Concrete

Pump
Used With Remote
Attachment Control
Service
Manual

Dealer Copy -- Not for Resale

S/N 235400101 & Above

6903713 (12-07) Printed in U.S.A. © Bobcat Company 2007

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2 of 143
Dealer Copy -- Not for Resale
 MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.

CORRECT

Dealer Copy -- Not for Resale

B-10731a

Never service attachments without instructions. See

Operation & Maintenance Manual and Attachment Service
Manual.

Cleaning and maintenance are required daily.

Never service or adjust attachment with the engine running

unless instructed to do so in manual.

Always lower the attachment to the ground before

lubricating or servicing.

Avoid contact with leaking hydraulic fluid or diesel fuel

under pressure. It can penetrate skin or eyes.

Stop, cool and clean engine of flammable materials before

checking fluids.

Keep body, loose objects and clothing away from moving

parts, electrical contacts, hot parts and exhaust.

Safety glasses are needed for eye protection from electrical

arcs. battery acid, compressed springs, fluids under
pressure and flying debris or when tools are used. Use eye
protection approved for type of welding.

MSW30-0805

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4 of 143
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 ALPHABETICAL INDEX

AGITATOR ........................................................... 30-60-1

AGITATOR CONTROL VALVE..............................20-11-1
AGITATOR HYDRAULIC MOTOR ....................... 20-50-1
ATTACHMENT DELIVERY REPORT ........................... III

CONCRETE TUBES ........................................... 30-20-1

GLOSSARY OF HYDRAULIC SYMBOLS FOR

ATTACHMENTS............................................. SPEC-40-1

HOPPER .............................................................. 30-70-1

HOPPER CLEAN-OUT ........................................ 30-90-1

INSPECTION ....................................................... 10-20-1

IDENTIFICATION.......................................................... IV

LUBRICATION ..................................................... 10-30-1

OUTLET HOUSING ............................................. 30-30-1

PISTON CUP REPLACEMENT ........................... 30-10-1

PRESSURE GAUGE ........................................... 20-40-1

Dealer Copy -- Not for Resale

PUMP CONTROL VALVE ................................... 20-10-1
PUMP CYLINDERS ............................................ 20--20-1

REMOTE ATTACHMENT CONTROL .................. 40-10-1

REMOTE CONTROL ........................................... 30-50-1

SERIAL NUMBER LOCATION.......................................III

SPECIFICATIONS ......................................... SPEC-10-1
SWING VALVE AND CRANK ARM...................... 30-80-1
SWING VALVE CYLINDER.................................. 20-30-1
SWING VALVE PROXIMITY SENSORS ............. 40-20-1

TROUBLESHOOTING ......................................... 10-10-1

WEAR PLATE ...................................................... 30-40-1

Concrete Pump
Service Manual
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 Dealer Copy -- Not for Resale

Concrete Pump
Service Manual
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 SAFETY AND
CONTENTS
MAINTENANCE
ATTACHMENT DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . III

IDENTIFICATION AND MACHINE SIGNS (DECALS) . . . . . . . . . . . IV HYDRAULIC

SYSTEM
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 MAIN

FRAME
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 ELECTRICAL

SYSTEM
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

SPECIFICATIONS AND SCHEMATICS . . . . . . . . . . . . . . . . SPEC-01 SPECIFICATIONS

AND
SCHEMATICS

Dealer Copy -- Not for Resale

CALIFORNIA

PROPOSITION 65 WARNING

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth
defects and other reproductive harm.

Concrete Pump
I Service Manual
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 Dealer Copy -- Not for Resale

Concrete Pump
II Service Manual
8 of 143
SERIAL NUMBER LOCATION ATTACHMENT DELIVERY REPORT

Figure 1 Figure 2

P-57520 P-20022

Always use the serial number of the Concrete Pump The Attachment Delivery Report must be filled out by the
when requesting service information or when ordering dealer and signed by the owner or operator when the
parts. Early or later models (identification made by serial Concrete Pump is delivered. An explanation of the form
number) may use different parts, or it may be necessary must be given to the owner. Make sure it is filled out

Dealer Copy -- Not for Resale

to use a different procedure in doing a specific service completely [Figure 2].
operation [Figure 1].

Concrete Pump
III Service Manual
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IDENTIFICATION AND MACHINE SIGNS (DECALS)

FLIP-UP WALKWAY
6905984

REMOVABLE WALKWAY

WASH BOX

Dealer Copy -- Not for Resale

CONCRETE TUBES
6905982

P-57531

6717648 6905983

6905979 HAND GRAB

OPERATOR MANUAL
VIDEO CONTAINER

PRESSURE GAUGE SWING VALVE CYLINDER

AGITATOR CONTROL (Guard removed
LEVER
MAIN HYDRAULIC CYLINDERS for illustration only)

LOOP FOR HYDRAULIC HOSES

AND
ELECTRICAL HARNESS P-57578
P-57532

Concrete Pump
IV Service Manual
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IDENTIFICATION AND MACHINE SIGNS (DECALS) (CONT’D)

(grate raised for picture clarity)

HOPPER GRATE
AGITATOR ASSEMBLY AGITATOR PADDLES (6)

SWING VALVE

Dealer Copy -- Not for Resale

P-57536
P-57535

D-RING

HOPPER COVER
6905981

AGITATOR MOTOR
6905980

HOPPER OUTLET

SUPPORT STANDS HOPPER CLEANOUT SUPPORT STANDS

P-57534

Concrete Pump
V Service Manual
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 Dealer Copy -- Not for Resale

Concrete Pump
VI Service Manual
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 SAFETY AND MAINTENANCE SAFETY AND
MAINTENANCE
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Concrete Pump Mount Inspection . . . . . . . . . . . . . . . . . . . 10-20-3
Delivery System Inspection . . . . . . . . . . . . . . . . . . . . . . . . 10-20-4
Hand Lever Bob-Tach Inspection. . . . . . . . . . . . . . . . . . . . 10-20-1
Power Bob-Tach Inspection . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Wash Box Fluid Inspection . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Dealer Copy -- Not for Resale

Concrete Pump
10-01 Service Manual
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 Dealer Copy -- Not for Resale

Concrete Pump
10-02 Service Manual
14 of 143
TROUBLESHOOTING

Concrete Pump

PROBLEM CAUSE CORRECTION

Concrete Pump does not seat properly on Bob-Tach wedges are not fully retracted Retract Bob-Tach wedges before
the Bob-Tach. before installation. installation.
Mud, dirt or stones are lodged between the Remove debris between Bob-Tach and
Bob-Tach and the Concrete Pump. Concrete Pump.
Loader will not start with loader key switch Engine stop switch on Remote Attachment Turn the engine stop switch clockwise to
with Concrete Pump installed. Control engaged. release the switch.
Key switch on Remote Attachment Control Turn the key switch to the OFF position.
in the run position.
Loader will not start with the Remote Engine stop switch on Remote Attachment Turn the engine stop switch clockwise to
Attachment Control key switch. Control engaged. release the switch.
Loader key switch in the run position. Turn the loader key switch to the OFF
position, or press the stop button.
Concrete Pump does not pump. No hydraulic flow. Check quick couplers connection. Check
for damaged hose ends and fittings.
Electrical connections not made. Check electrical connections.
Press RAC PUMP ON switch.

Dealer Copy -- Not for Resale

Delivery system plugs. Mix is not pumpable. Consult mix supplier.
Delivery system components are too small. Be sure delivery system hoses and tubes
are 3 to 4 times the size of the largest
aggregate to be pumped.
Delivery system not lubricated before Disassemble and clean delivery system
pumping. and hopper. Lubricate the delivery system
before pumping.
Old concrete set up in delivery system. Disassemble, clean and inspect delivery
system.
Damaged or defective couplings or Disassemble, clean and inspect delivery
gaskets. system.
Bends or kinks in delivery system hoses or Inspect delivery system. Run delivery
tubes. system in a line as short and straight as
possible to placement area.
Concrete mix leaking at coupling joints. Coupling and gasket not installed properly Dip gasket in warm, soapy water or oil
or worn. before applying. Correctly align
components to be connected before
applying coupling.
Disassemble, clean and inspect coupling
and gasket for wear.
Wash box oil rapidly becomes Worn piston cups. Replace piston cups.
contaminated with concrete mix.
Oil dripping from cylinder block. Worn rod seals. Replace cylinder rod seals.
Pumping rate is decreasing. Worn piston cups. Replace piston cups.
Wear ring not tight against wear plate. Tighten nut on crank arm assembly.
Worn or scored concrete tubes. Replace concrete tubes.

Concrete Pump
10-10-1 Service Manual
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TROUBLESHOOTING (CONT’D)

Agitator

PROBLEM CAUSE CORRECTION

Agitator Not Turning Valve Not Turned On. Turn Valve On.
Loader Hydraulics Not Turned On. Start Loader Hydraulics.

Radio Remote Control

PROBLEM CAUSE CORRECTION

Transmitter Doesn’t Work Weak Battery Replace Battery
Not Activated Turn Toggle Off And On To Reset
Antenna Cord Is Coiled Up Uncoil Antenna Cord
Poor Antenna Placement Place On Cab Or Away From Pump
Steel Covered Building Blocking Signal Place Antenna In Line Of Sight With
Transmitter

Dealer Copy -- Not for Resale

Loose Receiver Wire Connection Check Wire Connections

Concrete Pump
10-10-2 Service Manual
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INSPECTION Figure 10-20-2

Hand Lever Bob-Tach Inspection

1

WARNING 2

Bob-Tach wedges must extend through the holes in

attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to Wedge must
contact lower
come off and cause injury or death. edge of hole in
W-2102-0497 the attachment
N-17022
Figure 10-20-1
The wedges must extend through the holes in the
attachment mounting frame (Item 2) [Figure 10-20-2].
The spring loaded wedge (Item 1) must contact the lower
edge of the hole in the attachment (Item 2) [Figure 10-
20-2].
If the wedge does not contact the lower edge of the hole
the attachment will be loose and can come off the Bob-

Dealer Copy -- Not for Resale

Tach.
Figure 10-20-3

P10631

Move the Bob-Tach levers down to engage the wedges

[Figure 10-20-1].

The levers and wedges must move freely.

B-17460

Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage. Replace any parts that are damaged, bent, or
missing [Figure 10-20-3].

Keep all fasteners tight.

Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.

Lubricate the wedges. (See the correct Loader Operation

& Maintenance Manual for LUBRICATION OF THE
BOBCAT MACHINE.)

Concrete Pump
10-20-1 Service Manual
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INSPECTION (CONT’D) Figure 10-20-5

Power Bob-Tach Inspection

1

WARNING 2

Bob-Tach wedges must extend through the holes in

attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to Wedge must
contact lower
come off and cause injury or death. edge of hole in
W-2102-0497 the attachment
N-17022
Figure 10-20-4
The wedges must extend through the holes in the
attachment mounting frame (Item 2) [Figure 10-20-5].

The spring loaded wedge (Item 1) must contact the lower

edge of the hole in the attachment (Item 2) [Figure 10-
20-5].

If the wedge does not contact the lower edge of the hole

Dealer Copy -- Not for Resale

[Figure 10-20-5] the attachment will be loose and can
come off the Bob-Tach.

Figure 10-20-6

B-15993

Push and hold the BOB-TACH WEDGES UP switch until

wedges are fully raised. Push and hold the BOB-TACH
WEDGES DOWN switch until the wedges are fully down
[Figure 10-20-4].

The wedges must move freely.

NOTE: The Power Bob-Tach system has continuous

pressurized hydraulic oil to keep the wedges
in the engaged position and prevent
attachment disengagement. Because the B-17460
wedges can slowly lower, the operator may
need to reactivate the switch (WEDGES UP) Inspect the mounting frame on the attachment and the
before installing an attachment to be sure Bob-Tach, linkages and wedges for excessive wear or
both wedges are fully raised before installing damage [Figure 10-20-6]. Replace any parts that are
the attachment. damaged, bent, or missing. Keep all fasteners tight.
Inspect the hoses and fittings for leaks.

Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.

Lubricate the wedges. (See the correct loader Operation

& Maintenance Manual for LUBRICATION OF THE
BOBCAT LOADER.)

Concrete Pump
10-20-2 Service Manual
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INSPECTION (CONT’D) Figure 10-20-9

Concrete Pump Mount Inspection

Figure 10-20-7

P-57528

2
The wash box should be kept filled with up to 3 gallons of
1 SAE #30 motor oil [Figure 10-20-9].
P-57531
NOTE: The oil should be checked daily.
Inspect the Bob-Tach wedge mounts (Item 1), mounting NOTE: DO NOT use transmission fluid in the wash
flange (Item 2) and all welds on the Concrete Pump box or piston cup damage may occur.
mount for wear and damage each time the Concrete

Dealer Copy -- Not for Resale

Pump is removed from the loader [Figure 10-20-7]. Position a drain pan under the wash box to collect the
hydraulic fluid.

Figure 10-20-10
Wash Box Fluid Inspection

Figure 10-20-8

P-57529

Remove the drain plug (Item 1) [Figure 10-20-10] and

drain the fluid from the wash box. Clean any sediment
from the bottom of the wash box, then reinstall the drain
plug and fill the wash box as described above.
P-57527

Inspect the fluid level in the wash box (Item 1) [Figure

10-20-8] after every other use. If more than 1 inch of IMPORTANT
sediment is present in the bottom of the wash box, the
fluid must be changed. Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be disposed of in an
environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal.
I-2067-0499

Concrete Pump
10-20-3 Service Manual
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INSPECTION (CONT’D)

Delivery System Inspection

All delivery system components must be inspected for

wear AFTER EVERY USE:

Hoses, tubes, elbows and bends must be inspected for

inside diameter wear. An ultrasonic wall gauge can be
used to measure steel pipe wall thickness. Replace worn
components.

The inner liners and outer covers of hoses must be

inspected for exposed braiding or reinforcing plies.
Replace hoses which have breaks or frays.

Inspect hose and tube ends, and couplings for wear and
cleanliness. Material buildup can interfere with safe
coupling.

Inspect all gaskets and coupling retainer locking pins for

cleanliness and wear. Each coupling must have a gasket
and a retainer locking pin.

Dealer Copy -- Not for Resale

Concrete Pump
10-20-4 Service Manual
20 of 143
LUBRICATION Lubricate the following four grease fittings [Figure 10-30-
3] & [Figure 10-30-4] AFTER EVERY POUR AND
Always use a good quality lithium base grease when EVERY 8 HOURS OF OPERATION:
lubricating the Concrete Pump. Apply the lubricant until
extra grease shows. Figure 10-30-3

IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be disposed of in an
environmentally safe manner. Some regulations
require that certain spills and leaks on the ground 1
must be cleaned in a specific manner. See local, state
1
and federal regulations for the correct disposal.
I-2067-0499 P-57571

Lubrication Points 3. Concrete Cylinders (Item 1) [Figure 10-30-3].

Figure 10-30-4
Lubrication of the Concrete Pump is very important to
keep concrete mix out of the wear areas. Lubricate the Top Bottom
following five grease fittings [Figure 10-30-1] & [Figure
10-30-2] AFTER EVERY POUR AND EVERY 2 HOURS 2

Dealer Copy -- Not for Resale

OF OPERATION:
Figure 10-30-1

1 P-57524 P-57525

4. Lubricate the top and bottom Swing Valve Cylinder

bushings (Item 1) [Figure 10-30-4].

P-57523

1. Outlet Housing (Item 1) [Figure 10-30-1].

Figure 10-30-2

P-57526

2. Crank Arm Bearing (Item 1) [Figure 10-30-2].

Concrete Pump
10-30-1 Service Manual
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 Dealer Copy -- Not for Resale

Concrete Pump
10-30-2 Service Manual
22 of 143
 HYDRAULIC SYSTEM

AGITATOR CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . 20-11-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-1 HYDRAULIC
SYSTEM
AGITATOR HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . 20-50-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-10
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

PRESSURE GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

PUMP CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

PUMP CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Dealer Copy -- Not for Resale

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

SWING VALVE CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3

Concrete Pump
20-01 Service Manual
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 Dealer Copy -- Not for Resale

Concrete Pump
20-02 Service Manual
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PUMP CONTROL VALVE Figure 20-10-2

Removal And Installation

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 1
I-2003-0888

P-14440

IMPORTANT Unplug the two wire connectors (Item 1) [Figure 20-10-2]

which connect the wash box limit switches to the wire
harness. Note the black band on the right wires and the
Contain and dispose of any oil leakage in an white band on the left wires for installation.
environmentally safe manner.
I-2066-0395 Figure 20-10-3

Dealer Copy -- Not for Resale

Figure 20-10-1

1
1
1

P-14441

P-57760
Unplug the five wire connectors (Item 1) [Figure 20-10-3]
which connect the control valve to the wire harness. Note
Remove the six nuts (Item 1) [Figure 20-10-1] attaching the colored bands on the wire connectors and the wires
the removable walkway to the Concrete Pump frame. for installation.
Remove the walkway.

Mark the hoses and tubelines for correct installation.

Concrete Pump
20-10-1 Service Manual
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PUMP CONTROL VALVE (CONT’D) Figure 20-10-6

Removal And Installation (Cont’d)

Figure 20-10-4

1
1
P-14444

Remove the pressure gauge hose (Item 1) from control

P-57859 valve port G (Item 2) [Figure 20-10-6].

Figure 20-10-7
Loosen the three mounting bolts (Item 1) [Figure 20-10-
4] on the control valve just enough to allow you to slide

Dealer Copy -- Not for Resale

the control valve in the mounting slots.

Figure 20-10-5
2 3

2 3

1 1
1

P-14445

Mark and remove the two hoses (Item 1) from control

valve ports C1 (Item 2) and C2 (Item 3) [Figure 20-10-7].
P-14443
The hose connected to port C1 runs to the left pump
cylinder. The hose connected to port C2 runs to the right
Remove the two tubelines (Item 1) which run from the pump cylinder.
pump cylinder bases to control valve ports C3 (Item 2)
and C4 (Item 3) [Figure 20-10-5]. Slide the control valve
in the mounting slots to remove the tubelines.

Concrete Pump
20-10-2 Service Manual
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PUMP CONTROL VALVE (CONT’D) Figure 20-10-10

Removal And Installation (Cont’d)

2
Figure 20-10-8

1 1

2
1
3

P-14448

NOTE: Before installation, loosen the four mounting

P-14446 bolts (Item 1) to allow the support bracket
(Item 2) to slide in the mounting slots when
installing the tubelines on the control valve
Remove the two hydraulic coupler hoses (Item 1) from [Figure 20-10-10].
control valve ports T (Item 2) and P (Item 3) [Figure 20-

Dealer Copy -- Not for Resale

10-8]. The male coupler is connected to the hose in port Installation: Tighten the mounting bolts to 40 ft.-lbs. (54
P. The female coupler is connected to the hose in port T. Nm) torque.

Figure 20-10-9

P-57859

Remove the three mounting bolts (Item 1) [Figure 20-10-

9]. Remove the control valve.

Installation: Tighten the mounting bolts to 40 ft.-lbs. (54

Nm) torque.

Concrete Pump
20-10-3 Service Manual
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PUMP CONTROL VALVE (CONT’D)

Parts Identification

1. Manifold Block
2. Plug
3. Spool
4. Coil (Orange Cable Tie)
1
5. Spacer 2
6. Coil (Blue Cable Tie)
7. Valve
8. Plug
9. Orifice
10. Check Valve
11. O-Ring
12. Manifold Block 3
13. Connector (Red Cable Tie)
14. Coil (Brown Cable Tie)
15. Spool
16. Retainer
17. Poppet

Dealer Copy -- Not for Resale

18. Orifice
19. Plug
20. Logic Va;ve
21. Connector (Green Cable Tie)
5

20 6 4

8
19
9

10 7
11
12
18

17

21

16

15
14

13
P-60493

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20-10-4 Service Manual
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PUMP CONTROL VALVE (CONT’D) Figure 20-10-12

Disassembly
1

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-14450

Loosen and remove the two spools (Item 1) [Figure 20-

IMPORTANT 10-12].

Figure 20-10-13
Contain and dispose of any oil leakage in an
environmentally safe manner.
I-2066-0395

Dealer Copy -- Not for Resale

1
Figure 20-10-11 1
2 2
1
2
1

2 P-14451

Remove the O-rings (Item 1) and back-up rings (Item 2)

from the spool [Figure 20-10-13].

P-14449 Figure 20-10-14

Remove the two nuts (Item 1) and the three coils (Item 2)
and spacer from the two spools [Figure 20-10-11].
2 2
2

1 1
1 1 P-14452

Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-10-14] from the spool.

Concrete Pump
20-10-5 Service Manual
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PUMP CONTROL VALVE (CONT’D) Figure 20-10-18

Disassembly (Cont’d)

Figure 20-10-15
1 1

1 1

P-14456

P-14453
Loosen and remove the four cap screws (Item 1).
Remove the D03 valve (Item 2) [Figure 20-10-18] from
the manifold block.
Remove the two caps (Item 1) [Figure 20-10-15].
Figure 20-10-19
Figure 20-10-16

Dealer Copy -- Not for Resale

1
1

P-14454
P-14457

Remove the two O-rings (Item 1) [Figure 20-10-16] from Remove the four O-rings (Item 1) [Figure 20-10-19] from
the D03 valve. the D03 valve.
Figure 20-10-17 Figure 20-10-20

1 1
1

P-14455
P-14458

Loosen and remove the two coils (Item 1). Remove the
Remove the two plugs (Item 1) [Figure 20-10-20] from
D03 valve (Item 2) from the manifold block [Figure 20-
the manifold block.
10-17].

Concrete Pump
20-10-6 Service Manual
30 of 143
PUMP CONTROL VALVE (CONT’D) Figure 20-10-23

Disassembly (Cont’d)

Figure 20-10-21 2
2
2

1 1 1
1
P-14461

Remove the O-rings (Item 1) and back-up rings (Item 2)

P-14459
from the two valves [Figure 20-10-23].

Figure 20-10-24
Remove the O-ring (Item 1) [Figure 20-10-21] from the
two plugs.

Dealer Copy -- Not for Resale

Figure 20-10-22

P-14462
1

Remove the logic valve (Item 1) [Figure 20-10-24] from

the manifold block.
P-14460
Figure 20-10-25

Remove the two valves (Item 1) [Figure 20-10-22] from

the manifold block.
2
2

1 1
1
P-14463

Remove the O-rings (Item 1) and back-up rings (Item 2)

from the logic valve [Figure 20-10-25].

Concrete Pump
20-10-7 Service Manual
31 of 143
PUMP CONTROL VALVE (CONT’D) Figure 20-10-28

Disassembly (Cont’d)

Figure 20-10-26
1

1 P-14465

Remove the five plugs (Item 1) [Figure 20-10-28] from

P-14464
the manifold block.

Remove the plug (Item 1) [Figure 20-10-26] from the Figure 20-10-29
manifold block.

Figure 20-10-27

Dealer Copy -- Not for Resale

1
1

P-14466

Remove the O-rings (Item 1) [Figure 20-10-29] from the

P-14459 five plugs.

Figure 20-10-30
Remove the O-ring (Item 1) [Figure 20-10-27] from the
plug.
1 2

2
P-14467

Remove the four orifices (Item 1) from the ports (Item 2)

in the manifold block [Figure 20-10-30].

Concrete Pump
20-10-8 Service Manual
32 of 143
PUMP CONTROL VALVE (CONT’D) Figure 20-10-33

Disassembly (Cont’d)

Figure 20-10-31

1
2
1

P-14470

2
Remove the plug (Item 1) [Figure 20-10-33] from the
P-14468 manifold block.

Figure 20-10-34
Remove the four check valves (Item 1) from the ports
(Item 2) in the manifold block [Figure 20-10-31].

Dealer Copy -- Not for Resale

Figure 20-10-32 1

1
2

P-14459

1
Remove the O-ring (Item 1) [Figure 20-10-34] from the
plug.
P-14469

Figure 20-10-35
Remove the four O-rings (Item 1) from the ports (Item 2)
in the manifold block [Figure 20-10-32].

P-14471

Remove the plug (Item 1) [Figure 20-10-35] from the

manifold block.

Concrete Pump
20-10-9 Service Manual
33 of 143
PUMP CONTROL VALVE (CONT’D) Figure 20-10-39

Disassembly (Cont’d)

Figure 20-10-36

1
1

P-14473

P-14459 Remove the plug (Item 1) [Figure 20-10-39] from the

manifold block.

Remove the O-ring (Item 1) [Figure 20-10-36] from the Figure 20-10-40
plug.

Figure 20-10-37

Dealer Copy -- Not for Resale

1

P-14459

1
P-14472 Remove the O-ring (Item 1) [Figure 20-10-40] from the
plug.

Remove the two plugs (Item 1) [Figure 20-10-37] from

the manifold block.

Figure 20-10-38

P-14466

Remove the O-rings (Item 1) [Figure 20-10-38] from the

two plugs.
Concrete Pump
20-10-10 Service Manual
34 of 143
PUMP CONTROL VALVE (CONT’D) Figure 20-10-44

Disassembly (Cont’d)

Figure 20-10-41

P-14466

P-14474 Remove the O-ring (Item 1) [Figure 20-10-44] from the

two plugs.
Remove the two plugs (Item 1) [Figure 20-10-41] from
the manifold block.

Figure 20-10-42

Dealer Copy -- Not for Resale

1

P-14466

Remove the O-ring (Item 1) [Figure 20-10-42] from the

two plugs.

Figure 20-10-43

P-14474

Remove the two plugs (Item 1) [Figure 20-10-43] from

the manifold block.

Concrete Pump
20-10-11 Service Manual
35 of 143
PUMP CONTROL VALVE (CONT’D) Figure 20-10-46

Assembly

Clean all components in clean solvent and dry with

compressed air. Discard all the O-rings and back-up
rings and replace them with new O-rings and back-up
rings. Apply clean hydraulic fluid to all O-rings, back-up
rings, spools and valves.

IMPORTANT
P-14474
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, Install the two plugs (Item 1) [Figure 20-10-46] in the
tubelines and ports to keep dirt out. Dirt can quickly manifold block. Tighten the plugs to 10 ft.-lb. (14 Nm)
damage the system. torque.
I-2003-0888
Figure 20-10-47

Dealer Copy -- Not for Resale

IMPORTANT 1

Contain and dispose of any oil leakage in an

environmentally safe manner.
I-2066-0395

Figure 20-10-45

P-14459

1 Install the O-ring (Item 1) [Figure 20-10-47] on the plug.

Figure 20-10-48

P-14466 1

Install the O-ring (Item 1) [Figure 20-10-45] on the two

plugs.

P-14473

Install the plug (Item 1) [Figure 20-10-48] in the manifold

block. Tighten the plug to 41 ft.-lb. (55 N•m) torque.

Concrete Pump
20-10-12 Service Manual
36 of 143
PUMP CONTROL VALVE (CONT’D) Figure 20-10-51

Assembly (Cont’d)

Figure 20-10-49
1

P-14459

Install the O-ring (Item 1) [Figure 20-10-51] on the plug.

P-14466
Figure 20-10-52

Install the O-rings (Item 1) [Figure 20-10-49] on the two

plugs.

Figure 20-10-50

Dealer Copy -- Not for Resale

1 1

P-14471

Install the plug (Item 1) [Figure 20-10-52] in the manifold

block. Tighten the plug to 41 ft.-lb. (55 N•m) torque.
1
P-14472
Figure 20-10-53

Install the two plugs (Item 1) [Figure 20-10-50] in the

manifold block. Tighten the plugs to 10 ft.-lb. (14 N•m)
torque. 1

P-14459

Install the O-ring (Item 1) [Figure 20-10-53] on the plug.

Concrete Pump
20-10-13 Service Manual
37 of 143
PUMP CONTROL VALVE (CONT’D) Figure 20-10-56

Assembly (Cont’d)
1
Figure 20-10-54 2

P-14468

Install the four check valves (Item 1) in the ports (Item 2)

P-14470
in the manifold block [Figure 20-10-56].

Install the plug (Item 1) [Figure 20-10-54] in the manifold Figure 20-10-57
block. Tighten the plug to 41 ft.-lb. (55 N•m) torque.
1
Figure 20-10-55 2

Dealer Copy -- Not for Resale

1
2

P-14467
2
Install the four orifices (Item 1) in the ports (Item 2) in the
P-14469 manifold block [Figure 20-10-57].

Figure 20-10-58
Install the four O-rings (Item 1) in the ports (Item 2) in the
manifold block [Figure 20-10-55].

P-14466

Install the O-rings (Item 1) [Figure 20-10-58] on the five

plugs.

Concrete Pump
20-10-14 Service Manual
38 of 143
PUMP CONTROL VALVE (CONT’D) Figure 20-10-62

Assembly (Cont’d)

Figure 20-10-59
2
2

1
1

1 1
1 P-14463

1 P-14465 Install the O-rings (Item 1) and back-up rings (Item 2) on

the logic valve [Figure 20-10-62].
Install the five plugs (Item 1) [Figure 20-10-59] in the
Figure 20-10-63
manifold block. Tighten the plugs to 10 ft.-lb. (14 N•m)
torque.

Dealer Copy -- Not for Resale

Figure 20-10-60

1 1

P-14462

Install the logic valve (Item 1) [Figure 20-10-63] in the

P-14459
manifold block. Tighten the logic valve to 50 ft.-lb. (68
N•m) torque.
Install the O-ring (Item 1) [Figure 20-10-60] on the plug.

Figure 20-10-61

P-14464

Install the plug (Item 1) [Figure 20-10-61] in the manifold

block. Tighten the plug to 41 ft.-lb. (55 N•m) torque.

Concrete Pump
20-10-15 Service Manual
39 of 143
PUMP CONTROL VALVE (CONT’D) Figure 20-10-67

Assembly (Cont’d)

Figure 20-10-64

1
2
2
2

P-14458

1
1 1 1 Install the two plugs (Item 1) [Figure 20-10-67] in the
P-14461
manifold block. Tighten the plugs to 41 ft.-lb. (55 N•m)
torque.
Install the O-rings (Item 1) and back-up rings (Item 2) on
the two valves [Figure 20-10-64]. Figure 20-10-68

Figure 20-10-65

Dealer Copy -- Not for Resale

1

1
1

P-14457

P-14460

Install the four O-rings (Item 1) [Figure 20-10-68] on the

Install the two valves (Item 1) [Figure 20-10-65] in the D03 valve.
manifold block. TIghten the valves to 50 ft.-lb. (68 N•m)
torque.

Figure 20-10-66

P-14459

Install the O-ring (Item 1) [Figure 20-10-66] on the two

plugs.

Concrete Pump
20-10-16 Service Manual
40 of 143
PUMP CONTROL VALVE (CONT’D) Figure 20-10-71

Assembly (Cont’d)

Figure 20-10-69 1

1 1

2
P-14454

P-14456 Install the O-ring (Item 1) [Figure 20-10-71] on both

sides of the D03 valve.
Install the D03 valve (Item 1) on the manifold block. Figure 20-10-72
Install the four cap screws (Item 2) [Figure 20-10-69].

Tighten the screws to 60 in.-lb. (7 Nm) torque.

Dealer Copy -- Not for Resale

Figure 20-10-70 1 1

1 1

P-14453

Install and tighten the two caps (Item 1) [Figure 20-10-

72].

P-14455 Figure 20-10-73

Install the two coils (Item 1) [Figure 20-10-70] on the

D03 valve.

2
2 2

1 1 1 1
P-14452

Install the O-rings (Item 1) and back-up rings (Item 2) on

the spool [Figure 20-10-73].

Concrete Pump
20-10-17 Service Manual
41 of 143
PUMP CONTROL VALVE (CONT’D) Figure 20-10-76

Assembly (Cont’d)
1
Figure 20-10-74 2 1

1 2
1
2 2

P-14449

Install the three coils (Item 1) with the spacer on the two
P-14451
spools. Install the nuts (Item 2) on the two spools [Figure
20-10-76].
Install the O-rings (Item 1) and back-up rings (Item 2) on
the spool [Figure 20-10-74]. Tighten the nuts to 5 ft.-lb. (7 N•m) torque.

Dealer Copy -- Not for Resale

Figure 20-10-75

P-14450

Install the two spools (Item 1) [Figure 20-10-75] on the

manifold block. Tighten the spools to 20 ft.-lb. (27 N•m)
torque.

Concrete Pump
20-10-18 Service Manual
42 of 143
AGITATOR CONTROL VALVE Figure 20-11-2

Removal And Installation

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-57538A

IMPORTANT Remove hoses (Item 1) [Figure 20-11-2].

Figure 20-11-3
Contain and dispose of any oil leakage in an
environmentally safe manner.
I-2066-0395

Dealer Copy -- Not for Resale

1
Figure 20-11-1

P-57538B

1 1 Remove bolts (Item 1) [Figure 20-11-3].

Installation: Tighten bolts to 25-28 ft.-lb. (34-38 N•m)

P-57538
torque.

Remove hoses (Item 1) [Figure 20-11-1].

NOTE: Mark all hoses to insure proper installation.

Concrete Pump
20-11-1 Service Manual
43 of 143
AGITATOR CONTROL VALVE (CONT’D)

Parts Identification

1. Control Handle
2. Nut
3. Bolt
4. Linkage
5. Nut
6. Stud
7. Check Valve
8. O-ring
9. Spring
12
10. Poppet
11. Seat
12. Manifold 11
13. Spool 10
9
14. O-ring

Dealer Copy -- Not for Resale

8
15. O-ring 1
7
16. Flange 14
17. Collar 6

18. Cover 5

19. Bolt 13 19
17 18
2
15 16

3 4

P-60383

Concrete Pump
20-11-2 Service Manual
44 of 143
AGITATOR CONTROL VALVE (CONT’D) Figure 20-11-5

Disassembly

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-57794

IMPORTANT Remove collar (Item 1) [Figure 20-11-5].

NOTE: When removing the casing, be careful not to

Contain and dispose of any oil leakage in an drop or lose the ball and spring inside the
environmentally safe manner. casing.
I-2066-0395

Dealer Copy -- Not for Resale

Figure 20-11-6
Figure 20-11-4

2 3
1

1 2

P-57795

P-57793

Remove spring (Item 1) and ball (Item 2), then remove

Place the control valve in a vise [Figure 20-11-4]. the collar (Item 3) [Figure 20-11-6].

Remove the bolts (Item 1) and remove the cap (Item 2)

[Figure 20-11-4].

Concrete Pump
20-11-3 Service Manual
45 of 143
AGITATOR CONTROL VALVE (CONT’D) Figure 20-11-9

Disassembly (Cont’d)
2
Figure 20-11-7 Measure Distance 1

P-57797

1 Measure and record the distance between the the top of

the screw and the flow control housing. This will help
when installing the flow control housing to insure that the
P-57923
adjustment srcew is in correct position to keep the
agitator turning at the same speed as before.
Loosen nut (Item 1) [Figure 20-11-7] and remove the Loosen jam nut (Item 1) and adjustment bolt (Item 2)
handle. [Figure 20-11-9].

Dealer Copy -- Not for Resale

Figure 20-11-8 Remove flow control housing (Item 3) [Figure 20-11-9].
Figure 20-11-10

2
1

P-57801
P-57796
Remove spring (Item 1) [Figure 20-11-10].
Remove the two bolts (Item 1) and remove the handle Figure 20-11-11
housing (Item 2) [Figure 20-11-8].

P-57800

Remove flow control (Item 1) [Figure 20-11-11].

Concrete Pump
20-11-4 Service Manual
46 of 143
AGITATOR CONTROL VALVE (CONT’D) Figure 20-11-14

Assembly

Figure 20-11-12

P-57799
1

P-57924

P-57800 Install flow control housing (Item 1) [Figure 20-11-14].

Figure 20-11-15
Install flow control (Item 1) [Figure 20-11-12].

Figure 20-11-13
1

Dealer Copy -- Not for Resale

2

P-57797

P-57801 Install adjustment bolt (Item 1) and tighten jam nut (Item
2) [Figure 20-11-15].
Install spring (Item 1) [Figure 20-11-13].

Concrete Pump
20-11-5 Service Manual
47 of 143
AGITATOR CONTROL VALVE (CONT’D) Figure 20-11-18

Assembly (Cont’d)
1
Figure 20-11-16

2 3
1

P-57795

Install the collar (Item 1), then install the spring (Item 2)
and ball (Item 3) [Figure 20-11-18].
P-57796
Figure 20-11-19

Install the housing (Item 1), then install the two bolts
(Item 2) [Figure 20-11-16].

Dealer Copy -- Not for Resale

Installation: Tighten bolts to 80-90 in.-lb. (9-10 N•m) 1
torque.

Figure 20-11-17

P-57794

Install casing (Item 1) [Figure 20-11-19].

Figure 20-11-20

1 1
2
P-57923

Install handle and tighten jam nut (Item 1) [Figure 20-11-

17].

P-57793

Install the cap (Item 1), then install the bolts (Item 2)
[Figure 20-11-20].

Tighten bolts to 80-90 in.-lb. (9-10 N•m) torque.

Concrete Pump
20-11-6 Service Manual
48 of 143
PUMP CYLINDERS Remove hopper. (See Removal And Installation on Page
30-70-1.)
Removal And Installation
Remove piston cups. (See Removal on Page 30-10-2.)

Remove walkway. (See Removal And Installation on

WARNING Page 20-10-1.)

Remove pump control valve. (See Removal And

AVOID INJURY OR DEATH
Installation on Page 20-10-1.)
Before cleaning, servicing or inspecting the
Concrete Pump, stop the loader engine and
Remove washbox limit switches. (See Removal And
disconnect the hydraulic hoses and electrical
Installation on Page 40-10-1.)
harnesses from the loader.
W-2366-0500
Figure 20-20-1

IMPORTANT 1

If the engine stop switch is used to stop the loader

engine, turn the key switch to the OFF position. If the
Remote Attachment Control key switch is left in the

Dealer Copy -- Not for Resale

ON position, there will be a constant current draw on
the battery resulting in a weak or discharged battery.
I-2188-0998

P-57844

IMPORTANT
Remove tubeline (Item 1) [Figure 20-20-1].
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Figure 20-20-2
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1 1

IMPORTANT
2 2
Contain and dispose of any oil leakage in an
environmentally safe manner.
I-2066-0395
P-14443A

Remove tubelines (Item 1) [Figure 20-20-2].

Remove fittings (Item 2) [Figure 20-20-2] and install

plugs.

Concrete Pump
20-20-1 Service Manual
49 of 143
PUMP CYLINDERS (CONT’D) Figure 20-20-5

Removal And Installation (Cont’d)

1
Figure 20-20-3

1
1

P-57926

Remove the four bolts (Item 1) [Figure 20-20-5] and

P-57925 flange mounting the cylinder to the washbox.

Installation: Apply silicone sealant to mounting flange,

Remove fittings (Item 1) [Figure 20-20-3]. install bolts and tighten to 25-28 ft.-lb. (34-38 N•m)
torque.

Dealer Copy -- Not for Resale

Figure 20-20-4
Figure 20-20-6

1 1 1

P-57926 P-57835

Install plugs (Item 1) [Figure 20-20-4]. Remove cotter pin (Item 1), then remove pin (Item 2)
[Figure 20-20-6].

NOTE: Slide the pin toward the center of the concrete

pump or you will not be able to remove the
pin.

Remove the cylinder.

Concrete Pump
20-20-2 Service Manual
50 of 143
PUMP CYLINDERS (CONT’D)

Parts Identification

1. Case
2. Cap
3. Set Screw
4. O-ring 17
5. O-ring 15
16
6. Inner Head
7. Seal 1

8. Head
9. O-ring 13

10. Seal
12
11. O-ring
12. Piston 11

13. Set Screw 10

14. Rod

Dealer Copy -- Not for Resale

9
15. Steel Ball
8
16. Plug
17. Spring 7
6
5
3
4
2

14

P-60382

Concrete Pump
20-20-3 Service Manual
51 of 143
PUMP CYLINDERS (CONT’D) Figure 20-20-8

Disassembly
2

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888 P-57805

Loosen set screw (Item 1) [Figure 20-20-8].

IMPORTANT Use a spanner wrench to remove the head (Item 2)

[Figure 20-20-8].

Contain and dispose of any oil leakage in an Figure 20-20-9

environmentally safe manner.
I-2066-0395

Dealer Copy -- Not for Resale

1
OEM6193 - Spanner Wrench

Place the base end of the cylinder in a drain pan. Move

the rod in and out to remove the fluid from the cylinder.
Move the rod slowly so the fluid will go directly into the
drain pan.

Figure 20-20-7

P-57806

Remove the rod assembly (Item 1) [Figure 20-20-9] from

the casing.

Figure 20-20-10

P-57804

Place the cylinder in a vise [Figure 20-20-7].

P-57807

Remove seal (Item 1) [Figure 20-20-10].

Concrete Pump
20-20-4 Service Manual
52 of 143
PUMP CYLINDERS (CONT’D) Figure 20-20-13

Disassembly (Cont’d)

Figure 20-20-11

1
2
1

P-57811

3 Remove seal (Item 1) [Figure 20-20-13].

P-57808
Figure 20-20-14

Remove O-ring (Item 1) [Figure 20-20-11].

Dealer Copy -- Not for Resale

Loosen set screw (Item 2) [Figure 20-20-11].

Use a spanner wrench to remove the piston (Item 3)

[Figure 20-20-11]. 1

Figure 20-20-12

P-57812

Remove O-ring (Item 1) [Figure 20-20-14].

Figure 20-20-15

P-57809

Remove head (Item 1) [Figure 20-20-12].

P-57813

Remove inner head (Item 1) [Figure 20-20-15].

Concrete Pump
20-20-5 Service Manual
53 of 143
PUMP CYLINDERS (CONT’D) Figure 20-20-17

Disassembly (Cont’d)

Figure 20-20-16 1

P-57810

Remove O-ring (Item 1) [Figure 20-20-17].

P-57815

Remove seal (Item 1) and O-ring (Item 2) [Figure 20-20-

16].

Dealer Copy -- Not for Resale

Concrete Pump
20-20-6 Service Manual
54 of 143
PUMP CYLINDERS (CONT’D) Figure 20-20-20

Assembly

Clean all components in clean solvent and dry with

compressed air. Discard all the O-rings and back-up
rings and replace them with new O-rings and back-up
rings. Apply clean hydraulic fluid to all O-rings, back-up
rings, spools and valves.
1
Figure 20-20-18

1
P-57811

Install seal (Item 1) [Figure 20-20-20].

Figure 20-20-21

Dealer Copy -- Not for Resale

P-57810

Install O-ring (Item 1) [Figure 20-20-18].

Figure 20-20-19

P-57813

2
Install inner head (Item 1) [Figure 20-20-21].
1
Figure 20-20-22

P-57815

1
Install seal (Item 1) and O-ring (Item 2) [Figure 20-20-
19].

P-57812

Install O-ring (Item 1) [Figure 20-20-22].

Concrete Pump
20-20-7 Service Manual
55 of 143
PUMP CYLINDERS (CONT’D) Figure 20-20-25

Assembly (Cont’d)
1
Figure 20-20-23

P-57807

Install seal (Item 1) [Figure 20-20-25].

P-57809
Figure 20-20-26

Install head (Item 1) [Figure 20-20-23]. 1

Dealer Copy -- Not for Resale

Figure 20-20-24

P-57806

Install the rod assembly (Item 1) [Figure 20-20-26] into

the casing.

2 Figure 20-20-27
P-57808

NOTE: Apply Loctite 271 (Red) to the threads of the 1

rod before installing the piston.

Install O-ring (Item 1) [Figure 20-20-24].

Use a spanner wrench to install the piston (Item 2)

[Figure 20-20-24].

2
P-57805

Use a spanner wrench to install the head (Item 1) [Figure

20-20-27].

Tighten set screw (Item 2) [Figure 20-20-27].

Concrete Pump
20-20-8 Service Manual
56 of 143
SWING VALVE CYLINDER Figure 20-30-2

Removal And Installation 1

WARNING
AVOID INJURY OR DEATH 1
Before cleaning, servicing or inspecting the
Concrete Pump, stop the loader engine and
disconnect the hydraulic hoses and electrical
harnesses from the loader.
W-2366-0500

P-57927

IMPORTANT Remove hydraulic hoses (Item 1) [Figure 20-30-2].

Figure 20-30-3
If the engine stop switch is used to stop the loader
engine, turn the key switch to the OFF position. If the
Remote Attachment Control key switch is left in the

Dealer Copy -- Not for Resale

ON position, there will be a constant current draw on
the battery resulting in a weak or discharged battery.
I-2188-0998

Figure 20-30-1 1

2
1

P-57767

Remove cotter pin (Item 1) [Figure 20-30-3]

Figure 20-30-4

P-57597

Flip up the walkway, loosen the two bolts (Item 1) [Figure

20-30-1] attaching the guard to the concrete pump frame.

Remove the guard (Item 2) [Figure 20-30-1].

1

P-57769

Remove pin (Item 1) [Figure 20-30-4].

Concrete Pump
20-30-1 Service Manual
57 of 143
SWING VALVE CYLINDER (CONT’D) Figure 20-30-6

Removal And Installation (Cont’d)

Figure 20-30-5

P-57768

Remove the four bolts (Item 1) [Figure 20-30-6].

P-57770
Installation: Tighten bolts to 25-28 ft.-lb. (34-38 N•m)
torque.
Move cylinder away from crank arm [Figure 20-30-5].
Remove cylinder.

Dealer Copy -- Not for Resale

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SWING VALVE CYLINDER (CONT’D)

Parts Identification

1. Gland
2. Piston Rod
3. Cushion Sleeve
4. Piston
5. Tie Rod
6. Cap
7. Nut
4
8. O-ring
9. Needle Valve
10. Cushion Bushing 3
6
11. Retaining Ring
12. Cylinder Body
2 7
13. O-ring
14. Plug/Check Valve

Dealer Copy -- Not for Resale

15. O-ring
16. Check Valve Ball 5

17. Head
10
18. O-ring 11
19. Retainer
8
12 9

13

16 14
15
18 17

19

P-60310

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SWING VALVE CYLINDER (CONT’D) Figure 20-30-8

Disassembly
1

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-57817

IMPORTANT Remove fittings (Item 1) [Figure 20-30-8].

Figure 20-30-9
Contain and dispose of any oil leakage in an
environmentally safe manner.
I-2066-0395

Dealer Copy -- Not for Resale

Figure 20-30-7
1

P-57821

1 Remove O-ring (Item 1) [Figure 20-30-9].

Figure 20-30-10
2
P-57816

Remove cotter pin (Item 1), then remove pin (Item 2) and
remove mounting plate (Item 3) [Figure 20-30-7].

P-57818

Place the cylinder in a vise [Figure 20-30-10].

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SWING VALVE CYLINDER (CONT’D) Figure 20-30-13

Disassembly (Cont’d)

Figure 20-30-11
1

3 P-60384

1
NOTE: Inspect the piston rod to make sure it is free
of burrs or other displaced metal which would
prevent sliding the gland off the rod.
P-57819
Remove gland (Item 1) [Figure 20-30-13] from the
retainer. The gland protrudes from the face of the retainer
Measure the distance between the retainer (Item 1) and and can be removed with vise grip pliers or gland
the clevis (Item 2) and record this measurement to wrench.
assure the clevis is installed correctly [Figure 20-30-11].

Dealer Copy -- Not for Resale

Figure 20-30-14
Loosen jam nut (Item 3), then remove clevis (Item 2)
[Figure 20-30-11].

Figure 20-30-12

1
1

P-57827

Remove seals (Item 1) [Figure 20-30-14].

P-57820
Thoroughly clean gland and seal grooves. Inspect the
gland bore for wear. Replace gland if necessary.
Remove the jam nut (Item 1) [Figure 20-30-12].

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SWING VALVE CYLINDER (CONT’D) Figure 20-30-18

Disassembly (Cont’d)

Figure 20-30-15 1

2
P-57830
3

Remove rod assembly (Item 1) [Figure 20-30-18].

P-60385

Figure 20-30-19
Remove the four nuts (Item 1), then remove retainer
(Item 2) and head (Item 3) [Figure 20-30-15].

Figure 20-30-16

Dealer Copy -- Not for Resale

1

P-57829

1
Remove cylinder casing (Item 1) [Figure 20-30-19].
P-57823
Figure 20-30-20
Remove O-ring (Item 1) [Figure 20-30-16].
1
Figure 20-30-17

P-57825

P-57828 Remove O-ring (Item 1) [Figure 20-30-20].

Remove O-ring (Item 1) [Figure 20-30-17].

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SWING VALVE CYLINDER (CONT’D) Figure 20-30-23

Disassembly (Cont’d)
Thread Sealant
Figure 20-30-21

1
1

P-60387

Assemble parts to make sure components are properly

fitted together. Then disassemble the components.
Using Loctite 642 or 648, apply one strip of sealant about
as wide as the wrench flats to both internal and external
threads [Figure 20-30-23].
2 2
P-57824 Figure 20-30-24

Clean Clean
Remove O-rings (Item 1) and back-up rings (Item 2) Excess Sealant Excess Sealant
[Figure 20-30-21].

Dealer Copy -- Not for Resale

NOTE: The piston is sealed and securely locked to Rod
the piston rod.

Use the following procedure if the piston needs to be Piston

replaced. P-60388

Figure 20-30-22
Install the piston on the rod to full engagement. Back-off
two turns to distribute the thread sealant. Tighten the
components as much as possible using a strap wrench.
Wipe off any excess thread sealant with a clean cloth. Do
Not use solvent [Figure 20-30-24].
Figure 20-30-25

Peen The Steel Rod

Piston

Piston Rod
Set Screw
P-60386

P-60389
Clean internal and external threads using a tap, die or
wire brush [Figure 20-30-22].
Using a #7 drill bit, drill a hole 5/8 “ deep, then tap hole
Using a slovent, thoroughly clean all parts until they are using 1/4-20 tap, tap the hole 7/16” deep. Apply a strip of
free of oil, water, grease and any old thread sealant. Loctite to a 1/4-20 x 3/8” long set screw. Install and
Allow solvent to evaporate until all components are dry. tighten set screw making sure it engages both the piston
and the rod. Peen rod side of hole. Do Not peen cast iron
NOTE: DO NOT dry parts by blowing components piston side of hole [Figure 20-30-25].
with shop air. This will only spray the
Allow at least 6 hours before installing the rod assemblt
components with water and oil found in the air
into the cylinder.
line.

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SWING VALVE CYLINDER (CONT’D) Figure 20-30-27

Assembly

Clean all components in clean solvent and dry with

compressed air. Discard all the O-rings and back-up
rings and replace them with new O-rings and back-up
rings. Apply clean hydraulic fluid to all O-rings, back-up
1
rings, spools and valves.

IMPORTANT
P-57829
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, Install cylinder casing (Item 1) [Figure 20-30-27].
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Figure 20-30-28
I-2003-0888
1
1

Dealer Copy -- Not for Resale

IMPORTANT
Contain and dispose of any oil leakage in an
environmentally safe manner.
I-2066-0395

Figure 20-30-26
2
2
P-57824
1

Install O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-30-28].

Figure 20-30-29

P-57825

Install O-ring (Item 1) [Figure 20-30-26].

P-57830

Install rod assembly (Item 1) [Figure 20-30-29].

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SWING VALVE CYLINDER (CONT’D) Figure 20-30-33

Assembly (Cont’d)

Figure 20-30-30
1

1 P-60384

NOTE: Inspect the surface of the piston rod for

scratches, burrs, dents or other damage. A
damaged piston rod suface will result in
P-57828
premature rod seal failure.

Install O-ring (Item 1) [Figure 20-30-30]. Lubricate the bore of the gland and the seals, then slide
the gland over the end of the piston rod.
Figure 20-30-31
Install gland (Item 1) [Figure 20-30-33] into the retainer

Dealer Copy -- Not for Resale

until it is seated firmly against the head. The gland to
head O-ring serves as a torque prevailing lock.

Figure 20-30-34

2
1

P-57823

Install O-ring (Item 1) [Figure 20-30-31].

P-57820
Figure 20-30-32

Install the jam nut (Item 1), then install the four nuts (Item
1) [Figure 20-30-34].
3
Installation: Tighten nuts to 65-70 ft.-lb. (88-95 N•m)
torque.

P-60385

Install head (Item 1) and retainer (Item 2), then install the
four nuts (Item 3) and tighten to 120 ft.-lb. (163 N•m)
torque [Figure 20-30-32].

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SWING VALVE CYLINDER (CONT’D) Figure 20-30-37

Assembly (Cont’d)
1
Figure 20-30-35

P-57817

Install fittings (Item 1) [Figure 20-30-37].

P-57819
Figure 20-30-38

Install clevis (Item 1), then tighten jam nut (Item 2)

[Figure 20-30-35]. 1

Dealer Copy -- Not for Resale

Figure 20-30-36

3
1

2
P-57816

P-57821 Install mounting plate (Item 1), then install pin (Item 2)
and install cotter pin (Item 3) [Figure 20-30-38].
Install O-ring (Item 1) [Figure 20-30-36].

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PRESSURE GAUGE Figure 20-40-3

Removal And Installation

Figure 20-40-1

P-14532

1
Loosen the handle (Item 1) [Figure 20-40-3] on the
1 remote attachment control arm and remove the remote
attachment control (RAC) box from the Concrete Pump.
P-14530
Figure 20-40-4

Remove the wire ties (Item 1) [Figure 20-40-1] securing

the pressure gauge hose and wire harness.

Dealer Copy -- Not for Resale

Figure 20-40-2

1
2

P-14533

1
Remove the four bolts (Item 1) [Figure 20-40-4] from the
control panel mount. Remove the control panel mount
from the RAC box.

Figure 20-40-5
P-14531

Disconnect the hose (Item 1) from the back of the

pressure gauge (Item 2) [Figure 20-40-2]. Connect a
plug to the end of the hose to prevent hydraulic fluid from
leaking.

1 1

P-14534

Remove the four bolts (Item 1) [Figure 20-40-5] from the

control panel mount. Remove the control panel mount
from the RAC box.

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 Dealer Copy -- Not for Resale

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AGITATOR HYDRAULIC MOTOR Figure 20-50-1

Removal And Installation

1
WARNING
AVOID INJURY OR DEATH
Before cleaning, servicing or inspecting the
Concrete Pump, stop the loader engine and
disconnect the hydraulic hoses and electrical 1
harnesses from the loader.
W-2366-0500

P-57557

IMPORTANT Remove the hydraulic hoses (Item 1) [Figure 20-50-1].

Mark hoses for correct installation.

If the engine stop switch is used to stop the loader
engine, turn the key switch to the OFF position. If the Figure 20-50-2
Remote Attachment Control key switch is left in the

Dealer Copy -- Not for Resale

ON position, there will be a constant current draw on
the battery resulting in a weak or discharged battery.
I-2188-0998

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. P-57560
I-2003-0888

Remove bolts (Item 1) [Figure 20-50-2] from both sides

of the motor. Remove the motor.

IMPORTANT Installation: Tighten bolts to 65-70 ft.-lb. (88-95 N•m)

torque.
Contain and dispose of any oil leakage in an
environmentally safe manner.
I-2066-0395

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AGITATOR HYDRAULIC MOTOR (CONT’D)

Parts Identification
1. Dirt & Water Seal
2. Outer Bushing
3. Housing
4. Back-up Ring
5. Back-up Washer
6. Seal
7. Thrust Washer
8. Thrust Bearing
3
9. Inner Bushing 1 2 10
10. Key 4 6 8 12 14
11. Coupling Shaft
13
12. O-ring
13. Drive
14. Wear Plate

Dealer Copy -- Not for Resale

15. Bolt
5
16. End Plate 7
9 11
17. Commutator Ring
25
18. O-ring
23 21 20
19. Commutator
17 16
20. Manifold 19
21. Stator Half
22. Vane (small) 15

23. Rotor
24. Vane (large)
24
25. Stator Half 22
18

P-60381

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AGITATOR HYDRAULIC MOTOR (CONT’D) Figure 20-50-4

Disassembly

The following pictures may not show the exact motor

your working on but the procedure is correct.

1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
P-60312
damage the system.
I-2003-0888
Remove bolts (Item 1) [Figure 20-50-4].

Figure 20-50-5

IMPORTANT

Dealer Copy -- Not for Resale

Contain and dispose of any oil leakage in an
environmentally safe manner.
I-2066-0395
1

Figure 20-50-3

P-60318

Remove end plate (Item 1) [Figure 20-50-5] and O-ring.

Discard O-ring.

Installation: Always use new O-rings during assembly.

Figure 20-50-6
P-60314

Place the motor in a soft jawed vice, with coupling shaft

pointed down and the vise jaws clamping firmly on the
sides of the housing mounting flange or port bosses
[Figure 20-50-3].
1
Scribe an alignment mark down and across the motor
components from end cover to housing for correct
assembly [Figure 20-50-3].

P-60315

Remove commutator ring (Item 1) [Figure 20-50-6].

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AGITATOR HYDRAULIC MOTOR (CONT’D) Figure 20-50-9

Disassembly (Cont’d)

Figure 20-50-7

1
2

P-60321

P-60319 Remove manifold (Item 1) [Figure 20-50-9] and inspect

for excessive wear or damage. Replace if necessary.

Remove commutator (Item 1) [Figure 20-50-7]. NOTE: A polished pattern on the ground surface
from commutator or rotor rotation is normal.
Figure 20-50-8
Remove O-rings (Item 2) [Figure 20-50-9] from both

Dealer Copy -- Not for Resale

sides of the manifold. Discard O-rings.

Installation: Always use new O-rings during assembly.

P-60320

Remove O-ring (Item 1) [Figure 20-50-8] from the

commutator by blowing air into ring grooves until the O-
ring is lifted out. Discard O-ring.

Installation: Always use new O-rings during assembly.

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AGITATOR HYDRAULIC MOTOR (CONT’D) Figure 20-50-11

Disassembly (Cont’d)

Figure 20-50-10

1
2 1

P-60326

P-60322
The drive link (Item 1) [Figure 20-50-11] may come away
from the coupling shaft with the rotor set, and wear plate.
Remove rotor set (Item 1) and wear plate (Item 2) to You may have to shift the rotor set on the wear plate to
retain rotor set in it’s assembled form, maintaining the work the drive link out of the rotor and wear plate.
same rotor vane to stator contact surfaces [Figure 20-
50-10]. Figure 20-50-12

Dealer Copy -- Not for Resale

Inspect the rotor set in its assembled form for nicks,
scoring, or spalling on any surface and for broken or
worn splines. If the rotor set component requires
replacement, the complete rotor set must be replaced as
it is a matched set. Inspect the wear plate for cracks,
brinelling, or scoring. Remove and discard seal ring that
is between the rotor set and wear plate.

NOTE: The rotor set components may become

disassembled during service procedures.
Marking the surface of the rotor and stator
that is facing UP, with etching ink or grease
pencil before removal from motor will ensure
correct reassembly of rotor into stator and
P-60325
rotor set into motor. Marking all rotor
components and mating spline components
for exact repositioning at assembly will Place rotor set and wear plate on a flat surface and
ensure maximum wear life and performance center rotor in stator such that two rotor lobes (180
of rotor set and motor. degrees apart) and a roller vane center line are on the
same stator center line. Check the rotor lobe to roller
NOTE: A polished pattern on the wear plate from vane clearance with a feeler gage at this common center
rotor rotation is normal. line. If there is more than .005 inches (0.13 mm) of
clearance, replace rotor set [Figure 20-50-12].

NOTE: If rotor set has two stator halves and two sets
of seven vanes, check the rotor lobe to roller
vane clearance at both ends of rotor.

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AGITATOR HYDRAULIC MOTOR (CONT’D) Figure 20-50-15

Disassembly (Cont’d)

Figure 20-50-13
1

P-60329

Remove coupling shaft (Item 1) [Figure 20-50-15], by

P-60324 pushing on the output end of shaft.

Figure 20-50-16
Remove drive link (Item 1) [Figure 20-50-13] from
coupling shaft if it was not removed with rotor set and Inspection Areas

Dealer Copy -- Not for Resale

wear plate. Inspect drive link for cracks and worn or
damaged splines. No perceptible lash (play) should be
noted between mating spline parts. Remove and discard
O-ring from housing.

Figure 20-50-14

P-60328

Inspect coupling shaft bearing and seal surfaces for

spalling, nicks, grooves, severe wear or corrosion and
discoloration. Inspect for damaged or worn internal and
external splines or keyway. Replace coupling shaft if any
of these conditions exist [Figure 20-50-16].
P-60330
NOTE: Minor shaft wear in seal area is permissible. If
wear exceeds .020 inches (0.51 mm)
Check exposed portion of coupling shaft to be sure you diametrically, replace coupling shaft.
have removed all signs of rust and corrosion which might
prevent its withdrawal through the seal and bearing. NOTE: A slight “polish” is permissible in the shaft
Crocus cloth or fine emery paper may be used [Figure bearing areas. Anything more would require
20-50-14]. coupling shaft replacement.

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AGITATOR HYDRAULIC MOTOR (CONT’D) Figure 20-50-19

Disassembly (Cont’d)

Figure 20-50-17

1
2

P-60333

Remove housing from vise, invert it then remove and

P-60327 discard seal (Item 1) [Figure 20-50-19].

Figure 20-50-20
Remove O-ring (Item 1) [Figure 20-50-17] from housing.
Discard O-ring.

Dealer Copy -- Not for Resale

Installation: Always use new O-rings during assembly.

Remove thrust bearing (Item 2) and thrust washer (Item

3), then inspect for wear, brinelling, corrosion and a full
complement of retained rollers [Figure 20-50-17].

Figure 20-50-18

P-60334
1

Inspect housing assembly for cracks, the machined

surfaces for nicks, burrs, brinelling or corrosion. Remove
burrs that can be removed without changing dimensional
2 characteristics. Inspect tapped holes for thread damage.
If the housing is defective in these areas, discard the
housing assembly [Figure 20-50-20].

P-60331

Remove seal (Item 1) and back-up ring (Item 2) from

housing and backup washer [Figure 20-50-18].

NOTE: The original motor design did not include

backup washer, but must include backup
washer when reassembled for service.

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AGITATOR HYDRAULIC MOTOR (CONT’D) Figure 20-50-23

Disassembly (Cont’d)

Figure 20-50-21

P-60337

Measure and record the depth or location of bearing/

P-60335 bushing in relation to the housing wear plate surface and
the depth or location of bearing/bushing in relation to the
beginning of bearing/bushing counter bore before
Inspect the housing bearings/bushings and if they are removing the bearings/ bushing for correct assembly of
captured in the housing cavity the two thrust washers and new bearings/bushings [Figure 20-50-23].

Dealer Copy -- Not for Resale

thrust bearing. The bearing rollers must be firmly retained
in the bearing cages, but must rotate and orbit freely. All Figure 20-50-24
rollers and thrust washers must be free of brinelling and
corrosion [Figure 20-50-21].

NOTE: A bearing, bushing, or thrust washer that

does not pass inspection must be replaced. 1

Figure 20-50-22

P-60338

Remove bearing/bushing (Item 1) from housing (Item 2)

without damaging the housing [Figure 20-50-24].

P-60336

The bushing to coupling shaft diameter clearance must

not exceed .010 inch (.025 mm) [Figure 20-50-22].

NOTE: If the housing has passed this inspection the

disassembly of the motor is completed.
However, if the bearings, bushing or thrust
washers must be replaced. Use the following
procedure to remove the bearings, bushing or
thrust washers.

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AGITATOR HYDRAULIC MOTOR (CONT’D)

Disassembly (Cont’d)

Figure 20-50-25

P-60339

Remove thrust washers and thrust bearing if they were

previously retained in the housing by bearing [Figure 20-

Dealer Copy -- Not for Resale

50-25].

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AGITATOR HYDRAULIC MOTOR (CONT’D) Figure 20-50-27

Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-60343
Figure 20-50-26

Press the inner housing bearing/bushing into its

counterbore in the housing until its flush to .03 inch (.76
mm) below the housing wear plate contact face [Figure
20-50-27].

Figure 20-50-28

Dealer Copy -- Not for Resale

P-60340

NOTE: If the housing bearing components were

removed for replacement, thoroughly coat
and pack a new outer bearing/bushing with
clean corrosion resistant grease.
P-60349
Press the new bearing/bushing into the counterbore at
the mounting flange end of the housing. Press bearing/
bushing into the housing to a required depth of .151/.161 Press a new dirt and water seal into the housing outer
inches (3.84/4.09 mm) from the end of the bearing bearing counterbore [Figure 20-50-28].
counterbore [Figure 20-50-26].

NOTE: Bearing mandrel must be pressed against the

lettered end of bearing shell. Take care that
the housing bore is square with the press
base and the bearing/bushing is not cocked
when pressing a bearing/bushing into the
housing. The bearing/bushing depths
specified must be achieved to insure
adequate bearing support and correct
relationship to adjacent components when
assembled.

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AGITATOR HYDRAULIC MOTOR (CONT’D) Figure 20-50-31

Assembly (Cont’d)

Figure 20-50-29

P-60353

Install a new backup ring, new backup washer and new

P-60348 seal with the seal lip facing toward the inside of motor
[Figure 20-50-31].

Press the dirt and water seal into the housing until its Figure 20-50-32
flange is flush against the housing [Figure 20-50-29].

Dealer Copy -- Not for Resale

Figure 20-50-30
2

P-60351

P-60346 Install thrust washer (Item 1), then thrust bearing (Item 2)
[Figure 20-50-32].

Place housing assembly into a soft jawed vise with the

coupling shaft bore down, clamping against the mounting
flange [Figure 20-50-30].

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AGITATOR HYDRAULIC MOTOR (CONT’D) Figure 20-50-35

Assembly (Cont’d)

Figure 20-50-33

P-60355

The coupling shaft will be flush or just below the housing

P-60350 wear surface when properly seated [Figure 20-50-35].

Figure 20-50-36
Apply masking tape around splines or keyway on shaft to
prevent damage to seal [Figure 20-50-33].

Dealer Copy -- Not for Resale

Figure 20-50-34

P-60357

Apply a small amount of clean grease to a new O-ring

P-60354 and install it into the housing [Figure 20-50-36].

Apply a generous amount of clean corrosion resistant

grease to the lower (outer) housing bearing/bushing.
Install the coupling shaft (Item 1) [Figure 20-50-34] into
housing, seating it against the thrust bearing.

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AGITATOR HYDRAULIC MOTOR (CONT’D) Figure 20-50-39

Assembly (Cont’d)

Figure 20-50-37

1 P-60360

2
Apply a small amount of clean grease to a new O-ring
and install it into the groove on the wear plate side of the
rotor set stator [Figure 20-50-39].
P-60358
Figure 20-50-40

Install One or two alignment studs (Item 1) [Figure 20-

50-37] screwed finger tight into housing bolt holes,

Dealer Copy -- Not for Resale

approximately 180 degrees apart, will facilitate the
assembly and alignment of components as required in 1
the following procedures.

Install drive link (Item 2) the long splined end down into
the coupling shaft and engage the drive link splines into
mesh with the coupling shaft splines [Figure 20-50-37].

Figure 20-50-38

P-60361

1
NOTE: It may be necessary to turn one alignment
stud out of the housing temporarily to
assemble rotor set or manifold over the drive
link.

Install the assembled rotor set (Item 1) [Figure 20-50-40]

onto wear plate with rotor counterbore and seal ring side
down and the splines into mesh with the drive link
splines.
P-60359
NOTE: The rotor set rotor counterbore side must be
down against wear plate for drive link
Install wear plate (Item 1) [Figure 20-50-38] over the clearance and to maintain the original rotor-
drive link and alignment studs onto the housing. drive link spline contact. A rotor set without a
counterbore and that was not etched before
disassembly can be reinstalled using the
drive link spline pattern on the rotor splines if
apparent, to determine which side was down.
The rotor set seal ring groove faces toward
the wear plate.

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AGITATOR HYDRAULIC MOTOR (CONT’D) Figure 20-50-43

Assembly (Cont’d)

Figure 20-50-41

P-60364

Apply grease to a new O-ring and install it in the groove

P-60362 exposed on the manifold [Figure 20-50-43].

Figure 20-50-44
Apply clean grease to a new O-ring and install it in the
groove in the rotor set contact side of manifold [Figure

Dealer Copy -- Not for Resale

20-50-41].

NOTE: The manifold is made up of several plates

bonded together permanently to form an
integral component. The manifold surface
that must contact the rotor set has it’s series
of irregular shaped cavities on the largest
circumference or circle around the inside
diameter. The polished impression left on the
manifold by the rotor set is another indication
of which surface must contact the rotor set. 1

Figure 20-50-42 P-60365

Assemble the commutator ring (Item 1) [Figure 20-50-

44] over alignment studs onto the manifold.
1

P-60363

Install the manifold (Item 1) [Figure 20-50-42] over the

alignment stud and drive link and onto the rotor set. Be
sure the correct manifold surface is against the rotor set.

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20-50-14 Service Manual
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AGITATOR HYDRAULIC MOTOR (CONT’D) Figure 20-50-47

Assembly (Cont’d)

Figure 20-50-45

P-60370

Install a new O-ring in the end plate [Figure 20-50-47].

P-60366
Figure 20-50-48

Install a new O-ring flat side up, into commutator [Figure

20-50-45].

Dealer Copy -- Not for Resale

Figure 20-50-46

P-60371

Install end plate (Item 1) [Figure 20-50-48] over the

alignment studs and onto the commutator set.
P-60367

Install commutator over the end of drive link onto

manifold with seal ring side up [Figure 20-50-46].

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20-50-15 Service Manual
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AGITATOR HYDRAULIC MOTOR (CONT’D) Figure 20-50-51

Assembly (Cont’d)

Figure 20-50-49
4 3

2 1

P-60375

Alternately and progressively tighten the bolts to pull the

P-60372 end plate and other components into place with a final
torque of 22-26 ft. lb. (30-35 N•m) [Figure 20-50-51].

5 bolt end plate bolt hole relationship to housing port

bosses [Figure 20-50-49].

Dealer Copy -- Not for Resale

Figure 20-50-50

P-60373

Install bolts and screw in finger tight. Remove and

replace the two alignment studs with bolts after the other
bolts are in place [Figure 20-50-50].

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 MAIN FRAME

AGITATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

CONCRETE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

HOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-3 MAIN
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1 FRAME

HOPPER CLEAN OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 30-90-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90-1

OUTLET HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

REMOTE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-5

Dealer Copy -- Not for Resale

Battery Compartment Removal And Installation . . . . . . . . 30-50-4
Engine Stop Switch Removal And Installation . . . . . . . . . . 30-50-1
Power Switch Removal And Installation . . . . . . . . . . . . . . 30-50-3
Pump OFF/ON Switch Removal And Installation. . . . . . . . 30-50-2
Radio Antenna Removal And Installation . . . . . . . . . . . . . 30-50-4
Radio Assembly And Disassembly . . . . . . . . . . . . . . . . . . 30-50-1
Radio Harness Removal And Installation . . . . . . . . . . . . . 30-50-2
Receiver Removal And Installation . . . . . . . . . . . . . . . . . . 30-50-5
Receiver Board Removal And Installation . . . . . . . . . . . . . 30-50-5
Remote Antenna Disassembly And Assembly. . . . . . . . . . 30-50-4
Reverse Pump Switch Removal And Installation. . . . . . . . 30-50-2
STD Flow/HIGH Flow Switch Removal And Installation . . 30-50-3
Switch Guard Removal And Installation. . . . . . . . . . . . . . . 30-50-3

PISTON CUP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2

SWING VALVE AND CRANK ARM. . . . . . . . . . . . . . . . . . . . . 30-80-1

Crank Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-5
Crank Arm Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-5
Crank Arm Removal And Installation . . . . . . . . . . . . . . . . . 30-80-3
Swing Valve Removal And Installation. . . . . . . . . . . . . . . . 30-80-1

WEAR PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

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 Dealer Copy -- Not for Resale

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30-02 Service Manual
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PISTON CUP REPLACEMENT

Parts Identification

1. Cylinder
2. Stop
3. Bolt
4. Washer
5. Washer
6. O-Ring
7. Plate
8. Plate
9. Ring
10. Ring
11. Cup
12. Spacer
13. Plate
14. Bolt
15. O-ring
16. Plate
17. Nut
18. Bolt
19. Bolt
20. Washer
21. Bolt
22. Cylinder

Dealer Copy -- Not for Resale

23. STA Strap
24. Grease Zerk
25. Grease Zerk
26. Pin
27. Cotter Pin
28. Housing
29. Plug
30. Bolt
31. Cover
32. Latch
33. Rivet
34. Flange
35. Seal
36. Bolt
37. Seal
38. Switch
39. Extension
40. Bolt
41. Grommet
42. Plate
43. Clamp
44. Bolt
45. Washer
46. Nut
47. Nut
48. Shaft
49. Washer
50. Tubeline

P-60578

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PISTON CUP REPLACEMENT (CONT’D)

Removal
WARNING
The piston cups will occasionally require replacement
depending on the following factors. AVOID INJURY OR DEATH
Do not release couplings until pressure in a plugged
• The fluid level and cleanliness of the lubrication box. delivery system has been relieved by reversing the
• The size and type of aggregate. pump. Pressurized concrete can blow out when
couplings are released.
• The type of concrete being pumped. When removing a coupling in a plugged delivery
Replace the piston cups when increasingly large particles system, turn your face away from the coupling as
of sand and cement pass into the lubrication box. you release the coupling handle.
W-2368-0500
NOTE: Do not allow the cups to become so worn that
they begin to pass lubrication into the
Start the engine and turn on the auxiliary hydraulics.
material cylinders. If the liquid level of the
Cycle the pump in reverse until one of the pistons
lubrication box becomes too low, the piston
reaches the fully discharged position at the end of the
cups will severely deform due to excessive
concrete cylinder.
heat.
Whenever replacement is due, both piston cups should Stop the engine.
be replaced.
Disconnect the hydraulic lines from the loader.

Dealer Copy -- Not for Resale

WARNING Remove hopper. (See Removal And Installation on Page
30-70-1.)

AVOID INJURY OR DEATH Figure 30-10-1

Before cleaning, servicing or inspecting the
Concrete Pump, stop the loader engine and
disconnect the hydraulic hoses and electrical 1
harnesses from the loader.
W-2366-0500

IMPORTANT
If the engine stop switch is used to stop the loader
2
engine, turn the key switch to the OFF position. If the
Remote Attachment Control key switch is left in the P-57563
ON position, there will be a constant current draw on
the battery resulting in a weak or discharged battery.
I-2188-0998 NOTE: Before removing bolts from the piston,
concrete may need to be removed from
around each bolt. When removing concrete be
careful not to damage the front face plate.

Remove the three bolts (Item 1) [Figure 30-10-1] from

the piston.

Remove the front face plate (Item 2) [Figure 30-10-1].

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PISTON CUP REPLACEMENT (CONT’D)

Removal (Cont’d)

Figure 30-10-2

P-57593A

Install two full thread studs (Item 1) [Figure 30-10-2] into

the piston. Do not tighten. Use the two studs as

Dealer Copy -- Not for Resale

leverage to remove the rubber piston cup and rear
components.

NOTE: Use two 3/8 - 16 - 7” full thread studs as an

aide while removing the cylinder components.

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30-10-3 Service Manual
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PISTON CUP REPLACEMENT (CONT’D) Figure 30-10-5

Installation
1
NOTE: Use two 3/8 - 16 - 7” full thread studs as an
alignment aide while installing the cylinder
components.

NOTE: Inspect the end of the concrete tubes for

damage before re-installing the piston cups.
Damaged tubes will greatly reduce the service
life of the piston cups.

Figure 30-10-3
O-RING

O-ring with four oil passage grooves (Item 1) [Figure 30-

10-5].
Figure 30-10-6

Tube Damage 2

Dealer Copy -- Not for Resale

P-60576

Inspect the end of the concrete tubes for damage [Figure

30-10-3]. 1
P-57575
Figure 30-10-4

Install the O-ring (Item 1) with the four oil passage

grooves on the oiler plate (Item 2) [Figure 30-10-6].
Install the oiler plate into the concrete cylinder utilizing
the studs for alignment.
Figure 30-10-7

1
P-57574

Install the two full thread studs (Item 1) [Figure 30-10-4] 1

into the piston adapter. P-57573A

Coat the inside of the cylinder with grease. NOTE: The felt ring must be saturated in clean engine
oil or hydraulic fluid prior to installation.
Install the felt holder over the oiler plate, then install felt
ring (Item 1) [Figure 30-10-7] into the felt holder.

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PISTON CUP REPLACEMENT (CONT’D) Figure 30-10-10

Installation (Cont’d)

Figure 30-10-8 1

P-57569A

P-57572A
NOTE: Place a bead of silicone sealant on the rear of
the face plate.
Install the bronze ring (Item 1) [Figure 30-10-8].
Install the face plate (Item 1) [Figure 30-10-10].
Figure 30-10-9
Figure 30-10-11

Dealer Copy -- Not for Resale

1
1
2

P-57570A
P-57569B

NOTE: Place a bead of silicone sealant on the front of NOTE: Add a small amount of silicone to the threads
the rubber piston cup. of the three bolts before reinstalling them.

NOTE: DO NOT get silicone on the side of the piston Install one bolt (Item 1) into the open bolt hole, then
cup that faces the felt ring. remove the alignment studs (Item 2) and install the
remaining bolts [Figure 30-10-11].
Install the piston cup (Item 1) and three bushings (Item 2)
[Figure 30-10-9]. Installation: Tighten bolts to 55 ft.-lb. (74 N•m) torque.

NOTE: Failure to install the 3 bushings in the piston Connect the hydraulic lines to the loader.
cup will cause the cup to deform and will
result in reduced service life. Start the loader and engage the auxiliary hydraulics.
Cycle pump until the opposite piston in the fully
discharged position at the end of the concrete cylinder.

Repeat piston cup removal procedure.

Install hopper. (See Removal And Installation on Page

30-70-1.)

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 Dealer Copy -- Not for Resale

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30-10-6 Service Manual
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CONCRETE TUBES Remove hopper. (See Removal And Installation on Page
30-70-1.)
Removal And Installation
Remove swing valve and crank arm. (See Swing Valve
Removal And Installation on Page 30-80-1.)

WARNING Remove piston cups. (See Removal on Page 30-10-2.)

Remove wear plate. (See Removal And Installation on

AVOID INJURY OR DEATH
Page 30-40-1.)
Before cleaning, servicing or inspecting the
Concrete Pump, stop the loader engine and
Figure 30-20-1
disconnect the hydraulic hoses and electrical
harnesses from the loader.
W-2366-0500

IMPORTANT
If the engine stop switch is used to stop the loader 1
engine, turn the key switch to the OFF position. If the
Remote Attachment Control key switch is left in the

Dealer Copy -- Not for Resale

ON position, there will be a constant current draw on
the battery resulting in a weak or discharged battery. P-57832
I-2188-0998

Remove the four bolts (Item 1) mounting the concrete

tube wedges (Item 2) to the concrete tubes [Figure 30-
20-1].
WARNING Installation: Tighten bolts to 25-28 ft.-lb. (34-38 N•m)
AVOID INJURY OR DEATH torque.
Do not release couplings until pressure in a plugged
delivery system has been relieved by reversing the Figure 30-20-2
pump. Pressurized concrete can blow out when
couplings are released.
1
When removing a coupling in a plugged delivery
system, turn your face away from the coupling as
you release the coupling handle.
W-2368-0500

WARNING
Wear safety glasses to prevent eye injury when any P-57833

of the following conditions exist:

• When fluids are under pressure. Remove the two wedges (Item 1) [Figure 30-20-2].
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285

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30-20-1 Service Manual
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CONCRETE TUBES (CONT’D)

Removal And Installation (Cont’d)

Figure 30-20-3

P-57834

Slide the concrete tube (Item 1) [Figure 30-20-3] forward

removing it from the frame.

Dealer Copy -- Not for Resale

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30-20-2 Service Manual
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OUTLET HOUSING

Removal And Installation

Figure 30-30-1

P-57762

Remove the six bolts (Item 1), then remove the outlet
housing (Item 2) [Figure 30-30-1].

Dealer Copy -- Not for Resale

Remove and inspect the outlet housing gasket. Replace
the outlet housing gasket if it is damaged.

Installation: Apply silicone sealant to the back side of

the outlet housing mounting flange. Align the holes of the
outlet housing with the holes in the hopper, then install
bolts and tighten to 65-70 ft.-lb (88-95 N•m) torque.

NOTE: When installing the outlet housing, check the

clearence between the swing valve and the
outlet housing. The space should not be
greater than 1/32 of an inch (.793 mm).

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30-30-1 Service Manual
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 Dealer Copy -- Not for Resale

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30-30-2 Service Manual
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WEAR PLATE Remove hopper. (See Removal And Installation on Page
30-70-1.)
Removal And Installation
Remove swing valve and crank arm. (See Swing Valve
Removal And Installation on Page 30-80-1.) (See Crank
Arm Removal And Installation on Page 30-80-3.)
WARNING Figure 30-40-1
AVOID INJURY OR DEATH
Before cleaning, servicing or inspecting the
Concrete Pump, stop the loader engine and
disconnect the hydraulic hoses and electrical
harnesses from the loader.
W-2366-0500

IMPORTANT 2
If the engine stop switch is used to stop the loader
engine, turn the key switch to the OFF position. If the P-57922
Remote Attachment Control key switch is left in the

Dealer Copy -- Not for Resale

ON position, there will be a constant current draw on
the battery resulting in a weak or discharged battery. Remove the five bolts (Item 1) then remove the wear
I-2188-0998 plate (Item 2) [Figure 30-40-1].
NOTE: Inspect all components for wear and damage.
The hard surface of the wear components
may appear to have small cracks on the face.
WARNING This is natural and is NOT a defect. Use
silicone on the face to seal the cracks.
AVOID INJURY OR DEATH Installation: The five bolts need to be equally snugged
Do not release couplings until pressure in a plugged and tightened to 90-100 ft.-lb. (125-135 N•m) torque.
delivery system has been relieved by reversing the Figure 30-40-2
pump. Pressurized concrete can blow out when
couplings are released.
When removing a coupling in a plugged delivery
system, turn your face away from the coupling as
you release the coupling handle.
W-2368-0500

OUT
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
P-60577

Be sure to install the wear plate with the hard surface

face out [Figure 30-40-2].

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30-40-1 Service Manual
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WEAR PLATE (CONT’D)

Removal And Installation (Cont’d)

Figure 30-40-3

P-57779

Remove O-rings (Item 1) [Figure 30-40-3].

NOTE: Always use new O-rings during installation.
Installation: Apply silicone sealant around the

Dealer Copy -- Not for Resale

circumference of the concrete tubes, install new O-rings.
Apply Silicone sealant to the back of the wear plate and
around the five bolt holes. Install the wear plate.

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30-40-2 Service Manual
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REMOTE CONTROL Engine Stop Switch Removal And Installation

Radio Assembly And Disassembly Figure 30-50-3

Figure 30-50-1

P-20956

P-20851
Remove Engine Stop switch nut (Item 1) [Figure 30-50-
3].
Loosen the four screws (Item 1) [Figure 30-50-1].
Remove switch and harness.

Dealer Copy -- Not for Resale

Remove the face plate (Item 2) [Figure 30-50-1].
Install new switch and harness on face plate.
Figure 30-50-2

P-20955

Unplug the Radio wire harness (Item 1) [Figure 30-50-2]

from radio board.

Installation: Radio wire harness plugs into the lower

right part of the radio board.

Unplug the Engine Stop wire harness (Item 2) [Figure

30-50-2] from the radio board.

Installation: Engine Stop wire harness plugs in just left

of the Radio wire harness.

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30-50-1 Service Manual
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REMOTE CONTROL (CONT'D) Reverse Pump Switch Removal And Installation

Radio Harness Removal And Installation Figure 30-50-5

Figure 30-50-4

1
1
3

2
1
2
P-20957

P-20957
Remove orange wire (Item 1) and green wire (Item 2)
[Figure 30-50-5].
Remove wires from toggle switch terminals (Item 1)
[Figure 30-50-4]. Remove the switch nut (Item 3) [Figure 30-50-5].

Dealer Copy -- Not for Resale

Remove orange wire (Item 2) [Figure 30-50-4] from Remove switch.
Reverse Pump switch (soldered connection).
Installation: Replace switch, then solder orange and
Installation: Connect new harness wires to the proper green wires to switch.
terminals on each switch.

Reverse Pump Switch - Orange and green (green

attached to No. 3 terminal of STD/HIGH Flow switch. Pump OFF/ON Switch Removal And Installation

Pump OFF/ON switch - Terminal No. 1 brown, No. 2 Figure 30-50-6

blue and No. 3 purple.

STD/HIGH Flow switch - Terminal No. 1 yellow, No. 2

blue (jumper from terminal No. 2 on Pump OFF/ON
switch) and No. 3 green.

P-20958

Remove wires from switch terminals.

Remove switch nut (Item 1) [Figure 30-50-6].

Remove switch.
Installation: Replace switch, then connect wires to the
proper switch terminals. Terminal No. 1 brown, No. 2 blue
and No. 3 purple.
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30-50-2 Service Manual
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REMOTE CONTROL (CONT'D) Power Switch Removal And Installation

STD Flow/HIGH Flow Switch Removal And Figure 30-50-9

Installation

Figure 30-50-7
2
1

P-20961
1

P-20958 Remove switch nut (Item 1) [Figure 30-50-9].

Remove power switch (Item 2) [Figure 30-50-9].

Remove wires from switch terminals.

Dealer Copy -- Not for Resale

Figure 30-50-10
Remove switch nut (Item 1) [Figure 30-50-7].

Remove switch.

Installation: Replace switch, then connect wires to the

proper switch terminals. Terminal No. 1 yellow, No. 2 blue
(jumper from terminal No. 2 on Pump OFF/ON switch) 1
and No. 3 green.

Switch Guard Removal And Installation

3
Figure 30-50-8
2

P-20962

2
1 Unplug power switch harness (Item 1) [Figure 30-50-10]
from radio board.

Remove red (Item 2) and black (Item 3) wires from

1
battery compartment [Figure 30-50-10].

Installation: Replace switch and harness, then solder

red and black wires to battery compartment.

P-20958 P-20959

Remove the two screws (Item 1) [Figure 30-50-8].

Remove the switch guard (Item 2) [Figure 30-50-8].

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30-50-3 Service Manual
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REMOTE CONTROL (CONT'D) Remote Antenna Disassembly And Assembly

Battery Compartment Removal And Installation Figure 30-50-13

Figure 30-50-11

2
3

1 1 2

P-20965

P-20964
Replace individual components as necessary.

Remove red and black wires from battery compartment. Remove the bolt (Item 1) [Figure 30-50-13].
Using a screwdriver, press snap locks (Item 1) in and

Dealer Copy -- Not for Resale

remove the battery compartment (Item 2) [Figure 30-50- Remove magnetic base (Item 2) [Figure 30-50-13].
11].
Remove antenna base (Item 3) [Figure 30-50-13]
Installation: Replace battery compartment, then solder
red and black wires to battery compartment. Figure 30-50-14

Radio Antenna Removal And Installation

2
Figure 30-50-12

P-20966

Holding on to antenna base (Item 1) turn antenna (Item

2
2) counterclockwise until free from base [Figure 30-50-
14].
P-20963

Assembly: Holding on to antenna base (Item 1) turn

Remove radio antenna (Item 1) by holding bolt (Item 2) antenna (Item 2) clockwise until tight [Figure 30-50-14].
and turning antenna counterclockwise until free from bolt
[Figure 30-50-12].

Installation: Replace radio antenna by holding bolt (Item

2) and turning antenna (Item 1) clockwise until tight
[Figure 30-50-12].

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30-50-4 Service Manual
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REMOTE CONTROL (CONT'D) Receiver Board Removal And Installation

Assembly Figure 30-50-17

Figure 30-50-15

3 1
P-20952

P-20965
Remove nut (Item 1) [Figure 30-50-17] from the antenna
cord hook-up.
Place magnetic base (Item 1) on antenna base (Item 2)
[Figure 30-50-15]. Figure 30-50-18

Dealer Copy -- Not for Resale

Insert bolt (Item 3) [Figure 30-50-15] and tighten. 2

Receiver Removal And Installation

Figure 30-50-16 1
1

1 1 1 P-20952

Remove four bolts (Item 1) mounting receiver board

(Item 2) to receiver [Figure 30-50-18].

2 Installation: Replace receiver board, then insert and

tighten bolts.
P-20954

Loosen bolts (Item 1) [Figure 30-50-16] (bolts will remain

in cover).

Remove receiver cover (Item 2) [Figure 30-50-16].

Disconnect wire harness.

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30-50-5 Service Manual
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REMOTE CONTROL (CONT'D)

Receiver Board Removal And Installation (Cont’d)

Figure 30-50-19

P-20952

Install nut (Item 1) [Figure 30-50-19] on the antenna cord

hook-up.

Dealer Copy -- Not for Resale

Figure 30-50-20

2
1

P-20954

Place cover (Item 1) on receiver and tighten bolts (Item

2) [Figure 30-50-20].

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AGITATOR Figure 30-60-1

Removal And Installation

WARNING
AVOID INJURY OR DEATH
Before cleaning, servicing or inspecting the
Concrete Pump, stop the loader engine and
disconnect the hydraulic hoses and electrical 1
harnesses from the loader.
W-2366-0500 P-57535

Lift and lock hopper cover open.

IMPORTANT Remove the bolt(s) (Item 1) from both sides of the hopper
grate [Figure 30-60-1].
If the engine stop switch is used to stop the loader
Installation: Tighten bolts to 65-70 ft.-lb. (88-95 N•m)
engine, turn the key switch to the OFF position. If the
torque.
Remote Attachment Control key switch is left in the

Dealer Copy -- Not for Resale

ON position, there will be a constant current draw on
Figure 30-60-2
the battery resulting in a weak or discharged battery.
I-2188-0998

1
WARNING 1
AVOID INJURY OR DEATH
Do not release couplings until pressure in a plugged
delivery system has been relieved by reversing the
pump. Pressurized concrete can blow out when
couplings are released. 2
P-57558
When removing a coupling in a plugged delivery
system, turn your face away from the coupling as
you release the coupling handle. NOTE: Use chains that are in good condition and of
W-2368-0500
adequate size to lift the attachment.

Install a chain (Item 1) on the hopper grate (Item 2), then

remove the hopper grate [Figure 30-60-2].
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285

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30-60-1 Service Manual
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AGITATOR (CONT’D) Figure 30-60-4

Removal And Installation (Cont’d)

1
Figure 30-60-3

1 P-57840

Loosen the two set screws (Item 1) and remove the

P-57536 locking collar (Item 2) from the left (motor) side of the
hopper [Figure 30-60-4].

Remove the two bolts (Item 1) and nuts, then remove the Figure 30-60-5
agitator paddles (Item 2) [Figure 30-60-3] from the shaft.

Dealer Copy -- Not for Resale

Installation: Tighten bolts to 25-28 ft.-lb. (34-38 N•m)
torque. 1

Repeat procedure for remaining agitator paddles.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
P-57841
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 Remove the four bolts (Item 1) then remove the bearing
housing (Item 2) [Figure 30-60-5].
Remove agitator motor. (See Removal And Installation
on Page 20-50-1.) Installation: Tighten bolts to 40-45 ft.-lb. (54-61 N•m)
torque.

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30-60-2 Service Manual
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AGITATOR (CONT’D) Figure 30-60-9

Removal And Installation (Cont’d)

Figure 30-60-6

P-57837

P-57842 Remove spring (Item 1) [Figure 30-60-9].

Figure 30-60-10
Remove and replace bearing (Item 1) [Figure 30-60-6].

Figure 30-60-7

Dealer Copy -- Not for Resale

1

P-57921 P-57838

Remove end cap (Item 1) [Figure 30-60-7]. Installation: When installing the bearing on the right side
of the hopper, install the components in this order
Figure 30-60-8 [Figure 30-60-10].

P-57836

Loosen the two set screws (Item 1) and remove the

locking collar (Item 2) from the right side of the hopper
[Figure 30-60-8].

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30-60-3 Service Manual
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AGITATOR (CONT’D) Figure 30-60-12

Removal And Installation (Cont’d)

WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285 P-57847

Figure 30-60-11 Installation: Apply a light coat of oil to seals and install
the seals in this order [Figure 30-60-12] from left to right.

NOTE: Install the seals so that the seam of the

previous seal is not in line with the seam of
the seal being installed next.

Dealer Copy -- Not for Resale

Figure 30-60-13

P-57846

Use a hammer and punch to remove the seals around

both ends of agitator shaft [Figure 30-60-11].

NOTE: Drive the seals out from the inside of the

hopper.
P-57848

Remove agitator shaft (Item 1) [Figure 30-60-13].

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HOPPER Figure 30-70-1

Removal And Installation

WARNING 1

AVOID INJURY OR DEATH

Before cleaning, servicing or inspecting the
Concrete Pump, stop the loader engine and
disconnect the hydraulic hoses and electrical 1
harnesses from the loader.
W-2366-0500

P-57557

IMPORTANT Remove the two hydraulic hoses (Item 1) [Figure 30-70-

1] from the agitator motor.

If the engine stop switch is used to stop the loader

engine, turn the key switch to the OFF position. If the
Remote Attachment Control key switch is left in the
WARNING

Dealer Copy -- Not for Resale

ON position, there will be a constant current draw on
the battery resulting in a weak or discharged battery.
I-2188-0998 Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.

WARNING • Engine is running.

• Tools are being used.
W-2019-1285
AVOID INJURY OR DEATH
Do not release couplings until pressure in a plugged Figure 30-70-2
delivery system has been relieved by reversing the
pump. Pressurized concrete can blow out when
couplings are released.
When removing a coupling in a plugged delivery
system, turn your face away from the coupling as
you release the coupling handle.
W-2368-0500

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all P-57535
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Lift and lock hopper cover open.
I-2003-0888
Remove the bolt(s) (Item 1) from both sides of the hopper
grate [Figure 30-70-2].

Installation: Tighten bolts to 65-70 ft.-lb. (88-95 N•m)

torque.

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30-70-1 Service Manual
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HOPPER (CONT’D) Figure 30-70-5

Removal And Installation (Cont’d) Eyebolt

1 4
Figure 30-70-3 2

3 2
1 Sequence
1
1
2

P-57560

2
Remove the tie rod nuts (Item 1) on both sides, then
P-57558 loosen the four eyebolts (Item 2) on both sides [Figure
30-70-5].

NOTE: Use chains that are in good condition and of Installation: Tighten eyebolts in sequence until the
adequate size to lift the attachment. silicone sealant is squeezed out around the hopper.

Dealer Copy -- Not for Resale

Install a chain (Item 1) on the hopper grate (Item 2) and Figure 30-70-6
remove the hopper grate [Figure 30-70-3].

Figure 30-70-4 1

Silicone Sealant

1
1

P-57562

P-57559 Move the hopper (Item 1) [Figure 30-70-6] away from

the concrete pump frame.

NOTE: Use chains that are in good condition and of NOTE: When removing the hopper, use extreme care
adequate size to lift the attachment. not to damage the hopper seal.

Install a chain (Item 1) [Figure 30-70-4] around the Installation: Place a bead of silicone sealant on the
agitator shaft. hopper flange before installing the hopper. Move the
hopper into position, align the hopper and tighten eye
bolts and tie rod nuts.

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30-70-2 Service Manual
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HOPPER (CONT’D) Figure 30-70-8

Alignment Procedure

1 1
WARNING
AVOID INJURY OR DEATH
Before cleaning, servicing or inspecting the
Concrete Pump, stop the loader engine and
disconnect the hydraulic hoses and electrical
harnesses from the loader. P-57534
W-2366-0500

Install the two tie rods (Item 1)[Figure 30-70-8] and nuts.
The tie rods will hold the hopper during the alignment
procedure.
WARNING Figure 30-70-9

Wear safety glasses to prevent eye injury when any

of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present. 1 1

Dealer Copy -- Not for Resale

• Engine is running.
• Tools are being used.
W-2019-1285

Figure 30-70-7 2

P-57553 A P-57792

Equal Spacing Use the two side adjustment bolts (Item 1) [Figure 30-
70-9] to move the hopper left or right.
Use the bottom adjustment bolt (Item 2) [Figure 30-70-9]
1 to move the hopper up and down.
Adjust the hopper until it is centered on the swing valve
P-57920
outlet, then install and tighten the eyebolts.
When installing and aligning the hopper, the spacing from Install hydraulics hoses and electrical connections to the
the top of the hopper (Item 1) [Figure 30-70-7] to the top loader.
of the mounting frame should be equal. Cycle the concrete pump until the swing valve is
positioned over the opposite concrete tube.
Remove hydraulics hoses and electrical connections
from the loader.
Check the alignment of the hopper. If the hopper moved
during the swing valve operation, the eyebolts need to be
loosened and removed. Loosen the tie rods.
NOTE: Repeat the alignment procedure until the
hopper stays centered on the swing valve
outlet. It is very important that the swing valve
and the hopper are aligned properly.

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 Dealer Copy -- Not for Resale

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30-70-4 Service Manual
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SWING VALVE AND CRANK ARM Figure 30-80-1

Swing Valve Removal And Installation

2

WARNING 1

AVOID INJURY OR DEATH

Before cleaning, servicing or inspecting the
Concrete Pump, stop the loader engine and
disconnect the hydraulic hoses and electrical
harnesses from the loader.
W-2366-0500
P-57763

Remove outlet housing. (See Removal And Installation

on Page 30-30-1.)
IMPORTANT Remove hopper. (See Removal And Installation on Page
30-70-1.)
If the engine stop switch is used to stop the loader
engine, turn the key switch to the OFF position. If the Remove the four bolts (Item 1), then remove the swing
Remote Attachment Control key switch is left in the valve outlet (Item 2) [Figure 30-80-1].

Dealer Copy -- Not for Resale

ON position, there will be a constant current draw on Installation: Tighten bolts to 65-70 ft.-lb. (88-95 N•m)
the battery resulting in a weak or discharged battery. torque.
I-2188-0998

WARNING
WARNING Wear safety glasses to prevent eye injury when any
of the following conditions exist:
AVOID INJURY OR DEATH • When fluids are under pressure.
Do not release couplings until pressure in a plugged • Flying debris or loose material is present.
delivery system has been relieved by reversing the • Engine is running.
pump. Pressurized concrete can blow out when • Tools are being used.
couplings are released. W-2019-1285
When removing a coupling in a plugged delivery
system, turn your face away from the coupling as
you release the coupling handle.
W-2368-0500

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

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SWING VALVE AND CRANK ARM (CONT’D) Figure 30-80-4

Swing Valve Removal And Installation (Cont’d)

Figure 30-80-2

2 1

P-57765
P-57764

Remove energizer ring (Item 1) [Figure 30-80-4] and

Remove the four bolt(s) (Item 1), then remove the swing steel insert ring.
valve (Item 2) [Figure 30-80-2].
NOTE: Replace energizer ring when replacing wear
Figure 30-80-3 ring to obtain maximum wear ring service life.

Dealer Copy -- Not for Resale

2 Figure 30-80-5

P-57576

Install the swing valve on the alignment pin (Item 1) and

install the four bolts (Item 2) [Figure 30-80-3].
P-57766
Installation: Tighten bolts to 65-70 ft.-lb. (88-95 N•m)
torque.
Remove wear ring (Item 1) [Figure 30-80-5].

Installation: Wear ring must be installed with the hard

surface side facing the wear plate. (See Removal And
Installation on Page 30-40-1.)

NOTE: Inspect all components for wear and damage.

The hard surface of the wear components
may appear to have small cracks on the face.
This is natural and is NOT a defect. Use
silicone on the face to seal the cracks.

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SWING VALVE AND CRANK ARM (CONT’D) Figure 30-80-8

Crank Arm Removal And Installation

Figure 30-80-6

1
1
2

P-57770

Remove lock nut (Item 1) [Figure 30-80-8].

P-57767
Remove nut (Item 2) [Figure 30-80-8].
Remove cotter pin (Item 1) [Figure 30-80-6].
Installation: Tighten nut (Item 2) snuggly against the
Figure 30-80-7 spacer, then tighten lock nut (Item 1) to 180-200 in.-lb.
(Not ft.-lb.) (21-23 N•m) torque [Figure 30-80-8].

Dealer Copy -- Not for Resale

NOTE: DO NOT Overtorque this nut!

Figure 30-80-9
1

P-57769

Remove pin (Item 1) [Figure 30-80-7].

P-57771

Remove spacer (Item 1) [Figure 30-80-9].

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30-80-3 Service Manual
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SWING VALVE AND CRANK ARM (CONT’D) Figure 30-80-12

Crank Arm Removal And Installation (Cont’d)

Figure 30-80-10
1

P-57778

Inspect the brass bushing (Item 1) [Figure 30-80-12].

P-57772
NOTE: If the bushing is worn or damaged remove
and replace the bushing.
Mark the position of the crank arm, then remove control
arm (Item 1) [Figure 30-80-10].

Installation: Align the marks placed on the control arm

Dealer Copy -- Not for Resale

and drive, then install the control arm.

Figure 30-80-11

P-57773

Remove crank arm (Item 1) [Figure 30-80-11].

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30-80-4 Service Manual
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SWING VALVE AND CRANK ARM (CONT’D) Crank Arm Assembly

Crank Arm Disassembly Figure 30-80-15

Figure 30-80-13

1
2

P-57776

P-57775
NOTE: Always use new O-rings during installation.
Apply clean hydraulic fluid to O-rings before
Remove O-ring (Item 1) and spacer (Item 2) [Figure 30- installation.
80-13].
Install O-ring (Item 1) [Figure 30-80-15].
Figure 30-80-14

Dealer Copy -- Not for Resale

Figure 30-80-16

1
1

P-57777

P-57776
Install spacer (Item 1) [Figure 30-80-16].

Remove O-ring (Item 1) [Figure 30-80-14]. Figure 30-80-17

P-57775

NOTE: Always use new O-rings during installation.

Apply clean hydraulic fluid to O-rings before
installation.

Install O-ring (Item 1) [Figure 30-80-17].

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30-80-5 Service Manual
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 Dealer Copy -- Not for Resale

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30-80-6 Service Manual
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HOPPER CLEAN OUT Figure 30-90-1

Removal And Installation

WARNING
AVOID INJURY OR DEATH
Before cleaning, servicing or inspecting the
Concrete Pump, stop the loader engine and
disconnect the hydraulic hoses and electrical
1
harnesses from the loader.
W-2366-0500
P-57555

Move the handle (Item 1) [Figure 30-90-1] to the left until

it’s free from the support, then remove the hopper clean
IMPORTANT out.

If the engine stop switch is used to stop the loader

engine, turn the key switch to the OFF position. If the
Remote Attachment Control key switch is left in the

Dealer Copy -- Not for Resale

ON position, there will be a constant current draw on
the battery resulting in a weak or discharged battery.
I-2188-0998

WARNING
AVOID INJURY OR DEATH
Do not release couplings until pressure in a plugged
delivery system has been relieved by reversing the
pump. Pressurized concrete can blow out when
couplings are released.
When removing a coupling in a plugged delivery
system, turn your face away from the coupling as
you release the coupling handle.
W-2368-0500

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30-90-1 Service Manual
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HOPPER CLEAN OUT (CONT’D) Figure 30-90-4

Disassembly And Assembly

Figure 30-90-2
1

1
P-57851

Remove the seal mounting plate (Item 1) [Figure 30-90-

P-57849 4].

Figure 30-90-5
Remove the four bolts (Item 1) [Figure 30-90-2].

Installation: Tighten bolts to 25-28 ft.-lb. (34-38 N•m)

torque. 1

Dealer Copy -- Not for Resale

Figure 30-90-3

P-57852

Align the seal (Item 1) [Figure 30-90-5] with the

mounting plate and install the seal.

P-57850

Using a flat screwdriver, remove seal (Item 1) [Figure 30-

90-3].

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30-90-2 Service Manual
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 ELECTRICAL SYSTEM

REMOTE ATTACHMENT CONTROL . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Key Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . 40-10-4
Operation Light Removal And Installation . . . . . . . . . . . . . . . . . 40-10-5 ELECTRICAL
Hydraulic Pressure Release Switch Removal And Installation . 40-10-5 SYSTEM
High Flow/Std. Flow Switch Removal And Installation. . . . . . . . 40-10-6
Reverse Pump Switch Removal And Installation. . . . . . . . . . . . 40-10-6
Reverse Pump Switch Removal And Installation. . . . . . . . . . . . 40-10-6
Pump On/Pump Off Switch Removal And Installation . . . . . . . . 40-10-7
Hyd On/Off Switch Removal And Installation. . . . . . . . . . . . . . . 40-10-7
Engine Stop Switch Removal And Installation . . . . . . . . . . . . . . 40-10-8
Controller Removal And Installation. . . . . . . . . . . . . . . . . . . . . . 40-10-9
Magnetic Switches Removal And Installation . . . . . . . . . . . . . 40-10-10

SWING VALVE PROXIMITY SENSORS. . . . . . . . . . . . . . . . . . . . . 40-20-1

Adjusting Proximity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Dealer Copy -- Not for Resale

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40-01 Service Manual
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 Dealer Copy -- Not for Resale

Concrete Pump
40-02 Service Manual
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REMOTE ATTACHMENT CONTROL Figure 40-10-3

Removal And Installation

Figure 40-10-1
2
1

P-57597

Flip up the walkway. Loosen the two bolts (Item 1)

[Figure 40-10-3] attaching the guard to the Concrete
P-57522
Pump frame.
Remove the guard (Item 2) [Figure 40-10-3].
Remove the wire ties (Item 1) [Figure 40-10-1] securing Figure 40-10-4
the pressure gauge hose and wire harness.

Dealer Copy -- Not for Resale

Figure 40-10-2 1

P-57596
1

Remove any wire ties (Item 1) [Figure 40-10-4] securing

the pressure gauge hose and wire harness.

P-14531
Figure 40-10-5

Disconnect the hose (Item 1) from the back of the

pressure gauge. Install a plug in the end of the hose to
prevent hydraulic oil from leaking.

P-57760

For easier access, remove the three nuts (Item 1)

[Figure 40-10-5] attaching the removable walkway to the
Concrete Pump frame. Remove the walkway.

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40-10-1 Service Manual
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REMOTE ATTACHMENT CONTROL (CONT’D) Figure 40-10-8

Removal And Installation (Cont’d)

Figure 40-10-6

1 1

P-14532

P-57844
Loosen the handle (Item 1) [Figure 40-10-8] on the
remote attachment control arm and remove the remote
Disconnect the two wire connectors (Item 1) [Figure 40- attachment control (RAC) box and wire harness from the
10-6] which connect the washbox limit switches to the Concrete Pump.
wire harness. Note the black band on the right wires and
the white band on the left wires for installation. Figure 40-10-9

Dealer Copy -- Not for Resale

Figure 40-10-7

1 1

P-14441 P-14533

Disconnect the five wire connectors (Item 1) [Figure 40- Remove the four bolts (Item 1) [Figure 40-10-9] from the
10-7] which connect the control valve to the wire control panel mount. Remove the control panel mount
harness. Note the colored bands on the wire connectors from the RAC box.
and the wires for installation.
NOTE: Removal and installation of switches and the
controller is shown on the following pages
with the RAC box upside down as shown in
[Figure 40-10-9].

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REMOTE ATTACHMENT CONTROL (CONT'D)

Parts Identification

1. Wire Harness
2. Magnetic Switch (Qty. 5)
3. Controller
4. Key Switch
5. Engine Stop Switch
6. Collar
7. RAC Box
8. Operation Light
9. Key Switch Nut
10. Hydraulic Pressure Release Switch
11. High Flow/Std. Flow Switch
12. Reverse Pump Switch
13. Pump ON/Pump OFF Switch
14. HYD ON/OFF Switch
15. Engine Stop Switch Front
8
9

10
11
12
3 13

Dealer Copy -- Not for Resale

7 14

15
4

6
5

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REMOTE ATTACHMENT CONTROL (CONT’D) Figure 40-10-12

Key Switch Removal And Installation

Figure 40-10-10
1

P-14640

Disconnect the wire connector (Item1) [Figure 40-10-12]

P-14639 which connects the key switch to the wire harness.

Remove the key switch nut (Item 1) [Figure 40-10-10]

from the remote attachment control (RAC) box.

Dealer Copy -- Not for Resale

Figure 40-10-11

P-14534

Remove the key switch (Item 1) [Figure 40-10-11] from

the RAC box.

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40-10-4 Service Manual
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REMOTE ATTACHMENT CONTROL (CONT’D) Hydraulic Pressure Release Switch Removal And
Installation
Operation Light Removal And Installation
Figure 40-10-15
Figure 40-10-13

P-14643
P-14641

Remove the connector (Item 1) [Figure 40-10-15] from

Remove the connector (Item 1) [Figure 40-10-13] from the hydraulic pressure release switch. The connector
the operation light. The connector includes wires #2740 includes wires #1770 and 5950.

Dealer Copy -- Not for Resale

and 5340.
Figure 40-10-16
Figure 40-10-14

1
1

P-14644
P-14642

Push the hydraulic pressure release switch (Item 1)

Push the operation light (Item 1) [Figure 40-10-14] out [Figure 40-10-16] out the front of the RAC box.
the front of the RAC box.

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40-10-5 Service Manual
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REMOTE ATTACHMENT CONTROL (CONT’D) Reverse Pump Switch Removal And Installation

High Flow/Std. Flow Switch Removal And Installation Figure 40-10-19

Figure 40-10-17

P-14647

P-14645
Remove the connector (Item 1) [Figure 40-10-19] from
the reverse pump switch. The connector includes wires
Remove the connector (Item 1) [Figure 40-10-17] from #1630 and 5810.
the high flow/std. flow switch. The connector includes

Dealer Copy -- Not for Resale

wires #1640, 2860 and 5760. Figure 40-10-20

Figure 40-10-18

P-14648

P-14646
Push the reverse pump switch (Item 1) [Figure 40-10-20]
out the front of the RAC box.
Push the high flow/std. flow switch (Item 1) [Figure 40-
10-18] out the front of the RAC box.

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REMOTE ATTACHMENT CONTROL (CONT’D) Hyd On/Off Switch Removal And Installation

Pump On/Pump Off Switch Removal And Installation Figure 40-10-23

Figure 40-10-21

P-14651

P-14649
Remove the connector (Item 1) [Figure 40-10-23] from
the hyd on/off switch. The connector includes wires
Remove the connector (Item 1) [Figure 40-10-21] from #1780, 2750, 5350 and 5900.
the pump on/pump off switch. The connector includes

Dealer Copy -- Not for Resale

wires #1610, 1620, 2870, 5510, 5520 and 5480. Figure 40-10-24

Figure 40-10-22
1

P-14652

P-14650
Push the hyd on/off switch (Item 1) [Figure 40-10-24] out
the front of the RAC box.
Push the pump on/pump off switch (Item 1) [Figure 40-
10-22] out the front of the RAC box.

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REMOTE ATTACHMENT CONTROL (CONT’D) Figure 40-10-28

Engine Stop Switch Removal And Installation

Figure 40-10-25

1
1
P-14656

Remove the front part of the switch (Item 1) [Figure 40-

P-14653 10-28] from the RAC box.

Remove the connector (Item 1) [Figure 40-10-25] from Figure 40-10-29

the engine stop switch. The connector includes wires
#5570, 5650, 5660, 1740 and 5680.
Figure 40-10-26

Dealer Copy -- Not for Resale

1

B-15331
1

Figure 40-10-30
P-14654

Remove the five wires (Item 1) [Figure 40-10-26] from

the switch.
Figure 40-10-27

RED SIDE GREEN SIDE

1

1 P-14653

P-14655
NOTE: Be sure the switch is positioned correctly
Loosen the screws (Item 1) and remove the collar (Item when installing the switch with the wires on the
2) from the RAC box [Figure 40-10-27]. collar [Figure 40-10-29] and [Figure 40-10-30].

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REMOTE ATTACHMENT CONTROL (CONT’D) Figure 40-10-33

Controller Removal And Installation

Figure 40-10-31

1 1

1 P-14659

Remove the four mounting bolts (Item 1) [Figure 40-10-

33] attaching the controller to the RAC box. Remove the
controller and wire harness from the RAC box.
P-14657
Figure 40-10-34
Disconnect the connector (Item 1) [Figure 40-10-31]
from the controller. The connector includes wires #5550,

Dealer Copy -- Not for Resale

5700, 5600, 5650, 5900 and 5950.

Figure 40-10-32 1

P-14660

1 Disconnect the connector (Item 1) [Figure 40-10-34]

from the controller. The connector includes wires #5250,
5300 and 5350.

Figure 40-10-35
P-14658

Disconnect the connector (Item 1) [Figure 40-10-32]

from the controller. The connector includes wires #2720,
1720, 9510 and 9610. 1

P-14661

Installation: For easier access, first install the controller

(Item 1) [Figure 40-10-35] without the connector
installed.

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REMOTE ATTACHMENT CONTROL (CONT’D)

Magnetic Switches Removal And Installation

Figure 40-10-36

P-14662

Remove the five magnetic switches (Item 1) [Figure 40-

10-36] from the wire harness.

Dealer Copy -- Not for Resale

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40-10-10 Service Manual
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SWING VALVE PROXIMITY SENSORS Adjusting Proximity Sensors

Removal And Installation Figure 40-20-3

NOTE: Some of the back ground has been removed Upper Proximity Sensor
for picture clarity.
1/8 Inch
2 (3.175 mm)
Figure 40-20-1

Upper Proximity Sensor

P-57541

1 Loosen nut (Item 1), then adjust the proximity sensor

(Item 2) until the gap between the sensor and pivot pin is
1/8 Inch (3.175 mm) [Figure 40-20-3].
P-57541

Tighten nut (Item 1) [Figure 40-20-3] to maintain the gap.

Dealer Copy -- Not for Resale

Remove nut (Item 1) and washer, then remove the
sensor (Item 2) from the bracket [Figure 40-20-1]. Figure 40-20-4

Lower Proximity Sensor

Disconnect electrical connector.
1/8 Inch
Figure 40-20-2 2 (3.175 mm)

Lower Proximity Sensor

P-57542

1 Loosen nut (Item 1), then adjust the proximity sensor

(Item 2) until the gap between the sensor and pivot pin is
P-57542 1/8 Inch (3.175 mm) [Figure 40-20-4].

Remove nut (Item 1) and washer, then remove the Tighten nut (Item 1) [Figure 40-20-4] to maintain the gap.
sensor (Item 2) from the bracket [Figure 40-20-2].

Disconnect electrical connector.

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 Dealer Copy -- Not for Resale

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 SPECIFICATIONS AND SCHEMATICS

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1

SPECIFICATIONS
AND
SCHEMATICS

Dealer Copy -- Not for Resale

Concrete Pump
SPEC-01 Service Manual
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 Dealer Copy -- Not for Resale

Concrete Pump
SPEC- 02 Service Manual
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SPECIFICATIONS

• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

• Where applicable, specifications conform to SAE and ISO standards and are subject to change without notice.

54.9 In.
(1395 mm)

102.9 In. 47.9 In.

(2615 mm) (1216 mm)

P-60267

Dealer Copy -- Not for Resale

DESCRIPTION CONCRETE PUMP
Width 47.9 in. (1216 mm)
Length 102.9 in. (2615 mm)
Height 54.9 in. (1395 mm)
Weight 2200 lb. (998 kg)
Swing Valve and Outlet Diameter 5 in. (127 mm)
Swing Valve Cylinder Diameter 3 in. (76 mm)
Swing Valve Cylinder Stroke 6 in. (152 mm)
Concrete Cylinder Diameter 6 in. (152 mm)
Concrete Cylinder Stroke 24 in. (607 mm)
Pumping Cylinder Diameter 3 in. (76 mm)
Maximum Concrete Pressure 750 PSI (5171 kPa)
Maximum Hydraulic Pressure 3000 PSI (20684 kPa)
Maximum Hydraulic Flow 40 GPM (152 L/min.)
Minimum Hydraulic Flow 15 GPM (57 L/min.)
Pumping Rate *Up to 30 cu. yds. (23 cu. m) per hour
Pumping Method Reciprocating Piston/Swing Valve
Maximum Aggregate Size 1 1/2 in. minus (38 mm)
Vertical Pumping Height Up to 50 ft. (15 m)
Horizontal Pumping Distance 250 ft. (76 m)
Wash Box Capacity 5 Gal. (18.9 l)
Hopper Capacity 10 cu. ft. (0.28 cu. m) with fwd/rev agitator
*Volume output will vary depending on mix design, slump, line size used and job site conditions.

Concrete Pump
SPEC-10-1 Service Manual
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 Dealer Copy -- Not for Resale

Concrete Pump
SPEC-10-2 Service Manual
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HYDRAULIC SCHEMATIC

Dealer Copy -- Not for Resale

P-60257

Concrete Pump
SPEC-20-1 Service Manual
139 of 143
 Dealer Copy -- Not for Resale

Concrete Pump
SPEC-20-2 Service Manual
140 of 143
 ELECTRICAL SCHEMATIC OFF

2750
CONCRETE PUMP

1780
RUN

(S/N 235400101 & ABOVE) START

PRINTED DECEMBER 2007

7 3
V-0968

Printable Version Click Here ST

WHT
B
RED
HYD 8 2
ON/OFF
SWITCH

5350

5900
B B 5600
GRN C C 9800 9800 D
I
A A OPEN 2710 3
IGNITION SWITCH D D 1165 1160 SEVEN PIN
5350 2
H J 5900 RAC
1710 1
OPEN A C 5600 2 3 CONNECTOR
OPEN 5950 5950 1770 9700 C
B K
OPEN OPEN 9600 B
C D
9500 A
OPEN D J3 J2 B 5550
OPEN E H OPEN HIGH FLOW PRESSURE
OPEN F G OPEN STD FLOW RELIEF
OPEN J F OPEN SWITCH SWITCH
OPEN K A OPEN 5550 1730
2 3
2270 5300 G E 5700 5760 1640 5620 1740
E STOP

5670
OPERATIONAL
DETENT
LIGHT
A OPEN SWITCH
7 1730
C OPEN 2860 H
5620 C
F OPEN
J1 CONNECTOR 5670 G
G OPEN
B = SWITCHED POWER J1 OPEN D
D = CAN HIGH B 1720
1780 2760 B REMOTE
E = CAN LOW H 2720
H = GROUND
E 9610 9600 CONTROL
9510 9500 CONNECTOR
D
J2 CONNECTOR
REVERSE
Dealer Copy -- Not for Resale
ATTACHMENT
B = ENGINE STOP ON / OFF SWITCH
C = ATTACHMENT KEY START SWITCH
E = ID BITI 2 3 5640 F
3 2
J = AUX DETENT FORWARD 1620 5480 5630 E
K = AUX DETENT REVERSE 5810 1630
S5 ENABLE 5610 A
SOLENOID
5 6
J3 CONNECTOR 1610 5510 5640
G = CAB KEY INDICATOR
H = AUX FORWARD INDICATOR

5515
R1 8 7
5520 2870 A B
5470
85 86 2810 A B

5515

5490
2900
30 87 5630
5410
87A
5250
5610
R3 5810
R8 R5
R7
PUMP C C
2980 2980 S4 SWING
SOLENOID
86 85 86 85 B B 85 86 85 86 SOLENOID
S2 (BOTTOM) 2830 5830 5270 5750 5750 5280 5850 2850
A A
5450 5450
A A 5080 5130 5170 5380 5380 5180 5150 5070 A A
87 30 87 30 PROXIMITY PROXIMITY 30 87 30 87
B B 2930 SWITCH – LS1 SWITCH – LS1 2920 B B
5030 5050
87A SOLID STATE SOLID STATE
87A 87A R4 87A
5280
R2 R9
R6
A A 5090
5420 5440 S3 SWING
A A
B B 2940 86 85 86 85 85 86 85 86 SOLENOID
2820 5820 5260 5730 5740 5290 5840 2840
B B
PUMP 2970 2980
SOLENOID 5120 5160 5370 C C 5390 5180 5140 5060 A A
87 30 87 30 PROXIMITY PROXIMITY 30 87 30 87
S1 (TOP) 2910 B B
5020 SWITCH – LS4 SWITCH – LS2 5040
87A 87A SOLID STATE SOLID STATE 87A 87A
V-0968 11-29-07)
PRINTED IN U.S.A.
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 ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: Concrete Pump-1

Date: 6 December 2007
Product: Attachment
Model: Concrete Pump
Manual No: 6903713 (12-07)

The following pages are a revision to the above Service Manual.

COVER
ALPHABETICAL INDEX

Dealer Copy -- Not for Resale

REMOVE SPEC-30

ADDED ELECTRICAL SCHEMATIC

Printed in U.S.A.
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143 of 143
Dealer Copy -- Not for Resale