
– setting mode (assembly and dismantling) A small selection of important information leaf-
lets can be found in the annex.
– maintenance (repair, servicing, cleaning)
– emergency operation.
Control elements must not be used for normal

working operation.
ILLUSTRATIONS
The illustrations in the operating instructions are

designed to clarify the texts.
They may deviate from the specific machine

version without the technical information given
in the operating instructions being affected.
Fig. 1
002.897.00-en
PRESENTATION 1
TI 11(GB)
PRESENTATION 1.1
TABLE OF CONTENTS - PART 1
Chapter Title
1.1 TABLE OF CONTENTS
1.2 PREFACE
DECLARATION OF CONFORMITY
NON-VALIDITY OF THE DECLARATION OF CONFORMITY
1.3 MACHINE CHARACTERISTICS
1.4 TECHNICAL DATA
1.5 MACHINE DESCRIPTION
1.6 PICTOGRAPHS
1.7 CONTROL, WARNING AND MONITORING ELEMENTS
1.8 CONTROL SYSTEM
002.898.05-en
1.2-1
PREFACE
These operating instructions are intended for In addition to the operating instructions ob-
all persons who are entrusted with the opera- serve the legal and other regulations for pre-
tion and maintenance of the vention of accidents which may govern in the
country of use.
SCHWING MACHINE
described below and for the owner resp. user In the event of failures, possible questions and
of the machine. for ordering spare parts, please contact the
authorized representative for your area or
The operating instructions shall assist you in

Schwing GmbH
- becoming familiar with the machine to be able
to use it properly, P.O. Box 20 03 62
- running it safely to prevent accidents, D - 44647 Herne
- applying it to the purpose and economically to Telephone : +49 2325 987-0

save money. Fax : +49 2325 72922
Telex : 820348
E-Mail : [email protected]
The machine complies with the level of tech-
nology and the relevant safety regulations.
Our departments
Nevertheless it may constitute a hazard for
persons and material if it is applied, operated, - SPARE PARTS SALES
maintained or repaired incorrectly.
- AFTER-SALES SERVICE
Any handling of the machine implies knowl- - WARRANTY

edge and strict observation of the operating
instructions.
can be reached under
It is therefore advisable - especially prior to
commissioning - to read the instructions care- telex no. : 820352
fully several times and to acquaint oneself with fax no. : +49 2325 74674
the machine. E-Mail : [email protected]
During operation it would be too late to do so.

Please use this telex number only for your cor-
respondence with these departments.
Always quote the model and the serial num-

ber of your machine.
001.200.06-en
1.2-2
OTHER OPERATING MANUALS DECLARATION OF CONFORMITY
SCHWING installs their truck-mounted concrete SCHWING declares that the machines brought
pumps on chassis from various manufacturers. into circulation by us inside the European Eco-
nomic Area are in conformity with the respec-
These manufacturers supply their products tive EC directives.
with special operating manuals.
The same applies to the manufacturers of the This is certified by us with a "declaration of
motors and engines that are incorporated in conformity" and with the application of the "CE"
our trailer concrete pumps. mark on the machine. See also chapter 1.3.
Special operating manuals are sometimes also

supplied together with the equipment options
installed in your SCHWING machine.
As the information supplied in these docu-

ments is generally not covered by the present
operating instructions, the user is obliged to
NON-VALIDITY OF THE DECLARATION OF
observe these documents as well.
CONFORMITY
For a safe, approriate and economical operation
The CE mark and the declaration of conformity
and maintenance of the machine as a whole,
are only valid for the machine type and the
the perfect knowledge of these manuals is
scope of supply as delivered ex factory.
equally indispensable.
Both will lose their validity, if the machine is
Please note that the safety instructions set modified without SCHWING's consent or if
out in those manuals are of utmost impor- accessories are used which do not have the
tance. approval of SCHWING.
If you have trouble with your truck or with your The machines concerned can be immobilized
engine/motor or if you need spare parts, by the competent authorities.
please contact directly the addresses indicated
in the operating manuals of the respective SCHWING does not assume any responsibility
manufacturers. whatsoever for the consequences of the above
manipulations. The responsibility lies entirely
with user and the owner of the machine.
001.200.06-en
1.3-1
MACHINE CHARACTERISTICS
Truck-mounted concrete pump type designa- CE-SIGN

tion:
Machines brought into circulation in the coun-
S 34 X tries of the European Economic Area (EEA)
after January 1, 1995 must conform to the
S............ = SCHWING common directives concerning accident pre-
vention and health protection.
34...... = reaching height in m
The manufacturers of machines acknowledge
X.... = X stabilizers observance of these directives by attaching a
sign (Fig. 1) to the machine and by issuing a
Placing boom type designation: "declaration of conformity".
34 R The CE sign is attached to the chassis of the

machine beside the concrete pump identifica-
34.......... = reaching height in m tion plate.
R....... = roll-and-fold system

Communauté Européenne
(European Community)
The type of concrete pump installed is desig-
nated by its technical characteristics.
Fig. 1
For example:
P 2023 - 110/75
P...................... = (concrete) pump
20.................. = 2000 mm stroke of pump-

ing cylinders
23.............. = ∅ 230 mm of pumping

cylinders
- 110.... = ∅ 110 mm of pistons in

hydraulic cylinders
/75 = ∅ 75 mm of piston rods of

hydraulic cylinders
For better identification, the designation can be

supplemented by different indications.
Identification plates see next page.
003.932.01-en
1.3-2
IDENTIFICATION PLATES
The concrete pump identification plate is at-

tached to the left side of the chassis viewed in
the direction of driving (Fig.1).
Fig. 1
The placing boom identification plate is at-

tached on the right of the first boom segment
viewed in the direction of driving (Fig.2).
Fig. 2
The pumping line identification plate is attached

beside the placing boom identification plate
(Fig.3).
Fig. 3
The most important characteristics identifying the concrete pump and the vehicle can be displayed by
the Vector control unit. Scroll down the menu 'Functions' to submenus ' Machine data' or 'Vehicle
data' (see chapter. 1.8) and note them hereunder:
SCHWING machine data Vehicle data
Machine no.: Manufacturer:

...................................... ......................................
Machine type: Type:
...................................... ......................................
CP type: Chassis no.:
...................................... ......................................
Hydraulics type:
......................................
Please always state these data when writing to us.
003.932.00-en
1.4-1.1
TECHNICAL SPECIFICATIONS
CONCRETE PUMP
SCHWING truck-mounted concrete pumps can The lower of the two values is the maximum
be supplied with pump units having different possible concrete pressure for rod-side admis-
power ratings. sion.
In machines equipped with the VECTOR control The hígher of the two values is the maximum
system, the most important machine identifica- possible concrete pressure for piston-side ad-
tion data can be displayed in the "Machine mission.
data" menu.
In the interest of achieving high concrete pump-
Further information is set out on the type identi- ing rates, these concrete pumps are generally
fication plate of the concrete pump. See pre- delivered with rod-side admission.
ceding page.
Besides the correct pump unit designation, the

plate specifies the maximum hydraulic oil pres- ATTENTION:
sure and the maximum concrete pressure. RISK OF ACCIDENT AND DAMAGE
After reconnection of the pump for
Under "Concrete pressure" one or two values piston-side admission, these concrete
may be specified. pumps can generate concrete pres-
sures exceeding the burst pressure of
Example 1 the boom pumping line.
Special equipment installed in the pump-
ing line as, for instance the chamber
max - / 85 bar Beton
valve, would be overloaded as well.
For pumping, only a separate high-
This concrete pump may only be driven hydrau- pressure pumping line must be used.
lically by piston-side admission. See also chapter 3.22.
To prevent overloading of the con-
ATTENTION: crete pump, it may be necessary to
RISK OF ACCIDENT AND DAMAGE adjust the pressure limiting threshold
The hydraulic connections of this of the hydraulic system to a lower va-
pump unit must not be changed! lue.
It is absolutely recommended to
contact our after-sales service be-
fore changing the hydraulic con-
Example 2 nections of the concrete pump!
max 60 / 108 bar Beton
This concrete pump may be driven by rod-side

or piston-side admission.
Changing of the hydraulic connections is per-

mitted.
p.t.o.
004.175.01-en
1.4-1.2
TECHNICAL SPECIFICATIONS FOR TRUCK-MOUNTED CONCRETE PUMPS
(see table next page)
KSB = piston-side admission
SSB = rod-side admission
Column 1 : type of concrete pump, see example page 1.3-1
Column 2 : maximum pumping rate of hydraulic pump(s) in l/min
Column 3 : maximum hydraulic oil pressure (pressure cut-off setting) in bars
Column 4 : maximum theoretical concrete pumping rate in m³/hour
Column 5 : maximum concrete pressure in bars
Column 6 : maximum number of strokes of the concrete pump (strokes/minute)
Important:
Maximum values can only be achieved with drive engines of sufficient power.
Installation of concrete pump only after technical clarification.
004.175.01-en
1.4-1.3
1. 2. 3. 4. 5. 6. 4. 5. 6.
KSB SSB
l/min bar m³/h bar s/min m³/h bar s/min
P 0618-70/50 125 300 (280) 40 45 42 / / /
P 0618-80/50 HD 185 300 (280) 48 59 50 / / /
P 0618-80/50 HD begr. 160 300 (280) 41 59 43 / / /
P 1020-80/50 150 300 (280) 51 48 27 / / /
P 1020-80/50 185 300 (280) 62 48 33 / / /
P 1020-90/50 225 350 (330) 61 71 32 / / /
P 1620-120/80 320 300 51 108 17 89 60 30
P 2020-120/80 320 300 52 108 14 91 60 24
P 2020-120/80 MPS 320 300 53 108 14 94 60 25
P 2023-110/75 450 350 114 80 23 / / /
P 2023-110/75 380 350 (330) 96 80 19 / / /
P 2023-110/75 MPS 636 370 (330) 161 85 32 / / /
P 2023-110/75 MPS 535 370 (330) 137 85 27 / / /
P 2023-110/75 MPS 456 370 (330) 117 85 23 / / /
P 2023-125/80 320 325 63 96 13 105 57 21
P 2023-125/80 450 325 (305) 89 96 18 147 57 30
P 2023-125/80 MPS 450 325 (305) 90 96 18 150 57 30
P 2023-125/80 MPS 320 325 (305) 64 96 13 108 57 22
P 2023-130/80 380 300 69 96 14 110 60 22
P 2023-130/80 450 300 82 96 17 130 60 26
P 2023-130/80 MPS 450 300 (280) 83 96 17 132 60 27
P 2023-130/80 MPS 535 300 (280) 99 96 20 157 60 31
P 2025-120/80 MPS 636 370 (330) 161 85 27 / / /
P 2025-120/80 MPS 535 370 (330) 136 85 23 / / /
P 2025-120/80 MPS 450 370 (330) 115 85 20 / / /
P 2025-125/80 MPS 636 340 149 85 25 / / /
P 2025-125/80 MPS 535 340 126 85 21 / / /
P 2025-125/80 MPS 450 340 106 85 18 / / /
P 2025-130/80 MPS 450 315 98 85 17 156 53 27
P 2025-130/80 MPS 535 315 116 85 20 185 53 31
P 2025-130/80 MPS 636 315 138 85 23 / / /
P 2525-120/85 450 370 (330) 114 85 16 / / /
P 2525-120/85 MPS 636 370 (330) 162 85 22 / / /
P 2525-120/85 MPS 535 370 (330) 137 85 19 / / /
P 2525-120/85 MPS 450 370 (330) 115 85 16 / / /
004.174.01
1.4-2
PLACING BOOM S 32X
Pumping line diameter DN 125
End hose length 4m
Max. working height approx. 31.82 m
Max. reach from center of slewing axis approx. 28.0 m
Max working depth approx. 16.0 m
Min. unfolding height approx. 7.55 m
Number of folding points 4
Slewing angle of boom column approx. 540°
Rotation angles of boom sections Joint A: approx. 96°
Joint B: approx. 180°
Joint C: approx. 180°
Joint D: approx. 238°
Height of folding points Joint A: approx. 3.7 m
Joint B: approx. 11.5 m
Joint C: approx. 18.4 m.
Joint D: approx. 25.4 m
004.292.01-en
1.4-3
S 32X
1.4-4
S 32X
1.4-5
PLACING BOOM S 34X
Pumping line diameter DN 125
End hose length 4m
Max. working height approx. 34.0 m
Max. reach from center of slewing axis approx. 30.0 m
Max working depth approx. 23.0 m
Min. unfolding height approx. 7.8 m
Number of folding points 4
Slewing angle of boom column approx. 540°
Rotation angles of boom sections Joint A: approx. 96°
Joint B: approx. 180°
Joint C: approx. 180°
Joint D: approx. 238°
Height of folding points Joint A: approx. 3.9 m
Joint B: approx. 12.1 m
Joint C: approx. 19,3 m.
Joint D: approx. 26.5 m
004.292.01-en
1.4-6
S 34X
1.4-7
S 34X
1.4-X
NOISE SPECIFICATIONS for truck-mounted concrete pumps

(acc. to EC Machine Directive 98 / 37 EG)
1. Sound power level (DIN 45635, Part 1) LWA = 117 dB (A)

2. Workplace-related noise emission not applicable. The workplace is the portable re-
mote-control unit
3. Measuring instrument sound level precision meter:RION NA 29 E
4. Test conditions machine in transport position
machine at operating speed
machine at operating temperature
reverse operation (concrete pump in suction
mode)
max. number of strokes
concrete feeding hopper filled with water
5. Protective measures Within close range of the machine 85 dB(A) are
partly exceeded.
For this reason, personal ear protectors must be
worn inside the entire close range of the machine
when persons stay near the machine for prolonged
periods.
A distance of
less than 15 m
measured from the water-box of the concrete
pump is considered as close range.
Details of measuring method, individual measurements, etc. are set out in our measuring records.
Since 03. 01. 2002 a rating plate providing As to noise emissions, please observe the
information on the noise emission of the re- working time restrictions in force at the
spective machine must be mounted on all ma- place of use.
chines of the above type (Fig. 1). This applies
throughout the EU. In countries of the European Community, di-
rective 2000/14/EC as transposed to national
The stated value represents a mean value for law is applicable.
the corresponding type series plus a safety
margin.
SCHWING guarantees that this value is not

exceeded in new machines delivered ex works.
Fig. 1
002.420.03-en
1.5-1
MAIN ASSEMBLIES OF THE MACHINE
1 - Truck chassis with SCHWING pump drive 6 - Concrete pump with
2 - Placing boom with pumping line (see page 2) 6.1 - Rock valve
3 - Base frame with 6.2 - Concrete feeding hopper
3.1 - Oil reservoir 6.3 - Pumping cylinders
3.2 - Water tank 6.4 - Differential cylinders
3.3 - Boom slewing base 6.5 - Water-box
3.4 - Slewing drive 6.6 - Control block
4 - Front X-type stabilizers 6.7 - Switching cylinder
5 - Rear stabilizers
003.974.00-en
1.5-2
PLACING BOOM
1 - Section 1 B - Joint „B“
2 - Section 2 C - Joint „C“
3 - Section 3 D - Joint „D“
4 - Section 4 ZA1 - Cylinder, joint „A“, section 1
5 - Pumping line ZB1 - Cylinder, joint „B“, section 1
6 - End hose ZC2 - Cylinder, joint „C“, section 2
A - Joint „A“ ZD3 - Cylinder, joint „D“, section 3
003.974.00-en
1.5-3
CONCISE DESCRIPTION
MACHINE FRAME
The truck-mounted concrete pump and the The rear stabilizers are telescoped at right an-
placing boom are installed on a special mount- gles (90°) to the truck's longitudinal axis where-
ing frame. as the front stabilizers are X-type stabilizers.
The special frame is suitable for being mounted This construction does not need the space re-
on vehicle chassis of different manufacturers. quired for the swinging out of conventional sta-
bilizers during set-up operations.
As a rule, the frame is installed on a 3-axle
chassis.
1- Drive engine
DRIVETRAIN 2- Truck gearbox
Concrete pump, placing boom and most of the 5- Rear axle

auxiliary units are driven by oil hydraulics.
6- Truck PTO
The hydraulic system is driven by the truck en-
gine. 9- Hydraulic pumps with
through-shaft
The machine is preferably installed on trucks
equipped with a free PTO.
In this configuration, all hydraulic pumps are Fig. 1

arranged in the same drivetrain and equipped
with a through-shaft (Fig. 1).
The pumps are driven by a cardan shaft. A 1- Drive engine

pump transfer gearbox is not needed.
2- Truck gearbox
A switchable divider gearbox can be installed
as an alternative (Fig. 2) after technical exami- 3- Switchable divider
nation. The switchable divider gearbox is in- gearbox
stalled in the cardan shaft of the truck and can
be switched from travelling to pumping mode. 4- Hydraulic pumps
5- Rear axle
PLACING BOOM AND STABILIZERS
The placing boom is designed as a 'roll-and-

fold' system.
Fig. 2
003.943.00-en
1.5-4
A constant-displacement pump supplies the ROCK VALVE

boom, the stabilizers, the water pump and vari-
ous options of the truck-mounted concrete As in a reciprocating engine, the pumping pis-
pump with oil. tons of the twin-cylinder piston pump constantly
change their sense of movement.
A pressure filter is installed ahead of the control
block. Both pistons work in opposite direction.
While the retracting piston sucks in concrete

CONCRETE PUMP from the feeding hopper, the advancing piston
pushes the concrete sucked in during the previ-
The concrete pump is a two-cylinder piston ous stroke into the delivery line.
pump with a Rock valve.
During this cycle, the Rock valve pivots in such
The most important components are (Fig. 1): a way that the 'sucking' cylinder is always con-
nected to the feeding hopper and the 'pushing'
1- Rock valve cylinder to the delivery line.
2- Pumping cylinder and pistons By switching over to SUCTION (reverse pump-

ing), the concrete can be sucked back from the
3- Water-box delivery line into the feeding hopper.
4- Hydraulic drive cylinders In the limit positions, the hydraulic cylinders of

the concrete pump and of the Rock valve actu-
Two controlled axial piston pumps with output ate the hydraulic control valves coordinating the
regulation supply the hydraulic cylinders of the movement of the cylinders.
concrete pump and the Rock valve with hydrau-
lic oil. A hydraulic accumulator supports fast switching
of the Rock valve.
The control is fully hydraulic. See ROCK
VALVE:
The concrete pump is equipped with an MPS

system (optional with 380l drive).
The Mini–Pause–System (MPS) ensures a

'quiet' end hose and pump switching without
'knocking'.
The hydraulic pressure accumulator required

for MPS control is recharged by its own adjust-
able hydraulic pump.
Fig. 1
003.943.00-en
1.5-5
AUXILIARY UNITS CONTROL SYSTEM
In the standard version, the machine is The placing boom is operated by means of a
equipped with an agitator in the concrete feed- proportional control unit and has an electro-
ing hopper and a water pump. hydraulic pilot-control system.
The 'agitator pump' also supplies the concrete The concrete pump and the agitator have an
pump pilot control whereas the 'placing boom electro-pneumatic pilot-control system.
pump' drives the water pump.
Power for the electrical system is supplied from
The oil cooler and the oil filter of the concrete the truck's power supply and compressed air for
pump are located in the same housing. the electro-pneumatic pilot control is taken from
the truck's compressed-air reservoirs.
Hydraulic oil is pumped in a separate circuit
through this cooler-filter combination. The consumer shuttle valves are grouped in
control blocks and equipped with hand opera-
This system is active immediately after activation levers.
tion of the drive unit and independent of other
functions. Except for the stabilizers, the hand control lev-
ers are used for emergency control purposes.
Further units, such as compressor, concrete
shutoff valve, high-pressure cleaner, etc. are In the standard version, the machine is
available as an option. equipped with a radio remote-control unit.
A cable remote-control is available as an op-

tion.
003.943.00-en
1.6-1
PICTOGRAPHS
Pictographs are placed near switches, control levers, lamps, etc. They simplify the attribution of the
control, warning and monitoring elements to the individual machine functions. Depending on the re-
spective functions, it is possible to combine the symbols.
DRIVE
Motor / engine
Speed control Motor / engine Battery temperature
Engine oil Engine stop PID control Radiator
Coolant- Air cooling: Fluid filter:

temperature Oil cooler malfunction malfunction
Temperature
min. level too high vehicle engine Engine oil pressure
Engine air filter con- Diesel engine pre-

taminated heating monitor
001.945.04-en
1.6-2
CONTROL
Radio
Control Remote control remote control Automatik control
Direct / Remote con-

Manual control trol
CONCRETE PUMP
Piston- / Rodside Output

Concrete pump admission adjustment Attenuation
OUTRIGGER SYSTEM
Folding of
Support foot in support foot Retractable box in
001.945.04-en
1.6-3
SECONDARY GROUPS / ACCESSORY PARTS
Water pump Compressor Piston pump Agitator
Vibrator Shut-off valve Horn Spotlight
Lifting / Lowering Warning beacon Shutting Opening
MIXER
Chute: Prop. Mixer control Mixer control

Mixing -0- Discharge Raising -0- Lowering Mixing -0- Discharge Sensor -0- Manual
001.945.04-en
1.6-4
PLACING BOOM
Proportional
Lowering of Slewing of Slewing of slewing of
placing boom boom section placing boom placing boom
Lowering of Boom movements

boom column
SAFETY
Pumping line under During normal opera-

pressure. tion, it is forbidden
Do not open. to stand on the ma-
chine unless the ma-
chine is equipped
with control stands
especially provided
for this purpose.
001.945.04-en
Page 1 of 1
INFORMATION Staff members, agents, K 194.1

customers (replaces K 194)
DC-Actros MP 2 SHE/VVW 2007 / 01
SCHWING switches in the cab
When a SCHWING machine is mounted on an 7 – Toggle-switch: trailing axle*

"Actros MP 2" DaimlerChrysler truck, the switch
block provided in the cab must be used for the (S 42SX and higher)
SCHWING components.
8 – Toggle-switch: trailing axle *
Depending on the equipment version, the follow-
ing switches and lamps may be provided: (S 42SX and higher)
1 – Pilot lamp: * see vehicle operating instructions

SCHWING control ON
Note:
2 – Toggle switch:
SCHWING control 1 - 0 - 2 In the afore-mentioned vehicles, the stabilizer
illumination can be configured in such a way
Pos. 1 = pumping operation that the lateral floodlamps are on up to a
truck speed of 20 km/h and are then shut off
Pos. 0 = control OFF automatically.
This can be helpful for manoeuvring on the
Pos. 2 = mixing during transport (only for construction site .
truck-mixer concrete pumps)
In truck-mounted concrete pumps, the

SCHWING control is switched off in position
2.
3 – Toggle switch: ABS*
4 – Toggle switch: rotary beacon(s)
(SCHWING optional equipment)
5 – Toggle switch: P.T.O.*
6 – Toggle switch: stabilizer lighting
(SCHWING optional equipment,

series equipment with S 58SX)
Fig. 1
004.109.01-en
1.7-1
MONITORING, WARNING AND CONTROL

ELEMENTS
OVERVIEW
1 - Key-switch of SCHWING control
- Control lever for switchable divider gear-

box (optional equipment)
2 - Emergency control
3 - Emergency shut-off button
4 - Stabilizer control
5 - Switch cabinet of control unit
6 - Ballcock: CP pressure check
7 - Ballcock: MPS
8 - Control panel of local control
- Supply connections: air, water
9 - Accumulator safety block
10 - Inspection glass for hydraulic oil level

checking
11 - Switchbox of special control for piston

replacement
Depending on the equipment installed in the

machine, there may be other (additional)
monitoring, warning and control elements.
All elements are identified by symbols in
acc. with chapter 1.6: PICTOGRAMS.
003.935.00-en
1.7-2
DRIVER'S CAB (Fig. 1)
1- Key-switch:
SCHWING control ON / OFF
2- Pilot lamp:
SCHWING control ON
3- Switch: side-mounted floodlamps
CONTROL
Fig. 1
The hydraulic emergency control 1 and the
switch-cabinet of the electrical control 2 are
located in lockable compartment on the side of
the machine (Fig. 2)
REAR OF TRUCK, righthand side (Fig. 3)
1 - EMERGENCY SHUT-OFF button
2 - Local control panel (see chapter 1.8)
3 - Pushbutton: warning hooter
4/5 - Air and water connections depending on Fig. 2

equipment installed
6 - Pushbutton: change-over of agitator

sense of rotation
7 - Socket outlets for vibrator and flood-

lamps
Fig. 3
003.935.00-en
1.7-3
SPECIAL CONTROL: PUMPING PISTON RE-

PLACEMENT (Fig. 1)
1 - Momentary-contact switch:
engine ON / OFF
2 - Momentary-contact switch:
concrete pump 'inching' operation
Fig. 1
STABILIZERS (Fig. 2+3) left viewed in the sense of driving:

Control levers on both sides of the machine.
Function assigned see symbols, e.g.:
1 - Front outrigger: in -0- out
2 - Rear outrigger: in -0- out
3 - Front supporting cylinder: in -0- out
4 - Front supporting cylinder: in -0- out
5 - Pushbutton: stabilizer enable

Fig. 2
6 - Spirit level
right viewed in the sense of driving:
Fig. 3
003.935.00-en
1.7-4
EMERGENCY CONTROL
The control valves of the hydraulic system are 7 - Control lever:

located in a lockable compartment on the right. Water pump -0- optional equipment
The valves are equipped with hand levers for
emergency control. 8 - Control lever:
Concrete pump: Pumping -0- Suction
1 - Control lever: section 1 up -0- down
9 - Control lever: Agitator
2 - Control lever: section 2 up -0- down forwards -0- reverse
3 - Control lever: section 3 up -0- down 10 - Pressure gauge:

Concrete pump hydraulic pressure
4 - Control lever: section 4 up -0- down
11 - Shut-off valve for item 10
5 - Control lever: boom slew
right -0- left 12 - Emergency shut-off valves
6 - Control lever: 13 - Pressure gauge: Pneumatic pilot control

Boom control -0- stabilizer control
003.935.00-en
1.7-5
OPERATING AND MONITORING ELEMENTS

OF THE VECTOR CONTROL
(see summary instructions chapter 1.8)
CONTROL CABINET (Fig. 1)
LOCAL CONTROL (Fig. 2)
REMOTE CONTROL (Figs. 3+4) Fig. 2
Cable and radio remote control units with 2 or 3

boom control levers are available.
Important:
The above control and monitoring panels are
pre-equipped with controls for optional
equipment such as:
– high-pressure cleaning system,
– compressor,
– chamber valve etc.
These controls are without function if the ma- Fig. 3
chine is supplied without this equipment.
Fig. 4
Fig. 1
003.935.00-en
1.8-1
VECTOR CONTROL
The Vector Control includes a standard radio

remote control (see Section 5) and an
integrated diagnosis system.
The diagnosis system monitors the machine

and the control unit for malfunctions and for-
bidden states of operation.
Faults are signalled acoustically and indicated

on the display 1 (Fig. 1).
Besides its monitoring function, the diagnosis

system can show all important operation data
Fig. 1
on a display.
For this reason, you will find no conventional

indicator instruments on the machine.
The following INSTRUCTIONS are intended as

a quick overview over the control system.
Note:
The number of characters that can be dis-
played per text message on the screen are
limited. Certain messages are abbreviated and
are therefore not necessarily fully identical to
the messages printed out in these instructions.
003.911.03-en
SCHWING – Control system " VECTOR "
OPERATING INSTRUCTIONS
valid from software version V 1.11 onwards
The operating instructions consist of two parts:
PART 1: OPERATION
(machine operator)
TEIL 2: BOOM TEACHING
(only for specially qualified personnel)

Published by: SCHWING GmbH
Dept.: VVW
Postfach : 20 03 62
D - 44647 Herne
Id. no.: 10207417
02/10/2008 13:58:00
All rights reserved. Reproduction - in whole or in part - only with the express written permission of SCHWING GmbH.
004.103.03-en
START SCREEN:
Software version V 1.30
The above-mentioned software version will be introduced from February 2008 onwards. Compared to
the previous version, this software is characterized by some new features, as for instance:
– In the event of a quiet diagnosis, the horn signals automatically generated by the control system
will be suppressed. The beeper signal in the control cabinet will be maintained. In the remote-
control unit FW 28 with data feedback option, an additional beeper signal will be activated in the
control transmitter.
– The water pump starts up with a ramp function. This means that the water pump starts up slowly
and reaches the maximum discharge capacity after 2 seconds. This feature reduces the switch-on
pressure when the spraying hose is connected.
– In certain machines, the supporting pressure exerted by the placing boom on the boom support is
limited. The hydraulic pressure value is indicated on the operation data display of the control sys-
tem.
– In an emergency stop situation, the engine speed is lowered to minimum speed.
– The selected display contrast setting is stored.
– Further changes apply to internal improvements in the control system. They are not immediately
evident to the user.
004.103.03-en
PART 1 -1-
SCHWING control system 'VECTOR'
OPERATING
The present instructions are intended to serve as a 'memory aid'. They do not refer to any par-
ticular type of machine and do not relieve the user of familiarizing himself with the operating
manual of the machine in question.
CONTENTS
1. COMMISSIONING 3.1 CONTROL CABINET
1.1 LOCAL CONTROL 3.1.1 DISPLAY
1.2 REMOTE CONTROL 3.1.2 MENU CONTROL
1.3 PUMPING PISTON REPLACEMENT 3.2 LOCAL CONTROL
2.1 ENGINE START / STOP 3.3 REMOTE CONTROL
2.2 EMERGENCY SHUT-OFF 4. MENU OVERVIEW - MAIN MENU /

SUBMENUS
2.3 EMERGENCY SHUT-OFF BYPASS 5. MENU OPERATION - EXAMPLE
3. CONTROL AND MONITORING 6. DIAGNOSIS SYSTEM

ELEMENTS FAULT HANDLING
6.1 SUMMARY OF MESSAGES
004.104.04-en
PART 1 -2-
1. COMMISSIONING Now, the following functions can be activated:
The electrical machine control system can only – signal horn on

be activated if the drive configuration has been
properly selected: – engine off
– Switch on the ignition of the vehicle. – speed reduction
– Shift the travel gearbox to neutral position

(idling)*.
– Apply the parking brake.
– Switch on the P.T.O*.
* For vehicles without P.T.O. see machine op-

erating instructions.
– Switch on the machine control in the driver's

cab.
The system is being initialized as indicated

by the bar graph on the display.
The starting screen is displayed after the Fig. 1

initialization (Fig. 1).
– Select the desired mode of operation with

switch 3 (Fig. 2):
local control
remote control
pumping piston replacement Fig. 2
The mode selected is indicated in display

section 5 (Fig. 1).
004.104.04-en
PART 1 -3-
1.1 LOCAL CONTROL
This symbol is displayed in section 5

(Fig. 1) of the screen.
This symbol flashes in section 4

when a shut-off button on the ma-
chine has been pressed:
Unlock all emergency shut-off but-

tons.
Fig. 1

when one a of the switches on the
local control panel is on (Fig. 2):
Set all switches to '0'.

when the system is ready for start-
up.
Start the control with pushbutton 4 Fig. 2

(Fig. 3).
Starting is confirmed by a brief

acoustic signal and the symbol on
the left is displayed in section 4 (Fig.
1).
Fig. 3
004.104.04-en
PART 1 -4-
1.2 REMOTE CONTROL

of the screen (Fig. 1).

when an emergency shut-off button
on the machine or on the remote-
control box (Figs. 2 or 3) has been
pressed:
Fig. 1
The symbol flashes also when the
remote-control box is off:

tons or switch on the remote-control
box.

when a switch on the remote-control
box is on.
Fig. 2
Set all switches to '0'

when the system is ready for start-
up:
Start up the control with this push-

button on the remote-control box.
Fig. 3
Starting is confirmed by a brief Important:

the left is displayed in section 4 (Fig. Depending on the type of machine, remote-
1). control boxes with two or three three boom con-
trol levers are used.
004.104.04-en
PART 1 -5-
1.3 PUMPING PISTON REPLACEMENT

of the screen (Fig. 1).

when a shut-off button on the ma-
chine has been pressed:

tons.

when the system is ready for start- Fig. 1
up.
Start up the control with pushbutton

4 (Fig. 2).

the left is displayed in section 4
(Fig. 1).
Fig. 2
The activation of the 'PUMPING PISTON RE-
PLACEMENT MODE' automatically reduces the
speed of the engine.
The concrete pump and the diesel engine can

now be controlled with the switches on the spe-
cial control box (Fig. 3).
See machine operating instructions, chapter

4.43: 'PUMPING PISTON'.
Fig. 3
004.104.04-en
PART 1 -6-
2.1 ENGINE START / STOP
To prevent inadvertent starting of a machine

function, the engine can only be started when
all selector switches (lighting excepted) are in
their neutral (0) position.
Shutting off the engine when a function is active

is possible, but should be avoided.
If there is no emergency, always proceed as

follows.
– deactivate the function(s), then
– reduce the engine speed to idling and then
– shut off the engine.
2.2 EMERGENCY SHUT-OFF
When an emergency shut-off button is de-

pressed, the 'VECTOR control' can stop - be-
sides the hydraulic functions - also the drive
engine.
Whether this option is used depends on vehicle

electronics and the approval of the engine
manufacturer.
Use the emergency shut-off buttons only in

cases of emergency. This is of particular
importance when the machine is equipped
with the above-mentioned engine shut-off
function.
In normal operating conditions always stop the

machine functions and the engine with the con-
trols provided for this purpose.
004.104.04-en
PART 1 -7-
2.3 EMERGENCY SHUT-OFF BYPASS

ATTENTION:
The emergency shut-off valves of the machine RISK OF ACCIDENT AND DAMAGE
are open without current. This means: Perform all machine movements with
the lowest possible speed and under
These valves will open when the power supply permanent supervision.
has been interrupted (emergency-shut off acti- Commands from electrical controls will
vated or due to defects). not be executed.
The emergency shut-off system and
The hydraulic fluid is returned pressureless to all safety limit switches are not opera-
the reservoir. Working movement commands tional.
already given will not be executed.
During the work, the key must not
be left in the key-switch. It must be
ATTENTION: RISK OF ACCIDENT withdrawn and kept in a safe place.
The machine may only be used when
the emergency shut-off system is per-
fectly operational.
If - in certain emergency situations (machine

loaded with concrete) - the machine cannot be
repaired immediately, the power supply to the
emergency shut-off valves can be reactivated
manually:
– To do so, insert the key into key-switch 7

(Fig. 1) and turn it to the locked position.
In this position, the key cannot be withdrawn.

Fig. 1
– Control the machine movements with the
levers of the emergency control valves.
– Clean the machine and bring to it transport

position.
– Stop working on the job and have the emer-

gency shut-off system be repaired imme-
diately.
004.104.04-en
PART 1 -8-
3. CONTROL AND MONITORING ELE-

MENTS
3.1 CONTROL CABINET (Fig. 1)
1 - Display
2 - Key: menu control
3 - Operating mode selector:
- local control
- remote control
- pumping piston replacement
4 - Momentary-contact switch: control on
5 - Switch:
Select EASy working range *
Fig. 1
6 - Switch: EASy* off
7 - Key-switch:
Emergency shut-off bypass
8 - Connector: radio or cable remote con-
trol
* Optional equipment: Single-Sided Support-

ing System (EASy), see separate operating
instructions
3.1.1 DISPLAY
On start-up, the following data are displayed on

screen (Fig. 2):
1 - P.T.O. speed Fig. 2

2 - Hydraulic oil temperature in reservoir
3 - Fan of oil cooler on
4 - Control status
5 - Selected mode of operation
6 - Concrete pump delivery rate
7 - Menu options
004.104.04-en
PART 1 -9-
Operating mode display:

Important note:
Section 5 (Fig. 1) of the screen displays the
After pressing the key on the menu
following modes of operation:
control panel, further operational data can be
displayed:
Remote-control (radio or cable)
– concrete pump hydraulic oil pressure
– hydraulic oil reservoir level indication

(optional equipment)
Local control
– drive engine load factor
(optional equipment independent of vehi-
cle)
Pumping piston replacement
Control status indications:
Section 4 (Fig. 1) of the screen displays the

following conditions:
Control unit in operation
Control off, start up.
Starting not possible: switches not in

'0' position ?
Fig. 1
Starting not possible: emergency

shut-off activated
004.104.04-en
PART 1 - 10 -
3.1.2 MENU CONTROL
Basic functions of the keys (2) in Fig. 1:

One step back in menu.
Select indicated menu item or activ-

ate changes
Confirmation and reset of diagnostic

messages.
Fig. 1
Fast selection / abbreviated function keys
When a key pressed, the corresponding func- (shortcuts):
tion is identified by a symbol in the upper left
corner of the display. Press the following keys at the same:
Full return to starting screen
and or
to set the contrast of the LC display manually.

Up one item in the menu selection
list. During setting, the contrast is indicated on dis-
play between 0 and 99 %.
Down one item in the menu selec-

tion list.
and
Supplementary information for cer-
to go to the manual language selection for all
tain screens of the diagnostic func-
displays.
tion. Presently not implemented.
Execution of certain actions, e.g. re-

setting of the concrete pump's deli-
very rate counter.
004.104.04-en
PART 1 - 11 -
3.2 LOCAL CONTROL
Compressor on
Concrete pump delivery rate

(+) = increase
(-) = reduce
Agitator on
(P) = forwards (pumping)
P
Speed of vehicle engine Agitator on

(+) = increase (R) = reverse (suction)
R
(-) = reduce
Vehicle engine Concrete pump on

(I) = on (starting) forwards (pumping)
(0) = off (stopping)
Concrete pump on
reverse (suction)
Floodlamps on
Water pump on 3.3 REMOTE CONTROL

(I) = locked (continuous)
Important:
(T)= momentary (special control)
Depending on the type of machine, remote-
control boxes with two or three three boom con-
trol levers are used.
Vibrator in automatic mode on
Chamber slide-valve activated
High-pressure water pump on
004.104.04-en
PART 1 - 12 -
Water pump on
Agitator in automatic mode on
Compressor on
Speed of vehicle engine

(+) = increase Concrete pump on
(-) = reduce forwards (pumping)
Vehicle engine Concrete pump on

(I) = on (starting reverse (suction)
(0) = off (stopping)
boom speed slow

Control on (placing operations)
Diagnostic horn signal confirm (0) boom functions shut off
(shut-off) boom speed fast
(set-up and take-down)
Vehicle signal horn on

Radio remote control only:
Concrete run-out protection activate Transmitter on: transmit frequency 1
(0) Remote control off
Transmitter on: transmit frequency 2

Chamber slide valve activate
LED:
Concrete pump delivery rate charge condition of transmitter battery
(+) = increase
(-) = reduce LED:
tansmitter state of operation:
continuously on = transmitter ready
Vibrator in automatic mode on flashing = transmitting con-
trol signals
004.104.04-en
PART 1 - 13 -
4.1 MENU OVERVIEW – MAIN MENU
Menu line display / key: Key: Reaction / Submenu:
⏐↓⏐↑⏐Menu: [ENTER] = ON [↑] [↓] change to 2nd opening screen
[ENTER] > call up main menu
⏐↓⏐ ⏐Functions? ⏐E⏐C⏐ [ENTER] > ⏐↓⏐ ⏐Emergency shut-off ⏐ ⏐C⏐

with [ ↑ ] [ ↓ ] function selection direct func-
tion display
[↑] [↓] < [CLEAR] return
⏐↓⏐↑⏐Pumping rate ⏐E⏐C⏐ [ENTER] > Screen: pumping rate

⏐ ⏐ ⏐Pumping rate ⏐S⏐C⏐
with [START] reset concrete pump daily
delivery rate counter
⏐↓⏐↑⏐Fault list? ⏐E⏐C⏐ [ENTER] > Screen: fault list

⏐↓⏐ ⏐Fault list ⏐?⏐C⏐
presently not yet implemented
⏐↓⏐↑⏐Operat. data? ⏐E⏐C⏐ [ENTER] > Screen: operational data

⏐↓⏐↑⏐Operational data ⏐ ⏐C⏐
with [ ↑ ] [ ↓ ] scroll through operational
data
⏐↓⏐↑⏐I/O display? ⏐E⏐C⏐ [ENTER] > ⏐↓⏐ ⏐Digital Inp? ⏐E⏐C⏐

with [ ↑ ] [ ↓ ] select I/O range
with [ENTER] display I/O status
⏐ ⏐↑⏐Parameter? ⏐E⏐C⏐ [ENTER] > ⏐↓⏐ ⏐Quiet diagnostic? ⏐E⏐C⏐

with [ ↑ ] [ ↓ ] select parameter range
with [ENTER] change parameter
< [CLEAR] return
Meaning of abbreviations: E = ENTER C = CLEAR S = START I / O = INPUT / OUTPUT
004.104.04-en
PART 1 - 14 -
4.2 MENU OVERVIEW - SUBMENUS
Functions? Pumping rate? Fault list? Operat. data? I/O display? Parameters?
• emergency • pumping rate • • oil parame- • digital input? • quiet diag-

shut-off counter ters - DI11-DI58 nostic
• remote con-
trol
• operating • digital output • language
• placing boom hours: - DO11-DO38 MMI?
• concrete - P.T.O
pump - CP • analog input?
• display
• water pump - boom - AI11-AI22
- cbm / cby?
• high-pressure
water pump • prop output?
• operating • password:
• compressor hours: - PO41-PO56
- limit CP
• diesel engine - other pumping
• MMI input? rate?
• oil cooler
• CP delivery - SI11-SI34 - ETA vol
• stabilizers rate: CP?
• agitator - day / total
• remote con-
• vibrator - strokes trol?
• machine data - RI11-RI38
• vehicle data • moving
hours:
• system data
- boom • Module I/O?
• system clock
- slew drive
- stabilizers
004.104.04-en
PART 1 - 15 -
5. MENU OPERATION – EXAMPLE:
RESETTING THE CONCRETE PUMP DAILY DELIVERY RATE
ACTION: RESULT:
menu line in opening screen:

Press:
⏐↓⏐↑⏐ Menu: [ENTER] = ON
next menu line:

Press:
⏐↓⏐ ⏐Functions? ⏐E⏐C⏐
next menu line:

Press:
⏐↓⏐↑⏐Pumping rate? ⏐E⏐C⏐
Press: display of daily pumping rate, e.g.:

18,0 m³
Press: daily pumping rate reset to

0.0 m³
Press: return to opening screen
004.104.04-en
PART 1 - 17 -
6. DIAGNOSIS SYSTEM /
"FAULT HANDLING"
(from software version V 1.11 onwards)
The integrated diagnosis system informs the The following message origins are available
operator about certain operating states, dis- (1st column):
plays faults and indicates the possible causes.
B = Boom (placing boom control)
The corresponding messages are displayed on
the screen of the control unit 1 (Fig. 1). D = Diesel engine (truck diesel engine)
The information displayed is always composed M = Machine

of a code and the corresponding message. (general machine control)
0 = Optional
(Optional control functions)
MESSAGE
P = Pump (concrete pump)
CODE
R = Remote (remote control system)
CODE S = System
The four-digit code is composed as follows:

The following types of message are existing:
X xx X
M = Message
X............: Origin of message
L = Low-level fault (minor fault
xx........: Number of message
X : Type of message H = High-level fault (severe fault)
Example:
P01M
P............: Pump (concrete pump)
01.......: Number of message
M.....: Message
Fig. 1
004.139.00-en
PART 1 - 18 -
DISPLAY LANGUAGE
Texts can be displayed in three languages. Text messages as well as international symbols
may include additional information for service
The language of text displays can be selected personnel.
in the "Parameter?" menu under "Language
MMI?". Example 1: Text display
If "International" is selected, the messages are Disconnected / Overload

displayed without text by means of symbols. Solenoid Slewing Right
- PO41 !
Chapter 6.1 contains a complete list of the text
messages together with the international sym-
bols.
Example 2: International display
The messages are sorted by their code in alpa-
betical order.
PO41
Example 1: Text display
PO41 designates, for instance:

Message: Pressure Limiter
Concrete Pump
Activated ! Proportional Output 41
P01M The following additional information is possible:

Code:
PO = Proportional Output
Example 2: International display DO = Digital Output
K = Relay
Message: F = Fuse
Code: P01M
Important:
Since the international display makes multiple
use of the various symbols, it is absolutely
essential to consult chapter 6.1 for a clear
identification of the message.
004.139.00-en
PART 1 - 19 -
ACKNOWLEDGING MESSAGES
Messages (M) are no faults!
They are announced only visully on

display and can be acknowledged ATTENTION:
with the "CLEAR" key. RISK OF ACCIDENT AND DAMAGE
SCHWING assumes no liability for
damage caused by faults not recti-
ACKNOWLEDGING FAULTS fied.
When a "minor fault" is reported, this
Minor faults are announced visually on the does not mean that it can be com-
screen and acoustically by an intermittent tone. pletely ignored, but only that the job
can be finished, probably with certain
These faults can be acknowledged via remote restrictions.
control or directly on the control cabinet.
The operator is responsible that a
Severe faults are announced visually on display fault once signalled is rectified imme-
and acoustically by an intermittent tone. diately in order to prevent potential
damage to the machine.
They can only be acknowledged on the control If a fault message is cancelled without
cabinet. the fault having been rectified, the
fault message will not be repeated.
In both cases, the acoustic signal can be shut
off via remote control.
For a detailed description see below
FAULT DEFINITION
Fault messages are in first place concerned

with the operational safety of the machine.
When reading the fault message, the operator

must decide in how far the faults displayed has
an influence on operational safety.
In the event of a "minor fault", the job can still

be finished even if only with certain restrictions.
"Severe faults" will cause direct damage to the

machine.
Since the availability of the machine has high

priority in concrete placing work, only a few
faults are classified as "severe" faults .
004.139.00-en
PART 1 - 20 -
QUIET DIAGNOSIS
In the "Parameter?" menu under "Quiet diag?" the operator can select whether a fault is signalled
in the "REMOTE" mode of operation by the horn or the buzzer in the control cabinet.
MENU OVERVIEW – Quiet diagnosis
Display menu line / Key:
⏐↓⏐↑⏐Menu: [ENTER] = EIN

[ENTER]
⏐↓⏐ ⏐ Functions? ⏐E⏐C⏐
[↓]
⏐↓⏐↑⏐ Pumped qty? ⏐E⏐C⏐
[↓]
⏐↓⏐↑⏐ Fault list? ⏐E⏐C⏐
[↓]
⏐↓⏐↑⏐ Oper. data? ⏐E⏐C⏐
[↓]
⏐↓⏐↑⏐ I/O display? ⏐E⏐C⏐
[↓]
⏐ ⏐↑⏐ Parameter? ⏐E⏐C⏐ [ENTER] > ⏐↓⏐ ⏐Quiet diagnosis? ⏐E⏐C⏐
[ENTER]
Actual : No !
Change? [ENTER]
Select yes/no [↑][↓]
Save? [ENTER]
⏐ ⏐ ⏐ Quiet diagnosis? ⏐E⏐C⏐
Quiet diagnosis: Yes
– message displayed on the screen
– acoustic signal from buzzer
Quiet diagnosis: No
– message displayed on the screen
– acoustic signal from horn
004.139.00-en
PART 1 - 21 -
REPORTING AND ACKNOWLEDGING OF

FAULTS
Faults are acknowledged dependent on the 2. Mode of operation : LOCAL

selected mode of operation (LOCAL or
REMOTE) and on the severity of the fault: Quiet diagnosis : Yes or No
1. Mode of operation : LOCAL Severe fault
Quiet diagnosis : Yes or No

In the LOCAL mode of operation, severe faults
Minor fault are reported and acknowledged as described
under 1.
In the LOCAL mode of operation, minor faults
are reported and acknowledged in the same In addition, the control system is switched off.
way and irrespective of whether Yes or No has Optional shutdown of the engine is also possi-
been selected for the quiet diagnosis: ble.
The fault is displayed on the screen and an- A severe fault can only be acknowledged from
nounced by the buzzer in the control cabinet. LOCAL.
– Depress the "QUIT" key on the

control panel (Fig. 1) once. ATTENTION:
RISK OF ACCIDENT AND DAMAGE
The buzzer stops sounding. After shut-off by a severe fault, the
control system and, if applicable, also
The message continues to be the drive engine must be restarted.
displayed and can be read in no – It is absolutely vital to have a
hurry. severe fault rectified before re-
starting. There is otherwise the
– Depress "QUIT" once more. risk of irreparable damage to the
machine.
The fault message is definitely
acknowledged.
The message is deleted from

the display and logged in the
faults list.
Fig. 1
004.139.00-en
PART 1 - 22 -
3. Mode of operation : LOCAL
Quiet diagnosis : No
Minor fault
The fault is displayed on the screen and an-

nounced by a horn signal.
– Activate "QUIT" on the remote Important:

control box (Fig. 1) once.
Minor faults acknowledged immedi-
ately with the "QUIT" key on the
The horns stop sounding.
control cabinet in the REMOTE
mode are not reported again when
The message is deleted from the
switching over from LOCAL to
display.
REMOTE.
– After switching the mode of op-
eration from REMOTE to LOCAL,
the fault is displayed on the
screen and announced by the
buzzer in the control cabinet.

control cabinet (Fig. 2) once.
The buzzer stops sounding.
The message continues to be

displayed an can be read in no
hurry. Fig. 1
– Depress "QUIT" once more.

acknowledged.

display and logged in the faults
list.
Fig. 2
004.139.00-en
PART 1 - 23 -
4. Mode of operation : REMOTE
Quiet diagnosis : Yes
Minor fault

nounced by the buzzer in the control cabinet.
– Activate "QUIT" on the remote Important:

Minor faults acknowledged immedi-
ately with the "QUIT" key on the
The buzzer stops sounding (if not
control cabinet in the REMOTE
switched off manually, the buzzer
mode are not reported again when
will be stopped automatically after
switching over from LOCAL to
60 seconds).
REMOTE.
display.
– After switching the mode of op-

eration from REMOTE to LOCAL,
the fault is displayed on the
screen and announced by the
buzzer in the control cabinet.

control cabinet (Fig. 2) once.
The buzzer stops sounding.

Fig. 1
displayed and can be read in no
hurry.

control cabinet (Fig. 2) once
more.

acknowledged.

list.
Fig. 2
004.139.00-en
PART 1 - 24 -
Quiet diagnosis : No
Severe fault

Important:
nounced by the horns.
Severe faults can only be acknowl-
In addition, the control system is switched off. edged with the "QUIT" key on the
Optional shutdown of the engine is also possi- control cabinet irrespective of the
ble. selected mode LOCAL or REMOTE.
– Activate "QUIT" on the remote

The horns stop sounding.

displayed and can be read in no
hurry.

control cabinet (Fig. 2).
The fault message is definitely Fig. 1

acknowledged.

list..
ATTENTION:
After shut-off by a severe fault, the
the drive engine must be restarted.
– It is absolutely vital to have a
severe fault rectified before re-
Fig. 2
risk of irreparable damage to the
machine.
004.139.00-en
PART 1 - 25 -
Quiet diagnosis : Yes
Severe fault

Important:
nounced by the buzzer in the control cabinet
Severe faults can only be acknowl-
In addition, the control system is switched off. edged with the "QUIT" key on the
Optional shutdown of the engine is also possi- control cabinet irrespective of the
ble. selected mode LOCAL or REMOTE.
– Activate "QUIT" on the remote

The buzzer stops sounding (if

not switched off manually, the
buzzer will be stopped auto-
matically after 60 seconds).

displayed and can be read in
no hurry.
– Depress the "QUIT" key on the Fig. 1

control cabinet (Fig. 2).

acknowledged.
The message is deleted from

the display and logged in the
faults list.
ATTENTION:
After shut-off by a severe fault, the
the drive engine must be restarted.
Fig. 2
– It is absolutely vital to have a
severe fault rectified before re-
risk of irreparable damage to the
machine.
004.139.00-en
PART 1 - 26 -
ACKNOWLEDGING OF SEVERAL FAULTS
If several messages are existing, a

symbol appears in the lower right-
hand corner of the display:
– Acknowledge the first message

as usual.
The next message appears and

the buzzer sounds.
– Acknowledge this and also any

following message until no mes-
sage is displayed anymore.
SWITCHING OFF THE CONTROL SYSTEM
Switching off of the electrical control leads to

the definite acknowledgement of fault mes-
sages.
A permanently prevailing fault is, however,

redetected and reported again by the diag-
nosis system.
A fault once detected and reported (minor and

severe faults alike) is redetected only after the
control has been shut off once.
This is independent of whether the fault was

acknowledged or not.
004.139.00-en
PART 1 - 27 -
6.1 SUMMARY OF MESSAGES
Important note:
This list does not pretend to be exhaustive.
The messages on grey background are intended for future software versions and are
presently not available.
Troubleshooting:
The machine operator is responsible that faults once signalled (code 'L' or 'H') are recti-
fied immediately (see page 19).
Contact the SCHWING after-sales service, if you do not have qualified technical person-
nel at your disposal. Always mention the fault code reported in your correspondence with
the after-sales service.
Code international version (symbolic) plain text messages
B = Boom
Limitation
Slewing Gear
B01M Activated !
BOOM Limitation
Activated !
B02M
Disconnected / Overload
E-Stop Solenoid BOOM !
B04L
Solenoid Slewing Right
PO41 - PO41 !
B05L
The messages on grey background are intended for future software versions and are presently not available.
All rights reserved. Reproduction - in whole or in part - only with the express written permission of
SCHWING GmbH.
004.138.02-en
PART 1 - 28 -
Solenoid Slewing Left
PO42 - PO42 !
B06L
Solenoid BOOM A extend
PO43 - PO43 !
B07L
Solenoid BOOM A retract
PO44 - PO44 !
B08L
Solenoid BOOM B extend
PO45 - PO45 !
B09L
Solenoid BOOM B retract
PO46 - PO46 !
B10L
Solenoid BOOM C extend
PO47 - PO47 !
B11L
Solenoid BOOM C retract
PO48 - PO48 !
B12L
Solenoid BOOM D extend
PO51 - PO51 !
B13L
Solenoid BOOM D retract
PO52 - PO52 !
B14L
Solenoid BOOM E extend
PO53 - PO53 !
B15L
Solenoid BOOM E retract
PO54 - PO54 !
B16L
! Machine Safety Stop !
BOOM Control Fault !

B17H
SCHWING GmbH.
004.138.02-en
PART 1 - 29 -
D = Diesel Engine
Some Hydraulic Functions

Not In Neutral!
Diesel Start Disabled!
D01M
Power Limitation
Diesel Engine
Activated !
D02M
PTO is not working or
Prox-Switch PTO-RPM
Fault !
D03L
PTO RPM-Limit exceeded !

D04L
Indicator-Switch
PTO = ON/OFF
Fault !
D05L
Indicator-Signal
Engine Load
Fault !
D06L
Indicator Lvel
Diesel-Reservoir
Fault !
D07L
Disconnected
Truck Interface
DO31 Diesel Start - D031 !
D08L
Overload
Truck Interface
DO31 Diesel Start - D031 !
D09L
Disconnected
Truck Interface
DO32 Diesel Stop - D032 !
D10L
Overload
Truck Interface
DO32 Diesel Stop - D032 !
D11L
SCHWING GmbH.
004.138.02-en
PART 1 - 30 -
Disconnected
Truck Interface
DO33 RPM (+) - D033 !
D12L
Overload
Truck Interface
DO33 RPM (+) - D033 !
D13L
Disconnected
Truck Interface
DO34 RPM (-) - D034 !
D14L
Overload
Truck Interface
DO34 RPM (-) - D034 !
D15L
High Truck Coolant
Temperature !
D16H
Low Level
Hydraulic Oil !
D17H
Low Truck Oil Pressure !
D18H
Battery charging
On Truck Fault !
D19H
E = Expansion
CAN-Communication to FBP
or FBP Module Fault !
E01L
SCHWING GmbH.
004.138.02-en
PART 1 - 31 -
M = Machine
Ball Injector
Activated !
M01M
End-Hose Shut-Off
Activated !
M02M
Temperature Transmitter
Hydraulic Oil Fault !
M03L
Hydraulic Oil Filter
BOOM Contaminated !
Please Exchange Filter!
M04L
Hydraulic Oil Filter
CP Contaminated !
Please Exchange Filter!
M05L
Low Level
Hydraulic Oil
Reservoir !
M06L
High Temperature
Air Compressor !
M07L
Level Transmitter
Hydraulic Reservoir
Fault !
M08L
Transmitter
Oil Pressure Service
Fault !
M09L
Transmitter
Cleaning Ball Detection
Fault !
M10L
Disconnected PowerOutput
DO13 Oil Cooler - DO13 !
M11L
SCHWING GmbH.
004.138.02-en
PART 1 - 32 -
Overload / Fuse
PowerOutput
DO13 Oil Cooler - DO13 !
M12L
DO12 Vibrator - DO12 !
M13L
Overload / Fuse
PowerOutput
DO12 Vibrator - DO12 !
M14L
DO16 Horn Boom C - DO16 !
M15L
Overload / Fuse
PowerOutput
DO16 Horn Boom C - DO16 !
M16L
DO17 Horn Slew - DO17 !
M17L
Overload / Fuse
PowerOutput
DO17 Horn Slew - DO17 !
M18L
Disconnected Solenoid
Ball-Injector
DO38 - DO38 !
M19L
Overload Solenoid
Ball-Injector
DO38 - DO38 !
M20L
DO26 Water Pump - DO26 !
M21L
Overload Solenoid
M22L
Kabelbruch Schaltventil
Kompressor - DO28 !
DO28
M23L
SCHWING GmbH.
004.138.02-en
PART 1 - 33 -
DO28 Air-Compressor - DO28 !
M24L
Agitator
DO21 Forward - DO21 !
M25L
Overload Solenoid
Agitator
M26L
Agitator
DO22 Reverse - DO22 !
M27L
Overload Solenoid
Agitator
M28L
Hydraulic On Outriggers
DO25 - DO25 !
M29L
Overload Solenoid
Hydraulic On Outriggers
DO25 - DO25 !
M30L
High Pressure
M31L
Overload Solenoid
High Pressure
M32L
End-Hose Shut-Off
DO37 - DO37 !
M33L
Overload Solenoid
End-Hose Shut-Off
DO37 - DO37 !
M34L
Solenoid Hydraulic On
PO56 Outrigger - PO56 !
M35L
SCHWING GmbH.
004.138.02-en
PART 1 - 34 -

Hydraulic Oil
Temperature Exceeded !
M36H
O = Optional
Central Lubrication
DO15 CP active / Pump - DO15!
O01L
Overload PowerOutput
Central Lubrication
DO15 CP active / Pump - DO15!
O02L
Disconnected Output
Central Lubrication
DO35 BOOM active - DO35 !
O03L
Overload Output
Central Lubrication
DO35 BOOM active - DO35 !
O04L
Disconnected LED-Output
DO36 BOOM above rest - DO36 !
O05L
Overload LED-Output
DO36 BOOM above rest - DO36 !
O06L
SCHWING GmbH.
004.138.02-en
PART 1 - 35 -
P = Pump
Pressure Limiter
Concrete Pump
Activated !
P01M
Stroke Rate Limitation
Concrete Pump
Activated !
P02M
Hopper Grate Open !

P03M
Low Level
Water Reservoir !
P04M
Oil Temperature High,
Power Limiter Concrete
Pump Activated !
P05L
Transmitter
Oil Pressure Concrete
Pump Fault !
P06L
Prox-Switch Stroke
Counter Fault or
CP jammed !
P07L
E-Stop Solenoid CP !
P08L
E-Stop Solenoid MPS !
P09L
Concrete Pump
P10L
Overload Solenoid
Concrete Pump
P11L
SCHWING GmbH.
004.138.02-en
PART 1 - 36 -
Concrete Pump
P12L
Overload Solenoid
Concrete Pump
P13L
Solenoid Stroke Limiter
PO55 - PO55 !
P14L
R = Remote
R01M Emergency-Stop On
Radio Control Box
Activated !
R02M Low Battery In Radio

Control Box !
R03M CAN-FST /
Transmission With
Remote Control Fault !
R04M No Radio Control

Transmission !
R05L Joy-Stick 1 From



R08L Emergency-Stop Switch

On Radio Control Box
Fault !
SCHWING GmbH.
004.138.02-en
PART 1 - 37 -
Radio Control Signal

With Faulty Address
Received !
R09L
Disconnected
Boom Release
Solenoid !
R10L
Overload
Boom Release
Solenoid !
R11L
Hydraulic Enable Fault!
R12H
S = System
Disconnected
Rear Panel !
S01M
Power Supply
MAIN-Board
Fault !
S02L
Power Supply
MMI-Board
Fault !
S03L
CAN-Communication to MMI
or MMI-Board Fault !
S04L
Relay Contact
K 13
K 13 Override / Fault !
S05L
Fuse F 18 Fault !
F 18
S06L
Fuse F 20 Fault !
F 20
S07L
SCHWING GmbH.
004.138.02-en
PART 1 - 38 -
Fuse F 16 Fault !
F 16
S08L
Fuse F 31 Fault !
F 31
S09L
Fuse F 32 Fault !
F 32
S10L
MF1 : Power Supply
Diagnosis E-Stop Board
MF1 DI15 - DI18 Fault !
S11L
MF2 : Power Supply
Truck Interface etc.
MF2 DI21 - DI27 Fault !
S12L
MF3 : Power Supply
DI28,DI38,DI46,DI48
MF3 Fault !
S13L
MF4 : Power Supply
DI31-DI37,DI43,DI44
MF4 Fault !
S14L
MF5 : Power Supply
DI36,DI37,DI45
MF5 Fault !
S15L
MF6 : Power Supply
DI41,DI42,DI47,AI21,AI22
MF6 Fault !
S16L
MF7 : Power Supply
RAM-Change Station
MF7 DI51-DI54 Fault !
S17L
MF8 : Power Supply
DI55 - DI58
MF8 Fault !
S18L
SCHWING GmbH.
004.138.02-en
PART 1 - 39 -
Reference Voltage for

analog Sensors AI12,
AI13,AI14,AI16 Fault !
S19L
Multi Fuse
MMI-Board
Fault !
S20L
SCHWING GmbH.
004.138.02-en
PART 1 - 41 -
7. ECONOMIC ENGINE CONTROL (EEC)
The Economic Engine Control is a software After reducing the delivery rate to below 98%
supplement for our Vector Control. the system sets the speed to "ECO".
The "EEC" provides assistance to the operator When the CP is switched off and then on again,
during operation concerning the speed setting the following speeds will be preset:
of the drive engine.
1. speed greater than = "ECO" speed is pre-
At present, "EEC" can only be activated with "ECO" set
"DC-Actros" trucks as only the motor man-
agement of these trucks provides the required 2. speed lower than = old speed is preset
signals. "ECO"
The "EEC" software can only be activated or When the CP is off and when no boom move-
deactivated by SCHWING. ments are made, the speed will be reduced
after 10 sec. to "MIN".
"EEC" is active only in the "REMOTE" mode.
When the engine is started in the "REMOTE" AUTOMATIC SPEED CONTROL

mode, the "EEC" software is activated auto- (BOOM OPERATION)
matically.
During boom movements, automatic speed
The "EEC" symbol is then visible in the speed- changes will only be made when the concrete
ometer display of the Vector control. pump is off.
The "EEC" will set the speed in many cases to If the "Snail / Rabbit" switch
the "ECO" mode. This is a speed that saves
fuel especially during concrete placing opera-
tions.
Even with "EEC", the operator can readjust the

speed at any time. After a manual adjustment,
the "EEC" is stopped for a minute.
The operator can adjust the speed within the – is set to „ “, the system sets the speed
"MIN / MAX" limits. If the engine is working at to "MAX".
the load limit, the manual reduction of the
speed is blocked.
– is set back to „0 / “, the system sets
the speed to "ECO".
AUTOMATIC SPEED CONTROL
(PUMPING OPERATION) After 10 sec. without boom movements, the
speed is reduced further to "MIN".
After switching on the concrete pump in the
"PUMPING" mode, the systems sets the speed If the boom is then moved with the switch in
to "ECO".
the „ “ position, the speed will not be
If the delivery rate is set to 98% or higher, the increased.
system sets the speed to "MAX".
Abbreviations see overleaf
004.455.00-en
Abbreviations used:
DC DaimlerCrysler
ECO economical engine speed
EEC Economic Engine Control
REMOTE Remote control
MAX maximum speed adjustable with

the SCHWING control
MIN minimum speed adjustable with the

SCHWING control
PART 2 -1-
SCHWING – Control system " VECTOR "
BOOM TEACHING
The present instructions are intended to serve as a 'memory aid'. They do not refer to any par-
ticular type of machine and do not relieve the user of familiarizing himself with the operating
manual of the machine in question.
ATTENTION: RISK OF ACCIDENTS AND DAMAGE
The activities described in the present instructions may only be performed by specially
trained persons having demonstrated their ability to do such work.
SCHWING does not assume any liability for damage resulting from inappropriate attempts
to perform machine adjustments.
The movement speeds must not be increased beyond the maximum values preset at the
factory.
The electronic key used for boom speed programming is identified by the system and the
key number is saved in the machine-specific parameter set. Persons authorized for pro-
gramming of the system are obliged not to hand this key over to non-authorized persons.
For controlling of the the truck-mounted concrete pump during testing and adjustment, the
operating instructions of the machine concerned and of the pertaining radio remote-control
unit must be observed.
For training please contact:
SCHWING GmbH
After-sales service
Postfach 200362
D - 44647 Herne
Tel. : +49 (0)2325 / 987-0*

Fax : +49 (0)2325 / 74674
Telex : 820352
or your local SCHWING representative.
004.105.02-en
PART 2 -2-
PROGRAMMING OF BOOM FUNCTIONS
In the so-called teaching mode, the movement

speeds of the placing boom can be readjusted
within certain fixed limits.
ATTENTION
During the setting procedure, the
boom performs movements.
The teaching mode is started at the transmitter

of the radio remote-control box. To start:
– Switch on the machine control. Fig. 2
– Select REMOTE control.
– Activate the radio remote-control system.
– Start the engine and adjust to maximum

speed.
– Plug the programming key (Fig. 1) into the

upper connector on the left side of the
VECTOR control cabinet (Figs. 2+3) and se-
cure with the screws.
Attention: the key is non-interchangeable

when plugged into the connector.
Fig. 3
Fig. 1
004.105.02-en
PART 2 -3-
Screen (Fig. 1) is displayed and

START is flashing.
– Start the control with the pushbut-

ton on the remote-control trans-
mitter.
Successful starting is confirmed

by a brief acoustic signal and the
'OK" symbol. Fig. 1
Screen (Fig. 2) is displayed.
In the teaching mode, the concrete pump and

auxiliary unit functions are disabled.
The boom control and diesel engine functions

are available without restrictions until the pro-
gramming mode is activated.
To switch over to the programming mode:
- Depress the pushbutton (fault ac- Fig. 2

knowledge) on the transmitter
panel and keep it depressed.
– Select the function to be changed by setting

the corresponding joystick to maximum posi-
tion.
(With ramp control, select stage 3 and de-

press the button on the corresponding joy-
stick.)
- Release the pushbutton (fault ac-

knowledge), but hold joystick and /
or button in activated position.
004.105.02-en
PART 2 -4-
The selected boom function can now be pro- Example 1:

grammed.
Retracting boom section 1 (A), MIN value
The minimum and maximum movement speed (snail)
can be adjusted between fixed limits:
– Select the speed to be adjusted with the

'Snail / Rabbit' switch:
'Snail' = adjusts MIN value
'Rabbit' = adjusts MAX value
Fig. 1
Depending on the value to be changed, the
following screens are displayed:
Example 2:
Retracting boom section 1 (A), MAX value (rab-

bit)
Fig. 2
004.105.02-en
PART 2 -5-
– Change the value within the pre- – When all values are OK, end the
set limits by depressing the speed teach mode by switching over
adjustment pushbutton: from remote-control to
(+) = increase local control or to
(-) = decrease
piston replacement
When either limit is reached, the

value can only be changed in op-
posite direction.
Example:
– Save the new value provisionally Retracting boom section 1 (A), MAX value
by depressing the horn button.
The value provisionally saved is

displayed on the screen (exam-
ple, Fig. 1).
Important:
The set value is transmitted to the boom con-
trol valve as long as the joystick is held in
actuated position. Fig. 1
Moving the joystick to neutral position or ac-
tuating the 'Snail / Rabbit' switch discards the
new value.
After provisional saving, the next boom function

can be changed and provisionally saved in the
same way.
When the joystick is moved out of

neutral position without depressing
the pushbutton (fault acknowledge),
the old or the newly saved values
are displayed.
004.105.02-en
PART 2 -6-
To end the programming mode, the provision-

ally saved values must be saved permanently.
The values are permanently saved with the

ENTER and CLEAR keys on the display panel
2 (Fig. 1)
ENTER = yes
Fig. 2
CLEAR = no
If at least one new boom function has been

saved, the screen displays the message of
Fig. 2.
If the procedure is ended with YES (ENTER),

the provisionally saved values are permanently
saved in the machine set of parameters and the
teach mode is terminated.
If NO (CLEAR) is pressed or if no boom func- Fig. 3

tion has been changed, the screen displays the
message of Fig. 3.
If YES (ENTER) is pressed, the newly pro-

grammed values will be overwritten by the fac-
tory-adjusted set of parameters.
If NO (CLEAR) is pressed, the last values per-

manently saved will be maintained.
– Withdraw the teach connector (Fig. 4) and

restart the control unit.
Fig. 4
Fig. 1
004.105.02-en
PART 2 -7-
SUMMARY:
– Switch on the machine control. – Change the value:
– Select the REMOTE mode of operation. (+) = increase
– Activate the radio remote-control system. or
– Start the engine and adjust to maximum (-) = decrease

speed.
– Plug teach key into the connector of the

transmitter. – Save the new value provisionally.
– Start the control unit.
– End the teach mode by switching

Starting is acknowledged by a over from remote control to
short acoustic signal and the
symbol OK.
local control or to
– Depress this button and hold
down.
piston replacement
– Select the function to be adjusted

by moving the corresponding joy-
stick to maximum position. – End the teach mode on the dis-
play panel.
(With ramp control, select stage
3 and depress the button on the
respective joystick.)
– Withdraw the teach connector
and restart the control unit.
– Release the button, leaving the

joystick or the button actuated.
– Select the value to be set:
MIN value
or
MAX value
004.105.02-en
SAFETY 2
TI 21(GB)
OPERATION 3
TI 31(GB)
OPERATION 3.1
Chapter Title
3.2 DRIVING
3.3 SELECTION OF THE PLACE OF INSTALLATION
3.5 EMERGENCY STOP SYSTEM
3.10 PREPARING THE MACHINE FOR WORK
3.11 DRIVE CONFIGURATION
3.12 WARMING UP THE HYDRAULIC SYSTEM
3.20 INSTALLING THE MACHINE (SET-UP AND TAKE-DOWN)
3.22 PIPELINE
3.25 LOCAL CONTROL
3.26 REMOTE CONTROL
3.31 OPERATION: PLACING BOOM
3.32 OPERATION: CONCRETE PUMP
3.33 OPERATION: WATER SUPPLY SYSTEM
3.34 OPERATION: AIR SYSTEM
3.35 OPERATION MONITORING / OPERATING DATA DISPLAY
3.36 RESPONDING TO MALFUNCTIONS / FAULT HANDLING
3.37 EMERGENCY OPERATING
3.38 EMERGENCY OIL SUPPLY OF THE PLACING-BOOM HYDRAULICS
3.40 CLEANING
003.912.01-en
OPERATION 3.1
3.50 FOLDING OF THE PLACING BOOM
3.51 PREPARING THE MACHINE FOR ROAD TRANSPORT
3.60 OPERATING UNDER EXTREME WORKING CONDITIONS (winter, tropics, etc.)
3.70 PROLONGED DECOMMISSIONING
3.80 CONCRETE TECHNOLOGICAL REQUIREMENTS
003.912.01-en
3.2-1
TRAVELLING
OBSERVE THE INSTRUCTIONS OF

THE "SAFETY MANUAL"
– Truck-mounted concrete pumps must not be Press against covers and drawers until the
driven on the highway unless licensed to do locking mechanisms engage.
so.
Close locks and withdraw keys.
Observe the rules in force in the country
concerned. – Bring fold-down devices (e.g. Fig. 1) into
transport position.
– Before driving to unfamiliar sites, plan your
route in detail, as not all bridges, under-
passes etc. are accessible to concrete IMPORTANT:
pumps. RISK OF POLLUTION AND SOILED
ROAD SURFACE
– Observe the instructions issued by the
vehicle manufacturer for travelling or for – Check the machine for loss of fluid.
checking the vehicle prior to travelling.
– Clean the vehicle as far as possible (tyre
In the case of machines with a distributor tread etc.) before leaving the construction
gearbox which are mounted on trucks with site.
exceptionally high-torque drives, the distri-
butor gearbox may be overloaded when
driving in low gears. ATTENTION:
RISK OF ACCIDENTS
Where applicable, observe the instructions through outriggers being extended
on an instruction plate in the cab. automatically during travel.
ATTENTION: – Check that the hydraulic pump drive is

RISK OF ACCIDENTS switched off and that the outrigger is
through lost accessories and un- secured.
authorized opening of stowaway
boxes etc.
– Check that all equipment and accessories

are well secured.
Make sure that stowaway boxes, drawers

etc. are safely locked.
Fig. 1
003.931.02-en
3.2-2
ATTENTION - RISK OF ACCIDENT
Retracted vertical supports can

descend slowly due to their own
weight.
Therefore, check the supports before

driving the truck and, if necessary,
raise them to the limit stop.
TRANSPORT RESTRICTIONS
Truck-mounted concrete pumps and placing

booms are machines designed for working.
They must not be used for the transport of

persons and goods.
This applies also to the transport of concrete in

the feeding hopper of the concrete pump.
In this case, the unfavourable weight

distribution has a negative impact on the road-
holding properties of the vehicle and may cause
damage to the chassis and the superstructure.
Accessories required for working are excepted.

The accessories must be stowed away safely.
The admissible total weight and the maximum
axle loads must not be exceeded.
003.931.02-en
3.3-1
SELECTION OF THE PLACE OF INSTALLA-

TION

THE "SAFETY MANUAL"
The machine operator must select the location

of the machine so that
- the stability is ensured,
- the truck mixers have easy access to the con-

crete charging hopper,
- the outreach of the placing boom can be used

in the best way,
Fig. 1
- a repositioning of the machine will not be re-
quired,
- the ventilation is adequate (waste gas, over-

heating, fire hazard),
- collisions with other construction site equip-

ment, overhead lines, etc. are impossible,
- any obstruction of construction site or road

traffic is avoided.
Secure the place of installation in accordance

with the relevant regulations if the machine
protrudes into the traffic zone (example,
Fig. 1).
When portable concrete pumps are used for

upward or downward pumping, it is advisable to
provide a certain starting distance by means of
horizontal pipes.
001.462.02-en
3.5-1
EMERGENCY SHUT-OFF SYSTEM
OBSERVE THE INSTRUCTIONS OF Therefore: press immediately the nearest

THE SAFETY MANUAL emergency shut-off button in reach, if the
placing boom moves in an uncontrolled man-
ner or if the machine does not respond cor-
rectly or not at all to control commands.
ATTENTION:
RISK OF ACCIDENT Please inform other helpers (e.g. the truck
mixer driver) about the function, the purpose
Before each use of the machine, and the location of the emergency shut-off
check all EMERGENCY SHUT-OFF buttons on the machine, when you leave the
buttons for proper functioning. machine with the remote control box.
Operating the machine with a de-
fective emergency shut-off system To go back in operation after an EMERGENCY
is forbidden. SHUT-OFF:
– Rectify the fault.

The machine is equipped with several
EMERGENCY SHUT-OFF buttons. – Set all latched switches of the active control
to position '0' or to the central position and
unlock all EMERGENCY SHUT-OFF buttons
by turning them clockwise.
The control panels of the cable and of the radio
remote control boxes are also equipped with an The machine can otherwise not be put
EMERGENCY SHUT-OFF button. into operation.
Depressing an EMERGENCY SHUT-OFF but- – Put the control into operation.

ton in case of emergency or trouble stops the
main functions of the machine immediately.
This is achieved by activation of the emergency

shut-off valves which – when deenergized –
direct the hydraulic oil flow back to the reservoir
without pressure.
The EMERGENCY SHUT-OFF buttons on the

machine are always functional whereas the
EMERGENCY SHUT-OFF button on the remote
control box can only be functional when the
remote control is active.
Important information:
Do not hesitate to press immediately the
nearest emergency shut-off button in reach if
this can help to avert an imminent danger.
In the event of uncontrolled machine move-
ments any shifting of the control lever in op-
posite direction remains without effect, if the
malfunction is caused, for instance, by jam-
ming of the corresponding hydraulic pilot
valve.
003.886.02-en
3.5-2
The restart protection ensures that no ma- ENGINE START / STOP

chine function is started up simply by un-
locking the depressed EMERGENCY SHUT- To prevent inadvertent launching of a function,
OFF button. the engine can only be started when all swit-
ches (except the lighting switch) are in neutral
The control system monitors the positions of position (position '0').
the EMERGENCY SHUT-OFF buttons and
of the switches of the active control box. Although it is possible to switch off the engine
while a function is activated, this should be
A corresponding message is shown on dis- avoided.
play 1 (Fig. 1).
In normal conditions, always
Important:
– switch off the function(s), then
On actuation of an EMERGENCY SHUT-OFF
button, the VECTOR control unit can stop the – lower the speed to idle, then
drive engine in addition to stopping the hy-
draulic functions. – shut off the engine.
Whether this option is used depends on the
vehicle electronics and the approval of the
engine manufacturer.
Use the emergency shut-off buttons only
in cases of emergency, especially if your
machine is equipped with the above-
mentioned engine shut-off function.
Under normal operating conditions, always
stop the machine functions and the engine
with the control elements provided for this
purpose.
Fig. 1
003.886.02-en
3.10-1
PREPARATIONS BEFORE COMMISSIONING

THE "SAFETY MANUAL"
Important:
For reasons of expediency, some of the ac-
tivities described below should be performed
at the builder's yard before the machine
moves to the place of use:
– Carry out the servicing work in compliance

with the maintenance plan (greasing, etc.). Fig. 1
– The water tank is on the left. Check the wa-

ter level indicated by the level indicator 2
(Fig. 1).
Fill in clean water through the filler neck on

top of the reservoir.
Do not fill in dirty water to prevent rapid

wear of the water pump.
– Observe the level indicator during filling and

reduce or stop the inflow in time.
If the machine is equipped with a "C"-type

hose coupling, this connection may only be
used for filling of the water tank if special
care is taken:
– Close the ballcock in the suction line of

the water pump 2 (Fig. 2). Fig. 2
– Connect "C"-type hose to the coupling and

open ballcock 1 (Fig. 2).
– Open the filler cap on the water tank

(Fig. 3).
Fig. 3
003.933.02-en
3.10-2
Ballcock 1 is used for blocking of the concrete

ATTENTION: RISK OF DAMAGE pump during servicing and pressure checking
When the reservoir is filled through activities.
the 'C'-type connection, the pressure
building up inside may damage the Ballcock 2 is only installed in machines with
reservoir. MPS. It is also used for pressure checking (see
The existing overflows are not suited chapter 4.21).
for handling the amount of water filled
in.
Avoid filling under high pressure. ATTENTION:
It is forbidden to fill the tank from a RISK OF DAMAGE
hydrant. Working operation is allowed only
Water reservoirs made of plastic are with ballcock 2 in operating position.
suitable for water temperatures up to
max. 60° C (140° F).
Never fill in water with a higher tem-
perature. The reservoir might be de-
formed.
– Fill in water with a normal water hose

through the filler cap on top of the tank, if
safe filling through the "C"-type connection is
not possible.
– Check the fuel reserve.
Refuel the machine if necessary.
Work only in absolutely clean conditions.
ATTENTION:
RISK OF EXPLOSION
Shut off the engine and the backup
heating when refuelling the ma-
chine.
Observe the safety instructions
concerning the handling of fuels. Fig. 1
– Check that the ballcocks 1+2 on the con-

crete pump control block (Fig. 1) are in the
operating position.
In operating position, these ballcocks are

open (notch on valve head pointing in the di-
rection of flow).
003.933.02-en
3.10-3
– Check the oil level in the hydraulic oil reser-

voir. The reservoir is located on the right side
of the machine.
Check the fluid level only while the oil is cold

before starting the hydraulic pump drive for
the first time at the beginning of your daily
work.
For this check, the machine must be in a hori-

zontal position ready for driving.
Ready for driving means in this case that the

placing boom and the stabilizers are in trans-
port position.
The oil level must be visible in the center of

the inspection glass 1 (Fig. 1) when the oil
is cold.
As the hydraulic oil expands when its tempera- Fig. 1

ture rises, the levels indicated in the inspection
glass would then be different.
If necessary, top up with the same sort of oil.

See chapter 4.20.
Important:
As an option, the diagnosis system can also
monitor the oil level. In this case, a fault mes-
sage is displayed when the oil level is too
low.
– Check locking of the grid in the concrete

feeding hopper (latch 5, Fig. 2).
Fig. 2
If the grid is not properly locked in operation, it
may be raised by the concrete in the hopper.
The machine would then be shut off by a

limit switch (CE model).
003.933.02-en
3.10-4
Important:
The working cycle always begins with the

installation of the machine. For installation,
the LOCAL control mode must be selected.
To operate the machine with the local control,
the connector of
– the radio receiver or of
– the cable remote control

Fig. 1
must be plugged into socket 8 (Fig. 1).

The machine can otherwise not be be put into
operation since the emergency shut-off
valves in the hydraulic system are then open
(EMERGENCY SHUT-OFF bypass).
003.933.02-en
3.11-1
DRIVE CONFIGURATION
OBSERVE THE INSTRUCTIONS OF To prevent slipping, this clutch re-

quires a certain hydraulic pressure
THE "SAFETY MANUAL"
which is available only after the ve-
hicle engine is running at a certain
speed.
The electric machine control unit can be activ- For this reason, SCHWING makes
ated only after correct selection of the drive use of the automatic speed increase
configuration. function whenever provided by the
vehicle manufacturer.
1. Switch on the ignition of the vehicle.
The speed increase function is activ-
2. Set gearshift lever to neutral (engine idling ated when the PTO is engaged.
speed). If there is no such function avail-
able, the engine speed must be in-
3. Apply the parking brake. creased manually by the machine
operator, if nedeed.
For 1 to 3 please refer to the vehicle manu-
The required minimum number of
facturer's operating instructions.
revolutions is indicated in the
driver's manual issued by the vehi-
4. Switch on the pump drive.
cle manufacturer.
As described in chapter 1.5, the pumps can
be driven in different ways depending on
the type of vehicle used. 4b. Switch the divider gearbox over to pump-
ing.
The switch-on procedure varies accordingly.
Observe the instruction signs in the
4a. Power take-off: cab.
SWITCHING ON of the power take-offs de- The divider gearbox is generally switched
pends on the type of vehicle. over pneumatically with a control lever in
the cab (example: 3, Fig. 1).
ATTENTION: RISK OF DAMAGE
Some PTOs may be engaged only
when the travel gearbox is disen-
gaged from the engine and others
only when the engine is running.
The engine-dependent PTOs of some
vehicles are equipped with a hydraulic
clutch.
Fig. 1
004.123.05-en
3.11-2
ATTENTION: RISK OF DAMAGE Important note:

Make sure the amount of compressed From 2008 onwards, our switchable divider
air available is sufficient for proper gearboxes will be preferably equipped with
switching. an electro-pneumatically-operated switch-
over system.
If necessary, start the engine briefly to
fill up the air reservoirs. Machines so equipped can be recognized by
their electrical control unit (Fig. 2) in the cab.
– Shut off the engine. Pneumatic valve 3 (Fig. 1) is omitted.
– Wait ca. 5 seconds before shifting lever 3 Switching over from

(Fig. 1) to the "Pumping" position. D = driving operation
The divider gearbox may only be to
switched over while the engine is sta- P = pumping operation
tionary.
and vice versa requires that the above-des-
– Start the engine and allow to run at idling cribed conditions for switching over be ful-
speed. filled as well.
– Depress the clutch and shift into the gear

required for pumping.
The gear required for pumping is indicated

on a sign in the driver's cab.
– Release the clutch pedal gently.

Do not shift into any other gear.
Excessive speeds will cause irre-
parable damage to the hydraulic
pumps.
Fig. 1
Fig. 2
004.123.05-en
3.11-3
AIR SUSPENSION / SELF-LEVELLING

ATTENTION:
To ensure the required stability of the machine RISK OF ACCIDENT
it may be necessary depending on the type of For the safe operation of the truck-
truck to depressurize the spring bellows of mounted concrete pump it is indis-
trailer axles with air suspension. pensable that an activation of the
air suspension during the work is
In most cases, the spring bellows are auto- definitely prevented.
matically depressurized after activation of
the power take-off down to a residual pres- The pressurization of the spring bel-
sure. lows while the machine is standing
on its supports presses the wheels
The pressurization after deactivation of the against the ground.
power take-off is also automatic. The machine is thus "raised out of
its supports" and can topple over.
The spring bellows are then pressurized within
a short time corresponding to the axle load.
In some trucks, the actual state of the spring

bellows is indicated in the driver's cab.
See also the operating instructions of the

truck or axle manufacturer.
If the truck is equipped with a chassis self-

levelling function, the corresponding system
must be deactivated before the machine is sta-
bilized since the levelling system endangers the
stability of the supported machine.
In conjunction with air suspension and self-

levelling, further truck-specific measures for the
safe stabilization of the machine may prove
necessary.
If required, customers will be informed with a

special information bulletin.
004.123.05-en
3.11-4
SWITCHING ON THE MACHINE CONTROL
– Switch on the machine control with key-

switch 1 (Fig. 1) in the driver's cab.
The processor starts the boot sequence as

shown by a bargraph on the display 1
(Fig. 2).
The start picture appears.
– If desired, switch on the working floodlamp

on the side with switch 3 (Fig. 1).
Fig. 1
– Leave the cab. Lock it up to prevent unau-
thorized persons from entering the cab.
– Go around your machine once and check the

place of installation.
– Release the transport safety locks of the

stabilizers during this check.
– Set switch 3 (Fig. 2) to the 'LOCAL' position

symbol .
Fig. 2
004.123.05-en
3.11-5
– Set all locked-position switches on the local

control panel (Fig. 1) to neutral position ('0') ATTENTION:
and unlock all emergency shut-off buttons on RISK OF DAMAGE
the machine. Never increase the engine speed
with the travel accelerator pedal or
The machine can otherwise not be put into the cruise control in the driver's
operation. cab when the pump drive is on.
In these cases, the speed limitation
Important: preset at the factory is ineffective.
The control unit monitors the position of the Risk of irreparable damage to the hy-
EMERGENCY SHUT-OFF buttons and of the draulic pumps due to overspeeding.
switches on the active control.
A corresponding information is shown on the
display 1 (Fig. 2). See chapter 1.8.
When the system is ready, the

symbol on the left flashes on the
display.
– Start the control unit with mo-

mentary-contact switch 4
(Fig. 2).
Fig. 1
audible signal and the display
shows the symbol on the left.
– Go to the local control panel (Fig. 1).
– Start the diesel engine.
– Increase the speed of the die-

sel.
Fig. 2
004.123.05-en
3.11-6
Display 1 (Fig. 1) indicates the speed of the
PTO or the drive speed of the switchable di-
vider gearbox.
This speed is not identical with that of the
engine.
The admissible speeds for engine and gear-
box are indicated on a sign in the cab.
Reduce immediately the engine speed when
the maximum speed has been exceeded and
check the drive configuration and the engine
Fig. 1
speed adsjustment.
004.123.05-en
3.12-1
WARMING UP THE HYDRAULIC SYSTEM
The cold-starting limit is dependent on the viscos-

OBSERVE THE INSTRUCTIONS OF ity of the oil, see table below:
THE "SAFETY MANUAL"
ISO viscosity class Cold-starting limit
VG 32 ca. - 18° C
For proper functioning and low wear of the hy- VG 46 ca. - 10° C
draulic system and the hydraulic oil, the correct VG 68 ca. - 3° C
operating temperature is of great importance.
VG 100 ca. 3° C
In our machines, the operating temperature is
situated between 40 and 60° C. The multigrade oil filled into the system at the
factory in Herne has a cold-starting limit of -10 °C.
The hydraulic system is designed in such a way
that When lower temperatures are expected, it is ad-
visable to place the machine in a closed hangar if
– when the machine is used in accordance with it is be used the other day in the morning.
its designated use,
See also chapter 3.60.
– when all components are in perfect working
order,
WARMING UP THE STABILIZER CONTROL
– and when a suitable hydraulic oil has been BLOCKS
selected (see chapter 4.4)
During working operation, the hydraulic system of
an operating temperature of 80 C is not ex- the stabilizers is separated from the rest of the
ceeded. hydraulic system.
In the opposite case, it is of advantage to warm The temperature of all parts of the stabilizing sys-
up the system before the machine is put into op- tem including the hydraulic oil contained in the
eration. control elements drops to ambient temperature.
Warming up can be done as follows: If the stabilizers are to be retracted after the work
in these circumstances, the control blocks of the
– Switch on the pump drive and operate the hy- stabilizer hydraulics will be filled with inrushing hot
draulic system unloaded at medium motor oil from the system.
speed.
As a result of this 'temperature shock', the control
The hydraulic oil warms up while being recircu- blocks might get jammed.
lated 'without pressure' by the pumps.
We therefore recommend to observe the following
procedure at low ambient temperatures:
COLD-STARTING LIMIT
If the cold-starting limit of an oil is exceeded (oil

too viscous), the oil cannot produce a perfect lu-
bricating film with the result of so-called 'cold-
starting wear' caused by excessive friction. The
hydraulic pumps cannot draw in oil properly when
it is too viscous. They suck in air instead (oil
foaming) and are damaged in the process.
003.917.02-en
3.12-2
– Depress the stabilizer enable button for about

20 to 30 seconds before moving any of the
stabilizer control levers.
The control spools are flooded by pressureless

oil and warm up in the process.
– Repeat the procedure if after a 'prewarming

phase' you still find the control spools sluggish.
ATTENTION:
RISK OF DAMAGE
Do not use force to move jamming
control spools.
HOSE DRUMS
Hose drums are used, for instance, with arc-

shaped outriggers in our S 39SX to S 61SX types.
Since hydraulic hoses will lose part of their elas-

ticity in very low temperatures, there may be prob-
lems when the hoses are being wound up.
Execute all movements with not more than 50% of

the speed when temperatures are below freezing.
003.917.02-en
3.20-1
INSTALLING THE MACHINE
The maximum ground pressure is then calcu-

OBSERVE THE INSTRUCTIONS OF lated as follows
THE "SAFETY MANUAL"
180kN kN kg
in front: = 428 (4.28 )
0.42m 2 m2 cm2
– The value of the admissible ground pres-
sure on site must be known before the in- 160kN kN kg
at the rear: = 381 (3.81 )
stallation. 0.42m 2 m2 cm2
The maximum pressure exerted on the

ground by a stabilizer is then calculated as
follows: ATTENTION:
RISK OF ACCIDENT
max. SUPPORTING FORCE kN The machine must not be installed
= 2
SUPPORTING SURFACE m if the maximum pressure exerted
on the ground exceeds the admis-
The supporting force depends on the type of sible ground pressure.
machine and is:
in front max. 180 kN (18.0 t) If required, the supporting surface must be

enlarged by appropriate means until the
at the rear max. 160 kN (16.0 t). admissible ground pressure is no longer
exceeded.
The max. supporting force is indicated on each
stabilizer (Example Fig. 1).
The rating plates must always be attached

to the stabilizers and legible.
– Use the standard load distribution boards 2

(Fig. 1).
One board of:
650 x 650 mm
is placed in the middle under each supporting Fig. 1

leg.
The supporting surface is then
650 x 650 mm = 0.42 m².
003.934.00-en
3.20-2
The stabilizers can only be operated in the "Lo-

cal control" position of switch 3 (Fig. 1).
For reasons of safety, the machine is equipped

with a "stand-bound stabilizer control".
This means that the stabilizer cylinders can only

be extended or retracted if the control levers
and the ENABLE button (e.g. 5, Fig. 2) are de-
pressed at the same time.
Fig. 1
No cylinder movement is possible if only one of

these control elements is actuated or if one of
them is released during the control function.
The hydraulic stabilizer cylinders can be oper-

ated only from the control blocks on the corre-
sponding side of the machine.
– Check that the transport safety devices of

the stabilizers are unlocked (Fig. 3):
Fig. 2
„A“ = locked / „B“ = unlocked
– Extend all outriggers to the stop and reinsert

the safey devices.
– Check the ground under the supporting legs.

The surface must be even and firm. See
SAFETY chapter 2.30.
– Place the supporting boards in the middle

under each supporting leg..
Fig. 3
003.934.00-en
3.20-3
– Extend the front and rear supporting cylin- For checking, the machine is equipped with
ders until the supporting plates are in con- spirit levels (Fig. 1) close to the stabilizer con-
tact with the boards. trol blocks.
– The vehicle is properly stabilized when the

ATTENTION:
rear wheels are just clear of the ground and
RISK OF ACCIDENT
when the front wheel springs are relieved
To improve the stability, change only with the wheels, however, still being in con-
the position of the supporting boards, tact with the ground.
if necessary. DO NOT extend or re-
tract the outriggers. – The load-distributing pads must be intact
Do not try to improve the position and free from ice, oil, grease, etc.
when the supporting legs are in mo-
tion.
Always stop the movement of the
supporting leg cylinders.
– Jack up the machine in several steps by

actuating the control levers alternatingly on
both sides of the machine.
Unnecessary strain on the stabilizers as

would be exerted, for instance, if only one of
the legs were extended completey, can thus Fig. 1
be avoided.
Observe the following instructions when putting Supporting sequence:

the machine on its supports:
– Nobody must stand in the moving range of

the stabilizers. Risk of crushing.
– Extend the stabilizers until they reach their

maximum final position. Leaving the stabi-
lizers in any other intermediate position
is forbidden.
– Avoid knocking the stabilizers against the

limit stops by actuating the control levers
sensitively.
– Jack up the machine uniformly and in se-

veral steps.
Never extend one supporting leg completely

while the others are still halfway in to avoid
exerting unnecessary strain on the stabiliz-
ers and the machine frame.
– The vehicle must be in nearly horizontal po-

sition. The maximum admissible inclination is
3°.
003.934.00-en
3.22-1
PUMPING LINE

THE "SAFETY MANUAL"
1. CHECKING THE LINE IN OPERATION
During the operation, the personnel must check The marks are engraved on the flange of the
the pumping line for leaks (water leaking out). pumping pipeline. (Fig. 3).
Leaks cause "bleeding" of the concrete and will
lead to line blockages. Stop the operation im-
mediately and repair the leak.
Leaks may, for instance, also occur at pipe

couplings when the seals are defective.
ATTENTION: RISK OF ACCIDENT

When liquids seep through the
walls of pipes and bends there is
an extremely high risk of accident
caused by pipe bursts.
Stop the work immediately and de-
pressurize the pumping line by Fig. 1
sucking the concrete back into the
pump.
Check the pumping line with a wall-
thickness tester (Fig. 1) as often as
required by the working conditions.
See chapter 4.44.
2. MARKING OF INDIVIDUAL PARTS Fig. 2
All SCHWING pumping lines, pipe bends, cou-

plings, hosepipes etc. are marked as follows
(e.g. Fig. 2):
– manufacturer's name (SCHWING or

SH for SCHWING-HERNE)
– nominal diameter (DN) in mm
– admissible operating over-pressure (PN) of Fig. 3

the new part in bars
– Pumping lines are moreover identified by the

wall thickness (s) of the new part in mm.
003.336.04-en
3.22-2
3. PUMPING LINE AT THE PLACING BOOM
A truck-mounted concrete pump (BPL) gener- In truck-mounted concrete pumps, the identifi-
ally pumps concrete to the placing site directly cation plate of the pumping line (Fig. 1) speci-
through the pumping line installed on the plac- fies in addition the maximum concrete pressure
ing boom (KVM). that can be generated by the pump installed.
Separate placing booms generally receive their If the specification for rod-side admission is
concrete from a separate concrete *--pump. missing, the concrete pump in question works
with piston-side admission.
The pumping line installed on the placing
boom is an integral part of the machine and The admission side of this concrete pump
must not be modified. must NOT be changed!! See chapter 1.4!
The pumping line has its own identification plate

on the placing boom (Fig. 1). 3.1 CONCRETE PUMPS WITH REVERSIBLE
ADMISSION SIDE
The diameters (DN) indicated on this identifica-
tion plate are the maximum admissible diame- In the interest of high concrete delivery rates,
ters. concrete pumps with reversible admission side
are mostly supplied with the pump connected
The installation of thick-walled (too heavy) for rod-side admission of the hydraulic oil.
pumping lines on the placing boom is therfore
forbidden.
ATTENTION:
The pressures (PN) indicated for the pumping RISK OF PIPE FRACTURE
line and the end hose are the maximum admis- With piston-side admission of the
sible operating pressures for new pipes with the oil, some of these concrete pumps
specified wall thickness. are capable of generating concrete
pressures which can easily exceed
the burst pressure of the boom
ATTENTION: pumping line and of other compo-
RISK OF DAMAGE AND ACCI- nents.
DENTS
These concrete pumps must NOT be
Pumping lines with an excessive used for pumping concrete through
dead-weight and pumping lines of a
the end hose and the boom line when
larger diameter will overload the plac-
set to piston-side admission. See
ing boom.
type rating plate (Fig. 1).
These pipes will cause damage to the
Aditionally, it may also be necessary
boom (broken pipe supports, cracking
to reduce the pressure in the hydrau-
in boom section, etc.).
lic system in order to avoid overload-
In extreme cases, the resulting in- ing of other system components. See
creased moment of tilt may cause the chapter 1.4!
machine to topple over.
We urgently recommend to use only original

SCHWING parts for replacement.
See "Exclusion of liability", point 7.
Fig. 1
003.336.04-en
3.22-3
4. ROTARY OUTLET (BPL models only)
For easier connection of a separate pumping To reconnect the outlet with the placing boom
line, certain SCHWING truck-mounted concrete pumping line:
pumps can be equipped with a rotary concrete
outlet as an option (Fig. 1). – Start by detaching the separate pumping line
from the outlet.
The rotary reducer piece (outlet) can be com-
pletely substituted for the normal short outlet – Remove wedge 2 and swing the outlet open.
piece.
– Loosen the retaining screws 4 and turn the
To turn the outlet pipe bend back to the original position.
– At first, remove wedge 1 and coupling 5. – Swing the outlet back in place and refit coup-
ling 5.
– Remove wedge 2.
– Swing the outlet aside.
– Slacken the lock-nuts of the two retaining

screws 4 and loosen these screws by ca. a
half turn.
(The second retaining screw is at 180° from

item 4!)
– Turn the pipe bend into the desired position

and swing the outlet back in place.
– Refit wedge 2, but do not yet drive it in com-

pletely.
Fig. 1
– If necessary, correct the position of the pipe
bend and drive in wedge 2 completely.
Secure the wedge with the cotter pin.
– Retighten the retaining screws 4 and secure

them with the lock-nut.
003.336.04-en
3.22-4
– Insert the wedges 1 and 2 (Fig. 1) and drive SCHWING assumes no liability whatsoever
them in completely. for damage caused by the use of unsuitable
material.
– Secure both wedges with the cotter pins.
The most important criterion for selecting a
– Retighten the retaining screws 4 and secure separate pumping line is given by the maximum
them with the lock-nuts. concrete pressure which the concrete pump is
able to generate.
4.1 SERVICING OF THE ROTARY OUTLET This pressure is dependent on
Inject some grease once every week into greasing – drive power
nipple 3 and into the nipple on the opposite
side. – the pump unit installed and
Keep the trigger of the grease gun pressed until – the type of oil admission to the differential
the grease can be seen emerging form the nip- cylinders.
ple.
Certain site pumps are capable, for instance, of
generating a concrete pressure of more than
5. SEPARATE PUMPING LINE 200 bars!
The use of a construction site concrete pump

must always be planned with great care. See "Technical Data" chapter 1.4.
Apart from choosing the right kind of pump,

selection and laying of the pumping line is of
utmost importance.
Both these tasks require great care and exper-

tise.
SCHWING offers an extensive range of pump-

ing lines and accessories.
We urgently recommend to install the pumping

line only with suitable material from SCHWING.
This is an important contribution to high opera-

tional safety and economic efficiency.
Fig. 1
An unsuitable coupling alone can cause failure
of the pumping line and lead to accidents.
003.336.04-en
3.22-5
These peak values are seldom reached during The type of coupling used with our high-
normal operation. pressure pipes is the cup-type tension coupling
for rigid connection of the pipe sections.
Since - in the event of line blockages - the
whole length of line between concrete pump
and blockage is under maximum pressure, the
line must be designed to cope with such situa-
tion.
Separate pumping lines are available in differ-

ent designs:
1. Pumping pipelines for cup-type couplings

allowing for pipe movements (Fig. 1) Fig. 1
Fig. 1 1 - flange
These lines correspond to the line system
installed on placing booms and can be 3 - seal
used depending on diameter (DN) up to
pressures of 110 bars. 4 - cup-type coupling
Since the seal 3 on the outside of the pipe

must be removed and cleaned whenever
the line is dismantled and reassembled,
this solution, if used for separate pumping
lines, is economically less efficient than the
following solutions.
2. Pumping lines with tongue-and-groove flan-

ges for cup-type tension couplings (Fig. 2) Fig. 2
These pipes can be delivered in the follow-

ing versions.
2a. Normal pipes with up to 4.5 mm wall thick-

ness (dependent on nominal width) are
suited for operation up to max. 110 bars
2b. Thick-walled pipes with 71 mm-thick walls Fig. 3

are suited for operation up to max. 160
bars Figs. 2 + 3 1 - tongue-ended flange
These pipes are used if very high durability 2 - groove-ended flange

is required.
3 - seal
3. High-pressure pipes with wall thicknesses
ranging from 7.1 to 10 mm (depending on 4 - cup-type tension coupling
nominal width) are suited for operation up
to 200 bars concrete pressure Important:
These pipes come with special high- The figures show the typical flange design.
pressure flanges (Fig. 3). Their use in Depending on the nominal diameter of the
conjunction with our concrete pumps: pipe, the flange design may deviate slightly
from the drawings.
BP/SP 3500 - 8800 HDR
is mandatory.
003.336.04-en
3.22-6
6. CONCRETE PUMPING LINES 6.4 LAYING AND OPERATION OF A HOSE-

PIPE
6.1 END HOSES
Laying of the hosepipe as well as operation of
End hoses are connecred at the end of the the same require special care and know-how.
pumping line and serve the purpose of distribut-
ing the concrete to be placed. Laying and operation may therefore only be
performed by specially trained personnel.
To protect the placing team from harm and in-
jury, the outlet of the hose must have no clamp During the pumping operations, the con-
fittings and be free from attached parts. crete pump operator must always be ready
to press the EMERGENGY SHUTOFF button.
With placing booms, the maximum length and
the diameter of the end hose are fixed. To prevent trouble, premature failure and pos-
sible accidents, please observe:
Modifications and extensions are not permitted.
– For assembly of a hosepipe, use only flaw-
See Safety Manual less, clean hoses, couplings, seals etc. of
the same system.
6.2 CONNECTING HOSES – The maximum possible concrete pressure of

the pump must not exceed the admissible
Connecting hoses with band clamp fittings at concrete pressure of all other parts of the
both ends can be used depending on their ad- pumping line.
missible concrete pressure as flexible interme-
diate tubing in rigid pumping lines. – The placing team at the placing site must be
informed about possible dangers and be fa-
It is forbidden to use them as end hose. miliar with all the necessary work.
– Lay the hoses if possible with a large bend-

6.3 HOSEPIPES ing radius - do not kink.
In mobile refurbishment units, several connect- Too narrow radii result in unilateral wear and
ing hoses are often assembled into hosepipes. kinks will damage the hose in a very short
time.
The hoses are mostly carried on a specially
equipped truck-mounted concrete pump, laid Narrow radii and kinks cause clogging of the
befor use and removed after use. line and cause the line to jerk.
– Do not pull hoses and especially not over

sharp edges.
– Do not twist hoses.
– Do not let hoses hang down.
– Do not beat on hoses.
003.336.04-en
3.22-7
– Place hoses on supports and fasten safely – Always make sure the line system is per-
with belts. Do not use cutting fastening ma- fectly clean.
terial.
A clean line helps avoiding the formation of
– Do not drive over hoses. Lay the hosepipe plugs.
under a protection.
Dried concrete can react with rubber.
– During the pumping operations, nobody must
stand near the hosepipe. This means that at the next pumping start
not only the remaining concrete, but also a
Bar the hazard area and cover up the line piece of rubber may detach from the line.
by suitable means if necessary.
– Wet the line with water and then start pump-

ing with a premix. 7. EXCLUSION OF LIABILITY
– Pay attention to the largest grain size with Unauthorized modifications of the machine and
respect to the line diameter. the use of spare parts and accessories not
approved by SCHWING constitute a case of
– Pump with low stroking speed, the line must utilization contrary to the designated use.
be quiet.
This applies also to the use of indidvidual parts
such as pipes, bends, couplings, etc.
6.5 CLEANING OF THE HOSEPIPE
It is pointed out explicitely once again that
– Clean the hoses carefully after each job. SCHWING cannot be held liable for damage
caused by incorrect or negligent operation,
It is especially important to clean the inside maintenance and repair or as a result of any
of the hoses carefully: utilization contrary to the machine's designated
use.
Soiled hoses wear faster and cause clog-
ging. The same applies to conversions and attach-
ments or other modifications to the machine not
Suck the cleaning ball back, then detach explicitely authorized by SCHWING.
individual hose sections and rinse carefully
with water. For fitting and operation of separate pump-
ing lines (pipes or hoses) the user alone is
If sucking back is not possible, detach indi- responsible.
vidual hose sections, pour out the contents
and rinse carefully with water.
ATTENTION:
RISK OF ACCIDENT
Do not clean pumping hoses with
compressed air. Risk of the hoses
beating.
003.336.04-en
3.25-1
LOCAL CONTROL
The agitator can be switched over manually,

OBSERVE THE INSTRUCTIONS OF whereas with remote control only automatic
THE "SAFETY MANUAL" operation is available.
During the working operations, the machine P = „pump“ (pumping)

must always be controlled with the remote- = pumping
control unit. See chapter 3.26. P
The controls on the machine are provided for R = „reverse“ (backwards)
special operating modes such as = suction
R
– setting up operations
– servicing work
– and for emergency operations
The covers over the emergency operation

control elements on the machine must be
locked up.
– Operate the local control as described in

chapter 3.11.
SPECIAL FEATURES
The following controls are available only on the Fig. 1

local control panel (Fig. 1):
The display on the panel of control cabinet 1
(Fig. 2) shows operation data and faults.
Floodlamp on
High-presure water pump on (op-

tional equipment)
Contrary to the adjustment by remote control

(potentiometer), the delivery rate of the con-
crete pump is adjusted with a momentary-
contact switch on the local controlp panel.
Concrete pump delivery rate

(+) = increase
(-) = reduce Fig. 2
003.890.01-en
3.25-2
CONTROL MODE CHANGE
If the control mode is to be changed in oper-

ation (e.g. from remote to local control or from
cable to radio control), all permanent-contact
switches must be switched to neutral position
('0').
The machine can otherwise not be put into

operation.
The display 1 (Fig. 1) shows the corresponding

fault message.
If the operator switches over to an inactive

transmitter (emergency shut-off active, Fig. 1
transmitter off), the engine is stopped.
ENGINE START / STOP
To prevent inadvertent launching of a function,

the engine can only be started when all swit-
ches are in neutral position (position '0').
Although it is possible to switch off the engine

avoided.
– lower the speed to idle, then
– shut off the engine
003.890.01-en
3.26-1
REMOTE CONTROL
OBSERVE THE INSTRUCTIONS OF A cable remote control unit can be supplied on

THE "SAFETY MANUAL" request.
The cable unit is used in cases where radio op-

eration is not possible.
CONTROL STAND
Our concrete pumping and placing machines PREPARATIONS FOR WORKING

cannot be operated from a control stand at the
machine. – The connector 8 (Fig. 1) of the receiver cable
must always be in the corresponding socket of
During the work, the machine MUST ALWAYS the control cabinet.
be operated by remote control.
– If the machne is to be operated with the cable
Choose your location in such a way that you have remote control box, this connector must be re-
an overview over the whole concrete placing site placed by the connector of the remote control
and that you can always communicate with the cable.
mixer driver.
Changing the connectors switches the ma-
During the working operations, the covers of chine over to cable remote control.
the emergency control elements on the ma-
chine must be locked. – Hang the remote control box round your neck.
The controls provided on the machine may be – Set all latched switches on the remote control
used exclusively box to neutral position ('0') and unlock all
EMERGENCY SHUT-OFF BUTTONS.
– for set-up and take-down operations (instal-
lation and dismantling) The machine can otherwise not be put into
operation.
– for maintenance purposes (repair, servicing
and cleaning) – Set switch 3 to the 'remote control' position
.
– and for emergency operation of the machine.
REMOTE-CONTROL UNITS
Important note:
Our machine may only be operated with the re-

mote controls described in Part 5.
SCHWING assumes no responsibility whatsoever

if other control units are used.
Machines with the VECTOR control system are

supplied with a radio remote control as a standard
feature. Fig. 1
003.891.03
3.26-2
Important: This symbol flashes on the display

(Fig. 1) when the system is ready.
The VECTOR control monitors the positions
of the EMERGENCY SHUT-OFF buttons and
of the switches of the active control unit.
Start the control unit with this
A corresponding message is issued on the switch on the transmitter.
The control panel layout of both remote control Starting is confirmed by a short
units is basically the same: acoustic signal and the display
(Fig. 1) shows this symbol.
RADIO REMOTE CONTROL
– Activate the transmitter (Fig. 2) by selecting

a frequency:
HF1 = Transmitter on:

transmit frequency 1
0= Remote control off
HF2 = Transmitter on:
transmit frequency 2
The red LED above the EMERGENCY SHUT-

Fig. 1
OFF button flashes requesting the operator to
perform an emergency shut-off test:
Depress the EMERGENCY SHUT-OFF button

(the red LED flashes faster). Release the button
again by turning in the direction of the arrow.
A permanently lit transmit indicator LED

indicates that the transmitter is ready
for operation:
For more detailed information about the ra-

dio remote control see separate operating
instructions in SECTION 5. Fig. 2
003.891.03
3.26-3
CABLE REMOTE CONTROL
Switch on the cable remote control

(Fig. 1) with this switch:
„POWER ON“
This symbol flashes on the display

when the system is ready (Fig. 2).
Start the control unit with this Fig. 1

switch on the cable remote control.
Starting is confirmed by a short

acoustic signal and the display
(Fig. 1) shows this symbol.
For more detailed information about the ca-

ble remote control see separate operating
instructions in SECTION 5.
ATTENTION: DANGER Fig. 2

Always lock up all covers protecting
the control elements of your machine
when you take the remote-control box
with you and leave the machine.
Withdraw the key!
With this measure, any unauthorized
access to the machine control is made
more difficult.
003.891.03
3.26-4
CHANGING THE MODE OF OPERATION
If the mode of operation is to be changed during

the work (from remote to local control or from
cable remote to radio remote-control) it is nec-
essary to set all switches to "0".

operation.
Display 1 (Fig. 1) shows a corresponding fault

message.
If, for instance, the system is switched over

to a non active transmitter (emergency shut-
Fig. 1
off activated, transmitter off), the engine is
stopped.
ENGINE START / STOP
To prevent inadvertent starting of a function, the

engine can be started only after all switches
have been set to neutral position ('0').
Although the engine can be switched off when a

function is active, this should be avoided.
Under normal operating conditions, always
– shut off the function(s), then
– lower the speed to idling, then
– shut off the engine.
003.891.03
3.31-1
OPERATION: PLACING BOOM

THE "SAFETY MANUAL"
During normal work, the placing boom is gen- – Select 'Snail' or 'Hare.
erally operated with the radio remote-control
box. 'Snail' = slow is intended for normal working
operations.
ATTENTION: The boom can be used with speeds ranging
RISK OF DAMAGE AND ACCIDENT from 0 to 50%.
Operation of the boom with the
emergency control elements on the 'Hare' = fast is provided for setting up the plac-
machine is permitted only in cases ing boom.
of emergency.
The boom can be used with speeds ranging
from 0 to 100%.
During the work, the flaps covering the emer-
gency control elements must be closed and
locked up.
RAMP CONTROL
All boom movements are proportional to the
From 2008 onwards, this function is only
movement of the corresponding control levers.
available in FW 26 remote-control systems
See symbols on the front of the control panel. with 2 joy-sticks.
The ramp control is used to operate only the

'HARE' / 'SNAIL' boom section 2 with a constant speed at three
levels.
In the center position (0) of switch 5 all boom
functions are deactivated. – Select the desired speed:
slow
medium
fast
– Move boom section 2 only by depressing

When a boom control lever is actuated, the the pushbuttons in the upper part of the joy-
sticks without moving the joysticks them-
LED flashes and is permanently lit up. selves.
All other functions are available. This is impor-

tant to prevent the boom from making inadver- 'up' 'down'
tent movements during pumping.
003.936.01-en
3.31-2
MONITORING OF THE PLACING BOOM 1.
To prevent the hydraulic hoses from being

ripped off, the slewing movement of the placing
is stopped electrically in the end positions.
If the operator continues to actuate the joystick

on the remote-control box, an acoustic signal is 2.
sounded.
The shutoff condition is displayed on the moni-

tor of the VECTOR control unit.
The shutoff range can be left by slewing the

boom in opposite direction.
3.
ATTENTION:
RISK OF ACCIDENT
The automatic monitoring function
does not relieve the operator of his
duty to watch the placing boom care-
fully during the work.
When the electrical monitoring func-
tion is defective or when the machine
is operated by means of the emer- 4.
gency controls, all control commands
will be executed.
Observe the placing boom in per-
manence to avoid collisions.
WORKING POSITION
5.
– Install the machine in a stable place as de-
scribed in chapter 3.20.
– Raise boom section 1.
– Check that the remaining boom package

does not drop away from section 1.
This can be due, for instance, to air in the 6.

hydraulic system.
Stop raising of the boom in this case and

readjust the boom package (pressing it
slightly against boom 1).
003.936.01-en
3.31-3
– Slew the boom package into working posi- – Check that the end hose retaining device
tion. (Fig. 2) is in place and in good working or-
der.
The slewing angles with respect to transport
position are: – Continue with chapter 3.32:
OPERATION: CONCRETE PUMP
„A“: CCW approximately 360°
“B“: CW approximately 180°.
– If the space available is sufficient, unfold

sections 2, 3 and 4.
ATTENTION:
RISK OF DAMAGE
Observe the correct working se- Fig. 1
quence avoiding any incorrect
movements:
When the boom is in transport po-
sition, only the hydraulic cylinder
of the first section ("Raise section
1") must be actuated. Activating
any other placing boom function
may damage the boom and the su-
perstructure.
Take care that the angles between
sections 1+2 and 2+3 are wide
enough before unfolding the next
boom section.
Be careful when operating several Fig. 2
movements at the same time.
PUMP START
– Bring section 4 near the ground into horizon-

tal position and unlatch the end hose (Fig.
1).
003.936.01-en
3.32-1
OPERATION: CONCRETE PUMP
– Never switch on the concrete pump when

OBSERVE THE INSTRUCTIONS OF the feeding hopper is empty. Dry running
THE "SAFETY MANUAL" leads to premature wear of the pumping pis-
tons and the kidney seal. For servicing and
cleaning fill the hopper with water.
– Fill up the water-box of the concrete pump
as described in chapter 3.33. – Fill concrete into the feeding hopper before
the lubricating mixture has been pumped out
In the event of imminent frost, fill in water completely.
only immediately before placing concrete.
– Do not start pumping with the maximum
number of strokes, but rather adjust the re-
– Spray a thin layer of formwork oil on the out-
quired pumping rate after the first concrete
side of the concrete feeding hopper before
emerges from the end of the delivery line.
starting the pumping operations to facilitate
later cleaning.
– During waiting cycles, especially in warm
weather, the concrete should be moved to
Make sure that no oil gets into the hopper to
and fro by pumping forwards and in reverse.
avoid deterioration of the concrete quality.
– Clean the machine from time to time during
Use only agents that have no detrimental
the work with a jet of water to prevent con-
effect on rubber.
crete from adhering firmly to parts of the ma-
chine.
– Switch on the agitator and/or the vibrator.
– Increase the concrete pumping rate slowly.
– Fill the lubricating mixture into the concrete
feeding hopper.
The mixture consists of two parts of cement, ATTENTION:

one part of sand and water. RISK OF ACCIDENT
Make sure the concrete feeding hop-
The required amount depends on length and per is not pumped empty during the
diameter of the delivery line. work.
Air sucked into the pumping line is
For short delivery lines or when pumping
compressed there and escapes with
ready-mix concrete, the lubricating mixture
force from the end of the line.
may consist of cement and water only.
Persons in the hazard range can be
injured by the beating end hose
and by ejected stones.
SEE SAFETY MANUAL
003.892.03-en
3.32-2
HOPPER COVER
The optional folding hopper cover serves as

splash protection when raised.
To open the cover:
– Unlock the safety pin 1 (Fig. 1).
– Lift the cover 3 until the pin engages in one

of the holes of latch 2.
– Make sure the pin engages safely.
Important: Fig. 1
Latch 2 has two holes since the possible
opening angle varies with some machines.
To close the cover:
– Lift the cover slightly until the safety pin can

be easily unlocked.
– Lower the cover slowly.

(do not drop it).
ATTENTION:
RISK OF CRUSHING
Make sure not to injure others or
yourself with the cover.
003.892.03-en
3.32-3
OPERATION SETTINGS
(see active control)
VIBRATOR (optional equipment) CONCRETE PUMP
– Switch on the concrete pump:

– Switch on the vibrator.
forwards (pumping)
The vibrator starts up only after the concrete
pump has been switched on and stops auto-
matically after the concrete pump is switched
off. reverse (suction)
AGITATOR – Adjust the delivery rate of the concrete

pump:
– Switch on the agitator. (+) = higher delivery rate
(-) = lower delivery rate

Important:
It may also be necessary to switch on the CONCRETE PUMP OPERATING DATA
agitator if pilot-control pressure for switching
on of the concrete pump is needed. The display in the control cabinet 1 (Fig. 1) can
show various concrete pump operating data.
The agitator starts up in the normal sense of
operation (pumping). When the concrete pump The menu is controlled with the keys 2.
is switched over from pumping to suction and
vice versa, the operating direction of the agita- The menu permits concrete delivery rate com-
tor is adapted automatically. putations and reset to zero.
With the pushbutton: See chapter 3.35.
at the rear of the machine, the running direction

of the agitator can be changed (e.g. in case of
trouble).
After releasing the button, the agitator turns

again in its normal direction.
Fig. 1
003.892.03-en
3.33-1
OPERATION: WATER SUPPLY SYSTEM

– Switch on the water pump with the
THE "SAFETY MANUAL" switch of the active control.
The hydraulically driven water pump 4 (Fig. 1)

is located on the left of the boom column.
The pump delivers the water required to clean

the machine, to fill the water-box and to prepare
the lubricating mixture to ballcocks at the rear of
the machine (Fig. 2).
By setting these ball valves to the correspond-

ing positions they can be used as local water
taps or to direct the flow of water directly into
Fig. 1
the water-box of the concrete pump (ballcock
arrangement depending on machine equip-
ment)
OPERATIONAL ADJUSTMENTS
– Check the water level in the tank (level indi-

cator 2, Fig. 1).
A float switch in the water tank stops the

water pump or prevents it from being started
when the water level is insufficient.
Fig. 2
This condition is indicated by a correspond-
ing message on the display of the VECTOR
control.
ATTENTION:
RISK OF DAMAGE
Do not switch on the water pump
when the shut-off valve is closed.
– Open the shut-off valve 2 (Fig. 3) in the suc-

tion line of the water pump.
– Turn the ballcocks (Fig. 2) into the desired

position.
– Connect the water hose if needed.

Fig. 3
003.944.00-en
3.33-2
DRAINING THE WATER SUPPLY SYSTEM
In the event of imminent frost, the whole

water line MUST be emptied after each op-
erating cycle:
– Close ballcock 2 (Fig. 1) to prevent the water

tank from emptying.
– Open the drain valves 3 (Fig. 1+2)
– Disconnect the spraying hose at the rear of

the machine and empty it fully.
– Empty the water lines by setting the ball-

cocks at the rear of the machine to the cor-
responding position. Fig. 1
If the machine is to be left outside overnight,

the water-box of the concrete pump and the
water tank must be emptied, too:
– Open the drain valve of the concrete pump

water-box with lever 3 (Fig. 3).
– Let the concrete pump run for a short time at

low stroking to pump the water out of the
pumping cylinders.
– Stop the concrete pump off (risk of wear).
– Open the drain valve of the water tank 1 Fig. 2

(Fig. 1) to empty it.
Do not forget to fill the water tank and

to open the ballcock 2 (Fig. 1) in the
suction line before switching on the
water pump or the high-pressure
cleaning system (optional equipment).
Fig. 3
003.944.00-en
3.33-3
HIGH-PRESSURE CLEANING SYSTEM
A high-pressure cleaning system is available as

an option.
The hydraulically driven high-pressure water

pump 4 (Fig. 1) is located near the water tank.
The cleaning system can only be acti-

vated with the corresponding switch of
the active local control.
The system can be supplied with a rolling-up

attachment for the high-pressure hose (Fig. 2).
ATTENTION:
RISK OF ACCIDENT Fig. 1
The water jet expelled from the spray-
ing gun 1 (Fig. 2) at high pressure is
very dangerous.
Any inappropriate use of the cleaning
system and the rolling-up attachment
can cause injury and damage.
Do no put the cleaning system into
operation unless you have read and
understood the operating instructions
set out in the Appendix.
– Empty the high-pressure cleaning system in

case of imminent frost as described in the
operating instructions in the Appendix.
Fig. 2
003.944.00-en
3.34-1
OPERATION: COMPRESSED-AIR SUPPLY
OBSERVE THE INSTRUCTIONS OF CHAMBER VALVES

THE "SAFETY MANUAL"
Chamber valves (Fig. 2) are generally used to-
gether with a compressor for cleaning of the con-
crete pumping line.
As an option, the machine can be equipped with
an extensive compressed-air supply system.
– Activate the shuttle valve of the
The following elements can be ordered as individ- machine with the corresponding
ual components. switch of the active control.
The chamber is extended or re-
ATTENTION: tracted with another control lever
RISK OF ACCIDENT on the machine.
Compressed air can be very See operating instructions in the
dangerous. Appendix.
Please observe the corresponding
operating instructions for cleaning
(3.40) and the manual of the
chamber valve in the Appendix.
Use only such accessories for
your compressed-air system
that are in perfect working order
and approved by SCHWING.
COMPRESSED AIR WITH 5.5 BARS
The machine can be equipped with a port for the

connection of compressed-air hoses.
Fig. 1
This port permits connecting a spraying gun for
parting agents.
The required air is taken from the truck's com-

pressed-air system.
COMPRESSOR
The compressor (Fig. 1) supplies compressed air

up to 10 bars to the stopcocks on the machine.
– Open these stopcocks to avoid pressure peaks

on start-up.
– Switch on the compressor with the Fig. 2

corresponding switch of the active
control.
003.895.01-en
3.34-2
CONCRETE RUN-OUT PREVENTER

ATTENTION:
PREVENT CORROSION DAMAGE The run-out preventer (Fig. 2) prevents empty-
Independent of its relative humidity, ing of the concrete pumping line at the end of
the air sucked in by a compressor pumping.
always contains a certain amount of
water. A separate operating manual is supplied in the
This water is normally evaporated in Appendix.
the hot compressor and evacuated
together with the compressed air.
In the typical use of a compressor on
a concrete pump (cleaning of pumping
line) the short duty cycle is often not
sufficient for the compressor to reach
its operating temperature.
Water can therefore collect in the
compressor (Fig. 1) and cause dam-
age.
For this reason, it is recommended:
1. to switch on the compressor and let
it run once a week continuously
for at least 30 minutes. Fig. 1
2. to observe the servicing intervals
prescribed for the compressor.
3. to use only original spare parts and
the prescribed type of compressor
oil for servicing of your compres-
sor.
Our service packs
10170389 (standard maintenance)
and
10170388 (oil separator cartridge)
contain all the spare parts necessary
for the maintenance of your com-
pressor including the compressor oil.
Fig. 2
003.895.01-en
3.36-1
TROUBLESHOOTING / FAULT HANDLING

THE "SAFETY MANUAL"
From software version V 1.11 onwards, the

Vector control unit is equipped with an exten-
sive diagnosis system.
This system informs the machine operator

about certain operating states, displays faults
and provides specific information on possible
fault causes.
The messages are divided into 3 categories:
– info messages
Fig. 1
– minor faults
– severe faults
Info messages are simply displayed on the

screen 1 (Fig. 1).
Faults are displayed on the screen and sig-

nalled acoustically by an intermittent tone.
The visual message can be displayed in differ-

ent languages.
In addition, the machine uses an "international

language" in the form of symbols.
Diagnosis system and fault handling are de-

scribed in detail in chapter 1.8.
003.915.03-en
SINGLE-CIRCUIT HYDRAULICS 3.37-1
EMERGENCY OPERATION During emergency control operation, the elec-

trical control unit must be on. If the electrical
Important: control unit is off, all EMERGENCY SHUT-OFF
valves are open.
Concrete pumps without MPS (Mini-Pause-
System) work with a single-circuit hydraulic – Set the switch on the control cabinet panel to
system. the 'LOCAL CONTROL' position .
The single-circuit hydraulic system can be
identified by the missing accumulator at the The levers of the boom and concrete pump
rear of the machine. emergency control elements (Fig. 1) are located
behind a lockable flap in front at the right.
AND DAMAGE Important:
Do not forget to shift control lever 6 to the
OBSERVE THE INSTRUCTIONS OF "Placing boom" position and to maintain it
THE SAFETY MANUAL there if you want to move the boom with one
Emergency operations must be of control levers 1, 2, 3, 4 or 5.
carried out with the lowest possible In normal operation, control lever 6 is
speed and with extreme caution. switched over to stabilizer control by depress-
Emergency operation is admissible ing the "Enable" button at the stabilizer con-
only to bring the machine back into trol block.
transport position. If this is not possible ask a helper to set lever
When the placing boom is operated 6 to the "Stabilizer" position and to maintain it
with the emergency controls, the there.
electric safety function is not avail- Retract the stabilizers by actuating the cor-
able. responding control levers.
Watch the boom permanently to
avoid collisions with vehicle and The emergency operation control valves are
machine parts. spring-centered and return to their neutral posi-
Exceeding the boom's slewing tion when released.
range involves the risk of ripping
off the hydraulic hoses The boom movements are proportional to the
deflection of the control levers.
SWITCHING VALVE EMERGENCY OPERA-

TION
ATTENTION:
THE CONTROL ELEMENTS ON THE MA-
CHINE MUST NOT BE USED FOR NORMAL
OPERATION.
THEY MAY BE USED ONLY IN CASES OF
EMERGENCY AND FOR SET-UP AND
TAKE-DOWN OPERATIONS, CLEANING,
SERVICING AND MAINTENANCE.
Fig. 1
004.283.01-en
EMERGENCY OPERATION: CP DELIVERY

RATE ADJUSTMENT
– If the electrical delivery rate adjustment sys-

tem fails, set ballcock 4 (Fig. 1) to "Emer-
gency operation".
– Slacken the lock-nut on the spindle of pres-

sure-reducer valve 3.
– Adjust the CP delivery rate with pressure-

reducer valve 3.
To enable electrical adjustment, the spin-

dle of the pressure reducer valve 3 must
be completely screwed down during nor-
mal operation. Fig. 1
– Have the electrical concrete-pump delivery

rate adjustment repaired as soon as possi-
ble.
– Turn the spindle of the pressure reducer

valve 3 back to its original position (without
using force).
– Secure the spindle by tightening the locknut.
– Set ball valve 4 back to "Normalbetrieb"

(Normal Operation).
004.283.01-en
SWITCH-OVER DAMPING FUNCTION
SCHWING truck-mounted concrete pumps with – Perform the check / readjustment when the
single-circuit hydraulics are equipped with a hydraulic system is at operating temperature.
hydraulic switch-over damping function.
– Connect a test pressure gauge to the mini-
The distinguishing feature of the single-circuit mess port "MX 1" (e.g. Fig. 1). The lettering
hydraulic system is that it has no hydraulic is engraved in the control block.
pressure accumulator.
The Rock valve switch-over damping value

is adjusted at the factory. This setting
should not be modified except for impera-
tive reasons.
– If the Rock valve is heard in operation to

produce loud knocking switch-over noises,
the limit-stop contact of the rocking cylin-
der(s) can be further dampened by screwing
down a pressure-reducer valve.
This is, however, accompanied by a reduc-

tion of the pump stroking frequency.
– If the Rock valve does not fully switch over

due to a stiff concrete consistency, the de-
gree of damping can be reduced by turning
back the pressure-reducer valve. Fig. 1
ATTENTION:
The work described below must be
performed only by qualified personnel.
The damping value may only be read-
justed with a test pressure gauge and
within certain limits (see next page).
004.283.01-en
– Block the concrete pump by closing the ball-

cock 1 (Fig. 1) on the control block of the ATTENTION:
concrete pump. RISK OF DAMAGE
Readjust the damping degree only with-
– Start up the concrete pump and set to maxi- in the specified limits.
mum number of strokes. Never set a value less or greater
than the one specified on the left.
– Read the test pressure gauge: the value Values above or below the specified
indicated should be between 10 (15) and 15 limits will result in unnecessary load-
(18) bars, and preferably 12 (15) bars. ing of the system and cause damage.
10 (15) bars = low damping
15 (18) bars = high damping
ATTENTION - IMPORTANT
The values in parentheses refer to hydraulic

pumps which have their regulation start set to
betweeen 8 and 10 bars.
A11VO190 from serial no.: 21006318
A11VO130 from serial no.: 21034174
In hydraulic pumps with serial numbers below

those above, the regulation start is set to 5
bars.
– If necessary, remove the cap over the damp- Fig. 1

ing valve.
– Loosen the lock-nut 1 (Fig. 2).
– Increase the degree of damping by screwing

down spindle 2 carefully,
or
reduce the degree of damping by screwing

out spindle 2 carefully.
– Tighten the lock-nut, refit the valve cap and

remove the test pressure gauge.
– Switch off the concrete pump and open ball-

cock 1 (Fig. 1).
Fig. 2
004.283.01-en
EMERGENCY SHUNTING EMERGENCY SHUT-OFF VALVES
When an emergency shut-off button is de- The emergency shut-off valves for the placing
pressed, the power supply to the emergency boom and the concrete pump are combined in a
shut-off valves is cut out. The valves open and single block 12 (Fig. 2).
the hydraulically operated movements are
stopped. The solenoids of the valve block are equipped
with hand levers. The corresponding emer-
These movements are also stopped when the gency shut-off valve can be closed by actuating
power supply to these valves fails because of a one of these levers.
defect.
During normal operation, emergency shut-off ATTENTION: RISK OF ACCIDENT

valves must neither be shunted electrically nor These hand levers are provided ex-
separated hydraulically from the system. clusively for test purposes.
It is strictly forbidden to block
If immediate repair is not possible, the valves these levers!
can be activated manually:
– Turn key-switch 7 (Fig. 1) to position 'I'.
ATTENTION:
RISK OF ACCIDENT
The emergency shut-off valves are
closed.
The emergency shut-off function is
no longer active.
During normal operation, the key-
switch must be in position '0' and
the key withdrawn.
Fig. 1
– Use the emergency controls to bring the ma-
chine to transport position (Fig. 2).
– Turn the key-switch back to position '0'.
– Withdraw the key and keep it in a safe place.
Important:
In position 'I' of the key-switch, the entire
electrical control is shut off. Local or remote
control with the electrical control elements is
not possible.
Fig. 2
004.283.01-en
3.38-1
EMERGENCY OIL SUPPLY FOR PLACING

BOOM HYDRAULICS
ATTENTION: Important:
RISK OF DAMAGE AND ACCIDENT When a unit with a lower delivery rate is
OBSERVE PAGE 3.37-1. used, a thinner pressure hose can be
connected to port 'P' with a reducer.
EXTERNAL HYDRAULIC PUMP

The work specified below may be carried
In order to enable the operator to bring the ma- out EXCLUSIVELY
chine into transport position after a drive failure,
the hydraulic system is equipped with ports for – by specially trained persons
the connection of an external hydraulic pump.
– in compliance with the rules for safety
The ports are located near the pressure filter 1 at work, and
(Fig. 1). The pressure filter is installed beside
the boom control block on the right side of the – only in cases of emergency.
machine. The pressure port (P) is marked red
and the return port (T) blue.
For emergency operation please observe the

following points:
– Max. power of the hydraulic oil pump:

18 l/min at 280 bars
– Quality and viscosity of the hydraulic oil are

the same as for the oil in the system (see
our recommendations in chapter 4.4)
– Required pressure hose:

20/4 x 5700
– Required return-flow hose:

20/4 x 5700
– The threaded unions required for connec-

tion are enclosed with the tool kit
– Work on the hydraulic system must be Fig. 1

carried out only in conditions of ABSO-
LUTE CLEANLINESS.
003.939.01-en
3.38-2
It is possible that only part of the oil supplied

ATTENTION: flows back into the reservoir of the auxiliary
RISK OF ACCIDENT machine, so that permanent refilling is neces-
When opening port P, the oil sary.
captured in the line can be ejected
under high pressure. Pressure-regulated pumps require a control
– When the drive is stationary, shift all signal at their load-sensing port.
control levers of the connected con-
trol block several times in both direc- For emergency operation of the boom we there-
tions to eliminate the pressure. fore recommend the use of an emergency
pump unit as described above.
– Wait at least 15 minutes before open-
ing port P .
– Thereafter, open port P very careful- CONNECTING AN EMERGENCY UNIT
ly.
We recommend to use our emgency unit Id.-no.
10131131 (Fig. 1):
ATTENTION: – Install the emergency unit at an appropriate

ENVIRONMENT PROTECTION place above the oil level of the hydraulic oil
During the works described below, reservoir.
oil losses cannot be completely
avoided. – Open the cleaning cover above the oil level.
For this reason, ALL tools and
– Insert a suction hose through the opening.
auxiliary means must be at hand
before the fitting work is started.
Keep recipients ready to collect
any escaping oil.
– Switch off the drive engine of the defective

machine, but leave the machine control on.
The EMERGENCY SHUT-OFF valves of the

machine are otherwise open and the hydrau-
lic oil flows back to the reservoir in pressure-
less circulation.
CONNECTING AN AUXILIARY MACHINE

Fig. 1
Operating the machine from another machine is
mostly problematic, even if the machine has
connection facilities and offers the same con-
ditions as fas as pump performance and oil
quality are concerned.
003.939.01-en
3.38-3
– Connect the P port of our pump unit with the

P port of the machine (Fig. 1).
– The T port must not be opened in this case

since the oil flows back to the hydraulic res-
ervoir.
ATTENTION:
In order to be able to start the motor of the

emergency unit against the existing back-
pressure, the EMERGENCY SHUTOFF VALVE
of the boom hydraulics must be opened.
– Depress an EMERGENCY SHUT-OFF but-

ton on the machine.
– Start up the drive motor of the pump unit.

Fig. 1
– Unlock the emergency shut-off button and
start the machine control.
– Bring placing boom and stabilizers in trans-

port position.
– During interruptions of the work, always de-

press AN EMERGENCY SHUT-OFF button
to remove load from the auxliary unit.
003.939.01-en
3.40-1
CLEANING
OBSERVE THE INSTRUCTIONS OF – Ensure that no unauthorized person puts the

THE SAFETY MANUAL concrete pump into operation:
Remove the remote control cable,lock the

transmitter of the radio control in, etc.
– After concreting, the pipeline and the con-
crete pump must be carefully cleaned. – Reduce the concrete pump output (number
of strokes) to the minimum.
– The supply of the concrete should be ter-
minated at such an early stage that the con- – Use the local control for the operation of the
crete contained in the hopper and pipeline concrete pump.
can still be placed on the site.
– Be careful with aggressive cleaning agents:
– After the work the pipeline must be cleaned
first as the concrete therein sets mor Wear protective clothing!
quickly.
Aggressive cleaning agents attack rubber
The total volume of concrete in the pipeline parts.
can be calculated as follows:
Do not use such agents for cleaning the
DN 50 = 2,0 l/m Rock valve.
DN 65 = 3,3 l/m
DN 75 = 4,4 l/m They could DESTROY the pressure spring
DN 100 = 7,8 l/m and the kidney-shaped seal.
DN 112 = 9,8 l/m
DN 125 = 12,3 l/m – Do not use highly inflammable agents.
Fire hazard.
ATTENTION:
RISK OF ACCIDENT ATTENTION.
On principle the driving engine DANGER DUE TO VOLTAGE
must always be switched off when SPARKING OVER!
cleaning the concrete pump. Do not direct a water jet at electrical
components of the machine.
– Remove the ignition key resp. turn the main
switch off.
Different methods are employed for cleaning
If this is not possible, e.g. when cleaning the the pipeline:
valve system, the machine operator has to
ensure that no unauthorized person stays a) Sucking out: normal way of cleaning the
near the open valve housing. boom pipeline
b) Cleaning with application as BP, in case
air or water: of unfavourable concrete
mixes also boom pipeline
c) Flushing with additional cleaning
water:
001.177.13-en
3.40-2
CLEANING DEVICES
SCHWING supplies suitable devices for clean-

ing the machine and the pumping line as stan-
dard or optional equipment or as accessories.
For example:
– Compressor (Fig. 1)
– Water pump 1 and high-pressure cleaning

system 3 (Fig. 2)
Fig. 1
– Pipe cleaning head and trap basket (Fig. 3).
For cleaning of the machine and the pump-

ing line use only material which is in perfect
condition and approved by SCHWING.
SCHWING is not liable for damage caused

by defective or unsuitable equipment.
Important:
Observe the separate operating instructions
for the optional high-pressure cleaning system
annexed to the present manual. Fig. 2
SCHWING offers a special cleaning system
for separately laid pumping lines. This system
makes use of the concrete pump to pump wa-
ter through the lines.
The operating instructions for this system are
attached to the Owner's Manual of our trailer-
mounted concrete pumps.
If these instructions are of interest to you as
an Owner of a truck-mounted concrete pump,
you can order them from SCHWING under
Id.no.: 10182049.
Fig. 3
ATTENTION:
RISK OF ACCIDENT
Before opening the
pumping line, the con-
crete column pressure
must be relieved by
sucking the concrete
back into the pump.
001.177.12-en
3.40-3
A. SUCKING OUT THE DELIVERY PIPELINE
– Prepare concrete of a thin consistency and

pump until it fills the pipeline.
– Close the hinge-mounted hopper cover if the

machine is so equipped.

Secure the cover to prevent it from
being ejected by overpressure building
up inside the feeding hopper.
Depending on the type of machine,
the hopper is equipped with different
safety devices, as, for instance, chain
and hook as shown in Fig. 1.
Make sure the securing device is in
Fig. 1
good condition.
Do not bend hook 1 open to facilitate
attaching it to the hole.
Do not change the length of the chain.
The length of chain 2 is such that the
overpressure in the concrete feeding
hopper can lift the cover slightly for
pressure relief.
– Pump the hopper slowly as empty as possi-

ble.
– Bring the placing boom into the position

shown in Fig. 2.
A pumping line with a cleaning cover as

shown in 2 (Fig. 3) is available as an option. Fig. 2
This cover - when fitted the other way round
- retains the cleaning ball when the concrete
is sucked back.
Fig. 3
001.177.12-en
3.40-4
– Switch the agitator to reverse rotation, if

the machine does not change the sense of
rotation automatically when switched over
from pumping to suction mode.
All machines equipped with Vector Control

switch over automatically.
Do not forget to switch over: risk of dam-

age to the agitator.
– At first, push the wet sponge rubber ball

into the end hose (Fig. 1), then switch the Fig. 1
concrete pump over to the "suction" mode
(reverse rotation) and let it run at slow
stroking speed.
Noncompliance with these instructions may

result in deposits in the delivery pipeline,
subsequent blockages and damage to the
agitator.
– Knock briefly on the pumping line short be-

fore the cleaning opening using the handle
Fig. 2 Fig. 3
of a hammer.
If there is still concrete in the line at this

place, a low and dull sound will be heard
(Fig. 2).
If the concrete and the sponge ball have

passed the area, a bright and high sound will
be heard (Fig. 3).
Use only a hammer handle for knocking on
the line. Do not use metal objects:
– Bulges in the pipe will lead to premature
wear! Fig. 4
– The internal hardfacing layer in high-resis-
tance pipes can chip off.
– The ball is retained by cover 2 (Fig. 4) and

can be taken out after the latter has been
removed.
– Refit the cover in "working position".
001.177.12-en
3.40-5
Important information: This quantity, however, would cause the hopper

to overflow.
When sucking back concrete, note that the
contents of the pumping line can easily ex-
In this case, it is recommended to interrupt the
ceed the volume of the concrete feeding hop-
operation of sucking back concrete at the latest
per.
after 4 strokes and to empty the hopper:
In these cases, it is necessary to interrupt the
operation and to empty the hopper in be- 4x 120 l = 480 l
tween.
Experience with these things is of course quite
Whether the concrete feeding hopper can cope helpful.
with the full amount of backflowing concrete (or,
in other words, how long it will last until the Basic rules:
hopper is full) depends on several factors:
The longer the pumping line the sooner the
1. volume of the feeding hopper feeding hopper will overflow when concrete is
being sucked back.
2. volume of the pumping line
The greater the volume of the pumping cylin-
3. volume of the pumping cylinder ders the smaller the number of strokes needed
to empty the pumping line.
4. degree of filling of pumping cylinders
Especially for larger machines we recommend
our chamber valve (Fig. 1) for cleaning of the
Example: pumping line.
S 58SX with pump unit 2525 See separate operating instructions in the An-
nex.
1. = approx. 600 l
2. = approx. 850 l
3. = approx. 125 l (one cylinder)
4. = unknown
A theoretical filling of the pumping cylinders of

100% would then require about 7 strokes to
empty the pumping line.
850 l / 120 l = abt. 7 strokes
Fig. 1
001.177.12-en
3.40-6
B. PRESSING OUT THE PIPELINE USING A

WATER PUMP
This method is most suitable for long pipelines,

vertical lines or lines followed by a placing
boom.
If the concrete is stiff, rough, rich in fines and

lacking in sand, this method can also be rec-
ommended for the boom pipeline of the truck-
mounted concrete pump.
In addition to a powerful water pump the follow-

ing equipment is needed (Fig. 1):
1 - Pipe cleaning head with water connection

Fig. 1
2 - Soft sponge rubber ball
3 - Paper plug
The paper plug is made of soaked, double

folded, tightly rolled-up and empty cement
bags.
It must be absolutely tight to prevent wash-

ing out of the concrete.
001.177.12-en
3.40-7
C. BLOWING OUT THE PIPELINE USING A

COMPRESSOR
11. Individual pipes and short trains of pipes of

ATTENTION: RISK OF ACCIDENT no more than 10 m length must not be
In view of the increased RISK OF ACCIDENT blown out.
when blowing out the pipeline with com-
HIGHEST RISK OF ACCIDENT DUE TO
pressed air, the following must be observed
RECOIL - too small mass!
by all means:
1. Blowing out has to be made under the di-
rection of a SPECIALIST. In addition to a paper plug made in accordance
with the description under "B", a HARD sponge
2. When blowing out, neither pipe bends nor rubber ball is used for blowing out.
hoses must be attached to the end of the
pipeline.
3. Nobody is allowed to stand in the area of
concrete discharge.
4. Empty and flush reduction pipes by hand.
Blow out pipelines of the same diameter
only.
5. A TRAP BASKET must be connected at
the concrete discharge end (Fig. 1).
6. The concrete discharge end must be put up
in such a manner that the concrete can
discharge freely.
7. The pipe cleaning head must be equipped
with an operative pressure gauge and an
amply dimensioned aire escape cock (Fig.
2).
8. The plug must be long enough to seal the
pipeline hermetically at the trap basket at Fig. 1
the end of the blowing-out procedure.
9. The plug must be tight so that the com-
pressed air cannot pass it over and get into
the concrete.
10. Only works on a pressureless pipeline are
permitted. Ensure that the air has escaped
completely.
CONCRETE DISCHARGING UNDER

PRESSURE CAN INJURE PERSONS.
Fig. 2
001.177.12-en
3.40-8
D. FLUSHING THE PIPELINE
By flushing the emptied pipeline, any cement

residues are removed from the pipe walls.
– To this effect, push a soft sponge rubber ball

about 1 m into the delivery pipe.
– Attach the pipe cleaning head with inserted

soft sponge rubber ball to the pipeline.
– Fill the space between the two balls with wa-

ter.
– Push both balls together with the water cush-

ion through the pipeline - as described for
blowing-out. Fig. 1
– Drain the water from the pipeline when-

ever frost is to be expected.
In case of need unfold the placing boom.
001.177.12-en
3.40-9
E. CLEANING THE CONCRETE PUMP
– Connect the water hose and clean the feed-

ATTENTION: ing hopper with the water jet (Fig. 1).
RISK OF ACCIDENT
Do NOT remove the cover grid in The concrete pump sucks in water and the
the concrete pump feeding hopper* pumping cylinders are flushed.
Do NOT step on the grid.
– Shut off the concrete pump and the engine.
Do NOT stick your hand into the
machine or hold objects into ma-
– Open the cleaning trap (Fig. 2) under the
chine openings when the drive en-
Rock valve housing and clean housing with
gine is running or when pressure water.
accumulators are charged.
ATTENTION:
RISK OF DAMAGE
New lacquers need ca. 2 months to
harden completely.
Do not clean the machine during this
time with a high-pressure cleaner to
prevent damage to the paint coat.
* In the 'CE' model, all active concrete pump

and agitator functions are stopped by a limit
switch when the grid is being opened.
This is not an EMERGENCY SHUT-OFF func-

tion.
After closing of the grid, the interrupted function

will start running again.
Fig. 1
– Switch off the concrete pump and the drive
engine.
– Prepare a recipient for residual concrete.
– Remove the reducer from the trailer pump

or, in case of a truck-mounted pump, swing
the connecting piece between pump outlet
and placing boom line aside.
– Start up the concrete pump with the lowest

number of strokes and pump off the concrete
remaining in the hopper.
Dispose of the residual concrete (have con- Fig. 2

crete collected).
001.177.12-en
3.40-10
– Clean agitator, valve housing, outlet etc. with

a strong water jet.
Hold only the water jet, but not the nozzle

into the openings of the valve housing
(Fig. 1).
– Flush the water-box by switching on the con-

crete pump at the lowest stroking frequency
when the outlet valve is open.
Fig. 1
Shut off the concrete pump immediately
when no water flows out anymore – risk of
wear.
– Clean the water-box with water under pres-

sure (Fig. 2). Do not remove the grid from
the water-box.
– Fill the water-box with fresh water.
– Check the water-box every week for deposits

which could not be removed by normal flush-
ing.
ATTENTION:
RISK OF CRUSHING
Always shut off the drive engine and Fig. 2
depressurize any existing pressure
accumulators before opening the co-
vers of the water-box.
Protection grates are provided only in
such cases where the water-box co-
vers can be opened without tools.
After the work, the protection grates
and the water-box covers must be
refitted properly.
001.177.12-en
3.40-11
– Close and secure the cleaning trap of the

Rock valve (Fig. 1).
Secure by knocking several times in axial

direction with a hammer on the end of the
trap handle.
The trap is thus jammed in the wedge-

shaped trap guides.
DO NOT FORGET TO SECURE THE Fig. 1

TRAP.
The trap might otherwise be opened by

machine vibrations. A = open
B = close
– Let machines equipped with a flat-gate
valve run for a few more cycles so that the C = secure
valve rods will be covered by a lubricating
film from the flushing oil.
– Do not let Rock valve machines run 'dry'.
The kidney seal may be damaged.
– After cleaning, lubricate all greasing points.
For corrosion protection it is recommended

to spray the machine after drying with a wax-
containing preserving agent.
001.177.12-en
3.50-1
COLLAPSING THE PLACING BOOM
1.
THE "SAFETY MANUAL"
ATTENTION:
Observe the placing boom in perma- 2.
nence and avoid contacts with ma-
chine parts and other obstacles.
Make sure the angles between sec-
tions 2+3 and 1+2 are wide enough
before collapsing sections 4 and 3.
Be careful when performing several
movements at the same time. 3.
Observe the correct working se-
quence. Any non-observance may
cause damage.
The appropriate method for collapsing the plac-

ing boom depends on the actual position of the
boom and might be as follows: 4.
– Raise section 1 as far as possible.
– Fold up section 4 against section 3.
– Fold up against section 2.
– Fold up against section 1. 5.
– Bring the boom into alignment with the truck.
– Lower the folded boom sections.
6.
003.940.00-en
3.50-2
Make sure that
– the end hose is placed on the transport sup-

ports.
– the reference marks on the boom column are

properly aligned (Fig. 1).
– no pressure is exerted when the boom sec-

tions are lowered onto the supports on the
machine frame.
Fig. 1
003.940.00-en
3.51-1
PREPARING THE MACHINE FOR ROAD

TRANSPORT
– Retract the supporting cylinders completely.

THE "SAFETY MANUAL" – Stow away the load distribution boards.
RETRACTING THE STABILIZERS
The stabilizers can only be operated when the

local control stand is activated.
ATTENTION:
RISK OF CRUSHING
Check that nobody stands in the
moving range of the stabilizers.
For reasons of safety, the machine is equipped Fig. 1

with a 'stand-bound stabilizer control'.
In order to be able to move the supporting cyl-

inders, the control levers and the enable button
5 (Figs. 1+2) beside the stabilizer control block
must be operated at the same time.
No cylinder movement is possible if only one of

these control elements is actuated or if one of
them is released during the control function.
The hydraulic stabilizer cylinders can be oper-

ated only from the control blocks on the corre-
sponding side of the machine.
– Start lowering the machine in small steps by

actuating the control levers alternately on
both sides of the machine. Fig. 2
This avoids unnecessary loading of the

stabilizers which would be the case if
only one of the supporting cylinders were
retracted completely.
003.941.01-en
3.51-2
– Undo the transport safety latches on all sta-

bilizers (Fig. 1).
'A' = latched / 'B' = unlatched
– Retract the stabilizers to their final positions

and reinstall the safety latches.
– Retract the stabilizers by operating the con-

trol levers sensitively.
Avoid knocking the stabilizers against the Fig. 1

end stops.
ATTENTION
RISK OF ACCIDENT
Do not forget to secure the stabiliz-
ers to prevent uncontrolled exten-
sion during transport.
– Stow away all the accessories to prevent

loss during transport.
– Go round the machine and check that every-

thing is on board.
Sequence of retracting the stabilizers:
003.941.01-en
3.51-3
PUTTING OPTIONAL EQUIPMENT OUT OF b) Switching the divider gearbox to travelling:

OPERATION
- Reduce the engine speed to idling.
Your machine may be equipped with equipment
options which have to be taken out of operation - Depress the clutch pedal and switch the
before driving the machine on the road (e.g. the travel gearbox to idling position.
end hose stop valve).
The operating instructions for optional equip- - Shut off the engine.
ment are contained in part 6 (Annex) of this
operating manual. - Wait approx. 5 seconds and set lever 3
(Fig. 2) to 'travelling'.
– Observe the optional equipment decommis-
sioning procedure described in the above in- The divider gearbox may only be
structions before setting off. switched when the truck is stationary.
SWITCHING OFF THE CONTROL THE MACHINE IS READY FOR ROAD

TRAVEL
– Reduce the engine speed to idling.
– Lock up all flaps on the machine.
– Switch off the voltage supply of the machine

control with key-switch 1 (Fig. 1) in the cab.
– Do not forget to switch off the floodlamps

on the side of the machine with switch 3.
The pilot lamp in the switch must be off.
SWITCHING OFF THE PUMP DRIVE
a) Switching off the PTO(s): Fig. 1
The procedure of switching off the PTO(s)

depends on the truck type.
Observe the truck manufacturer's operating

instructions.
Fig. 2
003.941.01-en
3.60-1
SEVERE OPERATING CONDITIONS

THE SAFETY MANUAL
Heat, cold, dust, dirt, high air humidity, sea- 1. LOW AMBIENT TEMPERATURES
water, continuous running,etc. are among the (down to -15° C)
conditions aggravating the operation of your
SCHWING MACHINE. 1.1 GENERAL
Under certain circumstances, these working con- – If possible, park the machine overnight in a
ditions may even exceed the "limits of the ma- closed hangar.
chine". See chapter 1.3:
1.2 TRUCK ENGINE / BUILT-IN ENGINE

THEORETICAL LIFETIME OF THE MACHINE
Observe the operating instructions issued by
Our machines can generally be operated in am- the manufacturer. Experience has shown that at
bient temperatures ranging from -15° C to +30° least the following measures must be taken:
C, if the consumables used comply with our re-
commendations set out in chapter 4.4. – Change the oil and the filters if the machine
does not run on suitable multi-grade oil.
Placing booms must not be used in ambient
temperatures below -15° C (Fig. 1). There is – Check the antifreeze compound.
otherwise the risk of brittle fracture in steel
components. Extreme cold can moreover cause – Adjust the defroster in the air intake system
irreparable damage to rubber and plastic for winter operation.
plarts.
– Refuel the machine with winter diesel.
Frost, imminent frost and great heat require
special precautions that are outlined below un- – Check that the electrical system is in good
der the headings: condition. See 1.8.
1. LOW AMBIENT TEMPERATURES
and
2. HIGH AMBIENT TEMPERATURES
Fig. 1
002.368.05-en
3.60-2
1.3 WATER SYSTEM 1.4 HYDRAULIC SYSTEM
SCHWING recommends using hydraulic fluids

ATTENTION: adapted to different climates and applications.
RISK OF DAMAGE See chapter 4.4
Do not put frozen units (e.g. water pump)
into operation. The multi-grade hydraulic oil SHELL Tellus T 46
Do not warm up with an open flame or filled into the machine at the factory in Herne
by pouring boiling water over the unit. can remain in the system as long as the starting
Let the machine thaw out slowly in a temperature does not drop below -10° C.
closed hangar.
SHELL Tellus T 46 covers the viscosity ranges*
VG 46 and VG 68.
– Fill water into the water-box and into the wa-
ter tank only immediately before starting work. If work is to be carried out at temperatures be-
tween -10° C and -15° C, the machine must be
ATTENTION: Make sure the inner walls of operated with a winter oil (VG 32).
the water-box and the pumping cylinders
are not covered up with a layer of ice. There is otherwise the risk of the system being
Risk of irreparable damage to gaskets and damaged during cold starting by too viscous oil.
pumping pistons. The hydraulic pumps suck in air (so that the oil
is foaming) and will be damaged in the process.
If necessary, fill in lukewarm water (do not
use hot water). When changing the oil, replace the filters as
well.
The water in the water-box does not freeze
as long as it is in motion and as long as all Note that also for hydraulic oils of viscosity class
units give off sufficient amounts of heat. VG 32 the optimal viscosity in operation (16 to
36 mm²/s) is reached with an oil temperature
If needed, antifreeze compound can be added to between approx. 30 and 55° C.
the water in the water tank of the truck-
mounted concrete pump. The system may be operated at full load
only inside the range of the optimal operat-
Water containing antifreeze compound ing viscosity.
must, however, not come into conctact
with concrete The highest temperature admissible for a VG
32 oil is, however, lower than that for a VG 46
– Empty the whole water system (water lines or a VG 68 oil.
and water pump, water-box, water tank) after
the work. Switch on the concrete pump See diagram overleaf:
briefly to remove the water in the pumping
cylinders. (a) = cold starting limits in ° C
(b) = oil temperature in ° C
(c) = viscosity in mm²/s
(d) = optimal operating temperature and viscos-

ity
* viscosity = quality of being thick and sticky
002.368.05-en
3.60-3
With certain winter oils, the user must also If properly maintained, rotary compressors can
make concessions as far as pressure loading be used down to -15° C.
and wear protection are concerned.
As the electro-pneumatical pilot control of some
Please ask your supplier for the precautions to truck-mounted concrete pumps is supplied with
be taken when using his oil. air from the compressed-air system of the truck,
switching over of the truck's compressed-air sys-
We recommend using a hydraulic oil from the tem to winter operation is important for this
same manufacturer and of the same type as reason, too.
that used for "summer operation". In this case,
the quality losses to be expected are generally To avoid the formation of condensed water and
lower. Due to oil remaining in the system, the to prevent the water from freezing up, the com-
visosity range will, however, be modified. pressed-air systems of trucks are equipped with
air driers and defrosters.
If oil of another type or another manufacturer is
to be used, it is necessary to flush the system
once with the new oil type. Actuate all valves 1.6 GEARBOXES
repeatedly during the flushing cycle. Retract
and extend all cylinders to the limit stop. A change of the gearbox oil is necessary only
at temperatures below -10° C.
1.5 COMPRESSED-AIR SYSTEM It is also possible to use an appropriate multi-

grade oil instead.
For reasons of design, piston compressors must
not be operated at ambient temperatures be-
low +1° C (risk of damage due to frozen con-
densed water).
002.368.05-en
3.60-4
If no such oil is available, fill in an oil which is 1.8 ELECTRICAL SYSTEM

one vicosity grade "thinner" than the recom-
mended gearbox oil (see gearbox rating plate), The starting capacity of the batteries depends
i.e. on the charging condition and the ambient tem-
perature.
VG 150 instead of VG 220 (industry gearbox
oil) – Make sure the batteries are always properly
charged. If the machine is not in use, re-
or move the batteries.
SAE 80 instead of SAE 90 (gearbox oil for mo- Store the batteries in a warm and dry place
tor vehicles) and recharge, if necessary.
Comparison between viscosity classes – Ensure good contact of the battery termi-
nals.
Industry Motor vehicle standard
standard – Check the V-belt tension and the charging
e.g. performance of the alternator.
hydraulic engine oil gearbox oil
oil
1.9 RADIO REMOTE CONTROL
ISO-VG SAE SAE
The radio remote-control unit can be used down
22 5W "thin" to -20° C.
32 10 W 75
ATTENTION: At temperatures below +10° C,
46 15 W recharging of the rechargeable batteries be-
68 20 W / 20
comes problematic.
100 30 80 Heat up the driver's cab or use a separate

charger, if possible, at a room temperature of
150 40
+20° C.
220 50 90
320 1.10 INSTALLATION OF THE MACHINE

460 140
Forst, thaw and rain can lead to extreme changes
680 140 in the bearing capacity of the soil.
1000 250 "thick"
– Check the soil conditions before starting the
work and keep an eye on them during the
placing operations.
1.7 GREASING POINTS
The KP2K greases listed in chapter 4.4 are

suited for temperatures down to -20° C.
002.368.05-en
3.60-5
1.11 COLD STARTING 1.13 PUTTING THE MACHINE OUT OF

OPERATION
– If possible, park the machine overnight in a
closed hangar. – Clean the machine after the work.
– After cold starting, let the hydraulic system Remove ice and dirt from steps, platforms
run for a few minutes at low engine speed and so on.
and without load.
– Park the machine on firm and dry ground.
The units and the oil will warm up during
this time and a stable lubricating film can – Secure the machine by adequate means
build up. See chapter 3.12. against inadvertent movements.
– Extend the stabilizers at low speed of the Release the parking brake (risk of freezing
hydraulic pump. up when applied) if the machine can be effi-
ciently secured in any other way against in-
– Install the placing boom at low hydraulic advertent movements.
pump speed and extend and retract all boom
cylinders.
– Run the concrete pump at reduced stroking

speed until the hydraulic system reaches the
operating temperature.
1.12 PUMPING OPERATION
Placing jobs below freezing are generally car-

ried out with warmed up concrete. For this rea-
son, the concrete setting times to be expected
are short.
To prevent "bleeding", warmed up concrete must

be mixed intensively.
– Keep pumping interruptions as short as pos-

sible.
– Clean the pumping line and the concrete

pump immediately after the pumping opera-
tions.
– Do not forget to remove immediately and

completely any water remaining after the
cleaning operations.
002.368.05-en
3.60-6
2. HIGH AMBIENT TEMPERATURES – Replace the cartridge of the engine air filter
when necessary.
2.1 GENERAL – Do not open the servicing flaps in order to

improve the cooling efficiency.
In high ambient temperatures it is generally ad-
visable to "keep an eye" on the temperature of This might disrupt the air circulation and just
the pumping line, the individual units and the have the opposite effect.
fluids.
– Make sure the hydraulic system is proper-
Perhaps it is also possible to install the ma- perly tuned. Pressure-reducing valves set for
chine in a place protected from direct sunlight. too low values, for instance, will lead to an in-
crease of the oil temperature since oil is con-
The machine and the pumping line should be tinuously ejected at high pressure through a
painted in light colours. small cross-section.
If possible, lay separate pumping lines in the – Replace the water in the water-box by fresh
shade and cover them up, if needed. water if it has heated up excessively.
Note that the VECTOR control of our truck- – Spray water on the differential cylinders of
mounted concrete pumps monitors the hydrau- the concrete pump using a waterhose.
lic temperature and reduces the output of the
concrete pump beyond +85° C. At +95° C, the Do not direct the water jet towards the
concrete pump will be shut off. hydraulic oil reservoir.
The temperatures of the engine coolant and of This would result in the formation of large
the compressor can be monitored, too. amounts of condensed water inside the re-
servoir.
This monitoring function can also be combined
with a shut-off function. – Do not pump the concrete with the maxi-
mum stroking rate of the pump.
For this reason it makes sense to ensure the
best possible cooling: High stroking rates increase the temperature
of the hydraulic system and are not very use-
– Top up all oils and the coolant to the max. ful especially with stiff concrete mixes as the
mark. pump will not suck in these mixes as easily
as others.
Do not fill in too much fluid. Fluids ex-
pand when heated and the reservoirs will The aspiration of air increases the risk of
overflow. accidents caused by an unsteady boom
and a jerking end hose.
– Keep the fins of the engine radiator and
hydraulic coolers clean. – Let the system run at idling during interrup-
tions of the pumping operations.
Clean them more often when the machine is
used in dusty conditions. During idling, the hydraulic oil continues to
circulate in the cooler and the engine oil
carries the heat away from the hot turbo-
charger.
002.368.05-en
3.60-7
2.2 TRUCK ENGINE / BUILT-IN ENGINE
Observe the operating instructions issued by Please contact us if these oils are not sufficient
the manufacturer. Experience has shown that in spite of perfect tuning of the hydraulic sys-
at least the following measures must be taken: tem and optimal cooling (see 2.1).
– Change oil and filters if the machine does Note that a "thicker" hydraulic oil of viscosity
not run on suitable multigrade oil. class VG 100 has a cold starting limit of +3 C
and that the optimal operating viscosity is far
– Adjust the defroster in the air intake system above this value.
for winter operation.
This may cause trouble in areas with strong tem-
perature differences between night and day.
2.3 WATER SUPPLY SYSTEM
– Make sure the water tank is always full. The See diagram below:
water may be required for cooling of the con-
crete pump. ((a) = cold starting limits in ° C
(b) = oil temperature in ° C

2.4 HYDRAULIC SYSTEM
(c) = viscosity in mm²/s
The multi-grade hydraulic oil SHELL Tellus T
46 filled into the machine at the factory in (d) = optimal operating temperature and vis-
Herne covers viscosity class VG 46 and viscosity
cosity class VG 68 provided for use in the trop-
ics. See chapter 4.4.
If the machine runs on a single-grade VG 46

oil, the oil must be replaced by a a VG 68 oil.
Replace also the filters when changing the oil.
002.368.05-en
3.60-8
2.5 COMPRESSED-AIR SYSTEM Comparison between viscosity classes
Use a compressor oil of viscosity class VG 150 Industry Motor vehicle standard
for the piston compressor. standard
e.g.
The synthetic oil prescribed for our rotary com- hydraulic engine oil gearbox oil
pressors is suited for ambient temperatures up oil
to +40° C.
ISO-VG SAE SAE
This is sufficient for normal concrete pump use
(no continuous operation). 22 5W "thin"
32 10 W 75
Should the machine nevertheless be shut off
by the VECTOR control for reasons of over- 46 15 W
temperature, please contact us for advice. 68 20 W / 20
100 30 80
2.6 GEARBOX
150 40
The gearbox oils proposed in chapter 4.4 are 220 50 90
suited for continuous ambient temperatures of
ca. -10° C to ca. +40° C. 320
460 140
A gearbox oil change becomes necessary only
if the temperature exceeds +40 C in per- 680 140
manence.
1000 250 "thick"
It is also possible to use a suitable multigrade
oil.
2.7 GREASING POINTS
If such an oil is not available, use an oil that is
one viscosity grade "thicker" than the recom- The KP2K greases listed in chapter 4.4 are
mended gearbox oil (see gearbox rating plate), suitable for temperatures from -20 to +140° C.
i.e., use
VG 320 instead of VG 220 (industrial gearbox 2.8 ELECTRICAL SYSTEM

oil)
– At high temperatures, check the acid level
or use in the battery cells more often.
SAE 140 instead of SAE 90 (gearbox oil for Top up with distilled water only.
motor vehicles)
2.9 RADIO REMOTE CONTROL
The radio remote control can be used up +60

C.
002.368.05-en
3.60-9
2.10 INSTALLATION OF THE MACHINE 2.13 PUTTING THE MACHINE OUT OF

OPERATION
At rising ambient temperatures, the bearing ca-
pacity of heat-sensitive grounds, e.g. asphalt, – Let the machine run at idling for a few min-
is reduced. utes with the pump drive engaged.
– Make sure the ground has sufficient bearing During idling, the heat is carried away from
capacity. the turbocharger of the diesel engine and
the hydraulic oil is cooled since it continues
to circulate through the cooler.
2.11 COLD START
– It is especially important to start up the ma-

chine smoothly, especially if it has been filled
with special lubricants for the high-tempera-
ture range.
High-viscosity lubricants (thicker) reach their

optimal operating viscosity only after a cer-
tain time.
The hydraulic pumps can be damaged as

described under 1.11.
2.12 PUMPING OPERATION
In hot areas, the concrete is often prepared with

cooled aggregates or with cold water.
The concrete placing operations should pref-

erably be performed during the cooler hours of
the day in the morning or in the evening.
– Flush a heated pumping line with water be-

fore starting the pumping operations.
– Prepare a somewhat more fluid mix for starting

if the pumping lines are longer.
– Ensure good pumpability of the concrete.
– Avoid longer pauses.
Cover up the concrete in the hopper during

pumping interruptions, for instance, with
wetted bags.
– Begin cleaning immediately after the pump-

ing operations.
002.368.05-en
3.70-1
PUTTING OUT OF OPERATION
OBSERVE THE INSTRUCTIONS OF - Check the tyre pressure.

THE "SAFETY MANUAL"
- Release the parking brake.
- Dismantle the batteries and store them in a

If the machine is to be put out of operation for room at approx. 20° C.
a longer period, the following work is to be car-
ried out: - Connect the batteries to a "charge maintain-
ing device" resp. CHARGE THEM EVERY
- Thoroughly clean and grease the machine. MONTH (NO QUICK CHARGE).
- Check the concentration of antifreeze in the - Keep the batteries clean and dry.
cooling system of liquid-cooled engines and
top up if necessary. Never leave the batteries discharged.
- Drain the condensation water from the tanks

of the fuel, hydraulic and air systems. RESUMPTION OF WORK
Fill the fuel and oil tanks up to the brim. - Remove the preservation.
Change the oil if it is in bad condition. - Check all oil levels.
- Grease the bare parts of the machine with Discharge the brimful hydraulic oil tanks until
acid-free grease or spray them with pre- the sight glass level is reached.
servative oil.
- Check and install the batteries.
- Push a cleaning wool plug soaked in pre-
servative oil through the pipeline. - Check the tyre pressure.
- Retract all hydraulic cylinders. - Grease all parts of the machine.
- Relieve the hydraulic accumulator from - Check the performance.

pressure.
- Preserve the engine according to the engine Note:

operating instructions.
Special guidelines apply if the machine is to be
- Drain the water tank, water pump and water stored under aggravated conditions.
box. Flush them with a rust inhibitor.
Aggravated conditions include:
- Make all openings watertight.
– storage time exceeding 6 months,
- Jack the vehicle up to remove the pressure
from the tyres. – high relative humidity,
– sea air, etc.
Ask the SCHWING after-sales service.
001.158.03-en
3.80-1
CONCRETE TECHNOLOGICAL REQUIRE-

MENTS

THE "SAFETY MANUAL"
Pumping concrete is no special concrete

but a standardized quality concrete.
It features e.g.:
- a minimum fines content of approx. 400 kg

per m³ (with a max. grain size of 32 mm)
- a minimum cement content of approx. 240 kg

per m³ (with a max. grain size of 32 mm)
- a water/cement ratio of 0.42 - 0.65
- a granulometric composition according to the

grading curve
- a consistency in the range of K2 and K3.
In addition to a wrong concrete composition

(see above), imperfect maintenance of the
machine and the pipeline (cleaning!) the fol-
lowing may give rise to non-pumpability of
the concrete:
- insufficient mixing quality
- segregation owing to inexpert transportation
- wrongly selected max. grain size in relation to

the pipeline diameter
- bleeding of the fresh concrete
- incorrect use of additives.
001.156.01-en
MAINTENANCE 4
TI 41(GB)
MAINTENANCE 4.1-1
Chapter Title
4.2 GENERAL MAINTENANCE INSTRUCTIONS
4.3 CONSUMABLES AND REFILLING QUANTITIES
4.4 RECOMMENDED CONSUMABLES AND LUBRICANTS
4.5 TIGHTENING TORQUES
4.6 SPARE PARTS AND ACCESSORIES
4.10 MAINTENANCE SCHEDULE
4.11 MAINTENANCE REPORT (MASTER COPIES)
DESCRIPTION OF SERVICING WORKS
4.20 HYDRAULIC OIL AND FILTERS
4.21 HYDRAULIC PRESSURE TESTS
4.22 OIL COOLER / ENGINE RADIATOR
4.23 PRESSURE ACCUMULATOR
4.30 CARDAN SHAFTS IN THE PUMP DRIVE
4.35 PUMP GEAR
4.36 SLEWING GEAR
4.40 ROCK VALVE
4.42 PUMPING AND DIFFERENTIAL CYLINDERS, PUMPING PISTONS
4.44 PUMPING LINE
003.979.04-en
MAINTENANCE 4.1-2
Chapter Title
4.51 BOOM COLUMN SLEWING-RING BEARING
4.55 COMPRESSOR
4.56 HIGH-PRESSURE CLEANING SYSTEM
4.60 ELECTRICAL / ELECTRONIC SYSTEM, SOFTWARE
4.65 SAFETY INSPECTIONS
4.70 REPAIR WELDING
4.80 CENTRAL LUBRICATING SYSTEM
003.979.04-en
4.2-1
GENERAL MAINTENANCE INSTRUCTIONS
OBSERVE THE INSTRUCTIONS OF CHECK THE OIL LEVEL

THE SAFETY MANUAL
Unless otherwise prescribed, the oil level is
checked in general
Preventive maintenance is the most eco-
nomical maintenance. – with the machine in horizontal position
Carry out all maintenance works punctually and – after the drive has been stopped for approx.
thoroughly. 10 minutes
We recommend to duplicate the maintenance – with mobile machines being ready for tra-
report (chapter 4.11). velling (outriggers in transport position)
The maintenance men will then be able to list Important:

off the work done in the copies and to sign
Whenever the oil level is checked (also in gear-
them.
boxes, compressors, etc.) it is recommended
to perform also a visual inspection of the oil.
If neither TRAINED personnel nor adequate
In the event of extreme contamination or of
workshop equipment are at your disposal,
water contained in the oil (milky emulsion) try
entrust the SCHWING after-sales service
to locate the cause and change the oil. The
with the maintenance of your machine. table in chapter 4.20 for assessing the quality
of hydraulic oils can also be used for other
oils.
CLEANLINESS
– Before commencing the maintenance work

clean all units located within the working CHANGE THE OIL
range.
– For better removal of impurities, the oil should
Do not use steam jets for cleaning rubber be drained from the units while they are at
and electric parts. operating temperature.
– Avoid the penetration of dirt, especially into ATTENTION: RISK OF ACCIDENT

the hydraulic system.
Wear protective clothing!
– Grease the machine after steam jet clean-
ning. – Pour hydraulic fluid from clean containers in-
to the reservoir through the filler neck pro-
vided for this purpose.
PROTECTION AGAINST CORROSION
If possible, use a flushing and filtering unit.
– Considerable rust deposits weaken the ma- See page 4.2-3.
terial and can lead to ruptures and cracks.
Touch up damaged varnish surfaces in time

and grease bare machine parts.
001.154.10-en
4.2-2
LUBRICATION
ATTENTION:
RISK OF DAMAGE – Clean the grease nipples before and after
Do not use pressure to fill the res- the lubrication.
ervoir! Make sure the air displaced
can escape from the reservoir without – Remove the excessive grease from the lu-
hindrance. bricating points.
Simply stick the filler hose into the
reservoir. Do not screw on the hose
airtight! TIGHTNESS
– Check the tanks, hoses, screw joints, etc. at

– Do not overfill the reservoir. regular intervals.
– Check the oil level after a test run.

ENVIRONMENTAL PROTECTION!
– Do not store the hydraulic oil barrels in the Oil leakages must be avoided under
open air. all circumstances.
The barrels should not be moved for some

time before the oil is taken out. – Replace damaged pipes and damaged or
damp hydraulic hoses immediately.
Do not roll them to the place where they are
to be emptied. BURSTING LINES RESP. OPERAT-
ING AGENTS ESCAPING UNDER
Do not suck the oil off the bottom of the bar- PRESSURE ENDANGER PERSONS.
rel.
Important:
REPAIR, EXCHANGE
At each oil change, we recommend to exam-
ine an oil sample for colouring and contained – Under certain circumstances the exchange
solid particles in view of taking the required of complete units can be more economical
measures of preventive maintenance. than a repair.
Consult the SCHWING after-sales service.

SEALINGS, SAFETY ELEMENTS
– Use only genuine SCHWING spare parts.
– Pay attention to sealings, spring washers,
etc. when dismantling covers, screw plugs, SCHWING is not liable for damages re-
etc. sulting from the use of outside products
or inadequate operating agents.
– Clean sealing surfaces, do not damage
them.
– Replace sealings, split pins, spring washers,

etc.
001.154.10-en
4.2-3
– For mounting work on the hydraulic system

use greases BASED ON MINERAL OIL only.
– After the breakdown of a unit (pump, motor,

etc.) flush the hydraulic system and replace
the filter to avoid consequential damages
due to metal abrasion.
SCHWING supplies suitable flushing filter

units (Fig. 1). Ask for information mate-
rial.
Fig. 1
– Carry out a trial run of the machine and

check the oil level.
Note any unusual noises, temperatures and

leakages.
– Carry out maintenance work on repaired or

exchanged units as on new machines.
WELDING
Welding work may only be carried out in com-

pliance with the instructions of the manufac-
turer.
See chapter 4.70.
001.154.10-en
4.3-1
CONSUMABLES AND REFILLING QUANTITIES
Machine type : S 34 X
DESIGNATION : CONSUMABLE QUANTITY

chapter 4.4 :
Water reservoir CLEAN water ca. 400,00 l
Hydraulic oil reservoir No. 1 ca. 350,00 l
*Distributor gearbox No. 2 ca. 5,50 l
Slewing gear No. 2 ca. 3,00 l
Greasing nipples No. 4 / 4.1 /
Central lubricating system (optional) No. 4 ca. 6,00 l
Toothing of slewing drive Nr. 5 /
* = vehicle WITHOUT power take-off
004.020.01-en
4.3-1
CONSUMABLES AND REFILLING QUANTITIES
Machine type : S 34 X
DESIGNATION : CONSUMABLE QUANTITY

chapter 4.4 :
Water reservoir CLEAN water ca. 400,00 l
Hydraulic oil reservoir No. 1 ca. 350,00 l
*Distributor gearbox No. 2 ca. 5,50 l
Slewing gear No. 2 ca. 3,00 l
Greasing nipples No. 4 / 4.1 /
Central lubricating system (optional) No. 4 ca. 6,00 l
Toothing of slewing drive Nr. 5 /
* = vehicle WITHOUT power take-off
004.020.01-en
4.4-1
INFORMATION Staff members, agents, customers K 224
Hydraulic systems S I W, V V W 2007 / 02
IMPORTANT SUPPLEMENT TO THE ATTENTION!

OPERATING INSTRUCTIONS RISK OF ACCIDENT
Please keep this Information bulletin with Hydraulic oil under pressure is capable
the operating instructions for your ma- of penetrating the skin and of causing
chine. severe damage to human tissue.
Consult a specialist immediately.
INJURIES CAUSED BY OIL UNDER

PRESSURE MEASURES TO BE TAKEN IN CASE OF
INJURY
Due to a regrettable accident which happened
during bleeding of an hydraulic system we at- Go immediately to a doctor who is familiar with
tract your attention to the following rules: See this type of injuries.
also the safety manual in our operating instruc-
tions: Consult a doctor anyway even if the wound
seems to be insignificant.
– Work on hydraulic systems may only be
carried out by qualified personnel. Hydraulic oil injected under the skin must be
removed immediately to prevent severe circu-
– The person carrying out the work must wear latory disturbances (gangrene).
his/her personal protective equipment (gog-
gles, suitable gloves and clothing). Serious cases of gangrene may require an
extensive operation.
– Work only on depressurized systems. En-
closed oil may still be under pressure even if As a gangrene is in most cases accompanied
the drive is stationary and the pressure ac- by bacteria, the resulting infection may lead to
cumulator depressurized. an accelerated dying of cells.
– If it is necessary – e.g. for bleeding opera- The presence of such bacteria in the blood
tions – to open pressurized systems, install circulation is a life-threatening condition.
a bleeding line beforehand when the ma-
chine is pressureless or use existing mini-
mess ports. CONCLUSION
– If this is not possible – for instance due to Insist on immediate treatment by a specialist
insufficient space – make sure nobody can even if an injury caused by an oil jet seems
be hit by ejected oil. to be insignificant.
– Open the bleeding port very carefully until

oil emerges. NEVER open the port any fur-
ther and NEVER remove the connection.
000.869.14-en
4.4-2
RECOMMENDED LUBRICANTS AND CONSUMABLES

THE "SAFETY MANUAL"
Beginning on PAGE 4.4-3 you will find a limited number of suitable lubricants and consum-
ables. If these products are not available, others can be used provided the indicated STAN-
DARD DESIGNATIONS are complied with. The selection and order of the products listed
cannnot be interpreted as a judgement on their quality.
EXPLANATION OF ACRONYMS AND ABBREVIATIONS USED
1) GENERAL
BI = Main Association of the German Construction Industry. As an alternative to the

recommended lubricants and operating agents the standard lubricants listed in
column "BI" can be used.
DIN = German Industrial Standards
ISO = International Standardization Organization
MIL-L = American Military Standards for Lubricants
API = American Petroleum Institut
SAE = Society of Automotive Engineers
VG = Degree of viscosity in mm²/s at 40° C
2) HYDRAULC OIL
API-CD = Engine oil for heavily loaded Diesel engines with and without supercharger.
EO = BI standard lubricant, a quality engine oil
HLP = In accordance with DIN 51524, a hydraulic oil with additives to improve corrosion
protection, ageing stability and protection against wear in the mixed fricton area
HVLP = In accordance with DIN 51524, a hydraulic oil with low dependence of viscosity on
temperature, otherwise like HLP
000.869.14-en
4.4-3
3a) "INDUSTRIAL" GEAR LUBRICANT OIL
CLP = In accordance with DIN 51517, a circulation oil with addivites to improve corrosion
protection, ageing stability, protection against wear in the mixed friction area and to
increase gear stability under load
PG = Synthetic lubricating oil for extreme loading on a polyglycol base, suitable as long-
term lubricant
3b) MOTOR VEHICLE GEARBOX OIL
G0 90 = BI standard lubricant, a gearbox oil according to API-GL 5
MIL-L 2105 B = Hypoid gearbox oil for heavy-duty gearboxes and axles, roughly corresponding to
API-GL 5.
4) COMPRESSOR OIL
VDL = Mineral oil for air compressors with additives to improve corrosion protection and
ageing stability. Coke residue after ageing max. 3 % in accordance with DIN
51352.
Rotoröl 8000F2 = Synthetic four-seasons oil for rotational compressors
5) GREASE
KP 2 K = In accordance with DIN 51502, a grease for high pressure load in the working
temperature range from -20° C to +140° C, worked penetration 265 to 295, no or
only slight changes due to water.
MPG-A = BI standard lubricant, a grease according to KP 2 N, meeting the requirements of

KP 2 K and K 2 K.
MLE2N-40 = Special lubricant for plastic / metal compound materials for long-lasting lubrication
of the sliding surfaces in telescope arms
ID no.: SCHWING cardan shaft grease

10197297 Use only this grease for the lubrication of SCHWING cardan shafts
000.869.14-en
4.4-4
1. HYDRAULIC OIL RECOMMENDATIONS
Viscosity (ISO): VG 32 VG 46 VG 68
Quality (DIN): HLP HVLP HLP HVLP HLP HVLP
ARAL-Vitam GF 32 HF 32 GF 46 HF 46 GF 68 /
BP-Energol HLP HM 32 HM 46 HM 68
BP-Bartran HV 32 HV 46 HV 68
ESSO-Nuto H 32 H 46 H 68
ESSO-Univis N 32 N 46 N 68
KLÜBER-Lamora HLP 32 / HLP 46 / HLP 68 /
MOBIL-DTE 24 13 M 25 15 M 26 16 M
SHELL-Tellus 32 T 32 Multi Grade Hydraulic Oil Tellus T 46*
TEXACO-Rando HD 32 HDZ-32 HD 46 HDZ 46 HD 68 HDZ 68
TOTAL FINA ELF
-Azolla ZS 32 ZS 46 ZS 68
-Equivis ZS 32 ZS 46 ZS 68
WINTERSHALL- HS 32 HV 32 HS 46 HV 46 HS 68 HV 68
Wiolan
Engine oil SAE 10w / / SAE SAE SAE

(API-CD) 10w-30 20w-20 10w-30
BI EO 10 / / EO 1040B EO 20 EO 1040B
* = standard filling ex works Herne. SHELL Tellus T 46 can be used as all-season oil if the
starting temperature is not below -10 °C.
VG 32 = Winter application conditions in Central Europe

VG 46 = Summer application conditions in Central Europe
VG 68 = Rooms with great heat or tropics
DO NOT MIX HYDRAULIC OILS OF DIFFERENT MANUFACTURERS:

REDUCTION OF QUALITY POSSIBLE.
If hydraulic oil of another manufacturer is to be used or oil of another quality (e.g. BI instead of
HLP) is to be filled in, a complete oil and filter change is necessary. Viscosity mixes between
oils of one manufacturer are permissible in some cases (consultation with the oil manufac-
turer required). In this case, however, a change in viscosity of the oil filling (depending on the
mix ratio) is to be taken into account.
000.869.14-en
4.4-5
2. GEAR LUBRICANT OIL (see gear rating plate)
2.1: INDUSTRIAL GEAR LUBRICANT OIL
Viscosity according to ISO VG 220
Quality according to DIN CLP
ARAL Degol BG 220 / Degol BMB 220

BP Energol GR-XP 220
ESSO Spartan EP 220
KLÜBER Klüberoil GEM 1-220
MOBIL Mobilgear 630
SHELL Omala Öl 220
SUNOCO Sunep 1220
TEXACO Meropa 220
WINTERSHALL Wiolan IT 220
BI /
2.2: MOTOR VEHICLE GEARBOX OIL
Viscosity according to SAE 90 (85w-90)
Quality according to MIL-L 2105 B
ARAL Getriebeöl HYP

BP Energear HYPO 90 / Hypogear 90 EP
ESSO Gear Oil GX-D / Gear Oil GX
MOBIL Mobilube HD
SHELL Spirax HD / Spirax MB 90
SUNOCO GL-5
TEXACO Geartex EP-C
WINTERSHALL Wiolan Hypoid-Getriebeöl 90
BI GO 90
The above mentioned gear lubricant oils are suitable for continuous ambient temperatures of
approx. -10° C to approx. +40° C. For extreme operating conditions please inquire as to suit-
ability. Viscosity class ISO-VG 220 roughly corresponds to SAE 90.
000.869.14-en
4.4-6
2.3: INDUSTRIAL GEARBOX OIL (polyglycol base)
Viscosity acc. to ISO: VG 220
Quality acc. to DIN: PG
ARAL Degol GS 220

AVIA Avilub VSG 220
BP Energol SG - XP 220
ELF Syntherma P 270
ESSO Umlauföl S 220
FUCHS Renodiol PGP 220
MOBIL Glygoyle 30
SHELL Tivela WB
TEXACO Synlube CLP 220
BI /
ATTENTION:
The above-mentioned synthetic lubricating oils on polyglycol base must not be mixed with oils
of a different base.
3. OIL RECOMMENDATIONS FOR PISTON COMPRESSORS
3.1: PISTON COMPRESSOR
Viscosity acc. to ISO VG 100 VG 150
Quality acc. to DIN VDL VDL
ARAL Motanol HE 100 Motanol HE 150

BP Energol RC 100 Energol RC 150
SHELL Corena Öl H 100 D Corena Öl H 150 D
SUNOCO Sunvis 9100 Sunvis 9150
TEXACO Compr. Oil EP 100 Compr. Oil EP 150
MOBIL Rarus 427 Rarus 429
WINTERSHALL Wiolan CD 100 Wiolan CD 150
BI / /
3.2: ROTATIONAL COMPRESSOR
For our rotational compressors, the only oil to be used is the synthetic ROTORÖL
8000 F2. See chapter 4.55
000.869.14-en
4.4-7
4. GREASE RECOMMENDATIONS
4.1: SCHWING cardan shaft grease. Use only this grease for the lubrication of
SCHWING cardan shafts
SCHWING ID no.: 10197297 400g cartridge for manual grease gun
4.2: Lithium-saponified high-pressure grease KP 2 K acc. to DIN 51502 without solid lubri-
cant
ARAL Aralub HLP 2

BP Energrease LS-EP 2
ESSO Beacon EP 2
KLÜBER Centoplex 2 EP
SHELL Alvania EP Fett 2
SUNOCO Multi Duty EP-2
TEXACO Multifak EP 2
MOBIL Mobilux EP 2
WINTERSHALL Wiolub LFP 2
BI MPG-A
4.3: Special lubricants for severe operating conditions
For severe operating conditons we recommend a particularly adhesive and pressure-resistant lubri-
cant for the slide bearings of the boom column as well as for the sliding blocks of the turntable
drive unit, for example:
- OPTIMOL-OPTIPIT
- KLÜBER-COSTRAC GL 1501
Severe operating conditions include:
– high loading due to dust, dirt, heat, air humidity, seawater
– great shock load and vibrations
– operation downtimes of several weeks.
OPTIMOL-OPTIPIT should always be used when installing the above mentioned structural compo-
nents. It can be obtained from the SCHWING spare parts department in 400 g cartridges under ID
no.: 10087948
000.869.14-en
4.4-8
5. SPRAY GREASE RECOMMENDATIONS
Sprayable EP grease for open gears with MOS2 and graphite additive
ARAL Sinit FZ 2
BP Energol WR P
ESSO Surett Fluid 4K
KLÜBER Grafloscon C-SG 0 ULTRA
Grafloscon CA 901 ULTRA-SPRAY
SHELL Cardium Fluid D
TEXACO Crater XX Fluid
MOBIL Mobiltac A
BI LUB-A
6. SPECIAL LUBRICANT FOR PLASTIC SLIDERS IN TELESCOPE SECTIONS
Designation acc. to DIN: MLE2N-40
SCHWING ID no.: 10194658 10 kg can
7. SPECIAL LUBRICANTS FOR COUPLINGS AND SEALS OF PUMPING LINES
OPTIMOL OLIT CLS
Schwing Id. no.: 10149905 10 kg can
Optimol Olit CLS is a rubber-compatible and water-resistant heavy-duty grease on a

lithium / calcium base.
As an alternative to Optimol Olit CLS, high-pressure grease
SHELL Alvania EP Fett 2
mentioned in table 4.2 can be used as well. When changing over between these two sorts of
grease, all remainders of the old grease must be removed carefully.
000.869.14-en
4.4-9
EXTRACT FROM THE SAFETY DATA SHEET FOR HYDRAULIC OIL
In our factory in Herne, Germany, our machines are filled with SHELL Tellus T 46 hydraulic oil. The
present document is an extract from the manufacturer's data sheet in conformity with directive
91/155/EC
Please request the full safety data sheet from your oil supplier in the country of use.
TRADE NAME: Shell Tellus T 46 After contact with the eyes: Rinse thoroughly
for 15 minutes with running water with the ey-
lids spread apart and seek medical advice.
USE: hydraulic oil
After swallowing: Do not induce vomiting. Seek
medical advice.
PREPARATION:
Medical information: Treatment depending on
Mix of highly refined mineral oils and additives symptoms.
POTENTIAL HAZARDS: FIRE PREVENTION AND FIRE FIGHTING:
Prolonged and repeated contact with the skin When handling the product, do not smoke and
can cause degreasing, irritation and dermatitis. keep away open flames or heat sources of any
kind.
Avoid the formation of oil mists.
Fire classification in acc. with DIN EN2: B
Do no let the product get uncontrolled into the
environment. Not completely biodegradable. Suitable extinguishing agents: Foam, pow-
der, carbon dioxide, sand or earth.
FIRST-AID MEASURES: Do not use a water jet under high pressure.
After inhalation: Remove affected persons to

fresh air and keep at rest in a position comfort- MEASURES IN THE EVENT OF INADVER-
able for breathing. Seek medical advice. TENT RELEASE:
After contact with the skin: Remove stained Measures concerning persons: Ventilate con-
clothes and wash the skin with water and soap. cerned rooms thoroughly. Avoid contact with
the skin.
When oil has penetrated into the skin under
high pressure, consult a doctor immediately. Environment protection: Stop continued leak-
ing out of the product and penetration into the
sewerage.
Make barriers of sand or earth or use other

suitable stopping measures.
Inform the competent authorities when the pro-

duct threatens to penetrate into the waters, the
sewerage system or into the soil.
000.869.14-en
4.4-10
CLEANING AND ABSORPTION: SAFETY-RELATED DATA:
Absorb or confine the product using sand, earth Pour point : -45° C
or other absorbing material.
Flash point : 190° C
Fill the absorbed product into a properly marked
recipient and discard in compliance with legal Solubility in water : insoluble
regulations.
DISPOSAL
HANDLING AND STORAGE:
Product: by authorized disposal company. EU
Do not eat, drink, smoke or take snuff during waste code no.: 130110
the work. Avoid spilling the product.
Packing: when completely empty by autorized
When storing the product, avoid direct sunlight, disposal company.
heat and strong oxidizing agents. Store in a dry
place and do not expose to large temperature
fluctuations. MARKING
In acc. with the pertaining EC directive, the pro-

PERSONAL PROTECTIVE EQUIPMENT: duct is not subject to marking.
Respiratory mask: For oil mists, use a respi- Observe national regulations.
ratory mask equipped with a filter for organic
vapours and particles.
Hand protection: Wear protective gloves of

PVC or nitrile rubber, if admissible from a safe-
ty point of view.
Eye protection: Wear goggles to protect the

eyes against the risk of splashing.
Protection of the body: Avoid contact with

the skin; wear overalls.
General protection and measures of indus-

trial hygiene:
Do not put oil-stained cleaning rags into the

pockets of your clothing. Do not eat, drink,
smoke or take snuff during the work.
000.869.14-en
4.5-1
TIGHTENING TORQUES
OBSERVE THE INSTRUCTIONS OF These overall coefficients are assumed to be

THE "SAFETY MANUAL" the following:
SURFACE COLOUR OVERALL

High-strength bolts must be prestressed with a FRICTION
certain tightnening torque. COEFFICIENT
µges.
Tightening torques depend, among other
things, on bolt and nut type, thread, surface 1. phosphatized black 0,14
coating and lubrication.
2. yellow- golden- 0,14
The tightening torques set out in the follow- chromated yellow
ing tables are approximate values. They 3. Dacromet 500 silvern 0,10
contain a safety factor (0.9 x MA) to avoid
overstressing of the bolted connection. 4. as 1+2 with 0,10
fitting paste*
The tool must be precisely adjusted to these
torque values. The values are applicable * e.g. copper paste or MOS2
only in those cases where no other values
Bolts must be lubricated at the thread and the
are specified in the individual chapters of
turning head or nut seating plane. Thread and
the SCHWING servicing and repair in-
seating plane must be clean.
structions and assembly drawings.
The tables apply only to the above screws and
SCHWING uses hex bolts and cheese-head
nuts.
screws and hex nuts (DIN) with different sur-
face coatings.
They cannot be used for other types (e.g. re-
duced-shaft bolts).
The overall friction coefficients essential to de-
termine the tightening torques depend on the
They cannot be used with friction-increasing
type of coating and the lubrication.
agents either (e.g. liquid screw fixer).
ATTENTION – RISK OF DAMAGE

Only torque wrenches checked at
regular intervals (every six months,
for instance) must be used for
tightening. The maximum ad-
missible tolerance for torque
wrenches is +/- 10% of the respec-
tive tightening torque (MA).
000.024.06-en
4.5-2
SCREWS AND BOLTS WITH
STANDARD THREAD (µges = 0,14) STANDARD THREAD (µges = 0,10)
Size Tightening torque MA (Nm) Size Tightening torque MA (Nm)

for strength class for strength class
8.8 10.9 12.9 8.8 10.9 12.9
M4 2,7 4,0 4,6 M4 2,2 3,2 3,8
M5 5,3 7,8 9 M5 4,3 6,4 7,5
M6 8 13,5 16,2 M6 7,5 10,8 12,6
M8 22 32 38 M8 18 27 31
M10 44 64 75 M10 36 53 62
M12 76 112 130 M12 62 90 108
M14 120 180 210 M14 100 140 170
M16 185 275 325 M16 150 225 260
M18 270 385 450 M18 220 310 365
M20 380 550 640 M20 300 440 510
M22 520 740 870 M22 420 590 700
M24 650 940 1095 M24 530 750 880
M27 990 1390 1620 M27 780 1120 1300
M30 1300 1890 2200 M30 1080 1530 1750
FINE THREAD (µges = 0,14) FINE THREAD (µges = 0,10)
Size Tightening torque MA (Nm) Size Tightening torque MA (Nm)

for strength class for strength class
8.8 10.9 12.9 8.8 10.9 12.9
M8x1 24 35 41 M8x1 20 28 33
M 10 x 1 50 70 85 M 10 x 1 40 57 68
M 10 x 1,25 46 65 80 M 10 x 1,25 37 55 64
M 12 x 1,25 83 120 145 M 12 x 1,25 67 100 115
M 12 x 1,5 80 115 140 M 12 x 1,5 65 95 110
M 14 x 1,5 130 190 230 M 14 x 1,5 105 155 180
M16 x 1,5 200 295 350 M16 x 1,5 160 235 280
M 18 x 1,5 300 435 510 M 18 x 1,5 240 345 400
M 20 x 1,5 425 610 710 M 20 x 1,5 335 475 560
M 22 x 1,5 580 825 940 M 22 x 1,5 460 650 750
M 24 x 2 720 1030 1210 M 24 x 2 560 810 940
M 27 x 2 1030 1480 1750 M 27 x 2 820 1170 1390
M 30 x 2 1480 2110 2470 M 30 x 2 1170 1660 1930
000.024.06-en
4.10-1
Maintenance plan
Signs used in the maintenance plan below:
n = CHECK o = LUBRICATION p = CLEANING q = REPLACEMENT
c d e f = After starting-up the equipment
Frequency of maintenance: Data:

The "VECTOR system" keeps a record of worked
A = daily or after 10 hours working hours of different groups.
Boom, slewing device and stabilizers moving hours
B = weekly or after 50 hours working are recorded.
In the menu "Service data" we can read the
C = monthly or after 200 hours working working hours and how long the groups have been
in movement.
D = every 3 months or after 500 hours working Checking these data every now and then, makes it
possible to perform maintenance according to the
E = every 6 months or after 1000 hours working worked hours of each group.
F = every year or after 2000 hours working
G = every 2 years
What happens first!
003.980.02-pt
4.10-2
003.980.02-pt
4.10-3
MAINTENANCE PLAIN
For maintenance of the chassis, engine, optional equipment, etc, follow manufacturer instructions!
GENERAL (A): A B C D E F G CAP.
A1 Technical inspection performed by an expert. Intervals according to worked hours or m³ of estimated 2.61
pumped concrete; what happens first. 4.65
A2 Visual inspection of the equipment and its functions by the operators. n 4.65
A3 Checking of the hydraulic oil level (before starting the equipment). n 4.20
A4 Replacing of hydraulic oil (possibly every 2 years, after analysis) q q 4.20
A5 Drainage of the water in the hydraulic oil tank. p 4.20
A6 Cleaning of the hydraulic oil cooler and engine radiator vanes. p 4.22
A7 Checking of working pressure. n 4.21
A8 Lubrication of operating levers and articulations. o --
A9 Checking if there are leakages in the hydraulic system, tanks, concrete pipeline, etc. c n 4.44
A10 Checking whether the basic structures, stabilizers, pipeline, containers, pumping kit, articulations, etc c n 4.42
are well connected or tightened.
A11 Checking of the water tank level. n --
A12 Checking + lubrication of the pumps articulated axles (ordinary work). n o 4.30
A13 Checking + lubrication of the pumps articulated axles (heavy duty work). n o 100* 4.30
A14 Checking of the oil level in the transfer box. n 4.35
A15 Replacement of transfer box hydraulic oil. f q 4.35
* lubricate after 100 hours working
003.271.06-pt
4.10-4
BOOM (V): A B C D E F G CAP.
V1 If there's a failure message, replace the hydraulic oil filter not later than B3. q 4.20
V2 Lubricate boom and stabilizers nipples. o --
V3 Check conditions and right connection of end hose. n --
V4 Lubricate the bearing mounting of the slewing turret. o 100* 4.51
V5 Check the oil level of the slewing gear. n 4.36
V6 Replace the oil of the slewing device. f q 4.36
V7 Check the slewing device brake. n --
V8 Lubricate the gear teeth. o 4.51
V9 Check the right assembly of the slewing device. c n 4.51
* lubricate after 100 hours working
CONCRETE PUMP (B): A B C D E F G CAP.
B1 Wash the water box. p 3.35

B2 Check if the water box is dirty. If so, clean it. p 3.35
B3 When there's a failure message, replace the hydraulic oil return filter, but not later than 6 months or q 4.20
15000 m³ of pumped concrete; what happens first.
B4 Check the right assembly of the concrete cylinders. n 4.43
B5 Lubricate the Rock valve, slewing cylinder and hopper nipples. o 4.40
B6 Check if the Rock valve body is well assembled. n 4.40
B7 Check the right assembly of the Rock valve end plate. n 4.40
B8 Check if the Rock valve shaft is well tightened. n 4.40
B9 Check Rock valve shaft impermeability. n 4.40
B10 Check Rock valve cutting ring. n 4.40
B11 Check accumulator (When available). c c n 4.23
B12 Safety technical inspection of the accumulator (When available). n 4.23
003.271.06-pt
4.10-5
EXTRA EQUIPMENT (Z): A B C D E F G CAP.
Z1 Check the right functioning of the central lubrication system. n 4.80

Z2 Wipe the air filter of the high pressure cleaning system. p 4.56
Z3 Check oil level (before starting the equipment). n 4.55
Z4 Replace the oil (Use 8000 F2). f q 4.55
Z5 Replace oil filter. f q 4.55
Z6 Replace the oil return valves. f q 4.55
Z7 Clean / replace the air filters. p q 4.55
Z8 Clean the oil cooler. p 4.55
Z9 Replace the oil filtering cartridge. q 4.55
INTERVALS ACCORDING TO THE PUMPED CONCRETE:
The wearing of some structural elements depends a lot on the working conditions (type of concrete, concrete pump output, etc.).
For this reason, we recommend the checking of these components after a certain quantity of pumped concrete.
Then, after analyzing the level of wearing, a new schedule must be planned.
First check after: Other checks For further information,

check chapters:
P1 Concrete pipeline 5000 m³ If necessary. 2.34 / 4.44
P2 "Rock" valve body 15000 m³ If necessary. 4.40
003.271.06-pt
4.11
.....................................................................................................................................................................................................................................
MAINTENANCE REPORT
Maintenance:
A,B,C,D,E,F Date: Signature: Remarks:
(please list)
001.915.00 en
4.20-1
HYDRAULIC FLUID AND FILTERS

THE "SAFETY MANUAL"
CHECKING THE RESERVOIR LEVEL
The reservoir is equipped with an inspection

glass 1 (Fig. 1).
– Check the fluid level only while the oil is cold

before starting the hydraulic pump drive for
the first time at the beginning of your daily
work.
For this check, the machine must be in a hori-

zontal position ready for driving.
Ready for driving means in this case that the

placing boom and the stabilizers are in trans-
port position. Fig. 1
The oil level must be visible in the center of

the inspection glass when the oil is cold.
As the hydraulic oil expands when its tempera-

ture rises, the levels indicated in the inspection
glass would then be different.
– If necessary, top up fluid through the top

cleaning cover 3 (Fig. 2).
Work only in absolutely clean conditions.
For topping up we recommend to use our

FLUSHING AND FILTERING UNITS (see
page 4.2-2). Ask for supplementary informa-
tion.
Use only the same sort of fluid.
Fig. 2
003.942.01-en
4.20-2
LONGER INTERVALS BETWEEN HYDRAU-

LIC OIL CHANGES
In case of proper oil treatment and regular After some time, water settles on the bottom of
oil filter change, the hydraulic oil must be the test tube.
changed only after 2 years.
Foreign bodies and oxidation products darken
the oil.
VISUAL INSPECTION AND ODOUR TEST OF
HYDRAULIC FLUIDS ON A MINERAL-OIL BA- The colour is determined by comparing the
SIS sample to fresh oil of the same grade.
Simple oil inspections can be carried out on A precise analysis can be performed by the oil
site. manufacturer in a laboratory test.
The water content can be checked by filling a

sample into a test tube.
TEST CRITERION DIAGNOSIS REMEDIAL ACTION
COLOURING slight darkening without depo- none, normal state

sits
strong darkening with deposits change oil, for large systems
filter + carry out lab test
turbidity see below
CONTAMINATION BY FOREIGN oil clean and clear, no precipi- none
MATTER tation
clean and clear, slight precipita- shorten checking intervals
tion
suspended particles (turbidity) clean system, replace oil filling
or dirt deposits or filter, check nature of filter
contamination
WATER IN OIL milkiness (emulsion), visible drain off water, carry out lab test
separation of water and change oil, if required, re-
pair leaks.
FOAMING increased foaming, foam check suction line for leaks,
emerging check oil level
ODOUR smell of burnt oil check operating temperature, in
case of severe darkening and
deposit formation occurring at
the same time, see above.
sour smell, darkening, deposits change oil immediately and
clean system
003.942.01-en
4.20-3
DRAINING OFF CONDENSED WATER
After prolonged downtimes (at least 1 day) any During each change of the hydraulic fluid clean
condensed water in the hydraulic oil reservoir the walls and the bottom inside the reservoir.
must be drained off through drain valve at the
bottom of the reservoir.
ATTENTION: EXPLOSION HAZARD
– Unscrew cap 1 (Fig. 1) from the drain valve. Do not use unshielded light.
– Screw draining hose 2 onto the valve thread. Clean the oil reservoir whenever necessary.
– The valve opens automatically. To do so:
When clean hydraulic fluid flows out of the – Clean the surroundings of cleaning cover 3
valve remove hose immediately and refit (Fig. 2) and take off cover.
the valve cap.
Risk of unintentional draining.
– Check the fluid level.
CHANGING THE HYDRAULIC FLUID
– Bring the hydraulic system to operating tem-

perature.
– Prepare a recipient for used oil.
– Because of the large amount of oil, pump off Fig. 1

as much fluid as possible beforehand
through the upper cleaning opening.
For this purpose we recommend to use

our FLUSHING AND FILTERING UNITS.
– Drain off remaining oil through the drain

valve as described above.
– During each oil change clean the reservoir

and replace the filter insert (page 4.20-4).
CLEANING THE RESERVOIR
Hydraulic oil tends to precipitate (especially

after prolonged downtimes) dirt particles settling
on the bottom of the reservoir.
Fig. 2
003.942.01-en
4.20-4
– Detach the suction hoses of the hydraulic PRESSURE FILTER OF THE BOOM HY-
pumps from the reservoir and close the open DRAULICS
ends to prevent dirt from getting into the
pumps. The pressure filter 1 (Fig. 1) of the placing
boom hydraulics is an inline filter located beside
– Clean the inside of the reservoir with flushing the control blocks.
oil and lint-free cleaning rags.
Textile fibres and solvents are the enemy

of the hydraulic system. For this reason,
never use waste cotton, diesel oil, petrol,
etc. for cleaning.
RISK OF IRREPARABLE DAMAGE TO

THE PUMPS
– Wipe inside of the reservoir dry.
– Refit the cleaning cover.
REPLACING THE FILTER INSERTS
The machine is equipped with two hydraulic oil

filters:
Replace the filter inserts after a fault mes-

sage of the diagnosis system and after each
oil change. Fig. 1
To avoid false warnings, the filter monitoring

function is active only at oil temperatures above
30°.
Clean and check all individual parts. Pay atten-

tion to abraded metal in the filters (sign of
damage).
Never clean, but always replace the filter

cartridges.
Never use the machine without filter car-

tridges.
Used filter cartridges must be disposed of

as special waste.
003.942.01-en
4.20-5
Removal:
– Slacken filter housing 3 (Fig. 1) with a ring

spanner at the lower hex end of the housing.
– Remove the filter housing, pour out oil and

clean.
– Withdraw the old filter insert 2 from the filter

head.
Fitting:
– Check the 0-ring in the filter head 1, and

replace if necessary
– Stick the new filter cartridge 2 on the filter

head.
Fig. 1
Do not remove the bandage around the
filter cartridge.
– Install the filter head and tighten down to the

stop.
– Retighten the filter head by hand (ca. 20 Nm)

using a ring spanner applied at the lower hex
end of the housing.
REPLACING THE CARTRIDGE OF THE PAR-

TIAL FLOW FILTER
The partial flow filter (microfilter) is part of the

oil cooler circuit. A separate pump constantly
recirculates the hydraulic oil when the pump
drive is activated.
Cooler, filter and fan (Fig. 2) form a compact Fig. 2

unit.
003.942.01-en
4.20-6
– Loosen the four retaining screws of the filter

head. Remove the screws and the washers.
– Lever up the filter head a bit by applying a

large screwdriver on the surfaces provided
for this purpose.
– Draw the filter head 1 (Fig. 1) out of the filter

chamber by turning at the same.
– Rinse the filter sieve and remove dirt with a

soft brush.
– Dry the filter sieve with compressed air and

check for damage.
– Lay the filter head with the sieve on a clean

surface.
– Draw the filter cartridge 2 (Fig. 2) out of the

filter chamber by pulling the handle.
Fig. 1
– Check the two O-rings under the filter head
and replace them if needed.
– Check the filter chamber for depositis and

remove them, if any.
– Oil the upper and lower O-ring of the new

filter cartridge and insert the cartridge care-
fully into the filter chamber.
Do not remove the paper strip round the

filter cartridge.
– Install the filter carefully.
– Insert the four retaining screws with their

washers and tighten them carefully cross-
wise.
ATTENTION - aluminium housing
Fig. 2
003.942.01-en
4.20-7
FILLING THE EMPTY OIL RESERVOIR
– Fill the hydraulic oil reservoir as described on

page 4.20-1.
– Wait ca. 10 minutes until the oil is free from air

bubbles and top up with some oil, if neces-
sary.
– Try all hydraulic functions.
– Check the oil level once again while the oil is

still cold with the machine in horizontal po-
sition and ready for driving.
– If necessary, top up with hydraulic oil until the

oil level reaches the center of the inspection
glass. See page 4.20-1.
REPLACING THE BREATHER FILTER
The breather filter 4 (Fig. 1) on the hydraulic oil Fig. 1

reservoir
– filters the air flowing into the reservoir when

the oil level descends, and
– prevents the ejection of oil fumes from the

reservoir.
The filter insert 1 (Fig. 2) cannot be cleaned,

but has to be replaced in accordance with the
maintenance schedule.
Fig. 2
003.942.01-en
4.21-1
CHECKING THE PRESSURE SETTINGS
Combinations of A11V130 and A11V190 pumps

OBSERVE THE INSTRUCTIONS OF achieve different specific outputs (Fig. 1+2).
THE "SAFETY MANUAL"
A11 pumps are equipped with a 'pressure cut-
All hydraulic consumers are protected by pres- off' function. This function swivels the pump
sure relief valves. back before the max. operating pressure preset
at the pressure-limiting valve (DBV) is reached.
These valves are pre-set at the factory. Read-
justment is normally only necessary after re- The pressure cutoff function prevents power
placement or repair of hydraulic units. losses and oil heating occurring when hydraulic
oil is ejcted by the pressure-limiting valve.
These settings should nevertheless be checked
at regular intervals in order to detect possible The value indicated by the pressure gauge
faults in time. Check the settings when the ma- must be approximately 20 bars below the set-
chine is at operating temperature and running ting of pressure-limiting valve DB 1. See circuit
at service speed. diagram.
The factory-adjusted pressures must not be

View from above: A 11 V0,
changed. Any readjustment may only be
nominal size 130
carried out by qualified workshop person-
nel.

AND DAMAGE
Detach connections on the hydrau-
lic system only when the engine is
stationary and the pressure accu-
mulator (if the machine is so equip-
ped) depressurized. This is also re-
quired when test pressure gauges Fig. 1
are installed or removed.
For pressure checking purposes, the View from above: A 11 V0,
concrete pump hydraulics MUST be nominal size 190 + 260
set to 'Pumping'.
In the 'Suction' mode, the sealing ele-
ments of the concrete pump control
block may be squeezed out of their
seat.
CONCRETE PUMP SYSTEM
From series 3 onwards, the KVM 34 X truck- Fig. 2

mounted concrete pumps are driven by A11
hydraulic pumps.
003.981.01-en
4.21-2
The corresponding settings are performed at

the hydraulic pumps and on the pressure-limit- ATTENTION: RISK OF DAMAGE
ing valve. Working operation is allowed only
with ballcock 2 (Fig. 1) in operating
If the prescribed value is clearly above or position.
below the rating during the check, have the
necessary setting operations performed by
the SCHWING after-sales service.
Put the machine out of operation and inform the

after-sales service of the values recorded.
Checking:
Important:
– Close ballcock 1 (Fig. 1). If the concrete pump remains activated for
more than 120 seconds in blocked condition,
– In machines with MPS set ballcock 2 to the diagnosis system reports a fault.
position (II): 'Pressure control'.
– Adjust the concrete pump to maximum de-

livery rate (number of strokes) and open
shut-off valve 11 (Fig. 2) of the concrete
pressure gauge 10.
– Switch on the concrete pump.
The pumping pistons move to their final posi-

tions and stop.
The needle of concrete pump pressure

gauge must go up to the pressure cutoff set
value.
– After the pressure check, stop first the con-

crete pump and then set the ballcocks back
to the operating position to prevent uncon- Fig. 1
trolled starting of the concrete pump after
switching over of the ballcocks.
– Close the shut-off valve of the concrete

pump pressure gauge to protect it against
pressure peaks during operation.
Fig. 2
003.981.01-en
4.21-3
PLACING BOOM - AUXILIARY UNITS PNEUMATIC PILOT CONTROL
Pressure checking of the boom hydraulics is The shuttle valves of the concrete pump and
performed by installing test pressure gauges. agitator pilot control are operated by com-
pressed air.
Since the pressure relief valves of the individual
consumers may be pre-set to different values, Some equipment options must also be supplied
pressure checking is performed by moving the with compressed air.
corresponding cylinder against the limit stop.
The compressed air is taken from the truck's
In this case, it may be necessary to adjust the compressed-air system.
primary pressure-relief valve to a higher value.
For this purpose, the truck must be equipped
For checking of the primary pressure relief with a 4-way protection valve with a free port.
level, it is always necessary to execute a
movement with higher protection ('secondary
pressure-relief'). ATTENTION: RISK OF ACCIDENT
Work on the 4-way protection valve
Leave these works to the SCHWING after- may only be carried out by authorized
sales service if you lack the experience re- personnel of the truck manufacturer.
quired for this task. Mistakes may have an influence on
the truck's braking system.
HYDRAULIC PILOT CONTROL
When checking hydraulic pilot-control pres-

sures, always connect first a test pressure
gauge with a measuring range up to 600
bars.
The 40-bar gauge might be irreparably dam-

aged by over-pressure.
"S1" valve
Valve "S1" of the concrete pump is pilot-

controlled from the hydraulic agitator circuit.
To ensure a sufficient pressure level even when

the agitator is stationary, a pre-pressurizing
valve is installed in the agitator control block.
Placing boom
The pilot pressure is available behind a pres-

sure-reducing valve at the pilot-control port
plate of the placing boom control block.
003.981.01-en
4.22-1
COOLERS
In this case, observe the following rules:

THE "SAFETY MANUAL" – Remove the fan motor.
– Use only detergents that do not attack alu-
minium.
ATTENTION: – Apply the water or the steam jet carefully.
RISK OF ACCIDENT
Cleaning the inside of the hydraulic oil cooler:
from rotating fan blades and hot parts
of the machine. – Remove the cooler.
Before working on radiators: – Connect the cooler to a flushing unit with
– switch off all control units; filters.
– shut off the engine and the ignition; – Flush for at least 30 minutes.
– allow the radiator to cool down. – After cleaning, remove the flushing agent
Wear working gloves and goggles. without leaving residues.
Refit all protective elements after – Thereafter, flush the cooler with the type of
cleaning before putting the machine oil that will be used in the hydraulic system.
back into operation.
HYDRAULIC OIL COOLER
The oil cooler and the oil filter are located in the
same housing.
Hydraulic oil is pumped in a separate circuit

through this cooler-filter combination by a con-
stant-displacement pump.
This system is active immediately after activa-

tion of the drive unit and independent of other
functions.
Accumulated dust on the oil cooler ribs 2 (Fig.

1) reduces the cooling performance.
Cleaning the outside of the hydraulic oil cooler:
Dirt on the cooling ribs of the oil cooler 2 (Fig.

Fig. 1
1) reduces the cooling performance.
Clean the cooler cautiously using compressed

air. Direct the air flow parallel to the cooling ribs
and opposite the normal direction of internal
flow.
If heavily soiled, coolers can be cleaned with a

water-jet or a steam-jet appliance.
003.982.02-en
4.22-2
ENGINE RADIATOR
Water-cooled engines are equipped with a cor-

responding radiator.
Depending on type, the engine may be addi-

tionally equipped with an engine oil cooler.
– Do not forget to clean the cooling ribs of en-

gine radiators from time to time when the
machine is used on dusty construction sites.
The engine may otherwise be damaged due

to overheating.
– The procedure to be adopted for the clean-

ing of radiators and coolers is described in
the respective truck or engine operating in-
structions.
003.982.02-en
4.23-1
PRESSURE ACCUMULATOR
(BLADDER ACCUMULATOR)
OBSERVE THE INSTRUCTIONS OF The pressure drops slowly at first and then abrup-
tly when the accumulator is completely empty.
THE "SAFETY MANUAL"
The pressure value last indicated before the nee-
dle of the gauge drops abruptly to "0" corresponds
MAINTENANCE AND CHECKING OF THE to the nitrogen filling pressure.
BLADDER ACCUMULATOR 3 (Fig. 1)
Important:
The following checks must be carried out regu- Depending on machine type, pressure gauge 2
larly: is installed either directly on the accumulator
safety block (Fig. 1) or in another place in clear
– Check the nitrogen filling pressure. view of the machine operator, e.g. 2 (Fig. 2) in
the S 39 SX machine.
– Check connections for tight fit and leaks.
– Check fittings and safety devices for perfect

condition.
– Check the fastening elements.
CHECKING INTERVALS
Perform the above checks:
– After any new installation.
– One week after commissioning.
– Four weeks after commissioning. Fig. 1
If no significant gas leaks are detected, the regu-

lar checks must be carried out
– every three months.
CHECKING THE NITROGEN FILLING PRES-

SURE OF THE BLADDER ACCUMULATOR
– Start the engine and fill the accumulator.
– Shut off the engine.
The accumulator is discharged automatically (hy-

draulic fluid flowing out of the accumulator).
– Observe the pressure gauge

(e.g. 2, Fig.1 or 2).
Fig. 2
002.908.03-en
4.23-2
– If the filling pressure is not o.k., the accumu- – open the manual accumulator relief valve,
lator must be refilled with the original filling e.g. 1 (Fig. 1);
equipment from the accumulator manufac-
turer and in strict compliance with the manu- – check pressure gauge 2. The needle of the
facturer's instructions. gauge must indicate "0".
The filling pressure "P0" is indicated in the Any non-observance of these instructions in-
circuit diagram and/or on a sticker on the volves a RISK OF ACCIDENT (e.g.: due to un-
bladder accumulator itself. controlled switching of the Rock valve, hydraulic
oil ejected under pressure, etc.).
ATTENTION:
RISK OF DAMAGE! SAFETY INSPECTION OF THE BLADDER
Do not exceed the specified filling ACCUMULATOR
pressure.
Pressure vessels are subject to regular inspec-
tions in compliance with the regulations in force
ATTENTION: in the country of use.
RISK OF EXPLOSION!
In Germany, an inspection by an authorized
Use only nitrogen to charge the
testing institue is prescribed at the time of
accumulator.
commissioning and then after every 10 years at
Never use oxygen or compressed the latest.
air to charge the accumulator.
Within the limits of regular safety checks, the
bladder accumulator must be checked by a
WORKING ON MACHINES WITH BLADDER qualified person for apparent defects.
ACCUMULATOR
ATTENTION:
RISK OF ACCIDENT!
Depressurize the bladder accumulator
before working on the machine.
The relief valve in the accumulator block opens

automatically under certain operating conditions
so that the bladder accumulator is depressur-
ized.
For reasons of WORKING SAFETY, the follow-

ing additional precautions must be taken be-
fore any work (e.g.: cleaning, connection of test
gauges, repair, replacement of wear parts etc.)
is being undertaken on the machine: Fig. 1
– shut off the machine control unit;
– shut off the drive engine and secure against

inadvertent restarting (e.g. by withdrawing
the ignition key),
002.908.03-en
4.23-3
REPAIR OF THE ACCUMULATOR SYSTEM
ATTENTION - RISK OF ACCIDENT

– Only specially trained and qualified
persons are allowed to carry out
work on the bladder accumulator
and its ports.
Inapproriate fitting and handling can
result in severe accidents.
– Repairs must be carried out only in
strict compliance with the manufac-
turer's instructions.
– Defective parts may only be re-
placed by original spare parts.
– It is forbidden to make modifica-
tions on any part of the system.
You are urgently warned against
undertaking any unqualified re-
pairs.
– It is forbidden to carry out welding,
brazing and other mechanical work
on the body of the accumulator:
RISK OF EXPLOSION!
– After repairs on the accumulator
charging circuit, the circuit must be
completely bled.
002.908.03-en
4.30-1
CARDAN SHAFTS IN THE PUMP DRIVE
Only in very rare cases are the flanges ar-

OBSERVE THE INSTRUCTIONS OF ranged out of alignment with respect to each
THE "SAFETY MANUAL" other. The correct position is marked with two
opposite arrows 'B' on the cardan shaft.
If the shaft segments are joined incorrectly, the
TRANSPORT AND STORAGE second joint intensifies the non-uniform move-
ment of the first joint. The shaft runs noisily and
Cardan shafts from Schwing are supplied as wears faster. This will lead to vibrations and
ready-to-fit components of the pump drive. premature failure of the drive components.
They must be transported and stored in hori- All cardan shafts are filled with grease. After
zontal position. During transport and storage initial fitting, they must be regreased.
they must be protected from falling apart.
If the cardan shaft is to be painted, the greasing
Protect bright metallic parts such as flange con- nipples and the toothing of the length compen-
tact surfaces against corrosion and store car- sation telescope 'D' must be protected against
dan shafts in dry rooms. paint.
To maintain the shafts in the balanced state in Check the flanges of the units connected for
which they have left the factory avoid blows and perfect technical condition and perfect fasten-
impacts on the shafts. Do not remove the bal- ing. Pay special attention to proper centering fit.
ancing weights. Replace damaged flanges only with original
spare parts.
ATTENTION: Tighten the flange bolts crosswise with a torque

RISK OF CRUSHING wrench. The tightening torque values are set
Do not stick your hands into the ar- out in chapter 4.5 of the operating instructions.
ticulated joints when handling cardan Do not turn the cardan shafts in their articula-
shafts. tions with fitting levers: The bearing seals will
be damaged and the greasing nipples may be
ripped off.
FITTING
Use only O.E.M. screws and nuts with original
dimensions. See spare-parts list.
Before installing a cardan shaft, clean all flange
surfaces thoroughly of anti-corrosive agents,
dirt and grease.
The flange surfaces must be free from damage

to prevent 'setting' and wrong centering.
The claws of the inner driver fork 'A' (Fig. 1)

must lie in the same plane. The non-uniformity
of the rotary movement caused by the the first
joint is thus compensated by the second one.
Fig. 1
003.753.01-en
4.30-2
Do not use any MOS2 additives for screws and Continue to press grease into the joint nipples
nuts. until fresh grease emerges from all sealing lips.
Together with the old grease, dirt is being
Do not re-use bolts and nuts once fitted. squeezed out of the bearings, too. If it is not
possible to press grease through all of the bear-
After installing a cardan shaft, check the bolted ings, the shaft must be removed.
joints concerned after 50 operating hours for
proper and tight fitting. There is no risk of 'overgreasing' the shafts.
Wipe off any grease in excess.
GENERAL SERVICING INSTRUCTIONS The length compensation telescope section of

the cardan shafts is generally rilsan-coated and
Trouble-free and safe operation of cardan thus maintenance-free. A greasing nipple in this
shafts requires checking and lubricating work. section, if any, must be greased with only small
amounts of grease since part of the grease ac-
Before greasing, the articulated joint bearings cumulates inside the shaft.
'C' and the length compensation telescope sec-
tion 'D' must be checked for play. If the bear- If cardan shafts are cleaned with water under
ings have significant play, the cardan shaft pressure or with a steam-jet appliance, they
must be replaced. must be regreased after each cleaning. In no
case must cardan shafts be cleaned with che-
Pay attention to abnormal running noise and mical detergents. Detergents can attack the
vibrations when the machine is in operation. seals of the articulated joints.
Locate the cause and rectify.
Regreasing intervals:
A timely reaction to first signs of wear con-
tributes to keeping the machine in good op- The regreasing intervals are only deter-
erating condition and to reducing and avoid- mined by the actually prevailing operating
ing downtimes and consequential damage. conditons.
The intervals specified in the maintenance

GREASING plan are APPROXIMATE intervals. Under
certain circumstances, the intervals may
For regreasing of the cardan shafts, use also be shorter.
only SCHWING cardan shaft grease, ID. no.:
10197297. A regular visual inspection of the universal
joints is due after 50 operating hours at the
Regreasing with other greases should generally
latest. During this inspection, the joint clear-
be avoided.
ance must be checked as well.
Clean the high-pressure cleaning nipples before
regreasing.
The maximum admissible greasing pressure is

15 bars. Avoid excessive pressures to prevent
the seals from being damaged.
If a joint has greasing nipples on opposite

sides, greasing of one nipple is sufficient. The
central greasing nipple in the trunnion distrib-
utes the grease to the four bearings of the ar-
ticulated joint.
Fig. 1
003.753.01-en
4.36-1
SLEWING GEAR DRIVE

THE "SAFETY MANUAL"
CHECK THE OIL LEVEL
- Place the machine in horizontal position.
- Remove the control plug 4 (Fig. 1).
- Remove the covering hood above pinion as

well as the filler and vent plug 5.
- SLOWLY top up with oil through the opening

at pos. 5 until the oil level is visible approx. 1
- 2 cm below the pipe edge at pos. 4. Fig. 1
- Wash the filler and vent plug 5 out in petro-

leum ether and mount the positions 4 and 5.
- Slew the placing boom several times and

repeat the check.
CHANGE THE OIL
If possible change oil only with gear at

working temperature.
- Remove the filter and vent plug 5 (Fig. 2) and

the control plug 4 (Fig. 1). Fig. 2
- Unscrew one of the drain plugs 6 (Fig. 1) and

after completed draining screw it in again. At
low ambient temperatures rinse the gear with
a certain amount of new oil to flush dirt and
abrasion off.
- Pour gear oil in as described above.
000.499.02-en
4.36-2
CHECK THE SLEWING GEAR BRAKE
The set of multiple disks which is pressed

against the slewing gear at rest is hydraulically
lifted at the beginning of the slewing motion
resp. bled automatically at the end of the slew-
ing.
The multiple-disk brake only serves for

holding the boom.
Braking is effected by means of the in-

stalled braking valves.
A throttle provides for a uni-form rise resp. Fig. 1

drop of the pressure admission to prevent a
sudden braking.
Pressure increase and decrease can be

checked at the gauge 3 (Fig. 1).
The throttle is adjusted at our works

and must not be readjusted except by the
SCHWING aftersales service.
CHECK THE DRIVE PINION
Unscrew the loose pinion fastening screws 1 Fig. 2

(Fig. 2), clean them and put them in again us-
ing Loctite 243.
Tighten the screws with the torque as per table

on page 4.5.
000.499.02-en
4.35-1
SWITCHABLE DIVIDER GEAR BOX

THE "SAFETY MANUAL"
CHECK OIL LEVEL
- Place the machine in horizontal position.
- Unscrew the control screw 1 (Fig. 1).
- If necessary top up with oil via the oil filler

and vent screw 2 until it overflows at "1".
- Wash the screw 2 out in benzine and blow it

out with compressed air.
CHANGE OIL
- Unscrew the drain plug 3 screw in after dis-

charge.
- Top up with oil as described above.
Fig. 1
N.B.:
We recommend to check an oil sample for col-

ouring and solid particles at each oil change in
order to be able to take the suitable preventive
maintenance measures.
001.795.03-en
4.40-1
ROCK VALVE
Grease all nipples of the station every day. For

OBSERVE THE INSTRUCTIONS OF continuous operation, grease more often, i.e.
THE "SAFETY MANUAL" after 8 hours at the latest:
– Clean the greasing station.

ATTENTION:
LIFE-THREATING RISK – Withdraw the protective caps from the nip-
To prevent inadvertent working move- ples.
ments, always: – Inject grease into each greasing nipple until
– shut off the concrete pump and the old grease emerges from the bearing point.
agitator,
– shut off the drive engine/motor and – Wipe off old grease using cleaning rags. Dis-
protect against restarting, and card grease and cleaning rags without pollut-
ing the environment.
– depressurize the pressure accumu-
lator (if the machine is so equipped) – Refit the proctective caps.
before undertaking any work on the
Rock valve.
Greasing station „X“ of truck-mounted concrete
pumps:
GREASING THE BEARINGS
Concrete pumps without central greasing sys-

tem are equipped at the rear of the machine
with a central greasing station. See examples,
Fig. 1+2.
The greasing nipples of this station are con-

nected with the bearings of the Rock valve.
Greasing points:
– rocking shaft
Fig. 1
– rocking cylinder
Greasing station „X“ of portable concrete
– agitator pumps:
Important:
The number of greasing nipples may vary
with the type of Rock valve.
The greasing station of truck mixer concrete
pumps have further greasing nipples for the
mixer bearings.
Fig. 2
001.193.12-en
4.40-2
Important note:
In some pumping units, the moving part of the
Rock valve is driven by hydraulic cylinders
mounted on ball sockets.
The machine may be equipped with cylinders
which may have a ball bearing only on one
side or also on both sides.
The corresponding greasing points are con-
nected via greasing lines with the greasing
nipple block (or the central greasing system).
The additional greasing nipples, e.g. 1 (Fig.
1) need not be greased.
They are used for pressing out the ball sock-
ets during repairs.
CHECKING THE SCREWED CONNECTIONS Fig. 1

FOR TIGHTNESS
– Check the cover retaining screws 14 (Fig. 2)

and the clamping screws of the pivot unit 15
("big Rock" only) in acc. with the servicing
plan regularly for tightness.
If needed, retighten the screws with a torque

wrench as specified in the table of chapter
4.5.
CHECKING THE PIVOT SHAFT FOR AXIAL

PLAY
There must be no air gap between bearing

bush 4 (Fig. 3), arrestor disk 2 and adjusting nut
Fig. 2
1. This is also valid for the valve in operation.
Between pivoting unit (Rock) 5 and housing

lining 6 there must be a play of 1.5 to 3 mm,
whereas kidney seal 7 contacts the housing
lining (Fig. 4).
Fig. 3 Fig. 4
001.193.12-en
4.40-3
Metal contact between Rock 5 and housing

lining 6 (Figs 1+2) indicates a defect, as, for
instance:
– kidney seal defective
– adjusting nut 1 too tight
– cutting ring jamming
– too much grease used for fitting or parts not

properly cleaned.
ADJUSTING THE AXIAL PLAY OF THE PIVOT

SHAFT
Fig. 1
– Remove safety screw 3 (Fig. 1) and the
washer.
– Set spacing "B" = 1.5 bis 3 mm with adjust-

ing nut 1.
– Bring bore in the collar of the adjusting nut

into alignment with the nearest threaded
hole of arrestor disk 2 (by turning the nut
forwards or backwards).
– Fit safety screw 3 together with the washer.
CHECKING THE CUTTING RING
Due to external influences (e.g. different sorts Fig. 2

of concrete) and varying load conditions in par-
tial zones, the cutting ring and wearing layer of
the housing lining are subject to non-uniform
wear and tear (zone "C", Fig. 3).
Fig. 3
001.193.12-en
4.40-4
Scores are mainly caused by friction and the

breaking of stones.
They are of no importance unless the wear-

ing insert is completely worn.
The wearing insert used in series machines is a

single-piece wearing insert 9 (Fig. 1) of white
cast iron.
As an option, a two-piece wearing insert 9 (Fig.

2) of hard metal with a suitable carrier plate is
available.
To achieve uniform wear and therefore a much

longer service life of the parts, the following
measures are recommended: Fig. 1
– After thorough cleaning, move the Rock to

the lefthand and righthand limit stop posi-
tions and check the cutting ring and the
wearing insert for condition in acc. with the
servicing schedule.
Check the cutting ring all around its cir-

cumference.
– If a gap is visible between cutting ring 10

and wearing insert 9 (maximum admissible
play: 1 to 1.5 mm), the cutting ring should
be turned by 90°.
TURNING THE CUTTING RING
For turning of the cutting ring, proceed as fol- Fig. 2

lows:
– Detach the pumping line from the Rock valve

outlet.
To do so,
– remove the reducer pipe in trailer concrete

pumps,
– remove wedges 1+2 and coupling 3 (Fig. 3)

in truck-mounted concrete pumps,
– swing boom connection piece 4 aside.

Fig. 3
001.193.12-en
4.40-5
– Slacken adjusting nut 1 (Fig. 1) by two to – Tighten all cover screws 14 in several steps
three turns. crosswise with a torque wrench.
– Slacken the cover retaining screws 14 uni- Tightening torque see chapter 4.5.
formly by abt. 2 to 3 turns to relax the com-
pression spring of the cutting ring. – Coarse-adjust the axial play of the pivot shaft
so that the Rock valve can be switched to al-
Do not turn out the screws completely. low the parts to "settle" in place.
– Lever up the cover with two crowbars until For this purpose, screw adjusting nut 1
the cover contacts the loosened screws. against the contact face and then slacken
again by ½ turn.
The cover has special depressions in the rim
(arrow, Fig. 1) where the levers can be ap- – Wet the kidney seal with water and switch
plied. the Rock valve several times to and fro to al-
low all parts to "settle" in place.
– Pull back the pivot unit (Rock) until the cut-
ting ring can be moved freely. Do not switch the Rock valve in dry con-
dition - Risk of damage
If the cutting ring cannot yet be moved freely,
the cover screws must be loosened a little – Adjust the axial play of the pivot shaft as
further and the procedure repeated. described on page 4.40-2.
– Detach the cutting ring if necessary by tap-

ping slightly on it.
– Turn the cutting ring by 90°.
Always turn in the same direction.
– Make sure the cutting ring is safely guided

by the Rock and that it cannot drop out or
get jammed.
– Pay attention that no stones are getting

caught between the individual components
when tightening the cover screws.
– Tighten the cover screws 14 uniformly and

carefully.
Make sure the cutting ring slides into the

Rock without jamming.
Fig. 1
001.193.12-en
4.40-6
– Check the spacing between cutting ring 10

and Rock 5 (Fig. 1+2) after each turn of the
cutting ring.
If the spacing exceeds 8 mm, the cutting ring

is no longer guided safely in the Rock and
must be replaced.
– When replacing the cutting ring, check

wearing insert 9 and compression spring
11 for condition.
CHECKING THE PIVOT SHAFT SEALING
The bearings of the pivot shaft are sealed off

against the pumped substance by means of O- Fig. 1
rings (Fig. 3).
In the event of leaks (concrete fines are

squeezed out of the bearing), the O-rings must
be replaced immediately before the bearings
are destroyed.
For replacing the rings, the pivot shaft must be

removed. See:
ROCK VALVE REPAIR INSTRUCTIONS
PROLONGED DOWNTIMES Fig. 2
If the Rock valve is not used during prolonged

periods, we recommend to lubricate the kidney
seal and the housing lining with a lubricant and
anti-corrosive agent with a MIL 907D specifica-
tion (e.g. ANTI-SEIZE manufactured by
LOCTITE).
This agent prevents "sticking" of the seal.
Do not use sprays. Sprays attack rubber

parts.
Fig. 3
001.193.12-en
4.40-7
CHECKING THE WEAR OF THE ROCK

VALVE
To reduce wear, most of our Rock valves are – Move the Rock valve to the opposite end
protected on the inside and outside by a hard- position and repeat the check.
facing layer.
Depending on the condition of the valve, it is
The type of hardfacing chosen depends on ex- now possible to determine further checking in-
periences made in the main fields of application tervals.
of the individual Rock valves.
The Rock valve should be replaced when the
See example Fig. 1: base metal becomes visible in certain places.
1 = internal hardfacing The internal hardfacing layer will generally wear

faster than the outer layer.
2 = external hardfacing
The outside should be checked at the latest,
when a significant degree of wear is found on
PREVENTIVE MAINTENANCE the inside.
Due to the fact that wear depends strongly on

the conditions of use, we recommend checking
a new Rock valve on the inside for the first time
after ca. 5000 m³ of concrete pumped:
– For checking, clean the concrete pump as

usual.
– Move the Rock valve into one of its end posi-

tions.
ATTENTION:
RISK OF ACCIDENT
Shut off the engine and depressu-
rize the pressure accumulator to
prevent inadvertent movements of Fig. 1
the Rock valve.
– Remove the valve outlet and check the in- With the materials currently used, the
side of the Rock valve body with a torchlight. valves can no longer be regenerated by
hard-facing.
Clients are urgently warned against un-
qualified welding work and the use of re-
produced parts.
SCHWING assumes no liability whatso-
ever for damage caused by unqualified
repair attempts and the use of reproduced
parts.
001.193.12-en
4.42-1

THE "SAFETY MANUAL"
PUMPING AND DIFFERENTIAL CYLINDERS
Check the fastening screws of the differential

and pumping cylinders for tight fit.
Tighten loose fastening screws crosswise in

three steps with a torque wrench (Fig. 1).
Tightening torque according to table in chapter

4.5.
PUMPING PISTON REPLACEMENT
The machine is equipped with a special control

for replacement of the pumping pistons.
– Set switch 3 (Fig. 2) to the

pumping piston replacement po- Fig. 1
sition.
Important:
The control system monitors the positions of
the EMERGENCY SHUT-OFF buttons and of
the switches of the active control.
A corresponding message is indicated on the
This symbol flashes on the display

when the system is ready for oper-
ation.
Fig. 2
Start of the control system with

switch 4 (Fig. 2).

acoustic signal and this symbol is
indicated on the display.
003.899.02-en
4.42-2
The activation of the PISTON REPLACEMENT CHECKING THE FASTENING OF THE PUMP-
mode automatically reduces the speed of the ING PISTONS
diesel engine.
– Take off the water-box covers and remove
The control of the concrete pump and of the the protective grids.
diesel engine is handed over to the control box
of the special control unit (Fig. 1). – Move the adapter piece into the water-box.
Switches 1+2 are used to control the following – Drain off water.
functions:
– Check the pumping piston fastening screws
1 – Engine on / off for tightness (Fig. 2).
2 – Pumping piston operation forwards / re- – Move the second adapter piece into the wa-
verse in the inching mode*. ter-box and repeat the check.
* after actuation of switch 2 the pumping pis-

tons start in the selected direction and stop
when the switch is released.
When an emergency shut-off button is de-

pressed while the special control is active, the
control unit must be started again. See chapter
1.8.
ATTENTION:
RISK OF CRUSHING
Before working in the water-box
always shut off the drive engine Fig. 1
and depressurize the pressure ac-
cumulators to prevent inadvertent
movements of the concrete pump.
Keep at a safe distance when oper-
ating the concrete pump with the wa-
ter-box open.
Do not stick your hands into the
water-box.
During work on the pumping pistons
no other working activities must be
carried out on the concrete pump.
Make sure nobody is standing close to
the pipe-switching system. The Rock
valve can switch over.
Fig. 2
In case of danger, depress the emer-
gency shut-off button.
003.899.02-en
4.42-3
REPLACING THE PUMPING PISTONS
If sand is found in the water-box, the pump-

ing pistons are worn and must be replaced.
Leaking pistons cause premature wear of

the pumping cylinders.
If sand gets into the water-box in spite of

new pistons having been installed, the cyl-
inders must also be replaced.
ATTENTION:
RISK OF INJURY
Depending on size, a pumping piston
may have a weight of more than
25 kg. Fig. 1
Use a fitting aid (e.g. belt) for in-
stallation and removal of the piston
and seek assistance of a helper.
Instruct the helper beforehand. Reac-
tivate the engine only after the helper
has left the machine.
REMOVAL
– Close shut-off valve 1 (Fig. 1) on the con-

crete pump control block.
The notch in the valve head must point in a Fig. 2

direction perpendicular to the direction of
flow.
Closing the ball valve prevents switching of

the piston rods in the limit-stop positions.
– Move piston to a position short before the

rear limit stop. The adapter piece (Fig. 2)
must be fully visible in the water-box.
003.899.02-en
4.42-4
– Loosen fastening screws of the adapter

piece and remove screws completely.
When doing so, hold the adapter piece at the

hexagonal centre shaft with a spanner
(Fig. 1).
– Move the piston rod to the rear limit stop.
– Withdraw the adapter piece (Fig. 2).
– Moving the piston rod slowly towards the

pumping piston. Fig. 2
– Connect piston-rod flange 1 with pumping-

piston flange 2 as shown in Fig. 3, using an
bolt and an nut.
Tighten the bolt by hand.
– Retract piston rod slowly and draw piston out

of the cylinder (Fig. 4).
– Loosen bolted connection.
– Take pumping piston out of the water-box.
– Clean and check all parts. Fig. 3
Fig. 1 Fig. 4
003.899.02-en
4.42-5
REFITTING
– Smear a thick layer of grease on the new

piston and the cylinder walls.
– Fasten the new piston with bolt and nut to

the piston-rod flange.
– Move the pumping piston into the cylinder so

that the screwed connection is still access-
ible (Fig. 1).
– Remove bolt and nut.

Fig. 1
– Retract the piston rod.
– Insert adapter piece and screw onto the

pumping piston (Fig. 2).
– Move piston rod towards the adapter piece.
– Align adapter piece, if necessary, and screw

onto the piston rod.
– Fill water into the water-box and refit pro-

tective grid and cover.
Fig. 2
– Open shut-off valve 1 (Fig. 3) at the concrete
pump control block.
The notch in the valve head must point in the

direction of flow.
Fig. 3
003.899.02-en
4.44-1
DELIVERY LINE

THE "SAFETY MANUAL"
During operation of the pump, the machine op- The minimum admissible wall thickness de-
erator must permanently check the delivery line pends on the maximum concrete pressure de-
for leaks (water leaking out of the line). Leaks livered by the pump.
will cause plugs in the line due to "bleeding" of
the concrete. Stop working immediately and Replace pipes and elbows as soon as they fall
repair the leak. below the minimum wall thickness.
ATTENTION: RISK OF ACCIDENT!

Leaks in pipe couplings may be due
to defective seals.
If water leaks out of pipe walls and

bends, however, there is a high risk
of accident caused by pipe break.
Stop working immediately and de-

pressurize the pumping line by
sucking the concrete back to the
pump (reverse pumping). Fig. 1
– Check that delivery lines are suitable for the

application, using a wall-thickness meter
(Fig.1).
A daily check may be necessary under ex-

ceptionally tough conditions.
Tapping with a hammer is not recommended

because
– any denting leads to rapid wear,
– the hardened layer of highly wear-

resistant pipes may be damaged.
SCHWING supplies a suitable ultrasound

measuring instrument. Please ask for more
information.
002.514.07-en
4.44-2
DIAGRAMS
for determining the minimum wall thickness 3) Pipe 108x4

required for concrete delivery lines made of St
52-3 (with prescribed two-fold safety): 220
200
(Y) = concrete pressure PN in bars
180
160
140
(X) = minimum wall thickness in mm 120
100
(
80
60
1) Pipe 70x2.9 40
20
220 0
200 0 1 2 3 4
180
160 (X)
140
120
100 4) Pipe 114.3x7.1
(
80
60
40 220
20 200
0 180
160
0 1 2 3 140
(X)
120
100
(
80
60
2) Pipe 88.9x3.2 40
20
220 0
200 0 1 2 3 4 5 6 7
180
160 (X)
140
120
100
5) Pipe 133x4
(
80
60
40 220
20 200
0 180
0 1 2 3 160
140
(X) 120
100
(
80
60
40
20
0
0 1 2 3 4
(X)
002.514.07-en
4.44-3
6) Pipe 139.7x7.1 9) Pipe 165.1x7.1
220 220
200 200
180 180
160 160
140 140
120 120
100 100
(
(
80 80
60 60
40 40
20 20
0 0
0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
(X) (X)
7) Pipe 139.7x8.8 10) Pipe 168.3x10
270 240
240 210
210 180
180 150
150
120 120
(
90
(
90
60 60
30 30
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 10
(X) (X)
8) Pipe 159x4.5 11) Pipe 191x5.5
220 220
200 200
180 180
160 160
140 140
120 120
100 100
(
80 80
60 60
40 40
20 20
0 0
0 1 2 3 4 5 0 1 2 3 4 5 6
(X) (X)
002.514.07-en
4.44-4
MAIN AREAS OF WEAR

(to be given priority in checking)
Delivery pipes
Viewed in the direction of concrete flow, the

main area of wear is located ca. 100 mm after
the flange (Fig. 1).
Pipe bends
Fig. 1
Viewed in the direction of concrete flow, the
main area of wear is located in the "inflow"
bend (Fig. 2).
Super 2000/3000
Super 2000/3000 material must be replaced at

the latest when the inner hardfacing layer is
partly worn down to the outer layer (Fig. 3).
Fig. 2
Important note:
Super 3000 pumping lines and pipe bends of
the first series must only be installed in the
sense of pumping. For this purpose, the ma-
terial is marked with direction arrows. Al-
though these parts run out in 2001 they may
still be on stock. Therefore, pay attention to
any direction markings on the pipes when
replacing these elements.
Prolonged lifetime
(not applicable to Super 3000 series 1, see Fig. 3

above.)
The liftetime of pipes and bends can be pro-

longed if the position of the parts is changed
regularly.
– after detaching the fasteners, turn delivery

pipes by 180°;
– dismantle complete pipe bends and turn by

180°, i.e. fit the "inflow" bend at the "outflow"
side and vice versa (Fig. 4).
Fig. 4
002.514.07-en
4.44-5
REPLACEMENT OF PUMPING PIPES AND

PIPE BENDS
– Pay attention to the quality and correct di- Important note:

mensions of the spare parts.
During assembly at the factory, the location of
Only original SCHWING parts are exactly the points of articulation of the pumping line
identical to the factory-installed components. is determined by means of special devices.
If you intend to replace several parts of the
Specify the required length when ordering pumping line, always replace them one by
precision pipes. See spare-parts list. one and one after the other.
Do not dismantle the complete pumping line.
– During initial assembly at the factory, the In this case, the location of the points of ar-
boom pumping line is fitted stress-free with ticulation would have to be determined once
the placing boom in folded condition. again during fitting of the new line.
Such work should only be carried out by spe-
Incorrect fitting may put increased strain on cially trained personnel and with the help of
the placing boom kinematics and cause special devices.
damage such as broken pipe holders.
To avoid damage, make sure the boom is

folded when replacing any parts.
ATTENTION: RISK OF ACCIDENT!

Pumping lines and pipe bends may
be very heavy.
A 3 m-long piece of pumping line
DN 125 (Super 2000) weighs as
much as 45 kgs.
Support pipes and bends with lift-
ing tackle before dismantling them.
– Use new seals and safety cotter pins for the

couplings.
– Clean and check the couplings carefully and

grease them.
– Grease the couplings and seals with a

lubricant compatible with rubber, as, for
instance, 'Optimol Olit CLS'.
'Optimol Olit CLS' is a water-resistant

heavy-duty grease on a lithium / calcium
base.
002.514.07-en
4.44-6
CHECKING THE PUMPING HOSES VISUAL INPECTION (INSIDE)
Due to natural ageing, rubber hoses must – Place the cleaned hose on a horizontal sup-
not be older than 6 years maximum (incl. a port and use a torchlight.
storage time of 2 years).
– Pay attention to areas where the reinforce-
From the date of manufacture, they must be ment is visible or even protruding.
replaced after 6 years even if they still "look
good" from the the outside. – Pay attention to other loose parts of the rub-
ber coating, to bulges, cuts and areas of lo-
For end hoses and for connecting hoses, a cal wear.
daily visual inspection of the outside is manda-
tory. – Check especially the main wear areas near
the inlet side of the hose. The highest wear
Detached pumping hoses must be checked takes place on the first 30 cm of the rubber
before each use. coating behind the fitting).
Since the degree of wear strongly depends on Hoses with a damaged reinforcement or
the operating conditions (concrete, pressure, excessive wear must be replaced.
delivery rate, etc.) the inside of all new hoses
should be checked for the first time after
approx. 1000 m³ of concrete pumped: VISUAL INSPECTION OF THE HOSE FITTING
Plan further checks depending on the inspec- – Check the fitting for tightness.
tion result.
Hose and fitting must form a rigid connec-
tion.
VISUAL INPECTION (OUTSIDE)
– Check the inside of the fittings for wear.
– Check the retaining device of a placing boom
end hose for perfect condition. – Check the sealing faces for damage and re-
move any remaining concrete.
– The oulet end of an end hose must not be
"lacerated". Hoses with damaged or loose fittings
(hose leaving the fitting) must be re-
– Check the pumping hoses for bulges, kinks placed.
or other deformations which may be a sign of
a damaged or displaced hose reinforcement
layer (steel-cord inlay).
– Check the outer skin for cuts, missing mate-

rial and chafing marks which will result in
damage to the hose reinforcement.
Hoses with a damaged reinforcement

must be replaced.
002.514.07-en
4.44-7
Important note:
Because of higher loading, end hoses
equipped with a concrete stop valve (Fig. 1)
must be checked with special care in the
pinch-off area of the valve.
Fig. 1
002.514.07-en
4.51-1
BOOM COLUMN - LIVE RING BEARING
OBSERVE THE INSTRUCTIONS OF During the check the screw joint must not be
THE "SAFETY MANUAL" subjected to external forces (put the placing
boom on a rest).
This is the case, for instance, when the boom

GREASE THE ROLLER SLEWING JOINT sections are in vertical position.
The grease nipples of the roller slewing joint Tightening torque see chapter 4.5.
are located on the outside of the boom column
(Fig. 1). We recommend to have the slewing rim
screws replaced by the SCHWING after
They are connected to the bearing with greas- sales service every 3 years.
ing lines.
It is important to slew the placing boom several

times after each lubrication and then to repeat
the lubrication.
GREASE TOOTHING OF SLEWING JOINT
After the removal of the covering hood above

the pinion (Fig. 2) the toothing of the slewing
rim is accessible.
For careful maintenance, however, dismantling

of the complete toothing lining is recom-
mended.
Prior to the application of the lubricating agent

the toothing must be thoroughly cleaned with a
thinning agent - especially at the tooth base.
Fig. 1
CHECK TIGHTENING OF THE LIVE RING
DO NOT tighten loose slewing rim screws but

replace them together with washers and nuts.
In addition, the next two screw joints on the left

and on the right side of the loose screw must
be replaced.
Fig. 2
000.991.05-en
4.55-1
ROTARY COMPRESSOR

THE "SAFETY MANUAL"
SERVICING KITS Read the instructions before undertaking

any work on the compressor.
SCHWING supplies two different kits with the
material required for servicing of your compres- Do not use flammable substances and open
sor: fire when performing cleaning and servicing
work.
– Servicing kit 1 (standard maintenance)

Id. no.: 10197336 CHECKING THE OIL LEVEL
This kit includes all filters, sealing elements, – Check the oil level when the drive unit is
and a recipient with compressor oil for the ser- stationary and the compressor depressur-
vicing work described below. ized (pressure gauge at "O").
The oil quantity is sufficient for one oil change – Put the machine in horizontal position.
and for topping up between oil changes.
– The oil level is checked at inspection glass 4
(fig. 1).
– Servicing kit 2 (oil separator cartridge)
Id no.: 10170388 The oil level must lie above the upper edge of
the inspection glass.
This kit includes an oil separator cartridge and
all sealing elements required for replacing of
the cartridge. Important:
When the compressor is running, the oil level
should be visible in the middle of the inspec-
To ensure safe and troublefree tion glass.
operation of the compressor, use
only the above specified material.
SCHWING cannot be held respon-
sible for damage caused by inap-
propriate servicing and / or by the
use of unsuitable material.
Fig. 1
002.940.01-en
4.55-2
ATTENTION – RISK OF BURNS Important:

The compressor may be very New compressors are filled with a so-called
hot. run-in oil. At the first oil change, this oil must
be replaced by a special compressor oil rec-
ommended by the compressor manufacturer.
TOPPING UP OIL For the safe and reliable operation of the
compressor, the right sort of oil is of decisive
– Top up oil when the drive unit is stationary importance.
and the compressor depressurized (gauge at
Use only ROTORÖL 8000 F2 included in the
"O").
servicing kit.
– Unscrew the filling plug 1 (fig. 1) cautiously ROTORÖL 8000 F2 is a synthetic four-sea-
to relieve the pressure. son oil for ambient temperatures between -25
and 40°C.
Make sure that no oil foam spills out of opening
This oil must under no circumstances be
5.
mixed with other oils.
If necessary, wait a few minutes until the oil
foam has dissipated.
For topping up, use only the same oil as the the
one already in the compressor.
It is forbidden to mix different compressor

oils.
– Top up oil until it emerges from opening 5.
– Replace gasket 3, and screw filling plug 1

back in place.
CHANGING THE OIL Fig. 1

For perfect emptying, drain off the oil at operat-
ing temperature.
– Unscrew at first filling plug 1 as described

above.
– Open drain valve 2.
– Close the drain valve after complete drain-

ing.
– Fill in new oil as described above.
– Allow the compressor to run for a few min-

utes and check for leaks and correct oil
level. If necessary, top up oil.
002.940.01-en
4.55-3
CLEANING / REPLACING THE AIR INTAKE

FILTER
– Slacken knurled nut 1 (fig. 1).
– Remove sealing ring 2 and filter cap 3.
– Pull out filter cartridge 4.
– Blow all parts clean with compressed air (5

bars max.).
Clean filter cartridge from the inside with com-

pressed air moving the nozzle up and down
until all dust has been ejected from the car-
tridge. Fig. 1
– Replace the filter cartridge after several

cleaning cycles in acc. with the servicing
plan (page 4.10-4).
– Re-assemble the filter in reverse order.
CLEANING THE OIL COOLER
– Clean the oil cooler fins using a com-

pressed-air gun (fig. 2).
Soiling of the cooler leads to strong oil over-

heating and to over-temperature shut-down.
Fig.2
Overheated oil ages faster and loses its lubri-
cating properties. This results in higher wear of
the compressor.
– Clean the cooler by blowing compressed-air

through the cooling fins from the side where
the cooling air normally leaves the cooler.
REPLACING COMPRESSED-AIR HOSES
Compressed-air hoses must be replaced after 3

years at the latest. The date of manufacture is
stamped into the hoses.
002.940.01-en
4.55-4
REPLACING THE OIL FILTER
– Drain off used oil as described above.
– Slacken the screws 1 of filter cover 2 (fig. 1).
– Turn the cover through 90° and withdraw the

cover together with the filter.
– Detach filter 3 from the cover.
– Clean the cover and the contact surfaces at

the housing.
ATTENTION – RISK OF EXPLOSION

AND DAMAGE! Fig. 1
Do not use flammable detergents.
Make sure that no traces of the de-
tergent get into the compressor.
– Attach a new filter to the cover.
– Refit the cover with a new sealing ring 4.
– Fill in compressor oil as described above.
REPLACING THE OIL RETURN-FLOW

VALVES
Fig. 2
– Slacken the hollow screws 1 (fig. 2).
Pay attention to the sealing rings 3.
– Screw the return-flow valves 4 out of the

separator housing.
– Refit new valves with new 0-rings 5.
– Refit the threaded unions 2 using new seal-

ing rings 3.
002.940.01-en
4.55-5
REPLACING THE OIL SEPARATOR CAR-

TRIDGE
Dismantling: Make sure
– Detach the connector from solenoid valve 1 – that separator cover 8 is fitted in the posi-
at the separator housing 2 (fig. 1) and re- tion shown (arrow);
move air hose 3.
and
– Remove the oil return-flow valves 4 as
described above. – that connecting tube 7 is fitted in accor-
dance with its marking.
– Detach compressed-air tube 5 from the
separator housing.
– Slacken special nut 6.
Pay attention to the assembly marking on

connecting tube 7.
Mark the positions if necessary.
The connecting tube must be refitted later

on in exactly the same position.
– Detach the connecting tube and lift separator

housing 2 off the oil chamber.
– Pull connecting tube 7 out of the separator

housing.
– Lever cover 8 together with separator car- Fig. 1

tridge 12 cautiously out of the housing.
– Unscrew nut 9 and remove sealing ring 10

and cover 11.
– Remove the old oil separator cartridge 12

together with the O-rings 13.
Assembly:
– Re-assemble the parts in reverse order.
– Always use a new oil separator cartridge

and new seals 10, 13, 14, 15 and 16.
– Press the O-rings 13 with a small amount of

grease into the respective recesses of the oil
separator cartridge.
002.940.01-en
4.56-1
HIGH-PRESSURE CLEANING SYSTEM

THE "SAFETY MANUAL"
CLEANING THE SUCTION FILTER
Check the suction filter before each use of the

system and clean, if necessary.
Fix the cleaning intervals in accordance with the

operating conditions.
– Close the passage to the water tank by set-

ting ball-cock 6 to the other position.
– Unscrew the filter 4 by hand.
– Remove the filter insert 2 (Fig. 2) out of the

filter housing and rinse insert and housing
under running water. Fig. 1
Do not use detergents, brushes, etc.
– Replace strongly soiled or damaged inserts.

Do not operate the high-pressure pump
without the filter insert.
– Check the O-rings 1+3 at the filter head and

the filter sieve and replace, if required.
For further information cf. separate Operating

Instructions in the annex.
Fig. 2
002.523.02-en
4.60-1
ELECTRICAL / ELECTRONIC SYSTEM,

SOFTWARE
OBSERVE THE INSTRUCTIONS OF ATTENTION:

THE SAFETY MANUAL RISK OF DAMAGE
Installing fuses that are too strong or
bypassing fuses can cause irrepara-
ble damage to the electronic system.
ELECTRICAL PROTECTION OF THE
SCHWING COMPONENTS
Depending on the machine type, the system can Example:

be protected by means of: Switch cabinet of a truck-mounted concrete
pump
– a main fuse located near the starter batter-
ies;
– fuses located near the vehicle fuse-box

(generally in driver's cab of the truck-mounted
concrete pump);
– fuses in the switch cabinet or control panel of

the concrete pump (Figs. 1 + 2).
See also electrical circuit diagram.
REPLACING THE FUSES OF THE SCHWING Fig. 1

COMPONENTS
– Shut off the machine control and the engine. Example:

Control panel of a trailer concrete pump
– Open the cover of the switch cabinet or con-
trol panel with the special key.
– The fuse table is indicated on the plan on the

inside of the switch cabinet door or on the
electrical circuit diagram.
The fuses are marked with the letter "F".
– The fuses used are commercially available

automobile fuses.
– Replace defective fuses only by new ones of

the same type.
Fig. 2
002.617.06-en
4.60-2
– If the fuse blows again, the circuit is defec- Under certain circumstances, further protec-
tive. tive measures may be required for the vehi-
cle electronics (e.g. for the anti-blocking sys-
Immobilize the machine and have the elec- tem ABS) or for the drive engine.
trical system checked by a qualified electri-
cian. Read the operating instructions of the engine
or vehicle manufacturer and make yourself
familiar with the protective measures re-
WORKING ON ELECTRICAL / ELECTRONIC quired for his electronic systems.
COMPONENTS
– Do not touch live parts.
ATTENTION: DANGER! – Never check for the presence of voltage by
Work on the electrical control and on touching ground with a live wire.
the electronic system may be carried
out by qualified persons only. – Replace defectice warning and pilot lamps im-
Unqualified interventions are a risk to mediately.
the safety at the place of work and re-
sult in the loss of the operating per- – Never disconnect cables from the starter bat-
mission and of the CE approval. teries, the alternator or the regulator while the
engine is running.
– Before carrying out work on electrical or elec- – Ground the machine to make sure the ma-
tronic components chine and the soil are at the same electrical
potential.
disconnect first the negative (-) cable
and then the positive (+) cable SOFTWARE

from the starter batteries of the drive engine. Software corrections may only be made by per-
sons entrusted with such work by SCHWING.
This measure is sufficient to avoid short-cir- This applies also to software updating activities.
cuits and to protect the SCHWING control sys-
tem
ATTENTION! DANGER!
Reconnect the batteries in reverse order. Unauthorized software modifications
may result in severe damage and in
accidents.
ATTENTION:
RISK OF SHORT-CIRCUITS SCHWING assumes no liability for the
consequences of unauthorized soft-
Do not lay tools on the batteries.
ware modifications.
002.617.06-en
4.60-3
ELECTRICALLY DRIVEN MACHINES STEAM JET CLEANER
– Have the power supply disconnected by a Cover up electrical and electronic components.
qualified electrician before carrying out any
servicing work on the machine. Never direct a jet of water or steam at these com-
ponents.
– Work on the electrical system must be car-
ried out by qualiified electricians only. See pre- Moisture penetration results in malfunctions and
ceding page: can cause irreparable damage to electronic and
electrical components.
ATTENTION - DANGER!
STARTER BATTERIES
ELECTRIC WELDING PROCESSES
See chapter 4.70 CHECK THE ACID LEVEL
– Clean the surface of the battery and open

JUMP STARTING the caps.
Connect the jumper cable as described in the – The acid level must be about 10 to 15 mm
vehicle or engine operating instructions. above the plates (bottom of the checking in-
serts).
MECHANICAL WORKING PROCEDURES – If necessary, top up with distilled water. Do

not use acid.
Cover up equipment, cables, etc., if drilling, grind-
ing or similar work is to be carried out on the
machine. CHECK THE BATTERY CHARGE
Use a voltage tester or a hydrometer for testing.

PAINTING WORK AND WORK WITH AG-
GRESSIVE SUBSTANCES A fully charged battery has a voltage of about
2.4 Volt per cell and an acid density of 1.28 kg/l.
Cover up equipment, cables, etc. to protect them
against paint vapours and aggressive sub- If the acid density is below 1.23 kg/l at 20° C,
stances. charge the battery either through several hours
of operation or with a charger:
– Disconnect the positive and the negative

poles of the battery from the vehicle's
electrical system.
002.617.06-en
4.60-4
– Open the sealing caps.
– The charge current corresponds to max. 10 %

of the battery capacity
(e.g.: battery 120 Ah = charging current 12
amps.)
– Stop charging when the acid has reached a

density of 1.28 kg/l.
– Check the acid level, if necessary top up with

distilled water.
– Clean the battery poles and the battery-cable

terminals and apply a thin layer of acid-proof
grease on the poles.
– Tighten the terminals only by hand.
– Keep the battery clean and dry to avoid dis-

charging by leakage currents.
ATTENTION:
RISK OF DISCHARGE AND
EXPLOSION
During testing and charging the cells
give off EXPLOSIVE GASES. Do not
smoke, do not use unshielded lights
and avoid sparking.
Do not place tools on the battery.
Observe also the detailed information on

starter batteries set out in the operating in-
structions of the truck or engine manufac-
turer.
002.617.06-en
4.65-1
SAFETY INSPECTIONS
EXPERT
THE SAFETY MANUAL An expert must be called in after essential
modifications and extensive repairs (for in-
Besides regular servicing, permanent observa- stance when welding work has been carried out
tion of the machine and the required safety in- on load-bearing parts of the machine).
spections are indispensable to ensure the op-
erational safety of the machine and the safety The qualifications required for an expert are
at the place of work. described in the SAFETY MANUAL.
Persons in charge of these duties:

ADDITIONAL INSPECTIONS
MACHINE OPERATOR For special safety-related units as, for instance,

pressure accumulators, the relevant inspec-
The machine operator is responsible for visual tion regulations valid in the country of use must
inspections and function checks of 'his' ma- be observed.
chine and its accessories before and during the
work. If personnel with the required qualification is not
available, the inspection can be entrusted to the
The machine operator must stop the operations after-sales service of SCHWING.
when he detects deficiencies endangering the
safe working with the machine.
SAFETY INSPECTION
He is also responsible for the external aspect of
'his' machine. This means that he has to see to Since older machines are more prone to dam-
it that defects in the paint coat of the machine age than newer ones, the intervals at which
are repaired in due time. safety inspections have to be performed on con-
crete pumps and placing booms are dependent
Corrosion defects - especially at the placing on the age of the machine.
boom - may lead to cracking and fracturing.
This means that older machines must be in-
In his capacity as a driver, he is responsible spected more often than younger ones.
that his vehicle is in a safe driving condition as
prescribed by the regional regulations in the The corresponding inspection intervals are men-
country of use. tioned in the SAFETY MANUAL.
The observance of these inspection inter-

QUALIFIED PERSON (SPECIALIST) vals is of utmost importance.
A qualified person must perform the required The dynamic loads to which all machines are
safety inspection at regular intervals and exposed may in the course of time lead to fa-
document the result in the inspection booklet. tigue in steel components with the result of
cracking or fracturing.
The requirements for qualified persons are de-
scribed in the SAFETY MANUAL. Other components are of course also subject to
ageing caused by environmental influences and
On request, the inspection can be performed by should therefore be inspected at regular inter-
a specialist from SCHWING. vals.
001.162.05-en
4.65-2
The older the machine, the higher the probabil- In case of failure, S1 parts can be a risk to life
ity of damage. and limb of the users and of all other persons
inside the hazard range of the machine and
The graded safety inspection at regular intervals cause damage to private property and movable
is therefore an efficient means of detecting da- assets.
mage already at an early stage before machine
failures and (or) accidents are the result. The following parts are examples for S1 parts:
You must always bear in mind that in case – Placing boom sections
of damage and in the ensueing investigation – Levers and pins on the placing boom
of who is to blame for it, the fact whether the
– Hydraulic cylinders on the placing boom and
machine had been regularly and correctly
the stabilizers
inspected or not can be of decisive impor-
tance. – Stabilizers
– Emergency-stop parts and controls
SAFETY-RELATED COMPONENTS Failures of S2 parts affect mainly the essential

machine functions such as the "pumping or
If a safety-related component is found to be placing of concrete".
defective in a safety inspection or on any other
occasion, the machine must not be used any- The following parts are examples for S2 parts:
more until the defect has been repaired
– Hydraulic pumps
Since the repair normally requires special know- – Drives
ledge, it is is urgently recommended to have the – Gearboxes
work performed by the after-sales service of
– Material chutes
SCHWING.
– Concrete feeding hoppers
If you carry out the repair of safety-related com-
ponents yourself or if you entrust the execution In practice, the importance of a part with respect
of such work to a third party, we ask you to in- to safety varies, so that it will often be difficult to
form us about the damage and the work per- determine the degree to which a given part is
formed. relevant to safety.
With this information, you help us in our efforts The special circumstances always play an impor-
to improve our products and, if necessary, to tant part, too: Bursting concrete pumping lines or
take remedial action immediately. hydraulic hoses, for instance, will lead to ma-
chine failure, but at the same time they are are
For reporting, you can use a copy of the form also a risk to life and limb of persons in the vi-
overleaf. cinity of the machine.
Therefore don't hesitate to inform us also about

What are safety-related components? damage whose safety relevance is not immedi-
ately evident to you.
The SCHWING company standard distinguishes
between first-order (S1) and second-order (S2) In any case, you help us improve our products
safety-related components. and - what is more - you are on the safe side.
We thank you in advance for your kind help.
001.162.05-en
4.65-3
Please use a copy of this form
DAMAGE REPORT FOR SAFETY-RELATED COMPONENTS
Please fill in a copy of this questionnaire and send the copy to:
SCHWING GmbH
Service
Postfach 20 03 62
D-44647 Herne
You can, of course, also fax this page or answer by e-mail:
Fax: +49 (0)2325 74674 E-Mail: [email protected]
Customer no: ............................................... Tel.: ..............................................................
Address: ....................................................... Fax: ..............................................................
..................................................................... E-Mail: ..........................................................
..................................................................... Machine type: ...............................................
..................................................................... Machine no.: ................................................
..................................................................... Hours run: ....................................................
Contact: ....................................................... Concrete delivery rate in m³: ........................
Brief description of damage:
The following parts have been replaced (ID no. if known):
001.162.05-en
4.65-4
Welding required ? yes no
If yes, where?
Mechanical work executed?
drilling grinding others
If yes, where?
Has the work been documented with photos or drawings?
yes no
If yes, did you enclose this documentation enclosed with the present report?
yes no
001.162.05-en
4.70-1
REPAIR WELDING

THE "SAFETY MANUAL"
Welding work on the placing boom, the out-

rigger system or on other structural components
relevant to working safety may only be per- Attention
formed by persons duly authorized by the
manufacturer. The steel parts of this machine are made of
highly resistant fine-grained steel which is sub-
The work must be inspected by a competent ject to special working procedures from the
expert. point of view of welding technique. Welding
work performed on this machine without ap-
Observe the instruction sign on the machine proval of the manufacturer or by non-authorized
(Fig. 1). welding specialists will therefore free the manu-
facturer in the event of damage from his war-
– Before performing electric welding work dis- ranty obligations and in the event of conse-
connect the starter batteries (see chapter quential damage also from his product liability.
4.60) and take the necessary precautions to 10212778
protect the electronic systems of the vehicle Fig. 1
and of the engine
See the respective documentation of the ve-

hicle manufacturer and of the engine manu-
facturer.
– Disconnect the multiple plug of the cable

remote control resp. of the radio receiver
from the machine.
– Attach the negative terminal of the welding

machine directly to the component on which
welding is to be performed.
The welding current must not flow through

hydraulic cylinders. There is otherwise a risk
of damage to the chromium-plated piston
rods.
Protect the equipment, cables and cable

plugs from the effects of heat, slag etc.
001.918.03-en
4.80-1
CENTRAL LUBRICATING SYSTEM

Foreign objects, such as dirt, snow and wa-
OBSERVE THE INSTRUCTIONS OF ter, lead to malfunctions and must be pre-
THE "SAFETY MANUAL" vented from getting into the system.
During all works on the system (filling, re-
placing parts, etc.) make sure that the work is
SCHWING machines can be equipped with a carried out in absolutely clean conditions.
central lubricating system as an option.
The electrically driven piston pump, the reser- FILLING THE SYSTEM
voir and the electronic control unit form a com-
plete system (Fig. 1). Check the grease filling level in the reservoir
every day.
This system ensures the lubrication of the
greasing points on the machine via greasing The level must not fall below mark 2 (Fig. 1).
distributors and greasing lines.
If necessary, top up grease using a high-
The optimum amounts and greasing intervals pressure grease pump and filling nipple 1.
are adjusted at the factory.
Depending on the machine type, the grease
If you would like to have your lubricating system reservoir can also be filled in an easier way via
adapted to special operating conditions, please an external filling nipple.
consult the SCHWING after-sales service who
will be pleased to do the reprogramming of the – Clean the filling nipple and the nozzle of the
system for you. grease gun.
After activation of the "Concrete pump pump- – Fill in clean grease. Dirty grease in the
ing" function, the system starts up automatic- system will cause malfunctions.
ally.
After switching off this function, the greasing

cycle is interrupted and restarted when the
pump is switched on the next time.
This means that a greasing cycle always begins

with the "Residual greasing time" or the "Resi-
dual pause time".
Data stored in the system are protected even in

the event of a power failure.
With the grease prescribed for our machines,

the lubricating system can be operated down to
ca. -25 °C.
Fig. 1
002.078.05-en
4.80-2
– Start an intermediate greasing cycle during – If you find defects during this inspection,
the filling procedure by depressing pushbut- have the system immediately repaired by the
ton 3. SCHWING after-sales service to avoid con-
sequential damage caused by insufficient
After depressing this pushbutton, the piston greasing.
pump will be switched on for a complete
greasing cycle (4 minutes).
LUBRICATING POINTS NOT CON-
– Use a type of grease as indicated in our lu- NECTED TO THE CENTRAL
bricant recommendations (chapter 4.4): GREASING SYSTEM
The bearings of the pump drive car-
(KP 2 K in acc. with DIN 51502 without solid dan shafts cannot be connected to the
lubricant, NLGI class 2). central greasing system.
These lubricating points must there-
fore be greased "by hand" in accord-
ATTENTION:
ance with the servicing schedule.
DO NOT MIX UP GREASE TYPES
Other lubricating points not connected
Central lubricating systems for trucks
to the central greasing system at the
often use another type of grease.
customer's request must also be
If your truck is equipped with such a greased "by hand".
system, do not mix up the greases.
If wrong grease has been filled in, the
whole system (also the lines and the
distributors) must be emptied. 5-SECTION PLACING BOOMS
Truck-mounted concrete pumps with 5-section

If the system has been emptied, it must be placing boom must be equipped with two greas-
vented after refilling. ing systems if the boom and the concrete pump
are to be supplied with grease.
To do so, carry out intermediate greasing cy-
cles until grease emerges from all greasing One system is then designated for greasing the
points. concrete pump and the other for greasing the
placing boom.
This procedure is not recommended when
greasing lines have been replaced. In this case,
prefilled greasing lines must be used.
CHECKING THE SYSTEM
– Check the line system every day (visual in-

spection) for leaks and apparent damage.
– Check the bearings connected to the system

every day (visual inspection).
– The bearings must always present distinct

traces of grease.
002.078.05-en
RADIO-REMOTE-
CONTROLS 5
TI 51(GB)
3.26-4
REMOTE-CONTROL UNITS FW 26 / FW 28
At the beginning of 2008 SCHWING begins to

introduce the new remote-control system FW
28 for its truck-mounted concrete pumps.
This unit will then at first replace all FW 26 con-

trol units without and with 2 joysticks.
The additional control movements required for

4- and 5-section booms are implemented in the
FW 28 system by means of rotary functions for
the joysticks.
As an option, the FW 28 can be supplied with a

feedback system permitting to display machine
data on a screen on the transmitter.
Since the FW 28 cable remote control is in-

tended for emergency operations, this unit is
supplied without display.
If a remote-control unit with 3 joysticks is de-

sired, we continue for the time being to supply
the FW 26.
On the following pages you will find the operat-

ing instructions for the FW 26 and the FW 28.
Please check the type rating plates to find out

with which system your machine is equipped.
004.708.00-en
TELETEC FW 28
Operating instructions
Publisher: SCHWING GmbH

Abt.: TNS 2
RADIO REMOTE-CONTROL
Postfach : 20 03 62
D - 44647 Herne
08.04.08 15:33 FW 28
Id.-No.: 98322379
All rights reserved. - No part of this manual may be reproduced without permission from the publishers.
004.696.00-en
TELETEC FW 28
SCOPE OF APPLICATION
These operating instructions are applicable to all models of the FW 28 radio remote-control as they
are supplied with SCHWING truck-mounted concrete pumps that are equipped with „VECTOR-
Control" systems.
They do not contain any information about particular machines, but are rather intended to supplement
the machine operating manual.
MANUFACTURER
FW 28 radio remote-control units are manufactured for SCHWING by:
TELETEC GmbH
Paul-Lincke-Ufer 39/40
D - 10999 Berlin
+49 (0) 30 - 612 40 45

FAX +49 (0) 30 - 611 50 39
004.696.00-en
TELETEC FW 28
CONTENTS
1. DECLARATION OF CONFORMITY AND REGISTRATION
2. SAFETY INSTRUCTIONS
3. MONITORING, WARNING AND CONTROL ELEMENTS
4. COMMISSIONING
5. OPERATION
SELECTING THE BOOM SPEED
CHANGING THE RADIO CHANNEL
6. INTERRUPTIONS OF THE WORK
EMERGENCY STOP
ENGINE ON / OFF
END OF OPERATION
7. RADIO REMOTE-CONTROL WITH DATA FEEDBACK
DISPLAY OF FEEDBACK DATA
DATA FEEDBACK PROBLEMS
8. REPLACING, CHARGING AND DISCHARGING THE BATTERY
SERVICING
CLEANING
DISPOSAL
9. MALFUNCTIONS
OPERATION AND FAULT INDICATORS
10. CABLE REMOTE-CONTROL (OPTION)
004.697.00-en
TELETEC FW 28 1.1
DECLARATION OF CONFORMITY REGISTRATION (NOTIFICATION)
Radio-communication equipment used in the Registration in the countries of the community

countries of the European Economic Area must is effected by the respective manufacturer of
conform to the jointly accepted directives of this the radio equipment, in this case by TELETEC.
area.
In these countries, no further registration is re-
The system manufacturer (TELETEC) confirms quired and the use of the equipment is exempt
the conformity of his equipment by drawing up from charges.
corresponding declarations of conformity.
Equipment items are marked with the following

sign on the identification plate:
fw252
The following declarations of conformity have

been issued for the FW 28:
– Transmitter functional radio check
– Transmitter electromagnetic compatibility
– Receiver functional radio check
– Receiver electromagnetic compatibility
– Cable remote-control electromagnetic com-
patibility
See page 1.2 to 1.10.
The declarations of conformity are issued in the

European languages, but only in English by the
designated body.
They are part of the present operating instruc-

tions.
The operating instructions must be kept at the

place of use of the radio-communication equip-
ment.
The above-mentioned pages of the operating

instructions must be submitted on request to
the supervising personnel for inspection.
004.698.00-en
TELETEC FW 28 1.2
28ko12
TELETEC FW 28 1.3
28ko13
TELETEC FW 28 1.4
28ko14
TELETEC FW 28 1.5-1
28ko15
TELETEC FW 28 1.5-2
28ko15
TELETEC FW 28 1.6
28ko16
TELETEC FW 28 1.7
28ko17
TELETEC FW 28 1.8
28ko18
TELETEC FW 28 1.9-1
28ko19
TELETEC FW 28 1.9-2
28ko19
TELETEC FW 28 1.10-1
28ko110
TELETEC FW 28 1.10-2
28ko110
TELETEC FW 28 2.1
SAFETY INSTRUCTIONS
Please read these operating instructions com- Repair work on the remote-control unit may
pletely before putting your TELETEC remote- only be performed by TELETEC or by qualified
control into operation. personnel duly authorized by TELETEC.
Observe also the corresponding working safety Non-observance of the safety instructions will
and accident prevention regulations. discharge TELETEC and SCHWING from any
and all of their warranty and liability obligations.
The instructions relating to the operation of the
machine itself are contained in the machine
manual. ATTENTION: DANGER
Remote-control units may only be used by duly - Use only ORIGINAL rechargeable
authorized persons after they have been in- batteries from SCHWING:
structed by a specialist.
Unsuitable rechargeable batteries
Do not put the operational transmitter aside, but may damage the system.
always protect it against unauthorized use by
locking it away. - Do not use chargers from other
manufacturers:
The remote-control may only be used for
puposes complying with its designated use, i.e. The battery may explode.
only for controlling the machine or plant for
which it is designated. - Never open rechargeable batteries:
Any other use is forbidden. The toxic substances contained in

rechargeable batteries are a severe
Using the device for purposes other than its health risk.
designated use, faulty operation, insufficient
maintenance and unauthorized repairs of the - Old rechargeable batteries must be
remote-control unit may cause severe material disposed of in compliance with the
damage and injury to persons. pertaining regulations by a disposal
company.
In the event of malfunctions or defects of
the remote-control unit depress immediately
the red EMERGENCY SHUT-OFF button,
Ambient temperature:
switch the transmitter off and keep it in a
safe place. The FW 28 can be used at ambient temper-
atures between approximately -20 °C to 60 °C.
ATTENTION: At temperatures below 10 °C,

charging of the rechargeable battery may cause
problems.
Please heat the cab or use a separate charger,

if possible at an ambient temperature of 20 °C.
004.699.00-en
TELETEC FW 28 3.1

ELEMENTS
Depending on the type of machine, the trans-

mitter control panels may have a different lay- 4-
out. Switch: Transmitter on
(channel HF 1 or HF 2)
These operating instructions describe only
those functions that are necessary for radio
operation.
5-
They do not contain any information about a Switch: Boom speed
particular type of machine. slow -0- fast
Such information can be found in the operating

manual of the corresponding machine.
6- Momentary-contact switch:
horn -0- control enable /
TRANSMITTER (Fig. 1+2)
acknowledge fault message
LED, red: battery charge re- 7*- Display for monitoring certain machine
1-
quired states
2- LED, green: transmitting

8*- Side button, left: display backlighting
LED, red: EMERGENCY 9*- Side button, right: display select
3-
SHUT-OFF
Note: LED's 1, 2 and 3 are multi-functional * = option, see chapter 7.

indicators. Description see chapter 9.
004.700.00-en
TELETEC FW 28 3.2
RECEIVER
1- Connecting cable to switch cabinet of

the VECTOR control
2- Antenna cable
3- Charging bay for transmitter battery
4- LED, green:
Radio link established
5- LED, red:
Radio link interrupted or EMERGENCY
STOP pressed
Fig. 2
6- LED, green:
Battery being charged in charger
7- LED, yellow:
Battery being discharged in charger
8- Push-button:
Start battery discharge cycle in charger
Fig. 3
Fig. 1
004.700.00-en
TELETEC FW 28 4.1
COMMISSIONING
Transmitter and receiver are each equipped

with an identification plate.
The serial numbers and frequencies indicated

on these plates must be identical. Radio op-
eration is otherwise not possible.
To commission the units, proceed as follows:
1. SWITCHING ON THE RECEIVER
– Make sure cable connector 8 (Fig. 1) of the

radio receiver is plugged into the corre-
sponding socket on the control cabinet of the
machine.
– Switch on the machine control and install the

machine as described in the operating man-
ual of the truck-mounted concrete pump.
– Set switch 3 to 'Remote-control'.
The red "STOP" LED 5 (Fig. 3) of the re-

ceiver is lit up.
This means that the receiver is ready, but

still in the EMERGENCY STOP condition. Fig. 2
Fig. 3
Fig. 1
004.701.00-en
TELETEC FW 28 4.2
2. SWITCHING ON THE TRANSMITTER
– Insert the fully charged battery into the trans-

mitter and lock the battery case.
Set the slots in the lock-screws to horizontal

position and lock with a slight pressure, do
not turn the screws (Fig. 1).
Fig. 1
Observe the correct polarity. The transmitter
can otherwise not be put into operation.
– Set all switches on the transmitter to position

'0' and unlock all EMERGENCY SHUT-OFF
buttons (also those on the machine).

operation.
Important:
of all EMERGENCY SHUT-OFF buttons and
that of the switches of the active control. Fig. 2
The display 1 (Fig. 2) informs the operator
accordingly.
004.701.00-en
TELETEC FW 28 4.3
– Switch on the transmitter

(Fig. 1) with switch 4 by setting
it to position 'HF 1' or 'HF 2'
(channel selection):
The transmitter will then per-
form a self-test which lasts ap-
proximately 2 s. During the test,
LEDs 1 to 3 (Fig. 1+2) will light
up in a fast sequence.
Thereafter, the red LED 3

flashes requesting the operator Fig. 1
to perform the emergency-stop
test.
3. EMERGENCY SHUT-OFF TEST
– Depress the EMERGENCY SHUT-OFF but-

ton:
Fig. 2
– Release (unlock) the EMERGENCY SHUT-
OFF button.
The red LED 3 is now off and the green

LED 2 is lit up.
4. STARTING UP THE REMOTE CONTROL
When the system is ready, this

symbol flashes on the 'Vector'
control display (Fig. 3).
Fig. 3
– Set momentary-contact switch
6 on the transmitter briefly to:
.

shows (Fig. 3) 'OK'.
The transmitter is now ready for operation and

in its basic operating state:
LED 2 is lit up, 1+3 are off.
004.701.00-en
TELETEC FW 28 4.4
The green 4 on the receiver is lit up (Fig. 1).
The radio link is ready. Continue with chapter 4.
MALFUNCTIONS
Malfunctions are signalled by LEDs 1+3 on the

Fig. 1
transmitter control panel (Fig. 2).
When the radio link is interrupted, the red LED

'STOP' 5 of the receiver is lit up, too.
For more information see chapter 9.
Fig. 2
Important:
The VECTOR control signals various faults
acoustically and visually on the display 1
(Fig. 3).
In case of the FW 28 with feedback function
(optional), the transmitter signals a fault as
well.
See chapter 7.
Fig. 3
004.701.00-en
TELETEC FW 28 5.1
OPERATION
When the remote-control unit is ready for op- Important:

eration, all functions of the concrete pump im-
plemented in the control unit can be controlled Various faults are signalled by the VECTOR
from a distance. control acoustically and visually on the dis-
play 1 (Fig. 4).
When a control lever is operated, the green In case of the FW 28 with feedback function
LED 2 starts flashing to indicate that control (optional), the transmitter signals a fault as
commands are being transmitted. well.
See chapter 7.
The selected functions are executed.
When all control levers are set back to neutral

position, the transmitter goes back to standby. Fig. 1
LED 2 is permanently lit.
MALFUNCTIONS
Malfunctions are indicated by LEDs 1+3 on the

transmitter control panel.
Fig. 2
When the radio link is interrupted (or
EMERGENCY SHUT-OFF on transmitter
pressed), the red LED 5 "STOP" of the re-
ceiver is on in addtion (Fig. 1).
For details refer to chapter 9.
004.702.00-en
TELETEC FW 28 5.2
SELECTING THE BOOM SPEED The control levers must be back in position '0'
before the desired movements can be made.
The control of the boom functions must be acti-
vated with switch 5. When switch 5 is in neutral position, all func-
tions can be operated except for the boom
functions.
This is important when the placing boom
feeds a fixed pumping line and must there-
fore be prevented from being inadvertently
moved.
In center position "0" all boom functions are If transmission on the radio channel in use is
deactivated. disturbed (incomplete or no execution of com-
mand signals), the channel can be changed
When the control levers are actuated, the red from "HF1" to "HF2" and vice versa with switch
LED 3 lights up to indicate that the boom can- 4.
not be moved.
To activate the boom functions, select either the

"snail" or the "hare" position of the switch: Switch 4 selects another radio channel.
"Snail" = slow (0 - 50% of full speed) is the posi- After changing the channel, the transmitter
tion for normal working operations. must be restarted as described in chapter 4.
"Hare" = fast (0 - 100% of full speed) is the posi- The receiver is automatically tuned to the new
tion intended for setting up the placing boom. channel.
Important: If radio transmission disturbances persist or if

If switch 5 is moved out of position '0' while a the unit is defective, the control unit is auto-
boom control lever is being actuated, the cor- matically switched to the protected EMER-
responding movement is not executed. GENCY STOP mode.
There is also no movement, if the operator
switches over from the 'snail' to the 'hare'
function and vice versa while the boom con-
trol levers are being actuated.
004.702.00-en
TELETEC FW 28 6.1
INTERRUPTIONS OF THE WORK EMERGENCY SHUT-OFF
Depressing an emergency shut-off button stops

ATTENTION: DANGER the most important machine functions immedia-
Do not lay the activated transmitter tely.
aside, but always switch it off and lock
it away. In addition, the VECTOR control can also shut
off the drive engine.

– To stop individual functions, set the corre-
vehicle electronics and the approval of the en-
sponding switch on the control panel to posi-
gine manufacturer.
tion '0'.
– To switch off the transmitter in normal op-
cases of emergency, especially if your ma-
eration, set switch 4 (e.g. Fig. 1) to position
chine is equipped with the above-mentioned
'0'.
engine shut-off function.
Under normal operating conditions, always stop

the machine functions and the engine with the
control elements provided for this purpose.
Do not depress the EMERGENCY SHUT-OFF

button for interruptions of the work. The trans-
mitter continues to transmit the emergency
shut-off signal until the battery is empty.
To go back into operation, the transmitter must

be restarted as described in chapter 4.
Fig. 1
Important:
If the transmitter is switched off while switch 3
(Fig. 2) is in the "Remote-control" position,
the system switches automatically into the
protected EMERGENCY SHUT-OFF state.
If this is not desired, the control must be
switched over beforehand, e.g. to 'LOCAL'.
Fig. 2
004.703.00-en
TELETEC FW 28 6.2
RESTARTING AFTER EMERGENCY SHUT- END OF OPERATION

OFF
– Switch off the transmitter with the switch
– Rectify the fault. „POWER“.
– Set all latched switches of the active control

to position "0" (center position) and unlock
the previously pressed EMERGENCY SHUT-
OFF button.
Restarting is otherwise not possible.
– Start up the control unit.
The restart protection prevents restarting of the

– Lock up the transmitter in the driver's cab if it
machine functions by simple unlocking of the
is no longer needed.
pressed EMERGENCY SHUT-OFF button.
The control system monitors the positions of the – Stow away the transmitter safely to pre-
EMERGENCY SHUT-OFF buttons and of the vent uncontrolled transmissions.
switches on the active control box.
Always assure yourself that your trans-
A corresponding info is displayed on the screen mitter is in a safe place before setting off.
of the VECTOR control (Fig. 1).
– Switch off the P.T.O.
ENGINE START / STOP – Switch off the machine control with the
switch in the cab.
the engine can only be started when all
switches are in neutral position (position '0').

avoided.

Fig. 1
Important:
transmitter (emergency shut-off pressed, trans-
mitter off) at the switch cabinet of the VEC-
TOR control (Fig. 1), the system is automati-
cally switched into the protected EMERGEN-
CY SHUT-OFF state.
004.703.00-en
TELETEC FW 28 7.1
RADIO REMOTE-CONTROL WITH DATA

FEEDBACK
The optional feedback function of the FW 28

radio remote-control unit shows current ma-
chine data on a display screen on the remote-
control transmitter.
Important information from the VECTOR con-

trol system can thus be made available to the
operator standing at a distance from the ma-
chine.
The data are displayed on a display screen

(with backlighting, if needed) 7 (Fig. 1) which is
provided on the transmitter control panel. Fig. 1
The transmitter is moreover equipped with a

beeper which draws the operator's attention to
certain machine conditions or faults. See the
description of the VECTOR control.
DISPLAY BACKLIGHTING
The left-hand side button 8 (Fig. 1) can be

used for switching on the display backlighting
for 30 seconds.
If the light is switched on three times in suc- Fig. 2

cession within a short time, the system acti-
vates an "enforced suspension period" of one
minute to avoid unnecessary battery dis-
charge.
DISPLAY OF FEEDBACK DATA
Basic screen
When the transmitter is put into operation with

the receiver being on, the first screen to be
displayed is the basic screen (Fig. 2). The ba-
sic screen is subdivided into several display
areas. See next page.
004.704.00-en
TELETEC FW 28 7.2
I1 S1 S2 I2 Areas:
I1 charge condition of recharge-

able transmitter battery
I2 receiver signal strength
S1 control system status
S2 mode of operation
D 1+2 machine data with symbols

D1 D2
I 1: The bargraph in area I1 at the left margin is The information displayed in D1 and D2 is se-
a measure of the charge condition of the lected automatically by the control system de-
rechargeable transmitter battery. The pending on the control operation performed by
shorter the bar the lower the remaining the operator.
battery charge.
With button 9 (Fig. 2) controlling the display
I 2: The bargraph in area I2 at the right margin scrolling function, the operator can, however,
is a measure of the field strength pro- also select the information himself.
duced in the receiver by the transmitter
signal. The longer the bar the stronger the
signal in the receiver (for instance, when
the operator is standing closer to the
pump).
S 1: Status area S1 shows the control system

status. The information displayed is the
same as that appearing on the screen of
the VECTOR control cabinet. The exam-
ple above shows the ready-for-operation
state of the system.
S 2: The selected mode of operation is shown

in display area S2 In this case, the "RE- Fig. 2
MOTE" mode of operation has been se-
lected.
D 1 + D 2:
The data areas D1 and D2 at the lower
margin of the screen display current ma-
chine data together with the pertaining
symbols (pictograms). The example above
shows the engine speed display on the left
and the oil temperature display on the
right.
004.704.00-en
TELETEC FW 28 7.3
I1 Additional text Fault symbol I 2
Fault code
control. The code is displayed in white on a

Fault messages dark background.
In the event of faults, the screen will always

change automatically from the basic screen to
the fault screen which has always priority. The
fault screen is also subdivided into several
areas:
I1 + I2
The two bargraph displays I1 and I2 for battery

charge and received signal strength have the
same function as in the basic screen.
Fault symbol
The "Fault symbol" area on the right displays

the symbol (pictogram) pertaining to the de-
tected fault. See the description of the VEC-
TOR control.
Additional text
With certain faults, the additional text is dis-

played to provide the operator with more de-
tailed information.
Fault code
Together with each fault, a fault code is dis-

played. See the description of the VECTOR
004.704.00-en
TELETEC FW 28 7.4
The display scroll button 9 (Fig. 2) can also be

used with automatically displayed fault mes-
sages for switching over between the fault
display and the different data areas D1 and D2
(see previous page).
This is useful for taking a closer look at the

fault cause and can be achieved by pressing
the button repeatedly.
Fig. 2
004.704.00-en
TELETEC FW 28 7.5
DATA FEEDBACK PROBLEMS
If the radio link ensuring the transmission of

feedback data is not available or disturbed, the
screen shown in Fig. 1 with the crossed-out
antenna symbol is displayed on the transmitter.
This has absolutely no effect on the possibility

of continuing the remote-controlled operation
of the machine as the remote-control system
uses another independent radio link.
Fig. 1
If the data feedback system gets no data from

the VECTOR control in spite of a perfectly work-
ing radio link, the screen of Fig. 2 showing a
cross in a rectangle is displayed on the
transmitter.
Fig. 2
004.704.00-en
TELETEC FW 28 8.1
REPLACING, CHARGING AND DISCHAR-

GING THE BATTERY
Removal and insertion of the battery is the sa- After replacing, restart the transmitter as de-
me for transmitter and charger: scribed in chapter 4.
REMOVING THE BATTERY Insert the empty battery for recharging into the
charging bay 3 (Fig. 1) of the receiver and lock
– Turn the slots of the lock-screws to vertical up as described above.
position by pressing slightly on the screw. Do
not turn the screw. The green LED 6 ("Charge") on the receiver
panel (Fig. 2) lights up.
When the rechargeable battery is full after 3

hours max., this LED starts flashing. The bat-
tery charger switches over to trickle charge.
The battery can now either be removed from or

INSERTING THE BATTERY left in the charging bay.
– To lock the battery, turn the slots of the lock- In both ways, the battery will retain its full
screws to horizontzal position by pressing charge.
slightly on the screw. Do not turn the screw.
If you insert the battery by mistake (+ and –
terminals marked on the housing) with wrong
polarity into the charging bay, the green LED 6
('Charge') remains off.
In this case, withdraw the battery and re-insert

correctly.
Observe the polarity. The transmitter cannot be
put into operation if the polarity is incorrect.
CHARGING THE BATTERY
When the red LED 1 (battery) of the transmitter

starts to blink during normal operation, the bat-
tery is almost empty.
Fig. 1
Ca. 10 to 20 minutes later the transmitter will

shut off automatically.
During this time, shut off the transmitter and

replace the empty battery by a new one.
Fig. 2
004.705.00-en
TELETEC FW 28 8.2
DISCHARGING THE BATTERY MAINTENANCE
To ensure full capacity of the rechargeable The FW 26 radio remote-control unit is largely
battery for a long time, it is absolutely indis- maintenance-free.
pensable to discharge the battery completely
once every week before it is being recharged. You should nevertheless make sure that
For this purpose, your charger is equipped with
an automatic function: – damaged rubber bellows at the switches are
immediately replaced,
Proceed as follows:
– proper functioning of all control elements is
– If a battery is in the charging bay, remove it. checked at regular intervals,
With a battery in the bay, discharging cannot
be started. – all cables are disconnected from the receiver
before electric welding is performed on the
– Depress push-button 8 (Fig. 1). concrete pump.
The yellow LED (7) flashes. There is otherwise a risk of damage to elec-
tronic components.
– You have now 10 seconds to insert a battery
into the bay and to lock it in place.
The yellow LED (7) now flashes continuously

(discharging).
When the battery is completely discharged, the

charger switches automatically to "Charging"
and later to "Trickle charge".
Fig. 1
The green LED (6) lights up and flashes after
switching over to trickle charging.
ATTENTION: DANGER
– Use only ORIGINAL rechargeable
batteries from SCHWING:
may damage the system.
– Do not use chargers from other ma-
nufacturers:
The battery may explode.
– Never open rechargeable batteries:
The toxic substances contained in
health risk.
004.705.00-en
TELETEC FW 28 8.3
CLEANING
– Clean the equipment from outside with a wet

cloth. Do not open the housing.
If needed, add some washing-up liquid to the

water.
Dry with a soft cloth.
– Do not clean the equipment with a water jet,

do no immerse in water or hold under run-
ning water.
– Do not use spray oil, petrol, diesel fuel or

other detergents, except water and washing-
up liquid:
Risk of swelling for rubber bellows.
DISPOSAL
– Old rechargeable batteries must be disposed

of in compliance with the pertaining regula-
tions by a disposal company.
Batteries must not be disposed of with nor-

mal waste.
004.705.00-en
TELETEC FW 28 9.1
The light-emitting diodes indicate different operational states and malfunctions.
= ON =OFF = FLASHING
1. TRANSMITTER
START-UP / OPERATION
LED MESSAGE ACTION
STOP
Transmitter not in operation Slide rechargeable battery into the trans-

mitter observing the correct polarity and
switch on the transmitter (HF 1 or HF 2
Self-test (duration ca. 2 s after switch- While the self-test is running, the LEDs are
on) switched on an off continuously in succes-
sion from left to right
Transmitter is on; EMERGENCY STOP Press EMERGENCY-STOP button and

test required release
No function after EMERGENCY SHUT-

OFF test: Depress the switch.
enable required.
Enable accepted, transmitter ready for Start working
operation, no function activated (basic
position)
Enable not accepted, restart protection Set all switches to "0" position
active
One or more functions activated, Machine executes control commands

transmitter sending data
004.706.00-en
TELETEC FW 28 9.2
MALFUNCTIONS
LED MESSAGE ACTION
STOP
Boom functions de-actived, "STOP"

lamp lights up when joystick is moved
select or
EMERGENCY SHUT-OFF button actu- Set all switches to "0" position, unlock
ated EMERGENCY SHUT-OFF
Warning: battery nearly empty. Remain- Replace battery

ing operating time abt. 10 to 20 minutes.
Battery empty. No data transmission Replace battery

possible. Machine functions de-
activated.
Transmitter defective Repair by authorized personnel only
004.706.00-en
TELETEC FW 28 9.3
2. RECEIVER
LED MESSAGE ACTION
STOP
Radio control receiver not in op- Switch on radio control receiver,

eration set LOCAL/REMOTE switch to
REMOTE
Radio control receiver in operation No radio contact Switch on
(passive EMERGENCY STOP) transmitter; change radio channel;
change transmitter location
Radio link between transmitter and Radio contact between transmitter
receiver active and receiver has been established
Reception of valid control com- Radio receiver transmitting valid
mands in progress control commands to the machine
control system
Radio reception with EMER- Unlock emergency-stop button on
GENCY-STOP button pressed or transmitter; terminate EMER-
EMERGENCY STOP test not ter- GENCY-STOP test
minated
Battery charging in progress
Battery charge finished Remove battery or leave in charg-

ing bay (trickle charge)
Charger made ready for charging Slide battery within 10 seconds

with discharge button into charging bay and lock
Battery discharge in progress Charger switches automatically

over to charging when the battery
is completely discharged
004.706.00-en
TELETEC FW 28 10.1
CABLE REMOTE CONTROL (OPTION)
The operator panel layout of the optional cable

remote control is largely identical to the trans-
mitter panel.
The cable remote control (Fig. 1) is used where

radio operation is not possible.
Machine operation is the same as with the radio

remote control.
COMMISSIONING
Fig. 1
– Withdraw the connector of the receiver cable
8 (Fig. 2) and replace it by the connector of
the remote control cable.
The system is switched over to cable control.
– Unlock all emergency-stop buttons on the ma-

chine and on the remote-control.
Start-up is otherwise not possible.
– Set all latched selector switches on the remote-

control box to neutral position (0).
– Switch on the machine control and install the Fig. 2

machine as described in the concrete pump
– Set switch 3 (Fig. 2) to "Remote control"

.
Important:
of the EMERGENCY SHUT-OFF buttons of
the active control unit.
A corresponding message is displayed on the
screen (1).
004.707.00-en
TELETEC FW 28 10.2
– Switch on the cable remote con-

trol with switch 4 (Fig. 1):
"POWER ON"
When the system is ready, the sym-

bol on the left flashes on the screen
(Fig. 2).
Fig. 1
– Start the control with momentary
contact switch 6 (Fig. 1) on the
cable remote control panel.

the left is displayed on the screen
(Fig. 1).
Fig. 2
STATUS INDICATORS OF THE CABLE REMOTE CONTROL
STATUS ACTION
No supply voltage "POWER ON",

check cables and fuses.
"Rabbit" / "Snail" in "0" position and Select "Rabbit" or "Snail".
boom function activated.
Function selected. Transmission of control command.
"POWER ON" with switch activated. – Switch to "0",

– "POWER OFF"; then
– "POWER ON".
004.707.00-en
TELETEC FW 26
Operating instructions
Publisher: SCHWING GmbH

Abt.: VVW
RADIO REMOTE-CONTROL
Postfach : 20 03 62
D - 44647 Herne
02/10/2008 11:30:00 FW 26
Id.-No.: 10207104 (VECTOR)
All rights reserved. - No part of this manual may be reproduced without permission from the publishers.
004.141.00-en
TELETEC FW 26
SCOPE OF APPLICATION
These operating instructions are applicable to all models of the FW 26 radio remote-control as they
are supplied with SCHWING truck-mounted concrete pumps that are equipped with „VECTOR-
Control" systems.
They do not contain any information about particular machines, but are rather intended to supplement
the machine operating manual.
MANUFACTURER
FW 26 radio remote-control units are manufactured for SCHWING by:
TELETEC GmbH
Paul-Lincke-Ufer 39/40
D - 10999 Berlin
+49 (0) 30 - 612 40 45

FAX +49 (0) 30 - 611 50 39
004.141.00-en
TELETEC FW 26
CONTENTS
1. DECLARATION OF CONFORMITY AND REGISTRATION
2. SAFETY INSTRUCTIONS
3. MONITORING, WARNING AND CONTROL ELEMENTS
4. COMMISSIONING
5. OPERATION
SELECTING THE BOOM SPEED
6. INTERRUPTIONS OF THE WORK
EMERGENCY STOP
ENGINE ON / OFF
END OF OPERATION
7. REPLACING, CHARGING AND DISCHARGING THE BATTERY
SERVICING
CLEANING
DISPOSAL
8. MALFUNCTIONS
9. CABLE REMOTE CONTROL (OPTION)
004.142.00-en
TELETEC FW 26 1.1
DECLARATION OF CONFORMITY REGISTRATION (NOTIFICATION)
Radio-communication equipment used in the Registration in the countries of the community

countries of the European Economic Area must is effected by the respective manufacturer of
conform to the jointly accepted directives of this the radio equipment, in this case by TELETEC.
area.
In these countries, no further registration is re-
The system manufacturer (TELETEC) confirms quired and the use of the equipment is exempt
the conformity of his equipment by drawing up from charges.
corresponding declarations of conformity.
Equipment items are marked with the following

sign on the identification plate:
fw252
For the FW 26, the following declarations have

been issued:
Page Declaration of conformity

1.2 "Radio test"-transmitter
1.3 "Electromagnetic compatibility"
transmitter
1.4 "Radio test"- receiver
receiver
cable remote control
The declarations of conformity are established

only in the English language.
They are part of the present operating instruc-

tions.
The operating instructions must be kept at the

place of use of the radio-communication equip-
ment.
The above-mentioned pages of the operating

instructions must be submitted on request to
the supervising personnel for inspection.
004.143.00-en
TELETEC FW 26 1.2
kon1
TELETEC FW 26 1.3
kon2
TELETEC FW 26 1.4
kon3
TELETEC FW 26 1.5
kon4
TELETEC FW 26 1.6
kon5
TELETEC FW 26 1.7
kon6
TELETEC FW 26 1.7
kon6
TELETEC FW 26 1.8
kon7
TELETEC FW 26 1.8
kon7
TELETEC FW 26 2.1
SAFETY INSTRUCTIONS
Please read these operating instructions com- Repair work on the remote-control unit may
pletely before putting your TELETEC remote- only be performed by TELETEC or by qualified
control into operation. personnel duly authorized by TELETEC.
Observe also the corresponding working safety Non-observance of the safety instructions will
and accident prevention regulations. discharge TELETEC and SCHWING from any
and all of their warranty and liability obligations.
The instructions relating to the operation of the
machine itself are contained in the machine
manual. ATTENTION: DANGER
Remote-control units may only be used by duly - Use only ORIGINAL rechargeable
authorized persons after they have been in- batteries from SCHWING:
structed by a specialist.
Do not put the operational transmitter aside, but may damage the system.
always protect it against unauthorized use by
locking it away. - Do not use chargers from other
manufacturers:
The remote-control may only be used for pu-
poses complying with its designated use, i.e. The battery may explode.
only for controlling the machine or plant for
which it is designated. - Never open rechargeable batteries:
Any other use is forbidden. The toxic substances contained in

Using the device for purposes other than its health risk.
designated use, faulty operation, insufficient
maintenance and unauthorized repairs of the - Old rechargeable batteries must be
remote-control unit may cause severe material disposed of in compliance with the
damage and injury to persons. pertaining regulations by a disposal
company.
In the event of malfunctions or defects of
the remote-control unit depress immediately
the red EMERGENCY SHUT-OFF button,
Ambient temperature:
switch the transmitter off and keep it in a
safe place. The FW 26 can be used at ambient temper-
atures between approximately -20 °C to 55 °C.
ATTENTION: At temperatures below 10 °C,

charging of the rechargeable battery may cause
problems.
Please heat the cab or use a separate charger,

if possible at an ambient temperature of 20 °C.
004.144.00-en
TELETEC FW 26 3.1

ELEMENTS
Depending on the type of machine, the trans-

mitter control panels may have a different lay-
out.
These operating instructions describe only

those functions that are necessary for radio
operation.
They do not contain any information about a

particular type of machine.
Such information can be found in the operating

manual of the corresponding machine. FW 26: Ergonomie
Fig. 1
TRANSMITTER (Fig. 1+2)
LED, red: battery charge re-

1-
quired
2- LED, green: transmitting
LED, red: EMERGENCY

3-
SHUT-OFF
Note: LED's 1, 2 and 3 are multi-functional

indicators. Description see chapter 8. FW 26: Compakt
Fig. 2
4-
Switch: Transmitter on
(channel HF 1 or HF 2)
5-
Switch: Boom speed
slow -0- fast
6- Momentary-contact switch:
horn -0- control enable /
acknowledge fault message
004.145.00-en
TELETEC FW 26 3.2
RECEIVER
1- Connecting cable to switch cabinet of

the VECTOR control
2- Antenna cable
3- Charging bay for transmitter battery
4- LED, green:
Radio link established
5- LED, red:
Radio link interrupted or EMERGENCY
STOP pressed
Fig. 2
6- LED, green:
Battery being charged in charger
7- LED, yellow:
Battery being discharged in charger
8- Push-button:
Start battery discharge cycle in charger
Fig. 3
Fig. 1
004.145.00-en
TELETEC FW 26 4.1
COMMISSIONING
Transmitter and receiver are each equipped

with an identification plate.
The serial numbers and frequencies indicated

on these plates must be identical. Radio op-
eration is otherwise not possible.
To commission the units, proceed as follows:
1. SWITCHING ON THE RECEIVER
– Make sure cable connector 8 (Fig. 1) of the

radio receiver is plugged into the corre-
sponding socket on the control cabinet of the
machine.

machine as described in the operating man-
ual of the truck-mounted concrete pump.
– Set switch 3 to 'Remote-control'.
The red "STOP" LED 5 (Fig. 3) of the re-

ceiver is lit up.
This means that the receiver is ready, but

still in the EMERGENCY STOP condition. Fig. 2
Fig. 3
Fig. 1
004.146.00-en
TELETEC FW 26 4.2
2. SWITCHING ON THE TRANSMITTER
– Insert the fully charged battery into the trans-

mitter and lock the battery case.
Set the slots in the lock-screws to horizontal

position and lock with a slight pressure, do
not turn the screws (Fig. 1).
Fig. 1
Observe the correct polarity. The transmitter
can otherwise not be put into operation.
– Set all switches on the transmitter to position

'0' and unlock all EMERGENCY SHUT-OFF
buttons (also those on the machine).

operation.
Important:
of all EMERGENCY SHUT-OFF buttons and
that of the switches of the active control. Fig. 2
The display 1 (Fig. 2) informs the operator
accordingly.
004.146.00-en
TELETEC FW 26 4.3
– Switch on the transmitter (Fig. 1

or 2) with switch 4 by setting it
to position 'HF 1' or 'HF 2'
(channel selection):
The red LED 3 starts flashing
slowly (Fig. 3).
3. EMERGENCY SHUT-OFF TEST
– Depress the EMERGENCY SHUT-OFF but-

ton: Fig. 1
The red LED 3 nows flashes fast.
– Release (unlock) the EMERGENCY SHUT-

OFF button.
The red LED 3 is now off and the green LED

2 is lit up.
4. STARTING UP THE REMOTE CONTROL
When the system is ready, this

symbol flashes on the 'Vector' Fig. 2
control display (Fig. 4).
– Set momentary-contact switch

6 on the transmitter briefly to:
.
Fig. 3

shows (Fig. 4) 'OK'.
The transmitter is now ready for operation and

in its basic operating state:
LED 2 is lit up, 1+3 are off.
Fig. 4
004.146.00-en
TELETEC FW 26 4.4
The green 4 on the receiver is lit up (Fig. 1).
The radio link is ready. Continue with chapter 4.
MALFUNCTIONS
Malfunctions are signalled by LEDs 1+3 on the

transmitter control panel (Fig. 2 or 3).
Fig. 2
When the radio link is interrupted, the red LED

'STOP' 5 of the receiver is lit up, too.
For more information see chapter 8.
Important:
The VECTOR control signals various faults
acoustically and visually on the display 1
(Fig. 4). Fig. 3
Fig. 1
Fig. 4
004.146.00-en
TELETEC FW 26 5.1
OPERATION
When the remote-control unit is ready for op-

eration, all functions of the concrete pump im-
plemented in the control unit can be controlled
from a distance.
When a control lever is operated, the green

LED 2 starts flashing to indicate that control
commands are being transmitted.
Fig. 1
The selected functions are executed.
When all control levers are set back to neutral

position, the transmitter goes back to standby.
LED 2 is permanently lit.
MALFUNCTIONS Fig. 2
Malfunctions are indicated by LEDs 1+3 on the

transmitter control panel.
When the radio link is interrupted (or EMER-

GENCY SHUT-OFF on transmitter pressed),
the red LED 5 "STOP" of the receiver is on in
addtion (Fig. 1).
For details refer to chapter 8.
Important:
Various faults are signalled by the VECTOR
control acoustically and visually on the dis-
play 1 (Fig. 4).
004.147.00-en
TELETEC FW 26 5.2
SELECTING THE BOOM SPEED The control levers must be back in position '0'
before the desired movements can be made.
The control of the boom functions must be acti-
vated with switch 5. When switch 5 is in neutral position, all func-
tions can be operated except for the boom
functions.
This is important when the placing boom
feeds a fixed pumping line and must there-
fore be prevented from being inadvertently
moved.
In center position "0" all boom functions are If transmission on the radio channel in use is
deactivated. disturbed (incomplete or no execution of com-
mand signals), the channel can be changed
When the control levers are actuated, the red from "HF1" to "HF2" and vice versa with switch
LED 3 lights up to indicate that the boom can- 4.
not be moved.
To activate the boom functions, select either the

"snail" or the "hare" position of the switch: Switch 4 selects another radio channel.
"Snail" = slow (0 - 50% of full speed) is the posi- After changing the channel, the transmitter
tion for normal working operations. must be restarted as described in chapter 4.
"Hare" = fast (0 - 100% of full speed) is the posi- The receiver is automatically tuned to the new
tion intended for setting up the placing boom. channel.
Important: If radio transmission disturbances persist or if

If switch 5 is moved out of position '0' while a the unit is defective, the control unit is auto-
boom control lever is being actuated, the cor- matically switched to the protected EMER-
responding movement is not executed. GENCY STOP mode.
There is also no movement, if the operator
switches over from the 'snail' to the 'hare'
function and vice versa while the boom con-
trol levers are being actuated.
004.147.00-en
TELETEC FW 26 6.1
INTERRUPTIONS OF THE WORK EMERGENCY SHUT-OFF
Depressing an emergency shut-off button stops

ATTENTION: DANGER the most important machine functions immedi-
Do not lay the activated transmitter ately.
aside, but always switch it off and lock
it away. In addition, the VECTOR control can also shut
off the drive engine.

– To stop individual functions, set the corre-
vehicle electronics and the approval of the en-
sponding switch on the control panel to posi-
gine manufacturer.
tion '0'.
– To switch off the transmitter in normal opera-
cases of emergency, especially if your ma-
tion, set switch 4 (e.g. Fig. 1) to position '0'.
chine is equipped with the above-mentioned
engine shut-off function.
Under normal operating conditions, always stop

the machine functions and the engine with the
control elements provided for this purpose.
Do not depress the EMERGENCY SHUT-OFF

button for interruptions of the work. The trans-
mitter continues to transmit the emergency
shut-off signal until the battery is empty.
To go back into operation, the transmitter must

be restarted as described in chapter 4.
Important: Fig. 1
If the transmitter is switched off while switch 3
(Fig. 2) is in the "Remote-control" position,
the system switches automatically into the
protected EMERGENCY SHUT-OFF state.
If this is not desired, the control must be
switched over beforehand, e.g. to 'LOCAL'.
Fig. 2
004.148.00-en
TELETEC FW 26 6.2
RESTARTING AFTER EMERGENCY SHUT- END OF OPERATION

OFF
– Switch off the transmitter with the switch
– Rectify the fault. „POWER“.
– Set all latched switches of the active control

to position "0" (center position) and unlock
the previously pressed EMERGENCY SHUT-
OFF button.
Restarting is otherwise not possible.
– Start up the control unit.
The restart protection prevents restarting of the

– Lock up the transmitter in the driver's cab if it
machine functions by simple unlocking of the
is no longer needed.
pressed EMERGENCY SHUT-OFF button.
The control system monitors the positions of the – Stow away the transmitter safely to pre-
EMERGENCY SHUT-OFF buttons and of the vent uncontrolled transmissions.
switches on the active control box.
Always assure yourself that your trans-
A corresponding info is displayed on the screen mitter is in a safe place before setting off.
of the VECTOR control (Fig. 1).
– Switch off the P.T.O.
ENGINE START / STOP – Switch off the machine control with the
switch in the cab.
the engine can only be started when all
switches are in neutral position (position '0').

avoided.

Fig. 1
Important:
transmitter (emergency shut-off pressed, trans-
mitter off) at the switch cabinet of the VEC-
TOR control (Fig. 1), the system is automati-
cally switched into the protected EMER-
GENCY SHUT-OFF state.
004.148.00-en
TELETEC FW 26 7.1
REPLACING, CHARGING AND DISCHARG-

ING THE BATTERY
Removal and insertion of the battery is the After replacing, restart the transmitter as de-
same for transmitter and charger: scribed in chapter 4.
REMOVING THE BATTERY Insert the empty battery for recharging into the
charging bay 3 (Fig. 1) of the receiver and lock
– Turn the slots of the lock-screws to vertical up as described above.
position by pressing slightly on the screw. Do
not turn the screw. The green LED 6 ("Charge") on the receiver
panel (Fig. 2) lights up.
When the rechargeable battery is full after 3

hours max., this LED starts flashing. The bat-
tery charger switches over to trickle charge.
The battery can now either be removed from or

INSERTING THE BATTERY left in the charging bay.
– To lock the battery, turn the slots of the lock- In both ways, the battery will retain its full
screws to horizontzal position by pressing charge.
slightly on the screw. Do not turn the screw.
If you insert the battery by mistake (+ and –
terminals marked on the housing) with wrong
polarity into the charging bay, the green LED 6
('Charge') remains off.
In this case, withdraw the battery and re-insert

correctly.
Observe the polarity. The transmitter cannot be
put into operation if the polarity is incorrect.
CHARGING THE BATTERY
When the red LED 1 (battery) of the transmitter

starts to blink during normal operation, the bat-
tery is almost empty.
Fig. 1
Ca. 10 to 20 minutes later the transmitter will

shut off automatically.
During this time, shut off the transmitter and

replace the empty battery by a new one.
Fig. 2
004.149.00-en
TELETEC FW 26 7.2
DISCHARGING THE BATTERY MAINTENANCE
To ensure full capacity of the rechargeable bat- The FW 26 radio remote-control unit is largely
tery for a long time, it is absolutely indispensa- maintenance-free.
ble to discharge the battery completely once
every week before it is being recharged. For You should nevertheless make sure that
this purpose, your charger is equipped with an
automatic function: – damaged rubber bellows at the switches are
immediately replaced,
Proceed as follows:
– proper functioning of all control elements is
– If a battery is in the charging bay, remove it. checked at regular intervals,
With a battery in the bay, discharging cannot
be started. – all cables are disconnected from the receiver
before electric welding is performed on the
– Depress push-button 8 (Fig. 1). concrete pump.
The yellow LED (7) flashes. There is otherwise a risk of damage to elec-
tronic components.
– You have now 10 seconds to insert a battery
into the bay and to lock it in place.
The yellow LED (7) now flashes continuously

(discharging).
When the battery is completely discharged, the

charger switches automatically to "Charging"
and later to "Trickle charge".
Fig. 1
The green LED (6) lights up and flashes after
switching over to trickle charging.
ATTENTION: DANGER
– Use only ORIGINAL rechargeable
batteries from SCHWING:
may damage the system.
– Do not use chargers from other ma-
nufacturers:
The battery may explode.
– Never open rechargeable batteries:
The toxic substances contained in
health risk.
004.149.00-en
TELETEC FW 26 7.3
CLEANING
– Clean the equipment from outside with a wet

cloth. Do not open the housing.
If needed, add some washing-up liquid to the

water.
Dry with a soft cloth.
– Do not clean the equipment with a water jet,

do no immerse in water or hold under run-
ning water.
– Do not use spray oil, petrol, diesel fuel or

other detergents, except water and washing-
up liquid:
Risk of swelling for rubber bellows.
DISPOSAL
– Old rechargeable batteries must be disposed

of in compliance with the pertaining regula-
tions by a disposal company.
Batteries must not be disposed of with nor-

mal waste.
004.149.00-en
TELETEC FW 26 8.1
The light-emitting diodes indicate different operational states and malfunctions.
1. TRANSMITTER
START-UP / OPERATION
LED MESSAGE ACTION
transmitter activated, EMERGENCY depress EMERGENCY SHUT-OFF button

SHUT-OFF test required (LED flashing faster) and release
no function after EMERGENCY SHUT-

OFF test: depress the switch.
enable required.
enable accepted, transmitter ready for start working
operation, no function activated (basic
position)
enable not accepted, restart protection set all switches to "0" position
active
one or more functions activated, trans- machine executes control commands

mitter sending data
MALFUNCTIONS
LED MESSAGE ACTION
boom functions de-actived, "STOP"

lamp lights up when joystick is moved
select or
EMERGENCY SHUT-OFF button actu- set all switches to "0" position, unlock
ated EMERGENCY SHUT-OFF
Warning: battery nearly empty. Remain- replace battery

ing operating time abt. 10 to 20 minutes.
battery empty. No data transmission replace battery

possible. Machine functions de-
activated.
transmitter defective repair by authorized personnel only
004.150.00-en
TELETEC FW 26 8.2
2. RECEIVER
INFO ACTION
radio link ready not transmitting control

telegrams
receiving valid radio data machine executing control

telegrams commands
no reception or EMERGENCY start up transmitter; change

SHUT-OFF pressed frequency: change transmitter
location; if necessary, unlock
EMERGENCY SHUT-OFF
battery charging in progress
battery charged remove battery or leave in

charging bay (trickel charge)
charger in ready-to-discharge insert battery into charging

mode bay within 10 seconds and
lock
battery discharging in charger automatically

progress switched over to charging
when the battery is dis-
charged
004.150.00-en
TELETEC FW 26 9.1
CABLE REMOTE CONTROL (OPTION)
The operator panel layout of the optional cable

remote control is largely identical to the trans-
mitter panel.
The cable remote control (Fig. 1) is used where

radio operation is not possible.
Machine operation is the same as with the radio

remote control.
COMMISSIONING
Fig. 1
– Withdraw the connector of the receiver cable
8 (Fig. 2) and replace it by the connector of
the remote control cable.
The system is switched over to cable control.

machine as described in the concrete pump
– Set all latched switches on the remote con-

trol to neutral paosition (0) an unlock all
emergency shut-off buttons.
Commissioning is otherwise not possi-

ble. Fig. 2
– Set switch 3 (Fig. 2) to "Remote control"

.
Important:
of the EMERGENCY SHUT-OFF buttons of
the active control unit.
A corresponding message is displayed on the
screen (1).
004.151.00-en
TELETEC FW 26 9.2
– Switch on the cable remote con-

trol with switch 4 (Fig. 1):
"POWER ON"
When the system is ready, the sym-

bol on the left flashes on the screen
(Fig. 2).
– Start the control with momentary Fig. 1

contact switch 6 (Fig. 1) on the
cable remote control panel.

the left is displayed on the screen
(Fig. 1).
Fig. 2
STATUS INDICATORS OF THE CABLE REMOTE CONTROL
STATUS ACTION
No supply voltage "POWER ON",

check cables and fuses.
"Rabbit" / "Snail" in "0" position and Select "Rabbit" or "Snail".
boom function activated.
Function selected. Transmission of control command.
"POWER ON" with switch activated. – Switch to "0",

– "POWER OFF"; then
– "POWER ON".
004.151.00-en

Manual Operation S32-S34X

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Operating Instructions

Editor: Schwing Equipamentos

All rights reserved.

The relief valve in the accumulator block opens

OPERATING INSTRUCTIONS: STRUCTURE

MAIN SECTIONS TEXT LAYOUT

CHAPTERS ATTENTION - DANGER!

1............. = main section

A code number for internal text processing (e.g.

IMPORTANT TERMS MODIFICATIONS

Important modifications to the series status of

During normal working operation, the control

Control elements must not be used for normal

The illustrations in the operating instructions are

They may deviate from the specific machine

TABLE OF CONTENTS - PART 1

1.1 TABLE OF CONTENTS

NON-VALIDITY OF THE DECLARATION OF CONFORMITY

1.3 MACHINE CHARACTERISTICS

1.4 TECHNICAL DATA

1.5 MACHINE DESCRIPTION

1.7 CONTROL, WARNING AND MONITORING ELEMENTS

1.8 CONTROL SYSTEM

The operating instructions shall assist you in

- running it safely to prevent accidents, D - 44647 Herne

- applying it to the purpose and economically to Telephone : +49 2325 987-0

Any handling of the machine implies knowl- - WARRANTY

During operation it would be too late to do so.

Always quote the model and the serial num-

OTHER OPERATING MANUALS DECLARATION OF CONFORMITY

Special operating manuals are sometimes also

As the information supplied in these docu-

Truck-mounted concrete pump type designa- CE-SIGN

34 R The CE sign is attached to the chassis of the

R....... = roll-and-fold system

P...................... = (concrete) pump

20.................. = 2000 mm stroke of pump-

23.............. = ∅ 230 mm of pumping

- 110.... = ∅ 110 mm of pistons in

/75 = ∅ 75 mm of piston rods of

For better identification, the designation can be

Identification plates see next page.

The concrete pump identification plate is at-

The placing boom identification plate is at-

The pumping line identification plate is attached

SCHWING machine data Vehicle data

Machine no.: Manufacturer:

Please always state these data when writing to us.

Besides the correct pump unit designation, the

max 60 / 108 bar Beton

This concrete pump may be driven by rod-side

Changing of the hydraulic connections is per-

TECHNICAL SPECIFICATIONS FOR TRUCK-MOUNTED CONCRETE PUMPS

(see table next page)

KSB = piston-side admission

SSB = rod-side admission

Column 1 : type of concrete pump, see example page 1.3-1

Column 2 : maximum pumping rate of hydraulic pump(s) in l/min

Column 3 : maximum hydraulic oil pressure (pressure cut-off setting) in bars

Column 4 : maximum theoretical concrete pumping rate in m³/hour