MAINTENANCE 4.

1-1

TABLE OF CONTENTS - PART 4

Chapter Title

4.1 TABLE OF CONTENTS

4.2 GENERAL MAINTENANCE INSTRUCTIONS

4.3 CONSUMABLES AND REFILLING QUANTITIES

4.4 RECOMMENDED CONSUMABLES AND LUBRICANTS

4.5 TIGHTENING TORQUES

4.6 SPARE PARTS AND ACCESSORIES

4.10 MAINTENANCE SCHEDULE

4.11 MAINTENANCE REPORT (MASTER COPIES)

DESCRIPTION OF SERVICING WORKS

4.20 HYDRAULIC OIL AND FILTERS

4.21 HYDRAULIC PRESSURE TESTS

4.22 OIL COOLER / ENGINE RADIATOR

4.23 PRESSURE ACCUMULATOR

4.30 CARDAN SHAFTS IN THE PUMP DRIVE

4.35 PUMP GEAR

4.36 SLEWING GEAR

4.40 ROCK VALVE

4.42 PUMPING AND DIFFERENTIAL CYLINDERS, PUMPING PISTONS

4.44 BOOM PUMPING LINE

003.979.01-en
MAINTENANCE 4.1-2

Chapter Title

4.51 BOOM COLUMN SLEWING-RING BEARING

4.55 COMPRESSOR

4.56 HIGH-PRESSURE CLEANING SYSTEM

4.60 ELECTRICAL SYSTEM

4.65 SAFETY CHECKS

4.65 VISUAL AND PERFORMANCE CHECKS

4.70 REPAIR WELDING

4.80 CENTRAL LUBRICATING SYSTEM

003.979.01-en
 4.2-1

GENERAL MAINTENANCE INSTRUCTIONS

PAY ATTENTION TO CHECK THE OIL LEVEL

"SAFETY MANUAL“
Unless otherwise prescribed, the oil level is
checked in general

Preventive maintenance is the most - with the machine in horizontal position

economical maintenance.
Carry out all maintenance works punctually
and thoroughly.
We recommend to duplicate the maintenance
report (chapter 4.11).
The maintenance men will then be able to list
off the work done in the copies and to sign
them.
If neither TRAINED personnel nor adequate
workshop equipment are at your disposal,
entrust the SCHWING after-sales service
with the maintenance of your machine.
- after the drive has been stopped for approx.
10 minutes
- with mobile machines being ready for tra-
velling (outriggers in transport position)
Important:
Whenever the oil level is checked (also in
gearboxes, compressors, etc.) it is
recommended to perform also a visual
inspection of the oil. In the event of extreme
contamination or of water contained in the oil
(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
also be used for other oils.

CLEANLINESS
CHANGE THE OIL
- Before commencing the maintenance work
clean all units located within the working - Drain the oil only from units brought to
range. working temperatures.

Do not use steam jets for cleaning rubber - Pour hydraulic oil from clean vessels via the
and electric parts. filter chamber of the oil tank.

- Avoid the penetration of dirt, especially into Whenever possible, use a flushing filter unit.
the hydraulic system.
See page 4.2-2.
- Grease the machine after steam jet
cleanning. - Check the oil level after each test run.

PROTECTION AGAINST CORROSION

- 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.

001.154.09-en
 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

barrel. REPAIR, EXCHANGE

- Under certain circumstances the exchange of

Important: complete units can be more economical than
At each oil change, we recommend to a repair. Consult the SCHWING after-sales
examine an oil sample for colouring and service.
contained solid particles in view of taking the
required measures of preventive - Use only genuine SCHWING spare parts.
maintenance.
SCHWING is not liable for damages re-
sulting from the use of outside products
SEALINGS, SAFETY ELEMENTS
or inadequate operating agents.
- Pay attention to sealings, spring washers,
etc. when dismantling covers, screw plugs, - For mounting work on the hydraulic system
etc. use greases based on mineral oil only.

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

- Clean sealing surfaces, do not damage
etc.) flush the hydraulic system and replace
them.
the filter to avoid consequential damages due
to metal abrasion.
- Replace sealings, split pins, spring washers,
etc.
SCHWING supplies suitable flushing filter
units (Fig. 1). Ask for information material.
LUBRICATION

- Clean the grease nipples before and after

the lubrication.

- Remove the excessive grease from the

lubricating points.

TIGHTNESS

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

regular intervals.

ENVIRONMENTAL PROTECTION!
Oil leakages must be avoided under all Fig. 1
circumstances.

001.154.09-en
 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.

001.154.09-en
 4.3-1

CONSUMABLES AND REFILLING QUANTITIES

Machine type : KVM 34X / 37X (BR 03)

DESIGNATION : CONSUMABLE QUANTITY

chapter 4.4 :

Water reservoir CLEAN water ca. 400,00 l

Hydraulic oil reservoir No. 1 ca. 350,00 l

*Distributor gearbox No. 2 ca. 5,50 l

Slewing gear No. 2 ca. 3,00 l

Greasing nipples No. 4 / 4.1 /

Central lubricating system (optional) No. 4 ca. 6,00 l

Toothing of slewing drive Nr. 5 /

* = vehicle WITHOUT power take-off

004.020.00-en
 4.4-1

RECOMMENDED LUBRICANTS AND CONSUMABLES

PAY ATTENTION TO
"SAFETY MANUAL“

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

000.869.11-en
 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

000.869.11-en
 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.

000.869.11-en
 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.

000.869.11-en
 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

000.869.11-en
 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

000.869.11-en
 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.

000.869.11-en
 4.5-1

TIGHTENING TORQUES

PAY ATTENTION TO These overall coefficients are assumed to be

"SAFETY MANUAL“ the following:

SURFACE COLOUR OVERALL

High-strength bolts must be prestressed with a FRICTION
certain tightnening torque. COEFFICIENT
µges.
Tightening torques depend, among other
things, on bolt and nut type, thread, surface 1. phosphatized black 0,14
coating and lubrication.
2. yellow- golden- 0,14
The tightening torques set out in the chromated yellow
following tables are approximate values. 3. Dacromet 500 silvern 0,10
They contain a safety factor (0.9 x MA) to
avoid overstressing of the bolted 4. as 1+2 with 0,10
fitting paste*
connection.

The tool must be precisely adjusted to these * e.g. copper paste or MOS2
torque values. The values are applicable
Bolts must be lubricated at the thread and the
only in those cases where no other values
turning head or nut seating plane. Thread and
are specified in the individual chapters of
seating plane must be clean.
the SCHWING servicing and repair in-
structions and assembly drawings.
The tables apply only to the above screws and
nuts.
SCHWING uses hex bolts and cheese-head
screws and hex nuts (DIN) with different
They cannot be used for other types (e.g.
surface coatings.
reduced-shaft bolts).
The overall friction coefficients essential to
They cannot be used with friction-increasing
determine the tightening torques depend on the
agents either (e.g. liquid screw fixer).
type of coating and the lubrication.

ATTENTION – RISK OF DAMAGE

Only torque wrenches checked at
regular intervals (every six months,
for instance) must be used for
tightening. The maximum ad-
missible tolerance for torque
wrenches is +/- 10% of the
respective tightening torque (MA).

000.024.06-en
 4.5-2

SCREWS AND BOLTS WITH

STANDARD THREAD (µges = 0,14) STANDARD THREAD (µges = 0,10)

Size Tightening torque MA (Nm) Size Tightening torque MA (Nm)

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

FINE THREAD (µges = 0,14) FINE THREAD (µges = 0,10)

Size Tightening torque MA (Nm) Size Tightening torque MA (Nm)

for strength class for strength class
8.8 10.9 12.9 8.8 10.9 12.9
M8x1 24 35 41 M8x1 20 28 33
M 10 x 1 50 70 85 M 10 x 1 40 57 68
M 10 x 1,25 46 65 80 M 10 x 1,25 37 55 64
M 12 x 1,25 83 120 145 M 12 x 1,25 67 100 115
M 12 x 1,5 80 115 140 M 12 x 1,5 65 95 110
M 14 x 1,5 130 190 230 M 14 x 1,5 105 155 180
M16 x 1,5 200 295 350 M16 x 1,5 160 235 280
M 18 x 1,5 300 435 510 M 18 x 1,5 240 345 400
M 20 x 1,5 425 610 710 M 20 x 1,5 335 475 560
M 22 x 1,5 580 825 940 M 22 x 1,5 460 650 750
M 24 x 2 720 1030 1210 M 24 x 2 560 810 940
M 27 x 2 1030 1480 1750 M 27 x 2 820 1170 1390
M 30 x 2 1480 2110 2470 M 30 x 2 1170 1660 1930

000.024.06-en
 4.6-1

SPARE PARTS AND ACCESSORIES

PAY ATTENTION TO
"SAFETY MANUAL“

– Spare parts and accessories must comply

with SCHWING specifications and
requirements.

This can be ensured by using original spare

parts and accessories from SCHWING.

Beyond legal requirements, SCHWING 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.

004.290.00-en
 4.10-1

MAINTENANCE SCHEDULE:

Symbols used in the maintenance schedule:

n = CHECK o = GREASE p = CLEAN q = REPLACE

c d e f = as above, but after first commissioning

Time intervals in the following maintenance schedule:

A = daily or after 10 operating hours Important:

B = weekly or after 50 operating hours
C = monthly or after 200 operating hours
D = every 3 months or after 500 operating hours
E = every 6 months or after 1000 operating hours
F = yearly or after 2000 operating hours
G = every 2 years
whichever occurs first
The VECTOR control system records the
operating hours performed by the different
units.
For boom, slewing gear and stabilizers, the
system records the hours of movement.
Operating and movement hours performed are
displayed in the "Operation data" menu.
Regular checking of these data permits to carry
out servicing work exactly when required after
the corresponding intervals of use of the
individual units have elapsed.

003.980.02-en
 4.10-2

003.980.02-en
 4.10-3
MAINTENANCE SCHEDULE: KVM 34X / 37X

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

GENERAL (A): 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 n 4.65
A3 Check hydraulic oil level check (before each commissioning) n 4.20
A4 Change hydraulic oil (oil change every 2 years after oil analysis possible) q q 4.20
A5 Drain off condensed water from hydraulic oil reservoir p 4.20
A6 Clean hydraulic oil cooler fins and engine radiator fins p 4.22
A7 Check operating pressures n 4.21
A8 Grease control lever articulations o --
A9 Check hydraulic and water systems, units, reservoirs, pumping line, etc. for leaks c n 4.44
A10 Check fastening of base frames, outriggers, pumping line, reservoirs, units, pump unit, cardan shafts, etc. c n 4.42
A11 Check filling level of water reservoir n --
A12 Check + grease articulated shafts of pump drive (normal operating conditions) n o 4.30
A13 Check + grease articulated shafts of pump drive (severe operating conditions) n o 100* 4.30
A14 Check oil level of pump transfer or switchable divider gearbox (if provided) n 4.35
A15 Change gearbox oil f q 4.35
A16 Replace breather filter of the hydraulic oil reservoir (if provided) q 4.20

PLACING BOOM (V): A B C D E F G CH.

V1 Replace hydraulic oil pressure filter after a fault message and, at the latest, together with item B3 q 4.20
V2 Inject grease into nipples at boom and outriggers o --
V3 Check fastening and condition of end hose n --
V4 Grease roller bearings of slewing ring o 100* 4.51
V5 Check oil level of slewing gear n 4.36
V6 Replace slewing-gear oil f q 4.36
V7 Check slewing gear brake function n --
V8 Grease toothing of of slewing ring o 4.51
V9 Check fastening of drive pinion and slewing ring c n 4.51
* grease every 100 operating hours

003.271.06-en
 4.10-4

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

B1 Flush water box p 3.35

B2 Check water box for deposits and clean, if necessary p 3.35
B3 Replace hydraulic oil return-flow filter after a fault message, after 6 months at the latest, or after q 4.20
15,000 m3 of pumped concrete, whichever occurs first
B4 Check fastening of pumping pistons n 4.43
B5 Inject grease into nipple at Rock valve, slewing cylinder, agitator and feeding hopper o 4.40
B6 Check fastening screws of Rock valve pivoting body for tightness n 4.40
B7 Check screws on Rock valve cover for tightness n 4.40
B8 Check axial play of Rock valve pivoting shaft n 4.40
B9 Check sealing of Rock valve pivoting shaft for leaks n 4.40
B10 Check Rock valve cutting ring n 4.40
B11 Chech filling pressure of pressure accumulator (only with MPS) c c n 4.23
B12 Safety inspection of pressure accumulator (only with MPS) n 4.23

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

Z1 Check grease level and functioning of central lubricating system n 4.80

Z2 Clean suction filter of high-pressure cleaning system p 4.56
Rotational compressor:
Z3 Check oil level (before each commissioning) n 4.55
Z4 Change oil using ROTORÖL 8000 F2 f q 4.55
Z5 Replace oil filter f q 4.55
Z6 Replace oil return-flow valves f q 4.55
Z7 Clean / replace air intake filter p q 4.55
Z8 Clean oil cooler p 4.55
Z9 Replace oil separator cartridge q 4.55

003.271.06-en
 4.10-5

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

003.271.06-en
 4.11

.....................................................................................................................................................................................................................................

MAINTENANCE REPORT

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

001.915.00 en
 4.20-1

HYDRAULIC FLUID AND FILTERS

PAY ATTENTION TO
"SAFETY MANUAL“

CHECKING THE RESERVOIR LEVEL

The reservoir is equipped with an inspection

glass 1 (Fig. 1).

The fluid level must lie between the marks of

the top inspection glass when the following
conditions are met:

– machine at operating temperature,

– drive stationary for at least 10 minutes,

– machine in horizontal position ready for driv-

ing.
Fig. 1
If necessary, top up fluid through the top
cleaning cover 3 (Fig. 2).

Work only in absolutely clean conditions.

For topping up we recommend to use our

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

Ask for supplementary information.

Do not fill reservoir above the upper mark.

Use only the same sort of fluid.

Fig. 2

003.942.00-en
 4.20-2

LONGER INTERVALS BETWEEN HYDRAU-

LIC OIL CHANGES

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

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

The water content can be checked by filling a

sample into a test tube.

TEST CRITERION DIAGNOSIS REMEDIAL ACTION

COLOURING slight darkening without depo- none, normal state

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

003.942.00-en
 4.20-3

DRAINING OFF CONDENSED WATER

After prolonged downtimes (at least 1 day) any
condensed water in the hydraulic oil reservoir
must be drained off through drain valve at the
bottom of the reservoir.
– Unscrew cap 1 (Fig. 1) from the drain valve.
During each change of the hydraulic fluid clean
the walls and the bottom inside the reservoir.
ATTENTION: EXPLOSION HAZARD
Do not use unshielded light.

– Screw draining hose 2 onto the valve thread.
– The valve opens automatically.
When clean hydraulic fluid flows out of the
valve remove hose immediately and refit
the valve cap.
Clean the oil reservoir whenever necessary.
To do so:
– Clean the surroundings of cleaning cover 3
(Fig. 2) and take off cover.

Risk of unintentional draining.

– Check the fluid level.

CHANGING THE HYDRAULIC FLUID

– Bring the hydraulic system to operating tem-

perature.

– Prepare a recipient for used oil.

– Because of the large amount of oil, pump off Fig. 1

as much fluid as possible beforehand
through the upper cleaning opening.

For this purpose we recommend to use

our FLUSHING AND FILTERING UNITS.

– Drain off remaining oil through the drain

valve as described above.

– During each oil change clean the reservoir

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

CLEANING THE RESERVOIR

Hydraulic oil tends to precipitate (especially

after prolonged downtimes) dirt particles settling
on the bottom of the reservoir.

Fig. 2

003.942.00-en
 4.20-4

– Detach the suction hoses of the hydraulic
pumps from the reservoir and close the open
ends to prevent dirt from getting into the
pumps.
– Clean the inside of the reservoir with flushing
oil and lint-free cleaning rags.
PRESSURE FILTER OF THE BOOM
HYDRAULICS
The pressure filter 1 (Fig. 1) of the placing
boom hydraulics is an inline filter located beside
the control blocks.

Textile fibres and solvents are the enemy

of the hydraulic system. For this reason,
never use waste cotton, diesel oil, petrol,
etc. for cleaning.

RISK OF IRREPARABLE DAMAGE TO

THE PUMPS

– Wipe inside of the reservoir dry.

– Refit the cleaning cover.

REPLACING THE FILTER INSERTS

The machine is equipped with two hydraulic oil

filters:

Replace the filter inserts after a fault

message of the diagnosis system and after
each oil change. Fig. 1

To avoid false warnings, the filter monitoring

function is active only at oil temperatures above
30°.

Clean and check all individual parts. Pay

attention to abraded metal in the filters (sign of
damage).

Never clean, but always replace the filter

cartridges.

Never use the machine without filter

cartridges.

Used filter cartridges must be disposed of

as special waste.

003.942.00-en
 4.20-5

Removal:

– Slacken filter housing 3 (Fig. 1) with a ring

spanner at the lower hex end of the housing.

– Remove the filter housing, pour out oil and

clean.

– Withdraw the old filter insert 2 from the filter

head.

Fitting:

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

replace if necessary

– Stick the new filter cartridge 2 on the filter

head.
Fig. 1
Do not remove the bandage around the
filter cartridge.

– Install the filter head and tighten down to the

stop.

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

using a ring spanner applied at the lower hex
end of the housing.

REPLACING THE CARTRIDGE OF THE

PARTIAL FLOW FILTER

The partial flow filter (microfilter) is part of the

oil cooler circuit. A separate pump constantly
recirculates the hydraulic oil when the pump
drive is activated.

Cooler, filter and fan (Fig. 2) form a compact Fig. 2

unit.

003.942.00-en
 4.20-6

– Loosen the four retaining screws of the filter

head. Remove the screws and the washers.

– Lever up the filter head a bit by applying a

large screwdriver on the surfaces provided
for this purpose.

– Draw the filter head 1 (Fig. 1) out of the filter

chamber by turning at the same.

– Rinse the filter sieve and remove dirt with a

soft brush.

– Dry the filter sieve with compressed air and

check for damage.

– Lay the filter head with the sieve on a clean

surface.

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

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

– Check the filter chamber for depositis and

remove them, if any.

– Oil the upper and lower O-ring of the new

filter cartridge and insert the cartridge
carefully into the filter chamber.

Do not remove the paper strip round the

filter cartridge.

– Install the filter carefully.

– Insert the four retaining screws with their

washers and tighten them carefully cross-
wise.

ATTENTION - aluminium housing

Fig. 2

003.942.00-en
 4.20-7

FILLING THE OIL RESERVOIR

– Top up hydraulic fluid until the reservoir level

reaches the middle of the top inspection
glass.

ATTENTION

Hydraulic fluid expands at high tempera-

tures. For this reason, do not fill in cold fluid
beyond the above-stated limit.

Cleanliness is of utmost importance.

– Bring the hydraulic system to operating tem-

perature, check the fluid level and fill in
hydraulic oil if necessary.

Do not overfill the reservoir.

Fig. 1
REPLACING THE BREATHER FILTER

The breather filter 4 (Fig. 1) on the hydraulic oil

reservoir

– filters the air flowing into the reservoir when

the oil level descends, and

– prevents the ejection of oil fumes from the

reservoir.

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

but has to be replaced in accordance with the
maintenance schedule.

Fig. 2

003.942.00-en
 4.21-1

CHECKING THE PRESSURE SETTINGS

Combinations of A11V130 and A11V190 pumps

PAY ATTENTION TO
"SAFETY MANUAL“
All hydraulic consumers are protected by pres-
sure relief valves.
These valves are pre-set at the factory. Read-
justment is normally only necessary after re-
placement or repair of hydraulic units.
These settings should nevertheless be checked
at regular intervals in order to detect possible
faults in time. Check the settings when the
machine is at operating temperature and
running at service speed.
achieve different specific outputs (Fig. 1+2).
A11 pumps are equipped with a 'pressure
cutoff' function. This function swivels the pump
back before the max. operating pressure preset
at the pressure-limiting valve (DBV) is reached.
The pressure cutoff function prevents power
losses and oil heating occurring when hydraulic
oil is ejcted by the pressure-limiting valve.
The value indicated by the pressure gauge
must be approximately 20 bars below the
setting of pressure-limiting valve DB 1. See
circuit diagram.

The factory-adjusted pressures must not be

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

ATTENTION: RISK OF ACCIDENT

AND DAMAGE
Detach connections on the
hydraulic system only when the
engine is stationary and the
pressure accumulator (if the
machine is so equipped)
depressurized. This is also required Fig. 1
when test pressure gauges are
installed or removed. View from above: A 11 V0,
For pressure checking purposes, the nominal size 190 + 260
concrete pump hydraulics MUST be
set to 'Pumping'.
In the 'Suction' mode, the sealing ele-
ments of the concrete pump control
block may be squeezed out of their
seat.

CONCRETE PUMP SYSTEM

Fig. 2
From series 3 onwards, the KVM 34 X truck-
mounted concrete pumps are driven by A11
hydraulic pumps.

003.981.01-en
 4.21-2

The corresponding settings are performed at

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

Put the machine out of operation and inform the

after-sales service of the values recorded.

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

– Adjust the concrete pump to maximum de-

livery rate (number of strokes) and open
shut-off valve 11 (Fig. 2) of the concrete
pressure gauge 10.

– Switch on the concrete pump.

The pumping pistons move to their final

positions and stop.

The needle of concrete pump pressure

gauge must go up to the pressure cutoff set
value.

– After the pressure check, stop first the

concrete pump and then set the ballcocks
back to the operating position to prevent Fig. 1
uncontrolled starting of the concrete pump
after switching over of the ballcocks.

– Close the shut-off valve of the concrete

pump pressure gauge to protect it against
pressure peaks during operation.

Fig. 2

003.981.01-en
 4.21-3

PLACING BOOM - AUXILIARY UNITS PNEUMATIC PILOT CONTROL

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

HYDRAULIC PILOT CONTROL

When checking hydraulic pilot-control

pressures, always connect first a test
pressure gauge with a measuring range up
to 600 bars.

The 40-bar gauge might be irreparably

damaged by over-pressure.

"S1" valve

Valve "S1" of the concrete pump is pilot-

controlled from the hydraulic agitator circuit.

To ensure a sufficient pressure level even when

the agitator is stationary, a pre-pressurizing
valve is installed in the agitator control block.

Placing boom

The pilot pressure is available behind a

pressure-reducing valve at the pilot-control port
plate of the placing boom control block.

003.981.01-en
 4.22-1

COOLERS

In this case, observe the following rules:

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

HYDRAULIC OIL COOLER

The oil cooler and the oil filter are located in the
same housing.

Hydraulic oil is pumped in a separate circuit

through this cooler-filter combination by a
constant-displacement pump.

This system is active immediately after

activation of the drive unit and independent of
other functions.

Accumulated dust on the oil cooler ribs 2 (Fig.

1) reduces the cooling performance.

Cleaning the outside of the hydraulic oil cooler:

Dirt on the cooling ribs of the oil cooler 2 (Fig.

Fig. 1
1) reduces the cooling performance.

Clean the cooler cautiously using compressed

air. Direct the air flow parallel to the cooling ribs
and opposite the normal direction of internal
flow.

If heavily soiled, coolers can be cleaned with a

water-jet or a steam-jet appliance.

003.982.02-en
 4.22-2

ENGINE RADIATOR

Water-cooled engines are equipped with a

corresponding radiator.

Depending on type, the engine may be

additionally equipped with an engine oil cooler.

– Do not forget to clean the cooling ribs of

engine radiators from time to time when the
machine is used on dusty construction sites.

The engine may otherwise be damaged due

to overheating.

– The procedure to be adopted for the clean-

ing of radiators and coolers is described in
the respective truck or engine operating
instructions.

003.982.02-en
 4.23–1

PRESSURE ACCUMULATOR

PAY ATTENTION TO
"SAFETY MANUAL“

CHECKING THE GAS FILLING PRESSURE

OF THE DIAPHRAGM ACCUMULATOR

The gas filling pressure should preferably be
checked with the filling and testing device sup-
plied by the manufacturer. If no such device is
available, check the filling pressure as follows:
– Start the engine to fill the accumulator.
– Stop the engine.
The accumulator is depressurized auto-
matically (hydraulic fluid is discharged from
the accumulator).
– Observe pressure gauge 3 (Fig. 1) perma-
nently.
Never exceed the admissible filling pressure. If
the gauge pressure of the gas in the nitrogen
bottle exceeds the maximum accumulator pres-
sure, a reducer valve must be installed down-
stream.
To avoid damage to the accumulator dia-
phragm, the gas filling pressure must never
exceed 90 % of the minimum working pres-
sure.
The minimum working pressure is the lowest
pressure indicated by pressure gauge 3 (Fig. 1)
during Rock valve switching.

The pressure indicated by gauge 3 drops

slowly and then abruptly down to "0" as soon
as all the fluid has been discharged from the
accumulator.

The pressure value last indicated is the gas

filling pressure.

– If the filling pressure doen not correspond to

the rated value, the accumulator must be
refilled in accordance with the manufac-
turer's instructions.
Fig. 1
ATTENTION:
EXPLOSION HAZARD
Never use oxygen or air for re-
filling.

002.908.01-en
 4.23–2

WORK ON THE HYDRAULIC SYSTEM Defective components may only be replaced by

The relief valve of the accumulator safety block
opens automatically under certain operating
conditions - such as, for example, engine off -
and relieves the pressure accumulator.
For reasons of working safety, the following
additional safety measures must be taken
before carrying out any work on the machine
(such as, e.g., cleaning, connection of test
pressure gauges, repair, replacement of
wearing parts, etc.):
– The machine control unit must be switched
off.
original spare parts.
No changes may be made to any part of the
accumulator system. All users are urgently
warned against the hazards resulting from
inappropriate repairs.
No welding, soldering or mechnical work of any
kind must be carried out on the accumulator
body.
In the event of trouble with the automatic
discharging valve, the fluid under pressure can
be evacuated by opening the manual relief
valve 4.

– The engine must be shut off and the ignition
key withdrawn.
– The manual accumulator relief valve 4 (Fig.
1) must be opened.
Subsequent to any repair work on the accu-
mulator charging circuit, this circuit must be
thoroughly de-aerated.

The valve is located on the safety block (as

indicated by the arrow, Fig. 2) or (in case of
cast blocks) on top of the block.

– Read pressure gauge 3. The gauge must

indicate "0".

Disregarding these instructions MAY

CAUSE ACCIDENTS (e.g. by uncontrolled
switching of the Rock valve, hydraulic oil
ejected under pressure, etc.).
Fig. 1
PRESSURE-ACCUMULATOR SAFETY
INSPECTION

In accordance with the regulations in force in

the country were the machine is used, pressure
accumulators must be inspected at regular
intervals.

REPAIR OF ACCUMULATORS

Accumulators may only be repaired in accord-

ance with the manufacturer's instructions.

Fig. 2

002.908.01-en
 4.30-1
CARDAN SHAFTS IN THE PUMP DRIVE
PAY ATTENTION TO
"SAFETY MANUAL“
TRANSPORT AND STORAGE
Cardan shafts from Schwing are supplied as
ready-to-fit components of the pump drive.
They must be transported and stored in
horizontal position. During transport and
storage they must be protected from falling
apart.
Protect bright metallic parts such as flange
contact surfaces against corrosion and store
cardan shafts in dry rooms.
To maintain the shafts in the balanced state in
which they have left the factory avoid blows and
impacts on the shafts. Do not remove the
balancing weights.
ATTENTION:
RISK OF CRUSHING
Do not stick your hands into the
articulated joints when handling
cardan shafts.
FITTING
Before installing a cardan shaft, clean all flange
surfaces thoroughly of anti-corrosive agents,
dirt and grease.
The flange surfaces must be free from damage
to prevent 'setting' and wrong centering.
The claws of the inner driver fork 'A' (Fig. 1)
must lie in the same plane. The non-uniformity
of the rotary movement caused by the the first
joint is thus compensated by the second one.
003.753.01-en
Only in very rare cases are the flanges
arranged out of alignment with respect to each
other. The correct position is marked with two
opposite arrows 'B' on the cardan shaft.
If the shaft segments are joined incorrectly, the
second joint intensifies the non-uniform
movement of the first joint. The shaft runs
noisily and wears faster. This will lead to
vibrations and premature failure of the drive
components.
All cardan shafts are filled with grease. After
initial fitting, they must be regreased.
If the cardan shaft is to be painted, the greasing
nipples and the toothing of the length
compensation telescope 'D' must be protected
against paint.
Check the flanges of the units connected for
perfect technical condition and perfect
fastening. Pay special attention to proper
centering fit. Replace damaged flanges only
with original spare parts.
Tighten the flange bolts crosswise with a torque
wrench. The tightening torque values are set
out in chapter 4.5 of the operating instructions.
Do not turn the cardan shafts in their
articulations with fitting levers: The bearing
seals will be damaged and the greasing nipples
may be ripped off.
Use only O.E.M. screws and nuts with original
dimensions. See spare-parts list.
Fig. 1
 4.30-2
Do not use any MOS2 additives for screws and
nuts.
Do not re-use bolts and nuts once fitted.
After installing a cardan shaft, check the bolted
joints concerned after 50 operating hours for
proper and tight fitting.
GENERAL SERVICING INSTRUCTIONS
Trouble-free and safe operation of cardan
shafts requires checking and lubricating work.
Before greasing, the articulated joint bearings
'C' and the length compensation telescope
section 'D' must be checked for play. If the
bearings have significant play, the cardan shaft
must be replaced.
Pay attention to abnormal running noise and
vibrations when the machine is in operation.
Locate the cause and rectify.
A timely reaction to first signs of wear
contributes to keeping the machine in good
operating condition and to reducing and
avoiding downtimes and consequential
damage.
GREASING
For regreasing of the cardan shafts, use
only SCHWING cardan shaft grease, ID. no.:
10197297.
Regreasing with other greases should generally
be avoided.
Clean the high-pressure cleaning nipples before
regreasing.
The maximum admissible greasing pressure is
15 bars. Avoid excessive pressures to prevent
the seals from being damaged.
If a joint has greasing nipples on opposite
sides, greasing of one nipple is sufficient. The
central greasing nipple in the trunnion
distributes the grease to the four bearings of the
articulated joint.
003.753.01-en
Continue to press grease into the joint nipples
until fresh grease emerges from all sealing lips.
Together with the old grease, dirt is being
squeezed out of the bearings, too. If it is not
possible to press grease through all of the bear-
ings, the shaft must be removed.
There is no risk of 'overgreasing' the shafts.
Wipe off any grease in excess.
The length compensation telescope section of
the cardan shafts is generally rilsan-coated and
thus maintenance-free. A greasing nipple in this
section, if any, must be greased with only small
amounts of grease since part of the grease
accumulates inside the shaft.
If cardan shafts are cleaned with water under
pressure or with a steam-jet appliance, they
must be regreased after each cleaning. In no
case must cardan shafts be cleaned with che-
mical detergents. Detergents can attack the
seals of the articulated joints.
Regreasing intervals:
The regreasing intervals are only
determined by the actually prevailing
operating conditons.
The intervals specified in the maintenance
plan are APPROXIMATE intervals. Under
certain circumstances, the intervals may
also be shorter.
A regular visual inspection of the universal
joints is due after 50 operating hours at the
latest. During this inspection, the joint clear-
ance must be checked as well.
Fig. 1
 4.35-1

PUMP GEAR

N.B.:
PAY ATTENTION TO
"SAFETY MANUAL“
We recommend to check an oil sample for
colouring and solid particles at each oil change
in order to be able to take the suitable
POWER DIVIDER preventive maintenance measures.

CHECK OIL LEVEL

- Place the machine in horizontal position.

- Unscrew the control screw 1 (Fig. 1).

- If necessary top up with oil via the oil filler

and vent screw 2 (Fig. 2) until it overflows at
"1".

- Wash the screw 2 out in benzine and blow it

out with compressed air. Fig. 1

CHANGE OIL

- Unscrew the drain plug 3 (Fig. 2) screw in

after discharge.

- Top up with oil as described above.

SWITCHABLE DIVIDER GEAR BOX

(Fig. 3)
Fig. 2
- Checks and oil change as described above.

to Fig. 3

1 Filler and vent screw

2 Control screw

3 Drain plug

Fig. 3

001.795.02-en
 4.36-1

SLEWING GEAR DRIVE

PAY ATTENTION TO
"SAFETY MANUAL“

CHECK THE OIL LEVEL

- Place the machine in horizontal position.

- Remove the control plug 4 (Fig. 1).

- Remove the covering hood above pinion as

well as the filler and vent plug 5.

- SLOWLY top up with oil through the opening

at pos. 5 until the oil level is visible approx. 1
- 2 cm below the pipe edge at pos. 4. Fig. 1

- Wash the filler and vent plug 5 out in

petroleum ether and mount the positions 4
and 5.

- Slew the placing boom several times and

repeat the check.

CHANGE THE OIL

If possible change oil only with gear at

working temperature.

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

the control plug 4 (Fig. 1).

- Unscrew one of the drain plugs 6 (Fig. 1) and

after completed draining screw it in again. At
low ambient temperatures rinse the gear with
a certain amount of new oil to flush dirt and
abrasion off.

- Pour gear oil in as described above.

000.499.02-en
 4.36-2

CHECK THE SLEWING GEAR BRAKE

The set of multiple disks which is pressed

against the slewing gear at rest is hydraulically
lifted at the beginning of the slewing motion
resp. bled automatically at the end of the
slewing.

The multiple-disk brake only serves for

holding the boom.

Braking is effected by means of the

installed braking valves.

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

drop of the pressure admission to prevent a
sudden braking.

Pressure increase and decrease can be

checked at the gauge 3 (Fig. 1).

The throttle is adjusted at our works

and must not be readjusted except by the
SCHWING aftersales service.

CHECK THE DRIVE PINION

Unscrew the loose pinion fastening screws 1 Fig. 2

(Fig. 2), clean them and put them in again
using Loctite 243.

Tighten the screws with the torque as per table

on page 4.5.

000.499.02-en
 4.40-1

ROCK VALVE

Grease all nipples of the station every day. For

PAY ATTENTION TO continuous operation, grease more often, i.e.
"SAFETY MANUAL“ after 8 hours at the latest:

– Clean the greasing station.

ATTENTION:
LIFE-THREATING RISK – Withdraw the protective caps from the
To prevent inadvertent working move- nipples.
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
polluting the environment.
– depressurize the pressure
accumulator (if the machine is so – Refit the proctective caps.
equipped)
before undertaking any work on the
Rock valve. Greasing station „X“ of truck-mounted concrete
pumps:

GREASING THE BEARINGS

Concrete pumps without central greasing

system 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

connected with the bearings of the Rock valve.

Greasing points:

– rocking shaft Fig. 1

– rocking cylinder Greasing station „X“ of portable concrete

pumps:
– agitator

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

Fig. 2

001.193.10-en
 4.40-2

CHECKING THE SCREWED CONNECTIONS

FOR TIGHTNESS

– Check the cover retaining screws 14 (Fig. 1)

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

If needed, retighten the screws with a torque

wrench as specified in the table of chapter
4.5.

CHECKING THE PIVOT SHAFT FOR AXIAL

PLAY

There must be no air gap between bearing

bush 4 (Fig. 2), arrestor disk 2 and adjusting nut Fig. 1
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. 3).

Fig. 2

Fig. 3

001.193.10-en
 4.40-3

Metal contact between Rock 5 and housing

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

– kidney seal defective

– adjusting nut 1 too tight

– cutting ring jamming

– too much grease used for fitting or parts not

properly cleaned.

ADJUSTING THE AXIAL PLAY OF THE PIVOT

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

– Set spacing "B" = 1.5 bis 3 mm with

adjusting 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
partial zones, the cutting ring and wearing layer
of the housing lining are subject to non-uniform
wear and tear (zone "C", Fig. 3).

Fig. 3

001.193.10-en
 4.40-4

Scores are mainly caused by friction and the

breaking of stones.

They are of no importance unless the

wearing insert is completely worn.

The wearing insert used in series machines is a

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

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

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

To achieve uniform wear and therefore a much

longer service life of the parts, the following
measures are recommended: Fig. 1

– After thorough cleaning, move the Rock to

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

Check the cutting ring all around its

circumference.

– If a gap is visible between cutting ring 10

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

TURNING THE CUTTING RING

For turning of the cutting ring, proceed as Fig. 2

follows:

– Detach the pumping line from the Rock valve

outlet.

To do so,

– remove the reducer pipe in trailer concrete

pumps,

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

in truck-mounted concrete pumps,

– swing boom connection piece 4 aside.

Fig. 3

001.193.10-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
uniformly by abt. 2 to 3 turns to relax the
compression spring of the cutting ring.
Do not turn out the screws completely.
Tightening torque see chapter 4.5.
– Coarse-adjust the axial play of the pivot shaft
so that the Rock valve can be switched to
allow the parts to "settle" in place.

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

– Detach the cutting ring if necessary by

tapping slightly on it.

– Turn the cutting ring by 90°.

Always turn in the same direction.

– Make sure the cutting ring is safely guided

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

– Pay attention that no stones are getting

caught between the individual components
when tightening the cover screws.

– Tighten the cover screws 14 uniformly and

carefully.

Make sure the cutting ring slides into the

Rock without jamming.

Fig. 1

001.193.10-en
 4.40-6

– Check the spacing between cutting ring 10

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

If the spacing exceeds 8 mm, the cutting ring

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

– When replacing the cutting ring, check

wearing insert 9 and compression spring
11 for condition.

CHECKING THE PIVOT SHAFT SEALING

The bearings of the pivot shaft are sealed off

against the pumped substance by means of O- Fig. 1
rings (Fig. 3).

In the event of leaks (concrete fines are

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

For replacing the rings, the pivot shaft must be

removed. See:

ROCK VALVE REPAIR INSTRUCTIONS

PROLONGED DOWNTIMES Fig. 2

If the Rock valve is not used during prolonged

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

This agent prevents "sticking" of the seal.

Do not use sprays. Sprays attack rubber

parts.

Fig. 3

001.193.10-en
 4.40-7

CHECKING THE WEAR OF THE ROCK

VALVE

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

positions.

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
reproduced parts.
SCHWING assumes no liability
whatsoever for damage caused by
unqualified repair attempts and the use of
reproduced parts.

001.193.10-en
 4.42-1

PAY ATTENTION TO
"SAFETY MANUAL“

PUMPING AND DIFFERENTIAL CYLINDERS

Check the fastening screws of the differential

and pumping cylinders for tight fit.

Tighten loose fastening screws crosswise in

three steps with a torque wrench (Fig. 1).

Tightening torque according to table in chapter

4.5.

PUMPING PISTON REPLACEMENT

The machine is equipped with a special control

for replacement of the pumping pistons.

– Set switch 3 (Fig. 2) to the

pumping piston replacement po- Fig. 1
sition.

Important:
The control system monitors the positions of
the EMERGENCY SHUT-OFF buttons and of
the switches of the active control.
A corresponding message is indicated on the
display 1 (Fig. 2). See chapter 1.8.

This symbol flashes on the display

when the system is ready for oper-
ation.
Fig. 2

Start of the control system with

switch 4 (Fig. 2).

Starting is confirmed by a brief

acoustic signal and this symbol is
indicated on the display.

003.899.02-en
 4.42-2

The activation of the PISTON REPLACEMENT CHECKING THE FASTENING OF THE

mode automatically reduces the speed of the
diesel engine.
The control of the concrete pump and of the
diesel engine is handed over to the control box
of the special control unit (Fig. 1).
PUMPING PISTONS
– Take off the water-box covers and remove
the protective grids.
– Move the adapter piece into the water-box.

Switches 1+2 are used to control the following – Drain off water.
functions:
– Check the pumping piston fastening screws
1 – Engine on / off for tightness (Fig. 2).

2 – Pumping piston operation forwards / re- – Move the second adapter piece into the
verse in the inching mode*. water-box and repeat the check.

* after actuation of switch 2 the pumping

pistons start in the selected direction and
stop when the switch is released.

When an emergency shut-off button is de-

pressed while the special control is active, the
control unit must be started again. See chapter
1.8.

ATTENTION:
RISK OF CRUSHING
Before working in the water-box
always shut off the drive engine Fig. 1
and depressurize the pressure ac-
cumulators to prevent inadvertent
movements of the concrete pump.
Keep at a safe distance when oper-
ating the concrete pump with the
water-box open.
Do not stick your hands into the
water-box.
During work on the pumping pistons
no other working activities must be
carried out on the concrete pump.
Make sure nobody is standing close to
the pipe-switching system. The Rock
valve can switch over.
Fig. 2
In case of danger, depress the
emergency shut-off button.

003.899.02-en
 4.42-3

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.

If sand gets into the water-box in spite of

new pistons having been installed, the cyl-
inders must also be replaced.

ATTENTION:
RISK OF INJURY
Depending on size, a pumping piston
may have a weight of more than Fig. 1
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.

REMOVAL

– Close shut-off valve 1 (Fig. 1) on the

concrete pump control block.
Fig. 2
The notch in the valve head must point in a
direction perpendicular to the direction of
flow.

Closing the ball valve prevents switching of

the piston rods in the limit-stop positions.

– Move piston to a position short before the

rear limit stop. The adapter piece (Fig. 2)
must be fully visible in the water-box.

003.899.02-en
 4.42-4

– Loosen fastening screws of the adapter

piece and remove screws completely.

When doing so, hold the adapter piece at the

hexagonal centre shaft with a spanner
(Fig. 1).

– Move the piston rod to the rear limit stop.

– Withdraw the adapter piece (Fig. 2).

– Moving the piston rod slowly towards the

pumping piston. Fig. 2

– Connect piston-rod flange 1 with pumping-

piston flange 2 as shown in Fig. 3, using an
bolt and an nut.

Tighten the bolt by hand.

– Retract piston rod slowly and draw piston out

of the cylinder (Fig. 4).

– Loosen bolted connection.

– Take pumping piston out of the water-box.

– Clean and check all parts. Fig. 3

Fig. 1 Fig. 4

003.899.02-en
 4.42-5

REFITTING

– Smear a thick layer of grease on the new

piston and the cylinder walls.

– Fasten the new piston with bolt and nut to

the piston-rod flange.

– Move the pumping piston into the cylinder so

that the screwed connection is still access-
ible (Fig. 1).

– Remove bolt and nut.

Fig. 1
– Retract the piston rod.

– Insert adapter piece and screw onto the

pumping piston (Fig. 2).

– Move piston rod towards the adapter piece.

– Align adapter piece, if necessary, and screw

onto the piston rod.

– Fill water into the water-box and refit pro-

tective grid and cover.
Fig. 2
– Open shut-off valve 1 (Fig. 3) at the concrete
pump control block.

The notch in the valve head must point in the

direction of flow.

Fig. 3

003.899.02-en
 4.44-1

DELIVERY LINE AT PLACING BOOM

PAY ATTENTION TO
"SAFETY MANUAL“

During operation of the pump, the machine
operator must permanently check the delivery
line for leaks (water leaking out of the line).
Leaks will cause plugs in the line due to
"bleeding" of the concrete. Stop working
immediately and repair the leak.
The minimum admissible wall thickness
depends on the maximum concrete pressure
delivered by the pump.
Replace pipes and elbows as soon as they fall
below the minimum wall thickness.

ATTENTION: RISK OF ACCIDENT!

Leaks in pipe couplings may be due
to defective seals.

If water leaks out of pipe walls and

bends, however, there is a high risk
of accident caused by pipe break.

Stop working immediately and

depressurize the pumping line by
sucking the concrete back to the
pump (reverse pumping). Fig. 1

- Check that delivery lines are suitable for the

application, using a wall-thickness meter
(Fig.1).

A daily check may be necessary under

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.

SCHWING supplies a suitable ultrasound

measuring instrument. Please ask for more
information.

002.514.05-en
 4.44-2

DIAGRAMS

for determining the minimum wall thickness 3) Pipe 108x4

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

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

80
60
40 220
20 200
0 180
160
0 1 2 3 140
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)

002.514.05-en
 4.44-3

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

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

(
80 80
60 60
40 40
20 20
0 0
0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
(X) (X)

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

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

90
(

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

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

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

80 80
60 60
40 40
20 20
0 0
0 1 2 3 4 5 0 1 2 3 4 5 6
(X) (X)

002.514.05-en
 4.44-4

MAIN AREAS OF WEAR

(to be given priority in checking)

Delivery pipes

Viewed in the direction of concrete flow, the

main area of wear is located ca. 100 mm after
the flange (Fig. 1).

Pipe bends
Fig. 1
Viewed in the direction of concrete flow, the
main area of wear is located in the "inflow"
bend (Fig. 2).

Super 2000/3000

Super 2000/3000 material must be replaced at

the latest when the inner hardfacing layer is
partly worn down to the outer layer (Fig. 3).
Fig. 2
Important note:
Super 3000 pumping lines and pipe bends of
the first series must only be installed in the
sense of pumping. For this purpose, the
material is marked with direction arrows.
Although these parts run out in 2001 they
may still be on stock. Therefore, pay attention
to any direction markings on the pipes when
replacing these elements.

Prolonged lifetime

(not applicable to Super 3000 series 1, see Fig. 3

above.)

The liftetime of pipes and bends can be

prolonged if the position of the parts is changed
regularly.

– after detaching the fasteners, turn delivery

pipes by 180°;

– dismantle complete pipe bends and turn by

180°, i.e. fit the "inflow" bend at the "outflow"
side and vice versa (Fig. 4).

Fig. 4

002.514.05-en
 4.44-5

REPLACEMENT OF PUMPING PIPES AND

PIPE BENDS

– Pay attention to the quality and correct Important note:

dimensions of the spare parts.
Only original SCHWING parts are exactly
identical to the factory-installed components.
Specify the required length when ordering
precision pipes. See spare-parts list.
– During initial assembly at the factory, the
boom pumping line is fitted stress-free with
the placing boom in folded condition.
Incorrect fitting may put increased strain on
the placing boom kinematics and cause
damage such as broken pipe holders.
During assembly at the factory, the location of
the points of articulation of the pumping line
is determined by means of special devices.
If you intend to replace several parts of the
pumping line, always replace them one by
one and one after the other.
Do not dismantle the complete pumping line.
In this case, the location of the points of
articulation would have to be determined
once again during fitting of the new line.
Such work should only be carried out by
specially trained personnel and with the help
of special devices.

To avoid damage, make sure the boom is

folded when replacing any parts.

ATTENTION: RISK OF ACCIDENT!

Pumping lines and pipe bends may
be very heavy.
A 3 m-long piece of pumping line
DN 125 (Super 2000) weighs as
much as 45 kgs.
Support pipes and bends with
lifting tackle before dismantling
them.

– Use new seals and safety cotter pins for the

couplings.

– Clean and check the couplings carefully and

grease them.

– Grease the couplings and seals with a

lubricant compatible with rubber, as, for
instance, 'Optimol Olit CLS'.

'Optimol Olit CLS' is a water-resistant

heavy-duty grease on a lithium / calcium
base.

002.514.05-en
 4.51-1

BOOM COLUMN - LIVE RING BEARING

PAY ATTENTION TO During the check the screw joint must not be
"SAFETY MANUAL“ subjected to external forces (put the placing
boom on a rest).

This is the case, for instance, when the boom

GREASE THE ROLLER SLEWING JOINT sections are in vertical position.

The grease nipples of the roller slewing joint
are located on the outside of the boom column
(Fig. 1).
They are connected to the bearing with
greasing lines.
Tightening torque see chapter 4.5.
We recommend to have the slewing rim
screws replaced by the SCHWING after
sales service every 3 years.

It is important to slew the placing boom several

times after each lubrication and then to repeat
the lubrication.

GREASE TOOTHING OF SLEWING JOINT

After the removal of the covering hood above

the pinion (Fig. 2) the toothing of the slewing
rim is accessible.

For careful maintenance, however, dismantling

of the complete toothing lining is
recommended.

Prior to the application of the lubricating agent

the toothing must be thoroughly cleaned with a
thinning agent - especially at the tooth base.

Fig. 1
CHECK TIGHTENING OF THE LIVE RING

DO NOT tighten loose slewing rim screws but

replace them together with washers and nuts.

In addition, the next two screw joints on the left

and on the right side of the loose screw must
be replaced.

Fig. 2

000.991.05-en
 4.55-1

ROTARY COMPRESSOR

PAY ATTENTION TO
"SAFETY MANUAL“

SERVICING KITS Read the instructions before undertaking

SCHWING supplies two different kits with the
material required for servicing of your
compressor:
any work on the compressor.
Do not use flammable substances and open
fire when performing cleaning and servicing
work.

– Servicing kit 1 (standard maintenance)

Id. no.: 10197336 CHECKING THE OIL LEVEL

This kit includes all filters, sealing elements, – Check the oil level when the drive unit is
and a recipient with compressor oil for the stationary and the compressor
servicing work described below. depressurized (pressure gauge at "O").

The oil quantity is sufficient for one oil change – Put the machine in horizontal position.
and for topping up between oil changes.
– The oil level is checked at inspection glass 4
(fig. 1).
– Servicing kit 2 (oil separator cartridge)
Id no.: 10170388 The oil level must lie above the upper edge of
the inspection glass.
This kit includes an oil separator cartridge and
all sealing elements required for replacing of
the cartridge. Important:
When the compressor is running, the oil level
should be visible in the middle of the
To ensure safe and troublefree inspection glass.
operation of the compressor, use
only the above specified material.
SCHWING cannot be held
responsible for damage caused by
inappropriate servicing and / or by
the use of unsuitable material.

Fig. 1

002.940.01-en
 4.55-2

ATTENTION – RISK OF BURNS Important:

The compressor may be very New compressors are filled with a so-called
hot. run-in oil. At the first oil change, this oil must
be replaced by a special compressor oil
recommended by the compressor
TOPPING UP OIL manufacturer.
For the safe and reliable operation of the
– Top up oil when the drive unit is stationary compressor, the right sort of oil is of decisive
and the compressor depressurized (gauge at importance.
"O").
Use only ROTORÖL 8000 F2 included in the
servicing kit.
– Unscrew the filling plug 1 (fig. 1) cautiously
to relieve the pressure. ROTORÖL 8000 F2 is a synthetic four-sea-
son oil for ambient temperatures between -25
Make sure that no oil foam spills out of opening and 40°C.
5.
This oil must under no circumstances be
mixed with other oils.
If necessary, wait a few minutes until the oil
foam has dissipated.

For topping up, use only the same oil as the the
one already in the compressor.

It is forbidden to mix different compressor

oils.

– Top up oil until it emerges from opening 5.

– Replace gasket 3, and screw filling plug 1

back in place.

CHANGING THE OIL

Fig. 1
For perfect emptying, drain off the oil at
operating temperature.

– Unscrew at first filling plug 1 as described

above.

– Open drain valve 2.

– Close the drain valve after complete

draining.

– Fill in new oil as described above.

– Allow the compressor to run for a few

minutes and check for leaks and correct oil
level. If necessary, top up oil.

002.940.01-en
 4.55-3

CLEANING / REPLACING THE AIR INTAKE

FILTER

– Slacken knurled nut 1 (fig. 1).

– Remove sealing ring 2 and filter cap 3.

– Pull out filter cartridge 4.

– Blow all parts clean with compressed air (5

bars max.).

Clean filter cartridge from the inside with

compressed air moving the nozzle up and down
until all dust has been ejected from the
cartridge. Fig. 1

– Replace the filter cartridge after several

cleaning cycles in acc. with the servicing
plan (page 4.10-4).

– Re-assemble the filter in reverse order.

CLEANING THE OIL COOLER

– Clean the oil cooler fins using a

compressed-air gun (fig. 2).

Soiling of the cooler leads to strong oil

overheating and to over-temperature shut-
down. Fig.2

Overheated oil ages faster and loses its

lubricating properties. This results in higher
wear of the compressor.

– Clean the cooler by blowing compressed-air

through the cooling fins from the side where
the cooling air normally leaves the cooler.

REPLACING COMPRESSED-AIR HOSES

Compressed-air hoses must be replaced after 3

years at the latest. The date of manufacture is
stamped into the hoses.

002.940.01-en
 4.55-4

REPLACING THE OIL FILTER

– Drain off used oil as described above.

– Slacken the screws 1 of filter cover 2 (fig. 1).

– Turn the cover through 90° and withdraw the

cover together with the filter.

– Detach filter 3 from the cover.

– Clean the cover and the contact surfaces at

the housing.

ATTENTION – RISK OF EXPLOSION

AND DAMAGE! Fig. 1
Do not use flammable detergents.
Make sure that no traces of the
detergent get into the compressor.

– Attach a new filter to the cover.

– Refit the cover with a new sealing ring 4.

– Fill in compressor oil as described above.

REPLACING THE OIL RETURN-FLOW

VALVES
Fig. 2
– Slacken the hollow screws 1 (fig. 2).

Pay attention to the sealing rings 3.

– Screw the return-flow valves 4 out of the

separator housing.

– Refit new valves with new 0-rings 5.

– Refit the threaded unions 2 using new seal-

ing rings 3.

002.940.01-en
 4.55-5

REPLACING THE OIL SEPARATOR

CARTRIDGE

Dismantling: Make sure

– Detach the connector from solenoid valve 1 – that separator cover 8 is fitted in the
at the separator housing 2 (fig. 1) and position shown (arrow);
remove air hose 3.
and
– Remove the oil return-flow valves 4 as
described above. – that connecting tube 7 is fitted in
accordance with its marking.
– Detach compressed-air tube 5 from the
separator housing.

– Slacken special nut 6.

Pay attention to the assembly marking on

connecting tube 7.

Mark the positions if necessary.

The connecting tube must be refitted later

on in exactly the same position.

– Detach the connecting tube and lift separator

housing 2 off the oil chamber.

– Pull connecting tube 7 out of the separator

housing.

– Lever cover 8 together with separator Fig. 1

cartridge 12 cautiously out of the housing.

– Unscrew nut 9 and remove sealing ring 10

and cover 11.

– Remove the old oil separator cartridge 12

together with the O-rings 13.

Assembly:

– Re-assemble the parts in reverse order.

– Always use a new oil separator cartridge

and new seals 10, 13, 14, 15 and 16.

– Press the O-rings 13 with a small amount of

grease into the respective recesses of the oil
separator cartridge.

002.940.01-en
 4.56-1

HIGH-PRESSURE CLEANING SYSTEM

PAY ATTENTION TO
"SAFETY MANUAL“

CLEANING THE SUCTION FILTER

Check the suction filter before each use of the

system and clean, if necessary.

Fix the cleaning intervals in accordance with the

operating conditions.

– Close the passage to the water tank by

setting ball-cock 6 to the other position.

– Unscrew the filter 4 by hand.

– Remove the filter insert 2 (Fig. 2) out of the

filter housing and rinse insert and housing
under running water. Fig. 1

Do not use detergents, brushes, etc.

– Replace strongly soiled or damaged inserts.

Do not operate the high-pressure pump
without the filter insert.

– Check the O-rings 1+3 at the filter head and

the filter sieve and replace, if required.

For further information cf. separate Operating

Instructions in the annex.

Fig. 2

002.523.02-en
 4.60–1

ELECTRICAL SYSTEM

PAY ATTENTION TO
"SAFETY MANUAL“

ELECTRICAL PROTECTION

Depending on the type of machine, the

electrical control unit is equipped with protective
devices at different locations:

1. A main fuse in the battery box of the vehicle

2. Fuses near the fuse-box of the vehicle Fig. 1

(generally in the driver's cab).

3. Fuses in the switch cabinet of the machine

See also the circuit diagram in the Annex.

– Switch off the system.

– Open the switch cabinet cover

Fig. 1 = "MULTI-Control"

Fig. 2 = "COMFORT-Control"

Fig. 3 = „VECTOR-Control“ Fig. 2

– The assignment of the fuses is set out on

the plan on the inside of the switch
cabinet cover.

– Use only spare fuses of the same type

and rating as the original fuse.

– If the fuse burns out again, there must be

short-circuit. Have the electrical system
checked.

– Lock the switch cabinet.

Fig. 3

002.617.04-en
 4.60–2

WORKING ON ELECTRICAL / ELECTRONIC ELECTRIC WELDING

COMPONENTS
See chapter 4.70
ATTENTION:
DANGER JUMP-STARTING
Work on the electrical control unit
and the electronic modules may be Connect the jumper cable as described in the
carried out by qualified personnel vehicle or the engine operating instructions.
only.
Unqualified work is a risk to safety
and entails the forfeiture of the CARRYING OUT MECHANICAL WORK
operating permit and the CE
approval. Cover up the equipment, cables, etc. when
carrying out drilling , grinding or similar
operations on the machine.
– Prior to any work on electrical or electronic
components:
PAINTING AND WORK WITH AGGRESSIVE
disconnect first the negative (–) SUBSTANCES

and then the positive (+) terminal Cover up the equipment, cables, etc. to protect
them against spray dust and aggressive
from the drive engine's starter batteries. substances.

This measure is sufficient to avoid short-

circuits and to protect the SCHWING control STEAM-JET CLEANING
unit.
Never direct the spray nozzle of a steam-jet
Reconnect the cables by proceeding in cleaner directly at control panels, switch
reverse order. cabinets, cables etc.

Further measures may be required to protect Detergents under high pressure may penetrate
the electronic system of the vehicle (e.g. into these units and cause severe damage.
ABS anti-blocking system).

See also the vehicle manufacturer's

documentation.

– Have the power supply disconnected by a

qualified electrician if the machine is driven
by an electric motor.

– Ground the machine to ensure potential

bonding between the machine and the
ground.

002.617.04-en
 4.65-1

VISUAL INSPECTIONS AND FUNCTION

CHECKS

PAY ATTENTION TO
"SAFETY MANUAL“

Besides regular servicing, permanent
observation of the machine and the required
safety inspections are indispensable to ensure
the operational safety of the machine and the
safety at the place of work.
The qualifications required for specialists are
described in the SAFETY MANUAL.
On request, the inspection can be performed by
a specialist from SCHWING.

Persons in charge of these duties:

EXPERT

MACHINE OPERATOR An expert must be called in after essential

The machine operator is responsible for visual
inspections and function checks of 'his'
machine and its accessories before and during
the work.
The machine operator must stop the operations
if he detects deficiencies endangering the safe
working with the machine.
modifications and extensive repairs (for
instance when welding work has been carried
out on load-bearing parts of the machine).
The qualifications required for experts are
described in the SAFETY MANUAL.
ADDITIONAL INSPECTIONS

He is also responsible for the external aspect of For special safety-related units as, for instance,
'his' machine. He must therefore make sure that pressure accumulators, the relevant
defects in the paint coat of the machine are inspection regulations valid in the country of
repaired in due time. use must be observed.

Corrosion defects - especially at the placing If personnel with the required qualification is not
boom - may lead to cracking and fracturing! available, the inspection can be entrusted to the
After-Sales Service of SCHWING.
In his capacity as a driver, he is responsible
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.

001.162.04-en
 4.70-1

REPAIR WELDING

PAY ATTENTION TO
"SAFETY MANUAL“

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.

001.918.02-en
 4.80-1

CENTRAL LUBRICATING SYSTEM

Important information:
Foreign objects, such as dirt, snow and
PAY ATTENTION TO water, lead to malfunctions and must be pre-
"SAFETY MANUAL“ vented from getting into the system.
During all works on the system (filling, re-
placing parts, etc.) make sure that the work is
SCHWING machines can be equipped with a carried out in absolutely clean conditions.
central lubricating system as an option.

The electrically driven piston pump, the reser-
voir and the electronic control unit form a com-
plete system (Fig. 1).
This system ensures the lubrication of the
greasing points on the machine via greasing
distributors and greasing lines.
The optimum amounts and greasing intervals
are adjusted at the factory.
If you would like to have your lubricating system
adapted to special operating conditions, please
consult the SCHWING after-sales service who
will be pleased to do the reprogramming of the
system for you.
After activation of the "Concrete pump pump-
ing" function, the system starts up automatic-
ally.
After switching off this function, the greasing
cycle is interrupted and restarted when the
pump is switched on the next time.
FILLING THE SYSTEM
Check the grease filling level in the reservoir
every day.
The level must not fall below mark 2 (Fig. 1).
If necessary, top up grease using a high-
pressure grease pump and filling nipple 1.
– Clean the filling nipple and the nozzle of the
grease gun.
– Fill in clean grease. Dirty grease in the
system will cause malfunctions.
– Start an intermediate greasing cycle during
the filling procedure by depressing
pushbutton 3.
After depressing this pushbutton, the piston
pump will be switched on for a complete
greasing cycle (4 minutes).

This means that a greasing cycle always begins

with the "Residual greasing time" or the "Resi-
dual pause time".

Data stored in the system are protected even in

the event of a power failure.

With the grease prescribed for our machines,

the lubricating system can be operated down to
ca. -25 °C.

Fig. 1

002.078.04-en
 4.80-2
– Use a type of grease as indicated in our
lubricant recommendations (chapter 4.4):
(KP 2 K in acc. with DIN 51502 without solid
lubricant, NLGI class 2).
ATTENTION:
DO NOT MIX UP GREASE TYPES
Central lubricating systems for trucks
often use another type of grease.
If your truck is equipped with such a
system, do not mix up the greases.
If wrong grease has been filled in, the
whole system (also the lines and the
distributors) must be emptied.
If the system has been emptied, it must be
vented after refilling.
To do so, carry out intermediate greasing
cycles until grease emerges from all greasing
points.
This procedure is not recommended when
greasing lines have been replaced. In this case,
prefilled greasing lines must be used.
CHECKING THE SYSTEM
– Check the line system every day (visual
inspection) for leaks and apparent damage.
– Check the bearings connected to the system
every day (visual inspection).
– The bearings must always present distinct
traces of grease.
002.078.04-en
– If you find defects during this inspection,
have the system immediately repaired by the
SCHWING after-sales service to avoid
consequential damage caused by insufficient
greasing.
LUBRICATING POINTS NOT
CONNECTED TO THE CENTRAL
GREASING SYSTEM
The bearings of the pump drive
cardan shafts cannot be connected to
the central greasing system.
These lubricating points must there-
fore be greased "by hand" in accord-
ance with the servicing schedule.
Other lubricating points not connected
to the central greasing system at the
customer's request must also be
greased "by hand".
S 58SX
This type of machine is provided with a filling
nipple 1 (Fig. 1) on the outside of the machine
on the left viewed in the sense of driving.
– Have a second person check the filling level
of the reservoir when filling the system
through this nipple.
Fig. 1