CONCRETE PUMP

SP1200 D HDR
Catal. Document No. – 80154031

OPERATING INSTRUCTION
MANUAL

Edition : April '11

PRESENTATION----------------- 1

SAFETY --------------------------- 2

OPERATION---------------------- 3

MAINTANANCE----------------- 4

APPENDIX ----------------------- 5

CUSTOMER SERVICE --------- 6

 0.1

STRUCTURE OF THE OPERATING

INSTRUCTIONS

MAIN PARTS This symbol is intended to draw

attention to hazards and their prevention.
These operating instructions consist of 6 main
parts.
All points which are relevant to work safety
and the prevention of accidents are compi-
CHAPTERS led in main part 2 "SAFETY".

Each main part is preceded by a table of The main part 2 is of general nature and
contents for the individual chapters. does not refer to specific machines.

The operating instructions are complete even

if some of the chapters mentioned in the table POSITION INDICATION
of contents are not included.
Orientations such as "left" and "right" always
In such cases there are equipment refer to the direction of motion of the machine
specifications that do not apply to your (Fig. 1).
machine.

PAGES

The pages of each chapter are numbered

consecutively.

Example:

1.4-2

1..................= Main part

Fig. 1
4................= Chapter

-2..............= Page

The code number entered at the bottom on

each page is for internal reference and has no
significance for the reader of these operating
instructions.

TEXT LAYOUT

Particularly important passages are printed in

bold type.
 0.2

ILLUSTRATIONS

The illustrations in these operating instructions

are intended to clarify the text passages.

They may differ from the actual execution of

the machine without fundamentally altering
the factual information.

MODIFICATIONS

Important modifications to the standard

specification of the machine will be
incorporated in each new edition of the
operating instructions.

TECHNICAL INFORMATION MATERIAL

These pieces of information (Fig. 1) are

published by Messrs. SCHWING to impart the
latest knowledge to our customers and
agents.

They either deal with a specific machine Fig. 1

model or are of general interest.

They are distributed by our representatives

and complement our operating instructions
when required.

Some important pieces of information are

attached.
PRESENTATION 1.1

TABLE OF CONTENTS - PART 1

Chapter Title

1.1 TABLE OF CONTENTS

1.2 PREFACE

1.3 MACHINE CHARACTERISTICS

1.4 TECHNICAL DATA

1.5 MACHINE DESCRIPTION

1.7 CONTROL, WARNING AND MONITORING ELEMENTS (Diesel drive)

 1.2-1

PREFACE

These operating instructions are intended for In addition to the operating instructions
all persons who are entrusted with the observe the legal and other regulations for
operation and maintenance of the prevention of accidents which may govern in
the country of use.
SCHWING MACHINE

described below and for the owner resp. user In the event of failures, possible questions and
of the machine. for ordering spare parts, please contact the
authorized representative for your area or

The operating instructions shall assist you in

Schwing stetter India Private Limited
- becoming familiar with the machine to be
able to use it properly, F – 71 , Sipcot Industrial park

- running it safely to prevent accidents, Irungattukottai,Pin: 602105

- applying it to the purpose and economically Telephone : 044/27156780 & 47108100

to save money. Fax : 044/27156539

The machine complies with the level of Our departments

technology and the relevant safety
regulations. - SPARE PARTS SALES

Nevertheless it may constitute a hazard for - AFTER-SALES SERVICE

persons and material if it is applied, operated,
maintained or repaired incorrectly. - WARRANTY

Any handling of the machine implies can be reached under

knowledge and strict observation of the
operating instructions. Telephone : 044/27156781
Fax : 044/27156539
It is therefore advisable - especially prior to
commissioning - to read the instructions
carefully several times and to acquaint oneself Please use this telex number only for your
with the machine. correspondence with these departments.

During operation it would be too late to do so.

Always quote the model and the serial
number of your machine.
 1.3-1

MACHINE IDENTIFICATION

The concrete pump designation is to be read as follows:

SP 1200 D R L

SP ................................= STATIONARY PUMP

1200 .....................= Technical parameter (Average value)

D................. = Diesel drive

RL ....... = LONG ROCK

Additional designations:

SP1200 D RL 180 100 60 1200 D 48.6 kW

180...................................................... = Ø of Pumping cylinder (mm)

100...........................................= Ø of Differential cylinder piston (mm)

56................................... = Ø of Differential cylinder piston rod(mm)

1200..........................= Stroke (mm)

D...................... = Diesel drive

48.6 kW…..= Drive power in kilowatts

 1.3-2

Machine Label.

The rating plate of the concrete pump (Fig.1) is

attached to the machine frame. The machine
number is stamped into the frame under the
rating plate.

The Label plate of concrete pump is attached to

The machine frame. Carrying the following
Information.

Model No:carries the model code of concrete pump

Serial No: carries the serial no of concrete pump
P/M.SL.NO: carries the serial no of prime mover (ie
The main power source) whether, Diesel Engine or
Electric Motor as the case be. Fig. 1

Year of manufacture
Carries the month and year of manufacture of the
Equipment.
 1.4-X2

LWA = Lpmax =
SP / BP D E kW dB (A) dB (A) m
750 X 38 106 97 9,50
750 X 37 104 93 7,50
1000 X 39 105 95 8,40
1000 X 51 107 98 8,00
1000 X 55 103 97 9,50
1200 X 51 107 98 8,00
1400 X 51 107 98 8,00
1500 X 74 110 94 5,20
1500 X 75 100 93 5,50
1800 X 74 110 92 4,70
1800 X 75 100 93 5,50
1800 X 90 108 90 18,40
1800 X 112
2000 X 111 114 98 16,30
2000 X 90 108 90 18,40
2800 X 132
2800
3500 X 161 110 102 18,20
4000 X 231 113 98 9,70
4000 X 200 112 97 14,00
4000 X 160 107 95 8,00
4800 X 286
4800 X
8000 X 334 116 100 18,50
8000 X
8800 X 419 119 117 19,00
8800 X 2x200
8800 X 440 123 119 22,00
8800 X 440 123 119 22,00

LWA = Lpmax =
TSR 30/10 D E kW dB (A) dB (A) m

X 55 103 97 9,50
Specifications

SP 1200 DRL 180/1200 D 48,6kW

Technical parameter 1215
Engine performance kW 48,6
Nominal speed 1/min 2300
Engine type Kirloskar HA494
Pumping cylinder, DN x stroke mm 180 x 1200
Pumping cylinder volume l 30.50
Diff.-cylinder, DN / dn x stroke mm 100 / 56 x 1200
Drive of the diff.-cylinder piston side / rod side
Stroke per minute / max. / / 24
Stroke, basic adjustment / / /
Max. theor. concrete output m³/h / / 44
Max. concrete pressure bar / / 64
Hopper capacity l 400
Weight with hydraulic oil kg 4000
Delivery pipe until DN mm 150

Gear box type /

Transmission /
Hydr. pump A7V0 107
Max. output l/min 194
Adjusted perf. on the regulator kW 44
RPM 1/min 2150
Transmission power take off 1
Power take off / concrete pump //
Max. output l/min /
Total concrete output BP l/min 194
Power take off / accumulator //
Max. output l/min /
Power take off / agitator 1P 3072 22,84
Max. output l/min 49
Rock valve DN mm 180/190/160
Oil capacity per stroke (diff.-cyl.) l / 6.47
Switching oil per stroke l 0,06
Oil lost during switching (0,2s) l /
Slewing cylinder, dn x stroke mm RL, 65 x 177.5
Oil capacity per stroke l 0,589
Total oil capacity per stroke l / 7,1
Transmission F concr./ F h.-oil 1: / 4,72
Max. hydraulic pressure bar 300
/
 1.5-1

MACHINE DESCRIPTION ROCK VALVE

The Rock valve 1 (Fig. 1) is switched over
The concrete pumps of the SP1200 hydraulically and automatically when the
series are twin -cylinder piston pumps differential cylinders reverse their stroking
driven by hydraulic oil.They are designed for direction.
the conveyance of quality concrete through
a pumping line.
Depending on the position of the pistons in
Quality concrete is a concrete standardized the differential cylinders, cylinder 2 is
in concrete technology. switched over automatically by control
valves.
Ref. the SCHWING Stetter India Manual for:
The direction of movement of the differential
PUMPING CONCRETE AND CONCRETE cylinder pistons is reversed hydraulically
PUMPS when the Rock valve has reached its new
position.
Other materials, such as heavy concrete,
light concrete, screed, mortar, etc., can also In this case, the "sucking" cylinder is
be pumped with certain restrictions. Please connected to the feeding hopper and the
contact the SCHWING Stetter (India) "pumping" cylinder is connected to the
PVT.LTD company. pumping line.

TRANSPORT

As a rule, the pump is mounted on a chassis

with inflated tyres. It can also be mounted on
other types of chassis.

DRIVE

The pump can be driven by diesel engines

or alternatively by electric motors.

HYDRAULIC SYSTEM

The hydraulic system is an open circuit

system.The concrete pump is driven by a
variable displacement axial piston pump.
The auxiliary functions (auxiliary drive) such
as agitator,water pump and compressor are
controlled by a constant displacement pump.

Fig. 1
 1.6-1

PICTOGRAPHS

Pictographs are placed near switches, control levers, lamps, etc. They simplify the attribution of the
control, warning and monitoring elements to the individual machine functions. Depending on the
respective functions, it is possible to combine the symbols.

DRIVE

Motor / engine
Speed control Motor / engine Battery temperature

Engine oil Engine stop PID control Radiator

Coolant- Air cooling: Fluid filter:

temperature Oil cooler malfunction malfunction

Temperature
min. level too high vehicle engine Engine oil pressure

Engine oil filter Diesel engine

contaminated preheating monitor
 1.6-2

CONTROL

Radio
Control Remote control remote control Automatik control

Direct / Remote
Manual control control

CONCRETE PUMP

Piston- / Rodside Output

Concrete pump admission adjustment Attenuation

OUTRIGGER SYSTEM

Folding of
Support foot in support foot Retractable box in
 1.6-3

SECONDARY GROUPS / ACCESSORY PARTS

Water pump Compressor Piston pump Agitator

Vibrator Shut-off valve Horn Spotlight

Lifting / Lowering Warning beacon Shutting Opening

MIXER

Chute: Prop. Mixer control Mixer control

Mixing -0- Discharge Raising -0- Lowering Mixing -0- Discharge Sensor -0- Manual
 1.7-1

MONITORING, WARNING AND CONTROL

ELEMENTS (diesel engine)

1 Warning Lamp For Battery Charging

2 Warning For Filter Clog
3 Light for Warning When Engine Belt Get Cut
4 Fuel Indicator
5 Engine Running Hours (1/10)
6 Engine RPM Gauge
7 Switch For Lights In The Gauges
8 Panel Lock
9 Remote Control
10 Emergency Push Button
11 Pumping Reverse
12 Pumping Stop
13 Pumping Forward
14 Pumping Hours
15 Key For Starting The Engine
16 Shut-off Valve for Item 17
17 Pressure Gauge: Hydraulic oil pressure –
concrete pump
18 Pressure relief Valve ( for adjusting the strokes )
19 Engine Stop Button
20 Pressure Gauge (Engine Lube Oil )
21 Pressure Gauge: Hydraulic oil pressure Agitator

003.374.00(en)
 1.7-2

Fig. 1

1- Central greasing plate

Fig.2

2- Diesel engine speed adjust

Fig.3

(Cable -operated remote-control)

1- Illuminated pushbutton: Concrete pump suction

mode

2- Pushbutton: Concrete pump off

3- Il luminated pushbutton: Concrete pump pumping

mode

003.374.00 ( en )
 1.7-3

Fig. 1
Agitator control block (Fig. 1).

0- Control lever: Neutral

1- Control lever: Reverse

2- Control lever: Forward

 SAFETY MANUAL
for the operation of

CONCRETE PUMPS AND

PLACING BOOMS

This Safety Manual does not claim to be complete. It is not a substitute for national or regional
regulations. Any other safety rules and regulations issued by SCHWING for specific machines
retain their validity.
 UPDATED SUPPLEMENT TO THE SAFETY MANUAL

Please read carefully: Your attention is drawn to the risks resulting

from action not in accordance with the instruc-
When our concrete pumps are being operated tions for the designated use:
in accordance with their designated use, the
hopper guard is screwed down in closed posi-
WARNING: RISK OF FATAL INJURY
tion or - from 1995 models onwards - is con-
nected with a limit switch. NEVER switch on the machine
when the hopper guard is removed
This switch stops the drives of the Rock valve or opened.
and the agitator when the hopper guard is NEVER interfere with the limit
opened. switch.
When the hopper guard is removed
ATTENTION: or opened, there is a risk of fatal
LIFE-THREATENING RISK injury, e.g. due to falling in or being
trapped, crushed or caught in moving
Shut-offs brought about by the limit
parts.
switch have nothing to do with an
EMERGENCY SHUT-OFF. The Even when the hopper guard is
concrete pump and the agitator will closed, personnel not acting in ac-
restart automatically after closing cordance with the instructions for the
of the protective grid. designated use are exposed to resid-
ual risks, e.g. due to being trapped,
crushed or caught in moving parts.
Check the cutout mechanism each day and Actions not in accordance with the
have it repaired immediately if necessary. instructions for the designated use
are, for example:
Location and design of the hopper grid are in – reaching through the hopper guard,
conformity with pr EN 12001.
– letting objects (e.g. water hose, rod
Provided the personnel act in accordance with etc.) through the hopper guard.
the instructions for the designated use, job
safety is at the required standard in all
relevant operating states such as: Clean the concrete intake hopper with a
strong water jet, directing the jet onto the area
– working operation, to be cleaned but not letting the hose nozzle
through the hopper guard.
– cleaning,

– maintenance and repair.

Action in accordance with the instructions for

the designated use is detailed in our operating
instructions, in particular in the “SAFETY”
section.
Before using appropriate aids to remove stub-
born concrete deposits which cannot be re-
moved with a pressurized water jet:

– stop the machine,

– switch off the drive motor and secure it to

prevent inadvertent starting,

– depressurize the pressure accumulator (if

present).

Secure the machine in the same way before

opening the cleaning flap below the Rock
valve housing or the elbow of the concrete
pump outlet.

To illustrate the above risks more clearly, our

machines are being equipped forthwith with
additional hazard warning signs.

In the case of older machines, you are

requested to mount the hazard warning signs
(Fig. 1) to the left and right of the agitator
hopper or in its immediate vicinity. Fig. 1

Further hazard warning signs can be ordered

under

id. no.: 10172456.

The places to which the signs are to be

bonded must be clean and free from any trace
of grease.

Ensure that the signs are always in good order

and readily visible. Replace any damaged
signs immediately.
SAFETY

PREFACE

Occupational safety is one of the chief No safety manual can be detailed enough to
concerns for all those involved in producing cover each and every situation.
concrete pumps and placing booms.
So please observe the rules and regulations
This safety manual is addressed to all those but use your common sense too.
responsible for operating and servicing
SCHWING concrete pumps and placing booms The safety manual is not a source of infor-
and to owners and users of these machines. mation on individual machines but is designed
to supplement the operating instructions
To provide for optimum occupational safety, already issued to you.
general rules and regulations are issued by
the legislature, professional associations etc. While the safety manual does not claim to be
complete, it is subject to regular updating.
Additional, purpose-directed rules and re-
gulations are set out by manufacturers of You can have a say in its future layout. Please
equipment in their operating instructions. send any criticisms and suggestions to:

Know-how acquired in day-to-day practice plus Schwing stetter India private Limited
advancing technology necessitate constant F-71 Sipcot industrial park
updating of these rules and regulations. Irungattukottai
Pin: 602 105
This manual is designed to provide all our India.
customers with the same level of state-of-the-
art information. We are, of course, equally grateful for a word
of praise.
We have endeavoured not just to list the dos
and don´ts of safety procedure but to If you need any additional copies of the safety
emphasize the whys and wherefores. manual, please apply to the same address or
to your local agent.
This may have resulted in a somewhat thicker
manual than expected.

But please read it from cover to cover. Having

done that, you can find the section you need at
any specific time just by referring to the table of
contents.

The few specialized technical terms used are

explained in the glossary.
SAFETY 2.1 - 1

TABLE OF CONTENTS

Section Heading

2.1 TABLE OF CONTENTS

2.2 SUMMARY OF THE MOST IMPORTANT ACCIDENT PREVENTION AND

SAFETY REGULATIONS

2.3 POTENTIAL SOURCES OF INJURY

2.4 PROPER USE

2.5 INSTRUCTIONS FOR THE OWNER

2.6 QUALIFICATION DUTIES AND TRAINING OF THE MACHINE OPERATOR

2.7 ACCIDENT PREVENTION IN CONJUNCTION WITH LIQUID CONSUMABLES

2.8 FIRE AND EXPLOSION PROTECTION, FIRE-FIGHTING

2.10 TRANSPORT, TOWING, LOADING

2.11 POWER-SUPPLY CONNECTION / SAFETY INSTRUCTIONS FOR

OPERATING ELECTRICALLY DRIVEN MACHINES

2.12 PERSONAL PROTECTIVE GEAR, EMISSION PROTECTION

2.13 WORKING WITH UNSKILLED WORKERS

2.20 GENERAL OPERATING INSTRUCTIONS

2.21 SELECTION OF INSTALLATION SITE

2.22 PREPARATION FOR SERVICE

2.30 MACHINE INSTALLATION

2.31 STABILITY MONITORING

2.32 OPERATION: CONCRETE PUMP

2.33 OPERATION: PLACING BOOM

2.34 OPERATION: DELIVERY LINE AND END HOSE

2.35 OPERATION: REMOTE CONTROL

2.36 OPERATION: WET-MIX SHOTCRETING

SAFETY 2.1 - 2

Section Heading

2.40 CLEANING

2.50 SHUTTING DOWN

2.51 PREPARING TO MOVE THE MACHINE BY ROAD

2.60 MAINTENANCE AND REPAIR

2.61 SAFETY INSPECTIONS

2.90 GLOSSARY
SAFETY 2.2 - 1

SUMMARY

THE MOST IMPORTANT ACCIDENT

PREVENTION AND SAFETY REGULATIONS:

Operation, maintenance and repair may be All safety devices must be present and in
carried out only by persons trained and working order. Alterations are forbidden.
authorized to do so.
Pinpoint the responsibilities of personnel! Safety provisions and hazard warnings on the
machine must be kept complete and legible at
The updated operating instructions must be all times.
attached to the machine. Any damaged or illegible safety and hazard
The machine operator must sign that he has plates must be replaced without delay by the
"noted the contents" of the operating user.
instructions.
Personal safety gear must be worn in the
The user must act in accordance with the entire operating area of the machine.
operating instructions.
The manufacturer´s warranty is invalid if your Stabilize the machine.
machine is not operated and serviced in line Monitor stability during operation.
with the operating instructions.
Maintain a safe distance from pits, slopes,
Observe the operating instructions, safety overhead lines and any other obstacles.
provisions and hazard warnings on the
machine and comply with the generally Unauthorized modifications to the machine,
accepted accident prevention regulations. such as

In Germany, the regulations issued by the – extensions to the placing boom or end hose,
Employer´s Liability Insurance Associations
(ZH 1/573) must be observed. – readjustment of the safety pressures,
Observe the relevant accident prevention speeds, outputs, numbers of revolutions etc.
regulations and the other generally accepted set at the factory,
rules governing safety, occupational medicine
and road traffic (UVV, TBG, StVZO etc.).or – mounting a delivery line with a larger dia-
those in force in the relevant country. meter or a higher dead weight on the
The user and machine operator are re- placing boom,
sponsible for compliance.
The user must ensure that the corresponding – slinging loads or load lifting gear from the
rules and regulations in their latest version placing boom,
are available at the place of work and inform
his personnel accordingly. – program modifications ( software ) on
computer systems,
Use the machine for its designated use only.
are forbidden.
SAFETY 2.2 - 2

Never buckle the end hose during operation Only persons authorized by the manufacturer
(blockages!). may do welding work on load-bearing parts.
The work must be inspected by a competent
The end hose must be freely suspended at the expert.
start of pumping.
Never direct a water or steam jet at electrical
Fix the separate delivery line securely, components of the machine.
covering if necessary (to protect persons).
Cover electrical equipment or lock up (remote
Never set down the activated remote control control panel).
panel.
Carry the remote control panel in such a way Observe the servicing intervals and the safety
that none of the control elements can be check deadlines for the machine and the
activated inadvertently. accessories.
Always lock the remote control panel away
during pumping intervals. Always fold the placing boom into out-of-
operation position rep. "transport position" in
Never drive the machine with the placing the event of strong winds or thunderstorms and
boom extended. on finishing work.

When the view is obstructed, have another Before leaving, secure the machine to prevent
person to give directions. unauthorized use or inadvertent movement.

In the event of faults prejudicial to occu- Spares and accessories must meet the
pational safety, stop work immediately. requirements set by the manufacturer.
You are advised to use genuine SCHWING
Prior to opening or tapping the delivery line, spares and accessories.
always relieve pressure on the concrete
column by reverse pumping. Even if no damage is visible, hydraulic hoses
must be replaced every 6 years (including a
Remove end hose for pneumatic cleaning. maximum storage time of 2 years).
Use a blowing-out head and a trap basket.

Never reach into moving machine parts when

the motor is running or the hydraulic pressure
accumulator is charged.

Work on electrical or hydraulic systems may

be done by authorized qualified personnel
only.
The hydraulic system must be carefully vented
after any maintenance and repair work.
SAFETY 2.3 - 1

POTENTIAL SOURCES OF INJURY

When inexpertly handled, concrete pumps and Injuries due to falling pipeline components, as
placing booms are - like all construction a result of
machinery - a potential source of accidents of - loose screwed connections,
a general nature. - damaged brackets,
Some typical injuries are also involved, e.g.: - non-secured couplings.

Eye injuries due to splashed concrete, water- Injuries due to inadvertent activation of the
glass or other chemical substances. boom control and consequent inadvertent
movement of the boom.
Eye and skin injuries due to hydraulic oil being
ejected Head and shoulder injuries due to concrete
- from defective hoses, dropping out of the end hose when the placing
- when opening threaded joints without first boom is being slewed across the site (even
relieving pressure on the entire system when the pump is off).
( e.g. discharging accumulator pressure).
Injuries due to falling boom arms when locking
Scalding due to hot hydraulic oil or other hot devices have been removed without the boom
lubricants being ejected. being secured.

Burns due to touching hot machine com- Injuries to the hose operator caused by the
ponents, e.g. exhaust system and driving end hose jerking
motor. - at the start of pumping or when
- the end hose is caught in the reinforcement
Injuries caused by worn, bursting lines or by and is suddenly forced out as pumping
blockages being ejected from the delivery line, continues, or when
end hose and pump hopper. - a blockage is suddenly released.

Electric shock (sometimes fatal) due to the Injuries due to the pump running away as a
machine contacting power lines or to touching result of
electrically driven machines when - the brakes not holding,
- the electrical connection work has not been - incorrect stabilization,
expertly carried out, - incorrect or defective drive circuitry.
- the supply cable is damaged.
Injuries due to pressurized delivery lines being
Injuries due to the machine overturning as a opened (after blockages).
result of the stabilizers collapsing.
Injuries due to reaching or falling into the
Injuries due to slewing or telescopic stabilizing agitator.
gear being forced apart if the hydraulic circuit
has not been correctly vented. Injuries due to slipping on or down from the
soiled machine.

Injuries due to reaching into the water box

when the piston is moving.
 2.3 - 2

Injuries due to tripping over objects on the

machine or on the site.

Injuries due to falling from unsecured

locations.

Injuries due to being caught in the truck mixer

or parts of it (chute).

Injuries due to unsecured accessories slipping

or falling from the loading surface.

Injuries due to jamming when telescoping and

swivelling the stabilizers, e.g. between
- stabilizer and vehicle,
- stablizer and obstructions on the site.

Delayed damage due to absorbing noxious

substances through the skin and respiratory
system as a result of inadequate personal
protective gear.

Hearing damage due to poor noise control

(defective noise insulation or inadequate
personal protective gear).

Injuries due to rebound in the shotcreting

procedure.
SAFETY 2.4 -1

1. UTILZATION OF TRUCK-MOUNTED
CONCRETE PUMPS IN ACCORDANCE WITH
THEIR DESIGNATED USE

(with product-specific restrictions also When these limit values are exceeded, the
applicable to similar products) operation of the boom must be stopped and
the boom brought into transport position and
Concrete pumps are designed exclusively for secured.
the conveyance of quality concrete* through
special pumping lines provided for this – The standard basic models of our machines
purpose. can be used at ambient temperatures
ranging from -15°C to 30°C, if consumables
Placing booms are designed exclusively for as recommended by SCHWING (chapter
the conveyance and spreading of quality 4.4) are used.
concrete up to a bulk density of 2.4 kg/dm³
through the incorporated pumping line. At temperatures below 0°C, the instructions
set out in the Operator's Manual regarding
For the most often used pumping line type DN winter operation must be observed.
125, the size of the largest aggregate grains is
limited to 32 mm. Special measures are required, if the
machine is to be used outside the specified
Utilization in conformity with the designated temperature range of -15°C to 30°C.
use equally implies:
Optional equipment installed in the machine
(e.g. compressors) may have a narrower
1.1 REGULATIONS, RULES, DIRECTIVES operating temperature range. See
Operator's Manual.
– The User and the operator of the machine
must be familiar with and apply all
regulations for the safety at work and all 1.3 LIMITS OF THE MACHINE
legal regulations and rules in force in the
country of use. When used in conformity with their designated
use, our concrete pumps and placing booms
are designed for a theoretical service life of up
1.2 CONDITIONS OF USE to 15 years.

– The operation of machines equipped with A series machine is designed for the following
combustion engines is permitted as a matter working conditions:
of principle only if sufficient ventilation can
be ensured. – max. 8 hours of operation per placing job,

When used in hangars, tunnels, etc., it is – ambient temperature max. 30°C,

necessary to ensure sufficient ventilation
and/or to provide for the proper evacuation – place of installation max. 800 m above sea
of exhaust gases. level,

– Placing booms may be operated only up to – relative humidity max. 75 %,

wind force 8 (dynamic pressure = 250N/m²).
– duty cycle of concrete pump max. 60% of
For certain machines, a lower limit value is total time in use,
applicable. See operating instructions.

* see glossary of terms

SAFETY 2.4 -2

– hydraulic pressure in drive system of – For maintenance and service purposes,

concrete pump max. 60% of Pmax , use only original SCHWING parts and
lubricants and consumables in
– installed drive power presently 210 kW max. compliance with SCHWING
for the truck-mounted pump and more for recommendations.
trailer concrete pumps

– temperature of fresh concrete max. 15°C, 2. UTILIZATION CONTRARY TO THE

DESIGNATED USE
– concrete throughput max. 30000 m³ per
year SCHWING assumes no liability for damage
resulting from a utilization contrary to the
– max. 1000 placing jobs per year. designated use.
Please contact SCHWING, if the machine is See also our "Terms and Conditions for
expected to operate in conditions where one of
Delivery, Services and Payment"
the above parameters will be exceeded in
permanence or where several of these
The competent authorities are entitled to
parameters will be exceeded at the same time.
immobilize machines that are not used in
conformity with their designated use.
As a rule, SCHWING can give technical advice
concerning the measures required to adapt the
Typical utilizations contrary to the designated
machine to extreme conditions of use.
use are, among others:

– using the placing boom as lifting gear,

1.4 CONDITIONS OF OPERATION AND
MAINTENANCE
– using an end hose not approved by
SCHWING (excessive length, connection of
– Our machines may only be operated,
extensions, outlet pieces),
serviced or repaired by suitable, qualified
and specially trained personnel duly
– connecting a pumping line to the placing
authorized by the User*. Observe the
boom not approved by SCHWING,
Operating Instructions.
– unsafe working practices such as:
– The regular inspections must be performed
by specially trained persons (preferably
– operating the placing boom without
trained by SCHWING). The inspection
sufficient stabilization of the machine,
results must be documented in the
Inspection Log supplied with the machine.
– installing the machine at dangerous places
(near building pits, overhead power lines,
– Repair work on electrical, pneumatic and
etc.)
hydraulic systems may only be performed
by qualified specialists.
– Unauthorized modifications and use of
accessories without SCHWING approval
– Welding work on safety-related components
may only be performed by persons duly
authorized by the manufacturer and in
compliance with the manufacturer's
instructions.

* see glossary of terms

SAFETY 2.4 -3

Other cases of utilization contrary to the – The values set out on the rating plates at
designated use are: the machine and in the Technical Data
Sheets as, for instance:
2.1 TRANSPORT RESTRICTIONS
– pressures
Truck-mounted concrete pumps and placing
booms are machines designed for working. – delivery rates
They must not be used for the transport of
persons and goods. – pumping line diameters

This applies also to the transport of concrete in – end hose lengths

the feeding hopper of the concrete pump.
– placing boom lengths, etc.
In this case, the unfavourable weight
distribution has a negative impact on the are maximum values not to be exceeded.
road-holding properties of the vehicle and may
cause damage to the chassis and the The moving speeds adjusted at the factory
superstructure. must not be modified.

Accessories required for working are excepted. Important:

The accessories must be stowed away safely.
For machines brought into circulation in the
The admissible total weight and the maximum
countries of the European Economic Area we
axle loads must not be exceeded.
declare that they are in conformity with the
relevant basic health and safety regulations
of the EC Directive in force.
2.2 MODIFICATIONS AND CHANGES For this purpose, we establish a declaration
of conformity and affix the CE sign as a mark
– Modifications and changes of the machine of conformity.
are forbidden without express approval by
SCHWING. In the event of a modification of the
machine, both the declaration and the
This applies also to the use of accessories. mark of conformity will lose their validity.

You are urgently warned against non-

approved, non-authorized modifications 3. EXCEPTIONS / SPECIAL USE
of safety-related components such as
electrical control units, hydraulic In exceptional cases, SCHWING can approve
systems, load-bearing structural parts, deviations from the general regulations.
etc. and against changing settings and
programmed parameters. Subject to detailed knowledge of the specific
situation, SCHWING can, if necessary, develop
special solutions for certain applications.

These solutions may consist of design

modifications and / or of special rules to be
observed by the personnel.

SCHWING will not approve exceptions if the

required level of safety at the place of work
cannot be ensured.

* see glossary of terms

SAFETY 2.5 - 1

INSTRUCTIONS FOR THE OWNER (USER)*

Allow only instructed and trained personnel to - no safety devices are removed, disabled or
operate and service the machine. altered (EMERGENCY STOP, grating cover in
feeding hopper of concrete pump etc.),
If you have no qualified personnel, suitable
workshop equipment etc. at your disposal, put - safety devices dismantled for servicing
the maintenance and servicing of your machine purposes are re-installed immediately on
into the hands of the SCHWING after-sales completion of the work,
service department.
- welding work on load-bearing parts is done by
Provide your personnel with the operating a person authorized by the manufacturer and is
instructions and obtain their written confirmation inspected by a competent expert*.
of knowledge, understanding and application of
the operating, maintenance* and safety - the intervals for routine safety checks and
instructions. follow-up checks are adhered to.

Use the machine only for the proper purpose

specified by the manufacturer. It is explicity pointed out that SCHWING is not
liable for any damage resulting from:
The noise level in the immediate vicinity of
the machine may exceed 85 dB (A), depending - incorrect or negligent operation, maintenance
on design. or servicing,

Ear protection must be worn in such cases. - improper use,

Make it compulsory for personnel to wear other - unauthorized conversions or modifications,

protective clothing (helmet, safety footwear,
goggles, gloves etc.) if operating conditions - using other than genuine SCHWING spares
necessitate such measures. and accessories,

- natural wear and tear,

Ensure that
- exportation of the machine without adaptation
- all personnel involved with the machine are in to any relevant regulations in the country where
good health (relaxed and not affected by it is to be used.
alcohol, drugs or medication), .

- the machine is always operated in faultless

condition,

* see glossary
 SAFETY 2.5 - 2

SCHWING offers regular training courses for

machine operators.

We recommend attendance at such a course,

particularly for novices.

Apply to SCHWING for on-the-spot instruction

in the use of your new machine.

In the event of resale, pass on all relevant

documents (operating instructions, inspection
log book etc.) to the buyer.

Order new documents if necessary (quoting the

serial no. of the machine).

Never sell a machine without the relevant

documents.

Instruct the new owner and his personnel in the

use of the machine and have this instruction
confirmed in writing.

At your request, SCHWING can carry out the

instruction on your behalf.

* see glossary
SAFETY 2.6-1

QUALIFICATION AND DUTIES OF THE

MACHINE OPERATOR

Unsupervised operation of concrete pumps We recommend attendance at such a course,

and placing booms must be confined to particularly for novices.
persons who
Apply to SCHWING for on-the-spot instruction
- have reached the age of 18, in the use of your new machine.

- are physically and mentally fit, Familiarize yourself with the machine:

- have been instructed in operating the pump - Read and follow the operating instructions
and the placing boom and have given evidence and ask about anything you have not
to the company of their qualification to do so, understood.
and who
- Never operate the machine unless you are
- can be expected to perform the tasks as- absolutely and completely familiar with the
signed to them in a reliable way. layout and meaning of all control and
monitoring devices and with the functional
The machine operator must also notify his principles of machine operation.
employer immediately if he is unfit for work.
- Practise all operations described in the
The machine operator must not carry out operating instructions (installation, placing
maintenance work* unless he is suitably boom operation, preparation for road transport
trained and has been authorized to do so. etc.) under the supervision of a specialist* until
you have mastered them completely.
The machine operator is responsible for safety
within the working range (hazard range) of the - The trained machine operator must also
machine. familiarize himself with each new machine to
be operated by him.
- Before each shift, he must check the entire
machine for visually detectable defects and The user must instruct him or have him in-
have such defects eliminated immediately. structed accordingly.

- If defects representing a risk to occupational

safety cannot be eliminated immediately, the The machine operator is held responsible by
machine operator must stop work until they law for accidents resulting from failure to
have been eliminated. observe the safety and accident prevention
regulations or from inadequate care or
attention.
TRAINING
The user* and supervisory personnel are liable
SCHWING offers regular training courses for if the machine operator cannot be held
machine operators. responsible because of lack of qualification
(see above).

* see glossary
SAFETY 2.7-1

ACCIDENT PREVENTION IN CONJUNCTION HEALTH PROTECTION IN CONJUNCTION

WITH LIQUID CONSUMABLES WITH DIESEL FUEL AND HYDRAULIC FLUID

Construction machines are operated with many – Avoid inhaling fumes, spray mists, etc.
different liquid consumables such as
– Avoid contact with the eyes and any
fuel, hydraulic fluid, radiator anti-freeze, brake prolonged or frequent contact with the skin.
fluid, battery acid, concrete additives, Wear protective clothing (goggles, gloves,
detergents, water for cleaning purposes, etc. etc.).

All these liquids are a health hazard and a risk – Never eat or drink in the vicinity of the
to the environment. They are sometimes also machine nor keep foodstuffs anywhere near
flammable and explosive. the machine. Wash your hands before
breaks and never keep soaked or stained
All these liquids should therefore be handled cleaning rags in your working suit.
with the necessary precautions:
– Liquid that is ejected at high pressure from
– Avoid any unprotected contact with these leaks in the hydraulic system may penetrate
substances. into the skin and is then particularly
dangerous.
– Never allow these substances to soak into
the ground or into waters. Never work on hydraulic systems when they
are hot or pressurized. See chapter 2.60.
– Observe the fire and explosion protection
regulations

– Never handle liquids if the hazards involved First-aid measures after

are not known to you.

Observe the regulations in force in – contact with the skin:

your particular region and the
manufacturer's instructions when Remove soaked clothing. Clean the skin with
handling hazardous substances. water and soap and use skin-care products. In
the event of injury seek medical advice
The liquids most often encountered in large immediately.
amounts in construction machines are diesel
fuel and hydraulic fluid. They are: – contact with the eyes:

– a health-risk in the event of unprotected Rinse for about 10 minutes with large amounts
contact, of running water, keeping the eyelids wide
open. Seek medical advice immediately.
– a risk to the environment when allowed to
penetrate into the water or into the ground, – swallowing of mineral oil:

– combustible and explosive when they form Rinse the mouth with water. Do not induce
an inflammable mixture with air. vomiting. Seek medical advice immediately.
SAFETY 2.7-2

– swallowing of diesel fuel: STORAGE

Get casualty to rinse out his mouth and drink Oil drums must be stored on cool, dry and
plenty of water. Do not induce vomiting. Move well-ventilated premises. Use oil-collecting
casualty into a quiet, warm room. If he is troughs. Store away from strong oxidizing
unconscious, move him onto his side, agents (oxygen, acid, etc.) - RISK OF
supporting and transporting him in this position. EXPLOSION
If breathing stops or is irregular, attempt
mouth-to-mouth resuscitation or use respiratory Fuel must always be stored in special
equipment. Seek medical advice immediately. containers provided for this purpose.

– inhaling of oil fumes:

FIRE AND EXPLOSION PROTECTION
Move casualty into fresh air. If he feels unwell,
seek medical advice. See chapter 2.8.

– inhaling of diesel fumes:

Move casualty into fresh air in a quiet, warm

DISPOSAL OF WASTE
room. If he is unconscious, move him onto his
side, supporting and transporting him in this
position. If breathing stops or is irregular,
attempt mouth-to-mouth resuscitation or – useSeparate waste prior to disposal.
respiratory equipment. Seek medical advice
immediately. – Containers must be durable, lockable and
clearly marked.

ESCAPING FLUIDS Observe the manufacturer's

instructions when using oils other
– Keep escaping fuel or pressurized fluids than mineral oils as pressurized
away from sources of ignition (e.g. hot fluids.
machine parts).

– Ensure proper ventilation.

– Fuel or hydraulic fluids must not be allowed

to soak into the ground or into waters.
Prevent spreading of these liquids by
erecting oil barriers. Absorb with oil-binding
materials. Dispose of soaked material as
special waste.

– In the event of water or ground pollution try

to skim off or to dig out residues. Inform the
fire brigade and the competent authority.
SAFETY 2.8-1

FIRE AND EXPLOSION PROTECTION

FIRE-FIGHTING

Due to the heat produced and the presence of – when cleaning rags are left on the machine;
combustible substances there is always a risk
of fire and explosion with almost all types of – when heat insulation elements are damaged
machines. or have been removed;

Through appropriate design measures, these – when exhaust, fuel supply or hydraulic lines
risks are minimized. This means that are incorrectly laid;

fires and explosions are due in most cases – when hot gases are ejected from a defective
to accidents and incorrect handling of the exhaust system and hit flammable material.
machine.
Fires may also break out as a result of
For operation and maintenance, efforts are
therefore focused on: – short-circuits in the electrical system;

1. avoidance of fires and – electrical system overloading due to wrong

fuses;
2. fast reaction in tackling outbreaks of fire
– inexpert welding and cutting work;

COMBUSTIBLE SUBSTANCES – exploding or overheating of machine parts

after inappropriate servicing (e.g. lack of
The fuels and pressurized fluids encountered lubricant).
in considerable amounts in most types of
construction machines are flammable. – accidental voltage transfer on contacting or
approaching a power line.
Once alight, the heat produced is so high that
also other less flammable substances (grease,
paint, rubber, plastics, etc) quickly reach their EXPLOSION RISKS
ignition point.
There is a risk of explosion whenever volatile
components of combustible substances form
FIRE RISKS an explosive mixture with air.

Fires may break out, for instance, Sources of ignition:

– when leaking substances get onto hot parts – Welding operations

of the machine (exhaust, turbocharger, etc.).
Welding work on fuel and oil reservoirs may
Leaks have their origin not only in untight be performed only by qualified expert
systems, but also in spillage from overfilled welders and only under observance of the
reservoirs (liquids expand with rising relevant safety regulations.
temperatures).

Never overfill reservoirs when topping up

fluids and fuel.
SAFETY 2.8-2

Take the appropriate precautions when Even if not expressly required by law in the
carrying out welding and cutting operations country of use, it is recommended that a fire
close to reservoirs, lines, etc. (removing, extinguisher be provided on each truck-moun-
covering and cooling of components, etc.). ted concrete pump.

Machine operators must be familiar with the

– Sparking during refuelling proper use of these devices.

When refuelling the machine fill in diesel Advice on suitable fire extinguishers can be
fuel only at regular refuelling stations. obtained from the local representatives of fire
extinguisher manufacturers.
When refuelling from a tank truck the
container of the tank truck must be Operators of stationary machines must know
grounded. the location of the nearest fire-fighting devices
available on site.
Switch off auxiliary heaters and electrical
equipment.

Carry out refuelling operations only in the

open air.

Never smoke during refuelling or when Page 3 gives detailed information on suitable
carrying out work on the machine. extinguishing agents.

Sand is well suited as an emergency

– Sparking during recharging of starter extinguishing agent for class A and class B
batteries fires.

Charging the batteries with a charger unit Other soils such as loam and clay can also be
may lead to the formation of explosive used for such purposes.
gases.
Sand is very important for making dams to
No smoking. Ensure proper ventilation. confine spills.

Explosions may also occur when containers,

gas bottles, etc. are heated up by a nearby PREVENTIVE MAINTENANCE
fire.
Check reservoirs and lines regularly for proper
Conversely fires will often break out as a condition, fastening and leaks.
result of explosions.
Fire extinguishers must be checked at regular
Dusts, too, may be explosive. intervals. They must be intact and the
triggering mechanism must be protected with a
lead seal.
EXTINGUISHING AGENTS
Replace fire extinguishers after use. Fire
The chances of fighting a fire efficiently are extinguishers must be checked once a year by
best directly after the fire has broken out. a specialist.
SAFETY 2.8-3

FIRE-EXTINGUISHING AGENTS: APPLICATIONS

EXTINGUISHING FIRE CLASSIFICATION

AGENT
A* B* C* D*
Water yes no no no
ABC extinguishing powder yes yes yes no
Extinguishing powder for no no no yes
burning metals
Carbon dioxide (CO2) no yes ja no
Foam yes yes no no

* Class A fire = combustible solid substances (metals excepted) such as coal, wood, paper, straw,
textiles, etc.

* Class B fire = combustible liquid substances such as fuel, oil, dilutants, etc.

* Class C fire = combustible gaseous substances and gases under pressure such as acetylene,
butane, propane, hydrogen, etc.

* Class D fire = combustible metals such as aluminium, magnesium, etc and their compounds.

Powder extinguishers for fire classes A, B + C are universal extinguishers in general use.

PROPERTIES OF EXTINGUISHING AGENTS

WATER conducts electricity and may therefore FOAM conducts electricity and may therefore
only be used when electrical systems are only be used when electrical systems are
switched off. switched off.

Using water for extinguishing class B or D Foam is toxic and must not get into wounds or
fires is dangerous: into the groundwater, for example.

Combustible liquids float on top of the water CARBON DIOXIDE (CO2) can - to a limited
and enlarge the seat of the fire. The extent - also be used in the presence of
spontaneous expansion of water vapour will electricity. Observe the instructions on the
cause burning liquids to spread. extinguisher.

Light metals burn off explosively. Carbon dioxide leaves no residues and is
therefore well suited for extinguishing fires in
Calcium carbide forms explosive gases. sensitive equipment (switchgear cabinets, etc.).

Quicklime lime develops intense heat that can As it reduces the oxygen content in the
set combustible substances on fire. ambient air, even small concentrations of this
gas will quickly lead to unconsciousness and
EXTINGUISHING POWDER can - to a limited death.
extent - also be used in the presence of
electricity. Observe the instructions on the The use of carbon dioxide in closed rooms
extinguisher. is a life-threatening risk. Rooms filled with
this gas must not be entered.
SAFETY 2.8-4

FIRE-FIGHTING

Although fires require immediate action, keep a – Never open flaps or hoods when fighting
clear head and assess the situation. fires in engines, but extinguish through
ventilation openings or from the bottom.
Proceed as follows:
– Never drive burning liquids apart with the jet
– Depress the EMERGENCY-STOP button on from the extinguisher, but place a cloud of
the remote-control box. extinguishing agent over the source of the
fire.
– Is the power supply still on?

The first thing to do is to have the power

supply of electrically driven machines
disconnected at the power distribution
panel.

ATTENTION:
LIFE-THREATENING RISK
A voltage transfer involves the risk of
fatal electric shock to anybody
standing nearby.
The first thing to do before starting Fig. 1
any fire-fighting operations is to have
the electrical supply line
disconnected. See chapter 2.33.

– If it can be done safely, shut off the diesel

engine and disconnect the vehicle's
electrical system.

– Is safe fire-fighting possible?

Never take a risk. Fight only small fires and

call the fire brigade immediately in cases of
danger. Fig. 2

– If possible, extinguish fires downwind

(Fig. 1).

Never inhale smoke and extinguishing

agents. They are a health hazard.

– Start the extinguishing operations at the

seat of the fire.

– Hold the extinguisher vertically.

– Extinguish by proceeding from bottom to top

(Fig. 2) and from front to back (Fig. 3). Fig. 3
SAFETY 2.10 - 3

LOADING
Risk of accidents:
Always use ramps providing adequate support The standard slinging points on truck-mounted
and stability for loading purposes. concrete pumps are provided solely for
installation purposes. They are not suitable for
Ensure that no one can be jeopardized by the lifting the entire machine (Fig. 1).
machine overturning or slipping.
### With portable concrete pumps, use only the
The loading ramp must have a lower gradient
slinging points provided for that purpose
than that rated for the machine.
(example: Fig. 2).
Persons giving instructions must keep clear of
the driving zone.

Machines mounted on transport vehicles must

be secured against rolling off, slipping and
overturning.

CRANE LOADING

Truck-mounted concrete pumps may be loaded

by crane only if equipped with appropriate
slinging lugs.
Fig. 2

Lifting and slinging gear, chocks and other

devices must be reliable and safe. Ensure that
their load-bearing capacity is adequate.

Never walk under suspended loads (Fig. 3).

Fig. 1

Appropriate slinging lugs can be requested with

new orders or retrofitted if necessary.

Fig. 3
SAFETY 2.11 - 1

POWER SUPPLY CONNECTION

Life-threatening hazard:

Only qualified electricians may work on

electrical systems with a voltage in excess
of 50 V.

This applies to "simple" jobs too.

Only such qualified personnel may connect

and disconnect the machine or open
switchgear cabinets (Fig. 1).
Fig. 2

Secure the machine from being switched

on, warn other persons (set up warning
signs) and inform the competent qualified
electrician.

Life-threatening hazard from acci-

dental voltage transfer:

### Never direct a water or steam jet at

electrical machine components (Fig. 3).
Fig. 1

Power for on-site use must be taken from a

special feeder point (site-specific power
distributor).

SAFETY INSTRUCTIONS FOR OPERAT-

ING ELECTRICALLY DRIVEN MACHINES

### Use only the control devices designated

for the machine operator (cf. operating in-
structions).

### Switch the master switch off Fig. 3

immediately in the event of malfunctions or
damage to the electrical system (e.g.Fig. 2). The electrical system may also be dam-
aged.

*see glossary
SAFETY 2.11 - 2

In the event of accidents due to electric 54 = Water splashing against the machine
current, first switch off the system, then from any direction has no harmful effect.
initiate first-aid measures.
The system is splash-proof but not water-
Always switch the master switch 1 (Fig. 1) tight.
to "0" position on finishing work, before
longer intervals, before repair work etc. and
secure it from unauthorized activation (e.g. AVAILABILITY IN THE EVENT OF MAINS
with a padlock). VOLTAGE FLUCTUATIONS

SCHWING concrete pumps and placing

booms are equipped with electric motors
complying with ISO class B* as a standard
feature.

The voltage tolerance is -/+5 %.

Observe local regulations when working

in other countries.

Other protective systems, voltage toler-

Fig. 1 ances etc. are available on request.

PROTECTION AGAINST CONTACT

The switchgear cabinet, motor and control

elements have protection as per protective
system IP 54 in accordance with DIN
40050* and IEC 144* as a standard feature.

IP 54 means:

54 = Complete protection from contact with

live parts or with internal moving parts.
Protection from harmful dust deposits.

The system is not dust-tight, but dust is

prevented from penetrating in quantities
which might affect the functioning of the
system.

*see glossary
SAFETY 2.12-1

PERSONAL PROTECTIVE EQUIPMENT, BREATHING APPARATUS AND SAFTETY

EMISSION PROTECTION MASKS

Besides the personal protective equipment – Wear a breathing apparatus on all jobs
generally used on construction sites (helmet, where particles from building materials (mist
safety footwear) further special equipment may and dust) my get into the body through the
be required in the working range of the respiratory system.
machine.
– To protect the face against rebounding
material (shotcreting operations) a safety
mask must be worn in addition.

EAR PROTECTORS

For machines equipped with a portable remote-

control unit, the control box is the normal place
of work.
All injuries must be reported to supervisory
personnel. A firm and defined place of work exists only on
machines without remote-control.
HANDLING OF BUILDING MATERIALS Depending on design and application, a noise
level of 85 dB (A) may be exceeded within
– Observe the information provided by the close range of both versions.
manufacturer of the materials.
Close range is defined as an area confined by a
– Keep a first-aid kit at hand. circle around the center of the machine.
– Observe the emergency first-aid measures. The diameter of the circle depends on the type
and design of the machine concerned.
– Wear appropriate safety clothing:
– The specifications relating to your machine
are set out in the Owner's Manual.
GOGGLES AND PROTECTIVE GLOVES
– Always wear your personal ear protectors
Building materials containing cement produce a when within close range.
strong alkalinic reaction when in contact with
water (or sweat). – Inform your personnel in your capacity as the
Owner of the machine that the noise levels
Additives such as accelerating agents*, produced within close range of the machine
waterglass, etc. are toxic and caustic. may exceed 85 dB (A).

– Instruct your personnel to wear personal ear

protectors at all times when within close
range.

– As the Owner of the machine, you are

responsible for ensuring that your personnel
observe this rule.

* = see glossary of terms

SAFETY 2.13 - 1

WORKING WITH UNSKILLED WORKERS

Many accidents with concrete pumps and

placing booms are caused by unskilled
workers.

Prior to starting work, check whether on-the-job

safety is ensured with the unskilled personnel
assigned to you (language problems etc.).

We recommend that you agree upon clear-cut

manual signs with instructors, hose operators,
mixer drivers etc.

These manual signs may be as follows:

1. Increase pumping speed

2. Decrease pumping speed

3. Swivel or drive to left

4. Swivel or drive to right

5. Boom up

6. Boom down

7. Drive towards me

8. Drive away from me

9. Extend boom

10. Fold boom

11. Stop

12. EMERGENCY STOP

SAFETY 2.20 - 1

GENERAL OPERATING INSTRUCTIONS

During normal Examples of hazard zones are:

operation, it is
forbidden to stand on - installation site of the machine,
the machine unless the
machine is equipped with - working range of placing boom,
control stands especially
provided for this - within 3 meters of a separately laid delivery
purpose. line.

The machine operator must always have a

When access to the machine is necessary, e.g. clear view of the hazard zone. If necessary, he
to carry out maintenance work, the safety of the must have an assistant to instruct him.
personnel must be ensured. See chapter 2.12.
Warn all persons in the hazard zone and stop
Use the machine for its proper use only and work if they fail to leave it.
observe the operating instructions.
Have the hazard zone closed off if the
The operating instructions must always be operating conditions are likely to attract
available for reference at the machine. "spectators".

Wear personal protective gear during work. If unauthorized persons approach the hazard
zone, stop work and switch off the engine.
Have the machine operated, serviced or
repaired by trained, authorized persons only.
Watch for children:
Use the grab handles and steps to climb onto
or off the machine. It is very easy for children to creep under the
machine when it is supported by the outriggers.
Never jump down from the machine.
High risk of accidents, e.g. due to the rotating
Keep steps, platforms, control and monitoring drive shafts.
devices etc. free from dirt, oil, snow and ice.
Before starting work, always ensure that there
Risk of falls and risk due to malfunction. is no one in the hazard zone.

Keep all covers, maintenance flaps etc. closed Check the machine and the work area
and locked during operation. constantly for any potential hazards.

Risk of injury and risk from excessive noise Stop work if a failure occurs that might put
level. occupational safety at risk.

Unauthorized persons are forbidden to enter

the hazard zone.
SAFETY 2.20 - 2

INTERRUPTING OPERATION

Switch off the radio remote control or remove

the remote control cable from the machine.

Lock up the remote control panel (driver´s cab,

tool kit).

Bring the machine into transport position prior

to longer interruptions.

Before doing any work on the machine, switch

off the drive and depressurize any pressure
accumulator.

Safeguard the machine against unauthorized

starting and set up warning notices.

EMERGENCY STOP

The machine and remote control are equipped

with one or more EMERGENCY STOP
pushbuttons.

In hazardous situations, press an

EMERGENCY STOP PUSHBUTTON
immediately.

Pressing an EMERGENCY STOP pushbutton

depressurizes the hydraulic system and stops
all hydraulic functions.

If the machine has been stopped with

EMERGENCY STOP, rectify the fault before
restarting operation.
SAFETY 2.21 - 1

SELECTION OF INSTALLATION SITE

As a rule, the construction supervisor de- The maximum angular bearing pressure*
termines where the concrete pump is to be occurring is indicated on each outrigger of the
located and prepares the site accordingly. machine (example: Fig. 1).

However, the concrete pump operator is This specification must be kept in an eye-
responsible for installation safety. catching position.

He has to check the intended site and must

refuse to carry out installation if there are any
doubts as to safety.

When setting up the machine be sure that no

thoroughfares or escape routes are blocked.

Please check:

Approach route OK?

Walk along the on-site approach route before

driving on it.
Fig. 1
Check the route in the same way before
leaving the installation site. Calculate the max. ground pressure of your
machine as in the example below:
Ask for an assistant to give instructions if you
have to reverse to the installation site.
Permissible ground pressure daN
6
Agree on clear-cut signals with the assistant. specified by construction supervi- cm2
sor:
Have the route blocked off if necessary.

Demand the removal of any material or Max. angular bearing pressure of 18000daN
equipment blocking the approach route. machine:

Bearing capacity of the ground OK? Base plate area: 2500cm2

The permissible ground pressure is specified 18000daN daN

Max. ground pressure ( ): 7.2
by the construction supervisor. 2500cm 2
cm2

This calculated ground pressure is not

admissible.

*see glossary
SAFETY 2.21 - 2

After placing four pieces of squared timber

underneath, as shown in the example (Fig. 1),
the following recalculation results:

18000daN 18000daN daN

= = 3.1 2
64 cmx 90cm 5760cm2 cm

This ground pressure is admissible.

Fig. 2

Enough clearance from building pits,

slopes, etc.?

The force transmitted into the ground by each

outrigger spreads conically in the ground at an
angle of 45° (Fig. 3).

Fig. 1

Always use squared timber supports in the

case of placing booms with a horizontal reach
of more than 30 m.

Never set up the machine on filled ground.

Enough clearance for complete extension of

the outriggers?

It must be possible to extend all outriggers to Fig. 3

their limit positions.
The correct safety clearance depends on
Intermediate positions are forbidden as they various factors, e.g. type of soil, angle of slope,
cannot guarantee the necessary stability* (Fig. ground pressure of machine etc.
2).
In Germany, this clearance is specified in DIN*
4124 ( "Building pits and trenches" ).

*see glossary
SAFETY 2.21 - 3

Discuss the correct safety clearance with Is the complete range of action of the
the construction supervisor. placing boom clearly visible?

The "rule of thumb" is: An assistant may be required to give in-

structions.
The safety clearance A" (Fig. 1) is measured
from the bottom of the pit and is: Is the installation site adequately ventilated?

- for noncohesive or filled ground

= 2 x pit depth (A 2 x T). Exhaust gases are dangerous:
- for natural, cohesive ground Start up combustion engines in adequately
= 1 x pit depth (A 1 x T). ventilated rooms only.

Fig. 1

Ensure that there is always a minimum

clearance "a" between the edge of the pit and
the outer edge of the stabilizer (Fig. 1).

The clearance "a" must be

- more than 1m for machines with a gross

weight of up to 12 t,

- more than 2m for machines with a gross

weight of more than 12 t.

Enough clearance from any obstructions?

Overhead lines, cranes, buildings etc..

restrict the possible applications of the placing
boom.

*see glossary
SAFETY 2.22 - 1

PREPARATION FOR SERVICE

Top up all fuels and lubricants: - All control and monitoring devices must be in
good working order.
- Check all liquid levels with the machine level
and ready for service. - All safety circuits (EMERGENCY STOP,
placing boom overrun warning etc.) must be in
- Never fill tanks in enclosed rooms. good working order.

- Switch off engine and heating. - The machine must be free from visually
detectable defects (cracks, damage, loose or
- Wipe up any spilled fuel immediately. missing threaded connections, missing cotter
pins, rust on load-bearing parts, leakages etc.).
- When handling fuel, avoid open flame and
never smoke. Each lost drop of oil is harmful to the
ground water!
Risk of fire and explosion!
- Delivery lines, couplings and hoses must be
Take care when handling toxic or caustic properly fixed and secured against inadvertent
agents (brake fluid, battery acid, water-glass, opening (Fig. 1).
accelerating agent*, cement etc.).

Wear personal protective gear!

Check operational reliability of the machine

(visual and performance check):

- All devices provided for safety and accident

prevention purposes (warning and information
signs, cover grids, protective linings etc.) must
be present.
Fig. 1
They must not be removed, altered or dam-
aged.

- Keep steps, platforms, control and monitoring

devices etc. free from dirt, oil, snow and ice.

Risk of falls and risk due to malfunction!

* see glossary
 SAFETY 2.22 - 2

- All noise-protection devices must be present

in fault-free condition.

- Close maintenance flaps.

An excessively high noise level may damage

the hearing permanently (Fig. 1).

Fig. 1

* see glossary
SAFETY 2.30 - 2

If necessary, use the supports provided for this The timbers must not be laid over cavities (Fig.
purpose to increase the stabilizing areas. 3).

The supports must be undamaged and free Caution: the ground below asphalt, concrete
from ice, oil, grease etc. slabs etc. may be washed away.

Squared timbers must be placed under the

base plates in such a way that the load is
uniformly distributed over all timbers and there
is no risk of lateral slip (Fig. 1).

Fig. 3

Self-aligning base plates (Fig. 4) relieve

pressure on the hydraulic cylinders of the
outrigger system as they compensate for
slightly uneven surfaces.
Fig. 1

The ground surface must be level.

If necessary, prepare a level surface (Fig. 2).

Fig. 4

They are not designed to stabilize the

machine on slopes (Fig. 2).

The base plate may slip off the supporting

surface and the machine may overturn.
Fig. 2
This can also happen if the support is pressed
obliquely into the ground during operation.

*see glossary
SAFETY 2.30 - 5

Close all shutoff valves of the outrigger

hydraulic system (e.g. Fig. 1).

Fig. 1

Leakages may cause the outrigger system to

sink on one side.

Close off the operating area of the machine to

public traffic in the prescribed way (Fig. 2).

Fig. 2

*see glossary
SAFETY 2.31-1

STABILITY MONITORING

Check the stability* regularly during operation: ATTENTION - DANGER OF ACCIDENT

All base plates must contact the ground firmly If one outrigger penetrates into the ground,
at all times. there is an utmost danger of accident.

Relieve the outrigger of the load at once by

If stability is not guaranteed, stop work and slewing or/and folding the placing boom and
bring the machine into transport position. bring the boom into transport position.

One-sided sinking of the machine is

particularly dangerous. It can be caused by

- oil loss due to leakage in the outrigger

hydraulic system

- penetration of one outrigger into the

ground. This may be due to:

- insufficient bearing power of the

ground

- change of ground conditions (rain or

thaw)

- concelaled cavities (pipes, etc.)

- undersized supporting surface

- use of unsuitable material for load

distribution (boards, stones, etc.).

See also chapter 2.30.

* see glossary
SAFETY 2.32 - 1

OPERATION: CONCRETE PUMP

Use the machine for its proper use only.

Before starting up the concrete pump, ensure

that the grating cover is firmly screwed into
place in the feeding hopper.

Never set foot on the grating cover (Fig. 1).

Fig. 2

Switch off the concrete pump and the driving

motor prior to any work on the machine.

Safeguard the machine against unauthorized

starting.

If a hydraulic pressure accumulator is installed,

open the accumulator relief valve (Fig. 3) to
prevent any machine motions due to residual
pressure.

Fig. 1

Risk of crushing and cutting:

Never reach into the concrete valve (Fig. 1),

water box (Fig. 2), feeding hopper or any other
moving devices when the machine is running.

The same applies to the cleaning opening

below the feeding hopper.

Fig. 3
SAFETY 2.32 - 2

Pressure increases on the concrete side are

admissible only by changing over to piston-end
admission (Fig. 1).

Pressure increases by adjusting the pressure

relief valve (Fig. 2) are forbidden.

Never switch the concrete pump over to piston-

end admission unless a high-pressure
delivery line is connected.

High-pressure pumping (above 70 bars

concrete pressure) through the placing-boom
pipeline is forbidden.

The delivery line and end hose are suitable for

pressures up to 70 bars only.

Fig. 1
To prevent splashing through air intake, the
feeding hopper must always be filled up to the
agitator shaft.

No one is allowed to set foot on the concrete

pump during operation.

MIXER DRIVERS

In your capacity as pump operator, give

instructions to the mixer drivers delivering the
concrete.

Never let a mixer driver work on his own until

you are sure that he has fully understood your
instructions.

Fig. 2
Risk of crushing:

Ensure that no one is standing between the

approaching mixer and the concrete pump.
 Page 1 of 2

INFORMATION Members of staff, K 153

Representatives, Customers

Modifying the reach of concrete

placing booms T E C 10, V V W 1999 / 03

The prolongation of placing booms and end The example of Fig. 1 shows that the "resource-
hoses is incompatible with a placing boom's fulness" of certain users knows virtually no
designated use and thus forbidden. bounds.

Extensions will always put additional strain on These and similar constructions are of course
the placing boom and may damage the boom strictly forbidden:
itself and cause accidents.
Vibrations of the pipe bridge will be
The increased moment of tilt may topple the retransmitted to the placing boom and cause
machine over. damage as described above.

Instructions to this effect can be found in ZH * ZH 1/573 = Information brochure entitled

1/573*, pr EN 12001* and in the operating "Umgang mit Betonpumpen und
manuals issued by concrete pump Verteilermasten“ [Handling of concrete
manufacturers. pumps and placing booms] issued by the
Employers' Liability Insurance Association in
If the conditions prevailing on a construction Germany.
site make a greater reach of the boom
necessary or if concrete is to be pumped to * pr EN 12001 = Draft of the European
inaccessible places, the boom's reach may only Standard "Conveying, spraying and placing
be increased as specified in the manufacturer's machines for concrete and mortar - Safety
operating instructions. requirements"

See chapter 2.34 of our Safety Manual:

„Pumping lines and especially risers not

attached to placing booms must be securely
fastened so that the forces exerted on the line
can be safely transmitted to the building or to
other parts of the structure.“

„Extension pipes connected to the placing

boom must not add to the load on the boom.“

If possible, a truck-mounted concrete pump Fig. 1

offering the required reach as a standard Important:
feature should be used.
The prohibition mentioned at the beginning is
applicable to all types of concrete placing
booms whether chassis-mounted (e.g. on a
concrete pumping truck) or separately used.

K153
 Page 2 of 2

REDUCTION OF THE WORKING RANGE

SCHWING placing booms are designed

exclusively for the conveyance and placing of
quality concrete with a bulk density up to 2.4
kg/dm³ through the attached pumping line.

Any other utilization is considered contrary to

their designated use.

Under certain circumstances, an authorization

to operate the boom with concrete of higher
bulk density and reduced working range may be
granted. In these cases, please contact us for
further information.

EXCLUSION OF LIABILITY

It is pointed out explicitely once again, that

SCHWING cannot be held liable for damage
caused by incorrect or negligent operation,
maintenance and repair or as a result of any
utilization contrary to the machine's designated
use.

The same applies to conversions and

attachments or other modifications to the
machine not explicitely authorized by the
manufacturer.

K153
SAFETY 2.33 - 3

In Germany, VDE* 0105 stipulates the minimum If a voltage transfer has occurred despite all
clearances from overhead lines as follows: precautions:

– Keep calm, always remain stationary (pace

Rated voltage Minimum clearance voltage!), avoid touching anything.
up to 1000 V 1,00 m
over 1 kV to 110 kV 3,00 m – Instruct all uninvolved persons not to come
over 110 kV to 220 kV 4,00 m nearer (pace voltage!) but to have the line
over 220 kV to 380 kV 5,00 m
switched off.
or if rated voltage is unknown 5,00 m

Swinging of the overhead line and of the

Caution: Electric power stations are equipped
placing boom in the wind must also be taken
with an automatic cut-in system.
into account.
In other words:
– Bear in mind, too, that a high humidity
necessitates a greater minimum clearance.
– Once a fuse has responded, the short-
circuited line is switched on again after a
Observe the regulations in force in the
brief interval.
relevant country.
– Brief current-free intervals give a false sense
If the requisite minimum clearance cannot be of safety.
complied with in all feasible working
positions, it is essential to consult the – Never change location and retrieve injured
competent electricity supply company. persons until after an authorized person
from the electricity supply company has
reported that the line is switched off.
Caution:
– Initiate FIRST AID measures in the event of
– Clearances are mostly estimated incorrectly. accidents due to electric current.
– Take no risks.
Please bear in mind:
– If in doubt, do without the placing boom and
lay a separate delivery line, for example. – A radio remote control protects the
machine operator only if he is outside the
– The same minimum clearances are essential potential gradient area.
when driving beneath overhead cables.
In all other cases there is a life-threatening
risk to all persons, as stated above.

*see glossary
SAFETY 2.34 - 1

OPERATION: DELIVERY LINE AND END

HOSE

DELIVERY LINE

Use only fault-free delivery lines, end hoses, Replace pipes and elbows as soon as they fall
couplings etc. suitable for the job and produced below the minimum wall thickness.
by the manufacturer of the concrete pump.
The minimum wall thickness depends on the
Concrete delivery lines are subject to wear maximum possible concrete pressure of the
which varies according to concrete pressure concrete pump.
and composition, delivery-line material etc.
See diagrams on pages -2 und -3.
Check that delivery lines are suitable for the
application, using a wall-thickness meter (Fig. Install only good-as-new delivery lines close to
1). the pump where concrete pressure is at its
highest.

High-pressure pumping (above 7O bars

concrete pressure) through the delivery line of
the placing boom is forbidden.

For high-pressure pumping, connect the

concrete pump to a tested, separate high-
pressure delivery line only.

See diagrams on pages -2 und -3.

High-pressure pumping operations demand

special vigilance and know-how and special
material.
Fig. 1
They must always be carried out under the
A daily check may be necessary under supervision of a specialist*.
exceptionally tough conditions.

Tapping with a hammer is not recommended

because

- any denting leads to rapid wear,

- the hardened layer of highly wear-resistant

pipes (Super 2000) may be damaged.

*see glossary
SAFETY 2.34 - 2

DIAGRAMS

for determining the minimum wall thickness 3) Pipe 108x4

required for concrete delivery lines made of St
52-3 (with prescribed two-fold safety): 220
200
(Y) = concrete pressure PN in bars
180
160
140
(X) = minimum wall thickness in mm 120
100
80

(
60
1) Pipe 70x2.9 40
20
220 0
200 0 1 2 3 4
180
160 (X)
140
120
100 4) Pipe 114.3x7.1
80
(

60
40 220
20 200
0 180
160
0 1 2 3 140
120
(X) 100
80
(

60
2) Pipe 88.9x3.2 40
20
220 0
200 0 1 2 3 4 5 6 7
180
160 (X)
140
120
100 5) Pipe 133x4
80
(

60
40 220
20 200
0 180
0 1 2 3 160
140
(X) 120
100
80
(

60
40
20
0
0 1 2 3 4
(X)

*see glossary
SAFETY 2.34 - 3

6) Pipe 139.7x7.1 9) Pipe 165.1x7.1

220 220
200 200
180 180
160 160
140 140
120 120
100 100
80 80
(

(
60 60
40 40
20 20
0 0
0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
(X) (X)

7) Pipe 139.7x8.8 10) Pipe 168.3x10

270 240
240 210
210 180
180 150
150
120 120
90
(

90
60 60
30 30
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 10
(X) (X)

8) Pipe 159x4.5 11) Pipe 191x5.5

220 220
200 200
180 180
160 160
140 140
120 120
100 100
80 80
(

60 60
40 40
20 20
0 0
0 1 2 3 4 5 0 1 2 3 4 5 6
(X) (X)

*see glossary
SAFETY 2.34 - 4

Delivery lines, especially rising lines, which are - Send uninvolved persons out of the hazard
not guided in placing booms must be firmly zone.
secured in order to conduct the resulting forces
into the structure or other structural members. - Always secure couplings after installation
(Fig. 2).
The lines must be run in such a way that
buckling, sharp bends, stress and damage are
avoided during operation

Support horizontal delivery lines to facilitate

mounting the couplings. (Fig. 1).

Fig. 2

Separate delivery lines in whose hazard zone

(less than 3 m) persons have to set foot must
be screened with boards, metal etc. (Fig. 3).

Fig. 1

Never open or tap delivery pipes under

working pressure.

Concrete discharged under pressure may

cause injury.

- Before opening, relieve pressure on concrete

column by pumping briefly in reverse.
Fig. 3
- Bear in mind that not every blockage is
released by reverse pumping.
Run a water test at operating pressure on the
- Stand to the side of the pipeline securing delivery line at regular intervals.
device when opening it.

- Never bend over the coupling when working

on it.

*see glossary
SAFETY 2.35 - 1

OPERATION: REMOTE CONTROL

SCHWING machines may be operated only The working range must be fully visible,
with SCHWING-approved remote control otherwise an assistant is required to give the
systems. operator instructions.

SCHWING accepts no liability for any Because you have to focus your attention
damage resulting from the use of non- primarily on the placing site in your capacity as
approved systems. operator, position the assistant where he can
always see the entire placing boom.

Put all control and monitoring devices into "0" Agree on clear-cut signals with the assistant.
position before changing the control mode.
During breaks from work, safeguard the
Press the EMERGENCY STOP button. machine against unauthorized use:

The machine might otherwise execute un- - Remove the remote control cable from the
intended operating motions. machine,

Never set down the remote control panel when - Switch off the radio remote control,
the machine is ready for operation.
- Lock the remote control panel away (e.g. in
This is the only means of guaranteeing rapid the cab or tool kit).
access to the EMERGENCY STOP button in
emergencies.
Observe the separate operating in-
If the control panel has to be set down in structions for radio remote controls.
exceptional circumstances, press the
EMERGENCY STOP button and remove the
key if necessary.

Carry the remote control panel in such a way

that none of the control elements is activated
inadvertently.

Avoid damaging the remote control cable:

Risk due to malfunctions.

SAFETY 2.36 - 1

OPERATION: WET-MIX SHOTCRETING Hazard warnings:

In Germany, observe the code of practice of - Water-glass is slightly caustic and must not
the Employer´s Liability Insurance Associations come into contact with the skin or eyes.
(ZH 1/592):
- In the event of contact with the skin, rinse off
Safety regulations for shotcreting machines immediately with plenty of water.
(shotcreting procedures).
- In the event of contact with the eyes, rinse
Outside Germany, observe the regulations in out immediately with plenty of water and
force in the relevant country. consult an ophthalmologist without delay.

Observe the following additional rules for wet- - After swallowing: drink plenty of liquid
mix shotcreting: immediately, drink lemon juice.

- The nozzle operator must wear personal Immediate referral to hospital.

protective gear comprising face mask with
breathing equipment and goggles, helmet, - Wear personal protective gear as specified
gloves, safety footwear, rubber jacket and above.
rubber trousers.

- No one is allowed to set foot in the working Technical protective measures:

and rebound range.
- Use only TÜV-approved steel or plastic
- The nozzle operator must stop work if anyone containers (TÜV = German Technical In-
sets foot in the hazard zone. spectorate).

- Nobody must stand under spraying arms and

spraying manipulators when they are in Measures to be taken after spills and
operation. leakages:

- In the event of blockages, first stop the - Soak up, prevent from running into waters
compressed air supply. and drainage systems, neutralize.

- Relieve pressure on concrete delivery line by

reverse pumping. Disposal:

- Observe information provided by the at designated disposal sites with the approval
producers of the additives. of the competent authority.

WATER-GLASS
SAFETY 2.36 - 2

ACCELERATING
AGENTS

Hazard warnings:

- Causes severe burns (highly caustic).

Safety recommendations

- Keep out of reach of children.

- In the event of contact with the eyes or skin,

rinse off immediately with plenty of water and
consult a doctor.

- Wear personal protective gear as specified

overleaf.

- Remove soiled, soaked clothing immediately.

SAFETY 2.40 - 1

CLEANING

Empty the delivery line, concrete pump and

feeding hopper completely.

First clean the delivery line, where the

concrete sets more rapidly:

DELIVERY LINE

The delivery line is best cleaned by reverse

pumping (truck-mounted concrete pump) or
flushing out with water:

- Never use salt water for cleaning.

- For reverse pumping, always switch on the

agitator.

The concrete flowing back into the hopper may

otherwise distort the agitator shaft.

Blowing out the delivery line with compressed

air is very hazardous. Fig. 1

- It may be done only under the supervision of

a specialist*.

- Remove elbow and end hose at end of line.

- Use trap basket (Fig. 1), pipe-cleaning head

(Fig. 2) and cleaning ball.

- No one may be standing in the blow-out

direction:

Concrete discharged under pressure may

cause injury. Fig. 2

- When installing fixed delivery lines, check

that good cleaning facilities are available.

E.g. shutoff valves installed in downpipes

prevent concrete from being ejected under
gravitational force.

* see glossary
SAFETY 2.40 - 2

CONCRETE PUMP

Empty the concrete pump and feeding

hopper completely.

Residual concrete may be thrown out during

transport.

Switch off the concrete pump and drive and

safeguard the machine from unauthorized
starting.

Ensure that no unauthorized person sets foot

near the valve housing. Fig. 1

Direct only the water jet, not the nozzle, into

the hopper (Fig. 1), into the valve housing (Fig.
2), into the water box or other moving machine
components.

Put the machine into transport position if you

have to move it for cleaning purposes.

Even for short distances, the placing boom

must be folded and the stabilizing system
retracted and secured.

Fig. 2
Life-threatening risk due to voltage
transfer:

Never direct a water or steam jet at electrical

machine components (Fig. 3).

The electrical system may moreover be

damaged.

The electrical system is splash-proof, not

watertight.

Fig. 3

* see glossary
SAFETY 2.40 - 3

WEAR PROTECTIVE CLOTHING:

Be careful with aggressive cleaning agents.

Acid attacks rubber parts.

FIRE HAZARD :

Never use highly inflammable agents (petrol

etc.) for cleaning purposes.

RISK OF CRUSHING AND

CUTTING:

Never remove the grating cover in the

feeding hopper of the concrete
pump,

set foot on the grating,

reach into the machine when the

motor is running or the accumulator
charged. The same applies to the
cleaning opening below the feeding
hopper.

* see glossary
SAFETY 2.60-1

SERVICING AND REPAIR

GENERAL

ð Servicing and repair work may be carried ð Use only safe equipment and lifting gear,
out by specially trained and duly authorized trestles, etc. of sufficient strength.
persons only:
Observe the relevant accident prevention
Safety-relevant devices may be repaired, re- regulations when working with lifting gear.
adjusted or replaced only by specialists*.
The placing boom must NOT be
Appoint a person to supervise the work.
used as lifting gear.
The responsibilities of the personnel must
be clearly defined. ð Place a warning sign over the control panel
when work is being carried out on the
The operating staff must be informed before machine.
the works are carried out.
ð Keep unauthorized persons away from the
Respect the servicing instructions* specified machine.
by the manufacturer.
ð Secure any flaps and covers that may have
Inexpertly serviced and repaired machines been opened for servicing purposes.
are a risk to operational safety and to the
workplace. ð Refit any removed protective devices
properly and immediately on completion of
ð Park the machine on firm and level ground. the work.

ð Secure the machine against inadvertent ð Be careful when handling hazardous

movements and unauthorized starting: substances such as:

Apply the parking brake, withdraw the brake fluid, battery acid (toxic and caustic)
ignition key, switch off the main switch, lock
the door of the driver's cab etc. oil, petrol, diesel fuel (flammable and
explosive).
ð Keep the place of work and the working
equipment clean.

ð Avoid starting up combustion engines on

enclosed premises.

If this is impossible, make sure there is

sufficient ventilation and conduct exhaust
gases into the open air.

* see glossary of terms

SAFETY 2.60-4

REPLACEMENT
– Adjustable units such as pumps, valves and – deformations incompatible with the normal
control cards are supplied with a basic shape of the hosepipe.
factory setting:
Deformations may occur in the pressureless
They must be adapted to the machine and/or pressurized state of the hosepipe or
(adjusted) after the installation. as a result of bending.
Replacement of pipes
Typical deformations are, for instance: layer
– Do not repair damaged hydraulic and separation, blistering, crushing and kinking.
concrete pumping pipes, but rather replace
them. – leaks.
Replacement of hydraulic hoses and lines
– improper fitting.
– Replace damaged or soaked hydraulic
hoses immediately. – gradual detachment of hosepipe from fitting.

ATTENTION: DANGER – damage, deformation or corrosion of the

fitting affecting the function or the strength
Leaking hydraulic hoses are a risk of the hosepipe.
to persons and to the environment.
– unsuitable type of hosepipe.

Use original SCHWING parts only.

Even if apparently undamaged, hydraulic
hoses must be replaced every 6 years – storage time and/or duration of use excee-
(including a maximum storage time of 2 ded.
years).
This period must be calculated on the basis Hosepipe storage
of the marking on the fitting (hosepipe
manufacturing date). Proper storage of hosepipes is of utmost
importance for the service life of these parts
A regular check must be carried out in the
course of the MACHINE SAFETY Proper storage is regulated in Germany in DIN
INSPECTION. 7716. Here are the most important points:
The operator is obliged to check the
condition of his machine permanently. – Hosespipes are to be stored lying and
stress-free in a closed room
The manufacturer is not liable for damage
resulting from the use of worn-out or – Hosespipes are to be stored under typical
defective components. room conditions
Examples of possible damage (defects):
– Hosespipes are to be stored in their original
– damage of outer layer down to the packing (plastic foils) ends closed with plugs
reinforcement (chafing marks, cuts, cracks,
etc.). – Hosepipes must not be stored outdoors.

– embrittlement of outer layer (fissuring of

hose material).

* see glossary of terms

SAFETY 2.60-5

DISPOSAL

ð Collect used consumables separately and in ð Use only original fuses:

specially marked containers:
Overrated fuses or jumpered fuses may
Oils and greases must be collected cause irreparable damage to the electrical
separately depending on the base (mineral system.
oils, synthetic oils, biodegradable oils).
ð Prior to any work on the electrical system
Do not mix oils with other liquids. disconnect first the negative and then the
positive terminal from the battery.
Waste oil can be recycled only if properly Remove the battery or cover up with
separated. insulating material.

Oils contaminated by other liquids must be ð Reconnect the battery in reverse order, i.e.
disposed of at high cost. first the positive and then the negative pole.

Collect anti-freeze, brake fluid and other ð When recharging a battery remove the caps
liquids separately. to allow gases to escape:

Collect used filters, oil-stained cleaning

ATTENTION:
rags, etc. also in separate containers.
RISK OF EXPLOSION
Primary batteries and rechargeable batteries Battery gases are highly explosive.
are pollutants and must therefore be
disposed of accordingly.
Do not smoke, avoid sparks and naked flames
and ensure proper ventilation.
For further information please contact
your local waste-disposal center.
ATTENTION:
RISK OF INJURY
ELECTRICAL SYSTEM Battery acid is caustic.

ð Cut out the main switch of electrically driven

machines. In the event of contact with the skin and
clothes rinse immediately with much water.
ð Have the power supply line disconnected by
a qualified electrician. Rinse the eyes with much water and consult a
doctor.
ð Only qualified electricians are allowed to
work on electrical systems with voltages in ð Do not place tools on the battery.
excess of 50 volts.

* see glossary of terms

SAFETY 2.60-6

FUEL SYSTEM

ð Do not smoke and avoid sparks and naked

flames. Ensure sufficient ventilation.

ð Collect escaping fuel and dispose of

properly. Do not allow fuel to penetrate into
the ground.

ENGINE / CHASSIS / BUILT-IN UNITS

ð Observe the manufacturers' safety

instructions.
Fig. 1
ð Have brake systems, air conditioners, tyres,
remote-control systems, etc. serviced, Disconnect all cables from the receiver of
repaired and fitted only by specialized the radio remote-control unit (Fig. 2).
repair shops.
Protect the electronic system of the vehicle,
for instance, by:
WELDING OPERATIONS
removing the connectors from the control
ð Welding work on the placing boom, the units of the Anti-Blocking-System (ABS) or
outriggers or other safety-related the Electronic-Diesel-Control (EDC).
components may be carried out only duly
authorized agents of the manufacturer. See documentation of the vehicle
manufacturer.
The work must be inspected by a competent
expert*.

ð Electronic components in the radio or cable

remote control units may be irreparably
damaged by high transient voltages from
electric welding.

For this reason:

Disconnect the negative and the positive

supply cable from the battery.

Disconnect the remote-control cable from

the control unit (Fig. 1). Fig. 2

* see glossary of terms

SAFETY 2.60-7

Detach all connectors from the proportional

control blocks.

Protect the connectors by plugging them

into dummy sockets.

Protect socket outlets with plugs.

ð Always connect the grounding cable of the

welding machine directly to the component
on which welding is being done.

The welding current must not be allowed

to flow through joints , cylinders etc.:

Gap bridging my cause severe damage.

ATTENTION:
RISK OF EXPLOSION

ð Welding work on fuel and oil tanks may be

performed only by specially trained welders
and in observance of the relevant safety
regulations.

* see glossary of terms

SAFETY 2.60-1

SERVICING AND REPAIR

GENERAL

ð Servicing and repair work may be carried ð Use only safe equipment and lifting gear,
out by specially trained and duly authorized trestles, etc. of sufficient strength.
persons only:
Observe the relevant accident prevention
Safety-relevant devices may be repaired, re- regulations when working with lifting gear.
adjusted or replaced only by specialists*.
The placing boom must NOT be
Appoint a person to supervise the work.
used as lifting gear.
The responsibilities of the personnel must
be clearly defined. ð Place a warning sign over the control panel
when work is being carried out on the
The operating staff must be informed before machine.
the works are carried out.
ð Keep unauthorized persons away from the
Respect the servicing instructions* specified machine.
by the manufacturer.
ð Secure any flaps and covers that may have
Inexpertly serviced and repaired machines been opened for servicing purposes.
are a risk to operational safety and to the
workplace. ð Refit any removed protective devices
properly and immediately on completion of
ð Park the machine on firm and level ground. the work.

ð Secure the machine against inadvertent ð Be careful when handling hazardous

movements and unauthorized starting: substances such as:

Apply the parking brake, withdraw the brake fluid, battery acid (toxic and caustic)
ignition key, switch off the main switch, lock
the door of the driver's cab etc. oil, petrol, diesel fuel (flammable and
explosive).
ð Keep the place of work and the working
equipment clean.

ð Avoid starting up combustion engines on

enclosed premises.

If this is impossible, make sure there is

sufficient ventilation and conduct exhaust
gases into the open air.

* see glossary of terms

SAFETY 2.60-2

ð Support the machine ready for operation HYDRAULIC SYSTEM

when the placing boom is to be unfolded.

ð Secure the placing boom by means of ATTENTION:

appropriate trestles (Fig. 1) when work is to RISK OF INJURY
be carried out on the boom or on the boom
hydraulics. ð Wear a face mask and gloves whenever
work is to be carried out on the hydraulic
system:

The oil ejected is toxic and can penetrate

the skin.

ð Work only on depressurized systems.

ð Drain fluids only from unpressurized

systems and at the points provided for such
purpose (Fig. 2).
Fig. 1

ð Perform all works that cannot be done from

the ground from safe working platforms,
ladders, etc.

CLEANING

ð Do not use easily flammable substances

(petrol, etc) for cleaning.

ð Do not clean rubber parts and electrical Fig. 2

components with a steam-jet cleaner.
ð Be careful when draining off hot fluids: Risk
of scalding.
DELIVERY PIPES
ð Check after the work that the system is
The delivery pipes are fitted stress-free to the perfectly vented.
placing boom when the machine is in transport
position. Only in this position can the pipes be
replaced properly and without problems.

* see glossary of terms

SAFETY 2.60-3

ð If the machine is equipped with a pressure PREPRESSURIZED SYSTEMS

accumulator, open relief valve 4 (Fig. 1).
ð Never open gas-filled pressure springs
under (Fig. 2) like those used to keep
maintenance flaps open:

These springs are filled with gas under high

pressure which might escape explosively
during attempts to open the spring.

Fig. 1

ð Modifications to the hydraulic accumulator

circuit are forbidden.
Fig. 2
It is essential to have all repairs carried out
by qualified prsonnel only. ð Depressurize all mechanically prestressed
systems.
Repairs can be carried out by the After.-
Sales Service of SCHWING.
SETTINGS
Keep inspection certificates supplied with
the machine in a safe place ð Re-adjustable devices such as pressure-
limiting valves, potentiometer, etc. may only
The user of the machine is responsible for be re-adjusted by qualified workshop
proper operation of pressure accumulators mechanics.
and the observance of the legal intervals
prescribed for inspections. ð Changes to machine settings such as, for
instance, pressure increases, modification
Observe the regulations in force in the of speeds, etc. are forbidden.
country of use.
ð Lead seals may be removed only by
authorized SCHWING agents.

* see glossary of terms

SAFETY 2.60-4

REPLACEMENT
– Adjustable units such as pumps, valves and – deformations incompatible with the normal
control cards are supplied with a basic shape of the hosepipe.
factory setting:
Deformations may occur in the pressureless
They must be adapted to the machine and/or pressurized state of the hosepipe or
(adjusted) after the installation. as a result of bending.
Replacement of pipes
Typical deformations are, for instance: layer
– Do not repair damaged hydraulic and separation, blistering, crushing and kinking.
concrete pumping pipes, but rather replace
them. – leaks.
Replacement of hydraulic hoses and lines
– improper fitting.
– Replace damaged or soaked hydraulic
hoses immediately. – gradual detachment of hosepipe from fitting.

ATTENTION: DANGER – damage, deformation or corrosion of the

fitting affecting the function or the strength
Leaking hydraulic hoses are a risk of the hosepipe.
to persons and to the environment.
– unsuitable type of hosepipe.

Use original SCHWING parts only.

Even if apparently undamaged, hydraulic
hoses must be replaced every 6 years – storage time and/or duration of use excee-
(including a maximum storage time of 2 ded.
years).
This period must be calculated on the basis Hosepipe storage
of the marking on the fitting (hosepipe
manufacturing date). Proper storage of hosepipes is of utmost
importance for the service life of these parts
A regular check must be carried out in the
course of the MACHINE SAFETY Proper storage is regulated in Germany in DIN
INSPECTION. 7716. Here are the most important points:
The operator is obliged to check the
condition of his machine permanently. – Hosespipes are to be stored lying and
stress-free in a closed room
The manufacturer is not liable for damage
resulting from the use of worn-out or – Hosespipes are to be stored under typical
defective components. room conditions
Examples of possible damage (defects):
– Hosespipes are to be stored in their original
– damage of outer layer down to the packing (plastic foils) ends closed with plugs
reinforcement (chafing marks, cuts, cracks,
etc.). – Hosepipes must not be stored outdoors.

– embrittlement of outer layer (fissuring of

hose material).

* see glossary of terms

SAFETY 2.60-5

DISPOSAL

ð Collect used consumables separately and in ð Use only original fuses:

specially marked containers:
Overrated fuses or jumpered fuses may
Oils and greases must be collected cause irreparable damage to the electrical
separately depending on the base (mineral system.
oils, synthetic oils, biodegradable oils).
ð Prior to any work on the electrical system
Do not mix oils with other liquids. disconnect first the negative and then the
positive terminal from the battery.
Waste oil can be recycled only if properly Remove the battery or cover up with
separated. insulating material.

Oils contaminated by other liquids must be ð Reconnect the battery in reverse order, i.e.
disposed of at high cost. first the positive and then the negative pole.

Collect anti-freeze, brake fluid and other ð When recharging a battery remove the caps
liquids separately. to allow gases to escape:

Collect used filters, oil-stained cleaning

ATTENTION:
rags, etc. also in separate containers.
RISK OF EXPLOSION
Primary batteries and rechargeable batteries Battery gases are highly explosive.
are pollutants and must therefore be
disposed of accordingly.
Do not smoke, avoid sparks and naked flames
and ensure proper ventilation.
For further information please contact
your local waste-disposal center.
ATTENTION:
RISK OF INJURY
ELECTRICAL SYSTEM Battery acid is caustic.

ð Cut out the main switch of electrically driven

machines. In the event of contact with the skin and
clothes rinse immediately with much water.
ð Have the power supply line disconnected by
a qualified electrician. Rinse the eyes with much water and consult a
doctor.
ð Only qualified electricians are allowed to
work on electrical systems with voltages in ð Do not place tools on the battery.
excess of 50 volts.

* see glossary of terms

SAFETY 2.60-6

FUEL SYSTEM

ð Do not smoke and avoid sparks and naked

flames. Ensure sufficient ventilation.

ð Collect escaping fuel and dispose of

properly. Do not allow fuel to penetrate into
the ground.

ENGINE / CHASSIS / BUILT-IN UNITS

ð Observe the manufacturers' safety

instructions.
Fig. 1
ð Have brake systems, air conditioners, tyres,
remote-control systems, etc. serviced, Disconnect all cables from the receiver of
repaired and fitted only by specialized the radio remote-control unit (Fig. 2).
repair shops.
Protect the electronic system of the vehicle,
for instance, by:
WELDING OPERATIONS
removing the connectors from the control
ð Welding work on the placing boom, the units of the Anti-Blocking-System (ABS) or
outriggers or other safety-related the Electronic-Diesel-Control (EDC).
components may be carried out only duly
authorized agents of the manufacturer. See documentation of the vehicle
manufacturer.
The work must be inspected by a competent
expert*.

ð Electronic components in the radio or cable

remote control units may be irreparably
damaged by high transient voltages from
electric welding.

For this reason:

Disconnect the negative and the positive

supply cable from the battery.

Disconnect the remote-control cable from

the control unit (Fig. 1). Fig. 2

* see glossary of terms

SAFETY 2.60-7

Detach all connectors from the proportional

control blocks.

Protect the connectors by plugging them

into dummy sockets.

Protect socket outlets with plugs.

ð Always connect the grounding cable of the

welding machine directly to the component
on which welding is being done.

The welding current must not be allowed

to flow through joints , cylinders etc.:

Gap bridging my cause severe damage.

ATTENTION:
RISK OF EXPLOSION

ð Welding work on fuel and oil tanks may be

performed only by specially trained welders
and in observance of the relevant safety
regulations.

* see glossary of terms

SAFETY 2.61-1

SAFETY INSPECTIONS

INSPECTION BY THE MACHINE OPERATOR INSPECTION BY A SPECIALIST

The machine operator must check the machine After initial commissioning, the machine and its
and the accessories for visible defects prior to accessories must be checked regularly for
any operation. operational safety by a specialist*.

The correct functioning of all control and safety The inspection intervals are dependent on the
devices (e.g. EMERGENCY STOP) must also age of the machine:
be checked.

During operation, he must keep a constant From 0 to 5 years inclusive: every year
watch on the machine for any damage or
malfunctions. Should the machine reach 500 hours of
operation or 20,000 m³ of pumped concrete,
If defects representing a hazard to work safety before a a 12 months' term elapses, the
cannot be eliminated, the operator must stop inspection must be performed at either of the
work until the defects have been eliminated. above events occurring first.

INSPECTION BY A COMPETENT EXPERT Between 5 years and 10 years inclusive: every

6 months
After any major modifications, placing booms
must be inspected by a competent expert* prior Should the machine reach 250 hours of
to being started up again. operation or 10,000 m³ of pumped concrete,
before a 6 months' term elapses, the
Examples of major modifications are: inspection must be performed at either of the
above events occurring first.
– structural modifications to increase the load-
bearing capacity
Beyond 10 years: every three months
– replacement or repair of load-bearing parts
when this involves welding. Should the machine reach 125 hours of
operation or 5,000 m³ of pumped concrete,
before a 3 months' term elapses, the
inspection must be performed at either of the
above events occurring first.

* see glossary
SAFETY 2.61-2

If the machine is equipped with an operating-

hours meter, the time recorded on it is decisive.

Ensure that the operating-hours meter is

always working correctly.

The inspection must be arranged by the user*.

The results of inspections must be entered in a

log book and signed.

The log book must be available for inspection

on demand.

If defects are detected on components of

importance to working safety, the machine
must not be used again until these defects
have been eliminated.

Accessories must be approved by SCHWING.

Defective and unsuitable accessories must not
be used. See chapter 2.70.

The elimination of defects must be verified by a

FOLLOW-UP INSPECTION.

Inspection and log book are compulsory in

Germany.

Please observe the regulations in force in the

relevant country.

* see glossary
SAFETY 2.70-1

SPARE PARTS AND ACCESSORIES

– Spare parts and accessories must comply

with SCHWING specifications and
requirements.

This can be ensured by using original spareparts

and accessories from SCHWING Stetter India.

Beyond legal requirements,SCHWING Stetter is

also able to supply original spare parts for
older machines.

SCHWING also holds an extensive range of

accessories at their clients' disposal.

SCHWING assumes no liability whatsoever

for damage caused by the use of spare
parts and accessories not compatible with
the above requirements.

The use of unsuitable or non-approved

accessories may also constitute a case of
"utilization incompatible with the designated
use".

– During safety inspections, the accessories

of the machine are also subject to
inspection, irrespective of whether they are
firmly attached to the machine or carried
along as detached parts.

It must be ensured that these accessories

are not only in perfect condition, but also
suitable for their intended use and approved
by SCHWING.

* see glossary
SAFETY 2.90 - 1

GLOSSARY

ANGULAR BEARING PRESSURE EN

The maximum possible force transmitted into The European Standardization Organisations
the ground by each outrigger during operation. harmonize technical standards and rules and
establish them as European Standards (EN).

COMPETENT EXPERT These standards are binding for all member

states of the European Community.
Only competent experts from the Technical
Inspectorate or from the Employer´s Liability EN standards must be integrated into the
Insurance Association can be consulted for the national standards and conflicting national
inspection of concrete pumps and placing standards must be withdrawn.
booms.

The general prerequisites for authorization by IEC

the Employer´s Liability Insurance Association
are: International Electrotechnical Commission

– degree or diploma in engineering,

IP
– at least 5 years´ experience with concrete
pumps and placing booms, International Protection

– adequate knowledge of the relevant regula-

tions. IS0

International Standardization Organization

daN

decanewton = 10 newtons MAINTENANCE (DIN 31051)

Maintenance covers all servicing, inspection

DIN and repair measures.

Deutsche Industrie Norm Maintenance and inspection are measures

(German Industrial Standard) designed to retain the required state.

Repair is a measure designed to restore the

required state (repair).
SAFETY 2.90 - 2

OVERTURNING MOMENT STABILITY

cf. Stability The machine is positioned securely when the

"static moment" (MS) is greater than the
"overturning moment" (MK) (Fig. 1).
OWNER
The static moment is calculated as:
of a machine is a person, company etc. which MS = G1 x a
has acquired the rights of ownership, e.g. by
purchase. The overturning moment is calculated as:
MK = G2 x b

POTENTIAL G1 = vehicle weight

Performance, capacity, gauge of the strength a = distance from centre of vehicle to over-
of an electric field. turning line

G2 = weight of placing boom + concrete +

QUALITY CONCRETE end hose from overturning line

A concrete standardized by concreting tech- b = distance from overturning line to farther-

nology (DIN 1045) with a fine graining as most boom section
required in reinforced concrete.
The overturning moment increases inadmis-
sibly when, for example:
SPECIALIST
– the outriggers are not fully extended,
Specialists are persons who have adequate
know-how about machines, devices or pro- – the boom is overloaded (heavyweight con-
cesses on account of their specialized training crete, long end hose etc.),
and experience.
– one outrigger sinks into the ground,
They are sufficiently familiar with the relevant
occupational safety and accident prevention – the machine is in a sloping position.
regulations and with the guidelines and gener-
ally accepted engineering norms (e.g. DIN
standards, VDE regulations) to be able to
assess the safety status of machines or
devices or the application safety of processes.

Specialists may be: plant engineers, master

mechanics, specially trained and qualified
personnel, after-sales service engineers ap-
pointed by the manufacturer.

Unlike authorized COMPETENT EXPERTS, Fig. 1

specialists require no special authorization.
SAFETY 2.90 - 3

StvZO VDE

Straßenverkehrs - Zulassungs - Ordnung Verein Deutscher Elektrotechniker

(German regulations authorizing the use of (Association of German Electrical Engineers)
vehicles for road traffic)
WIND FORCE
TBG
The wind force is described with reference to
Tiefbau - Berufsgenossenschaft the Beaufort scale.
(Civil Engineering Employer´s Liability
Insurance Association) The Beaufort scale has 12 wind force ratings:

USER

of a machine can be a person, company etc.

which has acquired the rights of use from the
owner for a certain period of time (e.g. by
hiring).

Beaufort scale:

Beaufort Wind speed Wind name Observable wind

number (km/h) characteristics
0 <1 Calm Smoke rises vertically

1 1-5 Light air Wind direction shown by smoke

drift but not by wind vanes

2 6-11 Light breeze Wind felt on face; leaves rustle;

vanes moved by wind
3 12-19 Gentle breeze Leaves and small twigs in
constant motion; wind extends
light flag
4 20-28 Moderate Raises dust, loose paper; small
branches moved
5 29-38 Fresh Small trees in leaf begin to sway
6 39-49 Strong Large branches in motion;
difficult to use umbrellas
7 50-61 Near gale Whole trees in motion; difficult to
walk against wind
8 62-74 Gale Breaks twigs off trees; impedes
progress
9 75-88 Strong gale Slight structural damage caused
10 89-102 Storm Trees uprooted; considerable
structural damage occurs
11 103-117 Violent storm Widespread damage
12 > 118 Hurricane Severe destruction
 3.1-1

OPERATION
TABLE OF CONTENTS - PART 3

Chapter Title

3.1 TABLE OF CONTENTS

3.2 DRIVING

3.3 PLACE OF INSTALLATION

3.4 ELECTRICAL CONNECTION ON SITE

3.5 EMERGENCY SHUT-OFF SYSTEM

3.10 PREPARING THE MACHINE FOR OPERATION

3.11 STARTING THE DIESEL ENGINE / SHUTTING OFF

3.20 INSTALLING THE MACHINE

3.22 PUMPING LINE

3.30 GENERAL INSTRUCTIONS FOR WORKING

3.31 CONCRETE PUMP OPERATION

3.32 OPERATION OF AUXILIARY UNITS

3.34 OPERATION OF THE AIR SUPPLY SYTEM

3.38 OPERATION MONITORING

3.51 PREPARING THE MACHINE FOR TRANSPORT

3.60 OPERATION UNDER EXTREME WORKING CONDITIONS

3.70 PUTTING OUT OF OPERATION FOR PROLONGED PERIODS

3.80 CONCRETE TECHNOLOGY REQUIREMENTS FOR PUMPED

CONCRETE
 3.2-1

TRAVELLING

OBSERVE CHAPTER 2.10 "SAFETY"!

- Trailer concrete pumps may only participate TIRE PRESSURE TABLE

in the public traffic if they are licensed
accordingly. The driver of the towing vehicle Tire size Tire pressure
must have the required driving licence. bar / psi
Please observe the regulations in the country 6.50 R 16 C 5,0 / 70
of use.
7.00 R 16 6,0 / 85
7.50 R 16 6,5 / 90
- Prior to travelling check the driving safety of 8.25 R 16 7,0 / 95
the machine. The checks must include
8.50 R 17,5 6,0 / 85
- the tire pressure according to the list 9.00-20.14 PR 7,75 / 110
10 R 22.5 7,0 / 95
- the operatability of the lighting system
445 / 45R 19,5 9,0 / 130
- the operatability of the braking system

- the perfect chassis maintenance

- Put the equipment and the accessories in

safe places.

ENVIRONMENTAL AND ACCIDENT

PROTECTION

- Check the tightness of the tanks. If

necessary, empty the fuel and oil tanks.

- Protect the outriggers against extension of

their own.
 3.3-1

SELECTION OF THE PLACE OF

INSTALLATION

OBSERVE "SAFETY" CHAPTER 2.21!

The machine operator must select the location

of the machine so that

- the stability is ensured,

- the truck mixers have easy access to the

concrete charging hopper,

- the outreach of the placing boom can be used

in the best way,

- a repositioning of the machine will not be

required,

- the ventilation is adequate (waste gas,

overheating, fire hazard),

- collisions with other construction site

equipment, overhead lines, etc. are
impossible,

- any obstruction of construction site or road

traffic is avoided.

When portable concrete pumps are used for

upward or downward pumping, it is advisable
to provide a certain starting distance by means
of horizontal pipes.
 3.4-1

ELECTRIC CONNECTION ON THE SITE

-

OBSERVE "SAFETY" CHAPTER 2.11

Connected load: : see sign in switch
Electrically driven machines may only be box
connected, put in operation and locked up
by a TRAINED ELECTRICIAN. Circuit diagrams: : see sign in switch
box
Only such QUALIFIED PERSONNEL is
allowed to open the switch cabinet.

The user of the concrete pump has to Other types of protection, voltage tolerances,
arrange for the connection of the machine etc. are available upon special demand.
IN AN EXPERT WAY.

In the Federal Republic of Germany, a ATTENTION!

special feed point in compliance with VDE
0100 § 55 is prescribed (e.g. building site Definitely required prior to commissioning:
main cabinet with leakage current breaker).

Observe the prescriptions valid in the 1. Check the protection against inadmissible
country of operation. contact voltage.

INSTRUCTIONS FOR THE ELECTRICIAN 2. Retighten all connecting screws, especially

of main paths of current, as they might have
1. STANDARD EQUIPMENT loosened due to vibrations during transport.

3. Adjust motor protection relay to motor

Type of protection : IP 54
nominal current (for directly activated motors
up to 5.5 kW)
Working condition : ISO class B
in case of mains
ATTENTION:
fluctuations
For starting in star-delta connection:
Protection against : No interference in
radio and case of motor nominal current x 0.58
television asynchronous
interference with squirrel cage rotors
reception 4. Check the connected loads (see sign in the
switch box).
 3.4-2

2. FUSE RATING AND WIRE CROSS SECTIONS:

ELECTRIC MOTOR SUPPLY CABLE SUPPLY CABLE

max. 100m max. 200m

kW V A mm² Fuse (A) mm² Fuse (A)

30 400 58 4x16 80 4x25 80

45 400 85 4x25 100 4x35 100
75 400 140 4x50 160 4x70 160
90 400 170 4x70 225 4x70 225
110 400 220 4x75 225 4x95 225
132 400 245 4x120 300 4x120 300
160 400 315 4x185 315 4x185 315
200 400 400 4x240 400 4x240 400

3. CHECK THE DIRECTION OF ROTATION The direction of rotation must always be

OF THE ELECTRIC MOTORS checked:

Prior to any commissioning of the concrete - after any connection made on the site,
pump check the direction of rotation of the
electric motors. - after repairs of the electrical installation,

On new machines, it is marked by arrows on - after changing the supply cable or parts of
the motor fan. the cable,

If you look at the fan, the direction of - after an extension of the supply cable by
rotation is always right-hand (clockwise). means of additional cables.
See Fig. 1.

- Switch the motor on for a short time.

- Check the direction of rotation by looking at

the fan wheel.

- Exchange the phases if the direction of

rotation is wrong.

It is indispensable to put the main

switch into "0" position and to pull the
mains plug.

- Check the direction of rotation again.

Fig. 1
 3.5-1

EMERGENCY SHUT-OFF SYSTEM

Fig. 1
ATTENTION:
RISK OF ACCIDENTS

Check the function of all

EMERGENCY SHUT-OFF
buttons before each use of the
machine.
It is forbidden to operate the
Machine with defective
EMERGENCY SHUT-OFF circuits.

The machine is equipped with one

EMERGENCY SHUT-OFF pushbutton 1 on
the machine (Fig. 1)

In an emergency or in the event of

malfunctions, the hydraulic functions of the
machine are stopped immediately when an
EMERGENCY SHUT-OFF pushbutton is
depressed.

The drive engine/motor is NOT stopped.

If necessary, it must be stopped as
described in chapter 3.11 for the diesel
engine or in chapter 3.12 for the electric
motor.

RECOMMISSIONING AFTER AN
EMERGENCY SHUT-OFF:

– Set all maintained-contact switches and

control levers to center or "0" position.

– Rectify the fault.

–
– Unlock the EMERGENCY SHUT-OFF
buttons by turning in the direction of the
arrow with Provided Key.

– Switch on first the auxiliary drive (agitator)

and then the desired hydraulic functions as
described in the following chapters.

Important:
The restart protection prevents the
hydraulicfunctions from restarting
after simpleunlocking of the
EMERGENCY SHUT-OFFbutton.

003.380.00 ( en )
 3.10-1

PREPARING THE MACHINE

FOR OPERATION

OBSERVE CHAPTER 2.22 OF THE

"SAFETY INSTRUCTIONS"

– Check the hydraulic oil level in the reservoir.

The oil level must be visible in the upper half
of inspection glass 1 (Fig. 1). See chapter
4.20.

– Check all oil-filled units for leaks.If required,

check the oil levels and top up.

– Check the screwed joints in the hydraulic

system for tightness and retighten, if
required.

– Fill the water box (Fig. 2) up to the upper

edge of the pumping pistons.

In the event of imminent frost, fill in water

only shortly before using the machine.

ATTENTION:
RISK OF ACCIDENT
Do not open the water box unless
the drive engine is stationary and
the pressure accumulator (if
installed) depressurized.
Close the water box by using
Lever 1 as shown in Fig. 2.

003.381.00 ( en )
 3.10-2

– Check that ballcock 1 (Fig. 1) at the

concrete pump control block is in operating
position.

In the operationg position, the ballcock is

open (notch in valve head pointing in the
direction of flow).

The ballcock is used to shut off the concrete

pump during maintenance work.

– Check the grid in the concrete feeding

hopper.

ATTENTION:
LIFE-THREATENING RISK
The machine must only be put into
operation when the grid is firmly
closed.

In the export model, the grid is firmly bolted to

the hopper.

In the CE model, the grid is secured by means

of two latches 5 (Fig. 2):

Always install both latches. The grid might

otherwise be deformed or lifted up by the
concrete in the hopper.
 3.10-3

003.381.00(en)
 3.10-4

DIESEL ENGINE

– Carry out the work specified in the engine

operating instructions (oil level checking
etc.) before putting the drive engine into
operation.

– Turn key- operated starter switch 15 (Fig. 1)

into the first notch.

Warning lamps 1+3 light up.

– Check the fuel reserve indicated at fuel

gauge 4.

If necessary, top up with fuel. The fuel

grade can be inferred from the engine
operating instructions.

ATTENTION:
RISK OF ACCIDENT
Observe the safety instructions
with regard to fuel handling.
Absolute cleanliness is of utmost
importance.

The fuel tank has a capacity of approx. 65 l.

THEORETICAL TIME OF OPERATION

An average fuel consumption of ca. 220 g per

kW and hour yields the following theoretical
time of operation (example):

Drive power: 48 kW

Density of diesel fuel ca. 0.82 (at 15 °C)

Reservoir capacity: 65 l

65 x 0.82 . l.kg.kw.h = ca.5.23 h

0.22 x 0.48 kg.kw.l

Fig. 1

003.381.00(en)
 3.11-1

STARTING THE DIESEL ENGINE

– Prepare the machine as described in – Release the starter key immediately after
chapter 3.10. the engine has started.

– To prevent unintentional activation of – Lamps 1 + 3 must now go out.

any of the machine's functions,
If these lamps do not go out, shut off the
– set all switches to center position or to engine immediately and locate the fault.
position 0, Cf. chapter 3.35.

– shut off all hydraulic drives,

– and set all latched control levers to center

position.

– Set control Knob 1 (Fig. 1) to ca. ¼ of full

speed.
1
– Insert the key into key-operated starting
switch 15 (Fig. 2)

Depress the key slightly and turn clockwise

to the first notch:
Fig. – 1
The alternator charge monitor lamp
and the engine oil pressure monitoring
lamp

– Turn key further to the next notch.

Hold key in this position until the preheating

monitor lights up (only for engines
equipped with preheating).
The engine is ready for starting.

– Operate the starter by turning the key

further clockwise.

If the engine does not start up immediately,

do not keep on starting for more than 10
seconds.

Wait 1 minute after each attempt to start the

engine. Hints for cold starting are set out in
the engine operating instructions.

Fig. - 2

003.382.00(en)
 3.11-2

– Bring diesel engine to operating

temperature by allowing it to run at
moderate speed. Note any irregularities.

– Check the nominal speed(operating speed)

of the diesel engine (Betriebsdrehzahl)

To do so, turn the knob 1 (Fig.1) to full

maximum position and read the engine
speed on RPM indicator 6 (Fig. 2).

ATTENTION:
RISK OF DAMAGE
If the nominal speed (chapter 1.4) is
exceeded, release the control lever
immediately and have the settings
checked.

If the nominal speed is not reached, the

settings must also be checked.

– Reduce the engine speed to idling until the

operating speed is needed for pumping.

003.382.00(en)
 3.11-3

SHUTTING OFF THE DIESEL ENGINE

– Reduce the number of strokes of the

concrete pump as far as possible by means
of pressure reducing valve 18 (Fig. 1).

– To prevent unintentional activation of any

of the machine's functions during start-up:

– set all switches to center position or

position "0",

– Shut off all hydraulic drives,

– and set all latched control levers to

center position.

– Reduce engine speed to idling.

Unless there is an emergency, do not shut

off the diesel engine out of full load, but
rather allow it to run for a few minutes at
idling for temperature compensation.

Especially with turbo-charged engines,

disregarding this procedure may cause
severe engine damage from overheating.

Observe the ENGINE OPERATING

INSTRUCTIONS.

– Turn the starter-switch key 15

counterclockwise.

The engine is shut off electrically.

The alternator charge monitoring lamp 1

and the engine oil pressure monitoring lamp
3 light up.

Turn the key to the final position and

withdraw.

Fig. 1

003.382.00(en)
 3.20-1

INSTALLING THE MACHINE

1. STABILIZER VERSIONS
OBSERVE THE INSTRUCTIONS OF
THE SAFETY MANUAL The machine can be supplied with mechanical or
partially hydraulic stabilizers.

The place of installation must be selected in such On special request, the machine can also be
a way that transport vehicles can reach the supplied without axle.
conncrete feeding hopper easily and that the
machine is accessible for servicing and cleaning In this case, the machine must be set up with the
work. help of a crane.

– Inform yourself about the admissible ground- – Prepare a level surface suitable for installing
bearing pressure on site. The maximum the machine.
ground pressure of the concrete pump ready
for operation, filled with concrete and without – Use suitable slings and fasten them to the
lifting eylets of the machine only.
additional load-distributing pads under
each supporting leg is:
ATTENTION:
in front approx. daN kg RISK OF ACCIDENT
3 (3 )
cm2 cm2 Never stand under suspended
loads (Fig. 1)!
at the rear daN kg
approx. 6 (6 )
cm2 cm2 – Have the machine lifted to the prepared place
and check that the machine is in horizontal
Differently equipped models may have different position.
ground-pressure values.
– If necessary, have the machine lifted once
– If needed, use load-distributing blocks under again by a few centimeters in order to be
the supporting disks.
able to readjust the stabilizers.

ATTENTION:
RISK OF ACCIDENT
The machine must not be installed if
its maximum pressure exerted on
the ground is bigger than the ad-
missible one.

If necessary, the supporting area must be

enlarged by appropriate means until the
admissible ground-bearing pressure is no
longer exceeded.

Depending on job duration, we recommend using

our supporting pads (Id no.: 1095646) or to
create a suitable concrete foundation for the
machine.
Fig. 1

004.551.00-en
 3.20-2

2. MACHINE WITH CHASSIS

Fig. 1
- Drive the machine to the prepared place
of installation.

- Place a suitable supporting pad

(e.g.ID.no.: 1095646) under the wheel of
the crank operated machine support (Fig.
– 1)

- Before uncoupling the concrete pump

from the tractor vehicle, lower the
Wheel 2.
Unit the trailer coupling is no longer under
load.

- Lower the rear supports (Fig. 2) and

secure with pins and cotter pins.

- Secure the machine with chocks under the

wheels 1 (Fig. 3)

- Uncouple the tractor vehicle.

2.1 MECHANICAL STABILIZATION

- Lower the machine in front with (Fig. 1)

- Continue to lower the rear supports and

secure with pins and cotter pins.

- Raise the machine in front with the crank

(Fig.1) and install in horizontal position.

- Lower the front supports and secure with Fig. 2

the pins and cotter pins.

- Wind up the crank-operated leg with crank

(Fig. 1)

- The machine is correctly stabilized when

the axel is no longer loaded and when the
wheels can turn freely, the machine being
in horizontal position.

Fig. 3
 3.22-1

PUMPING LINE

OBSERVE CHAPTER 2.34 OF THE

"SAFETY MANUAL"

CHECKING THE LINE IN OPERATION

During the operation, the personnel must check The marks are engraved on the flange of the
the pumping line for leaks (water leaking out). pumping pipeline. (Fig. 3).
Leaks cause "bleeding" of the concrete and will
lead to line blockages. Stop the operation
immediately and repair the leak.

Leaks may, for instance, also occur at pipe

couplings when the seals are defective.

ATTENTION: RISK OF ACCIDENT

When liquids seep through the walls

of pipes and bends there is an
extremely high risk of accident
caused by pipe bursts.
Stop the work immediately and
depressurize the pumping line by Fig. 1
sucking the concrete back into the
pump.
Check the pumping line with a wall-
thickness tester (Fig. 1) as often as
required by the working conditions.

MARKING OF INDIVIDUAL PARTS Fig. 2

All SCHWING pumping lines, pipe bends,
couplings, hosepipes etc. are marked as follows
(e.g. Fig. 2):

– manufacturer's name (SCHWING or

SH for SCHWING-HERNE)

– nominal diameter (DN) in mm

– admissible operating over-pressure (PN) of the

new part in bars Fig. 3

– Pumping lines are moreover identified by the

wall thickness (s) of the new part in mm.
 3.22-3

This pressure is dependent on

– drive power

– the pump unit installed and

– the type of oil admission to the differential

cylinders.

SEPARATE PUMPING LINE

The use of a construction site concrete pump

must always be planned with great care.

Apart from choosing the right kind of pump,

selection and laying of the pumping line is of
utmost importance.

Both these tasks require great care and expertise.

SCHWING offers an extensive range of pumping

lines and accessories.

We urgently recommend to install the pumping

line only with suitable material from SCHWING.

This is an important contribution to high

operational safety and economic efficiency.

An unsuitable coupling alone can cause failure of

the pumping line and lead to accidents.

SCHWING assumes no liability whatsoever for

damage caused by the use of unsuitable
material.

The most important criterion for selecting a

separate pumping line is given by the maximum
concrete pressure which the concrete pump is
able to generate.
 3.22-4

These peak values are seldom reached during The type of coupling used with our high-pressure
normal operation. pipes is the cup-type tension coupling for rigid
connection of the pipe sections.
Since - in the event of line blockages - the whole
length of line between concrete pump and
blockage is under maximum pressure, the line
must be designed to cope with such situation.

Separate pumping lines are available in different

designs:

1. Pumping pipelines for cup-type couplings Fig. 1

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

Since the seal 3 on the outside of the pipe

must be removed and cleaned whenever the
line is dismantled and reassembled, this
solution, if used for separate pumping lines,
is economically less efficient than the
following solutions.

2. Pumping lines with tongue-and-groove flan- Fig. 2

ges for cup-type tension couplings (Fig. 2)

These pipes can be delivered in the following

versions.

2a. Normal pipes with up to 4.5 mm wall

thickness (dependent on nominal width) are
suited for operation up to max. 110 bars
Fig. 3
2b. Thick-walled pipes with 71 mm-thick walls
are suited for operation up to max. 160 bars Figs. 2 + 3 1 - tongue-ended flange

These pipes are used if very high durability is 2 - groove-ended flange

required.
3 - seal
3. High-pressure pipes with wall thicknesses
ranging from 7.1 to 10 mm (depending on 4 - cup-type tension coupling
nominal width) are suited for operation up to
200 bars concrete pressure Important:
The figures show the typical flange design.
These pipes come with special high-pressure Depending on the nominal diameter of the pipe,
flanges (Fig. 3). Their use in conjunction the flange design may deviate slightly from the
with our concrete pumps: drawings.
BP 3500 / 4000 / 8000 HDR
is mandatory.
 3.22-5

EXCLUSION OF LIABILITY

Unauthorized modifications of the machine and

the use of spare parts and accessories not
approved by SCHWING constitute a case of
utilization contrary to the designated use.

This applies also to the use of indidvidual parts

such as pipes, bends, couplings, etc.

It is pointed out explicitely once again that

SCHWING cannot be held liable for damage
caused by incorrect or negligent operation,
maintenance and repair or as a result of any
utilization contrary to the machine's designated
use.

The same applies to conversions and attachments

or other modifications to the machine not
explicitely authorized by SCHWING.
 3.30-1

GENERAL INSTRUCTIONS FOR WORKING

OBSERVE CHAPTERS 2.31 – 2.35

OF THE "SAFETY
INSTRUCTIONS"

OPTIONAL EQUIPMENT

– Before starting the concrete pump, check

and that any optional units the machine is
from the equipped with are switched off:

Hydraulic stabilizers, compressor, water

pump and the hydraulic shut-off valve are
supplied with oil from the auxiliary pump. Fig. 1

The latched control elements are located in

the hydraulic circuit ahaead of the control
block of the concrete pump pilot control
and the agitator (see circuit diagram).

ATTENTION: RISK OF
UNCONTROLLED START-UP
When optional units are switched on,
the concrete pump and the agitator
cannot be started whereas the
optional units start up on activation of
of the drive engine.
Fig. 2

– Set the corresponding control elements of

the optional units (e.g.. 3, Fig. 1and 1, Fig.
2) to their basic position

"Agitator“,

CONCRETE PUMP REMOTE CONTROL

– Plug the remote-control cable connector
into the socket (Fig. 3) and latch up.

During working operations, the "CP suc Fig. 3

tion "or" CP pumping" functions“may only be
controlled with the remote-control box.
The control lever on the machine is ni-
tended for EMERGENCY OPERATION
only.
003.385.00(en)
 3.30-2

CLOSING THE SERVICING FLAPS

– Close all servicing flaps provided on the

machine to reduce noise.

These flaps must also be closed in order to

protect the machine against dirt and
unauthorized tampering with the machine.

ATTENTION:
HEALTH RISK
Persons standing in the vicinity of
the machine for a longer time must
wear their personal ear protectors.
See noise information in chapter 1.4
 3.31-1

CONCRETE PUMP OPERATION

OBSERVE CHAPTER 2.32 OF THE

"SAFETY INSTRUCTIONS"

GENERAL

– Before starting to pump for the first time, – Fill the feeding hopper with concrete before
apply formwork oil thinly on the outside of the lubricating mixture has been completely
pumped off.
the concrete feeding hopper to facilitate
cleaning later on.
– Never start pumping at the highest pumping
frequency, but rather adjust the required
Make absolutely sure that no oil gets into
pumping rate only after the first concrete
the hopper (risk of concrete deterioration).
emerges from the end of the pumping line.
Use only agents compatible with rubber.
– In case of waiting cycles, especially in warm
weather, it is advisable to "rock" the con-
– Switch the agitator and the vibrator on.
crete from time to time by pumping it to and
fro.
– Fill a lubricating mixture into the concrete
feeding hopper.
– Clean the machine in operation from time to
time with a jet of water to prevent concrete
The lubricating mixture consists of two parts
from adhering to the machine.
of cement, one part of sand and water.

The amount of lubricating agent is deter-

mined by the length and the diameter of the ATTENTION:
pumping line. RISK OF ACCIDENT
Do not pump the concrete feeding
For short pumping lines or when pumping hopper empty during operation.
ready-mix concrete, the lubricating mixture
Air sucked into the pumping line is
may consist of cement and water only.
compressed and ejected at the end of
the line abruptly and with high
– Never switch on the concrete pump when
pressure.
the feeding hopper is empty. Dry running
will lead to premature wear of the pumping Persons may be injured by ejected
pistons and the kidney seal. For servicing stones.
and cleaning work, fill water into the feeding
hopper.
 3.31-2

– Unlock the EMERGENCY SHUT-OFF

buttons on the remote-control box and on
the machine by turning the button in the
direction of the arrow (CE model only).

– Adjust the operating speed of the diesel

engine with adjusting knob 2 (Fig. 1).

AGITATOR

– Switch on the agitator by using Lever

(Fig. 2).

The correct sense of rotation of the agitator

depends on the desired pumping direction
of the concrete pump:

If the concrete pump is to run in the

pumping mode, the agitator must convey
the concrete to the suction opening.

If the concrete pump is to run in the suction

mode, the agitator must suck the concrete
away from the suction opening.

Important
If needed, the agitator must also be
switched on in order to supply sufficient
pilot pressurefor switching on of the
concrete pump.

003.386.00 ( en)
 3.31-3

CONCRETE PUMP

– Switch on the concrete pump from the

remote control box (Fig. 1).

Pushbutton 3:
Concrete pump in pumping
ð

Pushbutton 1:
Concrete pump in suction

The corresponding push-button lights up

and the concrete pump starts up.

– Adjust the desired concrete-pump pumping

rate (stroke frequency) with pressure
reducing valve 18 (Fig. 2).

– Take the remote-control box and leave the

close range of the machine (noise
protection).

SWITCHING OFF THE AGITATOR ANDTHE

CONCRETE PUMP

The concrete pump is switched off by

depressing pushbutton 2 (Fig. 1).

The agitator can be switched-off by using

neutral Position of control lever.

Fig. - 1

Fig. - 2

003.386.00(en)
 3.31-4

CONCRETE PUMP'S DRIVE

CONFIGURATION

ROD-SIDE ADMISSION
As a rule, the a.m. concrete pumps are delivered with rod-side admission of the differential cylinders.
In this mode of operation, the oil coming from the hydraulic pump flows into the rod-side chamber of
a cylinder. The oil displaced on the piston side drives the second piston via a circuit bridge (Fig. 1).
This configuration permits relatively fast stroking of the concrete pump since the small rod-side
volume fills with oil very fast. A high stroking cycle, in turn, yields a high concrete pumping rate. The
maximum concrete pressure achieved in this configuration is sufficient for normal pumping jobs.

SP 1200 is supplied with rod –side admission only. Changing of the concrete pump’s drive
configuration to Piston-side admission is not allowed.

rod-side admission High concrete

(fig. 1) delivery rate

Fig. 1

003.386.00 ( en )
 3.32-1

OPERATION OF AUXILIARY UNITS

The hydraulic pump of the auxiliary drive

ATTENTION:
provides oil not only to the agitator and the
concrete pump's pilot-control system, but also RISK OF ACCIDENT DUE TO
to several optional units such as: INADVERTENT STARTING
Always switch off the concrete pump
and the agitator before starting any
–hydraulic stabilizers of the equipment options.
Switch off all equipment options im-
mediately after use with the hydraulic
– water supply system (water pump) control element (basic position:
'Agitator').
The risk of units being activated in-
– air supply system (compressor) advertently when the engine is star-
ted or when functions are switched is
thus avoided. There is moreover no
unnecessary warming of oil.
– hydraulic shut-off valves

Make the necessary preparations before When the machine is equipped with hydrau-
putting these units into operation. See lically operated stabilizers, the machine can be
chapters switched with a ballcock either to 'Stabilizers' or
'Agitator'.
– 3.20: INSTALLING THE MACHINE
In the Stabilizers position, only the stabilizers
– 3.33: WATER SUPPLY SYSTEM can be operated.

– 3.34: AIR SUPPLY SYSTEM. In the 'Agitator' position, the agitator and the
concrete pump pilot-control system or an
– 3.35: HYDRAULIC SHUT-OFF VALVE equipment option are supplied with oil. See
circuit diagram.
Distributing valves switched to the respective
position ensure that either the concrete pump
and the agitator or one of the optional 'Stabilizers'
equipment units can be operated. See circuit
diagram.

The operation of several optional equipment 'Agitator'

units at a time is not possible.
 3.34-1

OPERATION OF THE AIR SUPPLY SYSTEM END OF OPERATION

(optional equipment) – Open the air discharge valve in the pressure

line, e.g. 3 (Fig. 2).

– Set control lever 1 (Fig. 1) back to its basic

position (CP pilot control and agitator).
The compressor has a theoretical delivery rate
of 900 liters of air per minute at a pressure of
10 bars. WINTER OPERATION

If properly serviced (see chapter 4.55), the

PREPARATION rotary compressor can be used down to
temperatures of -15°.
ATTENTION: Contact SCHWING if the compressor is to be
RISK OF ACCIDENT used in lower temperatures.
Observe the instructions in chapter
3.40 if the compressor is used for
cleaning of the pumping line.

– Connect a suitable pressure hose to the

compressor.

– Connect the pressure hose to the cleaning

connection of the pumping line (Fig. 2).

– Open an air discharge valve (e.g. 3, Fig. 2)

to prevent pressure spikes when the
compressor is switched on.

OPERATION

– Start the drive engine/motor and adjust to

idling speed.

– Set control lever 1 (Fig. 1) to the

compressor

position.

– Select the operating speed of the drive

engine/motor and adjust the air delivery rate Fig. 2
by opening or closing the air discharge
valve (e.g. 3, Fig. 2).
 3.38-1

OPERATION MONITORING
Air sucked into the hopper will otherwise
OBSERVE CHAPTER 2.31 OF THE cause concrete splashes and increased
“SAFETY INSRUCTIONS” wear of the kidney seal and the pumping
piston due to dry running of the pump.

– Check the hydraulic oil level visible in

Depressing one of the EMERGENCY SHUT- inspection glasse 1 (Fig. 1).
OFF buttons stops the hydraulic functions.
The oil level must be visible in the upper
The drive engine does not stop. part of the insprection glass.

For recommissioning after an EMERGENCY Top up oil if necessary. See chapter 4.20.
SHUT-OFF refer to chapter 3.5.

– Pay attention to unusual noises, vibrations,

etc. of the machine.

They may be a sign of damage the

Consequences of which can be limited if
the machine is repaired in time.

– Check the stability and horizontal position

of the machine and correct the position, if
required.

All supporting disks must always be

firmly in contact with the ground.

– Ensure that the pumping pipe couplings

do not leak.

Eliminate any leaks as fast as possible.

3
"Bleeding" of the concrete leads to the
formation of concrete plugs.

CONCRETE PUMP

– During operation, the concrete feeding

hopper must always be filled by more than
two thirds with concrete.

003.390.00(en)
 3.38-2

– Check the oil temperature indicated by

thermometer 3 (Fig. 1).

If the temperature rises above 80° C, the

pumping speed must be reduced. If
required, shut off the machine, top up with
oil or check the cooling system.

– Check the operating pressure of the

Concrete pump when concrete is being
pumped.

To do so, open shut-off valve 16 (Fig. 2) and

read the operating pressure on pressure
gauge 17. If the operating pressure rises to
more than 90 % of the preset safety
pressure, pumping must be slowed down,a
pumping line with greater diameter be used
or the pumpability of the concrete be
improved.

For "Pmax" cf. "TECHNICAL DATA", chapt er

1.4.

The factory-adjusted safety pressures

must not be modified.

To protect the pressure gauge against

pressure peaks, shut-off valve 16 must be
closed immediately after checking.

Pressure gauge 21 indicates the operating

pressure of the auxiliary drive.

Fig. 2

003.390.00 ( en )
 3.38-3

– Check the water level and the

contamination of the water-box (Fig. 1).

If required, drain off dirty water and fill

in clean water up to the upper edge of
the pumping pistons. Remove firmly
adhering dirt.

ATTENTION:
RISK OF CRUSHING
Before carrying out work in the
water-box always shut off the drive
engine and depressurize the
pressure accumulator (if any) to
prevent uncontrolled working Fig. 1
movements of the concrete pump.

– After checking / cleaning, the cover of

the water-box must be properly refitted
and secured with Lever Mechanism
(Fig. 1).

– Prevent plugs from forming in the

pumping line right from the beginning
by sucking the concrete back:

– Stop the agitator and the concrete

pump.

– Switch the agitator to "Reverse" and

the concrete pump to "Suction".

Do not forget to switch over the

agitator to prevent the reflowing
concrete from deforming the agitator
mechanism.

If the plug cannot be removed by

sucking back the concrete, switch off the
concrete pump and eliminate the fault.

– Watch the agitator closely.

If the agitator gets jammed with stones,

switch over shortly to reverse operation.
 3.38-4

DIESEL ENGINE

– Check the fuel reserve at fuel gauge 4 (Fig.

1). Do not forget to refill fuel in time.

Cleanliness is of utmost importance.

ATTENTION:
RISK OF ACCIDENT
Observe the safetyinstructions
when handling fuel.

Do not run the fuel tank dry, since the whole

fuel system must otherwise be vented.

See ENGINEOPERATING INSTRUCTIONS

– Watch the warning lamps 1, 2 and 3.

These lamps must not light up when the

engine is running.
ATTENTION:
RISK OF DAMAGE
To avoid severe damage shut off
the engine immediately if any of
these three lampslights up.

Important:
Over-temperature and loss of cooling liquid
are additionally indicated by a horn signal.

– Watch the air filter servicing indicator:

The filter cartridge must be serviced when

the vacuum indicator 2 (Figs. 2+3) in the
suction line passes to "RED" and remains in
this position even when the engine is
stationary.

Servicing, see chapter 4.30.

003.390.00(en)
 3.39-1

EMERGENCY OPERATION AND

TROUBLESHOOTING

OBSERVE CHAPTERS 2.31 – 2.35

OF THE "SAFETY INSTRUCTIONS"

FAILURE OF CONTROL UNIT

In the event of a failure of the hydraulic

functions check first whether

– the drive engine is stationary,

– an EMERGENCY SHUT-OFF button has

been depressed (CE model),

– the auxiliary drive is off,

– the grid in the agitator feeding hopper is

open

(In the CE model, the concrete pump and

the agitator are shut off by a limit switch
when the grid is raised)

– a fuse has blown and a circuit-breaker has

been triggered.

ATTENTION:
LIFE-THREATENING RISK
Any shut-off caused by the limit
switch is not an EMERGENCY
SHUT-OFF. After closing of the
grid, the agitator and the concrete
pump will restart automatically.
 3.39-3

EMERGENCY OPERATION

– If the problems cannot be solved as

described above, contact the SCHWING
stetter (India) after-sales service.

– For checking, the distributing valves of the

concrete pump's pilot control system 1(Fig.
1) and of the agitator 2 are equipped with
control levers.

If it is absolutely necessary to finish a pla-

Cing job in spite of an electrical defect in the
pilot-control system, the concrete pump and
the agitator can be operated with these
levers.

The levers are spring-centered and return to

the neutral position after releasing.
ATTENTION:
RISK OF ACCIDENT
It is forbidden to block the control
lever in order to prevent it from
returning to neutral position.

– Keep away from moving machine parts.

– Finish the placing job, clean the machine

and put it out ofoperation until the defect
has been rectified.
 3.51-1

PREPARING THE MACHINE FOR

TRANSPORT

OBSERVE THE INSTRUCTIONS

OF THE SAFETY MANUAL

– Clean the machine and switch off the con-

crete pump, the auxiliary drive and the en-
gine/motor.

– Disconnect the remote-control cable from

the machine.

– Refit the wheels, if necessary.

– Secure the machine with chocks.

– Place a suitable supporting pad (e.g. ID no.:

1095646) under the disk of the crank-
operated support (Fig. 1).
Fig. 1
MECHANICAL STABILIZERS

– Raise the machine in front slightly with the

crank-operated support (Fig. 1) until the ma-
chine is no longer supported by the front sta-
bilizers 1 (Fig. 2).

– Raise the front stabilizers and secure them

with pins and cotter pins.

– Relieve the pressure on the rear stabilizers 2

(Fig. 2) by lowering the machine in front
slightly with the crank.

– Raise the rear stabilizers and secure them

with pins and cotter pins.

– Use the crank-operated support to bring the Fig. 2

machine to horizontal position.

004.552.00-en
 3.51-3

ATTACHING THE PUMP TO THE TRUCK

– Adjust the height of the draw-bar with crank 4

(Fig. 1) and couple the machine to the tractor
vehicle.

ATTENTION:
RISK OF CRUSHING
When coupling the machine to the
tractor vehicle, check that nobody
is standing between the concrete
pump and the truck.
The banksman must be visible in
the truck driver's rear view mirror. Fig. 1

– Open the clamping device 1, push back the

protective sleeve 2 and tighten the clamping
device.

CRANE LOADING

– Use suitable slinging devices and attach

them only to the lifting eyelets provided on the
machine.

ATTENTION:
RISK OF ACCIDENT
Never stand under suspended
loads (Fig. 2).

Fig. 2

004.552.00-en
 3.60-1

OPERATION UNDER EXTREME WORKING

CONDITIONS

Hot and cold weather, dust, dirt, high levels of WATER SYSTEM
air moisture, sea water, uninterrupted working,
etc. render the working conditions of your At temperatures below freezing, the water-box
and the water system must be drained upon
SCHWING MACHINE completion of the work (see chapter 3.33).

more difficult. Fill in water only immediately before the work

starts.
Under certain circumstances, these working
conditions may even exceed the machine's If an anti-freeze compound is added to the
operational limits. See chapter 2.4: water, this mixture must not be used for
concrete making.
UTILIZATION IN CONFORMITY WITH ITS
DESIGNATED USE
AIR SUPPLY SYSTEM
Aggravated conditions require special
preparation and adapted maintenance: Due to their design, piston-type compressors
are not suitable for operation at ambient
temperatures below 1°C (risk of damage due to
VEHICLE ENGINE - BUILT-IN ENGINE - FUEL frozen condensed water).
SYSTEM
Rotary compressors on the other hand, can be
Observe the manufacturer's operating instruc- used down to -15°C if properly serviced.
tions.

ELECTRICAL SYSTEM of the diesel engine

HYDRAULIC SYSTEM - GEARBOX - GREAS-
ING POINTS The capacity available for starting depends on
battery charge and ambient temperature.
SCHWING recommends to use suitable lubri-
cants and consumables for various climatic Make sure that the batteries are always well
zones and applications. charged. At very low temperatures, the bat-
teries must be removed from the machine
See chapter 4.4. every day after the work has ended.

After cold starting, allow the hydraulic system, Store the batteries in a warm and dry place
gearbox and compressor to run unloaded at and recharge, if required.
medium engine speed until a stable lubricating
film has formed. Make sure that there is good contact between
the battery terminals and the connecting ca-
If possible, the machine should be parked in bles.
winter in a closed hangar.
Check the drive belt tension and the charging
Using the machine under arctic conditions re- performance of the alternator.
quires special equipment.

For work at high ambient temperatures addi-

tional oil coolers can be supplied.

Consult the SCHWING after-sales service.

 3.60-2

MACHINE LOCATION

Frost, thaw and rain can bring about extreme

changes of the soil bearing capacity.

Check the soil conditions before starting the

work and during operation.

PUTTING THE MACHINE OUT OF OPERA-

TION

Clean the machine after the work and remove

ice and dirt from steps, platforms, etc.

Park the machine on firm and solid ground.

Secure the machine by appropriate means

against inadvertent movements.

Release the parking brake.

 3.70-1

PUTTING OUT OF OPERATION

OBSERVE "SAFETY" CHAPTER - Check the tyre pressure.

2.50!
- Release the parking brake.

- Dismantle the batteries and store them in a

If the machine is to be put out of operation for room at approx. 20° C.
a longer period, the following work is to be
carried out: - Connect the batteries to a "charge
maintaining device" resp. CHARGE THEM
- Thoroughly clean and grease the machine. EVERY MONTH (NO QUICK CHARGE).

- Check the concentration of antifreeze in the - Keep the batteries clean and dry.
cooling system of liquid-cooled engines and
top up if necessary. Never leave the batteries discharged.

- Drain the condensation water from the tanks

of the fuel, hydraulic and air systems. RESUMPTION OF WORK

Fill the fuel and oil tanks up to the brim. - Remove the preservation.

Change the oil if it is in bad condition. - Check all oil levels.

- Grease the bare parts of the machine with Discharge the brimful hydraulic oil tanks until
acid-free grease or spray them with the sight glass level is reached.
preservative oil.
- Check and install the batteries.
- Push a cleaning wool plug soaked in pre-
servative oil through the pipeline. - Check the tyre pressure.

- Retract all hydraulic cylinders. - Grease all parts of the machine.

- Relieve the hydraulic accumulator from - Check the performance.

pressure.

- Preserve the engine according to the engine Note:

operating instructions.
Special guidelines apply if the machine is to
- Drain the water tank, water pump and water be stored under aggravated conditions.
box. Flush them with a rust inhibitor.
Aggravated conditions include:
- Make all openings watertight.
– storage time exceeding 6 months,
- Jack the vehicle up to remove the pressure
from the tyres. – high relative humidity,

– sea air, etc.

Ask the SCHWING after-sales service.

 3.80-1

CONCRETE TECHNOLOGICAL REQUIRE-

MENTS

OBSERVE THE INSTRUCTIONS OF

THE "SAFETY MANUAL"

Pumping concrete is no special concrete

but a standardized quality concrete.

It features e.g.:

- a minimum fines content of approx. 400 kg

per m³ (with a max. grain size of 32 mm)

- a minimum cement content of approx. 240 kg

per m³ (with a max. grain size of 32 mm)

- a water/cement ratio of 0.42 - 0.65

- a granulometric composition according to the

grading curve

- a consistency in the range of K2 and K3.

The following may give rise to non-pumpability

of the concrete:

- a wrong concrete composition (see above)

- imperfect maintenance of the machine and

the pipeline (cleaning!)

- insufficient mixing quality

- segregation owing to inexpert transportation

- wrongly selected max. grain size in relation to

the pipeline diameter

- bleeding of the fresh concrete

- incorrect use of additives.

MAINTENANCE 4.1-1

TABLE OF CONTENTS - PART 4

Chapter Title

4.1 TABLE OF CONTENTS

4.2 GENERAL MAINTENANCE INSTRUCTIONS

4.3 OPERATING AGENTS AND FILLING CAPACITIES

4.4 EXAMPLES OF OPERATIONG AGENTS

4.5 TIGHTENING TORQUES

4.10 MAINTENANCE SCHEDULE

4.11 MAINTENANCE REPORT (TO BE COPIED)

DESCRIPTION OF THE MAINTENANCE WORK

4.20 HYDRAULIC OIL AND FILTER

4.21 HYDRAULIC PRESSURE TESTS

4.22 COOLER

4.30 AIR FILTER SYSTEM

4.37 AGITATOR GEAR

4.40 ROCK VALVE

4.42 PUMPING AND DIFFERENTIAL CYLINDERS

4.43 PUMPING PISTONS

4.55 COMPRESSOR

4.60 ELECTRICAL INSTALLATION

4.61 STARTER BATTERIES

4.65 SAFETY CHECKS

4.65 VISUAL AND PERFORMANCE CHECKS

MAINTENANCE 4.1-1

4.70 REPAIR WELDING

 4.2-1

GENERAL MAINTENANCE INSTRUCTIONS

OBSERVE "SAFETY" CHAPTER 2.60! CHECK THE OIL LEVEL

Preventive maintenance is the most Unless otherwise prescribed, the oil level is
economical maintenance. checked in general

Carry out all maintenance works punctually - with the machine in horizontal position
and thoroughly.
- after the drive has been stopped for approx.
We recommend to duplicate the maintenance 10 minutes
report (chapter 4.11).
- with mobile machines being ready for tra-
The maintenance men will then be able to list velling (outriggers in transport position)
off the work done in the copies and to sign
them. Important:
Whenever the oil level is checked (also in
If neither TRAINED personnel nor adequate gearboxes, compressors, etc.) it is
workshop equipment are at your disposal, recommended to perform also a visual
inspection of the oil. In the event of extreme
entrust the SCHWING after-sales service
contamination or of water contained in the oil
with the maintenance of your machine.
(milky emulsion) try to locate the cause and
change the oil. The table in chapter 4.20 for
assessing the quality of hydraulic oils can
CLEANLINESS
also be used for other oils.
- Before commencing the maintenance work
clean all units located within the working
range. CHANGE THE OIL

Do not use steam jets for cleaning rubber - Drain the oil only from units brought to
and electric parts. working temperatures.

- Avoid the penetration of dirt, especially into - Pour hydraulic oil from clean vessels via the
the hydraulic system. filter chamber of the oil tank.

- Grease the machine after steam jet Whenever possible, use a flushing filter unit.
cleanning.
See page 4.2-2.

PROTECTION AGAINST CORROSION - Check the oil level after each test run.

- Considerable rust deposits weaken the

material and can lead to ruptures and
cracks.

Touch up damaged varnish surfaces in time

and grease bare machine parts.
 4.2-2

- Do not store the hydraulic oil barrels in the - Replace damaged pipes and damaged or
open air. damp hydraulic hoses immediately.

The barrels should not be moved for some

time before the oil is taken out. BURSTING LINES RESP.
OPERATING AGENTS ESCAPING UNDER
Do not roll them to the place where they are PRESSURE ENDANGER PERSONS.
to be emptied.

Do not suck the oil off the bottom of the

REPAIR, EXCHANGE
barrel.
- Under certain circumstances the exchange of
complete units can be more economical than
SEALINGS, SAFETY ELEMENTS
a repair. Consult the SCHWING after-sales
service.
- Pay attention to sealings, spring washers,
etc. when dismantling covers, screw plugs,
- Use only genuine SCHWING spare parts.
etc.
SCHWING is not liable for damages re-
- Clean sealing surfaces, do not damage
sulting from the use of outside products
them.
or inadequate operating agents.
- Replace sealings, split pins, spring washers,
- For mounting work on the hydraulic system
etc.
use greases based on mineral oil only.

- After the breakdown of a unit (pump, motor,

LUBRICATION
etc.) flush the hydraulic system and replace
the filter to avoid consequential damages
- Clean the grease nipples before and after
due to metal abrasion.
the lubrication.
SCHWING supplies suitable flushing filter
- Remove the excessive grease from the
units (Fig. 1). Ask for information material.
lubricating points.

TIGHTNESS

- Check the tanks, hoses, screw joints, etc. at

regular intervals.

Oil leakages must be avoided under

all circumstances.

ENVIRONMENTAL PROTECTION!

Fig. 1
 4.2-3

- Carry out a trial run of the machine and

check the oil level.

Note any unusual noises, temperatures and

leakages.

- Carry out maintenance work on repaired or

exchanged units as on new machines.

WELDING

Welding work may only be carried out in

compliance with the instructions of the
manufacturer.

See chapter 4.70.

 4.3-1

CONSUMABLES AND REFILLING

QUANTITIES

LOCATION : CONSUMABLES Refilling quantity (ca.)

Chapter4.4 :

BPN 300 BP 1000 BP 1500 BP 1800 BP 2000 BP 3500 BP 4000 BP 8000 SP 1200

Drive engine see engine operating instructions

see engine
Fuel reservoir (Diesel 2x 165.00 2x 165.00 2x 275.00
operating 30.00 l 60.00 l 100.00 l 120.00 l 100.00 l 65 l
engine) l l l
instructions
Hydraulic oil reservoir No. 1 110.00 l 200 370.00 l 450.00 l 380.00 l 530.00l 570.00 l 1000.00 l 320 l
Water reservoir* CLEAN drinking
250.00 l
water
Pump transfer gearbox No. 2
in electric motor model 3.80 l 3.80 l
Standard agitator No. 2 0.25 l 0.25 l 0.25 l
gearbox
Reinforced agitator No. 2
1.00 l 1.00 l 1.00 l 1.00 l 1.00 l 1.00 l
gearbox
Piston compressor* No. 3 1.00 l 1.00 l 1.00 l 1.00 l 1.00 l 1.00 l
Rotary compressor* Rotor oil 8000 F2 ** **
Greasing points No. 4
Rotary compressor* NO. 4 6.00 l 6.00 l 6.00 l 6.00 l 6.00 l 6.00 l 6.00 l 6.00 l 6.00 l
* = optional equipment

** = included in servicing kit 10170389

 4.4-1

RECOMMENDED LUBRICANTS AND CONSUMABLES

Beginning on PAGE 4.4-3 you will find a limited number of suitable lubricants and
consumables. If these products are not available, others can be used provided the indicated
STANDARD DESIGNATIONS are complied with. The selection and order of the products listed
cannnot be interpreted as a judgement on their quality.

EXPLANATION OF ACRONYMS AND ABBREVIATIONS USED

1) GENERAL

BI = Main Association of the German Construction Industry. As an alternative to the

recommended lubricants and operating agents the standard lubricants listed in
column "BI" can be used.

DIN = German Industrial Standards

ISO = International Standardization Organization

MIL-L = American Military Standards for Lubricants

API = American Petroleum Institut

SAE = Society of Automotive Engineers

VG = Degree of viscosity in mm²/s at 40° C

2) HYDRAULC OIL

API-CD = Engine oil for heavily loaded Diesel engines with and without supercharger.

EO = BI standard lubricant, a quality engine oil

HLP = In accordance with DIN 51524, a hydraulic oil with additives to improve corrosion
protection, ageing stability and protection against wear in the mixed fricton area

HV = In accordance with DIN 51524, a hydraulic oil with low dependence of viscosity on
temperature, otherwise like HLP
 4.4-2

3a) "INDUSTRIAL" GEAR LUBRICANT OIL

CLP = In accordance with DIN 51517, a circulation oil with addivites to improve corrosion
protection, ageing stability, protection against wear in the mixed friction area and
to increase gear stability under load

PG = Synthetic lubricating oil for extreme loading on a polyglycol base, suitable as long-
term lubricant

3b) MOTOR VEHICLE GEARBOX OIL

G0 90 = BI standard lubricant, a gearbox oil according to API-GL 5

MIL-L 2105 B = Hypoid gearbox oil for heavy-duty gearboxes and axles, roughly corresponding to
API-GL 5.

4) COMPRESSOR OIL

VDL = Mineral oil for air compressors with additives to improve corrosion protection and
ageing stability. Coke residue after ageing max. 3 % in accordance with DIN
51352.

Rotoröl 8000F2 = Synthetic four-seasons oil for rotational compressors

5) GREASE

KP 2 K = In accordance with DIN 51502, a grease for high pressure load in the working
temperature range from -20° C to +140° C, worked penetration 265 to 295, no or
only slight changes due to water.

MPG-A = BI standard lubricant, a grease according to KP 2 N, meeting the requirements of

KP 2 K and K 2 K.

MLE2N-40 = Special lubricant for plastic / metal compound materials for long-lasting lubrication
of the sliding surfaces in telescope arms

ID no.: SCHWING cardan shaft grease

10197297 Use only this grease for the lubrication of SCHWING cardan shafts
 4.4-3

1. HYDRAULIC OIL RECOMMENDATIONS

ISO ISO ISO

Viscosity:
VG 32 VG 46 VG 68

DIN DIN DIN DIN DIN DIN

Quality:
HLP HV HLP HV HLP HV

ARAL-Vitam GF 32 HF 32 GF 46 HF 46 GF 68 /
BP-Energol HLP 32 HLP 46 HLP 68
BP-Bartran HV 32 HV 46 HV 68
ESSO-Nuto H 32 H 46 H 68
ESSO-Univis N 32 N 46 N 68
KLÜBER-Lamora HLP 32 / HLP 46 / HLP 68 /
MOBIL-DTE 24 13 25 15 26 16
SHELL Tellus Öl T 32 Multi Grade Hydraulic Oil Tellus T 46*
32
SUNOCO-Sunvis 832WR 832WR-HV 846WR 846WR-HV 868WR 868WR-HV
TOTAL-Azolla ZS 32 ZS 46 ZS 68
TOTAL-Equivis ZS 32 ZS 46 ZS 68
TEXACO-Rando-Oil HD A-32 HD AZ-32 HD B-46 / HD C-68 HD CZ-68
WINTERSHALL- HS 32 HV 32 HS 46 HV 46 HS 68 HV 68
Wiolan

Engine oil SAE 10w / / SAE SAE SAE

(API-CD) 10w-30 20w-20 10w-30

BI EO 10 / / EO 1040B EO 20 EO 1040B

* = standard filling ex works Herne. SHELL Tellus T 46 can be used as all-season oil if the
starting temperature is not below -10 °C.

VG 32 = Winter application conditions in Central Europe

VG 46 = Summer application conditions in Central Europe
VG 68 = Rooms with great heat or tropics

DO NOT MIX HYDRAULIC OILS OF DIFFERENT MANUFACTURERS:

REDUCTION OF QUALITY POSSIBLE.

If hydraulic oil of another manufacturer is to be used or oil of another quality (e.g. BI instead of
HLP) is to be filled in, a complete oil and filter change is necessary. Viscosity mixes between
oils of one manufacturer are permissible in some cases (consultation with the oil manufacturer
required). In this case, however, a change in viscosity of the oil filling (depending on the mix
ratio) is to be taken into account.
 4.4-4

2. GEAR LUBRICANT OIL (see gear rating plate)

2.1: INDUSTRIAL GEAR LUBRICANT OIL

Viscosity according to ISO VG 220

Quality according to DIN CLP

ARAL Degol BG 220 / Degol BMB 220

BP Energol GR-XP 220
ESSO Spartan EP 220
KLÜBER Klüberoil GEM 1-220
MOBIL Mobilgear 630
SHELL Omala Öl 220
SUNOCO Sunep 1220
TEXACO Meropa 220
WINTERSHALL Wiolan IT 220
BI /

2.2: MOTOR VEHICLE GEARBOX OIL

Viscosity according to SAE 90 (85w-90)

Quality according to MIL-L 2105 B

ARAL Getriebeöl HYP

BP Energear HYPO 90 / Hypogear 90 EP
ESSO Gear Oil GX-D / Gear Oil GX
MOBIL Mobilube HD
SHELL Spirax HD / Spirax MB 90
SUNOCO GL-5
TEXACO Geartex EP-C
WINTERSHALL Wiolan Hypoid-Getriebeöl 90
BI GO 90

The above mentioned gear lubricant oils are suitable for continuous ambient temperatures of
approx. -10° C to approx. +40° C. For extreme operating conditions please inquire as to
suitability. Viscosity class ISO-VG 220 roughly corresponds to SAE 90.
 4.4-5

2.3: INDUSTRIAL GEARBOX OIL (polyglycol base)

Viscosity acc. to ISO: VG 220

Quality acc. to DIN: PG

ARAL Degol GS 220

AVIA Avilub VSG 220
BP Energol SG - XP 220
ELF Syntherma P 270
ESSO Umlauföl S 220
FUCHS Renodiol PGP 220
MOBIL Glygoyle 30
SHELL Tivela WB
TEXACO Synlube CLP 220
BI /

ATTENTION:

The above-mentioned synthetic lubricating oils on polyglycol base must not be mixed with oils
of a different base.

3. OIL RECOMMENDATIONS FOR PISTON COMPRESSORS

3.1: PISTON COMPRESSOR

Viscosity acc. to ISO VG 100 VG 150

Quality acc. to DIN VDL VDL

ARAL Motanol HE 100 Motanol HE 150

BP Energol RC 100 Energol RC 150
SHELL Corena Öl H 100 D Corena Öl H 150 D
SUNOCO Sunvis 9100 Sunvis 9150
TEXACO Compr. Oil EP 100 Compr. Oil EP 150
MOBIL Rarus 427 Rarus 429
WINTERSHALL Wiolan CD 100 Wiolan CD 150
BI / /

3.2: ROTATIONAL COMPRESSOR

For our rotational compressors, the only oil to be used is the synthetic ROTORÖL
8000 F2. See chapter 4.55
 4.4-6

4. GREASE RECOMMENDATIONS

4.1: SCHWING cardan shaft grease. Use only this grease for the lubrication of
SCHWING cardan shafts

SCHWING ID no.: 10197297 400g cartridge for manual grease gun

4.2: Lithium-saponified high-pressure grease KP 2 K acc. to DIN 51502 without solid

lubricant

ARAL Aralub HLP 2

BP Energrease LS-EP 2
ESSO Beacon EP 2
KLÜBER Centoplex 2 EP
SHELL Alvania EP Fett 2
SUNOCO Multi Duty EP-2
TEXACO Multifak EP 2
MOBIL Mobilux EP 2
WINTERSHALL Wiolub LFP 2
BI MPG-A

4.3: Special lubricants for severe operating conditions

For severe operating conditons we recommend a particularly adhesive and pressure-resistant

lubricant for the slide bearings of the boom column as well as for the sliding blocks of the
turntable drive unit, for example:

- OPTIMOL-OPTIPIT

- KLÜBER-COSTRAC GL 1501

Severe operating conditions include:

– high loading due to dust, dirt, heat, air humidity, seawater

– great shock load and vibrations

– operation downtimes of several weeks.

OPTIMOL-OPTIPIT should always be used when installing the above mentioned structural
components. It can be obtained from the SCHWING spare parts department in 400 g cartridges
under ID no.: 10087948
 4.4-7

5. SPRAY GREASE RECOMMENDATIONS

Sprayable EP grease for open gears with MOS2 and graphite additive

ARAL Sinit FZ 2
BP Energol WR P
ESSO Surett Fluid 4K
KLÜBER Grafloscon C-SG 0 ULTRA
Grafloscon CA 901 ULTRA-SPRAY
SHELL Cardium Fluid D
TEXACO Crater XX Fluid
MOBIL Mobiltac A
BI LUB-A

6. SPECIAL LUBRICANT FOR PLASTIC SLIDERS IN TELESCOPE SECTIONS

Designation acc. to DIN: MLE2N-40

SCHWING ID no.: 10194658 10 kg can

7. SPECIAL LUBRICANTS FOR COUPLINGS AND SEALS OF PUMPING LINES

OPTIMOL OLIT CLS

Schwing Id. no.: 10149905 10 kg can

Optimol Olit CLS is a rubber-compatible and water-resistant heavy-duty grease on a

lithium / calcium base.
 4.10-1

MAINTENANCE SCHEDULE:

Symbols used in the maintenance schedule:

Œ = CHECK • = GREASE Ž = CLEAN • = REPLACE

• ‚ ƒ „ = as above, but after first commissioning

Time intervals in the following maintenance schedule:

A = daily or after 10 operating hours E = every 6 months or after 1000 operating

hours
B = weekly or after 50 operating hours
F = yearly or after 2000 operating hours
C = monthly or after 200 operating hours
G = every 2 years
D = every 3 months or after 500 operating
hours whichever occurs first

004.073.00-en
 4.10-2
MAINTENANCE SCHEDULE:

Maintenance of chassis, engine, special equipment etc. in acc. with manufacturer's instructions

GENERAL: A B C D E F G CH.

A1 Safety inspection by a specialist at intervals based either on time, operating hours or cubic meters of 2.61
concrete pumped, wichever occurs first 4.65
A2 Visual inspection and function check by the pump operator Π4.65
A3 Check hydraulic oil level check (before each commissioning) Π4.20
A4 Change hydraulic oil (oil change every 2 years after oil analysis possible) • • 4.20
A5 Drain off condensed water from hydraulic oil reservoir Ž 4.20
A6 Clean hydraulic oil cooler fins and engine radiator fins Ž 4.22
A7 Check operating pressures Π4.21
A8 Grease control lever articulations • --
A9 Check hydraulic and water systems, units, reservoirs, pumping line, etc. for leaks • Œ 4.44
A10 Check fastening of superstructure, stabilizers, reservoirs, units, CP unit etc • Œ 4.42
A13 Check oil level in pump transfer gearbox * Π4.35
A14 Change oil in pump transfer gearbox * „ • 4.35
A15 Check oil level in agitator gearbox * Π4.37
A16 Change oil in agitator gearbox * „ • 4.37
* = if the machine is so equipped

ADDITIONAL EQUIPMENT: A B C D E F G CH.

Z1 Check grease level and functioning of central lubricating system Π4.80

Rotational compressor:
Z3 Check oil level (before each commissioning) Π4.55
Z4 Change oil using ROTOR OIL 8000 F2 „ • 4.55
Z5 Replace oil filter „ • 4.55
Z6 Replace oil return-flow valves „ • 4.55
Z7 Clean / replace air intake filter Ž • 4.55
Z8 Clean oil cooler Ž 4.55
Z9 Replace oil separator cartridge • 4.55
 4.10-3

CONCRETE PUMP: A B C D E F G CH.

B1 Flush water box Ž 3.35

B2 Check water box for deposits and clean, if necessary Ž 3.35
B3 Replace hydraulic oil return-flow filter every 6 months or after 15000 m³ of concrete pumped, „ • 4.20
whichever occurs first
B4 Check fastening of pumping pistons Π4.43
B5 Inject grease into nipple at Rock valve, slewing cylinder, agitator and feeding hopper • 4.40
B6 Check fastening screws of Rock valve pivoting body for tightness Π4.40
B7 Check screws on Rock valve cover for tightness Π4.40
B8 Check axial play of Rock valve pivoting shaft Π4.40
B9 Check sealing of Rock valve pivoting shaft for leaks Π4.40
B10 Check Rock valve cutting ring Π4.40

DIESEL ENGINE: A B C D E F G KAP:

D1 Check fuel reserve every 4 hours Π3.10

D2 Check the starter batteries Π4.61
Air filter:
D3 Check contamination of air filter (servicing indicator) Π3.35
D4 Check dust discharge valve of air filter for damage and clean ŒŽ 4.30
D5 Check clean air line for damage and leaks Π4.30
D6 Replace filter element depending on servicing indicator reading, at the latest, however, after one • 4.30
year
D7 Check filter housing and support for damage (cracking) during each filter service 4.30
D8 Check servicing indicator for proper functioning Π4.30

For more details on engine maintenance refer to the manufacturer's operating instructions.
 4.10-4

CHECKING INTERVALS DEPENDING ON AMOUNT OF CONCRETE PUMPED

The wear of components in contact with concrete depends largely on the operating conditions (type of concrete, CP number of strokes, etc.).

It is therefore recommended to inspect the new components after a certain amount of concrete has been pumped.

Further intervals should then be planned in accordance with the amount of wear detected:

first check after m³ further checks for more information refer to chapter

P1 Concrete pumping line 5000 as required 2.34 / 4.44

P2 Rock valve body 15000 as required 4.40

 4.11

".....................................................................................................................................................................................................................................

MAINTENANCE REPORT

Maintenance:
A,B,C,D,E,F Date: Signature: Remarks:
(please list)
 4.20-1

HYDRAULIC FLUID AND FILTERS

OBSERVE THE INSTRUCTIONS OF THE

"SAFETY MANUAL"

CHECKING THE RESERVOIR LEVEL

The reservoir is equipped with an inspection glass 1

(Fig. 1).

The fluid level must be visible in the upper half of the

inspection glass when:

– the machine is at operating temperature,

– the drive has been stationary for at least 10 min-

utes,

– the machine is in horizontal position.

If required, fill in hydraulic fluid through the filler neck 2

(Fig. 2) on top of the reservoir.

Cleanliness is of utmost importance.

For topping up we recommend to use our

FLUSHING AND FILTERING UNITS (see page 4.2-
2).

Ask for supplementary information.

Do not fill the reservoir above the upper mark.

Use only the same sort of fluid.

Fig. 1

003.395.01(en)
 4.20-2

LONGER INTERVALS BETWEEN HYDRAU- The water content can be checked by filling a
LIC OIL CHANGES sample into a test tube.

In case of proper oil treatment and regular After some time, water settles on the bottom of
oil filter change, the hydraulic oil must be the test tube.
changed only after 2 years.
Foreign bodies and oxidation products darken
the oil.
VISUAL INSPECTION AND ODOUR TEST OF
HYDRAULIC FLUIDS ON A MINERAL-OIL BA- The colour is determined by comparing the
SIS sample to fresh oil of the same grade.

Simple oil inspections can be carried out on A precise analysis can be performed by the oil
site. manufacturer in a laboratory test.

TEST CRITERION DIAGNOSIS REMEDIAL ACTION

COLOURING slight darkening without depo- none, normal state

sits
strong darkening with deposits change oil, for large systems
filter + carry out lab test
turbidity see below
CONTAMINATION BY FOREIGN oil clean and clear, no precipi- none
MATTER tation
clean and clear, slight precipita- shorten checking intervals
tion
suspended particles (turbidity) clean system, replace oil filling
or dirt deposits or filter, check nature of filter
contamination
WATER IN OIL milkiness (emulsion), visible drain off water, carry out lab test
separation of water and change oil, if required,
repair leaks.
FOAMING increased foaming, foam check suction line for leaks,
emerging check oil level
ODOUR smell of burnt oil check operating temperature, if
severe darkening and deposit
formation occurs at the same
time, see above.
sour smell, darkening, deposits change oil immediately and
clean system
 4.20-3

DRAINING OFF CONDENSED WATER

ATTENTION:
After prolonged downtimes (at least 1 day) RISK OF EXPLOSION
drain off any condensed water from the Never use unshielded flames.
hydraulic reservoir using the drain valve at the
bottom of the reservoir.
Clean the oil reservoir if necessary.
– Unscrew cap 1 (Fig. 1) of drain valve.
To do so:
– Screw draining hose 2 onto the valve
– Clean the surroundings of the cleaning
thread.
cover and take off cover.
The valve opens automatically. – Detach the suction hoses of the hydraulic
pumps from the reservoir and close the
– When clean hydraulic fluid flows out of the open ends to prevent dirt from getting into
valve, remove hose immediately and refit the pumps.
the valve cap.
– Clean the inside of the reservoir with flush-
Risk of unintentional emptying of the ing oil and lint-free cleaning rags.
reservoir.
Textile fibres and solvents are the enemy
– Check the liquid level. of the hydraulic system. For this reason,
never use waste cotton, diesel oil, petrol,
etc. for cleaning.
CHANGING THE HYDRAULIC FLUID
RISK OF CAUSING IRREPARABLE DAM-
– Bring the hydraulic system to operating
AGE TO THE PUMPS
temperature.
– Wipe inside of the reservoir dry.
– Prepare a recipient for used oil.
– Refit the cleaning cover.
– Drain off fluid oil through the drain valve as
described above or pump off by means of
our FLUSHING AND FILTERING UNIT
(page 4.2-2) through the filler opening.

– During each oil change clean the reservoir

and replace the filter insert (page 4.20-4).

CLEANING THE RESERVOIR

During prolonged downtimes, dirt particles in

the hydraulic oil settle at the bottom of the
reservoir.

For this reason, clean the walls and the bottom

Fig. 1
inside the reservoir during each change of the
hydraulic fluid.
 4.20-4

REPLACING THE FILTER CARTRIDGE

The machine is equipped with a hydraulic

oil bypass- flow filter.

The oil filter 2 (Fig.1) is located inside the

machine.

Never clean,but always replace the return

flow filter cartridge.

Never use the hydraulic system without

filter cartridge.

Used filter cartridges must be disposed of

as special waste.

Clean and check all parts and watch for

abraded metal in the filter (sign of damage).

Dismantling :
Fig. 1
- Loosen the union nut (fig.2) with
both hands.
- Use a wooden block and a hammer if
the nut is too tight.

ATTENTION:
RISK OF DAMAGE
Do not hit the nut directly with a
hammer.
Do not use pointed objects such as
chisels.
Fig. 2
- Dismantle the filter housing , empty
and clean.
- Withdraw the old filter cartridge
from the filter head.
 4.20-6

VENT HYDRAULIC PUMPS

If the intake pipe of a hydraulic pump has been

emptied, the pump must be vented - with the
drive stationary - prior to being put into service:

- Depending on position of pump, slacken

topmost vent plug but do not remove it
(example, Fig. 1).

- Any air in the pumps is seen to escape.

- When fluid emerges without air, close vent

plug.

We recommend that the hydraulic pumps

should also be vented after longer down-times.
Fig. 1
When replacing a pump, fill the new pump with
hydraulic fluid prior to installation. For this
purpose fill in fluid through venting hole, turn-
ing the pump slowly until it is filled.

After installation, vent the pump as described

above.
 4.21-1

CHECKING THE PRESSURE SETTINGS

OBSERVE THE INSTRUCTIONS OF

THE SAFETY MANUAL

All hydraulic consumers are protected by pres- CONCRETE PUMP SYSTEM

sure relief valves.
The hydraulic pump of the concrete pump sys-
These valves are pre-set at the factory. Re-ad- tem is equipped with a 'pressure cut-off' func-
justment is normally only necessary after re- tion swivelling the pump back before the max.
placement or repair of hydraulic units. pressure adjusted on the pressure-reducing
valve is attained.
For prompt fault detection, the settings should
nevertheless be checked at regular intervals. The pressure cut-off function prevents loss of
performance and oil heating occurring when
Check the settings when the machine is at op- hydraulic oil is being ejected through the pres-
erating temperature and running at operating sure-reducing valve.
speed.
The value indicated on the pressure gauge dur-
The factory-adjusted pressures must not be ing pressure checking must be below the set-
changed. Any readjustment may only be ting of the pressure-reducing valve. See hy-
carried out by qualified workshop person- draulic circuit diagram.
nel.
The corresponding adjustments are made on
the hydraulic pump and on the pressure-reduc-
ATTENTION: ing valve.
RISK OF ACCIDENT AND DAMAGE
– Detach connections on the hy- If the value measured during the pressure
draulic system only when the check is clearly greater or smaller than the
engine is stationary and the prescribed value, leave the necessary ad-
pressure accumulator (if any) justment work to the SCHWING after-sales
depressurized. This is also re- service.
quired when test pressure
gauges are installed or removed. Put the machine out of operation and inform the
– For pressure checking of the con- after-sales service about the values noted.
crete pump hydraulics, the con-
crete pump MUST be set to the
"pumping" mode.
If the pump is operated in the "suc-
tion" mode, there is a risk of the
seals in the concrete pump control
block being forced out of their seat.
– After the pressure check, shut off
the concrete pump first before
switching over the ballcock (the
ballcocks) to prevent uncontrolled
starting of the concrete pump.
 4.21-2

Checking:

– Close ballcock 1 (Fig. 1) on the concrete

pump control block.

The notch in the plug points in the direction

perpendicular to the flow.

– Adjust the concrete pump for max. delivery

rate (number of strokes) and open shut-off
valve 16 (Fig. 2).
Fig. 1
– Switch on the concrete pump.

The pumping pistons move to their final posi-

tions and stop there.

The needle of the concrete pump pressure

gauge 17 must move up to the set value of the
pressure cut-off function.

– Note the set value and shut off the concrete

pump.

– Close shut-off valve 16 (Fig. 2) and set ball-

cock 1 (Fig. 1) back to operating position.

Fig. 2

004.596.00-en
 4.22-1

COOLER

OBSERVE CHAPTER. 2.60 OF THE

SAFETY INSTRUCTIONS

HYDRAULIC OIL COOLER

The hydraulic system may be equipped with an – The cooler cleaning procedure is
oil cooler. described in the corresponding engine or
vehicle operating instructions.
Dust deposited on the fins of the oil cooler 1
(Fig. 1) reduces the cooling efficiency.

– Clean the outside of the cooler using a soda

solution and a brush and dry with
compressed air.

ATTENTION – RISK OF DAMAGE

Do not clean the oil cooler with a
steam-jet cleaner.

ENGINE RADIATOR

Water-cooled engines are equipped with a ra-

Fig. 1
diator.

Depending on the type of machine, the drive

engine may be equipped with an additional
engine oil cooler.

– Please remember that the cooling fins of

engine radiators and coolers must be
cleaned from time to time if the machine is
used for work on dusty construction sites.

The engine may otherwise be damaged by

overheating.
 4.30-1

AIR FILTER SYSTEM

OBSERVE CHAPTER 2.60 OF THE

"SAFETY INSTRUCTIONS"

The engine must be stationary when the air

filter is being sercived. Do not start up the en-
gine with the filter element removed.

Check the suction line for condition and tight-

ness whenever the filter is serviced. A leaking
suction line must be repaired immediately.

DUST DISCHARGE VALVE

Check the automatic dust discharge valve(Fig.

1) for condition and proper functioning. Fig. 1
The valve must be unobstructed. Remove any
accumulated dust from the valve. If damaged,
the valve must be replaced.

After the installation, the valve must point

downwards.

REMOVING THE FILTER ELEMENT

Service the air filter element only when

Fig. 2
– the servicing indicator 2 has
switched to "RED" and if it remains in this
Position even after the engine is stationary.
Intermediate cleaning is not necessary.

– Loosen the snap-fastener and remove the

cover (Fig. 2).

– Witdraw the filter element turning it slightly in

both directions (Fig. 3).

– Clean the filter housing and especially

the line transporting filtered air to Fig. 3
the engine

004.491.01-en
 4.30-2

CLEANING THE FILTER ELEMENT

Replace the filter element after 3 cleaning

cycles and, at the latest, after one year.

ATTENTION: RISK OF DAMAGE

Never clean the filter element by
washing and brushing or by beating it
against hard objects.

Cleaning is performed with clean and dry

compressed air (max. pressure: 5 bars). When
blowing out the filter element, no dust must get
onto the inside of the element.

– The air gun should be prolonged with a tube

the end of which is bent approx.90°. The Fig. 1
tube must be long enough to reach the bot-
tom of the element (Fig. 1).

– Clean the element by moving the tube up

and down and by blowing air from the inside
towards the outside of the element until all
dust has been removed (Fig. 2).

Do not damage the element.

ATTENTION:
HEALTH HAZARD
Do not inhale the dust. Wear a respi-
ratory mask (dust protection mask).

– Before refitting, check the cleaned element

for damage (filter paper, seals).

Cracks and holes in the paper can be de- Fig. 2

tected when a hand lamp is held into the
element (Fig. 3).

ATTENTION:
RISK OF DAMAGING THE ENGINE
Never continue to use a damaged
filter element. In case of doubt, the
element must always be replaced by a
original spare filter element.

Fig. 3
004.491.01-en
 4.30-3

INSTALLING THE FILTER ELEMENT

– Slide the element carefully into the housing.

– Refit the cover paying attention that the dust

discharge valve points downwards.

On closing the cover, the filter element is

automatically brought to the correct position.

STORAGE

Filter element must be stored in an upright posi-

tion in the original packing and protected
against dust, moisture and damage.

DISPOSAL

The filter element consists of filter paper and

PU foam.

Used filter elements are classified as special

waste and must therefore be disposed of in
compliance with local regulations.

SERVICING INDICATOR FUNCTION CHECK

– With the engine running at idle, reduce the

intake opening of the air filter slowly (using
a piece of metal or cardboard, for instance)
until the maintenance indicator responds.

ATTENTION: RISK OF DAMAGE

Never close the suction opening
completely.

004.491.01-en
 4.40-1

ROCK VALVE

Grease all nipples of the station every day. For

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

– Clean the greasing station.

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

Concrete pumps without central greasing sys-

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

The greasing nipples of this station are con-

nected with the bearings of the Rock valve.

Greasing points:

– rocking shaft
Fig. 1
– rocking cylinder
Greasing station „X“ of portable concrete
– agitator pumps:

Important:
The number of greasing nipples may vary
with the type of Rock valve.
The greasing station of truck mixer concrete
pumps have further greasing nipples for the
mixer bearings.
 4.40-2

Important note:
In some pumping units, the moving part of the
Rock valve is driven by hydraulic cylinders
mounted on ball sockets.
The machine may be equipped with cylinders
which may have a ball bearing only on one
side or also on both sides.
The corresponding greasing points are con-
nected via greasing lines with the greasing
nipple block (or the central greasing system).
The additional greasing nipples, e.g. 1 (Fig.
1) need not be greased.
They are used for pressing out the ball sock-
ets during repairs.

CHECKING THE SCREWED CONNECTIONS Fig. 1

FOR TIGHTNESS

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

and the clamping screws of the pivot unit 15
("big Rock" only) in acc. with the servicing
plan regularly for tightness.

If needed, retighten the screws with a torque

wrench as specified in the table of chapter
4.5.

CHECKING THE PIVOT SHAFT FOR AXIAL

PLAY
Fig. 2
There must be no air gap between bearing
bush 4 (Fig. 3), arrestor disk 2 and adjusting nut
1. This is also valid for the valve in operation.

Between pivoting unit (Rock) 5 and housing

lining 6 there must be a play of 1.5 to 3 mm,
whereas kidney seal 7 contacts the housing
lining (Fig. 4).

Fig. 3 Fig. 4
 4.40-3

Metal contact between Rock 5 and housing

lining 6 (Figs 1+2) indicates a defect, as, for
instance:

– kidney seal defective

– adjusting nut 1 too tight

– cutting ring jamming

– too much grease used for fitting or parts not

properly cleaned.

ADJUSTING THE AXIAL PLAY OF THE PIVOT

SHAFT
Fig. 1
– Remove safety screw 3 (Fig. 1) and the
washer.

– Set spacing "B" = 1.5 bis 3 mm with adjust-

ing nut 1.

– Bring bore in the collar of the adjusting nut

into alignment with the nearest threaded
hole of arrestor disk 2 (by turning the nut
forwards or backwards).

– Fit safety screw 3 together with the washer.

CHECKING THE CUTTING RING

Due to external influences (e.g. different sorts Fig. 2

of concrete) and varying load conditions in par-
tial zones, the cutting ring and wearing layer of
the housing lining are subject to non-uniform
wear and tear (zone "C", Fig. 3).

Fig. 3
 4.40-4

Scores are mainly caused by friction and the

breaking of stones.

They are of no importance unless the wear-

ing insert is completely worn.

The wearing insert used in series machines is a

single-piece wearing insert 9 (Fig. 1) of white
cast iron.

As an option, a two-piece wearing insert 9 (Fig.

2) of hard metal with a suitable carrier plate is
available. Fig. 1

To achieve uniform wear and therefore a much

longer service life of the parts, the following
measures are recommended:

– After thorough cleaning, move the Rock to

the lefthand and righthand limit stop posi-
tions and check the cutting ring and the
wearing insert for condition in acc. with the
servicing schedule.

Check the cutting ring all around its cir-

cumference.

– If a gap is visible between cutting ring 10

Fig. 2
and wearing insert 9 (maximum admissible
play: 1 to 1.5 mm), the cutting ring should
be turned by 90°.

TURNING THE CUTTING RING

For turning of the cutting ring, proceed as fol-

lows:

– Detach the pumping line from the Rock valve

outlet.

To do so,

– remove the reducer pipe in trailer concrete Fig. 3

pumps,

– remove wedges 1+2 and coupling 3 (Fig. 3)

in truck-mounted concrete pumps,

– swing boom connection piece 4 aside.

001.193.12-en
 4.40-5

– Slacken adjusting nut 1 (Fig. 1) by two to – Tighten all cover screws 14 in several steps
three turns. crosswise with a torque wrench.

– Slacken the cover retaining screws 14 uni- Tightening torque see chapter 4.5.
formly by abt. 2 to 3 turns to relax the com-
pression spring of the cutting ring. – Coarse-adjust the axial play of the pivot shaft
so that the Rock valve can be switched to al-
Do not turn out the screws completely. low the parts to "settle" in place.

– Lever up the cover with two crowbars until For this purpose, screw adjusting nut 1
the cover contacts the loosened screws. against the contact face and then slacken
again by ½ turn.
The cover has special depressions in the rim
(arrow, Fig. 1) where the levers can be ap- – Wet the kidney seal with water and switch
plied. the Rock valve several times to and fro to al-
low all parts to "settle" in place.
– Pull back the pivot unit (Rock) until the cut-
ting ring can be moved freely. Do not switch the Rock valve in dry con-
dition - Risk of damage
If the cutting ring cannot yet be moved freely,
the cover screws must be loosened a little – Adjust the axial play of the pivot shaft as
further and the procedure repeated. described on page 4.40-2.

– Detach the cutting ring if necessary by tap-

ping slightly on it.

– Turn the cutting ring by 90°.

Always turn in the same direction.

– Make sure the cutting ring is safely guided

by the Rock and that it cannot drop out or
get jammed.

– Pay attention that no stones are getting

caught between the individual components
when tightening the cover screws.

– Tighten the cover screws 14 uniformly and

carefully.

Make sure the cutting ring slides into the

Rock without jamming.

Fig. 1
 4.40-6

– Check the spacing between cutting ring 10

and Rock 5 (Fig. 1+2) after each turn of the
cutting ring.

If the spacing exceeds 8 mm, the cutting ring

is no longer guided safely in the Rock and
must be replaced.

– When replacing the cutting ring, check

wearing insert 9 and compression spring
11 for condition.

Fig. 1
CHECKING THE PIVOT SHAFT SEALING

The bearings of the pivot shaft are sealed off

against the pumped substance by means of O-
rings (Fig. 3).

In the event of leaks (concrete fines are

squeezed out of the bearing), the O-rings must
be replaced immediately before the bearings
are destroyed.

For replacing the rings, the pivot shaft must be

removed. See:
Fig. 2
ROCK VALVE REPAIR INSTRUCTIONS

PROLONGED DOWNTIMES

If the Rock valve is not used during prolonged

periods, we recommend to lubricate the kidney
seal and the housing lining with a lubricant and
anti-corrosive agent with a MIL 907D specifica-
tion (e.g. ANTI-SEIZE manufactured by
LOCTITE).

This agent prevents "sticking" of the seal.

Do not use sprays. Sprays attack rubber

Fig. 3
parts.
 4.40-7

CHECKING THE WEAR OF THE ROCK

VALVE

To reduce wear, most of our Rock valves are – Move the Rock valve to the opposite end
protected on the inside and outside by a hard- position and repeat the check.
facing layer.
Depending on the condition of the valve, it is
The type of hardfacing chosen depends on ex- now possible to determine further checking in-
periences made in the main fields of application tervals.
of the individual Rock valves.
The Rock valve should be replaced when the
See example Fig. 1: base metal becomes visible in certain places.

1 = internal hardfacing The internal hardfacing layer will generally wear

faster than the outer layer.
2 = external hardfacing
The outside should be checked at the latest,
when a significant degree of wear is found on
PREVENTIVE MAINTENANCE the inside.

Due to the fact that wear depends strongly on

the conditions of use, we recommend checking
a new Rock valve on the inside for the first time
after ca. 5000 m³ of concrete pumped:

– For checking, clean the concrete pump as

usual.

– Move the Rock valve into one of its end posi-

tions.

ATTENTION:
RISK OF ACCIDENT
Shut off the engine and depressu-
rize the pressure accumulator to
prevent inadvertent movements of Fig. 1
the Rock valve.
Important information:
– Remove the valve outlet and check the in- With the materials currently used, the
side of the Rock valve body with a torchlight. valves can no longer be regenerated by
hard-facing.
Clients are urgently warned against un-
qualified welding work and the use of re-
produced parts.
SCHWING assumes no liability whatso-
ever for damage caused by unqualified
repair attempts and the use of reproduced
parts.
 4.42-1

OBSERVE THE INSTRUCTIONS OF

THE "SAFETY MANUAL"

PUMPING AND DIFFERENTIAL CYLINDERS Important note:

Depending on the type of concrete pump in-
Check the fastening screws of the differential
stalled the machine can be equipped with
and pumping cylinders for tightening.
different water-boxes.
Tighten loose screws crosswise in three steps The water-box covers vary accordingly.
using a torque wrench (Fig. 1). Basic rule:
Tightening torque see table 4.5. – If the water-box cover can be opened
without tools, then there are screwed
protective grids under the cover.
PUMPING PISTONS – There are no grids if the box covers can
only be opened with tools.
Work on the pumping pistons are performed
inside the water-box. Make sure the grids are always in place and
firmly bolted to the box. Place the cover on
the grids and secure, if necessary (using a
ATTENTION: wedge, for instance)
RISK OF CRUSHING
Before working in the water-box
always shut off the drive engine
and depressurize the pressure ac-
cumulators to prevent inadvertent
movements of the concrete pump.
Keep at a safe distance when oper-
ating the concrete pump with the wa-
ter-box open.
Do not stick your hands into the
water-box.
During work on the pumping pistons
no other working activities must be
carried out on the concrete pump.
Make sure nobody is standing close to
the pipe-switching system. The Rock
valve can switch over.
In case of danger, depress the emer-
gency shut-off button.

Fig. 1
 4.42-2

OPERATING THE CONCRETE PUMP IN

THE REPAIR MODE

– Take off the water-box cover (Fig. 1) .

– Drain off the water.

Close the ball valve 1 (Fig. 2) on the

concrete pump control block to prevent
switching of the piston rods in the limit-
stop positions.

Start the engine and select high-idle

speed.

– Set the concrete pump for the lowest Fig. 1

number of pump strokes.

– Operate the concrete pump with the

remote control.

CHECKING THE FASTENING OF THE

PUMPING PISTONS

– Move an adapter piece into the water-

box.

– Check the fastening screws for tightness

(Fig. 3) by holding the adapter piece tight Fig. 2
with a wrench on the hex shaft section.

– Move the second adapter piece into the

water- box and repeat the check

REPLACING THE PUMPING PISTONS

If sand is found in the water-box, the

pumping pistons are worn and must be
replaced.

Leaking pistons cause premature wear

of the pumping cylinders.
Fig. 3
If sand gets into the water-box in spite
of new pistons having been installed,
the cylinders must also be replaced.
 4.42-3

ATTENTION:
RISK OF INJURY
Depending on size, a pumping piston
may have a weight of more than
25 kg.
Use a fitting aid (e.g. belt) for in-
stallation and removal of the piston
and seek assistance of a helper.
Instruct the helper beforehand. Reac-
tivate the engine only after the helper
has left the machine.
Fig. 1

REMOVAL

– Move piston to a position short before the

rear limit stop. The adapter piece (Fig. 1)
must be fully visible in the water-box.

– Loosen the fastening screws of the adapter

piece and remove completely by holding the
adapter piece tight with a wrench on the hex
shaft section (Fig. 2).

– Move the piston rod to the rear limit stop.

– Withdraw the adapter piece (Fig. 3).

Fig. 2

Fig. 3
 4.42-4

– Moving the piston rod slowly towards the

pumping piston.

– Connect piston-rod flange 1 with pumping-

piston flange 2 as shown in Fig. 3, using
suitable nuts and bolts (Fig. 1).

Tighten the bolt by hand.

– Retract piston rod slowly and draw piston out

of the cylinder (Fig. 2).
Fig. 1
– Loosen bolted connection.

– Take pumping piston out of the water-box

– Clean and check all parts.

FITTING

Smear a thick layer of grease on the new

piston and the cylinder walls.
Fig. 2
– Fasten the new piston with bolt and nut to
the piston-rod flange.

– Move the pumping piston into the cylinder so

that the screwed connection is still access-
ible (Fig. 3).

– Remove bolt and nut.

– Retract the piston rod.

Fig. 3
– Insert adapter piece and screw onto the
pumping piston (Fig. 4).

– Move piston rod towards the adapter piece.

– Align adapter piece, if necessary, and screw

onto the piston rod.

Fig. 4
 4.42-5

– Fill water into the water-box and refit the

Cover.

– Open the ballcock 1 (Fig. 2) on the

concrete pump control block..

Fig. 1

Fig. 2
 4.60-1

ELECTRICAL INSTALLATION

OBSERVE CHAPTER 2.60 "SAFETY"!

WORK ON ELECTRIC / ELECTRONIC COM- ELECTRIC WELDING PROCESS

PONENTS
See chapter 4.70.
1. CONCRETE PUMP WITH DIESEL ENGINE

- Prior to any work on electric or electronic START BY BRIDGING-OVER

components
Connect the bridging-over cable according to
first of all disconnect the negative pole (-), the instructions in the operating manual for the
vehicle or the engine.
then the positive pole (+)

from the starter batteries of the driving MECHANICAL WORKING PROCESS

engine.
- Cover the equipment, cables etc. during the
This will be sufficient to avoid short circuits and boring, grinding or other work on the
to protect the SCHWING control system. machine.

The connection is made in reverse order.

LACQUERING AND WORKS WITH
Do not place tools on the battery. AGGRESSIVE SUBSTANCES

- Cover the equipment, cables, etc. to protect

2. CONCRETE PUMP WITH ELECTRIC them from colour mist and aggressive sub-
MOTOR stances.

- In case of electrically driven machines, have

the power supply interrupted by a qualified STEAM JET CLEANING
electrician.
- Never direct the nozzle of a steam jet at con-
- Works on the electrical system may be car- trol panels, switch boxes, cables, etc.
ried out only by a qualified electrician.
The cleaning agent penetrating under
pressure could cause great damages.
 4.61-1

STARTER BATTERIES

OBSERVE THE CHAPTER 2.60

"SAFETY"!

CHECK THE LEVEL OF THE ACID

- Clean the surface of the battery. - Tighten the terminal clips only manually.

- The acid level must be about 10 to 15 mm

above the plates (bottom of the inspection
inserts).
During the testing and charging
EXPLOSIVE GASES emanate from the
- If necessary, top up with DISTILLED
cells. No smoking, no naked lights, avoid
WATER. DO NOT REFILL ACID.
any sparking.

CHECK THE CHARGING CONDITION

Keep the battery clean and dry to avoid its
discharge by leak current.
For the test a voltage tester or a hydrometer
is used. A well charged battery has a voltage
of about 2.4 Volt per cell and an acid density
of 1.28 kg/l. If the acid density is lower than
1.23 kg/l at 20° C, charge the battery either
through several hours of operation or by
means of a charger:

- Disconnect the positive and the negative

poles of the battery from the vehicle's
electrical system.

- Open the sealing caps.

- The charging current corresponds to max. 10

% of the battery capacity (e.g. battery 120 Ah
= charging current = 12 amp.)

- End the charging process when the acid

density is 1.28 kg/l.

- Check the acid level, if necessary top up with

distilled water.

- Clean the battery poles and the terminal clips

and grease them lightly with acid proof
grease.
 4.65-1

SAFETY INSPECTIONS

VISUAL INSPECTIONS AND FUNCTION

CHECKS

The qualifications required for specialists are

OBSERVE CHAPTER 2.61 OF THE described in chapter 2.90 of the SAFETY
SAFETY INSTRUCTIONS MANUAL.

Besides regular servicing, permanent On request, the inspection can be performed

observation of the machine and the required by a specialist from SCHWING.
safety inspections are indispensable to ensure
the operational safety of the machine and the
safety at the place of work. EXPERT

Persons in charge of these duties: An expert must be called in after essential

modifications and extensive repairs (for
instance when welding work has been carried
MACHINE OPERATOR out on load-bearing parts of the machine).

The machine operator is responsible for visual The qualifications required for experts are
inspections and function checks of 'his' described in chapter 2.90 of the SAFETY
machine and its accessories before and during MANUAL.
the work.

The machine operator must stop the ADDITIONAL INSPECTIONS

operations if he detects deficiencies
endangering the safe working with the For special safety-related units as, for instance,
machine. pressure accumulators, the relevant
inspection regulations valid in the country of
He is also responsible for the external aspect use must be observed.
of 'his' machine. He must therefore make sure
that defects in the paint coat of the machine If personnel with the required qualification is
are repaired in due time. not available, the inspection can be entrusted
to the After-Sales Service of SCHWING.
Corrosion defects - especially at the placing
boom - may lead to cracking and fracturing!
For further information please refer to
In his capacity as a driver, he is responsible chapter 2.61 of the SAFETY MANUAL.
that his vehicle is in a safe driving condition as
prescribed by the regional regulations in the
country of use.

SPECIALIST

The specialist is obliged to perform the

required safety inspection at regular intervals
and to document the result in the inspection
booklet.
 4.65-1

SAFETY INSPECTIONS

VISUAL INSPECTIONS AND FUNCTION

CHECKS

The qualifications required for specialists are

OBSERVE CHAPTER 2.61 OF THE described in chapter 2.90 of the SAFETY
SAFETY INSTRUCTIONS MANUAL.

Besides regular servicing, permanent On request, the inspection can be performed

observation of the machine and the required by a specialist from SCHWING.
safety inspections are indispensable to ensure
the operational safety of the machine and the
safety at the place of work. EXPERT

Persons in charge of these duties: An expert must be called in after essential

modifications and extensive repairs (for
instance when welding work has been carried
MACHINE OPERATOR out on load-bearing parts of the machine).

The machine operator is responsible for visual The qualifications required for experts are
inspections and function checks of 'his' described in chapter 2.90 of the SAFETY
machine and its accessories before and during MANUAL.
the work.

The machine operator must stop the ADDITIONAL INSPECTIONS

operations if he detects deficiencies
endangering the safe working with the For special safety-related units as, for instance,
machine. pressure accumulators, the relevant
inspection regulations valid in the country of
He is also responsible for the external aspect use must be observed.
of 'his' machine. He must therefore make sure
that defects in the paint coat of the machine If personnel with the required qualification is
are repaired in due time. not available, the inspection can be entrusted
to the After-Sales Service of SCHWING.
Corrosion defects - especially at the placing
boom - may lead to cracking and fracturing!
For further information please refer to
In his capacity as a driver, he is responsible chapter 2.61 of the SAFETY MANUAL.
that his vehicle is in a safe driving condition as
prescribed by the regional regulations in the
country of use.

SPECIALIST

The specialist is obliged to perform the

required safety inspection at regular intervals
and to document the result in the inspection
booklet.
 4.70-1

REPAIR WELDING

OBSERVE THE SAFETY INSTRUC-

TIONS OF CHAPTER 2.60

Welding work on the placing boom, the out-

rigger system or on other structural
components relevant to working safety may
only be performed by persons duly authorized
by the manufacturer.

The work must be inspected by a competent

expert.

– Before performing electric welding work dis-

connect the starter batteries (see chapter
4.60) and take the necessary precautions to
protect the electronic systems of the vehicle
and of the engine

See the respective documentation of the ve-

hicle manufacturer and of the engine manu-
facturer.

– Disconnect the multiple plug of the cable

remote control resp. of the radio receiver
from the machine.

– Attach the negative terminal of the welding

machine directly to the component on which
welding is to be performed.

The welding current must not flow through

hydraulic cylinders. There is otherwise a risk
of damage to the chromium-plated piston
rods.

Protect the equipment, cables and cable

plugs from the effects of heat, slag etc.
Specifications

SP 1200 DRL 180/1200 D 48,6kW

Technical parameter 1215
Engine performance kW 48,6
Nominal speed 1/min 2300
Engine type Kirloskar HA494
Pumping cylinder, DN x stroke mm 180 x 1200
Pumping cylinder volume l 30.50
Diff.-cylinder, DN / dn x stroke mm 100 / 56 x 1200
Drive of the diff.-cylinder piston side / rod side
Stroke per minute / max. / / 24
Stroke, basic adjustment / / /
Max. theor. concrete output m³/h / / 44
Max. concrete pressure bar / / 64
Hopper capacity l 400
Weight with hydraulic oil kg 4000
Delivery pipe until DN mm 150

Gear box type /

Transmission /
Hydr. pump A7V0 107
Max. output l/min 194
Adjusted perf. on the regulator kW 44
RPM 1/min 2150
Transmission power take off 1
Power take off / concrete pump //
Max. output l/min /
Total concrete output BP l/min 194
Power take off / accumulator //
Max. output l/min /
Power take off / agitator 1P 3072 22,84
Max. output l/min 49
Rock valve DN mm 180/190/160
Oil capacity per stroke (diff.-cyl.) l / 6.47
Switching oil per stroke l 0,06
Oil lost during switching (0,2s) l /
Slewing cylinder, dn x stroke mm RL, 65 x 177.5
Oil capacity per stroke l 0,589
Total oil capacity per stroke l / 7,1
Transmission F concr./ F h.-oil 1: / 4,72
Max. hydraulic pressure bar 300
/
Operating instructions

Published by: SCHWING GmbH

Dept.: VVW
CLEANING SYSTEM
P.O.B : 20 03 62 DN 125
D - 44647 Herne

9/29/2004 6:11 PM

Id.-no..: 10182049

All rights reserved. Reprinting in any form whatsoever permitted only by express authorization of the publisher.
 -2-

5. Shut-off valve

The shut-off valve is installed near the concrete pump for up-pump-
ing operations and behind the down-pipe for down-pumping
operations.

The shut-off valve is not included in the scope of supply of the

cleaning system.

SCHWING supplies suitable shut-off valves.

Our trailer-mounted concrete pumps (BP 3500 models and higher)

are equipped with control and connection facilities for our hydraulic
shut-off valves. Smaller machines can also be equipped with these
facilities on request.

For down-pumping applications, the hydraulic shut-off valve must

be supplied with oil from a separate hydraulic unit.

6. Catching device 1 – Concrete pump

The catching device retains the plug and the cleaning balls. 2 – Flushing water tank

Together with the plug and the cleaning balls, the catching device 3 – Hose-pipe DN 50
prevents flushing water from flowing out of the line at the concrete
placing site. 4 – Cleaning head

To send the flushing water back to the water tank, the device is 5 – Hydraulic shut-off valve
equipped with connections for a compressor.
6 – Catching device
 -1-
The below-described system is intended for cleaning of separately laid DN 125 concrete pumping lines with the existing SCHWING concrete pump..
At the same time, the concrete remaining in the line after the pumping job can be used for placing into the structure. On account of the good
sealing properties of the Rock valve, only concrete pumps with the corresponding equipment can be used for this method.

SYSTEM DESCRIPTION
(Illustration see front or back page)

The concrete pump delivers water and pushes the concrete column 3. DN 50 hose-pipe with non-return valve
by means of a plug and two cleaning balls towards the placing site,
cleaning the pumping line at the same time. At the placing site, the The hose-pipe is used to connect the concrete pump outlet to the
plug and the cleaning balls are retained by a catching device. One of cleaning head. Depending on the outlet diameter, the hose-pipe is
the balls is then sent back down the line by means of a compressor. available with different flanges:
The flushing water reflows to the water tank.
CP outlet: Id. no. of line:
The plant is basically composed of the following components: DN 125 10181306
DN 150 10181286
1. SCHWING concrete pump with Rock valve DN 180 10181307
2. Flushing water tank
4. Cleaning head
The water tank must be supplied by the site owner.
The cleaning head is installed in the pumping line at the concrete
– The tank must be located higher than the level of the concrete
pump side. It is equipped with
pump feeding hopper.
– a ball-valve equipped connection for returning the flushing water to
– The tank must be equipped with a shut-off device to prevent water
the tank.
from flowing to the concrete pump feeding hopper.
– a pressure gauge for pressure control.
– The tank must have a capacity corresponding to approximately
twice the contents of the pumping line (ca 12.3 l/m for DN 125).
The cleaning head is supplied with a mouthpiece for introducing
the plug into the cleaning head. The mouthpiece has the id. no.:
The inlet of the flushing water return line must be above the water
10153494.
level.
 -3-

Important: Flanges for shell-type clamped couplings

The flanges of cleaning head and catching
device are designed to match our high-
pressure pumping line (Fig. 1).
For connection to SCHWING pumping lines
with lower pressure ratings, transition pipes
with flanges as shown in figs. 2+3 are
available. Fig. 2
Transition pipe for cleaning head and
connection to Wall thickness 4.5 mm = 110 bars max.

"110 bar-line" Id. no.: 10078212 Wall thickness 7.1 mm =160 bars max.
"160 bar-line" Id. no.: 10181325
1 – Projecting flange
Transition pipe for catching device and
connection to 2 – Recessed flange
"110 bar-line" Id. no.: 10181322
3 – Seal
"160 bar-line" Id. no.: 10181326
The figures show typical features of the 4 – Shell-type clamped coupling
flanges concerned. Depending on the
nomimal width of the pipes, the flange
design may deviate slightly from the
drawings. Flanges for shell-type coupling 110 bars
max.

High-pressure flanges for up to 200 bars

Fig. 3
Fig. 1 1 – Flange

1 – Projecting flange 3 – Seal

2 – Recessed flange 4 – Shell-type coupling

3 – Seal

4 – Shell-type clamped coupling

 -4-

SAFETY AT THE PLACE OF WORK BEFORE WORK

– When setting up the concrete pump, make

The cleaning system is designed to be used
sure there is enough space for the
exclusively with SCHWING concrete pumps
installation of the hose-pipe and the
and SCHWING pumping lines.
cleaning head.
The installation of the system must be
The hose-pipe must neither be stretched
performed with suitable couplings, seals,
nor kinked.
wedges, etc. from SCHWING.
The total length of the hose-pipe together
The system must only be installed and
with the cleaning head is ca. 4.70 m.
operated under the supervision of a
specialist.
– To ensure smooth concrete placing and
cleaning operations, a vocal communication
For operation of the system, the same safety link must be established between concrete
instructions as those laid down in chapters pump and concrete placing site.
2.40 and 3.40 (CLEANING) of our concrete
pump operating instructions are applicable.
CLEANING
It is moreover recommended to read the
instructions of chapter 3.22: "PUMPING LINE". Cleaning of the pumping line is teamwork. The
cleaning operations are divided into two
Apply to SCHWING, if these instructions are phases:
missing.
Phase 1: cleaning of the line by flushing with
Observe any special regulations existing at the pressurized water in the directiion of
place of use. the placing site.
The non-observance of any of the above Phase 2: pushing the water column back with
instructions constitutes a case of "utilization not compressed air in the direction of the
in accordance with the designated use". flushing water tank.
SCHWING assumes no liability for damage At either end of the line, a qualified worker
occurring as a result of utilization not in must be appointed as responsible for the
accordance with the designated use. operations.

The operators must remain in permanent

contact.

For this reason, the activities to be performed

by the persons concerned are described below
in two different columns.
 -5-

CLEANING: PHASE 1

Operations at the concrete pump: Operations at the placing site:

– Pump the concrete pump feeding hopper – Close the shut-off valve in the pumping line
empty as far as possible. (for down-pumping operation).
– Close the shut-off valve in the pumping line – Remove any hoses from the end of the
(for up-pumping operations). pumping line and clean by hand.
– Remove the reducer piece and clean by – Install the catching device at the end of the
hand. pumping line.
– Clean the concrete pump. There must be
ATTENTION:
no residual concrete in the feeding
RISK OF ACCIDENT
hopper and the pumping cylinders.
Place the catching device flat on the
– Attach the cleaning head to the pumping ground and fasten safely. Do not
line. stand the device upright on the
– Attach the mouthpiece to the cleaning head. narrow edge of the protection frame.
– Wet the DN 125 plug and push it into the
cleaning head. – Close the ballcock 1 (Fig. 3).
– Introduce two hard cleaning balls and
remove the mouthpiece.
– Connect the concrete pump to the cleaning
head using the hose-pipe with non-return
valve 3 facing the cleaning head (Figs. 1+2).
– Close ballcock 1 (Figs. 1+2).
– Fill the concrete pump feeding hopper with
water from the flushing water tank.

Fig. 2

Fig. 1

Fig. 3
 -6-

Operations at the concrete pump: Operations at the placing site:

– Start up the concrete pump and operate – Watch the outflow of concrete from the
with a low stroking frequency. catching device and spread at the site.
– Increase the stroking frequency carefully
until the concrete flow at a uniform rate. ATTENTION:
– Adjust the flow rate of the concrete by RISK OF ACCIDENT
varying the stroking frequency as requested Nobody must stand in the direction of
by the placing site operator. the outflowing concrete. Risk of ejec-
ted stones.
– Watch the water level in the feeding hopper
and top up if necessary.
– Coordinate the most favourable flow rate of
– Stop the concrete pump immediately
the concrete with the concrete pump
when requested by the placing site operator.
operator to do so.
Shortly before the plug and the cleaning
– Depressurize the pumping line by opening balls arrive at the catching device, the
ballcock 1 (Fig. 1). concrete begins to flow faster and more
The line pressure is now equal to the irregularly.
atmospheric pressure. Have the concrete pump's stroking
– Observe pressure gauge 2 and report: frequency reduced and give the "Concrete
"Pumping line depressurized" to the placing pump stop" order when the plug closes the
site when the pressure gauge reads "0" bar. concrete outlet opening (Fig 2).

Fig. 2
Fig. 1
 -7-

CLEANING: PHASE 2

Operations at the placing site: Operations at the concrete pump:

The catching device is designed in such a way – Open ballcock 1 (Fig. 3).
that the air inlet is located between the This opens the pumping line towards the
cleaning balls when the pumping line is flushing water tank.
depressurized (Fig. 1).
Non-returning valve 3 closes the opening to-
– Connect the delivery line of the compressor wards the concrete pump.
to coupling 3 and open the ballcock 3 (Fig.
2). – Give the order to start up the compressor at
the placing site.
– Open ballcocks 1+2.
– Observe the flow rate of the water (flow
noise) and coordinate the rate with the
ATTENTION: operator at the placing site.
RISK OF ACCIDENT
– Give the "Compressor stop" order when the
Nobody must stand in the blow-off
cleaning ball has arrived in the cleaning
direction of pipe 2.
head (flow noise changing).

– Start up the compressor at low delivery rate

when the other side gives the starting order.
The air flows out of blow-off pipe 2.
– Close ballcock 2 slowly until the water co-
lumn starts moving.
– Coordinate the flow speed with the operator
on the other side.
Adjust the flow speed of the water with the
lever of ballcock 2.
– Watch pressure gauge 4: open the ballcock
2 when the pressure rises suddenly Fig. 2
– Stop the compressor immediately when
requested to do so by the operator on the
other side.

Fig. 3
Fig. 1
 -8-

Operations at the placing site: Operations at the concrete pump:

– Close ballcock 3 (Fig. 1) and open ballcocks

1+2 to depressurize the pumping line. ATTENTION:
RISK OF ACCIDENT
– Open the pumping line only after the
Open the pumping line only when
pressure reading at pressure gauge 4 is "0"
completely depressurized.
bar.

– Report "Pumping line depressurized" to the – Open the pumping line only after having
operator at the other end of the line. been informed by the placing site operator
that the line is completely depressurized.
ATTENTION: – Detach the hose and the cleaning head and
RISK OF ACCIDENT remove the cleaning ball.
Open the pumping line only when
completely depressurized.

– Detach catching basket 5 and remove the

plug and the second cleaning ball.
– Detach the complete catching device.

Fig. 1