Saudi Training

Components Truckmounted
Concrete Pumps
1 Saudi Arabia 2016

Components Truckmounted Concrete Pumps
Overview
Control cabinet
Boom
Oil cooler
Water tank
Base frame
Outrigger Oil tank
Hydraulic drive
Pumpkit
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Pumpkit- Single Circuit
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Pumpkit - Twin Circuit
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Single Circuit Twin Circuit
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Hydraulic tank till S36X
Return lines
 Ventilation filter
 Pressure compensation
Collective return lines
Forced ventilation
Drain valve Suction lines
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Hydraulic tank S39SX
Suction lines
Forced ventilation
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Slewing cylinder
Working line
Working line
Drain oil
Grease point
(on both sides)
Slewing cylinder storage point Center punch point

 Bearing for slewing cylinder
 better absorption of the forces
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Oil cooler 2012
 16 KW Power
 Check valve outside of
the oil cooler
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Oil cooler from 2013 on
 21,5 KW Power
 Check valve inside of
the oil cooler
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Oil cooler Hydraulic drive (Optional)
 31 KW Power
 Check valve inside
of the oil cooler

MPS- Accumulator/S3 combination
Manual relife valve
 test every 10
years
 Change over
slewing cylinder
 Pressure 120 Bar
TÜV-cartridge Check valve

operation principles MPS-Accumulator
Nitrogen
Nitrogen
High-
pressure
Emergency- Accumulator Accumulator

stop charging discharging
enabled

MPS-Accumulator
MPS-Speicher

Control block combination
E-stop
Aggitator
forwards/reverse alternative
Concrete pump
foreward/reverse
Shut-off valve
Pressure
Pressure gauge filter
Outrigger enablel
Outrigger control block Control block
boom

Outrigger control block
Outrigger enable

Control block S1,S2 ( BP-BPL )
to differential cyl. from
from
pump 2
pump 1
Soft switch
shutoff valve
to differential cyl.
Lever damping
on / off
S2
S1
DB2
DB1

Hydraulic drive

Hydraulic drive S36X in line connection (old version)
A11VO190
A11VO130
A11VO40
A4FO22
ZRP31+31
ZRP11

Hydraulic drive S36X new version from 2013 on
A11VO190
A11VO130
A11VO40
A4FO22
ZRP62
ZRP11

Hydraulic drive S36X old version
Aggitator pump
Cooling and filter pump
Boom pump
Charging pump
Pumpkit pump 2
Pumpkit pump 1

Hydraulic drive S36X new version from 2013 on
Agitator pump
Boom pump
Charging pump
Pumpkit pump 2
Pumpkit pump 1

Explanation of the drive names
Old Drive
A11VO190 A11= Type, VO=Variabel Open, 190=190 l/min at 1000 RPM

A11VO130 A11= Type, VO= Variabel Open, 130=130 l/min at 1000 RPM
A4FO22 A4= Type, FO=Fixed(constant pump) Open, 22=22 l/min at
1000 RPM
ZRP31 ZRP= Gearpump, 31= 31 l/min at 1000 RPM

Erläuterung der Antriebsbezeichnungen
New Drive
A11VO190 A11= Type, VO=Variabel Open, 190=190 l/min at 1000 RPM

A4FO22 A4= Type, FO=Fixed(constant pump) Open, 22=22 l/min at
1000 RPM

Hydraulic drive installed on gearbox

Hydraulic drive installed on gearbox (new version)

Hydraulic drive new version

Rockvalve

Rockvalve

Rockvalve
Rockvalve (1980 System Schwing)
 The ROCK-Valve (1980)
 minimal deflection of the concrete flow reduced wear

Rockvalve
Rockvalve (1980 System Schwing)

Rockvalve
Rockvalve (System Schwing)
 Rock Piston is free of forces
from the Strokes
 Pressure and forces inside the

Rockvalve generate a auxiliary
pressure of cutting ring in the
direction of the spectical
plate…

Rockvalve
Rockvalve Systems
 M-Rock-System  B-Rock-System
 Funnel dives into the  flat surfaces between the

housing hopper and rock housing
 Counter nut with tool  Counter nut with holes for
holder tool storage
 better suction characteristics

Rockvalve
B-Rock System with Diameter of 220 mm
 Pusher-Case  Rock-Valve
 Slewing
Cylinder
 Connections
conveying cylinder

Rockvalve
Rockvalve (System SCHWING)
Housing-lining /
Specticalplate
Big-Rock

Rockvalve
 Easy Consumable
Change during
removable cover
Rockvalve

Rockvalve
2-Point tying up the

Rock-Element
Kidneyseal
Scrapeplate
Rockvalve
Cutring and Rubberspring

Rockvalve
Sealing Rockvalve (System SCHWING)
 The Concretepressure get

a Force out of the
pressurespring.
 The Pressurespring will
be wider  a better
insulation between the
Kidneyseal and Cutring.
 As higher the delivery
pressure, as higher the
pressure of the cutting
ring.
The Sealing

Rockvalve
Wear Parts

Rockvalve
Construction Pumpkit

Rockvalve
Slewingcylinder (Synchronos-Hydraulic-cylinder)

Rockvalve
Hardfacing
 Hardfacing by
welding robot

Rockvalve
Regenerated Rock
 Medals were
welded by hand

Rockvalve
Rockvalve (System SCHWING) Wear pictures
Full Wear + Armouring inside and outside

breakthrough
By Wear the ROCK can be regenerate.

Rockvalve
Rockvalve (System SCHWING) Verschleißbilder
Full Wear +
breakthrough

Rockschieber
Kidneyseal
 Frequent switching
intervals with empty
hopper (missing
lubrication)
 seen in the image

on one side Burned
kidney seal due to
incorrectly used
(concrete residues)
Verscheißeinsatz

Super-X-outrigger

Super-X-outrigger
From the idea to the Machine ... …to 3D-Model

Super-X-outrigger
Steel-Leightweight
 The twist- and rigid frame,

designed to the from
SCHWING developed
anti-torsion Principle.
 Super-X-outriggers
Integrated.
 Base frame in the middle is
free it´s possible to mount a
long stroke pump kit

Super-X-outrigger
Outrigger integrated into the Baseframe

Super-X-outrigger
An arcuate extension allows barriers to Donnybrook

Super-X-outrigger
Cable drive
 Cable drive

Super-X-outrigger
Controlmodule right side
 Central
Lubrication
 Control Block
 Vector Control
 Waterpump

Super-X-outrigger
Baseframe
 Flat construction and
inside offset feed line
brings you a wide
open space for long
Accessory racks.

Super-X-outrigger
Baseframe by the Example S39 SX
 The Super-X-Outrigger allows the use of a Long stroke pumpkit less

strokes  less wear

Super-X-outrigger
Location of the MPS control the example S39 SX
 MPS control sideways mounted by good accessibility

 Water tank mounted centrally in the base frame,
resulting in better weight distribution

Super-X-outrigger
Location of the Conrete pump kit S 39 SX

Super-X-outrigger
Availability
 By Intelligent installation of
the boom conveying line
replacement of the deck
conveyor line is possible
without trouble and without
raising the boom package

Super-X-outrigger
Super-X-outrigger
Into the groundsite of the Supporting
cylinder mounted:
 The hydraulic piloted Check Valve.
Strong and light:
 Round-Pipe-Support legs takes
every side forces.
 The Support cylinder is save inside
integrated.
 Feetplate
 The sensitive cylinder rods are
protected from concrete and other
damages

Super-X-outrigger
Examples

Super-X-outrigger
Examples

Super-X-outrigger
Examples

Functioning
emergency stop valve

Functioning emergency stop valve
Explanation e-stop-valve: Normal operation
Vector
oiltank
Connection of charging pump
Connection of control block CP
Boom control block

Boompump

Explanation e-stop-valve: E-stop active
Vector
oiltank
Boom control block

Boompump

Explanation e-stop-valve: Key switch activated
Vector
oiltank
Boom control block

Boompump

Explanation e-stop-valve: Normal operation S1
Vector
oiltank
Connection of boom pump
Pilot pressure system

Explanation e-stop-valve: E-stop activated
Vector
oiltank
Pilot pressure system

Explanation e-stop-valve: Normal operation charging pump
Vector
Hydrauliktank
oiltank
Accumulator
Charging pump

Explanation e-stop-valve: E-stop active charging pump
Vector
oiltank
Accumulator
Charging pump

Vector control
Vector sides of the cabinet 2014
MMI
Select the workspace for
EASy / EASplus
Confirming the operation mode
Control buttons for display
Preset operating mode

View MMI operator panel
HOME = back to Homescreen
= one screen back
HELP = Help screen will be called
START = Function / process is started
QUIT = Fault will be confirmed
ENTER = Selection is confirmed
= one screen before
CLEAR = Return to Parent menu point

Control elements front side
Confirm the selection
Switch: Selection to the left

Selection operating mode local
Validation of the selections on

the remote control
Switch: Selection to the middle

Selection operating mode remote control
Confirm the selection
Switch: Selection to the right

Selection piston change mode
Key-Switch
Key-switch for shunting of the

emergency stop circuits of the control
with simultaneous activation of all
emergency stop valves and safe
shutoff of the electrical control.

Maintenance and service

Introduction
 The maintenance work described in this presentation are exemplary and are
not automatically apply to all machine types.
 A detailed description of the maintenance to be performed in the operating
instructions that it came with the machine.

Tightening torques:
 High-strength bolted connections must be biased with a specific torque.
 Tightening torques depend on bolt and nut type, threads (fine / coarse thread),
surface coating and lubrication.
 The values given in the tables below are indicative and include a safety factor
(0.9 x MA) to avoid over-stretching of the screw.
 If in the SCHWING maintenance and repair manuals or installation drawings are
no other values called these values are valid.
 Depending on the coating and lubrication resulting total friction values that are
important to determine the torques.

Tightening torques:
Surface Colour Overall coefficient
of friction
1 phosphated Black 0,14
2 gold-chromated Gold 0,14

3 Dacromet 500 Silver 0,10
4 such as 1 + 2 with a paste 0,10

e.g. copper paste or MOS
 Lubrication is carried the thread at head and nut bearing.

 The tables are valid only for the above bolts and nuts.
 Use is not possible when funds increase friction (screw locking).
 It may only be used regularly checked torque wrench.
 The maximum allowable tolerance for torque wrench is + / - 10% of the
tightening torque.

Tightening torques:
Regular thread (friction factor= 0,14) Regular thread(friction factor = 0,10)
size Tightening torquesMA (Nm) for Abmess- Tightening torquesMA (Nm) for
strength class ung 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
M 10 44 64 75 M 10 36 53 62
M 12 76 112 130 M 12 62 90 108
M 14 120 180 210 M 14 100 140 170
M 16 185 275 325 M 16 150 225 260
M 18 270 385 450 M 18 220 310 365
M 20 380 550 640 M 20 300 440 510
M 22 520 740 870 M 22 420 590 700
M 24 650 940 1095 M 24 530 750 880
M 27 990 1390 1620 M 27 780 1120 300
M 30 1300 1890 2200 M 30 1080 1530 1750
M 36 **2000 M 36 **2000
** For octagonal tube mast column

Tightening torques:
Fine thread ( Friction factor = 0,14) Fine thread( Friction factor = 0,10)
size Tightening torquesMA (Nm) for size Tightening torquesMA (Nm) for
strength class strength class
8.8 10.9 12.9 8.8 10.9 12.9
M 8x1 24 35 41 M 8x1 20 28 33
M 10x1 50 70 85 M 10x1 40 57 68
M 10x1,25 46 65 80 M 10x1,25 37 55 64
M 12x1,25 83 120 145 M 12x1,25 67 100 115
M 12x1,5 80 115 140 M 12x1,5 65 95 110
M 14x1,5 130 190 230 M 14x1,5 105 155 180
M 16x1,5 200 295 350 M 16x1,5 160 235 280
M 18x1,5 300 435 510 M 18x1,5 240 345 400
M 20x1,5 425 610 710 M 20x1,5 335 475 590
M 20x2 680 M 20x2 560
M 22x1,5 580 825 940 M 22x1,5 460 650 750
M 24x2 720 1030 1210 M 24x2 560 810 940
M 27x2 1030 1480 1750 M 27x2 820 1170 1390
M 30x2 1480 2110 2470 M 30x2 1170 1660 1930

Hose fittings DKOL and DKOS:
Discription Wrench size Type Tightening torque(Nm)
Tolerance= +/- 10%
DKO 10 L 17 Hose DN 6 20
DKO 12 L 22 Hose DN 8 40
DKO 16 S 30 Hose DN 12 70
DKO 20 S 36 Hose DN 16 100
DKO 25 S 46 Hose DN 19 160
DKO 30 S 50 Hose DN 25 210
DKO 38 S 60 Hose DN 31 300
Mounting instructions:
 Tighten the nuts by hand and then tighten to specified torque.
 The threads are coated, do not oil!

Maintenance Plan:
Symbols in the maintenance plan: Time intervals in the maintenance plan:

= Check = Lubricate= Clean= Change A= daily or 10 Working hours
= after the first start up B= weekly or 50 Working hours
C= monthly or 200 Working hours
D= quaterly or 500 Working hours
E= half-yearlyor 1000 Working hours
F= yearly or 2000 Working hours
G= every 2 years
whichever occurs first!

Maintenence Plan:
Advice:
 The Vector Control detects the operating
hours of all units.
 For mast, slewing gear and support the
motion hours are recorded.
 The operation and movement hours can
be accessed at the Vector Control in the
Monitoring menu.

Allgemein: D W M ¼ ½ j 2j
A B C D E F G
A1 STÜ by an expert. Intervals by time, working hours or  = Check

funded by m³ concrete
A2 Visual and functional inspection by operator 

 = Lubricate
A3 Check the hydraulic oil level 
A4 Change hydraulicoil    = Clean

A5 Drain condensate from hydraulic oil tank 
 = Change
A6 Clean the cooling fins and oil cooler radiator 
A7 Check operating pressures 
A8 Lubricate the joints of the operating lever 
A9 Check tightness of hydraulic and water system,  


aggregates conveyor line, etc.
A10 Check fixtures of base frames, supports and

attachments, etc.
  after first start up
A11 Check water level watertank 
A12 Test PTO shafts of the pump drive and lubrication  

(normal mode)
A13 Check the pump drive PTO shafts and lubricate   100 Std.
(severe working)
A14 Check the oil level of the Pump distributor or gear box 
manual
A15 Change the gear oil  
A16 Change the hydraulic tank ventilation filter (if any) 

BOOM: D W M ¼ ½ j 2j
 = Check
A B C D E F G
V1 Change hydraulic oil filter with an error message at the 

latest together with item B3
V2 Lubricate grease fittings on the boom and supporting 

 = Lubricate
V3 Check fixings and condition of the end hose   = Clean
V4 Rolling bearings of rotary joint lubrication  100 Std.
 = Change
V5 Check oil level slewing gear 
V6 Change slewing gear oil  
V7 Check function of brake slewing gear 


V8 Lubricate the teeth of the rotary drive 
V9 Check drive pinion and slewing ring   after first set up

Concrete Pump: T W M ¼ ½ j 2j
 = Check
A B C D E F G
B1 Clean waterbox 
B2 Check water tank for deposits and clean if necessary   = Lubricate

B3 Change bypass filter with an error message, or at
least semi-annually funded by 15 000 cubic meters

 = Clean
of concrete
B4 Check the fixing of the delivery piston 

 = Change
B5 Lubricate grease fittings on rock slide, swing 
cylinders, hopper and agitator
B6 Check the screws of the rock for tightness 
B7 Rock slide cover screws for tightness testing 


B8 Check the axial play of the rock slide pivot shaft  after first set up
B9 Check the sealing of the rock slide pivot shaft 
B10 Check cutting ring of rock 
B11 Check accumulator (only MPS)   
B12 Safety review of the accumulator (only MPS) 

Optional units: T W M ¼ ½ j 2j
 = Check
A B C D E F G
Z1 Check grease reservoir and function of the central 

lubrication system
Z2 Clean the suction filter of the high-pressure cleaning 

 = Lubricate
system
Z3 Rotary compressor:  = Clean


 = Change
Z4 Check the oil level (before each use)
Z5 Oil change with ROTOR OIL 8000 F2  
Z6 Change oilfilter  
Z7 Replace oil-return valves  


Z8 Clean / replace air intake filter  
Z9 Clean the oil cooler  after first set up

Z10 Replace oil separator cartridge 

Inspection intervals by concrete delivery:
 The wear of the leading concrete components depends strongly on the
operating conditions (type of concrete, BP-strokes, etc.).
first Check after m³ next Check for more information chapter
P1 Pipeline 5000 requirements SHB/.44
P2 Rock valve 15000 requirements 4.40
 Assess wear after startup

 Maintenance intervals based on the result plan / arrange
 Maintenance of chassis, engine, special equipment, etc. by the
manufacturer's instructions.

Documentation
 The maintenance work performed shall be kept to logging and carried on the
machine.
Wartungsbericht
Mainanace: Date: Signature: Comments:
A,B,C,D,E,F,G

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Components Truckmounted

1 Saudi Arabia 2016

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Collective return lines

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Slewing cylinder storage point Center punch point

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Manual relife valve

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Emergency- Accumulator Accumulator

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Cooling and filter pump

Cooling and filter pump

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Cooling and filter pump

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A11VO190 A11= Type, VO=Variabel Open, 190=190 l/min at 1000 RPM

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A11VO190 A11= Type, VO=Variabel Open, 190=190 l/min at 1000 RPM

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 minimal deflection of the concrete flow reduced wear

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 Pressure and forces inside the

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 Funnel dives into the  flat surfaces between the

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2-Point tying up the

Cutring and Rubberspring

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 The Concretepressure get

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Full Wear + Armouring inside and outside

By Wear the ROCK can be regenerate.

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 seen in the image