You are on page 1of 235

OPERATION MANUAL

FOR TRUCK MOUNTED CONCRETE PUMPS

MODEL S 42 SXG

WARNING

on
Do not stand
hopper grates.

S 42 SXG SAFETY INSTRUCTIONS


BEFORE REMOVING HOPPER GRATE OR
PERFORMING ANY SERVICE:

Gasoline or Diesel Engines


1. Stop the engine.

2. Remove the key, place it


in your pocket, and put a
"DO NOT OPERATE" tag
on the switch.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.

2. Lock out the power


source according to an
approved lockout-tagout
program.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Version

1.0.1

Revision date

06/07
Table of Contents

Introduction
Manufacturer’s Statement......................................................................... 12
Safety Alert Symbol and Signal Word Explanation .......................... 12
How to reach us .................................................................................. 13
How to order parts .............................................................................. 13
Model Number Nomenclature .................................................................. 14
ID Tags...................................................................................................... 15
Main ID tag ......................................................................................... 15
Boom ID and makeup pipe tag ........................................................... 16
How to order missing tags .................................................................. 16

Specifications
Concrete Pump Specifications .................................................................. 18
Boom Specifications ................................................................................. 20
Outrigger Specifications ........................................................................... 21
Assembled Unit Specifications ................................................................. 21
Hydraulic Pressure Specifications ............................................................ 22
Boom Folding and Slewing Specifications............................................... 24
Outrigger Extension and Slewing Specifications ..................................... 24

Safety
How to Order Additional Safety Manuals ................................................ 26
Warning Labels (Decals) .......................................................................... 29
Emergency Stop Switches......................................................................... 29
Other Safety Devices ................................................................................ 29
By-pass key switch ............................................................................. 30
Agitator automatic shut-off circuit...................................................... 30
E-Stop manifold .................................................................................. 31
Safety valves (pressure relief valve) ................................................... 32
Safety guards....................................................................................... 32
Fuses and circuit breakers................................................................... 32
Hydraulic safety devices - boom and outriggers................................. 32
Laminated Book Container ....................................................................... 33
Do Not Use a Crane to Extend Boom Reach............................................ 34

Product Overview
First Commissioning................................................................................. 36
Installation of your new unit ............................................................... 36
Concrete Pump Circuit.............................................................................. 37
Hydraulic Components ............................................................................. 38
Hi-flo pumpkit components ................................................................ 38
Twin-circuit switching (MPS) ............................................................ 38
Accumulator safety rules .................................................................... 39
Twin circuit switching ........................................................................ 40
Hydraulic pump drive ......................................................................... 43

iv S 42 SX Operation Manual revDate


Table of Contents

Placing boom hydraulic pump ............................................................ 43


Function Diagrams.................................................................................... 44
Phase A Hi-flo..................................................................................... 44
Phase B Hi-flo..................................................................................... 47
Phase C Hi-flo..................................................................................... 48
Phase D Hi-flo..................................................................................... 51
Vector Control System.............................................................................. 52
Optional concrete shut-off valve............................................................... 53
In-line shut-off valve (pinch valve) .................................................... 53
Air supply line..................................................................................... 53
Pressure regulator/control valve ......................................................... 53
Options box......................................................................................... 54
Vector Control .................................................................................... 55
System components ............................................................................ 55
Controls and indication devices .......................................................... 56
LED status messages - Omnex Radio................................................. 59
LED status messages - Omnex Cable ................................................. 60
Safety Devices .......................................................................................... 61
Emergency stop switches.................................................................... 61
Hopper grate interlock ........................................................................ 61
Safety valves (pressure-relief valves) ................................................. 61
Emergency stop manifold ................................................................... 62
Emergency bypass procedure ............................................................. 62
Safety guards....................................................................................... 63
Hydraulic safety devices—boom and outriggers................................ 63
H.E.R. valves ...................................................................................... 63
Fuses ................................................................................................... 63
Warning labels .................................................................................... 63
Component Location and Identification ................................................... 64
Truck cab component identification ................................................... 64
Components formerly in cab............................................................... 65
Passenger side outrigger controls........................................................ 66
Driver side outrigger controls ............................................................. 67
Manual boom and pumpkit controls ................................................... 68
Hopper area......................................................................................... 70
Outrigger cribbing pad holders ........................................................... 72
Water reservoir.................................................................................... 72
Tool box compartments ...................................................................... 72
Fuel reservoir ...................................................................................... 74
The remote control cable receptacle ................................................... 75
Safety Manual Quick Index pocket..................................................... 76
Main hydraulic oil reservoir................................................................ 77
Waterbox............................................................................................. 78
Alignment arrows................................................................................ 79
Warning horns..................................................................................... 80

Operation Manual - S 42 SX v
Table of Contents

Operation
Preparation ................................................................................................ 82
Arrive alert and on time. ..................................................................... 82
Use the right machine for the job........................................................ 82
Have the right equipment.................................................................... 82
Use your personal protective equipment............................................. 84
Truck and pump checklist................................................................... 85
On the truck......................................................................................... 85
On the pump........................................................................................ 85
Driving the unit ................................................................................... 86
Licensing............................................................................................. 86
Backing up .......................................................................................... 86
Changing lanes.................................................................................... 86
Towing the unit ................................................................................... 86
Loading the unit for shipment............................................................. 86
For ramp loading / unloading.............................................................. 86
For crane loading / unloading ............................................................. 87
Unit Setup ................................................................................................. 87
Selecting the proper setup location on the job site ............................. 87
Soil Considerations ............................................................................. 88
Calculating the outrigger load............................................................. 88
42 SX Model calculations................................................................... 89
Activating the outrigger hydraulics .................................................... 89
Setting the outriggers .......................................................................... 90
Shortrigging ........................................................................................ 94
Additional dos and don’ts of outrigger stabilization........................... 95
Releasing the boom tie-down strap..................................................... 96
Setting up the boom ............................................................................ 96
Releasing the tip hose ......................................................................... 97
Inspecting the tip hose ........................................................................ 98
Hanging extra system from the boom................................................. 99
Pouring directly out of the boom ...................................................... 100
Attaching the tip hose to a slickline.................................................. 100
Prepare for the Ready-Mix Trucks ......................................................... 100
Lubricating the Pipeline.......................................................................... 104
Pumping the Job...................................................................................... 106
Controlling the speed of the unit....................................................... 108
Pumping the job ................................................................................ 109
Boom Bounce .......................................................................................... 110
Time constraints................................................................................ 110
Cold weather pumping...................................................................... 110
Stop the dripping concrete while moving ......................................... 111
Moving the boom.............................................................................. 111
Delays ............................................................................................... 111
Keeping the concrete alive................................................................ 111

vi S 42 SX Operation Manual revDate


Table of Contents

Keep the waterbox full...................................................................... 112


Using the vibrator ............................................................................. 112
Keep the hopper grate in place.......................................................... 112
Disassembling pipeline to remove blockages ................................... 113
Balance load...................................................................................... 113
Cleanout .................................................................................................. 114
Cleaning the boom pipeline .............................................................. 114
Folding-up the clean boom ............................................................... 116
Cleaning the hopper ................................................................................. 118
Cleaning the Rock Valve and material cylinders.............................. 121
Cleaning the waterbox ...................................................................... 122
Reassembling the unit ....................................................................... 123
Be careful with acid .......................................................................... 123
Preparing for travel ........................................................................... 124
Special Pumping Situations .................................................................... 124
Hurry up cleanout ............................................................................. 124
Moving the pump during a pour ....................................................... 125
Cold weather pumping...................................................................... 127
Preheating the boom pipeline............................................................ 128
Minimum temperature for boom operation is -40˚ ........................... 129
Preheating the hydraulic oil .............................................................. 129
Draining the water system ................................................................ 129
Emergency Procedures............................................................................ 130
Disabling the entire unit in an emergency ........................................ 130
Override of emergency stop manifold .............................................. 131
Do not operate the machine when:.................................................... 132
Loss of remote control ...................................................................... 132
Other Things You Need to Know ........................................................... 132
Reordering documentation or warning labels ................................... 132
Loss of radio remote signal............................................................... 132
Disposal of spent batteries ................................................................ 132

Maintenance
Filtration.................................................................................................. 134
General information .......................................................................... 134
Specific information.......................................................................... 134
External filtration .............................................................................. 135
Changing your hydraulic oil filters ................................................... 135
Changing high pressure water filter.................................................. 135
Hydraulic Oils......................................................................................... 135
General information .......................................................................... 135
Specific information.......................................................................... 136
When to change your hydraulic oil................................................... 136
Pressure, Hoses, and Fittings .................................................................. 136
General information .......................................................................... 136
Specific information.......................................................................... 137

Operation Manual - S 42 SX vii


Table of Contents

General Maintenance Tips ...................................................................... 138


Torque specifications ........................................................................ 138
Adjusting relief valves ...................................................................... 138
Removing safety devices .................................................................. 138
Welding precautions ......................................................................... 138
Replacing the hydraulic pump .......................................................... 138
Lock Out - Tag Out procedure.......................................................... 139
Maintenance Checklist............................................................................ 140
Daily Maintenance .................................................................................. 141
Weekly Maintenance .............................................................................. 142
Rotating the cutting ring ................................................................... 144
Monthly Maintenance ............................................................................. 145
Setting Pressures ..................................................................................... 150
Check all hydraulic pressures ........................................................... 150
Setting pressures on Hi-flo -5 pumpkits ........................................... 150
Setting boom circuit pressures .......................................................... 152
Load-sensing boom hydraulic controls............................................. 153
Setting delta P pressure..................................................................... 153
Setting Q-min.................................................................................... 155
Setting boom pressures ..................................................................... 156
Setting outrigger pressure ................................................................. 157
Setting the agitator pressure.............................................................. 158
Cleaning oil cooler fins..................................................................... 159
Quarterly Maintenance............................................................................ 159
Check the drive pinion and slewing joint ......................................... 159
Change the oil in the air compressor................................................. 159
Change the oil for temperature reasons ............................................ 159
Change oil in the distribution gearcase............................................. 160
Semiannual Maintenance ........................................................................ 160
Change the oil in the boom slewing gearcase................................... 160
Test the dirty filter warning circuit ................................................... 161
Annual Maintenance ............................................................................... 162
Check the pre- charge of accumulators............................................. 162
Charging procedure........................................................................... 163
Change the hydraulic oil ................................................................... 169
Clean the optional air compressor, if installed.................................. 169
Change the corrosion inhibitors ........................................................ 169
Time-related Maintenance ...................................................................... 169
Periodic - structural inspection ......................................................... 169
Unscheduled maintenance ...................................................................... 169
Frequent inspections ......................................................................... 169
Changing rams .................................................................................. 171
Changing material cylinders ............................................................. 175
Setting Vector Controller-Teach Mode ............................................ 175
Heat the oil first ................................................................................ 176

viii S 42 SX Operation Manual revDate


Table of Contents

Appendix
Hydraulic Oil Viscosity Chart ................................................................ 184
Torque Specifications for Metric Bolts................................................... 185
Recommended Emergency Hose Kit ...................................................... 189
Fitting Wrench Sizes............................................................................... 189
Grease Zerk Locations-Boom ................................................................. 191
Bearing Clearance Specifications ........................................................... 192
Maintenance Checklist............................................................................ 193
Weld-on Ends / Coupling Comparison ................................................... 194
Output Charts .......................................................................................... 195
Using the chart .................................................................................. 196
Using a Nomograph ................................................................................ 202
General information .......................................................................... 202
The quadrants.................................................................................... 204
Minimum Pipe Wall Thickness .............................................................. 210
Pictograms............................................................................................... 211
Glossary of Terms................................................................................... 212
Additional Reading Material............................................................. 217
List of Lubricants and Nitrogen.............................................................. 217
Hydraulic Schematic—Boom Circuit (1 of 2) ........................................ 221
Hydraulic Schematic—Boom Circuit (2 of 2) ........................................ 223
Hydraulic Schematic—Concrete Pump .................................................. 225
Output Chart ........................................................................................... 227
Nomograph ............................................................................................. 229

Operation Manual - S 42 SX ix
Table of Contents

x S 42 SX Operation Manual revDate


Introduction

WARNING

on
Do not stand
hopper grates.

S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR

PERFORMING ANY SERVICE:


Gasoline or Diesel Engines
1. Stop the engine.

2. Remove the key, place it


in your pocket, and put
a "DO NOT OPERATE"
tag on the switch.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.

2. Lock out the power


source according to an
approved lockout-tagout
program.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.

42SXside.eps

INTRODUCTION
Manufacturer’s Statement...................................................................... 12
Model Number Nomenclature................................................................ 14
ID Tags................................................................................................... 15

Operation Manual - S 42 SXG


Introduction

Introduction Safety Alert Symbol and Signal


Word Explanation
The triangle with the exclamation point inside is used
Manufacturer’s Statement to alert you to an important safety point and is called a
safety alert symbol. One of the following signal words
This operation manual contains Unit Specifications, will appear after the safety alert symbol:
Product Overview information, the Safety Manual,
• If the safety alert symbol is followed by the
Operation information, and Maintenance information
signal word DANGER, it indicates a
for your model S 42 SXG.
hazardous situation which, if not avoided,
The information contained in the operation manual is WILL lead to death or serious injury.
absolutely necessary for the safety, proper setup, • If the safety alert symbol is followed by the
operation, maintenance, and servicing of your concrete signal word WARNING, it indicates a
pump. By learning this information and practicing it potentially hazardous situation which, if not
every day, you can expect that your concrete pump unit avoided, COULD result in death or serious
will give you efficient and reliable service year after injury.
year. For your own benefit and safety, read the
• If the safety alert symbol is followed by the
information in this manual and follow the instructions
signal word CAUTION, it indicates a
to the letter.
potentially hazardous situation which, if not
Before you operate your concrete pump for the first avoided, MAY result in minor to moderate
time, you should read the operating instructions several injury.
times through. We recommend that you keep a copy • The signal word CAUTION used without the
with the concrete pump for quick reference while on safety alert symbol means the hazard COULD
the job site. However, the general knowledge must be cause damage to equipment or property.
in place before you arrive on the job site. Any person
that operates a concrete pump must be familiar with the The keywords listed above will be displayed
operating instructions. Even a temporary operator (for throughout the text of this manual in the form of
example, if the normal operator is ill or on vacation) information boxes like the ones shown in (Figure 1).
must be familiar with the operation instructions. It The text in the black area of the information box will
stands to reason that a person who has not operated a describe the hazard to beware of and the consequences
particular concrete pump before will not know how to which can occur if that hazard is encountered.
safely operate that concrete pump. The machine is built All persons working near the concrete pump unit must
to the latest technology and safety regulations, but it be able to recognize hazardous situations. They must
may still be dangerous to people and property if it is know how to avoid these situations and how to re-act
operated, maintained, repaired, or used incorrectly. quickly and appropriate whenever hazardous situations
The illustrations contained in this manual are intended arise.
to clarify text passages. They may look slightly
different from your unit, but this has only been allowed
if it does not fundamentally change the factual
information.
Technical modifications that are made to units will be
documented in each new edition of the operation
manual.

12 Operation Manual - S 42 SXG revDate


;;;;;;;;;;
Introduction
How to order parts

;;;;;;;;;;
To place an order for spare parts, you can call any of
DANGER the above numbers, or you can call our toll free parts
line from anywhere in the continental United States,
Hazard and consequence will be shown except Minnesota. Parts department hours are Monday
in this space. through Friday, 8:00 AM to 5:00 PM (central time).
Orders will also be accepted via fax, 24 hours/day.

D002.eps
• Spare Parts (small line) (0049)2325 - 987-0
WARNING •

Hazard and consequence will be shown
in this space.

Whenever you call the factory for spare parts or

W022.eps
service, always have the model number handy. You can
CAUTION find the model and serial number on the ID tag that is
mounted to the subframe of the unit (Figure 2).
Hazard and consequence will be shown For future reference, the model number and serial
in this space. number of your machine has been placed in the spaces
C008.eps
provided below.

CAUTION
Hazard and consequence will be shown
in this space.
C001.eps

Figure 1
Safety alert information boxes Model Number:

How to reach us
If you encounter a circumstance that is not covered by
this manual, Schwing Service Department
will be more than happy to assist you with all of your
parts and service needs. Serial Number:
.





speedy:opmanuals:42SX vector:42SXG:42SXG Introduction


Operation Manual - S 42 SXG 13
Introduction

Model Number Nomenclature


The complete model number of Schwing
concrete pumps is designated by a code, as in:

BPL 2023-5
S 42 SX- 125

The code is broken down as follows:

BP L 20 23 -5

Beton pumpe (concrete pump)


Lastkraftwagen (truck-mounted)
Stroke length (in decimeters)
Diameter of material cylinders (in centimeters)
Code for hydraulic pump output
(-5=535 Liters per minute)

S 42 / 38 SX -125

Schwing
Vertical reach (in meters)
Horizontal reach (in meters)
Super X outriggers
Diameter of boom pipeline (in millimeters)

In practical usage, this unit is referred to as the the same unit would become BPL 2525-6, S 42/38 -
“S 42 SX” or simply the “42.” 125. The code for hydraulic pump output is as follows:
The boom size generally determines the style of the -4 indicates that the pump is rated at 450 liters per
entire unit, because the structural requirements of the minute. -5 means 535 L/min, and -6, which is available
outrigger and tower dictate the design criteria to the only on the 2525, indicates that the pump will put out
engineers. Other pumpkits are available for this boom 636 L/min.
style, and using another pumpkit would change the The pumpkit has its own complete model number. You
model number of the unit. For example, if you ordered will find this used on the output charts and nomographs
the unit with a 2525-6 pumpkit, the model number of for specific machines. For example:

Pumpkit: 125/ 80 x 2000: 230

Differential cylinder bore diameter (in mm)


Differential cylinder rod diameter (in mm)
Stroke length (in mm)
Material cylinder bore diameter (in mm)

14 Operation Manual - S 42 SXG revDate


Introduction

WARNING

on
Do not stand
hopper grates.

S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR

PERFORMING ANY SERVICE:


Gasoline or Diesel Engines
1. Stop the engine.

2. Remove the key, place it


in your pocket, and put
a "DO NOT OPERATE"
tag on the switch.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.

2. Lock out the power


source according to an
approved lockout-tagout
program.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.

42SXIDtaglocate.eps

Main ID tag
Figure 2
Location of main ID tag and stamped serial number

ID Tags the front outrigger. The boom ID tag and the odd-
length pipeline tag (Figure 4) is located on the
NOTE! passenger side of the #1 (main) boom, just behind the
ID tags and serial numbers shown in this hollow pin.
manual are for “REFERENCE ONLY”.
Locate each of the tags on your own unit to Main ID tag
determine specific information for your
pump. The main ID tag (Figure 3) gives information about the
There are two information tags on the unit. The main entire unit, the pumpkit, the hydraulic systems, and the
ID tag (Figure 3) of the machine is located on the year of manufacture. The unit serial number is stamped
driver side of the subframe (Figure 2), just forward of into the subframe immediately below this tag.

HERNE 2/ GERMANY
PHONE (02325) 7871
TELEX 820 348

BPL 2023-5 170526006 2003


MODEL S 42SX-125 SERIAL NO. YEAR

MATERIAL
301733D

WEIGHT LBS. RS 32 RS 1007


STROKES PER MINUTE PS n/a MAX. PS n/a
PRESSURE
SYSTEM SYSTEM SYSTEM
MAXIMUM HYDRAULIC PRESSURE 5075 2900 4495
1 2 3

42SX MAIN ID tag-eps

1 7 0 5 2 6 0 0 6
Figure 3
Main ID tag

speedy:opmanuals:42SX vector:42SXG:42SXG Introduction


Operation Manual - S 42 SXG 15
Introduction

PRESSURE & WEIGHT INFORMATION WARNING!


Postfach 20 03 62 Pipeline wears with each pump stroke. Check
D-44647 Herne pipewall thickness regularly! See manuals.
www.schwing.de
PUMPKIT MODEL: 120 / 85 X 2500 : 250
Max. hyd. oil pressure in boom hyd. system: 350 bar
When configured for ROD side pumping, this unit will
produce a maximum material pressure of: Maximum total weight of system
1169 PSI components hanging from boom, (lbs): 376
YEAR:
When configured for PISTON side pumping, this unit will LENGTH of the MAKE UP PIPES
2003

30334197 C
produce a maximum material pressure of: (See parts book for standard lengths)
N/A PSI
BOOM MODEL: Maximum weight of boom pipeline MAIN 1630 mm
KVM S 42 SX WITHOUT CONCRETE is: 10.14 Lbs/ft

Maximum weight of boom pipeline


3rd 2610 / 1710 mm

SERIAL NUMBER: INCLUDING CONCRETE is: 29.97 Lbs/ft


Maximum allowable bulk density
17205058 of material to be pumped is: 150 Pounds per cubic foot 2nd 1205 / 1015 mm

boomidtag.eps

1 7 2 0 3 0 0 6

Boom ID tag

WARNING

on
Do not stand
hopper grates.

S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR

PERFORMING ANY SERVICE:


Gasoline or Diesel Engines
1. Stop the engine.

2. Remove the key, place it


in your pocket, and put
a "DO NOT OPERATE"
tag on the switch.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.

2. Lock out the power


source according to an
approved lockout-tagout
program.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.

42SXboomIDtag.eps

Figure 4
Location of boom ID tag

Boom ID and makeup pipe tag How to order missing tags


Concrete pump units built after September 1, 2003 will If the tags have been removed from the unit and you
have a new combined boom ID tag and boom makeup need some information about the unit, read the main
pipe tag (Figure 4). This tag will contain information serial number that is punched into the steel subframe.
about the boom reach, pipeline diameter, and boom The number is located just ahead of the front driver
serial number, as well as maximum allowable weights. side outrigger (Figure 2). When you find the number,
The boom serial number is stamped into the #1 boom call Schwing Service Department for the
section above or below the tag. The tag also gives the information you need. Schwing’s unit files are arranged
exact length of each section’s makeup pipe. The tip by this serial number, and we can get all the necessary
section does not have an odd length pipe, because the information about the unit from the file that
end clamp is movable, which allows a variance of any corresponds to this number. When we have the unit
length to be corrected. serial number, new tags can be sent to you. On units
built prior to January 1, 2000, the boom ID tag and
makeup pipe tag are separate and will be replaced with
the combination tag shown in Figure 4.

16 Operation Manual - S 42 SXG revDate


Specifications

WARNING

on
Do not stand
hopper grates.

S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR

PERFORMING ANY SERVICE:


Gasoline or Diesel Engines
1. Stop the engine.

2. Remove the key, place it


in your pocket, and put
a "DO NOT OPERATE"
tag on the switch.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.

2. Lock out the power


source according to an
approved lockout-tagout
program.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.

42SXside.eps

SPECIFICATIONS
Concrete Pump Specifications............................................................... 18
Boom Specifications .............................................................................. 20
Outrigger Specifications ........................................................................ 21
Assembled Unit Specifications .............................................................. 21
Hydraulic Pressure Specifications ......................................................... 22
Boom Folding and Slewing Specifications ............................................. 24
Outrigger Extension and Slewing Specifications ................................... 24

S 42 SXG Operation Manual


Specifications

Specifications
Concrete Pump Specifications
.

BPL 2525H 120/85 X 2500:250


2525H-5 2525H-6
(Piston side only)

Strokes / minute (max.) 18 22

Concrete Output (max.) 173 (cu. yds./hr.) 213 (cu. yds./hr.)


Concrete pressure (max) 81 bar (1169 PSI) 81 bar (1169 PSI)

Output (hydraulic pumps) 535 L/min (141 gpm) 636 L/min (168 gpm)

Speed (hydraulic pumps) 2100 RPM 2100 RPM

Hydraulic pressure (max.) 350 bar (5075 PSI)

Power (hydraulic pumps) 2 X 90 kw = 180 kw or

2525Hspc.eps
2 X 100 kw = 200 kw

18 Operation Manual - S 42 SXG revDate


Specifications

Note: 2100 RPM is an example. Your 2100 RPM is needed here at the gearcase
output, but there is no access here to check
machine may have a different speed
the RPM. You can find out what the input
requirement, which is documented in speed must be to deliver 2100 RPM to the
the output chart included with your output by dividing the needed output speed
parts book and operation manual. by the gear ratio.

Example: 2100 RPM needed ÷ 1.2856 ratio =


1633 RPM needed at the input shaft

Output
RPM
Input
Ratio
RPM

The Input shaft is where you can measure


RPM, but the speed is multiplied inside the
gearcase. To know what RPM the pumps
receive, you must multiply the input speed
times the gear ratio.

Example: 1633 RPM at the input shaft x


1.2856 gear ratio = 2100 RPM to the pumps

The ratio of input to


output speeds is shown
on the ID tag here.

A7VOside.eps

speedy:opmanuals:42SX vector:42SXG:42 SXG specifications


Operation Manual - S 42 SXG 19
Specifications

Boom Specifications
Placing Boom Model S 42/38 -125

Pipeline diameter 125 mm


Vertical reach from ground 41.8 m (137 ft. 2 in.)
Horizontal reach from
center of slewing axis 38.5 m (126 ft. 4 in.)
Height of folding point
#1 (hub) 3.7 m (12 ft., 1 in.)
Boom section lengths
#1 33 ft., 10 in.
#2 30 ft., 4 in.
#3 30 ft., 4 in
#4 (tip) 30 ft., 4 in
Number of articulations 4
Hub maximum angle 93°
Folding angles
#1 180°
#2 180°
#3 240°
Slewing rangea 370°
Minimum unfolding heightb 9.6 m (31 ft., 6 in.)
Design Fully articulating “ROLL and FOLD” ™
Boom pipeline—Maximum weight 10.14 lb/ft (empty)
Deck pipeline Hardened or double wall
Boom and Deck pipe elbows Quantity of 10 at 90°
Quantity of 4 at 45°

Boom elbow radius 250 mm (9.8 in.)


End hose
Maximum length 3.8 m (12 ft., 6 in.)
Material Rubber, 4-ply steel carcass
Burst pressure 165.5 bar (2400 PSI)

aElectrical
wire and hydraulic hose limitations.
bApproximate; varies with truck model.

20 Operation Manual - S 42 SXG revDate


Specifications

Outrigger Specifications
Design
front Fully hydraulic extension and jacking
rear Fully hydraulic slewing and jacking
Maximum outrigger force pounds
front 50,700
rear 52,900
Outrigger spread
front (side to side) 27 feet 3 inches
rear (side to side) 27 feet 3 inches
length 29 feet 0 inches
Outrigger footplate dimensions
front 11.81 inches x 13.78 inches
rear 11.81 inches x 13.78 inches
Maximum soil pressure (without any dunnage) PSI
front 313
rear 327
Maximum soil pressure (with supplied dunnage) PSI
front 88
rear 92

Assembled Unit Specifications


Charging hopper height * 53 inches
Charging hopper capacity 17.5 cubic feet
Water tank capacity 160 gallons
Hydaulic oil tank capacity (Fill to) 137 gallons
Water pump output ** 16 to 27 gal./minute
Water pump pressure (max.) 60 PSI (Not to exceed 500 RPM)
Water hose length 34 feet
3/ inches
Water hose diameter 4
Estimated overall dimensions *
max. height 13 feet 0 inches
max. length 36 feet 3 inches
max width 8 feet 6 inches
NOTE!
Estimated overall weight varies on each unit and can be found in the documentation which came
with your unit (usually in the cab of the truck). The specific document which shows the unit weights
is the actual, final prep weight ticket from the pump file. If you cannot find it, the information can be
obtained by calling Schwing with the unit serial number and asking the call center to check the
pump file.

speedy:opmanuals:42SX vector:42SXG:42 SXG specifications


Operation Manual - S 42 SXG 21
Specifications

Hydraulic Pressure Specifications


All hydraulic pressures found on this page and in the regular text flow of this manual are FOR REFERENCE
ONLY. The only document which shows the specific pressures for your unit is the hydraulic schematic, located in
the back of the Appendix section of this manual.

Concrete Pump
Main Pressure relief single circuit (2525H - 5) 350 bar (5076 PSI)
Main Pressure relief Twin circuit (2023 H -6) 320 bar (4641 PSI)
Main Pressure relief Twin circuit Hi-flo with A11VO 360 bar (5221 PSI)
Main Pressure relief Twin circuit Hi-flo with A7VO (2023 -4)350 bar (5076 PSI)
Main Pressure relief Twin circuit Hi-flo with 1418 2.5 310 bar (4496 PSI)

Soft switch relief (MPS only) 80 bar (1160 PSI)

Hydraulic pump pressure cut-off (A11VO pumps)


2525H -5 330 bar (4785 PSI)
2023 -5 350 bar (5076 PSI)
2023 H -6 310 bar (4496 PSI)
2020 -5 325 bar (4714 PSI)
1418 2.5 300 bar (4351 PSI)

Outriggers
Outrigger main pressure relief (for most units) 280 bar (4061 PSI)
Outrigger main pressure relief (for 45/47) 300 bar (4351 PSI)
Outrigger main pressure relief (52/55) Check schematic
Outrigger main pressure relief (1418 2.5) 200 bar (2900 PSI)

Agitator
Relief 200 bar (2900 PSI)

Water pump
Relief 200 bar (2900 PSI)

22 Operation Manual - S 42 SXG revDate


Specifications

Boom Pressures
Hydraulic pilot pressure (pre-set nonadjustable) 15 bar (508 PSI)

Pneumatic pilot pressure (if so equipped) 6 bar (87 PSI)

Delta P 18-30 bar (261-435 PSI)


Based upon optimum performance of
the boom
Q min (all units except 42SX 52/55 & 58/61) 42-45 bar (609-653 PSI)
Q min (for 52, 55, 58, and 61) 50-55 bar (752-798 PSI)
Q min (for 42 SX) 45 bar (652 PSI)

Electric pressure relief (E-stop) 330 bar (4786 PSI)

Main relief 350 bar (5076 PSI)

Pressure regulator (for 45/47, 52/55, & 58/61) 310 bar (4496 PSI)
Pressure regulator (for 32, 34, 39, & 42SX) 300 bar (4351 PSI)
Pressure regulator (for 24-4, 26-4, 28 & 42 290 bar (4206 PSI)
Pressure regulator (for 17 M) 280 bar (4061 PSI)

#1 down side relief (for 45/47 & 58/61) 230 bar (3336 PSI) + delta P
#1 down side relief (for 24-4, 26-4, 28, 32, & 34) 140 bar (2031 PSI)
#1 down side relief (for 17M) 170 bar (2466 PSI)
#1 down side relief (for 39, 52, 31, & 42) Is nonadjustable or doesn’t exist
#1 down side relief (for 42 SX) 90 bar (1305 PSI)
Notes:
1. Oil should be at 40˚ to 50˚ Celsius before testing
2. Specifications vary on different units. Always check hydraulic schematic for specific pressures on your unit.

speedy:opmanuals:42SX vector:42SXG:42 SXG specifications


Operation Manual - S 42 SXG 23
Specifications

Boom Folding and Slewing Specifications


Boom Boom Time
Number Direction Angle (sec.)
1 Up 90° 80
Down 90
2 Extend 90° 60
Retract 60
3 Extend 180° 80
Retract 83
4 Extend 180° 55
Retract 64
Boom slewing (left–right) 90° 65

Outrigger Extension and Slewing Specifications


Time
Outrigger Direction (sec.)
Front In 12
Out 12
Rear In 12
Out 12

Notes:
1. Oil must be at 40° - 50° Celsius before testing.
2. Times are without weights.
3. Boom times are considered within specifications at +/- 10 seconds.

24 Operation Manual - S 42 SXG revDate


WARNING

on
Do not stand
hopper grates.

S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR

PERFORMING ANY SERVICE:


Gasoline or Diesel Engines
1. Stop the engine.

2. Remove the key, place it


in your pocket, and put
a "DO NOT OPERATE"
tag on the switch.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.

2. Lock out the power


source according to an
approved lockout-tagout
program.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.

42SXside.eps

SAFETY
How to Order Additional Safety Manuals .................................................. 26
Warning Labels (Decals) .......................................................................... 29
Emergency Stop Switches........................................................................ 29
Other Safety Devices ................................................................................ 29
Laminated Book Container ....................................................................... 33
Do Not Use a Crane to Extend Boom Reach ........................................... 34

Operation Manual - S 42 SXG


Safety

April 28, 2006

Safety/Service Bulletin 1015-06


Subject: Release of Safety Manual version 5.x.1

Dear Schwing Customer,


The Safety Manual has been updated again. Safety Manual version 5 has two significant changes
from previous versions; the distance to stay away from a tip hose when starting or restarting, and
an update of the pipewall thickness chart found on page 73. In addition to the complete paperback
manual, we are including a sample of the unlaminated edition of the Co-worker Safety Rules
(version 5.1.1). The Co-worker Safety Rules are also available as laminated books intended to be
kept on the pump for easy reference. Please instruct your operators to make the co-worker
information available to the placing crew and laborers, and to read the information to the workers
if they believe the workers wouldn’t understand the printed text. Spanish versions of the updated
manual are also available now and can be ordered with the attached order form.
It is our objective to get a copy of each of these publications into the hands of every operator and
the workers around the pump. Please help us make these publications effective for jobsite safety
by obtaining a copy for each of your operators, and encourage them to read and understand the
rules. Older versions of the manual should be discarded when the new version is in hand.
To obtain more manuals, please fill out the attached form(s) and fax it to us at the number listed.
We will ship one set of manuals free of charge for each unit that is listed with its serial number
and current location. Additional manuals are available at a nominal fee for meetings,
presentations, or any other reason. If you are planning any safety training for your customers, the
Co-worker Safety Rules booklet is available in both English and Spanish in a non-laminated
version at a fraction of the cost of the laminated version. Of course, the non-laminated version is
not intended to be kept on the pump.
Thank you in advance for your consideration in this matter.

Best Regards,

Robert Edwards

1015_06_5x1.fm

speedy:opmanuals:42SX vector:42SXG:42SXG safety.fm


Operation Manual - S 42 SXG 27
Safety

Warning Labels (Decals) Other Safety Devices


Each machine is equipped with a set of warning labels The following paragraphs describe some other safety
specific to the model, boom style and installed options. devices found on the unit. The devices listed here must
Safety decals MUST be replaced if they are damaged, be maintained in good working condition to avoid
faded, missing, or unreadable for any reason. injury to concrete pump operators and persons working
Ultraviolet radiation, rain, steam cleaning, and other near the concrete pump. Bypassing a safety device for
factors cause these labels to fade in time. Sets include servicing, emergency fold-up, or clean out should only
outrigger load labels, but they do not include metal be done by persons that know what systems are
plates, which can be ordered separately. Schwing disabled by the bypass procedure. All bypassed devices
supplies warning labels without charge for as must be set back to their original position upon
long as the machine is in service. For installation completion of the service or emergency procedure.
locations, see the decal location guide insert found in In spite of these safety devices, it is important to
the Appendix section of this manual. To get remember that the concrete pump unit is made of
replacement labels, identify which label(s) you need machine parts that, according to Murphy’s Law, will
from the diagrams and lists, get the serial number of fail at the worst possible moment. Never put your
the unit from the serial number plate, and call the hands, arms, legs or any other body part into the hopper
Schwing Spare Parts Department. while the hydraulic system is energized.
The person taking the order will make a note
of the serial number of the unit for our files and send NOTE!
you the labels you need. You may order complete sets ALWAYS Lock Out - Tag Out according to the
or single labels. If the serial number plate is missing or procedure recommended on page 157 of
unreadable, the number is stamped into the subframe Maintenance before performing maintenance in any
just below the normal location of the serial number area that is normally guarded.
plate.

Emergency Stop Switches


Pressing one of the red Emergency Stop Switches shuts
off electrical power and accomplishes the same
function as MANIPULATING THE MANUAL DUMP
VALVE. All hydraulic oil is dumped to the reservoir
and no pressure build-up can occur.
There are five emergency stop switches on the unit,
plus one on each remote box. Locations are pointed out
in an illustration in the Overview section. One is
located near the rear control panel, one is on the driver
side of the truck near the hopper, one is found near the
water box, and one is near the boom hand valves and
outrigger control block on the passenger side. There is
also one near the outrigger control block on the driver
side. The emergency stop switches are clearly marked
and easily accessible for use in emergency conditions.
All emergency stop switches are wired in series, so
they all perform the exact same function. The
emergency stop switches cut off electricity to the
concrete pump forward/reverse pilot valve. In addition,
they open the electrical path to the normally open
bypass valve (E-Stop manifold valve), which causes
the valve to open and disable all hydraulic circuits.

speedy:opmanuals:42SX vector:42SXG:42SXG safety.fm


Operation Manual - S 42 SXG 29
Safety

By-pass key switch Agitator automatic shut-off circuit


The by-pass key switch (Figure 5) is located on the side Electrical power is cut to the pump, agitator, and
of the Vector Controller. This switch is used when accumulator coils and causes the agitator hydraulic
control is lost due to a control system electrical circuit, which runs through a separate dump valve, to
problem. When the key is in the BY-PASS position, the route oil directly from the pump back to the oil
controller is bypassed and electrical power is supplied reservoir (tank) if the following safety conditions are
directly to the solenoids on both override valves on the compromised:
E-Stop Manifold. The dump valves will close and • an emergency stop switch is activated.
restore hydrualic pressure. • electricity is lost on the unit (stopped engine,
blown fuse, broken wire).
WARNING • the hopper grate is raised (interlock switch
opens).
Emergency stop switches are disabled • the hopper grate is removed (interlock switch
when manual override is activated. opens).
Use the by-pass key switch only for
folding the boom in an emergency and
000360.eps

for clean out.

If hydraulic pressure is not restored, the problem is


likely hydraulic. Refer to the information in Figure 6
on how to bypass the inlet plumbing connected to the
hydraulic circuit that is not functioning.

BY-PASS
NORM. BY-PASS

000196.eps

Figure 5
By-pass key switch

30 Operation Manual - S 42 SXG revDate


Safety

E-Stop manifold
The E-Stop manifold is located in an easily accessible
location on each unit. To locate the e-stop for your unit
check the overview section of this manual. A
description of how the E-Stop manifold is plumbed in
the system and how it is used is shown in Figure 6.

Boom
Y66
Concrete Pump
Y63 Y64
Accumulator

Figure 6
E-Stop manifold

speedy:opmanuals:42SX vector:42SXG:42SXG safety.fm


Operation Manual - S 42 SXG 31
Safety

Safety valves (pressure relief valve) activating the circuit again. Refer to the Vector System
The hydraulic pressures listed on hydraulic schematics Configuration Manual or the component location
are not nominal figures. They are the hydraulic diagram on the cover of the electrical control system
pressures that the concrete pump was designed to work for location and function of each fuse or circuit
with and that the components were designed to breaker.
accommodate.
Hydraulic safety devices - boom and
NOTE! outriggers
Under no circumstances should you raise
hydraulic pressures arbitrarily or because The holding valves on the boom and outriggers are
you “think it might help.” Conversely, intended to stop the cylinders from retracting if
lowering the hydraulic pressure settings hydraulic pressure is lost for any reason. A cylinder
may cause poor performance, heat, and would stop, for example, if a hydraulic hose or fitting
related premature component failure. In fails.
some extreme cases, raising or lowering
hydraulic pressures may cause dangerous The way the holding valves are designed, pressure
operation. Check with the Schwing Service must be applied to the holding valves from the
Department before changing any hydraulic hydraulic system before the cylinders can extend or
pressure settings. retract.
Safety guards There is a relief valve located in the holding valves to
prevent cylinder failure due to excessive pressure and
Safety guards are placed over moving parts. These
to prevent boom damage due to excessive forces.
were placed on the concrete pump unit for your
protection. Do not operate the concrete pump without NEVER adjust the relief valve setting on a holding
all of the safety guards in place. If they become valve while it is on the boom. There is no way to tell
damaged, lost, stolen, or inoperable, they must be what pressure setting you are making, and structural
replaced before operation continues. damage could result.
Two hydraulically unlockable check valves (counter-
Fuses and circuit breakers balance valve, holding valve, or H.E.R. valve) on each
Fuses and circuit breakers are devices that are intended boom cylinder prevent the boom from coming down
to protect against circuit overload. They do so by unintentionally (Figure 7). See the boom circuit -
melting or opening when the current in an electrical hydraulic schematic in the Appendix section of this
circuit becomes higher than it was designed for. Here manual for additional information on the counter-
are a couple of examples of causes of over current: balance valves.
• Short circuits (positive goes to negative
without resistance)
• Component malfunction (a coil that has to
move a sticky valve)
• Mechanical interference (a shovel handle stuck
through the oil cooler fan blade) 000367.eps

In order to maintain this safety device, simply reset the


circuit breaker or replace an open (blown) fuse with the Figure 7
correct size and type of fuse, and never bypass a fuse. Counter balance or holding valves
A very good rule of thumb for fuses and circuit mounted on a boom hydraulic cylinder
breakers is this: If it opens (blows) once, reset or (HER valves)
replace it. If it opens (blows) again, there is a real
problem. Find the cause of the problem, and repair it
before activating the circuit again. In current
production, many of the fuses have been replaced with
circuit breakers. If the circuit breaker opens after being
reset, find the cause of the problem, and repair it before

32 Operation Manual - S 42 SXG revDate


Safety

Laminated Book Container

Vectorquickindex.eps

Figure 8
laminated book container (driver side tool box)

The laminated book container is located in an easily


accessible area of each unit. The exact location should
be pointed out on an illustration in the Overview
section of this manual. The container (Figure 8) will
hold a laminated copy of the Safety Manual Quick
Index, the Co-Worker Safety Rules, and the Short
Instructions. If any of these documents have been
removed, damaged, stolen, or are missing for any other
reason, Schwing will send you a new one
without charge. You can get these documents or the
complete Safety Manual by calling the Schwing.

speedy:opmanuals:42SX vector:42SXG:42SXG safety.fm


Operation Manual - S 42 SXG 33
Safety

superboom.eps

Figure 9
Do not use a crane to extend the reach of a concrete pump

Do Not Use a Crane to Extend placing boom and may compromise its
integrity. The ultimate result of this could be
Boom Reach boom damage and potential failure.
It is the position of Schwing, in conjunction • In normal operating conditions, a concrete
with the Concrete Pumping Association as delivery line will have natural vibrations and
well as major crane manufacturers, that cranes must movements that can be transmitted to the crane
never be used to suspend a working concrete delivery through its suspension lines. Crane
line in an attempt to extend the horizontal reach of the manufacturers do not design their machinery
boom (Figure 9). There are many reasons for this with this intended application and continued
restriction; the main points are as follows: use has been shown to create structural
• The boom and the crane have differing pivot problems in the unit. As in the boom, the
points and modes of control. It is not possible ultimate result of this could be damage and
to continuously and accurately coordinate their potential failure.
movements. This will always result in loads If for reasons related to the site layout, pumping must
being imparted into the boom. Many of these be carried out over a greater horizontal distance or into
loads will violate the design intent of the inaccessible places, it must be performed in accordance
with operating instructions included in this manual.

It is the position of the ACPA that suspending a horizontally configured


concrete delivery line (extending the reach) with the use of a crane is not
allowed!

34 Operation Manual - S 42 SXG revDate


WARNING

on
Do not stand
hopper grates.

S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR

PERFORMING ANY SERVICE:


Gasoline or Diesel Engines
1. Stop the engine.

2. Remove the key, place it


in your pocket, and put
a "DO NOT OPERATE"
tag on the switch.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.

2. Lock out the power


source according to an
approved lockout-tagout
program.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.

42SXside.eps

PRODUCT OVERVIEW
First Commissioning ................................................................................. 36
Concrete Pump Circuit.............................................................................. 37
Hydraulic Components ............................................................................. 38
Function Diagrams.................................................................................... 44
Vector Control System .............................................................................. 52
Optional concrete shut-off valve ............................................................... 53
Safety Devices .......................................................................................... 61
Component Location and Identification .................................................... 64

Operation Manual - S 42 SXG


Overview

Product Overview When your new Schwing was delivered, it was


accompanied by several documents in addition to this
First Commissioning operation manual. One of those important documents is
called the “DELIVERY INSPECTION REPORT”.
Each of the 35 items listed should be checked before
Installation of your new unit
your new pump is sent to the first job.

Operational Repair Comments*


Required (If repair is required)
1. Engine Coolant
2. Engine oil level
3.Transmission oil level
4. Oil level system l and ll
5. Oil level system lll
6. Transfer case or FTD oil level
7. Oil in gear compartment of Hyd. Pump 1
8. Oil level in dist. gear box (banana pumps)
9. Oil level in agitator gear box
10. Flushing oil level (gate valve system)
11. Oil level in compressor
12. Agitator greased
13. Rock valve greased (if equipped)
14. Drive line greased
15. Outriggers & boom greased
16. Manual & remote throttles set to proper
RPM’s ( RPM’s)
17. Setting of relief valve system l
18. Setting of relief valve system ll
19. Setting of relief valve system lll
20. Pressure gauges work system l&ll&lll
21. Hydraulic lines checked for leakage
(heat oil to 80˚ c)
22. Hydraulic oil cooler checked for
leakage and proper air flow
23. Water pump
24. Agitator
25. Forward-reverse for pumpkit
26. Outriggers
27. Remote control (boom) functions
28. Manual check of all hand valves
29. Holding valves on boom
30. All boom pin retainers in place
31. End hose cable hook installed
32. Tail light and clearance lights
33. Safety decals (see decal sheet)
34. Tools/Spare Parts (see tool check list)
35. Visual inspection of paint job
* Please note any other comments on back of white copy

36 Operation Manual - S 42 SXG revDate


Overview

This section provides an overview of the S 42 SXG in perfect synchronization. The Rock Valve is cycled
concrete pump circuit. It also identifies all of the unit’s back and forth by a third hydraulic cylinder called the
safety features and describes the functional Rock Valve slewing cylinder.
components of the truck cab, chassis, concrete pump, The method of getting the hydraulic cylinders to
and hopper area. change direction at the appropriate times is covered on
Schwing recommends that you read this section of the the following pages.
manual while you are near the unit so that you can
identify the components that are described. However, The hydraulic pumps that supply oil to the concrete
do not attempt to operate the concrete pump based on pumpkit adjust the amount of oil they deliver both by
information provided in this section alone. Read and internal pressure-sensing devices and by adjustment of
understand the entire manual before you attempt to external valves (the stroke limiter and/or the
operate the unit. dampener).
This operation manual deals primarily with the rock
type of concrete valve. If you have questions about
WARNING your concrete pump contact Schwing Service
Improper setup / operation creates
D-Herne.
hazards. Do not operate this machine
without training. Understand the
warnings in safety manuals and on
000099.eps

decals.

Differential
hydraulic
Concrete Pump Circuit cylinders

This Schwing concrete pump has a fully hydraulic,


twin-cylinder, reciprocating design (Figure 10). It
consists of two differential hydraulic cylinders
(differential cylinders), a waterbox that acts as a Water box

structural member for the mounting of the two pairs of


cylinders and as a container for flushing water, two Material
material cylinders, and a concrete valve (Rock Valve) cylinders
that directs the flow of concrete from the hopper to the
outlet piping.
During operation, when the hydraulic cylinder has
reached the end of its stroke, the Rock Valve cycles to
the opposite material cylinder (shown in Figure 10 as a
Rock Valve
dotted outline). The hydraulic cylinders then change
direction. The one that just finished pushing concrete
begins sucking concrete from the hopper, and the 000092.eps

cylinder that had been sucking concrete from the


hopper begins to push it into the pipeline through the
Rock Valve.
Figure 10
By switching to reverse operation, concrete can be Concrete pumpkit
sucked from the pipeline and pushed into the hopper.
The two differential hydraulic cylinders are connected
via hydraulic plumbing and share hydraulic oil on one
side of their pistons. This shared oil is called rocking
oil, and it is the rocking oil that keeps the two cylinders

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 37
Overview

Hydraulic Components

Soft switch
shutoff valve

Main pressure
gauge port
Soft switch
relief valve

000124.eps
Concrete pump
00
shutoff valve 01
03
.e
ps

Main relief valve

Figure 11
Locations of the concrete pump and soft switch shutoff valves (top)
and relief valves (bottom)

Hi-flo pumpkit components In a twin-circuit system, as soon as the S-3 spool


The Hi-flo pumpkit is assembled with some changes direction, oil is routed to the rock valve so it
components found in a different location than those can change direction, as well as to the valve that
which you may have seen on other pumpkits. The relief changes the direction of the differential cylinders. If
cartridges for setting the main concrete pump pressure the rock valve cylinder has enough pressure available
and the soft switch pressure (Figure 11, bottom) are to switch, it will do so. If it has insufficient pressure, it
mounted in the same block as the soft switch shutoff will wait.
valve. The quarter turn shutoff valves for the concrete When the differential cylinders change direction, one
pump and the soft switch (Figure 11, top) are both of the following happens:
located on the main control block (Brain). • If the rock valve has already switched,
concrete is drawn immediately from the
Twin-circuit switching (MPS) hopper and pushed into the pipeline with a
Twin-circuit systems have a hydraulic circuit to move normal stroke.
the differential cylinders, and a separate circuit to • If the rock valve has not already switched,
switch the Rock Valve. On Schwing units built before concrete begins to be drawn from the pipeline
1995, the main hydraulic pumps moved both the main and pushed into the hopper. This reduces the
differential cylinders and the rock valve. pressure in the pipeline to zero. As soon as
There are advantages to having a separate hydraulic pipeline pressure is relieved, the rock valve
circuit to switch the Rock Valve. For instance, with a moves across. Once the rock valve has moved,
stiff, lean mix and high pressure, a single-circuit concrete accelerates out of the pipeline in its
system does not always have enough pressure available normal fashion.
to move the rock valve. Generally, this deficit occurs The concrete is not pumped in reverse, because as soon
when the mix is being pumped straight up. The rock as the pressure in the pipeline drops to zero, the rock
valve must dislocate a column of concrete that still has valve switches. This system has the added benefit of
pressure on it from the stroke. The next stroke cannot reducing wear on the cutting ring, the spectacle plate,
begin until the rock valve has completed its travel. the kidney seal and kidney plate, and the rock valve
slewing cylinder. A complete description of the twin-

38 Operation Manual - S 42 SXG revDate


Overview

circuit switching sequence is shown in the function charged with dry, not liquid, nitrogen. Complete
diagrams contained in this section of the manual. recharging instructions are found in the
Single-circuit switching does have one advantage over Maintenance section of this manual.
twin-circuit switching: when a single-circuit pump is 3. Never charge an accumulator with oxygen or
shut off, no pressure exists in the system. Certain compressed air. Under pressure, oxygen can
hydraulic lines could be safely opened with the engine contact some of the molecules of hydraulic oil and
running and the concrete pump in the OFF position lower the flash point of the oil to below room
(But don’t do it. ALWAYS shut off the engine before temperature. If the oil flashes, the accumulator will
working on hydraulics.) explode.
This is not the case with twin-circuit switching. 4. Never work on the accumulator, the rock valve
Whenever the engine is running, pressure is being cylinder, the cutting ring, or any other connected
stored in an accumulator. If a line is removed, oil will component with the engine running. After shutting
be discharged, which raises the possibility of injury to off the engine, remove the key and place it in your
bystanders. pocket. Then verify zero pressure on the
Accumulator safety rules accumulator gauge before opening or working on
any of these items.
Whenever you work with accumulators, be sure to
5. Never improvise the tools or equipment needed to
follow these simple Accumulator Safety Rules.
recharge the accumulator. The correct tools are
1. Never assume that the accumulator has no stored shown in the Maintenance section of this manual.
pressure. Check the gauge before removing any
6. If the accumulator develops a gas leak, an oil leak,
lines, valves, or fittings. Verify zero pressure, and
or a ruptured bladder, return it to Schwing Germany
periodically check that the gauge is in good
or to the manufacturer for repair. Do not attempt to
working order.
repair the accumulator yourself.
2. Recharge an accumulator (i.e., add nitrogen) only
after you read and understand all the instructions When in doubt, find out. Never make any assumptions
for recharging accumulators. Accumulators are regarding accumulators or the circuits they drive. If
you are not sure, call the Schwing Germany Service.

00
01
Accumulator
25
.e
ps

MPS manifold

000126.eps

Figure 12
MPS manifold and system accumulator

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 39
Overview

Twin circuit switching


The fully hydraulic twin-circuit pump control system is
shown in Figure 13. This operation manual covers rock
type concrete valves.
;;
;;
5

;;
;; Emergency
stop
manifold

20

6 S3 boom

13
18
9A 16
14 15 17

9B

21
10A 10B

11

S2 7

S1 4

25

3
10C
23 12
22
2
24 10D 19
8A 8B

1
000130.eps

1. Hydraulic oil reservoir 15. Manual accumulator dump valve


2. Main hydraulic pumps 16. Accumulator pressure
3. Main pressure relief valve maintenance check valve
4. Directional control valve S1 17. Accumulator relief valve
5. Rock Valve slewing cylinder 18. Accumulator pressure gauge
6. Directional control valve S3 19. Accumulator hydraulic pump
7. Directional control valve S2 20. Accumulator redundant
8A - 8B. Differential hydraulic cylinders relief, E-stop manifold
9A - 9B. Reversing valves (MPS) 21. NG 10 valve for forward/reverse
10A - 10D. Check valves 22. Soft switch relief valve
11. Main shutoff valve (Ball cock) 23. Soft switch shutoff valve
12. Hydraulic return filter with bypass valve 24. Soft switch reversing valve
13. Accumulator 25. Main flow poppet valve
14. Pilot to close accumulator dump valve
Figure 13
Major components of the Schwing twin circuit, fully hydraulic pump control system

40 Operation Manual - S 42 SXG revDate


Overview

Switching groove Switching groove

Switching port Switching ports Tank Port


(for oil flushing)
;;;
;;;
;;;
;;;
;;;
;;;
000358.eps

;;;

Piston Switching ports


Oil port Oil port
to retract rod to extend rod

Figure 14
The Rock Valve slewing cylinder
(shown as item 5 in Figure 13)

Crossover position

Left end cap Right end cap


000091.eps

Parallel position

Figure 15
“S” valve diagram explanation for S2 and S3 valves
(shown as items 6 and 7 in Figure 13)

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 41
Overview

Guide bushing Piston

End stop

Rod
Rod Piston
side side

000131.eps

Cylinder at top dead center Cylinder at bottom dead center


(Fully extended) (Fully retracted)

Figure 16
Differential hydraulic cylinder diagram explanation
(shown as items 8A and 8B in Figure 13)

The term “differential cylinder” refers to the fact that The switching valves (Figure 17) have a logic function,
each of the hydraulic cylinders that push the concrete in that they sense multiple pressures simultaneously
have an area difference (referred to as an “area and will route oil from the poppet end port to the
differential”) between the two sides of the piston. This output port ONLY if the pressure from the poppet end
area differential is due to the fact that the rod extends port exceeds the pressure at the spring end port by
only from one side of the piston and not the other. This more than 2:1.
is in contrast to the rock slewing cylinder, for example,
which has a rod extending from both sides of the piston
and, therefore, has the same area on both sides of the
piston.

Spring end port

Spring

Output port Poppet


00
00
82
.ep
s

Poppet end port

Figure 17
Switching valve diagram explanation (shown as items 9A and 9B in Figure 13)

42 Operation Manual - S 42 SXG revDate


Overview

Hydraulic pump drive


All hydraulic pumps for the concrete pump, placing shaft, and into the rear end(s) of the truck. When you
boom, agitator, etc., are mounted on a distribution gear are operating the unit, the distribution gear case
case. When you are driving the truck, the power of the interrupts the power to the rear end(s) and transmits it
truck engine is transmitted through the truck to internal gears that turn the hydraulic pumps.
transmission, to a propeller shaft, through the bottom Changing between travel and pumping modes is
of the distribution gear case, to another propeller accomplished by means of a switch in the truck cab.

ps
96.e
0000

Figure 18
Distribution Gear case

Placing boom hydraulic pump


The hydraulic pump for the placing boom (Figure 19)
is a variable displacement pump, either a swash plate
(A11VO) or an axial piston (A7VO). Both have load
sensing control and feed all of the following
components:
• the hydraulic cylinders on the boom sections
• the hydraulic cylinders on the outriggers
• the hydraulic motor for the boom slewing gear 000132.eps

• the hydraulic motor for the water pump Figure 19


• the hydraulic motor of the compressor A11VO (above) Boom pumps and
(optional equipment) A7VO (below)
The directional control valves for each of the afore
mentioned circuits are incorporated into control blocks
and are equipped with hand levers. In addition, the
control block for the boom functions have electric over
oil piloting for operation via remote control.
000133.eps

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 43
Overview

Function Diagrams • The oil that is forced out of the piston side of
the right differential cylinder (8A) flows
The following diagrams A through D show the through hoses into the piston side of the left
switching functions of the fully hydraulic pump control differential cylinder (item 8B). This oil is
system plumbed on ROD SIDE with simplified called rocking oil (orange).
schematics. The agitator, boom, and S-1 control • The rocking oil forces the left side differential
circuits are not shown. For information on ROD SIDE cylinder (8B) to extend. The cylinder rod
and PISTON SIDE configurations, see the pages extends, pushing concrete out of the material
following these function diagrams. cylinder, through the Rock Valve, and into the
pipeline. (This is called the pressure stroke.)
Phase A Hi-flo
• The oil from the rod side of the left differential
Please note that right and left refer to the orientation cylinder (8B) is routed back to the tank
you would have if you stood on the unit by the Rock through the return filter (12). The low pressure
Valve, looking toward the cab of the truck. oil is shown in green.
• As soon as you switch the unit distribution • The oil shown as blue, such as the oil in the
gearcase to the pumping position, the accumu- reservoir, is at rest, or pressureless.
lator hydraulic pump (20) begins pumping
high pressure oil (red) to charge the accumula-
tors (14).
• High pressure oil (red) continues to flow into
the accumulator circuit until the accumulators
(14) are charged to the pressure cut-off point of
the accumulator hydraulic pump (20). When
the cut-off point is reached, the accumulator
pump reduces the hydraulic oil flow until there
is just enough to maintain the cut-off pressure.
• The high pressure oil (red) from the accumula-
tor circuit flows through the S3 directional
control valve (6), which is in the parallel posi-
tion, into the extend side oil port of the rock
slewing cylinder (5).
• The rod of the rock slewing cylinder (5)
extends, if not already extended.
• The S1 directional control valve (4), which
controls whether the unit pumps in forward,
neutral, or reverse, is put into the forward posi-
tion.
• A pilot signal (high pressure oil) is routed from
the accumulator circuit to the end cap of the S2
directional control valve (7), which moves into
the parallel position.
• High pressure oil (red) flows from the main
hydraulic pump (2) through the parallel posi-
tion of the S2 valve (7) into the rod side of the
right side differential cylinder (8A). The cylin-
der retracts, which creates a vacuum in the
material cylinder. The right side material cylin-
der fills with concrete. (This is called the suc-
tion stroke.)

44 Operation Manual - S 42 SXG revDate


Overview

5
;;
;;
Phase A Hi-Flo
;; KEY
High Pressure
Rocking Oil Pressure
Low Pressure
Zero Pressure
(Tank, or oil at rest)

6
S3

14
To e-stop
manifold
9A 17
15 16 18
9B

23
10A 10B

11

S2 7

S1 4

26

3
10C
25
24
27 10D
8A 8B

2
12
20

1
000134.eps

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 45
Overview

5
;;
;;
Phase B Hi-Flo
;; KEY
High Pressure
Rocking Oil Pressure
Low Pressure
Zero Pressure
(Tank, or oil at rest)

6
S3

14
To e-stop
manifold
9A 17
15 16 18
9B

23
10A 10B

11

S2 7

S1 4

26

3
10C
25
24
27 10D
8A 8B

2
12
20

1
000135.eps

46 Operation Manual - S 42 SXG revDate


Overview

Phase B Hi-flo
Please note that right and left refer to the orientation
you would have if you stood on the unit by the Rock
Valve, looking toward the cab of the truck.
• The left side differential cylinder (8B) reaches
top dead center. If there is so much rocking oil
in the loop that the right side differential cylin-
der (8A) cannot retract to the bottom dead cen-
ter position, then oil is removed now through
check valve 10C.
• The right side differential cylinder (8A)
reaches bottom dead center. As the piston
reaches the guide bushing, it exposes a port to
the end cap of the reversing valve (9A), which
becomes connected to high pressure oil (red).
The left end cap of the reversing valve (9A) is
connected to low pressure oil (green), so the
reversing valve slides into the parallel position,
sending high pressure oil (red) toward the end
cap of the S3 valve (6).
• The pressure signal reaches the S3 valve end
cap (6), pushing the valve into the cross-over
position.
• The oil on the right end cap of the S3 valve (6)
flows back to tank (1).
• In the cross-over position, the S3 valve (6)
routes oil from the accumulators to the retract
port of the Rock Valve slewing cylinder (5).
The cylinder begins to retract.
• The oil from the extend side of the Rock Valve
slewing cylinder (5) is routed back to tank (1).
• Shown in beginning position in phase B sche-
matic. A pilot signal (high pressure oil) is
routed from the accumulator circuit to the left
side end cap of the S2 directional control valve
(7). The S2 valve slides into the cross-over
position.
• As the rock slewing cylinder (5) retracts,
pressure in the accumulator circuit falls. When
it drops below the set point of the accumulator
hydraulic pump cut-off pressure, the
accumulator hydraulic pump (20) increases the
flow of hydraulic oil to charge the accumulator
circuit (14).

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 47
Overview

Phase C Hi-flo
Please note that right and left refer to the orientation
you would have if you stood on the unit by the Rock
Valve, looking toward the cab of the truck.
• The Rock Valve slewing cylinder (5) reaches
the bottom dead center position.
• High pressure oil (red) continues to flow into
the accumulator circuit until the accumulators
(14) are charged to the pressure cut-off point of
the accumulator hydraulic pump (20). When
the cut-off point is reached, the accumulator
pump reduces the hydraulic oil flow until there
is just enough to maintain the cut-off pressure.
• The S2 valve (7) has finished sliding. Oil is
now routed from the main hydraulic pump (2)
to the rod side of the left hand differential cyl-
inder (8B).
• As the left hand differential cylinder (8A)
moves, rocking oil (gold) reaches the left end
cap of the reversing valve (9A). The valve
closes because of the pressure applied and the
force of the return spring. This removes the
pilot signal to the left side of the S3 directional
control valve (6).
• As the left side differential cylinder (8B)
retracts, it creates a void in the material cylin-
der and concrete begins to flow in to fill that
void. (Suction stroke)
• The oil from the piston side of the left side dif-
ferential cylinder (8B) travels through the
hoses to the piston side of the right hand differ-
ential cylinder (8A), forcing it to extend. In the
material cylinder, the concrete from stage A is
forced out into the delivery pipeline. (Pressure
stroke)
• The oil from the rod side of the right hand
differential cylinder (8A) is routed through the
S2 valve (7), through the return filter (12), and
back to tank (1).

48 Operation Manual - S 42 SXG revDate


Overview

5
;;
;;
Phase C Hi-Flo
;; KEY
High Pressure
Rocking Oil Pressure
Low Pressure
Zero Pressure
(Tank, or oil at rest)

6
S3

14
To e-stop
manifold
9A 17
15 16 18
9B

23
10A 10B

11

S2 7

S1 4

26

3
10C
25
24

27 10D
8A 8B

2
12
20

1
000136.eps

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 49
Overview

5
;;
;;
Phase D Hi-Flo
;; KEY
High Pressure
Rocking Oil Pressure
Low Pressure
Zero Pressure
(Tank, or oil at rest)

6
S3

14
To e-stop
manifold
9A 17
15 16 18
9B

23
10A 10B

11

S2 7

S1 4

26

3
10C
25
24

27 10D
8A 8B

2
12
20

1
000137.eps

50 Operation Manual - S 42 SXG revDate


Overview

Phase D Hi-flo
Please note that right and left refer to the orientation
you would have if you stood on the unit by the Rock
Valve, looking toward the cab of the truck.
• The left side differential cylinder (8B) retracts
to bottom dead center. The right side differen-
tial cylinder (8A) approaches top dead center.
• If there is not enough rocking oil to completely
extend cylinder 8A, rocking oil will now be
added through check valve 10D.
• When the left side differential cylinder is in the
top dead center position, pressure is applied to
the right end cap of the reversing valve 9B. The
left end cap of the reversing valve is connected
to low pressure, so the valve slides into the par-
allel position. The reversing valve routes the
pilot signal to the right side end cap of the S3
valve (6).
• The S3 valve (6) moves to the parallel position
in response to the pilot signal. The oil in the
left side end cap of the S3 valve (6) escapes to
tank.
• High pressure oil (red) is routed from the accu-
mulator circuit through the S3 valve (6) to the
extend port of the Rock Valve slewing cylinder
(5).
• The Rock Valve slewing cylinder (5) extends,
sending the retract side oil back to tank (1)
through the S3 valve (6).
• As the rock slewing cylinder (5) extends, pres-
sure in the accumulator circuit falls. When it
drops below the set point of the accumulator
hydraulic pump cut-off pressure, the accumu-
lator hydraulic pump (20) increases the flow of
hydraulic oil to charge the accumulator circuit
(14).
• At the same time that the Rock Valve cylinder
is extending, a high pressure pilot signal is sent
to the right end port of the S2 spool. It slides
into the parallel position. When it has com-
pleted the travel, oil is routed from the main
pump (2) to the rod side of the right hand dif-
ferential cylinder (8A).
• This brings us back to phase A. The machine
has made one complete cycle, which consists
of 2 suction strokes and 2 pressure strokes.

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 51
Overview

Vector Control System


The S 42 SXG is controlled by the Vector control
system (Figure 20). The Vector system will interface
with the Omnex remote boxes, which allows
consistency of remote operation (similar to other
Schwing units), but gives you the opportunity to step
up to the next level of controller technology.
Figure 20 shows the location of the Vector control
system in the tool box near the hydraulic manual
control enclosure.

vectorcontrol.eps

Figure 20
Vector controller found in passenger side enclosure near hydraulic controls

52 Operation Manual - S 42 SXG revDate


Overview

Optional concrete shut-off valve

pinchvalve.eps

Figure 21 slider.eps

Concrete shutoff valve


Figure 22
The concrete shut-off valve is an optional piece of Pressure regulator/Control valve
equipment designed to stop the flow of concrete from
the end hose after the pump has been stopped. Slider (control) valve
The yellow slider valve shown in Figure 22 is the
In-line shut-off valve (pinch valve)
control valve which supplies air to the concrete shut-
The valve (Figure 21), sometimes referred to as a pinch off valve. When the slider creates an open path, air is
valve, is an in-line device attached to the tip elbow of supplied to the concrete shut-off valve. When the slider
the boom and never needs to be removed. Therefore, it is closed, air cannot reach the regulator; the hose shut-
is available with the elbow welded in place or with a off valve is disabled, and the entire air line is bled off.
standard flange, which allows it to be clamped to the
tip elbow. The inside portion of the valve is an Regulator location
inflatable bladder which closes off the 5-inch concrete The pressure regulator/control valve is located in one
supply line when inflated. An indicator on the side of of the unit’s tool boxes. Usually it will be mounted in
the valve protrudes to inform the operator when the the enclosure which houses the Vector controller
valve is closed. (Figure 23)

Air supply line


An air supply line runs from the air tank of the truck,
through a regulator in one of the truck’s toolboxes, up
the boom to a quick disconnect fitting located very near
the tip elbow. The air line from the shut-off valve can
be quick-coupled to the fitting on the boom.

Pressure regulator/control valve


sliderlocate.eps

Regulator
Figure 23
The concrete shut-off valve is designed to operate
Pressure regulator/control valve
normally at 40 PSI. Depending on the length of your
located in Vector controller enclosure
boom and the type of concrete you are pouring, the
pressure can be adjusted up or down to achieve the
desired performance of the valve. If concrete continues
to dribble out after the valve has inflated, you may wish
to increase the pressure in increments of five PSI until
it no longer drips. Pressure is adjusted by turning the
knob above the pressure gauge (Figure 22).

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 53
Overview

Options box The bottom switch (Figure 25) is used to control the
The “Options” electrical box is found on the wall of the function of the optional concrete shut-off valve.
enclosure housing the Vector controller. The three position switch allows the operator to control
the function of the valve in three different modes:
• Position number one is “Auto-mode”. This
mode should be used for normal operation.
The shut-off valve will work in relationship to
the concrete pump on-off switch. When the
machine is pumping, the concrete shut-off
valve is open, and when the pump is stopped,
power is removed from the solenoid and the
valve inflates to stop concrete from draining
out of the end hose. The valve can be
overridden via the remote box. If you are
standing near the boom with the remote box
and wish to drain the concrete from the boom,
activate the switch in Figure 25 to the down
position, which is the concrete shut-off valve
icon, and the valve will open. The switch is
located to the left of the E-stop button on the
remote box.
Concrete shut-off valve
disable switch

optionsbox.eps

Figure 24 shutoffswtch.eps

Electrical options box for Vector units 1


30356534 C
2
3

3036 2348
5 6
4
7
3

8
2

9
1

0 10

Night light switch switchlocation.eps

valveicon.eps

Figure 26
Switch on the remote box (left)
shut-off switch and valve icon (right)
lightswitch.eps

• Position number two closes the valve full time.


The top switch on the option box (Figure 24) is used to
activate the optional night light kit. NOTE!
Do not activate the concrete pump in this
Concrete shut-off valve switch mode with full air pressure on the valve.
Damage could occur!
• Position number three supplies power to the
concrete shut-off valve full time and disables
the valve. This position can be used instead of
the disable switch, shown in Figure 26, to
switch123.eps
allow the boom to drain prior to inserting a
cleanout ball or any time the concrete needs to
Figure 25 be removed from the boom by gravity.
Concrete shut-off valve switch

54 Operation Manual - S 42 SXG revDate


Overview

Vector Control • The information that is gathered by the control


Your unit is equipped with the Vector digital control system can be sent anywhere. Technology has
system. It is a completely digital control system, which made it possible, for example, to transmit the
means that the function movements are converted to control signals over a modem to a remote
numbers (0’s and 1’s). The numbers are sent to the location, where a service person can “watch”
controller (Figure 27) where they are analyzed, the unit pump in real time. This would be an
converted back to analog (voltage or current), and sent enormous help to someone engaged in
to the valves and indication devices. Digital systems troubleshooting. The data could also be
have several advantages over analog systems: recorded, so it could be analyzed at a later
time. These features are not yet available, but
• Only a few light gauge wires are needed to
the system is under development.
send and receive the information from the
control panels. This means you don’t have to
System components
drag a heavy remote cable around or wrestle
with very large, multipin connectors. The Vector Control system consists of the following
• No misadjustment is possible. Because the components:
signal is in the form of numbers, you simply • A cable remote control box
set the parameters that you desire and forget it. • A radio remote control box / transmitter
• The system is capable of self-testing. On (Omnex)
startup, the controller checks itself and certain • A radio receiver / battery charger
other components for errors. If any errors are • The rear operation panel (typically called the
found, they are displayed and/or remembered “rear panel”)
for troubleshooting purposes. Faults detected • The digital controller
at certain times and places are announced by • Various sensors (placed around the unit)
the system by sounding the warning horn(s).

ANALOG 0 mA
PROPORTIONAL 00
1
0 to

Potentiometers
7.5 volts
20

Proportional
amplifiers
6 to 9 v olts TO
BOOM

DIGITAL 0 mA
00
1

PROPORTIONAL
0 to

A/D Converters 010


20

Digital control
01010
system
(Comfort control)
1 10 1 0 110 TO
D/A Converters BOOM

000139.eps

Figure 27
Comparison of analog and digital systems

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 55
Overview

Controls and indication devices switch in the center disables the joysticks. Use this fea-
ture when you momentarily put the remote control box
down but want the concrete pump to continue. If you
∅=

27 mm
pushed the E-stop switch instead of centering the boom
speed switch, all functions would stop.
∅ = 47 mm ∅ = 47 mm

1
144P The emergency stop switch interrupts an
2
3 303623
49 active signal to the controller. This signal
303623
48

4
5 6
is always being sent, and when the con-
troller does not receive the signal, it acti-

7
3

8
2

9
1
estopswt.eps
0 10

Vectorr&fRadio.eps
vates the emergency stop circuit. The
machine has several emergency stop switches, which,
Figure 28 excluding the remote control box when the machine is
Omnex radio remote in the local mode, are all active.

The concrete pump switch selects


The remote control box, whether radio or cable, is to be reverse (top position), off (0), or
considered the primary control device for the unit dur- forward (bottom position).
ing operation. The control functions for the cable
remote control and the radio remote control are identi- vectorboxcp.eps

cal, but there are some differences in the LED indica- The agitator switch controls agi-
tion messages. The Omnex radio remote box is shown tator on/off. The direction of the
in Figure 28. agitator shaft can be chosen by
selecting down to make it move
Remote control box functions forward and up to put it in
Here we will cover the purpose of each remote box reverse. vectoragit.eps

control function. We will begin with the concrete The status LEDs on the
shutoff valve disable switch, and move more or less remote box indicate the sta-
clockwise around the remote box. tus of the power, communica-
vectorboxleds.eps

The concrete shutoff valve disable tions, and E-stop systems. A


switch is used to bleed the air bladder complete list of the LED messages is given on page 59.
of the concrete shut-off valve in order to Turning the stroke limiter knob
facilitate draining the boom for clockwise increases the concrete pump
4
5 6
vectorconcshutoff.eps
strokes per minute. Turning it counter-
vectorstrklmpicto.eps

cleanout when the switch is placed in


7
3

8
2

clockwise decreases strokes per


9
1

the down position. The switch is dead 0 10

when in the up position. The symbol shown represents minute.


the ball injection system used in Europe and other parts Lifting the horn-reset switch to the
of the world. up position sounds the horn(s) on
your unit. Sounding the horn is useful
The radio on/off switch is used to acti- for signaling people. The down posi-
vate the radio remote control. In the up tion will produce a short beep and
(0) position, the radio is off. Moving the reset the system after using an e-stop
hornpict.eps

toggle down to the “|” position activates or will stop the horn from sounding
the box. This switch is not used (or when it has been activated by a minor fault alarm.
vectorremoteon.eps
needed) on the cable remote control box. NOTE!
The boom speed selector and joy Major fault alarms cannot be addressed by
stick disable switch: use the fast this switch. If your horn continues to beep
speed (rabbit) when folding and after activating the switch to reset, you must
unfolding or when fast boom move-
vectorboomspeed.eps return to the main controller, located in the
ments are appropriate for the job tool box, and check the large LCD display to
conditions. Use the slow speed (snail) when job condi-
tions require precise boom movements. Positioning the

56 Operation Manual - S 42 SXG revDate


Overview

determine the fault. Stop the horn with the


reset switch located above the Local/
Remote/Ram change switch.
Some units are equipped with a remote 1. #1 cylinder begins to
control engine start/stop. If your unit is 2. As the boom goes extend…boom travels up
beyond center, cylinder
vectorengsrtpicto.eps

so equipped, use the truck engine start


switch for starting and stopping the extension means boom
travels down
engine. To start the engine, move the
switch to the bottom position (|). To stop
the engine, move the switch to the top position (0).
Use the engine throttle switch to con-
trol the truck engine RPM. Push down
vectorthrtlpicto.eps

bmextup&dwn.eps
on the (+) switch to increase RPM, and
lift up on the (-) switch to decrease
RPM. Figure 29
Extension vs. direction
The vibrator/water pump switch con-
trols the hopper vibrator and water pump. we have added the boom #2 speed control switch.
To activate the vibrator, push the switch Your speed choices range from slow (|) to medium (||)
to the down position. The vibrator will to fast (|||).
run automatically when the concrete
vectorvibrator.eps These are the symbols for boom #1
pump is operating in the forward position. extend and retract joystick axis. See
To activate the water pump, push the switch to the up Figure 30 for the function location in
#1ext/rtrct.eps

position. The middle (0) position is off. relation to the other functions.
These are the symbols for boom slew-
Boom functions ing counterclockwise (CCW) and
Boom movements are shown as extend and retract clockwise (CW) joystick axis. Coun-
slewpicto.eps

instead of as up and down (Figure 29). terclockwise means rotating to the left at
The #2 boom section is acti- the top, and clockwise means rotating to the right at the
vated by depressing the joy- top.
stick handle pushbuttons.
#2rtract.eps
These are the symbols for boom #3
#2xtend.eps
The left and right joystick extend and retract joystick axis. See
each have a pushbutton which extends or retracts the #3ext/rtrct.eps
Figure 30 for the function location rela-
cylinder as indicated by the pictogram shown on each. tionship to the other functions.
Boom #2 is unique in that it does not
vectorbm2picto.eps These are the symbols for boom #4
have its own joystick axis. Instead, it extend and retract joystick axis. See
1 is activated by the pushbuttons on the Figure 30 for the function location rela-
#4ext/rtrct.eps

2
top of the joystick. The pushbuttons tionship to the other functions.
3
are not proportional. For this reason,

LEFT JOYSTICK RIGHT JOYSTICK


TIP #1
#1 DOWN #1 DOWN
TIP RETRACT RETRACT DOWN
TIP RETRACT PLUS PLUS
PLUS PLUS SLEWING CCW SLEWING CW
NTT EXTEND NTT RETRACT
SLEWING
NTT NTT COUNTER- SLEWING
EXTEND OFF RETRACT CLOCKWISE OFF CLOCKWISE
(CCW) (CW)

#1 UP #1 UP
NTT EXTEND NTT RETRACT PLUS PLUS
PLUS PLUS SLEWING CCW SLEWING CW
TIP EXTEND TIP TIP EXTEND #1
Figure 30 EXTEND UP
PUSH LEFT JOYSTICK DOWN PUSH RIGHT JOYSTICK DOWN
Joystick movement identification TO ACTIVATE SECTION #2 RETRACT TO ACTIVATE SECTION #2 EXTEND bignewjoystick I.D.eps

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 57
Overview

Rear operation panel functions

Throttle Switch Illumination Switch


Up = Increase engine speed Toggles the work lights
Center = OFF Engine Start/Stop Switch Down = ON
Down = decrease engine speed Not functional on most units. Up = OFF

High pressure
Water Pump/Compressor Switch
Water Pump Switch Up = compressor
Up = Optional switch for future use Center = OFF
(Activates nothing at this time) Down = Activates pressure washer
Center = OFF
Down = activates water pump
while in local control HP Concrete Pump Switch
Up = forward
R Center = OFF
Vibrator/Hose shut-off Switch Down = reverse
Up = Optional ball injection P
clean out system
Down = Controls the vibrator in
vectorrearpanel.eps
“Auto” mode meaning vibrator is
on when pump is in forward only) Electric Stroke Limiter
Control Agitator Switch
Up = Decreases concrete Activates the agitator
pump strokes per minute Up = reverse (R)
Down = Increases concrete (Center OFF)
pump strokes per minute Down = (forward) pump mode (P)

Figure 31
Vector rear panel
The Vector rear panel houses nine switches with the information with, as inspectors, laborers, and redi-mix
noticeable absence of the local/remote switch, which is drivers could run you out of water before you need it to
now found on the main controller (Figure 32). clean out.
Figure 31, above, explains the location and function of vectorlclrmt.eps

each of the nine switches. Each switch will be


addressed individually in the operation section of this
manual, and for more specific information you may
refer to the separate Vector controller booklet that
accompanied your unit.
As you can see by the description in Figure 31, the rear
1 2
OK
panel houses two different water pump switches. The 0 x1000 3
OFF

one on the right activates the high pressure water NA 1350 U/min

Menu:[ENTER]=Ein

pump, while the switch on the left gives you the option
of activating the regular water pump while in either
‘local’ or ‘remote’ operation. Selecting the down HOME + HELP START

position of the left switch gives you continuous use of CLEAR - ENTER QUIT

the water pump in ‘local’ control. Placing the switch in


the ‘up’ position will give you momentary use of the
water pump while the unit is in ‘remote’ control. You Local/Remote/Ram change switches
may want to be careful who you chose to share that Figure 32
Local/Remote and Ram change switches

58 Operation Manual - S 42 SXG revDate


Overview

LED status messages - Omnex Radio

Key
STARTUP SEQUENCE OFF ON FLASHING SLOW FLASHING FAST

STOP Power is on. An E-stop self-test is requested. Push the E-stop switch
to begin the self-test procedure. When the LED flashes faster, the test
is done. Release the E-stop switch. If the LED continues to flash fast,
the E-stop failed. Cycle E-stop. If not remedied, circuit failed.

When the communications LED becomes steady green, the unit is


ready to operate.
If the communications LED flashes green and STOP LED flashes red,
some function is activated, and the unit cannot reset.

OPERATION
STOP

When the communications LED is steady green, the unit is ready to


operate, but no function is activated.
When the communications LED flashes green, one or more functions
are activated, and the remote box is sending data.

FAULT MESSAGES (OPERATIONAL MALFUNCTIONS)


STOP If the communications LED flashes green, and the STOP LED is
steady red, the boom disable/speed switch is in the off position
while you are trying to run the joysticks. Selecting the snail position
(slow) or the rabbit position (fast) eliminates the fault.
If the STOP LED is steady red, the emergency stop switch is
activated on the radio.
If the battery LED flashes red, there are about 10 minutes of battery
power remaining. Change batteries as soon as possible.

FAULT MESSAGES (ELECTRONIC MALFUNCTIONS) LEDstat3.eps

STOP If the battery LED flashes red, the communications LED flashes
green, and the STOP LED is flashing fast, cycle power by removing
and replacing the battery. If LED’s continue to flash, open control box.
Check LED’s on base of joysticks. LED should flash every three
seconds; if not, the joystick module has failed. If the joystick is
operational, replace the transmitter board for the radio circuit.
If the battery LED is steady red, the communications LED is off, and
the STOP LED is flashing red, the micro board has failed. Cycle
power by removing and replacing the battery. If not remedied, replace
the transmitter board.

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 59
Overview

LED status messages - Omnex Cable

START-UP SEQUENCE ON OFF FLASHING


omnxcbl.eps

STOP

With no LED illuminated there is no power. Connect cable, or check


fuse.
STOP

With power LED and communications LED both on steady, the unit
is indicating valid data, all functions are off, and unit is ready to
operate.
STOP
If power LED is on steady, communications LED flashes green, and
STOP LED flashes red, it means that some function is activated,
and the unit cannot reset. Return all functions to neutral, and recycle
the E-stop.
OPERATION
STOP

When the power LED is on steady and the communications LED is


flashing green, one or more functions are activated, and the remote
box is sending data.
STOP

FAULT MESSAGES
STOP
When the power LED is on steady, the communications LED is off,
and the STOP LED is flashing red, the unit is indicating internal
interface failure. Cycle power by unplugging the cable and hooking it
back up. If not remedied, check for a faulty board or internal wiring.*
STOP
When the power LED is flashing, the communications LED is off*,
and the stop LED is flashing, the unit is indicating CAN-bus interface
failure. Check cable/truck wiring. If wiring is good, the problem could
be faulty wiring or circuitry on the 124-MC board.
STOP
When the power LED is flashing, the communication LED is
flashing, and the stop LED is flashing, the unit is indicating joystick
failure. Cycle the power by unplugging the cable and hooking it back
up. If not remedied, open box and check bottom of joystick. LED at
base of stick should flash every three seconds if functioning
properly.
* Note: the communications LED may also flash occasionally on a CAN-bus failure but not
with any constant pattern.

60 Operation Manual - S 42 SXG revDate


Overview

Safety Devices
The emergency stop switches (Figure 33) are located
This section lists the safety devices found on your on the main control panel, as well as on both control
pump. The items listed here must be kept in good boxes, on either side of the hopper, on the manual
working condition, or injury may result. Bypassing a boom control pedestal, near the water box and by each
safety device for servicing, emergency foldup, or set of outrigger controls. All eight emergency stop
cleanout should be done only by persons who know switches are wired in series, so they do exactly the
what systems are disabled by the bypass procedure. same thing. The emergency stop switch on the remote
Any safety devices that have been bypassed must be set control box does not work when the remote box is not
back to the original position upon completion of the plugged in.
service or emergency procedure.
NOTE!
Emergency stop switches Whenever the cable remote control or the
radio remote control are not plugged into
The emergency stop switches cut off electricity to the the control receptacle, you must install the
boom and concrete pump forward/reverse pilot valve. dummy plug, or the unit will not function!
In addition, they stop the electrical path to the (Details are found on page 75.)
“emergency stop manifold”.
Hopper grate interlock
The agitator hydraulic circuit runs through a normally
open directional control valve that routes oil directly
from the pump back to the tank if the following safety
conditions are compromised:
• electricity is lost on the unit
Manual • the hopper grate is raised
boom • the hopper grate is removed
Outrigger controls Although this safety device is good protection, you still
controls need to remember to never put your hands, arms, legs,
or anything other than concrete into the hopper when
Outrigger the hydraulic system is engaged.
controls
Safety valves (pressure-relief valves)
Water box The pressures listed on hydraulic schematics and in
manuals and literature are not nominal figures. They
are the pressures with which the machine was designed
to work and which the components were designed to
accommodate. In a very few instances, pressures may
be adjusted to accomplish certain things, but this may
be done only with the advice and step-by-step
Rear control
instructions of an authorized Schwing representative
panel familiar with the system and safety devices. Under no
circumstances should you raise pressures arbitrarily or
Beside because you believe it “might help.” In addition,
Beside
hopper lowering pressure settings may cause poor machine
hopper
performance, heat and premature component
degradation, and, in extreme cases, dangerous
Figure 33 operation.
Location of emergency stop switches other
than the two control boxes

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 61
Overview

Emergency stop manifold


Since January 1997, all Schwing pumps have been
equipped with an emergency stop manifold (Figure
34). BY-PASS
Figure 35 NORM. BY-PASS
Boom /outrigger
bypass switch
Boom (right)
Y66 location of
Concrete Pump switch on
Y63 Vector controller
Y64 (below)
Accumulator 000196.eps

Bypass
key switch

Figure 34
Emergency stop manifold bypasskey.eps

Three emergency shutoff valves (“dump valves”) are


installed in the E-stop manifold. The dump valves
(Figure 34) are a normally open valve, which means
that electricity must be present before the valve can
close and pressure can develop in the hydraulic
circuits. If the electrical wiring develops a problem or
if an emergency stop switch is activated causing a
power loss to the solenoids, the dump valves open and
route all oil from the hydraulic pump directly back to
the oil tank. It is not possible to operate any of the
hydraulic circuits while the dump valves are open.

Emergency bypass procedure When the key is activated from normal to bypass, it
To fold up the boom after an electrical malfunction has supplies power to the dump valves and prevents them
opened the dump valves, the system is equipped with a from routing the oil back to tank. The bypass should be
manually operated bypass switch. This is a small key activated only if you have developed electrical
switch on the front wall of the enclosure that houses problems and must fold up the boom and outriggers to
the main controller (Figure 35). get to a location where repairs can be made. When any
dump valve is bypassed, the emergency stop switch is
not functional for that circuit.

62 Operation Manual - S 42 SXG revDate


Overview

Safety guards Never adjust the relief valve setting on a holding valve
In addition to the safety devices just discussed, there while it is on the boom. There is no way to tell what
are guards placed over moving parts: pressure setting you are making, and structural damage
could result.
• waterbox guards
• boom slewing gear drive
H.E.R. valves
• hopper grate
• water pump drive grate Two hydraulically unlockable check valves (H.E.R.
valves, or holding valves) on each boom cylinder
• slewing cylinder cover
(Figure 36) prevent the boom from coming down
These guards were placed for your protection. Do not unintentionally. See the boom schematic in the
operate the machine unless all the safety guards are in Appendix section of this manual for further details.
place. If they become damaged, lost, stolen, or
inoperable for any reason, they must be replaced before Fuses
operation continues.
Fuses are devices intended to protect against complete
system failure, fire, and dangerous operation. They do
Hydraulic safety devices—boom and
so by melting when the current in an electrical circuit
outriggers becomes higher than it is allowed to be. Some causes
The holding valves on the boom and outriggers stop the of overcurrent are shown in the following examples:
cylinders from retracting if hydraulic pressure is lost • short circuits (positive goes to negative without
for any reason, such as if a hydraulic hose or fitting resistance)
blows. Pressure must be applied to the holding valves • component malfunction (a coil that has to
from the hydraulic system before the cylinders can move a sticky valve)
extend or retract.
• mechanical interference (a shovel handle is
A relief valve is located in the holding valves to stuck through the oil cooler fan blade, for
prevent cylinder failure due to excessive pressures and example)
boom damage due to excessive forces.

000367.eps

Figure 36
Holding valves mounted on a hydraulic cylinder (H.E.R. Valves)

To maintain this safety device, simply replace a blown Warning labels


fuse with the correct size and type fuse, and never Each machine is equipped with a set of warning labels
bypass a fuse. A very good rule of thumb for fuses is specific to the model, boom style and installed options.
this: If it blows once, replace it. If it blows again, Ultraviolet radiation, rain, steam cleaning, and other
something is very wrong. Find the cause of the forces cause these labels to fade in time. It is very
problem, and repair it before activating the circuit important that the machine have a complete and
again. readable set of warning labels at all times. Schwing
supplies warning labels without charge for as
long as the machine is in service. To get replacement
labels, identify which label(s) you need from the

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 63
Overview

diagrams and lists on the fold-out brochure provided in Component Location and
the Appendix section of this manual. Then get the serial
number of the unit from the serial number plate, which Identification
is located on the subframe, behind the cab on the driver Location and identification of the operational
side, and call the Schwing Spare Parts. components of your concrete pump are discussed in the
The person taking the following pages. This information is for identification
order will make a note of the serial number of the unit only. Do not attempt to operate the machine from
for our files and send you the labels you need. You may information obtained from this section.
order complete sets or single labels. If the serial
number plate is missing or unreadable, the number is Truck cab component identification
stamped into the subframe just below the normal
location of the serial number plate. For installation Figure 37 shows the components in the truck cab. The
locations, see the decal location guide insert at the end components are usually mounted on a console to the
of the Appendix section. right of the driver’s seat or on the dash to the right of
the steering wheel.

PULL
TO APPLY
PARKING
BRAKE QUARTZ
PUSH TO 00000.1
RELEASE 1 HOURS

PTO pull switch


000156.eps Hour Meter
Warning lamp

Figure 37
Truck cab components

• Hour meter (Figure 37).The hour meter is


supplied with current whenever the hydraulic
pumps are engaged. It indicates how many
hours are on the hydraulic circuit. Do not rely
on this meter for information about the truck
hours, which will probably be much higher.
• Warning lamp (Figure 37).This lamp
illuminates when electricity is supplied to it by
the PTO pull switch. Whenever the lamp is
illuminated, the PTO is engaged and the truck
should not be driven.
• PTO pull switch (Figure 37).This knob
replaces the way valve and electrical switch on
older units. When this switch is pulled, the
PTO is engaged, the drive lines are
disconnected from the rear end, and electrical
power is supplied to the rear operating control
system.

64 Operation Manual - S 42 SXG revDate


Overview

Omnex receiver

smgrstim.eps

Autolube timers

Battery charger

vectoromnxrcvr.eps

Figure 38
Omnex receiver and battery charger

Components formerly in cab


• Omnex radio remote control receiver. If you
purchased the optional radio remote control,
the Omnex receiver is located on the back wall
of the same tool box as the main controller.
The battery charger is mounted in the same
area (Figure 38).
Frequency control
• Autolube timers (Figure 39). These timers
allow you to adjust frequency and duration of Recycle button
grease output from each of the autolube
feeders on the boom, pumpkit and chassis.
Locations of the feeders can be found in the
Appendix section of this manual. Timers on Duration control
vogltimr.eps

early production models were found in the cab


as shown in the top illustration of Figure 39.
On current production models they are located Figure 39
on the tub as shown in the lower illustration of Autolube timers
Figure 39. Other information about the
autolube system can be found in the VOGEL
Centralized Lubrication manual provided with
For more specific information about your truck, refer to
your new pump.
the manual supplied with the truck. Because our
customers use many different truck models, the
features of each different model are not covered in this
manual.

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 65
Overview

Passenger side outrigger controls • The Front Foot jacking handle controls the
The passenger side outrigger handles control the front jacking cylinder. Pull the handle to
slewing, extension, and jacking of the outriggers on the extend the cylinder, and push to retract the
passenger side. cylinder.
• The Front Extend/Retract handle activates
the hydraulic cable drive motor that extends
new45ps.eps

and retracts the front outrigger. Pull the handle


to extend, and push to retract.
Outrigger Pushbutton • The Rear Outrigger locking latch (Figure
REAR SLEW REAR JACKING FRONT JACKING FRONT EXTEND 41) is positioned near the hopper on the end of
the outrigger and is released by lifting the pin
30354359

and turning it to the unlocked position.

45 ps outrig latch.epsL

Rear Slewing Front Extend/Retract

Rear Foot Jacking Front Foot Jacking

Figure 40
Passenger side outrigger controls
Locked
The E-stop and outrigger enable button are the same on
both sides; however, the control handles on the passenger Figure 41
side of the unit are configured differently than those on the Rear outrigger locking latch
driver side (Figure 42). (passenger side)
The front and rear outriggers have locking latches that
must be released before activation. The process of
setting the outriggers is described in the Operation
section of this manual. The functions of the controls
are as follows:
• The Outrigger pushbutton routes hydraulic • The Front Outrigger locking latch (Figure
oil from the boom control block to the 43) is positioned near the pivot point of the
outrigger control blocks. The outrigger front outrigger and is released by pulling the
pushbutton must be pushed and held during handle up to the open position.
any outrigger operation.
• The Rear slewing handle controls the rear
outrigger slewing cylinder extension and
retraction. Pull the handle to slew open, and
push to slew closed.
• The Rear Foot jacking handle controls the
rear jacking cylinder. Pull the handle to extend
the cylinder, and push to retract the cylinder.

66 Operation Manual - S 42 SXG revDate


Overview

Driver side outrigger controls


The driver side outrigger handles (Figure 42) control
the slewing, extension, and jacking of the outriggers on
the driver side of the unit. Please take notice that the
handles on the driver side are configured differently 45 outrig latch F ps L.epsl
45 outrig latch F ps U.epsl

than those on the passenger side (Figure 40).


new45ds.eps

Outrigger Enable button E-stop button Locked Unlocked


FRONT EXTEND FRONT JACKING REAR JACKING REAR SLEW

Figure 43
30354500

Front outrigger locking latch

Rear Slewing
• The Rear Outrigger locking latch (Figure
Front Extend/Retract
44) is released by lifting the pin and turning it
Front Foot Jacking Rear Foot Jacking to the unlocked position as shown.

Figure 42
Driver side outrigger controls
• The Outrigger Pushbutton routes hydraulic 45 rear ds outrig latch A.epsL

oil from the boom control block to the


outrigger control blocks. The outrigger
pushbutton must be pushed and held during Unlocked
any outrigger operation.
• The Front Extend/Retract handle activates
the hydraulic cable drive motor that extends
and retracts the front outrigger. Pull the handle
to extend, and push to retract.
• The Front Foot jacking handle controls the
front outrigger jacking cylinder. Pull the Figure 44
handle to extend the cylinder, and push to Rear outrigger locking latch (driver side)
retract the cylinder.
• The Rear Foot jacking handle controls the
rear outrigger jacking cylinder. Pull the handle
to extend the cylinder, and push to retract the
cylinder.
• The Rear Slewing handle controls the rear
outrigger slewing cylinder extension and
retraction. Pull the handle to slew open, and
push to slew closed.
• The Front Outrigger locking latch (Figure
43) is released by pulling the handle up to the
open position.

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 67
Overview

12 11
1 9
7 5 3 10

8 6 4 2

42sxgbmvlv2.eps

Figure 45
Manual boom controls

All functions of the 42 SXG which can be controlled 5. The boom #4 control handle is used to extend and
by use of the remote control can also be controlled retract section #4 by moving the control handle in
manually. The remote control should always be and out.
considered the primary method of control; however, the 6. The boom slewing control handle controls the
following pages will provide you with the location and direction of boom rotation by moving the handle in
identification of the manual controls which can be used and out.
if the remote control fails.
7. The water pump handle activates the water pump
when pushed in and the optional high pressure
Manual boom and pumpkit controls
washer when moved out.
The manual boom controls (Figure 45) are located in a 8. The boom/outrigger handle activates the boom
forward enclosure on the passenger side of the unit. control block when pushed in and the outrigger
1. The E-stop manifold houses the system dump control block when pulled out. Pulling this handle
valves. If you lose electricity to the controller for performs the same function as using the outrigger
any reason, including any emergency stop button pushbutton.
being pushed, the dump valves in the E-stop 9. The concrete pump handle operates the concrete
manifold will open. This will route oil from the pump forward when the handle is pushed in and
hydraulic pump directly back to the tank. operates the pump in reverse when the handle is
2. The boom #1 control handle is used to extend and pulled out.
retract section #1 by moving the control handle in 10. The agitator handle activates the agitator to the
and out. forward position when pushed in and to the reverse
3. The boom #2 control handle is used to extend and position when pulled out.
retract section #2 by moving the control handle in 11. The concrete pump pressure gauge indicates the
and out. hydraulic pressure being required for the concrete
4. The boom #3 control handle is used to extend and pump, and the faucet valve below it can be closed
retract section #3 by moving the control handle in to remove the gauge from the system.
and out.

68 Operation Manual - S 42 SXG revDate


Overview

12. The manual stroke limiter manifold allows the


user to override the electric stroke limiter in the
event of an electrical failure.
13. The bypass key switch (Figure 46) allows for
boom and outrigger control after an electrical
malfunction activates the E-stop dump valves. The
dump valves have an electrical bypass located in
the passenger side tool box, on the end of the
Vector controller. By activating the electric dump
valve bypass key switch, you can fold up the
boom and outriggers so you can move your unit to
a place where it can be repaired. You should not
attempt to finish the job with the dump valves
bypassed. When the dump valves are bypassed,
the emergency stop buttons will not function. For
information on where to look and what to do if you
lose electricity on the unit, contact the Schwing
Service Department at (0049) 2325 / 987-0.

Bypass
key switch

bypasskey.eps

Figure 46
Bypass key switch

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 69
Overview

Hopper area

45amhppr1.eps

8. Emergency stop
switch

2. Hopper grate
interlock switch

5. External spotlight
power receptacle

6. Agitator reverse button 4. Vibrator power


receptacle
1. Agitator R
HP

motor P

3. Horn alert button

9. Rear control
panel

7. Water supply valve

Figure 47
Hopper area components

The passenger side of the hopper area houses important to remember that you should never put
the components shown in Figure 47. any part of your body in the hopper or in the
1. Agitator motor. The agitator motor is a hydraulic concrete valve either from above (through the
motor that is directly coupled to the agitator shaft. hopper) or from below (through the outlet pipe or
Pressure required to run this circuit is 200 bar clean out door). You could be seriously injured.
(2900 PSI). 3. Horn alert button. If this button is pushed, the
2. Hopper grate interlock switch. The hopper grate warning horns on the unit will sound. The horn is
interlock switch is set on a cam system that is used for signaling and is spring-loaded to OFF.
activated only when the hopper grate is in the down 4. Vibrator power receptacle. This receptacle is
(pumping) position. When the hopper grate is present on your unit whether you ordered the
lifted, the concrete pump stops pumping, the vibrator option or not. If you decide to install a
agitator stops turning, and, on twin-circuit vibrator later, simply plug the unit into the
machines, the accumulator dumps. This switch receptacle. This is a 12-volt, 25-amp DC circuit.
differs from an emergency stop in that it has no 5. External spotlight power receptacle. This mates
effect on the boom or the water pump circuits. The with the plug on the end of the spotlight (described
interlock, like any mechanical device, is not fail in Schwing parts books as a “working reflector”).
safe, and, even with this switch installed, it is

70 Operation Manual - S 42 SXG revDate


Overview

This receptacle is “hot” (has available electricity)


whenever the PTO is engaged. On-Off functions
are accomplished with the switch on the lamp.
6. Agitator reverse button. This button is a
momentary contact switch that allows you to
temporarily reverse the directional movement of
the agitator. If the agitator is turning in the forward
direction, this button will change it to the reverse
direction as long as the button is held down. Since
this is a momentary contact switch, the agitator
will return to the forward direction immediately
upon release of the button. If the agitator is turning
in the reverse direction, this button will change the
movement to forward for as long as the button is
held down.
7. Water supply valve. This valve is a two direction
quarter turn valve. When turned in the up position,
it directs flow to the water box; when turned to the
down position, it directs flow to the water hose.
The water supply is not available to this valve until
the water pump switch is activated either on the
remote box or on the rear control panel, depending
upon which way the local/remote switch is
positioned.
8. Emergency stop switch. Pushing this switch
causes a dump valve (page 62) to open, which
disables all hydraulic circuits.The dump valves are
a normally open valve, which means that
electricity must be present before the valve can
close and pressure can develop in the hydraulic
circuits. If the electrical wiring develops a problem
or an emergency stop switch is activated causing a
power loss to the solenoids, the dump valves open
and route all oil from the hydraulic pump directly
back to the oil tank.
9. Rear control panel. The rear panel is an important
operational control device of the 42 SXG. The
panel contains switches for operation which are
identical to those on the remote box.

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 71
Overview

Outrigger cribbing pad holders Water reservoir


There are two sets of holders (Figure 48) for the The water reservoir is the tank that holds the water
outrigger cribbing pads—one on the driver side and used for filling the waterbox and for cleaning out the
one on the passenger side. The cribbing pads should be pump. It is located in the passenger side rear outrigger
stowed in these holders and locked into place whenever and holds approximately 160 gallons. The filler cap for
the unit will be moved. In most cases, the metal pads the water tank (Figure 49) is on the top of the outrigger,
on the outrigger legs are too small to be used without near the slewing pivot point.
the wooden cribbing pads. Be sure that you read and
understand the soil pressure requirements found in the
Operation section of this manual.

Water tank
filler cap

Figure 49
Water tank filler cap
(top of passenger side
rear outrigger)

Tool box compartments


Use the tool box to store the accessories (Figure 50)
supplied with the unit. The 42 SXG has ample storage
for these and many other tools and spare parts that you
might want to carry with you each day. The passenger
side compartment, which houses the Vector Control
unit, has a remote control box storage bracket which
we recommend you use during transport or any other
time you won’t be using the remote. Subjecting the
Figure 48 remote box to temperature extremes by storing it in the
Outrigger cribbing pad holders: cab can cause condensation inside the box. Moisture in
(top) locked for travel; (bottom) unlocked the box can corrode the electronic components and
cause them to fail. To help with this problem, Schwing
is now including adhesive-backed corrosion inhibitors
inside the radio remote box, the hard wire remote box,
as well as any other location which houses a board for
electronic circuitry. They will require replacement
every year. See the Maintenance section for more
information.

72 Operation Manual - S 42 SXG revDate


Overview

12
2
14
1
8
3 6
7 13
4
10

5 9
11
000169.eps

- .
.
.

.
.

Figure 50
Supplied accessories stored in passenger side toolbox

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 73
Overview

Fuel reservoir
The fuel reservoir (Figure 51) is in the driver side rear
outrigger and holds about 150 gallons of fuel. The fuel
reservoir filler cap is located on the top of the outrigger.

Fuel reservoir
filler cap

45fueltn.epsL

Figure 51
Fuel reservoir

74 Operation Manual - S 42 SXG revDate


Overview

Remote control receptacle

vectorremoteplug.eps

Figure 52
Remote control cable receptacle

The remote control cable receptacle


The receptacle (Figure 52) for plugging in the remote
control cable is located on the end of the Vector control
housing.
Either the cable remote cord or the radio remote cord
must be installed in the remote control cable
receptacle.
This end of the cable system is equipped with a 15-pin
connector. It has a double locking clamp that should
always be employed when the receptacle is used.
Never steam-clean or power wash the receptacle.

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 75
Overview

Vectorquickindex.eps

Figure 53
Safety Manual Quick Index pocket

Safety Manual Quick Index pocket


The pocket on the side of the Vector controller (Figure
53) is for keeping the Safety Manual Quick Index and
the laminated Short Instructions. The Short
Instructions are a duplicate of the last section of this
book and contain brief instructions for setup and
operation, as well as locations and functions of controls
and indicators. The Quick Index is a plastic-coated,
bound version of every rule found in Schwing
Safety Manual. The Quick Index contains
only the rules. Explanations, illustrations, and
appendixes are found in the complete, bound version
that was shipped with your unit. If the Quick Index has
been removed, damaged, stolen, or is unusable for any
other reason, Schwing will send you a new
one without charge. You can get this or the complete
Safety Manual by calling the Spare Parts Department.
The part number for the Quick Index
is 30327536 and for the complete Safety Manual,
30327535. Additional copies of the Operation
Manuals, Parts Books, and Short Instructions can be
obtained through Schwing Spare Parts
Department for a nominal fee.

76 Operation Manual - S 42 SXG revDate


Overview

Main hydraulic oil reservoir level gauge on the tank that indicates proper oil level
The main hydraulic oil reservoir houses the suction (Figure 54). This reservoir holds 169 gallons of
lines for all pump circuits, the return lines, the main hydraulic oil.
return filter, and all of the oil on the unit. There is a

oilgauge.eps

Oil Gauge

Figure 54
Hydraulic oil level gauge

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 77
Overview

42 Waterbox

WARNING

rs closed.
if
required.
ne/motor
s out of

Keep cove
Keep hand
.
Stop engi
access is
waterbox
WARNING

rs closed.
if
required.
ne/motor
s out of

Keep cove
Keep hand
.
Stop engi
access is
waterbox
Figure 55
Waterbox
(Covers removed for illustrative purposes)

Waterbox
The waterbox (Figure 55) is actually part of the pump
kit. The water in the box flushes the differential
cylinder rods and the back sides of the rubber rams,
keeping them cool. You must be very careful when
entering the waterbox area, as the hydraulic cylinders
that operate there are capable of tremendous forces.
Under no circumstances should you remove the covers
or guard when the pump is operating or ready to
operate. See the warnings in the Safety Manual
regarding the waterbox.

78 Operation Manual - S 42 SXG revDate


Overview

42 align.arrows.epsL

Figure 56
Boom alignment arrows

Alignment arrows
Boom alignment arrows are welded to the boom turret
and to the turret gear shrouding (Figure 56). The boom
turret turns, and the turret gear shrouding remains
stationary. By aligning the two arrows so they are
directly in line with one another when folding up, bring
the boom into the correct left/right position to be
lowered into the cradle. It is still wise to position
yourself so you can see the boom and A-frame as they
come together, so you can make minor adjustments. If
the arrows become damaged, it is critical to repair and
correctly realign them to avoid damage caused by
setting the boom on the A-frame.

speedy:opmanuals:42SX vector:42SXG:42SXGOverview.fm
Operation Manual - S 42 SXG 79
Overview

52hornon.eps
45turret.epsL

GREASE TOWER BEARINGS


GREASE TOWER BEARINGS ONLY GREASE WHICH HAS
THE FOLLOWING CHARACTERISTICS. USE LUBRIPLATE
MO-LITH NO 2, TEXACO MOLYTEX EP 2 OR EQUAL.
BASE TYPE
NLGI NO LITHIUM
WORKING PENETRATION RANGE AT 77°F 2
MOLYBDENUM DISULPHIDE 265/295
ASTM DROPPING POINT °F 3% MINIMUM
350 MINIMUM

Figure 57
Warning horns 3rd boom section (left) and turret (right)

Warning horns
Warning horns are located on the turret and third boom
section (Figure 57). They activate, producing a loud
blast, when the Vector control system recognizes any
fault, such as the oil temperature sensors detecting an
overheat condition or any number of a long list of
possible faults.
• Once the horn is activated, you can stop the
horn blasts by activating the “reset” to the “I”
position.
• If you discover that the fault is minor and you
can correct it later, activate “I” twice, and the
Vector controller will store the fault in memory
and allow you to proceed with the pour.
• The horns can be manually sounded when the hrnbtn.eps

“I” switch on the main controller or the remote


box is activated, as well as by using the horn
button (Figure 58) on the passenger side of the
Figure 58
hopper.
Warning horn button on
On units with Vector control systems, the horn must be passenger side of hopper
sounded as part of the reset procedure after the
machine is shut down by an emergency stop button or
by the Local/Remote switch being moved from one
position to the other.

80 Operation Manual - S 42 SXG revDate


Operation

WARNING

on
Do not stand
hopper grates.

S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR

PERFORMING ANY SERVICE:


Gasoline or Diesel Engines
1. Stop the engine.

2. Remove the key, place it


in your pocket, and put
a "DO NOT OPERATE"
tag on the switch.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.

2. Lock out the power


source according to an
approved lockout-tagout
program.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.

42SXside.eps

OPERATION
Preparation ............................................................................................... 82
Unit Setup ................................................................................................. 87
Prepare for the Ready-Mix Trucks .......................................................... 100
Lubricating the Pipeline .......................................................................... 104
Pumping the Job..................................................................................... 106
Cleanout ................................................................................................. 114
Special Pumping Situations .................................................................... 124
Emergency Procedures .......................................................................... 130
Other Things You Need to Know ............................................................. 132

Operation Manual - S 42 SXG revDate


Operation

Operation Arrive alert and on time.


A professional pump operator knows that the day will
This section contains information on equipment, tools, go better if time is set aside to do the pre-checks
preparation, driving the concrete pump unit, setting up outlined in the following paragraphs. If you skip the
the unit, pumping the concrete, and cleaning out after pre-checks because you are late for work, you are
the job is complete, as well as very important safety setting yourself up for a bad day or perhaps an
information presented in the form of key words: accident. Performing the pre-checks every day before
CAUTION, WARNING, and DANGER. Please read starting the job will verify that the machine is in tip-top
each and every key word message very carefully for shape and that all equipment and accessories are in
your own safety and the safety of those around this unit good working order. You need to be on time.
while it is in operation. Showing up for work with a hangover or without
enough sleep creates dangerous situations. Remember
Preparation that your co-workers are depending upon you for their
safety.
Before you pump the first job with this machine, you
must understand what you are doing. If you have never Use the right machine for the job
pumped concrete, become familiar with this entire
manual, the safety rules for pumping concrete as This manual is for a boom-mounted concrete pump,
described in the Schwing Safety Manual (included as a which is the correct machine for hundreds of job types.
separate section of this manual), the features of the However, if you need to pump the seventy-first floor of
machine, and the procedures for pumping concrete. It a high-rise, you are using the wrong machine. Knowing
is a good idea to set up the machine in a safe location which machine is right for your job starts with being
and practice with the pump and boom controls before informed. Schwing Sales or Service
you ever put concrete into the machine. When you are Department can help you select the correct machine.
on a job site with the machine, the safety of many other You can use any boom truck with confidence on all of
people will be in your hands, and it would be the following job types:
inappropriate and unsafe to make mistakes. Only • Wall pours within the range of the boom
experience in running the unit—especially the boom— • Slab pours of all types, on grade or above
will give you the confidence and fine control your co- grade, to the limit of the boom reach
workers expect and deserve. • Footings
If you are an experienced pump operator already, read • Columns
this manual cover to cover anyway to be sure you • Bridge decks
understand the particulars of your new machine. Set up
• Any other type of pour for which pressure and
the unit for a trial run before you take it to a job. You
volume requirements are within the range of
will be more comfortable knowing the locations of the
the unit. This range is documented on output
controls and devices and having a feel for the boom
charts in the Appendix section of this manual.
response.
Job requirements can be determined using
This manual discusses specific setup, cleanout, nomographs, also found in the Appendix.
maintenance, and operation techniques as they relate to
this particular machine. It is not the intention of this Have the right equipment
manual to make you an expert concrete pump operator.
Use the following checklist to help you to determine
For that, you will need the information from this
your equipment needs:
manual, as well as information from several other
sources (listed under “Additional Reading Material” in • Pipe sections
the Appendix) and extensive on-the-job experience. • Adapter pipes, if all pipe ends are not identical
• End hoses
• Reducers
• Clamps for all pipe end styles and sizes

82 Operation Manual - S 42 SXG revDate


Operation

• Clamp pins clamps and hoppers. Many pump operators remove the
• End hose dead plug wooden handle and install the hammer head on a steel
• Safety chains, cables, straps, or whipchecks for pipe. This makes it ideal for installing pipeline because
any and all devices that will hang over workers the handle can be used to pry clamp handles up or
or equipment down. Experienced pump operators never walk from
the pump to the pipeline without a hammer.
Inspect all pipes and pipe accessories for wall thickness
and condition, and have them loaded and secured for Finally, you will need all of the items required by law
travel before moving the unit. Keep in mind the for safe operation of a motor vehicle, as well as the
pressure rating of your unit when you inspect the necessary items needed for the job:
condition of the pipe accessories. Refer to the chart • Valid driver’s license
regarding pipe wall thickness and pressure in the • Fuel permit
Appendix section of this manual. • Cab card
In addition to the above, you will also need common, • Registration
everyday pumping accessories. Use the following list • Insurance card
for the minimum requirements of a normal pumping • First aid kit
job:
• Flares
• Shovel
• Reflector signs
• Barrel for mixing slurry (keep the barrel with
• Fire extinguisher
the unit at all times, even if you don’t plan to
use the barrel often.) • Job ticket
• Pipeline lubrication mixes; enough for the • Maps
day’s job—either commercial lubricating • Job site phone number and contact person
powder or portland cement for mixing slurry, if
required. (Sometimes slurry will be delivered
to you; at other times, the portland cement will
be supplied at the job site. You must always
know how your lubrication will be
accomplished before you leave the yard.)
• Grease gun and grease tubes
• Spray can filled with form oil or Kleen Kote
(not necessary, but very helpful)
• Cleanout balls or Go devil
• Water hose and nozzle
• Cleanout rake
• Working lamps for night work
• An approved air blowout cap (See the Safety
Manual for blowout cap requirements.)
• Five-gallon bucket
• Hand tools
• Hammer (2lb. to 4lb. wedged head works best)
Of all of these items, the hammer is the tool you will
need most often. It can be used to set up and remove
pipeline, to knock the wedges out of the tapered bend
for cleanout, to tap pipe to locate blockages (follow the
instructions in the Safety Manual), and it makes a good
device for knocking out concrete that has set up in

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 83
Operation

Use your personal protective equipment work that will protect your feet from lime and
accidental impact. The following protective clothing
(Figure 59) should always be worn to protect you from
WARNING chemical and all other job site hazards:
Personal injury hazard. Always wear • Protective rubber gloves and boots
safety gear when working with concrete • Hard hat

W018.eps
or equipment. • Safety goggles/glasses
• Safety vest
Concrete is made from lime, which is extremely • Snug-fitting work clothes
alkaline. If wet concrete stays on your skin long • Hearing protection
enough, it can cause severe burns. In extreme cases, it
• Breathing protection (when cement dust or
can cause the affected skin to fall off. When you work
exhaust fumes are present)
around concrete, wear water resistant gloves and boots.
When you work in concrete wear waterproof gloves • Full face shield (when around shotcrete or
and boots. In either case the boots should have steel other flying debris)
toes. There are boots made especially for concrete

HARD HAT

SAFETY HEARING
GOGGLES PROTECTION

BREATHING
MASK
SNUG
SAFETY FITTING
VEST CLOTHES

GLOVES

STEEL TOED
SHOES

SafegearWvest.eps

Figure 59
Wear personal protective equipment

84 Operation Manual - S 42 SXG revDate


Operation

Truck and pump checklist there is most likely a problem with the
integrity of the hydraulic seals somewhere
Check the following items each day before the machine in the system.
is taken from the yard:
Top off oil levels only with the same type of oil that is
On the truck in the reservoir. Do not mix name brands even if they
have the same viscosity. Each oil manufacturer uses a
• Truck engine oil level and condition
different additive package to accomplish anti-foaming,
• Antifreeze / coolant level in the radiator silt settling, anti-wear, etc. Mixing the different
• Battery fluid level and condition chemical additive packages may render them useless.
• Tire condition and proper air pressure Drain water from the hydraulic reservoir each morning.
• Brake system air pressure and condition (bleed This is done by opening the faucet located under the
water from air tanks) hydraulic reservoir and allowing the fluid to run into a
• Clean the windows of ice, frost, mud, and pan until the water stops and oil begins. (Water is
obstructions heavier than oil, so it sits on the bottom of the tank and,
• Clean the mirrors of ice, frost, and mud, and therefore, drains out first.)
align them properly for clear vision Fill your water tank before leaving, if it is allowed. In
• Keep the cab free of debris, especially on the some localities, filling the water tank may cause an
floor. Accidents can happen when foreign overweight condition for driving. If you cannot carry
objects get stuck between the clutch or brake water with you, be sure that there will be an ample
pedal and the fire wall supply of water at your destination. It is not possible
to pump a job without water! It is used in the
On the pump waterbox to cool the rubber rams and differential
Structural integrity of the unit is vital. Visually inspect cylinder rods, and it is necessary for cleanout. Ready-
the outriggers, boom, and tower areas. Look for cracks, mix trucks often carry more water than they need for
chipped paint, rust (especially under paint), and their own uses and will usually give the extra supply to
missing parts. Clean and repaint areas where the paint you. Verify this with the ready-mix company before
is chipped to prevent damage to the structural steel. you leave for the job.
Replace missing parts before using the unit. Report any NOTE!
structural abnormalities to Schwing Use only clean water to refill water tank.
Engineering Department before using the unit. If Never use reclaimer water.
Schwing’s engineers determine that repair is necessary Visually check the unit for hydraulic leaks, and repair
for safe operation, do not operate the unit until any leaks before operating the machine. Lost hydraulic
repairs are completed. Pipeline must be complete and oil harms the environment, and it is expensive to clean
free of dents, cracks, and holes. Pipe must have up and replace the lost oil.
sufficient wall thickness to handle the maximum
pressure of the pump. Inspect it weekly with an Be sure that everything on the unit is ready for road
ultrasonic thickness tester (see the Maintenance travel. This includes locking the outriggers, pinning the
section of this manual). All boom clamps must be outrigger pad holders, and securing all pipeline,
secure and pinned closed. All safety guards must be in pipeline accessories, and miscellaneous equipment.
place and secured for travel.
Check hydraulic oil level and condition. The oil should
be clear and clean looking. Milky-looking oil or oil
with many entrained air bubbles should be replaced
before the next job begins.
NOTE!
Oil that holds air bubbles overnight should
be replaced, but if it becomes bubbly on the
job, it is not an oil problem. In that case,

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 85
Operation

Driving the unit • It is always best to use the towing pin supplied
Many accidents involving concrete pumps are traffic by the truck manufacturer. On trucks that are
accidents. To avoid an accident when driving a so equipped, the towing pin is usually located
concrete pump truck, you must obey all traffic laws and inside the front bumper.
warning signs. A boom mounted truck is top heavy and • The 42 SXG is equipped with tow hooks on the
must be driven accordingly. front of the truck as well as on the rear
outriggers. If you are not able to use the
Licensing designated tow hooks for any reason, always
use extreme caution when selecting a place to
If you do not have a valid commercial driver’s license,
hook the towing cable. Be sure that the place
do not drive this unit.
you select has adequate room for the cable to
move without hitting or damaging other parts
Backing up
and that it is capable of handling the load of
You will be able to see the road behind you on the left towing the unit.
and right sides, but you will not be able to see • Use only undamaged towing straps or cables
directly behind you. If you must back up and there is capable of handling the load of towing the unit.
any chance that traffic or pedestrians are behind you, Never use chain for towing, because if a link
you must use a guide. A guide is a person who watches breaks, the chain will whip in both directions
for traffic, pedestrians, and other obstructions and away from the broken link with great force.
stands where you can see him or her giving you This could cause injury or property damage.
instructions. The backup warning device can give you
some measure of safety, but you cannot rely on it. For Loading the unit for shipment
example, a child walking behind your unit when you
begin to back up may become frightened by the backup If the unit will be transported by some means other
warning sound and freeze on the spot. than its own truck power (such as by railroad or ship),
care must be taken so that people and property are
If you are in an isolated area where there is no traffic or protected during the loading process. In these cases,
pedestrians, you can get out of the cab and look for remember the following points:
obstructions before you start to back up.
For ramp loading / unloading
Changing lanes
• Use only ramps that provide adequate and
When driving, you have blind spots on your right and stable support for loading and unloading
left sides. Unfortunately, many other drivers are purposes. Take precautions to prevent personal
unaware of these spots and will travel in them for injury in the event the unit were to tip or slip
extended time periods. You can avoid these blind spots off the ramps.
by using convex mirrors, which attach on or below the • You must use ramps that have a lesser slope
outside rearview mirrors. Before changing lanes, check than the gradient climbing ability of the
the convex mirrors for other drivers who may be vehicle.
“hiding” in your blind spots. Signaling well in advance
• If you are using guides to provide instructions,
will warn other drivers of your intention to change
they must not remain in the driving zone.
lanes.
• Secure the machine on the transport vehicle
Towing the unit against rolling, slipping, or tipping.

Sometimes poor driving conditions on the construction


site make towing the unit necessary. If you encounter
deep mud, sand, snow, or other driving hazards, it is
better to tow the unit in and out of position than to risk
breaking an axle or sliding off the road. In these cases,
remember the following points:

86 Operation Manual - S 42 SXG revDate


Operation

For crane loading / unloading removed. In the case of electrical wires, do not set
• Truck-mounted concrete pumps may be moved up in a position that gives you less than the 17 feet
by crane only if they have been equipped with of clearance required.
slinging rings designed for that purpose. 2. You must be able to fully extend the outriggers.
Slinging rings can be ordered from Schwing The stability calculations of the unit were made
for installation on new units or for with the outriggers fully extended. Anything less
field retrofits. than full extension could allow the unit to tip.
• Never hook lifting devices to standard pump 3. The soil must be able to support the forces imposed
parts such as the boom, concrete valve, or by the outriggers. Even solid granite has been
hopper. These parts were definitely not known to give way when the unit has been set up
designed to support the entire unit weight. improperly.
• Check the load-bearing capacity of any slings, 4. Stay back from the base edge of any excavation or
cables, or other lifting devices that will be used cliff (Figure 60) the same distance as the vertical
to lift the machine. Never exceed the rated drop of the excavation or cliff. For example, if the
working capacity of the lifting device. excavation is 25 feet deep, you must be 25 feet
• No one is allowed to walk, stand, or work back from the bottom edge. (This is known as the
under suspended loads. Keep the area free of one-to-one rule.)
personnel. 5. At least one ready-mix truck must be able to get
safely to and from your hopper.
Unit Setup In addition to the requirements mentioned above, it is
desirable that the setup point also have these features:
Selecting the proper setup location on the 1. Ability to handle the safe arrival and departure of
job site all ready-mix trucks with accessibility for two
trucks to be at the hopper simultaneously,
2. Fairly level terrain to facilitate bringing the
machine within 3° of level before unfolding the
WARNING boom, and
Improper setup causes job site accidents: 3. Out of the way of major traffic flow.
• Look for power lines before unfolding
• Be sure of unit's stability
W024.eps

Sometimes the person in charge of the pour will have a


setup location ready for you. An experienced job
supervisor will pick an appropriate spot that will allow
a safe and efficient pour. At other times, you will be
told only what is to be poured, and you will have to
select the setup location yourself. In still other cases,
the job supervisor will have picked a totally
inappropriate spot for you. In that case, your ability to
be diplomatic may dictate how well your day is going
to go. If the location is not safe and efficient, you will
have to make it so on your own. In all cases, the setup
point is the operator’s responsibility and must have the
following features:
1. You must be able to reach the pour with the boom.
If power lines or other obstructions are in the way,
either select a different site or have the obstructions

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 87
Operation

1to1rule.eps

THE ONE-TO-ONE RULE:


FOR EVERY 1 FOOT OF VERTICAL DROP,
STAY BACK FROM THE BASE EDGE 1 FOOT.
(DISTANCE "B" MUST BE EQUAL TO
DISTANCE
B OR GREATER THAN DISTANCE "A")

base edge DISTANCE


A

Figure 60
One to One rule

Soil Considerations Calculating the outrigger load


Before setting the outriggers, read the safety Oh Boy!
MATH!
instructions from the Safety Manual, which is a
separate section of this document (placed between
Specifications and Overview).
After you find an appropriate spot to set up the unit,
you must provide a stable base for the outriggers. If the The following chart can be used as a guideline to help
site you have chosen does not have stable soil you determine the load-bearing capacity of various soil
conditions, select a different site. Under no types. If you do not know what type of soil is on your
circumstances should you compromise the stability of job site, the site manager may be able to tell you. Soil
the unit by setting up on unstable soil. analysis is generally completed before blueprints are
drawn.

Soil TypeLoad-bearing Capacity


Virgin ground ............................................................................ 22 PSI
Asphalt ......................................................................................29 PSI
Compressed, crushed stone .......................................................36 PSI
Clay/silt soil, firm ......................................................................43 PSI
Mixed granular soil ...................................................................51 PSI
Firm, compacted gravel............................................................. 58 PSI
Firm, compacted gravel (more compacted) ...............................72 PSI
Firm, compacted gravel (more compacted, class V) ................109 PSI
Brittle, weathered rock ............................................................145 PSI

88 Operation Manual - S 42 SXG revDate


Operation

Use the following equations to determine where you


can safely set up your unit.To determine the load your
outriggers will impose on the soil, divide the total force
of the outrigger (shown on a decal on the outrigger leg)
by the number of square inches of soil contact:

Soil pressure (PSI) = total outrigger force (lbs) ÷ area of soil contact (sq. in.)

Find the PSI on the soil type chart on page 88 to the outrigger leg. In this case, you would need 1,179
determine where you can safely set up your unit. square inches of cribbing. If you had a calculator
handy, you could use the square root function to
42 SX Model calculations determine what size cribbing square you would need.
The front outrigger decal on the 42 model shows a In this case, you would need a square 35 inches by 35
maximum force of 50,700 lb. The steel outrigger pads inches. For example, a 4 x 4 timber (actual width
are 11.81 in. by 13.78 in. (162 sq in.).Dividing 50,700 dimension of 3.5 inches) that is 40 inches long has 140
by 162 gives a soil pressure of 312 PSI: square inches of soil contact. Putting nine of these side
by side under the dunnage pad would give you 1,260
50,700 ÷162= 313
square inches of soil contact.
As you can see from the soil load bearing capacity
chart, the steel pads are not big enough to be used by Activating the outrigger hydraulics
themselves on any of the soil types listed. This is why To activate the hydraulics so you can set your
the unit comes equipped with dunnage pads. The pads outriggers:
are approximately 24 in. by 24 in. (576 sq in.). Now 1. Set the parking brake.
divide the maximum force of 50,700 by 576:
2. Depress the clutch.
50,700 ÷ 576 = 88 3. Select the proper pumping gear, as described on
the decal in the truck cab.
The pressure of 88 is suitable for firm, compacted
4. Select the pumping mode by pulling the PTO
gravel (more compacted, class V). If you had to set up
activation knob.
on virgin ground, asphalt, or one of the other soil types
listed, you would need to use additional cribbing 5. Slowly release the clutch until you feel the pump
(Figure 61). starting to engage, then depress the clutch again for
a second or two. Feathering in this way helps to
ensure that the gears engage properly. Now slowly
release the clutch again. If the engine lugs down,
immediately disengage the clutch, and verify that
you have selected the proper gear and that the PTO
activation knob is pulled all the way out. On most
trucks, the speedometer will register speed when
the pumps are turning properly.
Cribbing only.eps L 6. You should now have an illuminated warning lamp,
Figure 61 indicating that the PTO is engaged.
Add cribbing until you have adequate area 7. Get out of the truck cab and walk around the unit,
for the soil type unlocking the outrigger locking devices as you go.
(The locations are documented in the Product
Let’s assume that you had to set up on clay/silt soil, Overview section of this manual.) Double-check
which will bear a maximum of 43 PSI. If you divided that there are no obstructions or questionable soil
the maximum force by the pressure allowed (50,700 ÷ conditions while you are making this final safety
43) the answer would be how many square inches of check. If you see a problem, take care of it before
cribbing would have to be in contact with the soil under you set the outriggers.

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 89
Operation

Setting the outriggers The handles are all marked with decals (called
Start at the Vector controller located in the passenger pictograms), which present universal illustrations
side tool box. rather than text. You can find a complete display of the
pictograms in the Appendix section of this manual.
vectorlclrmt.eps
You may begin on either the driver side or the passenger
side of the unit. The E-stop and outrigger enable button
(Figure 63) are the same on both sides; however, the
control handles on the passenger side of the unit are
configured differently (see the Product Overview section
of this manual).

1 2
OK OFF

0 x1000 3
NA 1350 U/min

Menu:[ENTER]=Ein

HOME + HELP START new45ds.eps

CLEAR - ENTER QUIT

Outrigger Enable button E-stop button


FRONT EXTEND FRONT JACKING REAR JACKING REAR SLEW

30354500
Local/Remote/Ram change switches

Figure 62
Vector Controller local/remote switch Front Extend/Retract Rear Slewing

Front Foot Jacking Rear Foot Jacking


Place the Local/Remote/Ram change switch (Figure 62) in
the ‘local’ position, to enable the outriggers, then reset the
system by activating the “I” switch directly above it. If you Figure 63
advance the throttle first, the outriggers will respond Driver side outrigger controls
more quickly. To increase the RPM, the throttle switch
on either the rear panel or the remote box may
occasionally need be activated to the down position
first and then back to the throttle up position. This is
true especially when the unit is mounted on a Mack
truck.

WARNING
Improper setup / operation creates
hazards. Do not operate this machine
without training. Understand the
warnings in safety manuals and on
decals.
W025.eps

90 Operation Manual - S 42 SXG revDate


Operation

Remove the cribbing pads from their transport holder.


Position them on the ground approximately where the
outrigger will be positioned after extension. You can
adjust their position later.
Extension Look where the outrigger will be moving (Figure 65).
Be sure the area is clear of personnel and obstructions.

outrigger slew/ext/jack.eps
1. Verify that you have already released the outrigger
lock.
Slewing
Jacking 2. Depress and hold the outrigger pushbutton while
you move the handle for front outrigger extend.
The outrigger will then begin its movement.
Pushing the handle slightly will cause the outrigger
Figure 64 to move slowly. Pushing it down farther will cause
Extending, jacking, slewing it to move faster. This is known as proportional
control. Continue watching while the outrigger is
For clarity, we will use these terms (Figure 64): moving.
extension and extending mean moving the outrigger
3. Extend the outrigger completely by watching the
horizontally (including the curved Super-X front
alignment arrows (Figure 66) on the front gate.
outriggers); jacking means moving the outrigger leg up
(See the information about shortrigging on page 94
or down; slewing means swinging the outriggers open
of this section.)
or closed from a pivot point (rear outriggers).

pose.2.epsR3.0 L

Figure 65
Watch the outriggers while they are moving

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 91
Operation

DANGER
Stay clear.
Contact will result in
death or serious injury
if the unit becomes
electrically charged.

WARNING
This machine is
remote controlled
and may start at any
time. Stop engine
before servicing unit.

otrgalin.eps

Figure 66
Front outrigger alignment arrows

pose.3.epsR3.0 L

Figure 67
After the outriggers are extended, center
the cribbing pads
4. If your outrigger will hit an obstruction or obstruct
other traffic by extending it completely, reposition 9. Again, look where the outrigger will be moving,
the unit. and push the outrigger pushbutton as you move the
handle for front outrigger jacking to the extend
5. When the outrigger is completely extended, release position. The outrigger leg will begin to move
the handle, and the handle will spring back to a down. Stop before the steel contacts the cribbing
neutral position. pad.
6. While continuing to depress the outrigger 10. Before jacking the steel pad onto the cribbing pad,
pushbutton, activate the rear outrigger slewing look under the unit (Figure 68) to see that no one
handle to the extend position, and slew the rear has approached the pad on the opposite side of the
outrigger until it is fully extended. truck. When possible, use a spotter. When an
7. Repeat the previous steps on the other side of the outrigger is jacked, the entire unit tips the opposite
unit. direction. This tipping causes the outrigger on the
8. After extending all four outriggers, walk around opposite side to become closer to the ground. The
the unit, centering the cribbing pads under the steel weight and force of this movement could easily
outrigger pads (Figure 67). crush anything that comes between the outrigger
and the ground. Be careful when jacking the
outriggers!

92 Operation Manual - S 42 SXG revDate


Operation

Looking under.eps L

Figure 68
Look at opposite
outrigger before
jacking.

11. When you are sure the area is clear, jack the incline, and the boom will slew by the force of
outrigger pad onto the dunnage pad. Repeat the gravity to the lowest point, which can cause
jacking steps for the other three outriggers. property damage or injury to personnel as well as
12. Bring the unit to within 3˚ of level (Figure 69) by damage to the boom.
observing the level bubble located near the When you have finished jacking the outriggers, the
outrigger controls. Failure to bring the unit within weight should be off of the truck tires, but they should
3˚ of level may result in premature boom brake still be in contact with the ground. There is no reason to
wear or the inability to slew the boom uphill. In lift the entire truck off of the ground. However, in
severe cases, it is possible that the boom brakes extreme cases, one side of the unit may have to be
will not be able to hold the boom on a steep lifted off of the ground to obtain levelling within 3˚.

Figure 69
3˚ = 6 inches of variance per
Max. 3°
each 10 feet of distance
between the widest two 6 inches per 10 feet between points
points of contact with the
ground.

G N IN R A W

no dnats ton
oD
.setarg reppo
h

A
SNOITCURTSNI YTEF B
RO ETARG REPPOH

srotoM cirtcelE
GNIVOMER EROFE

rewop eht tuo kcoL .2


na ot gnidrocca ecruo
tuogat-tuokcol devorp
s
pa
.margorp

rotalumucca kcehC .3
eguag erusserp tiucric
yfirev ot )deppiuqe os
fi(
.erusserp metsys orez
senignE leseiD ro eni
:ESCI.V1RES YNA GN.IeM
.rotom cirtcele eht pot
nF
igO
nR hP
eReE
S

tup dna ,tekcop ruoy n


"ETAREPO TON OD" a
losaG
t potS .1

ti ecalp ,yek eht evome

.hctiws eht no gat


R .2

rotalumucca kcehC .3
eguag erusserp tiucric
yfirev ot )deppiuqe os
fi(
.erusserp metsys orez
i
S 42 SX

Max. 3°
42SX 3 degrees.eps

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 93
Operation

Shortrigging 2. If the boom is folded up the on the wrong side, you


Shortrigging describes the act of not extending the will need to move to an area where the outriggers
outriggers on the side away from the pour (Figure 70). can be fully extended while you unfold the boom
Shortrigging is not recommended, but under certain and swing it around to fold back up on the opposite
conditions it is unavoidable. If it is not possible to set- side. Then fold up the outriggers and drive back to
up the outriggers on the side away from the pour, the the area which will require shortrigging.
unit can be set-up with the outriggers jacked down but 3. Fully extend and jack the outriggers on the side of
not extended. When a unit is shortrigged, an accident is the pour (Figure 70). Be sure to use the same
more likely to occur. cribbing you would use in a standard setup.
To avoid an accident, you must follow a few rules: 4. Do not partially extend the outriggers on the side
• Whenever possible, completely extend the of the unit opposite the pour. They should,
outriggers. however, be jacked to provide stability.
• Never shortrig the machine on the side of the 5. After raising the boom from the cradle, do not
pour. unfold the boom until you have rotated to the area
between the two outriggers that have been fully
• Do not position the boom outside the center
extended and jacked. The boom may then be
lines of the outriggers. The unit can tip when
unfolded and the tip hose released or attached.
the center of gravity is beyond the outriggers.
• Remember that not all the outriggers are 6. At no point during the pour should the boom be
extended. Forgetting this fact is the most moved outside the area between the center lines of
frequent cause of accidental tipping. the fully extended outriggers (Figure 70).
7. Upon completion of the pour, the cleanout ball
The following steps will help you to shortrig in the should be inserted and sucked back before the
safest possible manner: boom is moved outside the center lines of the fully
1. Before extending any outrigger, check which way extended outriggers.
the hydraulic hoses are wrapped in the turret. You 8. The boom should then be folded up completely
must be able to unfold to the side with fully before being slewed back toward the cradle, while
extended outriggers without moving the boom to staying on the same side as the fully extended
the side with retracted outriggers. outriggers.
Do not retract the outriggers until the boom is secure in
the cradle.

The gray area


represents the area
in which the boom
CAUTION can be safely
moved. Use of the
boom in any other
Do not jack outriggers unless they are area could cause
fully extended or fully retracted. the machine to tip.
Intermediate positions could result in
outrigger damage.
C007.eps

Job to be
Never slew the boom outside of the grey area. pumped

Figure 70
Shortrigging
shrtrig2.eps

94 Operation Manual - S 42 SXG revDate


Operation

Additional dos and don’ts of outrigger


stabilization

OUTRIGGER ART-pad.EPS

A B

C D

Figure 71
Dos and don’ts of outrigger stabilization

• Do not set the outrigger on uneven soil (Figure When you have finished setting the outriggers, return
71A). If necessary, reposition the unit or level the Vector control local/remote switch to the ‘remote’
the soil. position (Figure 72) and activate the “I” reset switch on
• Do not bridge a hole with outrigger cribbing the remote box.
(Figure 71B). If there is no soil contact over
the hole, the pressure on the ends of the pad is
much greater. The soil could give way or the
cribbing could break.
• Do not set the outrigger on a hill (Figure 71C).
The force of the machine weight must be
transmitted straight down. If you were to set up
as shown in this example, the outrigger load
would be partially down and partially
sideways, putting undue strain on the outrigger
leg.
• If you determine that you need five pieces of
cribbing to support the load but the foot vectorswitch.eps

touches only three of them, the outrigger will


sink into the soil. To avoid this problem, lay Figure 72
the dunnage pad on top of the cribbing pieces Local / Remote/Ram change switch in
(Figure 71D). The dunnage pad must contact remote position
all of the cribbing pieces supporting it.

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 95
Operation

Releasing the boom tie-down strap


checking boom strap.eps

ratc
het
UP.ep
s
Lock 1. Release lock.

Handle 2. Lift handle.

hook.eps
Figure 73
(left) Unlocking the boom tie-down strap;
(right top) boom strap ratchet mechanism.
(right bottom) boom safety hook

;;;;;;;;;;
1. Pull the lock in the direction of the small white Setting up the boom
arrow until it is clear of the ratchet gear (Figure

;;;;;;;;;;
73).
DANGER
2. Pull out and up on the handle in the direction of the
curved arrow until it is positioned straight up. Now Electrocution hazard! Keep boom at
you can pull the strap out of the ratchet assembly. least 17 feet away from electrical wires.
D001.eps

Before proceeding, understand how the boom setup is


to be done by reading the information on boom setup The outriggers must be properly set before the boom
beginning on page 4 of the Safety Manual, which is a can be unfolded.
separate section of this document.
1. Raise section #1 until it is nearly vertical or until
NOTE! the safety hook (Figure 73 right bottom) releases
Always look up before starting to unfold the from section #2.
boom, to be sure there are no overhead lines 2. Extend section #2 until it is nearly parallel to the
or other obstructions.
ground.
3. Sections #3 and #4 can now be extended until the
tip section (#4) is parallel to the ground and the tip
hose release handles can be reached (Figure 74).

96 Operation Manual - S 42 SXG revDate


Operation

Rele
asin
g
hos
e.ep
sL
Hos
e on
gro
u
nd.e
ps L

Figure 74
Releasing the tip hose

Releasing the tip hose


When the boom is positioned appropriately, release the
tip hose (Figure 74). Do not stand under the tip hose
while you release it. Look down for anything that
might be damaged when the end of the hose falls to the
ground.

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 97
Operation

boomout-watch pads.eps

Figure 75
Slowly slew the boom around the unit and watch for outrigger sinking.

Inspecting the tip hose


;;;;;;;;;;
;;;;;;;;;; DANGER
Inspect the condition of the rubber tip hose each time
you are near it. Do not use the hose if either of the
raised ends is worn or if the rubber is movable inside Electrocution hazard! Keep boom at
the steel sleeve. The tip hose may be required to handle least 17 feet away from electrical wires.

D001.eps
the maximum possible concrete pressure that the pump
can generate, so it is imperative that the hose be If you see that the outrigger is sinking into the soil,
capable of handling that pressure. The tip hose immediately slew the boom back to the position it
supplied by Schwing is rated to handle the pressure of came from, and fold it back up. Then, adjust the
the pump when the hose is new, but the pressure rating amount of dunnage under the cribbing pads until you
must be lowered as wear dictates. When the original tip have enough soil contact to hold the unit without
hose becomes worn, replace it with a tip hose of like sinking. Repeat the procedure for the other outriggers.
pressure rating and end type. Do not use the hose if the The stability of the unit must be ensured. Each time
steel braids are showing inside or out. Small pieces of you switch between operation of the boom and
braid showing through on the outside could be a operation of the outriggers, you must reselect the
puncture hazard to anyone coming in contact with it. correct switch position with the local / remote switch
The clamp and rubber gasket on the tip hose must be in (Figure 76) on the Vector controller (local for
like-new condition and should be free of old concrete outriggers and remote for controlling the boom with
buildup, as should the elbow at the end of the tip the remote box), and then activate the appropriate “I”
section. The raised end must be free of concrete. Check reset switch to regain control in either mode.
this on a daily basis. Be sure that the pin that keeps the
clamp closed is in place and in good condition. The
safety cable that is bolted to the end of the boom must
be secured to the tip hose on the supplied ring.
Remember, this hose will be hanging over workers. Be
absolutely certain that all components are safely Figure 76
attached and in excellent shape. Local/Remote
Switch on
After the tip hose has been released, continue to extend Vector controller
the boom. Before you extend the boom over the pour,
however, always test the stability of the unit. Unfold
the boom, and slowly slew to the side until it is
positioned directly over an outrigger (Figure 75). vectorswitch.eps

98 Operation Manual - S 42 SXG revDate


Operation

Hanging extra system from the boom If you will be removing the supplied tip hose and
replacing it with a combination of reducers and hoses,
Concrete weighs about 150 pounds per cubic foot, so you must pay close attention to the overall weight that
the total weight of the supplied tip hose and the the boom will lift. The entire assembly you attach must
concrete inside is 376 pounds. This is the total weight not exceed 376 pounds, including the weight of the
allowed to be hung from the boom. concrete. Exceeding this weight limit will cause the
metal in the boom to fatigue and can lead to cracks. All
pieces that hang from the boom must be in like-new
WARNING condition and must be securely clamped and pinned.
Safety cables or whipchecks must be used on each
Boom cracking hazard. Do not hang piece. The illustration below (Figure 77) is a typical
more than 376 pounds from the end of reducer/hose combination.

000068.eps
the boom.

Adapter pipe from metric 148 mm to Heavy


Duty raised ends. Weight of pipe = 5 pounds
Weight of concrete in the pipe = 5 pounds

Heavy Duty 5" clamp.


Weight of clamp = 14 pounds

5" to 4" reducer, 36" long. HD ends.


Weight of reducer = 43 pounds
Weight of concrete in the reducer = 50 pounds

Heavy Duty 4" clamp.


Weight of clamp = 11 pounds

12 foot long, 4" concrete delivery hose,


coupled one end.
4 ply steel reinforced. Heavy Duty raised end.
Weight of hose = 77 pounds
Weight of concrete in the hose = 156 pounds Reducer/hose weights.eps

Total of all weights = 361 pounds

Figure 77
Example of adapter/reducer/hose combination with weights

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 99
Operation

Pouring directly out of the boom Prepare for the Ready-Mix


After you have safely attached the tip hose assembly Trucks
you require for the pour:
• If you will be pouring directly out of the boom If you have completed setup before the first ready-mix
tip hose, contact the person in charge and ask truck is due to arrive on the job (which is a highly
where you should position the boom for the recommended practice), prepare yourself for the day.
discharge of the slurry that will be used to • Find out who will be giving you signals
lubricate the pipeline. Sometimes you will be throughout the day. To avoid conflicts in
allowed to put the slurry into the form, but instructions, there must be only one person
usually you will be asked to put it elsewhere. giving you signals. Talk to the person about the
• If you will be pumping out of the boom into a signals you will use before you start pumping.
slickline, pump the slurry through the entire The Concrete Pumping Association
line because the slickline will need to be has standardized hand signals for concrete
lubricated in the same manner as the boom. pumping that are shown on decals on the unit.
This decal is also shown in the Appendix
Attaching the tip hose to a slickline section of the Safety Manual (which is a
separate section of this operation manual
Never use grooved or victaulic pipe or hose ends for placed between Specifications and Product
pumping concrete. They are not capable of Overview). In many cases, the job site
withstanding the pressure applied by a concrete pump. management will give you a two way radio on
It is not possible to safely connect hoses or pipes that their own frequency so that you can speak
have dissimilar ends. The hose supplied by Schwing directly to your signal man. Be aware that in
has 125-millimeter metric ends. If you are trying to some cases this radio may cause interference
attach it to any of the other end types (heavy-duty or with the Schwing radio remote control system.
male / female high-pressure) you must use an adapter Check it out before the pour begins, and if
pipe that has one of each coupling type (metric and the there is interference, hook up the hard wire
other) on either end. This adapter pipe will have controls.
weight, of course, and the weight will have to be • Talk to the foreman of the placing crew. Be
accounted for. The adapter pipe must also be secured sure that the crew is aware of the safety rules
by a safety cable, and all clamps must be pinned. for the placing crew as described in the safety
If you must hang more pipe or hose than is allowed manual mentioned in the previous paragraph.
because of the weight restrictions outlined, have a If they are not familiar with the rules, show
crane or another lifting device hold the weight of the them the rules that apply to them from the
system for the boom. Secure the system in such a Quick Index that was supplied with your unit.
manner that the placing boom will not carry the load, Make sure the crew members understand the
and be sure there is no danger to workers under the importance of not kinking the delivery hose.
system. • Go over the safety rules with any oilers or
If you will be pumping out of the boom into a slickline, laborers who have been assigned to work with
never attach the boom elbow directly to the slickline. you at the pump. Show them the emergency
Use the tip hose between the boom elbow and the stop switches and warning horn button on the
slickline. This will allow for movement of both the hopper.
boom and the slickline. Do not let the tip hose kink, as • If an oiler or laborer will be backing ready-mix
kinks create blockages of concrete, and blockages can trucks up to your hopper, emphasize the danger
cause accidents. they are in if they place themselves between
the pump and a ready-mix truck.

100 Operation Manual - S 42 SXG revDate


Operation

quarter turn valve will not provide water until


the water pump switch is activated on the
WARNING remote box, while in remote control or on the
Vector rear panel, while in local control
(Figure 78).
.eps
warn
bkup

T
0

I
waterpumpswtch.eps vectorswitch.eps

Never allow anyone to stand Figure 78


between the concrete mixer truck Activated water pump switch (left)
and the pump. Crushing hazard. Local/Remote switch in remote (right)

• Clear the unit’s decks and walkways of debris • If you will be using portland cement and water
and ice or snow to prevent tripping and falling. to make your lubricating slurry, prepare for
that by positioning your barrel, shovel, and
• If the air temperature is above freezing, place
sack of portland cement on the ground behind
your water hose in a position where it will be
your hopper. Fill your barrel with 25 or 30
out of the way but still handy for washing
gallons of water (Figure 79). You can skip this
pipes and clamps and spraying down the
step if slurry will be delivered to you from the
hopper. If it is below freezing, keep the hose in
ready-mix company or if you are using
the heated cab until needed.
commercial slurry mix (slick pack).
• When using the hard wire control box, position
your remote box and cable in a place where it
won’t be in the way but where you will be able
to move around freely with it once the pour
begins. It is critical to be able to see the point
of discharge once the pour begins. If this is not
possible, arrange for a spotter at this time.
• Get your breathing mask ready for mixing the
slurry. Have all of your personal protective
devices on or nearby.
• Be sure the cleanout door is closed tightly.
• Fill your waterbox with water if it is not
already full. Secure the controls so no one can
turn it on without your knowledge.
Spraying water into barrel.eps

WARNING
Crushing/amputation hazard. Disable the
hydraulic system before removing
waterbox guards.
W007.eps

Figure 79
• To supply water to the water hose, you must Spray 25 or 30 gallons of water into
turn the quarter turn supply valve, which is the barrel
located near the operator’s access ladder. The

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 101
Operation

Shoveling.eps L

Figure 80
Put a couple of shovelfuls of sand in
the bottom of the hopper, over the
cleanout door.

• Position your cleanout rake so it won’t be in NOTE!


the way but will still be easily accessible for Do not grease agitator bearings as you
cleanout. Never use your hands as a cleanout grease most other bearings. If you pump in
rake. grease until you see it squirting out
somewhere, you will ruin your agitator
• If your unit is equipped with a Rock Valve, put seals. When you grease the agitator
a couple of shovelfuls of sand in the bottom of bearings, watch the rubber grease cones
the Rock Valve housing, above the cleanout inside the hopper. You want the cones to
door (Figure 80). This will prevent concrete bulge out slightly because they are full of
from filling the recessed door area and setting grease, but grease should not come out
up during the course of the day. around the shaft. Where the grease comes
out, concrete cream (grout) will be able to
• If your unit is not equipped with auto-lube, go in. If concrete enters the grease cone, you
grease your agitator bearings (Figure 81). will quickly wear out the bearings. When
There is one zerk on each side of the hopper. you regrease after the hopper is full of
Regrease every 200 or 300 yards, as the pour concrete and you can no longer see the
cones, just give the zerks a couple of squirts.
allows. This is one of the few times when it is better
to under grease than over grease.
• If your unit is equipped with a Rock Valve,
grease the Rock Valve lubrication points
(Figure 81) before the pour begins. Once you
start, grease them every couple of hours. There
are six zerks to grease for the Rock Valve, plus
the two for the agitator.

102 Operation Manual - S 42 SXG revDate


Operation

1, 2, 3, 4, 5

zerks.eps L

Greasing agitator motor.eps L

Figure 81
Locations of the six Rock Valve greasing points (1–5, 7) and the
two agitator grease points (6, 8)
• Once again, if your unit is equipped with auto- functioning properly and to not check it on a
lube, greasing will be accomplished regular basis. If a port plugs or a pump stops
automatically. You will, however, need to set functioning, that particular grease point will
the proper times for each grease feeder by not receive any grease until you repair the
adjusting the timer settings in the cab. The problem.
timers are usually mounted on the top of the • You can keep your hopper and splash guard
doghouse between the seats. looking better and help yourself at cleanout
• The boom turret bearings must be greased time by spraying them with a release agent
daily. The auto-lube also takes care of that for before the pour begins. Schwing recommends
you automatically, but it is important for you to a product called Kleen Kote. This product is
check the grease tubs daily and to make certain specifically formulated to prevent concrete
that each grease point is actually receiving from sticking to forms. It also prevents
grease. The biggest drawback of the auto-lube concrete from sticking to any other surface.
system is the temptation to assume that it is Areas such as the tapered bend and elbows and

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 103
Operation

the back side of the outrigger beams are portland, and do not set like cement. If you use these
especially vulnerable to splashing concrete and products, pay close attention to the instructions and
should be sprayed. This will save you a warnings on the package.
considerable amount of time during your If you only have portland cement for lubricating your
cleanout process. pipeline, your options are mixing in a barrel or mixing
Be aware that release agents make for slippery footing, in the hopper, based on the job situation. Before you
so do not spray it directly on walking surfaces, and do begin to mix the slurry, put on your breathing mask and
not walk on surfaces that have been sprayed. If you do the rest of your personal protection equipment.
get over spray on a walking surface, clean it off
NOTE!
immediately.
Portland cement contains toxic chemicals.
Kleen Kote is a 100% water soluble formula used in Always wear your breathing mask and all
place of form oil or diesel fuel. It deposits a thin film other personal protective equipment when
that concrete, asphalt, dirt, or other debris will not stick mixing slurry.
to. Kleen Kote is environmentally safe and does not If you have a helper assigned to work at the pump, you
contain solvents, phosphates, or silicones. This product can mix the slurry in a barrel. This mixing method will
is biologically safe for use on all surfaces. Additionally, help you get good consistency and break up clumps of
Kleen Kote has an added rust inhibitor and is an cement that form in the slurry. However, you’ll need to
effective release alternative when diesel fuel and oils lift the barrel, which weighs 200 to 300 pounds, to pour
are not acceptable. This product is a non-hazardous the slurry into the hopper. Do not attempt to lift this
material and meets or exceeds all OSHA standards on barrel alone.
the MSDS Material Hazard Evaluation. Schwing is an To mix the slurry in a barrel, fill the barrel with about
authorized dealer of Kleen Kote which can be ordered 25 gallons of water. Lay a sack of portland cement on
in concentrate through the Spare Parts Department at top of the barrel. Break open the sack with a shovel
(0049) 2325-987-0. blade, and allow the cement to fall into the barrel
(Figure 82). When the bag is empty, set it off to the side
Lubricating the Pipeline and mix the cement and water with the shovel blade.
Break up any cement clumps and continue mixing until
When the ready-mix truck(s) arrive on the job, you can the mixture is smooth and creamy. Along with your
lubricate your pipeline. Schwing highly helper, pour the mixture into the hopper.
recommends that you prelubricate the boom or
separately laid pipeline each time you must pump into Make one barrel of slurry mix for each 100 feet of
dry pipe. In some parts of the United States and boom or separately laid pipeline that the concrete will
Canada, the concrete is so rich with cement fines that enter. Using the barrel method, you can add a little
operators do not prelubricate before beginning sand, if needed, to stretch the amount of slurry mixed.
pumping operations. This practice is not This would be helpful if you had to pump through 250
recommended. The amount of time you save by not feet of line and had only two sacks of cement. If you
prelubricating is far less than the time you’ll spend will be going through more than 200 feet of pipe
removing pipe sections from a separately laid pipeline however, arrangements should be made to have a grout
or, worse yet, removing the boom pipeline to unplug a mixture brought to you by the ready-mix plant.
rock jam caused by dry pipe. Most importantly, the If you have no one to help you lift the barrel, lay the
blockages caused by failure to lubricate can be sack of cement on the hopper grate, and break it open.
dangerous.
There are commercial products (slick packs) that will
lubricate a pipeline. These products usually come in WARNING
sandwich-size plastic bags and lubricate about 100 feet
Amputation/crushing hazard. Never
of 5-inch pipe per bag. Instructions for mixing vary by stand on hopper grate.
W013.eps

manufacturer. These products are less expensive than


portland cement, weigh much less than a bag of

104 Operation Manual - S 42 SXG revDate


Operation

breaking cement bag.eps L

Stirring cement.eps L

Lifting barrel.eps L

;;;;;
;;;;;
;;;;;
;;;;;
;;;;;
;;;;;
;;;;;

Figure 82
Mixing the slurry in a barrel

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 105
Operation

Direct the spray of the water hose into the hopper, When enough slurry has been placed in the hopper to
aiming at the edge of the pile of cement. This will wash meet your lubrication requirements, back the first
the cement into the bottom of the valve housing. Try to ready-mix truck up to your hopper.
break up clumps of cement with the spray, but do not
put your hands or anything else into the hopper. Mix
enough slurry to lubricate the entire pipeline. When all WARNING
the cement has been washed to the bottom, cycle the
pump in reverse using the Rock Valve to blend the
portland and water. Do not put the pump in forward warn
.eps
bkup
until you have concrete to push the slurry into the open
cylinder and through the boom.

To cycle the Rock Valve back and forth:


• From the rear control panel, place the local /
remote switch (Figure 83 left) in the ‘local’
position, and toggle the concrete pump switch
(Figure 83 right) between reverse and forward
positions. Hold the switch to one side just long Never allow anyone to stand
enough for the Rock Valve to switch, then between the concrete mixer truck
toggle it the other way. Cycle the pump just and the pump. Crushing hazard.
long enough for the Rock Valve to blend the
portland and water.
Pumping the Job
Look at the concrete before putting it into your hopper.
Occasionally you will receive a bad load (all rock or no
rock at all), or if the mixing fins of the truck are badly
worn, the concrete will not be properly mixed. Do not
allow a chute full of bad concrete to be put in your
0
hopper; you will almost certainly plug the line before
you get concrete out of the pipe. If you see that the end
HP
of the load is badly separated, have the driver dump the
vectorlocal.eps
concretepumprev.eps
first chute off to the side, and then display the next
available fin of concrete. In most cases, the mix will
look a lot better after the first chute is dumped. If it
Figure 83 doesn’t, dump the next chute to the side also. You will
Local/Remote switch shown in ‘local’ learn by experience what mixes can and cannot be
control (Left) pumped.
Concrete pump switch (Right) 1. When the mix looks good, before putting any
concrete into the hopper, activate the pump to the
forward mode. Take a couple of strokes to get the
slurry into the pipeline ahead of the concrete.
Position the Rock Valve so the open cylinder is on
• From the remote control box, put the local/ the opposite side of the hopper from the ready-mix
remote switch (Figure 83 left) in the ‘remote’ chute and shut the pump off at the beginning of the
position, and toggle the switch in the same stroke. The incoming concrete can then push the
manner. Again, cycle the switch just long remaining slurry, which is trapped below the Rock
enough for the Rock Valve to blend the Valve, into the open cylinder as the first stoke
portland and water. begins.

106 Operation Manual - S 42 SXG revDate


Operation

2. It can also be helpful to put the agitator in reverse,


which will help to pull the separated aggregate
from the first fin toward the end of the hopper, so
the creamy concrete will be forced below the Rock WARNING
Valve.
Expulsion hazard. Never open a
3. Have the driver start filling the hopper; then, as the
pressurized pipeline.

W002.eps
slurry is pushed into the open cylinder, you can put
the pump switch in the forward mode and begin
pumping.
4. Pump slowly (about 15 strokes per minute), and By putting the pump into reverse for several strokes,
watch the concrete pump circuit pressure gauge you release the pressure on the blockage. Understand
until the slurry starts to escape from the pipe or the safety rules for opening a blocked pipe as shown in
hose or the pump starts to pressure out (pressure the Safety Manual, which is a separate section of this
gauge approaches 300 bar). document.
5. If the pump does start to pressure out before The previous steps apply only to concrete passing
concrete is through the boom, immediately switch through the boom. If the blockage occurs in the slick
the pump to “reverse” mode, and notify the ready- line beyond the boom, the blockage most likely will
mix driver to stop dumping. Give the unit several not be freed by rocking back and forth, because you
strokes in reverse, then go back to forward. This need the assistance of gravity for that procedure to
“rocking” action will often pull a rock jam or work effectively. Once the concrete has passed the end
blockage from an elbow and reconfigure it enough of the boom, the blockage will need to be removed
to let it go through on the next attempt. If the from the pipeline manually.
concrete continues to slide without high pressure, 7. After concrete has emerged from the point of
continue pumping. discharge, stop pumping.
6. If pressure again rises toward the relief setting,
repeat the reverse cycle, but this time double the
number of strokes in reverse. That action might WARNING
cause the hopper to fill up and run concrete on the
ground, but if it causes the blockage to come free, Falling concrete hazard. Install a
it may save you from going through the slow blanking plug before swinging boom
process of breaking boom pipeline sections apart.

W014.eps
over workers or property.
This procedure works well if the boom is in the ‘A’
frame position (two sections up and two sections
down), because when you place the pump in 8. If you are pumping directly out of the boom, swing
reverse, you create a vacuum in the line. The the boom into the starting position, as directed by
combination of pump suction and gravity the hose handler or the concrete foreman. If you
sometimes works to pull the rock jam blockage will be moving the boom, which is now full of
loose; then when you push it through the highest concrete, over workers or property, attach the
set of elbows, gravity again will help by letting the blanking plug to the tip hose and secure it with the
separated rock free fall through the next two safety cable, or suck a ball into the tip hose by
sections and tip hose. Sometimes the plug will not putting the pump in reverse. Prevent the ball from
break loose, and you will need to find the source of falling out by putting the retainer pin in place
the blockage and remove it manually. before you move the boom. Be sure that the
blanking plug or ball and retainer are removed as
soon as the boom is in position.
9. If you are pumping into a slickline, wait for the
start signal before you begin to pour.

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 107
Operation

Controlling the speed of the unit NOTE!


There are three ways to control the speed on the unit: If electrical control of the stroke limiter is
(1) by using the stroke limiter, (2) by the engine lost, it can be adjusted manually at the
stroke limiter control block (Figure 85) by
throttle, and (3) by selecting a different transmission removing the cap nut located on the top of
gear (not recommended for operation). the solenoid assembly and loosening the
1. The stroke limiter is a hydraulic device that can be lock nut with a 1/2 inch wrench. The
electrically adjusted with a spring loaded toggle adjustment is then accomplished with a 5/
32” allen wrench by turning the screw in
switch, located on the rear panel or on the knob on (clockwise) to decrease strokes or out
the remote control box. Its function is to raise and (counterclockwise) to increase strokes.
lower the output of the hydraulic pumps that Always return the manual stroke limiter to
operate the concrete pump kit. This has the maximum strokes when electrical power is
advantage of allowing the truck engine to remain at restored.
higher RPM, where horsepower is at the Allen head
Cap nut
maximum. It also has the advantage of allowing manual stroke
full boom speed and control while pumping at low limiter
strokes per minute. Lock nut
Solenoid

Figure 84 Pressure reducing


valve (not manual
Stroke limiter control stroke limiter)
strklmpicto.eps

knob (left) and toggle


switch (right) T
strokelimitswtch.eps

P
T
MG
P s
G .ep
jst
• The stroke limiter has an adjustment range of MY Y str
ka

95 percent. That means it can go from as low


as 2 strokes per minute to maximum strokes Figure 85
per minute. The stroke limiter only adjusts the Stroke limiter (manual adjust)
output of the hydraulic pumps while the
differential cylinders are moving. That means 2. To control the speed of the unit by the engine
that when the differential cylinders are stopped throttle is not recommended for operation, but
at the end of the stroke and the Rock Valve is simply speeding up or slowing down the truck
moving, the pumps return to maximum output engine has the effect of turning the hydraulic
until the Rock Valve cylinder has completed its pumps slower, which results in less hydraulic fluid
travel. This interruption of the stroke limiter output. This method of speed control is used
signal is called “fast switch” on single circuit primarily when you want to limit all of the
units. When the job is underway, it is hydraulic circuits—boom, agitator, and concrete
recommended that all output adjustment be pump. It has the advantage of working at any time;
done with the stroke limiter (Figure 84) and you do not need to have pressure in the system to
not the engine throttle. slow down the unit by this method. It has the
disadvantage of lowering the horsepower output of
the truck engine. It is possible to kill the truck
engine with the hydraulics of the unit if you lower
the RPM too much.
3. Controlling the output of the unit by selecting a
different gear of the transmission is not
recommended for operation, but it does have some
uses in certain maintenance procedures.

108 Operation Manual - S 42 SXG revDate


Operation

Pumping the job Always keep an eye on the point of discharge or on


If you cannot see the point of discharge from where your spotter, so you can respond to dangerous
you must operate the unit, be sure your spotter is in situations quickly.
position before you start the pump. The boom movement is proportional. This means that
Point out the warning horn switch and the emergency the boom adjusts its speed in response to the movement
stop switches to the ready-mix driver. Instruct him at of the joysticks. The farther the joystick is moved, the
this time to be sure to push the E-stop and notify you faster the boom moves.
immediately if the hopper has gone empty or if any If you are pumping from the boom into a slickline,
other problem should arise. check frequently on the hose connecting the two. Never
As soon as you get the start signal, alert the ready-mix allow the boom to go down so low that the hose kinks
driver to start discharging, and activate the pump on/off nor up so high that the weight of the first pipe hangs
switch to the forward position. from the boom, and never allow the boom to rest on the
deck.
All the strength of the boom is in the vertical direction.
WARNING For this reason, never drag anything from side to side
Expulsion hazard. Keep hopper full to
with the boom. If it would get caught on anything, you
prevent air from entering material could bend the boom or guide levers. When this
happens, the boom will no longer fold up into its
W003.eps

cylinders.
original position and is no longer structurally sound.
Concrete must always cover the openings of the Wash the pipes, clamps, and gaskets with water as the
material cylinders or you will suck air into the pump. If day progresses and the crew removes pipe sections
this happens, concrete will blow back as compressed from the end of the slickline (Figure 86). If you do not
air escapes on the next shift of the Rock Valve. This wash the pipe sections until the pour is finished, you
can be dangerous, so warn the ready-mix driver to will not be able to get the hardened concrete out of
clear the area. If air has entered the material cylinders, them. This job can be done between loads of concrete
you can cushion the expulsion by stopping the concrete or by an oiler or laborer at almost any time. To
pump and filling the hopper with concrete before the conserve your water supply, you should ask to use the
next stroke. The mass of the concrete will prevent the ready-mix drivers’ water to wash out the pipe sections.
compressed air from pushing material out of the Washing Slick Line

hopper with force. When the hopper is full, it is still


not safe to resume pumping. If air is sucked into a
cylinder, even after the hopper is full of concrete, some
compressed air will have been introduced into the
delivery pipeline. This will cause “boom bounce” until
the air is expelled, and when the concrete reaches the
discharge point, it can violently whip the tip hose as the
concrete is expelled forcefully.
NOTE!
When initially starting the pump, or when
restarting for any reason, personnel should
stay a reasonable and prudent distance
beyond the reach of the end hose until the
concrete runs steadily and the boom is free
of compressed air. Air will be in the line
when first starting, restarting, or after the
line has been taken apart or opened for any
reason. Compressed air can cause the hose Figure 86
to whip violently. For more detailed Wash pipe sections and system
information see the Safety Manual. components as they are removed

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 109
Operation

Boom Bounce of level, and if possible have all of the unit’s tires in
contact with the ground after setting the outriggers. It is
vital that the outriggers are bearing the entire load but
that the tires are lightly touching the ground. The
friction created will prevent the chassis from swaying
when the Rock Valve shifts. Once you have set the
pump up properly, you must then put the boom in a
Distance "X"
A favorable position as shown in Figure 87. The reason
that example “B” has more boom bounce than example
“A” is due to vertical support at the pivots. This vertical
support is the same reason that houses have pitched
roofs and indoor stadiums have domes instead of flat
bmbounce.eps
roofs.
If the boom is still bouncing more than you prefer, the
only option you have left is to change the speed of the
Distance "X" concrete through the use of the stroke limiter.
B
Time constraints
Always keep the hopper at least half full, so if you
have trouble you will still be able to stroke the pump
Figure 87 periodically. If any problem arises with the unit while it
Two positions of the boom that result in the is pumping, you have just 15 to 30 minutes to solve it
same end hose location (Example “B” before the concrete will begin to set and possibly less
multiplies boom bounce) time than that if the temperature is extreme. You will
have less time with old concrete on a hot day and more
All booms bounce. A steady boom is one that simply time with fresh concrete on a cool, cloudy day. If you
doesn’t multiply its natural flex forces but, rather, know you will need more time, clean out before you
works against them. begin repairs. If the concrete is beginning to set, you
will have to clean out quickly and efficiently. Special
Every boom model has a “natural resonant frequency”
instructions for quick cleanout begin on page 124 of
that determines how it will perform under certain
this section. Keep moving, and you will usually be able
pumping conditions. Engineers can determine that a
to get the boom cleaned out. Old concrete and hot days
boom has an unsuitable resonant frequency for a
make for the worst conditions, in which the concrete
certain application after the fact, but predicting it in the
sets extremely quickly. This is called flashing, and if it
design stage is nearly impossible. Severe boom bounce
happens, you may lose some pipe.
is caused by taking the natural stiffening and relaxing
motion of the boom during the stroking of the pump
Cold weather pumping
and multiplying it. For example, when a stroke is
finished and the concrete valve is switching, the boom When you pump in very cold conditions (below 10°F),
relaxes with a downward droop. The worst case the concrete can freeze quickly. During a delay, the
scenario would be to repressurize the concrete as it machine might act like the concrete has set, but this is
reaches the limit of the droop and begins to “bounce” not necessarily the case. If your boom is not insulated,
upwards. When that happens, the natural spring of the the concrete may be frozen. As long as the concrete is
boom and the stiffening action of pressurizing the frozen, it cannot set. If this happens, you will be
concrete will work together to multiply the upward finished pumping for the day. If the concrete is frozen,
force. you may not be able to clean out the boom at the job
site, unless there is a heated area where you can move
To avoid these problems, some precautions must be
the pump for cleanout. If there is not, inform site
taken during setup. First you should make certain that
management and your company, gather up your things,
you have set up the pump on stable ground, within 3˚
and find a heated area to cleanout.

110 Operation Manual - S 42 SXG revDate


Operation

BLANKING PLUG eps


ps
p.e
ou
f fgr
uto
sh

Figure 88
Concrete shut-off valves (left) and
blanking plug with safety cable (right)

straight up out of the form, as you should be, you can


tell that something is caught if the hose appears to
WARNING stretch. If this happens, stop the boom immediately and
Falling concrete hazard. Be sure the hose begin to lower it carefully, so you don’t pinch the hose
shut-off is activated before swinging person’s hands. Lower it enough to take the tension off
the hose, and have the hose person free the hose from
000615.eps

boom over workers or property.


the obstruction before continuing.

Stop the dripping concrete while moving Delays


When you need to swing a full boom over personnel, a There will be delays. Sometimes you will have to wait
finished slab, or equipment, it is your responsibility to for concrete. Sometimes the workers will need to finish
protect the area below. Air activated concrete shut-off building the next form to be pumped. Sometimes a
valves are available to stop the flow of concrete when form will fail. You can make good use of this idle time
the pump is off. If your unit is not equipped with a by washing pipe, clamps, and gaskets that have been
concrete shutoff, remove the tip hose and attach an removed from the delivery system. You could also eat
approved blanking plug to the boom elbow. The lunch or take care of miscellaneous tasks. Remember
blanking plug, part # 30325945 (Figure 88), can be that concrete begins to set as soon as it becomes
ordered from the Schwing Spare Parts Department. motionless, so every 5 minutes or so give the pump a
stroke. This will make the concrete in the elbows and
NOTE! reducers change its shape, thus breaking the set.
Be sure your tip hose is capable of Concrete setting in the pipeline acts like a blockage.
withstanding the maximum pressure of the Blockages can be dangerous because the pump
concrete pump. creates maximum pressure on the concrete.
Moving the boom
Keeping the concrete alive
Be careful when moving the boom near concrete
Always keep the hopper at least half full. If you are
forms. This is especially important when you will be
waiting more than 15 to 30 minutes for concrete to
lowering a hose inside the form for a wall or column. It
arrive, keep the concrete alive by swinging your boom
is possible to catch part of the hose or safety cable on
around so that the discharge hose is on or very near
the form and break it. If you are pulling the boom
your hopper grate (Figure 89). Put the pump in gear

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 111
Operation

and slowly pump the concrete from your hopper, Another thing you need to consider is the age of the
through the boom, and back into the hopper. If the concrete in the ready-mix trucks. If you have three or
concrete gets stiff while you are pumping, add water to four trucks lined up behind the pump and they have
the hopper. A word of caution: the concrete will been waiting with you, their concrete is also setting.
eventually set up regardless of what you do, unless you Let’s assume that you have been waiting for 45 minutes
add so much water that it will never be able to set. In while a form is being repaired. The ready-mix plant is
this case, it will be difficult to pump and will tend to 25 minutes from the job. A driver waited, on the job, to
segregate. This type of concrete cannot be used in the get to your pump for 35 minutes before the form broke.
pour. Put it on the ground when fresh concrete does His concrete is now an hour and 45 minutes old. If it is
arrive. If you have to wait so long that you reach this a hot day, you are risking a “boom party” by pumping
point, it is better to clean out and start over when fresh his concrete. Only you can make this call.
concrete arrives. If you are waiting while concrete is
Keep the waterbox full
Remember to check the water in the waterbox
regularly. The water is very important for cooling the
differential cylinders and for lubricating the rubber
rams.

WARNING
Crushing/amputation hazard. Disable the
hydraulic system before removing
waterbox guards.

W007.eps
Using the vibrator
If you are pouring stiff concrete that is not flowing well
through the hopper grate, turn on your vibrator. The
vibrator helps low-slump concrete fall through the
hopper grate by shaking the hopper itself or the grate.
truck.back view.epsR
If you didn’t buy a vibrator with your unit, you can
Figure 89 purchase one for field retrofit by calling Schwing Spare
Rotate the boom to the hopper to Parts Department at (0049)2325-987-0.
circulate the concrete
Keep the hopper grate in place
available, you can stroke the pump for a longer time
because the ready-mix truck can fill your hopper. If you WARNING
cannot dump concrete to the ground or into the form, or
if you must wait more than 20 minutes, many ready- Amputation/crushing hazard. Keep
mix drivers will allow you to turn the boom around so hopper grate in place during operation
you can pump the hopper out into their truck while the
W015.eps

and cleaning.
drum is charging. Stop the pump before exposing an
open cylinder and have them mix your old concrete Under no circumstances should you operate the
with the fresh concrete in the truck, then discharge the machine when the grate is not in place. If your grate is
drum and refill your hopper with fresh concrete. If the in place, it will catch all manner of troublesome
concrete begins to set while it is being pumped, you objects: mixer fins, clumps of unmixed cement, cats,
have only minutes to get the machine cleaned out. dogs, rebar, golf clubs, tools of all sorts, and more. If
any of these items were to enter your hopper, it would

112 Operation Manual - S 42 SXG revDate


Operation

be capable of causing a blockage, which is always strike the outside of the hose with the hammer.
dangerous. When operating your unit, always keep Again, do not damage the hose by striking it so
the grate over the hopper. hard that the steel braids inside get permanently
disfigured.
Disassembling pipeline to remove 5. After the blockage has been removed, clean up the
blockages clamp, gasket, and pipe end with a rag. If you must
If you have a blockage in your pipeline that you cannot wipe off the concrete with your hands, be sure to
remove by the backward/forward rocking motion wear gloves. If you have no gloves, be sure to rinse
described in step 5 on page 107, you will have to your hands immediately afterwards. Re-assemble
disassemble the pipeline to find it. You will almost the pieces, and pin the clamps if they will hang
always find the blockage in a reducer, hose, or elbow, overhead.
unless one of the delivery pipes has a hole in it or one 6. Return to the pump, and start pumping in forward
of the clamps has a bad gasket. again, slowly at first, until you are sure that there
are no more blockages. If you encounter another
blockage, remember to relieve the pressure again
WARNING by pumping in reverse for several strokes before
Expulsion hazard. Never open a
looking for the remaining blockages.
pressurized pipeline.
W002.eps

Balance load
Follow these steps to disassemble the pipeline: At the end of the pour, it is an unfortunate fact of
concrete pumping that you will often have to wait for a
1. Pump in reverse for several strokes to relieve
“balance load” of concrete to arrive at your job site.
pressure in the pipeline.
The balance load becomes necessary at the end of a
2. Use your hammer to locate the blockage by pour because the contractor is very seldom able to be
tapping the pipeline. (“Tapping” is a key word exact on his original order. The balance load usually
here. You can damage the pipe by striking it hard.) arrives late in the day, which gives you time to prepare
A pipeline that has been relieved sounds different for cleanout and to stow pipeline, clamps, and other
when tapped than a pipe that is pressurized. An equipment. This waiting time has one disadvantage
empty pipe has a definite reverberating “tong” however, in that the concrete in your machine will be
sound. A full pipe without pressure has a meaty getting old by the time the balance load arrives. This is
“thak” sound, and a pressurized pipe full of the most dangerous time for concrete setting in the
concrete has a thin “tik” sound because the forces machine. Be aware of this, and take any steps
on the steel do not allow the pipe to vibrate. necessary to keep the concrete alive. Clean out if you
Consider tapping your pipeline in each of these must, but remember that if you do and the balance load
configurations when there is no blockage, just to is very small, you may have only enough concrete to
become familiar with each sound. refill the hopper, material cylinders, and pipeline
3. After locating the blockage, carefully remove the without ever delivering concrete to the form. When the
clamps from the blocked pieces. If you are not balance load arrives, it is usually fresh concrete. That
wearing a full face shield, turn away from the means that if you pump at least 1 yard, your machine
clamp as you pull the handle. If you have relieved will be filled with fresh concrete for cleanout, which is
pressure by stroking in reverse, there should be no to your advantage. If it is a hot day and the balance
pressure, but some blockages can store pressure if load is less than a yard, you will not be able to get fresh
there is another blockage upstream or down concrete all the way through the boom when you pump
stream. After the clamps have been removed and the balance load, so the concrete that is in the end of
concrete is flowing from the force of gravity, the the boom for cleaning is as old as the next-to-last load.
danger of excessive pressure is past. With old concrete, it is imperative that the boom be
4. Displace the blocked piece enough so that you can cleaned immediately upon finishing the pour.
push a piece of rebar or another long poking device
into it. If the blockage is in a hose, it will help to

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 113
Operation

boom for sucking back.eps

Figure 90
Positioning the boom for sucking the ball through the pipeline

Cleaning the boom pipeline


Cleanout Drain the boom as much as possible with the boom in
an “A” frame position, which is two sections up and
You will need water for cleanout. If you don’t have two sections down, (Figure 90) so that gravity will help
enough of your own, plan ahead and get as much as drain the concrete from the boom. If you cannot
you can from the ready-mix trucks before they leave circulate the concrete before cleaning out, try to add
the job site. water to the hopper before pumping it out. Remember
Sometime before you have to clean out the boom, wet to shut off the pump just before air is drawn into the
your sponge ball (cleanout ball) with water. Many material cylinders.
operators simply fill their 5-gallon bucket with water If you have a reducer and a smaller-diameter hose on
and throw the ball in it to soak when a half hour or so the end of the boom, remove the assembly before
of pumping is left. Other operators start soaking the sucking the ball back. Any pieces that have a diameter
ball first thing in the morning, but the ball won’t last as smaller than 5 inches (125 mm) will have to be cleaned
long if it is always in water. manually. In that case, you will suck the ball back
When you clean out it is helpful to circulate the directly through the tip elbow or the 5-inch adapter
concrete through the pump first, adding water to the pipe.
mix as you do. Thinner concrete is much easier to clean
out than stiff concrete.

114 Operation Manual - S 42 SXG revDate


Operation

Figure 91
Sucking the ball back 000183.eps

Set the stroke limiter to 50% or less before trying to the pump into reverse mode. The ball will be sucked
suck the ball back, because if the ball is brought back into the end of the pipe or hose. Continue pumping in
through the boom too quickly, it is possible to distort reverse.
the shape of the soft ball and not clean the boom as Position yourself on the deck of the pump, just forward
efficiently as when it comes through at a slower, steady of the hopper (Figure 92). Have the remote control box
pace. handy. When you hear the sound of the concrete falling
When the concrete has stopped dropping out of the through the #1 section pipeline and tower, start tapping
boom, walk to the end of the boom with the remote lightly on the pipeline. When the sound of the taps
control box and the sponge ball. Hold the cleanout changes from a “thak” sound to a “tong” sound, the
sponge ball up to the end of the delivery system with pipe is empty to your location. Give the pump one
the palm of your hand positioned flat (Figure 91). Put more stroke, which should bring the ball through the
reducer and into the reducing elbow; then shut the
pump off.

tapping pipe.eps L

Figure 92
Locate the cleanout ball by
tapping the deck pipe.

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 115
Operation

The condition of your sponge ball must be monitored


closely. When the ball begins to wear and you notice
that it slips into the tip hose or boom elbow much more
easily than when it was new, the ball should be
replaced. The sides of the ball must drag with enough
pressure to clean the pipe wall thoroughly, or the cream
that remains will harden, adding a new layer each day,
and it will eventually close off your pipeline and cause
a blockage. The tower elbows seem to be the most
likely to build up first as gravity will begin to draw the
excess cream to that location. Extra sponge balls may
be ordered from Schwing Spare Parts Department by
calling toll at (0049) 2325-987-0.

Folding-up the clean boom


Always watch for obstructions when moving the boom.
Construction sites change constantly, and new
obstructions can be present in a matter of moments.
To fold up the boom after it has been cleaned:
1. If you have been pumping through the 5-inch tip
hose, retract section #4 into section #3. Then
retract section #3 into section #2. When section #3
is in an upside-down position, the tip hose should
fall into the holding brackets (Figure 93). Folding up, hose.eps L

2. If you have removed the tip hose in order to use a Figure 93


reducer/hose combination, you can reinstall the Be sure the tip hose is secured in
hose either before folding up or upon arriving at the holders during foldup.
the next job.
7. If you don’t have to move to clean out, skip this
3. Again watching for obstructions, rotate the boom step because this is the time to begin the clean out
into the transport position (Figure 94). There are process. When the boom is aligned, lower it into
arrows welded to the turret and tower on the the cradle. You should just slightly compress the
passenger side of the unit that will line up when the steel and rubber boom rest.
boom is rotated to the correct spot (Figure 94).
8. Fold up the boom as described in the previous
4. With section #1 still raised, retract section #2 paragraphs, then fold up the outriggers by pushing
toward section #1. the push-button and retracting them in the opposite
5. Lower section #1 until the boom is sitting just order from which you extended them. When they
above the A-frame. are completely retracted, lock each one in that
6. Before lowering section #1 into the cradle, walk to position. Now put the truck transmission in neutral.
the back of the unit and check that the boom will Take the PTO out of gear. Release the parking
not hit any obstructions. Slew the boom left or brake, and drive to the cleanout spot. When you
right, if needed, to enter the A-frame cleanly. If the arrive, set the parking brake, and reengage the
boom alignment arrows are lined up, the boom PTO. If you feel you need to raise the boom prior
should be directly above the cradle. to clean out, reset the outriggers in the same
manner as your original setup. To clean the
machine, you need only raise the boom enough
to keep it from being splattered with concrete
from the wash out (approximately 10° or 15°
above horizontal).

116 Operation Manual - S 42 SXG revDate


Operation

45turret.epsL

GREASE TOWER BEARINGS


GREASE TOWER BEARINGS ONLY GREASE WHICH HAS
THE FOLLOWING CHARACTERISTICS. USE LUBRIPLATE
MO-LITH NO 2, TEXACO MOLYTEX EP 2 OR EQUAL.
BASE TYPE
NLGI NO LITHIUM
WORKING PENETRATION RANGE AT 77°F 2
MOLYBDENUM DISULPHIDE 265/295
ASTM DROPPING POINT °F 3% MINIMUM
350 MINIMUM

Figure 94
Boom slew alignment arrows

;;;;;;;;;; the 42 SX they will be found in the cable remote

;;;;;;;;;;
box and the radio remote, as well as inside the
DANGER Vector controller itself. The device is a yellow,
adhesive backed sponge, about two inches high and
Electrocution hazard! Keep boom at two inches wide. It will require replacement every
least 17 feet away from electrical wires. two years. The maintenance schedule is detailed in
D001.eps

the Maintenance section of this manual. To order


9. If, for some reason, you don’t have auto-lube and corrosion inhibitors part #30346014, call the
you will be greasing the turret bearings after Schwing Spare Parts Department at (0049) 2325-987-0
cleanout, be sure there are no electrical wires or .
other obstructions overhead. Then raise sections #2
and #1 until they are straight up.
10. Once you have reset the outriggers and raised the
boom, you can begin the clean out. You must now
move to the vector controller and select local
control by activating the toggle switch (Figure 95)
vectorlocal.eps
on the lower right corner of the panel. Local
control will give you control of the pump kit that
will be necessary for cleanout. This will allow you Figure 95
to place your remote box in a protected area Local/Remote switch in ‘local’
(preferably in one of the outside tool boxes). position
Extreme temperature changes from outside to You will need the remote box again to grease the
inside the cab can cause condensation to form turret and to fold up the boom as you prepare to
inside the box, which can result in internal leave the job, but storing it during cleanout will
corrosion and electronic component failure. To protect the box from splattering concrete and
help protect against such corrosion, Schwing is water. A clean, dry remote box is more likely to
now installing a stick-on corrosion inhibitor remain trouble-free during operation.
wherever there is an electronic circuit board. On

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 117
Operation

Cleaning the hopper

 






  

 
 
000240.eps
000241.eps

Figure 96 Figure 97
Parts identification for cleanout Remove the hairpin
000242.eps

000243.eps

Figure 98
Remove and store the wedge

Remove the hairpin, which is attached to a chain, from Knock the wedge from the pin on the tapered bend, and
the wedge (Figure 97) as well as the hairpin from the 6- store it in the wedge holder on the back of the hopper
inch clamp, and place the hairpin where you will be (Figure 98).
able to find it easily again. Remove the clamp (Figure
96) between the tapered bend and the first elbow or the
clamp between the 6-inch elbow and the reducer.

118 Operation Manual - S 42 SXG revDate


Operation

If your cleanout ball did not get pumped out in the


above step, it will be found in the tapered bend or in the
WARNING 6-in. elbow. Remove the ball, spray it off with water,
and store it so it doesn’t get buried in the cleanout
Amputation hazard. Stop pump before debris.
cleaning the Rock Valve and hopper.

W011.eps
Tap on the “T” handle that opens the cleanout door on
the bottom of the hopper with your hammer (Figure
Swing the tapered bend open. Do not put your hands 99). When the door opens, the concrete at the bottom of
into the outlet pipe under any circumstances. If your the hopper should fall out. If it doesn’t, turn the pump
cleanout ball is inside the outlet pipe, it will get to the neutral, or “off,” position.
pumped out in the following procedure. Move out of
Aim your hammer upward and pound any material that
the way of the outlet pipe, and put the pump in forward
is lodged in the cleanout door. A couple of taps will
mode. When the tapered bend is open, you don’t have
probably free the material. If not, keep tapping until it
to worry about compressing the air that gets sucked
is free. You can minimize or eliminate this procedure
into the material cylinders, so you can let the machine
by putting sand in the bottom of the Rock Valve
cycle until the hopper is completely empty. Do not let
housing before you begin pumping, as explained
the machine cycle dry for an extended time, because,
earlier.
without concrete for lubrication, the rubber rams and
kidney seal will get hot and eventually be damaged.

Tapping "t" with hammer.eps L

Figure 99
Open cleanout door

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 119
Operation

Spraying hopper.eps L Stop the agitator from turning by centering the agitator
toggle switch on the rear panel (Figure 101). Do not
proceed to the next step until you have done so. You
will be able to visually confirm that the agitator has
stopped by looking in the hopper.
Poke any material that has set in the corners of your
hopper with a metal bar (Figure 102).
Do this procedure quickly, or the concrete may set up
in the Rock Valve and material cylinders. Concrete that
has set in the valve and cylinders is much harder to
remove later than concrete set in the hopper. If any
concrete in the hopper has set completely, you will
need to use a chipping hammer or another power tool
to remove it.

Figure 101 0
Stop agitator by placing
the switch in center HP
P
(neutral) position
agitatorswitch.eps

Poking with re-bar.eps L

Figure 100
With the grate in place, clean the
agitator and hopper with water
When washing down the hopper, be sure of your
footing and keep the hopper grate in place (Figure
100). Stand on the tip down clean out step on either
side of the hopper. Spray water into the hopper from
above. Keep the agitator turning only until you have
sprayed the blades clean. Wash the material from the
hopper through the cleanout door on the bottom.

WARNING
Amputation/crushing hazard. Never use
the hopper grate interlock switch as an
ON-OFF switch! Switches can fail. Stop
engine and verify zero pressure in
gratewarn.eps

accumulator before opening grate.

Figure 102
Remove built-up concrete with a bar

120 Operation Manual - S 42 SXG revDate


Operation

• Using your cleanout rake, pull any material


from the exposed material cylinder, the Rock
WARNING Valve, and the outlet pipe (Figure 103).

Amputation/crushing hazard. Keep


hopper grate in place during operation

W015.eps
and cleaning.

If you must remove the grate for the purpose of


chipping out concrete, wait until you return to the shop
to do so.
NOTE!
First disable the hydraulic system by
stopping the engine and removing the key.
We suggest, for safety reasons, that you return to your rake.eps

shop before removing concrete that has completely set,


because after the concrete has set, there is no advantage Figure 103
to chipping it away at the job site. If possible, you can Use the rake to remove excess material.
make your job back at the shop much easier by getting
at least enough concrete removed from the hopper to
free up the agitator and the Rock Valve; then move • Spray water into the opening, washing the end
quickly to the inside of the Rock Valve and material of the rubber ram, the material cylinder, the
cylinders. By doing this, you will only have to chip Rock Valve and the outlet pipe (Figure 104).
concrete from flat surfaces. Continue washing until the water that leaves
the valve is clear and clean. Visually inspect to
Cleaning the Rock Valve and material be sure that no rocks, sand, or clumps of
cylinders concrete remain. If there is still material, you
When the hopper is clean, move to the Rock Valve and may choose to use the rake again or just
material cylinders. Before you begin, bring the engine continue spraying.
speed to an idle. Stroke the concrete pump one
complete stroke in reverse, until the Rock Valve shifts,
then stop the pump. This step ensures that the material
cylinder that is exposed will have the rubber ram
extended to the end, thereby eliminating the need to
pull material from deep inside the cylinder. Be sure the
concrete pump is turned to the “off” position before
proceeding.

WARNING
Amputation hazard. Stop pump before
cleaning the Rock Valve and hopper.
W011.eps

sprayOP.eps

Figure 104
Spray out the Rock Valve
and material cylinders.

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 121
Operation

• Be sure that your rake and everything else is Cleaning the waterbox
out of the valve area; then cycle the machine in
reverse for one more stroke. This will expose
the opposite material cylinder and completely
WARNING
extend its rubber ram. Pull any loose material Crushing/amputation hazard. Disable the
out with the cleanout rake, and then spray out hydraulic system before removing
the material cylinder as in the previous step. waterbox guards.

W007.eps
• By putting the pump in the “reverse” mode,
you are sucking from the direction of the
NOTE!
pipeline (which is not connected during the
The waterbox can now be cleaned and filled
cleanout procedure) and pumping into the without removing the cover. If for some
hopper. Because of this, you may find that you reason your waterbox cover is not securely
now have more material in the bottom of the in place, push the emergency stop button,
hopper, which needs to be rinsed out. which stops the pump and secures it against
unintentional starting. Then replace the
cover before restarting the pump.
To clean the waterbox:
1. Lower the truck RPM to an idle.
2. Leave the waterbox cover in place, open the drain
(Figure 106), and allow the water to flow out the
bottom of the waterbox.
3. When water stops flowing give the unit a few
sprayElb.eps
strokes in either forward or reverse. This will force
the water in the extended cylinder back into the
waterbox and, therefore, out the drain. The
waterbox is empty when no more water flows out
of the drain as the unit is cycled.
4. Close the drain and temporarily open the water
supply valve (Figure 106). Put the pump into
forward or reverse to clean any remaining cement
residue from the rams; then close the supply valve
sprayTB.eps
and open the drain to flush the remaining water
before returning the pump to the “off” position.
Figure 105
5. If you will be refilling the water box immediately
Washing the elbow and tapered bend
to start another pour, simply close the drain and
finish filling the water box.
6. A highly recommended practice is to not fill the
waterbox again until just before the next pour,
because when the water box is refilled immediately
• Spray out the tapered bend, the 6-inch elbow, after being dumped, the oil which is cooling in the
and the bottom of the 6-to-5-inch reducer, differential cylinders contracts and creates a
where the cleanout ball will not have touched vacuum behind the seals. This vacuum will pull
the sides (Figure 105). Pay attention to the flat water and other contaminants past the “v” shaped
surfaces and rubber parts because even small seals into the cylinder and will eventually destroy
pieces of debris will impede reassembly. the seals and score the cylinders.
• Spray off the clamps, gaskets, and wedges. It is especially important to drain the water box
• Close the hopper cleanout door, and reattach completely at the end of the day if the temperature is
the bungy cord, if used. below freezing

122 Operation Manual - S 42 SXG revDate


Operation

CAUTION
Pumpkit damage. Drain water out of
waterbox for transportation or storage in
freezing temperatures.

C003.eps
Waterbox drain

Waterbox supply
valve

wtrboxdrain.eps

Figure 106 waterboxsupply.eps

Waterbox drain (above) and supply valve (right)

Reassembling the unit 2. Replace the clamp between the 6-inch elbow and
To reassemble the concrete valve area, if it is feasible, the tapered bend or reducer. If you’re using the
you should move the truck ahead a few feet so you clamp between the elbow and the tapered bend,
don’t have to stand in the concrete and water left from orient the clamp with the opening on top and the
cleaning out. handle pointing rearward and down; that you may
have easier access when you need to remove it, and
Put the boom into the transport position before moving so it can’t be accidentally opened, as easily, by a
the unit even a few inches. mixer truck. You may have to tap the clamp with
your hammer to make it seat fully. This is normal
WARNING and ensures that you have a tight connection.
3. Replace the hairpins of the wedge and clamp.
Tipping/collision hazard. Do not move
the unit with the boom or outriggers
Be careful with acid
W016.eps

extended.

Do not drive for any distance with the concrete valve CAUTION
area still unassembled. It may be dangerous if the
tapered bend is swinging on its hinge while driving. In Chrome and rubber seal damage. Be very
careful when using aggressive cleaners
addition, the bumps, shaking, and turning forces may
Caution.eps

around chrome and rubber seals.


cause the pipeline brackets to bend, making reassembly
difficult.
Many aggressive cleaning compounds can do damage
1. Swing the tapered bend into the closed position,
to chrome and rubber seals. Always follow directions
and install the wedge. Pound the wedge into place
very carefully when using such cleansers.
with your hammer until the round 6-inch ends
become flush.

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 123
Operation

Preparing for travel Begin by attempting to clean the boom. If the ball will
To prepare your unit for travel: not come back, move to the hopper before dealing with
the boom.
1. Securely store your cleanout rake, sponge ball,
grease gun, hammer, shovel, and other accessories. Dump the hopper and material cylinders, and rake out
the bulk of the material from the concrete valve. If the
2. If you have been using the hard wire controls,
concrete is setting, don’t worry about getting each part
unhook your remote cable, and coil it neatly. Never
perfectly clean before moving on to the next area.
drive the unit with the remote box still attached to
When you have washed the bulk of the concrete from a
the pump. Store the cable and the control box in
component, the concrete will be thinned enough that it
the outside tool box of the truck. If you have been
will not set completely.
using the radio remote, it should also be placed in
one of the outside tool boxes. In the past we have If you were not able to suck the ball through the boom
advised storage of the box in the cab, but we have because the setting action was too far advanced, you
found that with extreme temperature changes, may be able to save some pipes and elbows by
condensation inside the box can cause internal disconnecting the elbows from each straight section.
corrosion, which can then cause electronic The elbows can be cleaned out by hand, and sometimes
component failure. For this reason, Schwing now straight sections of pipe will empty themselves by the
installs corrosion inhibitors in all locations that force of gravity, providing that the concrete doesn’t
contain an electronic circuit board. have to flow through an elbow. Use the boom to put the
straight sections of pipe in a vertical position after the
3. Before leaving the job, check to be sure that your
elbows are removed. Make sure that no one is standing
outriggers are closed and pinned, that your boom is
under the boom before raising or lowering, and don’t
secure in the cradle, and that the tie-down strap is
forget to watch for electrical wires or other
attached and tightened.
obstructions.
4. If you were collecting concrete delivery tickets on
your job, remember to give them to the concrete Do not use compressed air to clean single sections of
supervisor when you present your job ticket for pipe, because the concrete may develop very high
signing. velocity due to the relatively small mass. When the ball
or go devil exits the pipe under these conditions, it may
5. Before you get into the cab to drive, take a walk cause injury or property damage. Do not attempt to
around the truck. Look for items you may be remove sections of pipe from the boom by yourself if
forgetting, look under the unit for personnel and they are full of concrete. They will weigh more than
obstructions, and check the truck tires for air one person can safely handle alone.
pressure, as well as for anything that may be
protruding from them as a result of driving on the After the boom is clean, the remainder of the material
job site. Many driving accidents happen on the way in the hopper and valve can be chipped out if it will not
back to the shop after a job or on the way to a wash clean. Be sure to disable the hydraulic system on
second job. Think about your route, bearing in the unit by stopping the engine, putting the key in your
mind the time of day, road construction, and other pocket, putting a “Do Not Operate” tag on the ignition
factors. You want to begin driving with a fresh switch before entering the valve/hopper area for
attitude and a clear head. chipping.
After you have cleaned as much as possible, it may still
be worth while to try using a pressure washer to clean
Special Pumping Situations any unfinished components. If you know the location
of a pressure washer, drive there directly after leaving
Hurry up cleanout the job. Spraying concrete with a pressure washer
If concrete is setting up in your machine, you must usually results in sand, cement, and small rocks being
clean out in a hurry. Accidents happen when you panic, sent into the air as the water jet hits them, so do not
however, so remember to follow the safety rules as you attempt this procedure without wearing safety glasses
are working. Stay calm, and work as quickly as you can and, preferably, a full face shield.
without skipping any safety measures.

124 Operation Manual - S 42 SXG revDate


Operation

Moving the pump during a pour stretched out over another area that must be protected
If you have to move the pump during the pour, time from falling concrete, you may have to cap the hose
will be of the essence. If help is available, use it. with a blanking plug and fold it while it is still full of
Circulate the concrete, if possible, and add water to it. concrete. To fold up in this situation, you must be sure
that the concrete is fresh enough to remain stable
Fold up the boom after letting # 3 and #4 drain out in during your move. Because of the weight of the
the vertical position. Take a few strokes in reverse to concrete in the pipeline, the boom may have a hard
pull some of the concrete in #2 back toward the hopper. time pulling section #4 into section #3, as well as #3
Cap the tip hose with the blanking plug. If you don’t into #2. You can leave each section straight up until the
have a blanking plug, suck the cleanout ball several next section is fully retracted. As soon as sections #3
strokes into the boom and install a retainer pin, so you and #4 are in all the way against #2, you can fold up as
don’t drop any remaining concrete on personnel, normal. Leave the cap on the tip hose until you are
equipment, or your truck. extended again or at least until you can find a place
If the concrete is old, if temperatures are extreme, or if near the pump where it can be removed safely and the
you have to move a long distance, clean out the boom concrete allowed to drain out while the boom is in the
before moving. Position the boom in the “A” frame “A” frame position.
configuration, and suck the ball back according to the When you fold the boom for transport, bring it into a
instructions on page 114. Continue to stroke in reverse position that will allow the tip hose to catch in the
until the ball clears the deck pipe, take one more stoke, holding brackets (Figure 107). This position is reached
then stop the pump and quickly fold up the boom. when section #4 is retracted into section #3 and section
In some cases you may be forced to move without #3 is being brought into section #2.
being able to drain the boom of excess concrete. If, for
instance, you are pouring a deck with the boom

Figure 107
Seating the tip hose during boom foldup

Folding up, hose.eps L

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 125
Operation

If the boom is full of concrete and you have section #2 into a position that will allow you to physically reach
straight up and down while you are retracting section the fourth section and actually lift the tip hose into the
#3, the unit must be level for the hose to seat in the bracket assembly, where you can be certain that it is
holders. If it does not, you will have to put the boom locked into position inside the holders (Figure 108).

#2 section

#4 section

#3 section

Figure 108
Boom positioned to lock the tip hose into the holders

Once the boom is folded up, reposition the local/ When the unit is ready to move, bring the engine RPM
remote switch to the “local” position. Hold down the down to an idle, and take a look around before getting
outrigger pushbutton, and retract the outrigger pads in the cab. Be sure you have your shovel and barrel
from the cribbing. Have your assistant load the loaded, your remote box and cable stowed on the unit,
cribbing on the pump while you continue retracting the and the concrete tickets (if they are going to stay with
outriggers. If you will be moving only on the you). Generally, just make sure that you really are
construction site at low speeds, you can just lay the ready to move before you get into the cab.
cribbing on the truck. If you will be moving at higher
speeds or moving onto a public roadway at any time,
all loose items will have to be secured for travel. Be
sure that all outrigger pins are placed into the travel WARNING
position. Securing the unit for high speed or public
roadway travel will take considerably more time, so Tipping/collision hazard. Do not move
suck a cleanout ball through the boom and consider the unit with the boom or outriggers
W016.eps

whether or not you should also wash out the hopper extended.
and material cylinders. Remember, concrete is liquid
stone. If conditions are favorable for the concrete to
set, you will be much better off just cleaning out and
starting over when you have repositioned the machine. When you get into the cab, push in the clutch, take the
transmission out of gear, push in the PTO pull switch,
and be sure that the warning lamp in the dash goes off.

126 Operation Manual - S 42 SXG revDate


Operation

Listen for the telltale “clunk” that reveals whether the • If it is very cold, concrete can freeze in the
PTO has actually come out of gear. If you don’t hear boom while you are pumping.
the sound, make sure that you first attempt to move the • Concrete freezes in the hopper.
truck in a forward gear, because reverse will damage • The concrete may contain calcium chloride or
the hydraulic system if the PTO is still engaged. If you an equivalent accelerator which allows the
cannot get the PTO to respond to the pull switch, concrete to set before it freezes. This
instructions on getting it in and out of gear without the accelerates setting in much the same manner
air system can be obtained from Schwing that a hot day does.
Service Department.
• Anything you wash with water becomes coated
Remember to release the brake before you try to move. with ice, which will not melt and evaporate
When you arrive at the new setup spot, set your parking until the temperature rises above freezing.
brake, and get out of the cab to check over the new spot • Machine parts that you sometimes stand on or
for soil conditions, overhead power lines, obstructions, grasp with your hands become very slippery if
etc., just like you did for the original setup spot. If they contact any water.
something is not safe and you will need time to get the Some of these potential problems can be solved or
spot ready or find a new spot, finish cleaning out first. tolerated, while others cannot. The concrete will
Do not ignore safe procedure and common sense so usually be mixed using very hot water to keep the
that you can get back to pumping before the concrete from freezing during the delivery and waiting
concrete sets in the machine. On the other hand, it period.
doesn’t make sense to let the concrete set in the
machine while you are arranging for a safe setup spot. Here are some tips for cold-weather pumping:
If in doubt...clean out. 1. In locations that have cold winters, like the
There are many cases where you can fold up the boom northern United States and Canada, store the
and outriggers, move, safely setup, and be pumping machine indoors. If you do not have a heated shop
again in 10 or 15 minutes. Only hot or very cold for the winter, consider renting one.
weather conditions, old concrete, poor conditions for 2. If your unit does not have the optional, water tank
setup at the new location, and long drives make moving heater, do not put water in the water tank or the
without cleaning risky. Experienced operators should waterbox before driving to the job. If possible,
have no trouble recognizing if there is danger of contact the ready-mix company, and arrange for
concrete setting. Your job will be much easier if you the first driver to be loaded with hot water to fill
learn to understand the characteristics of concrete and your waterbox and to mix your slurry. Arrange for
make your decisions based on that knowledge. the last truck to be full of hot water for you to use
during cleanout. Many pump companies have
Cold weather pumping found that, if they insulate the water tank with
It is possible (and routine in some parts of the world) to styrofoam or large insulated construction blankets,
pump concrete with outside temperatures being they can fill the tank with hot water in the morning
subzero. This can present a variety of problems and have it still be warm for clean out. If you do
compared with pumping in moderate temperatures: this, however, you must be sure to keep an eye on
• Water in the water tank and waterbox can the tank for freezing, and leave the hose
freeze while you are driving to the job. disconnected and preferably stored in the heated
cab until clean out time.
• Moisture in the truck air system freezes,
effectively stopping air flow and freezing air- 3. You can prevent moisture in the air system from
operated components, including the PTO. freezing only by removing the moisture from the
• The boom and outrigger hydraulics are slow air. When temperatures are expected to be below
and sluggish to respond to your commands. freezing, drain the water from the air system each
day by opening the drain cock on the bottom of
• Slurry freezes in the boom when you are
each air tank. You should do this procedure at the
starting the pour.
end of the day, preferably in a warm shop. If cold-

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 127
Operation

weather operation is expected every day, you 9. If the concrete freezes in the hopper, you will also
should consider having an air dryer installed on the be done pumping. Find a warm place to bring the
truck air system. machine, and clean it as it thaws.
4. If you are expecting cold weather for extended 10. At the end of the cleanout procedure, open all drain
periods of time, such as winter in the northern cocks in the water supply system.
United States and Canada, you should change your
oil to a thinner viscosity type, such as an ISO VG Preheating the boom pipeline
32, which will give you a lower pour point. Be You can preheat your boom pipeline to help get the
aware, however, that this oil cannot protect the slurry through without freezing, but there is little you
components to as high a temperature as the can do about a separately laid pipeline that has laid
standard oil shipped with your unit (ISO VG 46). outside over night. In most cases, pours that require a
Another consideration is to preheat the hydraulic separate pipeline laid outside will cancel if it is very
oil before beginning the pour. This will require that cold. If they do not cancel, be certain that any pipeline
you arrive at the job early enough to do the laid outside is covered with insulated blankets and
procedure. Allow 10 or 15 extra minutes to preheat preferably not brought outside until just before the
the oil. pour (less than an hour prior). If not, there is a good
5. If the concrete contains calcium chloride or chance that you will not be able to get concrete through
another accelerator, you will have to keep the the line, because the slurry will freeze against the walls
concrete alive using the same techniques required of the pipe. Then the concrete will have to be pushed
for pumping on hot days. The calcium chloride through the pipe dry. This could result in a blockage
accelerates setting, but if the concrete does freeze, which we call flash freeze. If the motion of the concrete
the setting stops. When you begin to warm the is stopped in a frosted pipe, the heat will radiate from
machine, the concrete will begin to set again, even the concrete so quickly that the entire line can freeze
more quickly than on the job, because you are now completely in a matter of moments. Usually, if this
in a warm area. Do not waste time when cleaning a happens, the pour cannot be completed until the slick
machine under these circumstances. line is replaced, and the concrete sitting on the job will
6. Everything you wash on cold days will then have a be rejected before it can be placed. Many dollars are
layer of ice on it; be very careful when handling lost when this occurs.
these objects. Pipes and clamps could easily injure To preheat the boom pipeline:
you if they slip out of your hands. • Fully extend the outriggers as previously
7. Beware of slippery surfaces when pumping in cold described.
conditions. Don’t stand on ice coated pipes or other • Remove the wedge pin and the clamp from the
round objects. Some operators spray water on tapered bend to make an open path from the tip
decks and steps, allow it to freeze, then put a little hose to the hopper.
concrete on top of the ice for traction. The concrete • Look overhead for electrical wires or other
is easy to wash off when the machine is warmed obstructions.
because of the layer of ice that holds it away from
• Extend the boom and position it so that the tip
the steel. Be sure that you distribute concrete to all
hose slips over the exhaust stack of the truck
areas where you will be walking, if you choose to
engine and the exhaust is blowing into the
use this method.
hose. With an open path to the hopper, the
8. If the concrete does freeze in the boom, you will be exhaust should now travel through the
finished pumping until you have warmed up the pipeline, heating as it goes. Without an open
machine and cleaned out the boom. Fortunately, path, the hot air from the exhaust will be
the concrete will stop setting when it has frozen. forced backward and create excessive back
Once you bring the machine into a warm place, pressure on the engine of the truck.
you should be able to get it clean.
NOTE!
To prevent engine damage, the exhaust must
have a complete path to the hopper!

128 Operation Manual - S 42 SXG revDate


Operation

closed
s
ep
2.

o
its
ag
open

Figure 109
Agitator shutoff valve

To prevent concrete from freezing in the boom while move to the open position. Contact the Schwing
pumping, some companies wrap their boom pipeline Service Department if you have any questions
with insulation. In most cases, the insulation is a regarding installation.
styrofoam tube cut to accommodate the pipeline that is 2. Activate the agitator switch. The agitator will not
placed around the pipe, and taped together. The be able to turn, and the oil will be forced over the
styrofoam holds in the heat of the concrete. relief valve. At an idle (about 600 RPM), 4.5
horsepower is being converted to heat.
Minimum temperature for boom operation
3. When the temperature gauge shows 20˚C or higher,
is -40˚ open the shutoff valve.
Do not operate the boom if the temperature is colder
than -40˚. The material in this boom will become brittle Draining the water system
and likely to crack from normal boom bounce if
operated in temperatures colder than the minimum Drain the water system (when freezing)
temperature allowed for operation. The water pump and related plumbing on Schwing
-40˚ is the same temperature on both the Fahrenheit units may have several drain cocks installed along the
and Celsius scales (-40˚ F = -40˚C). water delivery system. After cleanout, it is very
important that you follow the water delivery line from
Preheating the hydraulic oil the pump to the outlet, open all drain cocks on your
unit, and then activate the water pump to be sure it isn’t
With load-sensing hydraulic systems and pressure cut-
holding water.
off hydraulic pumps, the hydraulic oil can no longer be
heated with the boom hydraulic system or the concrete NOTE!
pump hydraulic system. The agitator circuit must be It will not hurt the Hypro diaphragm pump
used to heat the hydraulic oil. to run it empty. After opening all drain
cocks and activating the pump, you may
To preheat the hydraulic oil, follow these steps: want to run the pump again to be sure all
1. Locate the agitator shutoff valve (Figure 109), and water has been removed.
close it. Note! If your unit does not have a shutoff
valve, you can order one, using part number
10004680 (shutoff valve) and number 30303432
(tube). Install the valve between the agitator hand
valve and the agitator motor. Position it so that if
the handle moves by the force of gravity, it will

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 129
Operation

Emergency Procedures
Disabling the entire unit in an emergency
If an emergency requires that the hydraulic system be
disabled completely—such as if a hose or fitting
breaks—you must stop the truck engine or at least take
the transmission out of gear. This can be done only
from the cab of the truck, unless you have purchased
the optional remote engine start/stop feature. If you are
faced with an emergency, first shut off the engine or
take the transmission out of gear, then investigate.
Keep one long length of each of the six possible
diameters of hose with the unit for such emergencies.
(For a list of the six hose diameters and the
recommended length of each, see the Appendix section
of this document.)
If there is an electrical malfunction in the E-stop
circuit, the dump valves (in the E-stop manifold) open.
This will route oil from the hydraulic pump directly
back to tank. This also happens when any emergency
stop button is pushed. To continue pumping, you will
have to find out what happened and fix it. If you cannot
find out what has happened within approximately 10
minutes, you will have to take action to prevent the
concrete from setting up or freezing. As discussed
earlier in this manual, the dump valves have a bypass
switch (Figure 110) located on the front wall of the tool
box containing the main controller.
By activating the dump valve bypass switch to the
‘bypass’ position, all electrical control of the unit is
lost. You should, however, be able to fold up the boom
and outriggers with the manual controls, so you can get
to a place where repairs are possible.

WARNING
Loss of emergency stop function.
Emergency stop switches are disabled
when manual override is activated.
W004.eps

When the dump valves are bypassed, the emergency


stop buttons will not function. For information on
where to look and what to do if you lose electricity on
the unit, contact the Schwing Germany Service.

130 Operation Manual - S 42 SXG revDate


Operation

Override of emergency stop manifold


1. Turn the bypass key switch (Figure 110) to “by-
pass” position. If manual control is not restored,
the problem is likely hydraulic.

BY-PASS Bypass
NORM. BY-PASS
key switch

by-pass2.eps

bypasskey.eps

Figure 110
Boom/Outrigger bypass switch (left)
Location of switch (right)

speedy:opmanuals:42SX vector:42SXG:42SXG Operation


Operation Manual - S 42 SXG 131
Operation

Do not operate the machine when: guide to their locations is shown in the Safety section of
• A crack or break in a boom, outrigger, or other this operation manual. There is no charge for warning
load-bearing structural member is discovered. labels.
• A guard is missing, damaged, or unusable.
Loss of radio remote signal
Loss of remote control If your radio remote stops functioning and the battery
The remote control box is considered the primary LED is off while the radio on/off switch is in the on
control source for the concrete pump and boom. If you position, the battery is probably dead. Remove the
lose the remote control for any reason, you can still battery from the remote box, and replace it with a fully
finish the job, but you must use extra caution. The charged battery. The dead battery should then be placed
manual control devices are shown in the Product in the charger (Figure 111). The charger is located in
Overview section of this document. Each manual the passenger side tool box which contains the main
control device does what its remote-control counterpart controller and the Omnex receiver (Figure 111).
does, but with less convenience. Get assistance, if
needed. The emergency override handles of hydraulic Disposal of spent batteries
valves are not always positioned at a work platform, so NiCd and NiMH batteries are recyclable. You can help
WATCH YOUR STEP if you need to access them. preserve our environment by returning your unwanted
batteries to the nearest location for collection,
Other Things You Need to Know recycling or proper disposal. Call 1-800-822-8837 toll
free for information about spent battery collection.
Reordering documentation or warning
labels CAUTION
To order replacement labels, operation manuals, safety Battery fluid is toxic. Do not handle
manuals, or any other unit documents, call the Schwing damaged or leaking batteries.

C006.eps
Spare Parts Department.
Have the serial number of the unit from the serial NOTE!
number plate handy when you call. Each safety label Do not dispose of nickel cadmium or nickel
has a part number on it. A complete list of labels and a metal hydride batteries in household or
business trash.

Omnex receiver

Figure 111
Omnex battery charger (left)
and location (right)
Battery charger

vectoromnxrcvr.eps
omnxchrg.eps

132 Operation Manual - S 42 SXG revDate


Maintenance

WARNING

on
Do not stand
hopper grates.

S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR

PERFORMING ANY SERVICE:


Gasoline or Diesel Engines
1. Stop the engine.

2. Remove the key, place it


in your pocket, and put
a "DO NOT OPERATE"
tag on the switch.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.

2. Lock out the power


source according to an
approved lockout-tagout
program.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.

42SXside.eps

MAINTENANCE
Filtration .................................................................................................. 134
Hydraulic Oils.......................................................................................... 135
Pressure, Hoses, and Fittings................................................................. 136
General Maintenance Tips...................................................................... 138
Maintenance Checklist............................................................................ 140
Daily Maintenance .................................................................................. 141
Weekly Maintenance .............................................................................. 142
Monthly Maintenance.............................................................................. 145
Setting Pressures ................................................................................... 149
Quarterly Maintenance ........................................................................... 159
Semiannual Maintenance ....................................................................... 160
Annual Maintenance ............................................................................... 162
Time-related Maintenance ...................................................................... 169
Unscheduled maintenance ..................................................................... 169

Operation Manual - S 42 SXG


Maintenance

Maintenance • the clean element pressure drop for a given


flow rate (in PSI and gallons per minute or bar
Keeping your machine in good working condition and liters per minute)
requires regular maintenance. There are two kinds of • the ratio of particles of a given size
maintenance: preventive and repairs. Preventive encountered versus particles passed (referred
maintenance will help you avoid unnecessary repairs, to as the “beta ratio”). An example of a beta
but eventually even well-maintained machine parts ratio would be β25 = 200 (pronounced “beta
wear out and require repair or replacement. twenty-five equals two hundred”). This means
that for every 200 particles of 25 microns or
Preventive maintenance needs to be done on a regularly
larger that hit the filter media, one makes it
scheduled basis. That schedule may be daily, weekly,
through. A finer filter would be β12 = 200. A
monthly, quarterly, semiannually, or annually. It is a
courser filter example would be β25 = 75. For
good idea to make a checklist that will tell you what
concrete pumps, medium to fine filtration is
maintenance is due and when. A checklist is included
required.
in the Appendix section of this manual. Keep accurate
records of maintenance performed and when the work
Specific information
was completed. By doing this, you will know that all
necessary work has been completed on time. With Here are some facts regarding filtration as they relate to
today’s computer technology, this task can be your pump:
accomplished very easily and efficiently, so there is no As delivered from the factory, each Schwing pump is
excuse not to do it. Complete maintenance records equipped with a system filter that is rated at 6μ
could also make the machine worth more money when absolute. The beta ratio is β6 = 200. This means that
the time comes to sell or trade it. for every 200 particles that are 6 microns or larger that
There are certain things you should know about the hit the filter media, one makes it through. Although we
maintenance of your machine that will not come up on are not happy about the one particle that is allowed
a timetable of things to do. We begin this section with through, we do not use finer filtration because (1) the
general information about some of these items. components don’t require it, and (2) a finer filter would
plug up with dirt too often, resulting in high
maintenance costs to you. We have settled on a
Filtration compromise that should afford long service life and
minimum maintenance costs. Don’t be fooled by the
General information one particle that gets through; this is an extremely
Filtration is the single most important method of high-quality element with very good trapping
keeping your unit’s hydraulic system operational. characteristics.
Particles that could damage the components are The filter is equipped with an integral bypass check
introduced into the oil by the differential cylinders, the valve with a spring force of 50 pounds. That means that
boom cylinders, the valves, the reservoir breather tube, when the system filter is clogged with dirt and oil is
and by internal wear in the components themselves. having a hard time making it through, the pressure
Additionally, when you change hydraulic oil, the new difference between the filter inlet and the tank rises.
oil is not clean enough to be used in a concrete pump This pressure difference (commonly referred to as a
without being prefiltered. New hydraulic oil is filtered pressure differential) is called Delta P and is shown as
at the refinery to only 40μ (40 microns). The oil in a ΔP. When the ΔP reaches 50 PSI, the check valve
Schwing pump needs to be filtered to a minimum of opens, a fault warning is sent to the Vector controller,
25μ and preferably finer than that. Filters are rated by: and the oil returns to the tank unfiltered. If the filter did
• the size of particles they trap and whether that not have the bypass check valve, it would simply break
size is nominal or absolute apart when it was clogged. That would put all of the
dirt that it ever trapped directly into the system, and the
• the dirt-holding capacity, in grams
element itself would become a contaminant.

134 Operation Manual - S 42 SXG revDate


Maintenance

External filtration hydraulic filters are replaced or when water is not


All units built at Schwing have been fi ltered flowing properly through the pump. The part number
by an external filtration system for the duration of the for the filter can be found in your parts book.
test period and are fitted with appropriate plumbing for
our customers to be able to do the same. Schwing Hydraulic Oils
highly recommends that all units be externally filtered
as often as possible during any extended period that the General information
machine is not in use. External filtration should be
accomplished at 55˚ F or warmer only after excess Hydraulic oils are rated for viscosity, heat dissipation,
moisture has been drained from the hydraulic tank. foaming characteristics, pour point, antiwear additives,
Portable filtration carts can be ordered from Schwing anticorrosive additives, lubricating qualities,
part # 30335910. compressibility, temperature range, temperature
stability, and other functions. Although many different
Changing your hydraulic oil filters brands of oil meet these specifications, they may use
different chemical additive packages to achieve the end
Your machine is equipped with a ΔP sensing switch in result. For this reason, you should not mix two
the filter housing. The Vector Control computer will different brands of oil. The additive package from one
disable the dirty filter circuit until the hydraulic oil brand may be incompatible with the additive package
reaches 30˚ C. The reason for this is to avoid an from the other, rendering both packages useless.
annoying horn alarm from sounding as a result of oil
below normal operating temperature being forced Recently, a few manufacturers have introduced
through the filter. After achieving 30˚ C, if your alarm biodegradable hydraulic oils onto the market. These
horn sounds and the display screen of the operator’s oils are based on vegetable extracts instead of mineral
panel reads “concrete pump hydraulic filter exchange extracts. They are considered safer for the environment
fault,” you should install a new filter at the first in the event of a spill, although the additive packages
opportunity. Remember, unfiltered oil wears out every are not inert. One brand, Mobil EAL 224-H has been
hydraulic component on the machine. accepted for use in Schwing pumps, and other brands
are under consideration and testing. These oils must
The boom / outrigger circuit is equipped with an in-line not be mixed with mineral-based hydraulic oils, even in
high-pressure filter. This filter is in a canister that is very small amounts. If you will be pumping a job in an
rated to handle the pressure that is felt by this circuit. environmentally sensitive location and want to use this
There is no integral bypass in this filter, and it is not type of hydraulic oil, please contact the Schwing
fitted with a ΔP switch, so the boom /outrigger filter Service Department at (0049) 2325-987-0 for instructions
should also be changed whenever the system filter on making the change from mineral oil to
is. The rating on the filter is β25 = 200. We install this biodegradable.
filter to catch large particles that may cause a boom
valve or holding valve to stick in an open position. The Viscosity of hydraulic oil is similar in concept to the
boom circuit gets its oil from the same tank as the different weights of motor oil. For example, in the
system filter, so the oil should be clean anyway. winter you may run 5W-30 in your car, while in the
summer you run 10W-40. The same is true for
The type of filters installed on your unit are the result hydraulic systems. If you live in a climate where the
of years of experience and testing. We recommend that weather is changing from extremely hot conditions to
you do not change the housing or element to some extremely cold conditions, you should consider
other type. You may learn that, in the long run, changing the weight of the hydraulic oil that you use
sometimes cheaper is more expensive. by the season. The International Standards
Organization (ISO) has developed a method of grading
Changing high pressure water filter hydraulic oils for viscosity. For summer in northern
If your unit is equipped with the optional high pressure North America, we recommend ISO VG 46 weight oil,
water pump, the pump is plumbed with an in-line filter while in the winter we recommend ISO VG 32 or even
between the water tank and the pump. This filter should VG 22, depending on how cold it gets in your area. For
be inspected and cleaned (or replaced) at the same time southern North America and Central America, we

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 135
Maintenance

recommend ISO VG 46 for the winter and ISO VG 68 Pressure, Hoses, and Fittings
or VG 100 for the summer, depending on how hot it
gets. The lower the ISO VG number, the thinner the oil
General information
is and the lower the pour point of the oil is. On the
other hand, the thinner the oil is, the lower the Most concrete pump hydraulic systems run with fairly
temperature will have to be before it breaks down the high pressures: in the 2000–5000 PSI range. The
lubricating film that protects your components. See the maximum pressure is determined by adjustment of the
chart in the Appendix section of this manual for help in main relief valve, and the machines are designed to
selecting the proper oil for your requirements. handle this pressure safely. Concrete pressure is just a
ratio of the hydraulic pressure.
The quality of the oil needed for use in a Schwing
machine is rated in the DIN system. The ratings have to If you lower the pressure at which the system runs, you
do with the chemical additive package that is can harm the system. For example, you ask the
introduced into the oil. Both the DIN rating HLP and machine to develop 3000 PSI of hydraulic pressure to
HV qualities are approved for use in our machines. push concrete. You want to replace a hydraulic hose
with a less expensive, lower pressure hose, so you
Specific information lower the relief valve setting from 4350 PSI to 2500
PSI. What happens? The concrete still requires 3000
All machines leave the Schwing factory filled with
PSI to get to where you want it to go, but your relief
Rando HD 46 hydraulic oil, which has an ISO viscosity
valve opens at 2500. Now the oil that should be
rating of VG 46. Rando HDZ 46, an extended-viscosity
pushing the concrete is traveling back to tank instead.
oil designed for use under severe conditions, is
All the horsepower it took to send the oil out of the
available on request. If you want your new machine
pumps at 2500 PSI is turned to heat, which boils the
filled with a different brand or different viscosity oil,
oil. The oil in this example loses its lubricating
you should specify it when ordering.
qualities at 80°C, so components begin to wear,
Many other brands of oil have been approved for use in sending debris downstream, which adds to the wear.
Schwing machines, including: The system would be destroyed in minutes if it
• Mobil DTE 25 continued to operate under these conditions.
• Shell Tellus oil If you raise the pressure at which the system runs, you
• BP Energol can also harm the system. Using a new example, the
• Aral Vitam concrete requires that the machine develop 5,200 PSI
• Esso Nuto hydraulic pressure to push it where you need it. Your
machine is factory set to run at a maximum of 5076
• Esso Univis
PSI (single circuit) so you raise the setting of the main
• Total Azolla relief to do the job. The hydraulic pump cannot
• Wintershall Wiolan withstand 5,200 PSI for more than a few minutes, and
The brands listed have been approved; however, any oil it breaks. Now you must replace a pump before you
that meets the quality and viscosity standards described can make another pour.
above can be used. If you leave the machine at the factory specifications,
you will not harm the system. It will give you years of
When to change your hydraulic oil dependable service. This means you should use only
Change your hydraulic oil at least once a year. If you fittings and hoses that have a sufficient working
use good filters and change them when they are dirty, pressure to handle the system requirements. If you take
the oil will be clean even after a year, but the chemical a job that needs more pressure than your machine is
additive packages that give the oil its properties will capable of handling, you should buy or rent a higher
break down with time and no amount of filtration will pressure machine.
bring them back.

136 Operation Manual - S 42 SXG revDate


Maintenance

Specific information Schwing uses metric fittings and hoses (TABLE 1)


Schwing uses high-pressure fittings and hoses on all with metric threads on the couplings. There are six
circuits, even if the relief valve for that circuit is set to sizes of tubes and fittings and six sizes of hoses all
low or medium pressure. The fittings and hoses are measured by diameter.
rated at a minimum of 5000 PSI working pressure and All block threads are metric or BSPP.
up to 15,000 PSI in some fittings. Schwing advises
against changing any circuit to lower rated hoses or
Instructions for setting the relief functions are shown
fittings.
later in this section, starting on page 150.

TABLE 1
Hose, Fitting, and Tube Sizes, and Equal Connection Sizes

42SXhose/fittings chart.eps

Hose ID Connects with Fitting


Hose Size (mm) and Tube Size
8 8 12
13 13 16
16 16 20
20 20 25
25 25 30
32 32 38

Tube and Tube and


Tube and Fitting OD Connects with Fitting ID
Fitting Size (mm) Hose Size (mm)
12 12 8 8
16 16 13 13
20 20 16 16
25 25 20 20
30 30 25 25
38 38 32 32

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 137
Maintenance

General Maintenance Tips

A B

TORQUE/FORCE GRAPHS
Force

Force
Time Time

Figure 112
Effects of proper torque on bolts

Torque specifications Removing safety devices


When performing maintenance that requires removal Sometimes you will have to remove a safety guard or
and replacement of bolts, you must adhere to the torque another safety device to perform maintenance. For
specifications for those bolts. these situations, you must take extra care to ensure
The graphs in Figure 112 demonstrate what happens to your own safety and that of your co-workers. If you
a bolt if it is not properly torqued. The dashed line have to put your hands, feet, or any other body part into
represents the prestress or tightness of the bolt. As the a part of the machine that would normally be guarded,
device that uses the bolt goes through its normal be sure to use an approved “Lock Out—Tag Out”
functions, the bolt in Example A, which is not tight procedure.
enough, gets stretched and relaxed with every duty
cycle, because the bolt is prestressed under the Welding precautions
maximum force of the cycle. In Example B, the torque
on the bolt has been raised to the proper level, which is X-10 connect.eps

more than the maximum force of the duty cycle, so the


bolt doesn’t ever feel the cycle. In this example, bolt B
would last much longer than bolt A. The torque
specifications for bolts used on Schwing equipment are
found in the Appendix section of this manual. 0
1 2

x1000 3
Start OFF

NA 1760 U/min 52˚C

Menu: [ENTER]=ON

Adjusting relief valves


While adjusting a relief valve is not normally a HOME + HELP START

dangerous procedure, you should remember that it has


CLEAR - ENTER QUIT

the potential to cause trouble. The main thing to watch


for is this: some operators may have a problem with a X-10 connector
machine and begin troubleshooting by raising the relief
valve setting. When that doesn’t help, they forget to Figure 113
lower it back down. Now when you check the pressure Unplug the X-10 connector before
by creating a hydraulic dead block, the pressure is set welding on the unit
too high. In extreme cases, this can cause hoses or
fittings to burst or other components to fail. To be safe, Replacing the hydraulic pump
you should begin the adjustment procedure by turning If you replace the hydraulic pump, grease the splines
the adjustment device to the lowest possible setting, on the new pump with Castrol Optimoly Paste White T
and then bring the device back up to the proper setting. or equivalent before installing it.

138 Operation Manual - S 42 SXG revDate


Maintenance

Lock Out - Tag Out procedure

Figure 114
Static cling tag for the windshield (left) and magnetic tag for the driver side door (right)

The manufacturer includes approved warning devices Store the labels in the glove box for future use.
with all new concrete pumps (Figure 114) and Before restarting the machine after performing
recommends the following procedure prior to maintenance, be sure to put away all tools, parts, and
performing any maintenance in an area of the unit that supplies, and clear the area of personnel.
would normally be guarded:
Concrete pumps are big enough to hide a man. Before
• Stop the truck engine.
starting the unit at any time, yell “Clear!” and allow
• Remove the key, and put it in your pocket. enough time for response before proceeding.
• Put the static cling “DO NOT OPERATE”
label on the inside of the windshield of the
truck. Place it in a location that is obvious to
anyone who enters the truck.
• After you leave the truck cab and close the
door, put the magnetic warning label “DO
NOT OPERATE” over the door handle. In this
way, no one can open the door without being
made aware that you are working on the
machine.
• Perform the needed service on the unit.
• Remove the labels, and reinstall the key.

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 139
Maintenance

Maintenance Checklist SCHEDULED MAINTENANCE


The following are the normal recommended
maintenance schedules (after the break-in period):

Item D* W M Q SA A Page
Changing your hydraulic oil filters When fault message is received..............................135
Changing boom oil filter When you change main system filter.......................135
Changing high pressure water filter When you change main system filter.......................135
Check truck fluid levels X ..............................................................................141
Bleed moisture from air tanks X ..............................................................................141
Check truck tires X ..............................................................................141
Check hydraulic fluid X ..............................................................................141
Bleed moisture from hydraulic tank X ..............................................................................141
Check differential cyl. rod packing X ..............................................................................142
Inspect bolts on Rock Valve and rams X ..............................................................................142
Grease rock and agitator bearings X ..............................................................................142
Grease boom bearings and hollow pin X ..............................................................................142
Check the grease tubs of the auto-lube system. X ..............................................................................142
Inspect for damage and leaks X ..............................................................................142
Check if maintenance is due X ..............................................................................142
Grease boom zerks .......X .......................................................................142
Check pipe wall thickness .......X .......................................................................142
Check oil in optional air compressor .......X .......................................................................143
Check Rock Valve tension nut .......X .......................................................................143
Inspect cutting ring and rotate, if needed .......X .......................................................................143
Lubricate mechanical moving parts .......X .......................................................................145
Check tapered bend wedge bolt .......X .......................................................................145
Check boom slewing gearcase level ......... ...... ...X...........................................................145
Clean slewing gearcase breather ......... ... ......X...........................................................145
Check function of mech. boom brake ......... ... ......X...........................................................146
Clean and repack the Rollix gear ......... . ........X...........................................................147
Inspect the turret bolts for tightness ......... . ........X...........................................................147
Check fluid in distribution gearcase ......... . ........X...........................................................149
Check unit mounting hardware ......... . ........X...........................................................149
Check hydraulic pressures ......... . ........X...........................................................149
Clean oil cooler fins ......... . ........X...........................................................159
Check drive pinion bolts ................... .........X .................................................159
Change oil in optional compressor ................... .........X .................................................159
Change oil for temperature reasons ................... .................. X .......................................159
Change oil in distribution gearcase ................... .........Δ ...... ..........X............................ .160
Change oil in boom slewing gearcase ............................. ........ X....... ................................160
Test the dirty filter warning circuit ................... .................. X .......................................161
Change oil for age reasons ...................................... ......... X..............................169
Complete cleaning of optional compressor ...................................... ......... X..............................169
Inspect boom, outriggers, and tower Changes with unit age .............................................169
Change corrosion inhibitors ...................................... ......... X..............................169

*D = daily, W = weekly, M = monthly, Q = quarterly,


SA = semi annually, A = annually
Δ = Break-in period

140 Operation Manual - S 42 SXG revDate


Maintenance

Daily Maintenance • Check the level and condition of the


hydraulic oil (Figure 116). Fill it, if necessary,
• Check the levels and condition of the with the same brand and type of oil. Add only
lubricants and coolant in the truck. Follow the filtered oil. Use a filter buggy to pump oil into
manufacturers’ recommendations for quantity the tank. New oil contains more contaminants
and type. than Schwing approves for their machines.
• Bleed the moisture out of the air system by Replace milky looking oil, which is a sign of
opening the petcocks located on the bottom of water contamination. Try to determine the
the air tanks. This is especially important if source of the water. If the oil has turned milky
there is a chance that the moisture will freeze. quickly, such as from one day to the next, then
• Check the condition of the truck tires. Do simply replacing the oil will not solve your
not drive the unit with bald, cracked, or problem. If you need ideas about where to look
damaged tires. for the source of water contamination, call
• Bleed the water out of the bottom of the Schwing Service Department at (0049)-
hydraulic oil reservoir by opening the drain 2325-987-0.
cock, or faucet, (Figure 115) at the bottom of
the reservoir. Place a drain pan under the outlet
hose, open the valve, and watch the liquid as it oilgaug2.eps

leaves the hose. When the liquid changes from


water to clean oil, close the valve. Because of
condensation, which increases with dramatic
Oil Gauge
heating–cooling cycles, there may be a small
amount of water in the tank every day.
However, it should settle to the bottom of the
tank overnight. The water that is drained
should be clean and so should the oil that
follows it.

Figure 116
Hydraulic oil level indicator

drain cock • Check hydraulic pressures. Each day you


45 oil drain cock.epsL should close the quarter turn (blocking cock)
valve and turn the concrete pump on. Let the
pump pressure out, with the driver side
Figure 115 differential cylinder fully extended. Check that
Drain cock or faucet used the operating pressure for each system is
to drain water from reservoir correct according to the hydraulic schematic in
the back of this section. Leave the pump on for
at least 60 seconds. This will not only let you
know that your equipment is in good working
condition but will purge the rocking oil of any
contaminants.

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 141
Maintenance

• Check the differential cylinder rod • Visually inspect the unit for damage or leaks
packings. The waterbox is fitted with a bolt- each day. Repairs should be made before the
down grate under the waterbox covers. To unit is operated.
check for rod packing wear, fill the waterbox • Once a day, check your maintenance
with water above the level of the differential checklist to see if any weekly, monthly,
cylinder rods (if no guards are installed) or semiannual, or annual maintenance is due.
above the bolt-down guards (if installed). Let it
sit for a few minutes. If oil begins to float to the If the auto-lube is not functioning:
top of the water, the rod packings are worn. • grease the Rock Valve and agitator bearings
Remember to let the water out after the check, as described in the Operation section of this
especially if freezing temperatures are manual.
expected. Failure to replace the rod packings • Grease the boom Rollix bearings and hollow
when they need it will result in contaminants pin as described in the Operation section of the
from the waterbox, including water, entering manual.
the hydraulic oil at the packings. This will
cause wearing on the rods, cylinder tubes,
guide bushings, pistons, and piston rings. The Weekly Maintenance
material that gets worn off these items also • Grease the boom. If you have an automatic
becomes a contaminant, accelerating wear. greaser installed, you must still remember to
Left unchecked, this wear will destroy a check each fitting to be certain that it is
differential cylinder. Under normal conditions, allowing grease to pass freely and to fill the
you are due for new packings after one to two grease pump reservoir as necessary. There are
years. many grease fittings on the boom, and each of
them should be pumped full of grease until
grease squirts out of the bearing area. The
WARNING location of each fitting is shown in the
Appendix section of this manual.
Changing cylinder rod packings can be
• Check the wall thickness of your boom
hazardous, including potential finger
amputation, hot oil burns, and oil
pipeline once a week. This should be checked
injections. You can remove the hazards by with an ultrasonic thickness tester (Figure
understanding the procedure. 117). These testers are available from suppliers
If you’re not familiar with the procedure, of quality control and testing equipment and
contact the Schwing Service Department from Construction Forms company
(Conforms). Conforms has its own brand and
000650.eps

before beginning.
model: the UT-100. Another common brand
• Visually inspect the bolts on the Rock Valve name is Krautkramer-Branson.
and the rubber rams each day. Notice if there is
any play. If you see something suspicious, shut
off the truck, put the key in your pocket, and
remove the hopper grate or waterbox covers
and guards, and inspect with a wrench. If you Figure 117
find that any bolts are loose, tighten with a Ultrasonic
torque wrench to the torque specifications thickness tester
found in the Appendix section of this manual. 000536.eps

Remember to replace the hopper grate or


waterbox covers and guards before restarting NOTE!
the machine.
The ultrasonic tester will not work on dual
• Check the grease tubs of the auto-lube system. wall pipes or elbows.

142 Operation Manual - S 42 SXG revDate


Maintenance

Main areas of wear • Check the Rock Valve tension nut for play
Delivery pipeline tends to wear about 4 inches beyond once a week. To check this nut, remove the
the flange at the end concrete enters (Figure 118). keeper bolt, grasp the tension nut (Figure 121)
by hand, and turn clockwise. There are many
holes for the keeper bolt on the spacer behind
the tension nut. The object is to place the
keeper bolt in the farthest hole you can reach
when you turn the tension nut by hand. If the
tension nut will turn only enough to reach
fig1.eps
partway to a new bolt hole, then turn the nut
4” back to the previous hole. Do not use a
wrench on the tension nut to get it to go to a
Figure 118 new hole. The wrench flats are on the tension
End of boom pipe where concrete enters ring for loosening only. Overtightening the
tension nut will cause premature wear on the
Elbows tend to wear on the upstream side, or where kidney seal. The tension nut adjusts the free
concrete enters the elbow (Figure 119). play of the Rock Valve on the kidney seal end.
The pressure spring automatically
compensates for wear on the cutting ring end.
Replace and tighten the keeper bolt. You do
not have to tighten the keeper bolt according to
the torque specifications that are normally used
fig2.eps for that bolt size. Just be sure the bolt is tight
enough to not vibrate out.
• Inspect the cutting ring and rotate if needed.
When to rotate the cutting ring depends more
Figure 119 on the type of concrete and the number of
Elbow wearing as concrete enters cubic yards pumped than on a time schedule,
but you should check it for wear at least once a
week and rotate it as needed.
Extend the life of your system 45 rock valve assembly.eps L

Spacer
The lifetime of pipe and elbows can be extended by
Keeper bolt
rotating each on a regular basis. Turn each pipe as well Tension nut
as complete sets of elbows 180˚ so concrete enters the Wrench flats
opposite end. Wedge

Tapered bend

6-inch clamp
ps

Cover bolts
4.e
fig

Figure 121
Tension nut may look like the flat one
Figure 120 (above) or the cone shaped one (below)
Rotate pipe and
elbows 180˚

• Check the oil level in the air compressor, if


your unit is so equipped. There is a dipstick on
the compressor for this purpose. 45rvcone.epsL

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 143
Maintenance

45 rock valve assembly.eps L

Spacer
Keeper bolt
Tension nut
Wrench flats
Wedge

Tapered bend

6-inch clamp
Cover bolts

Figure 122
Rock Valve assembly

Rotating the cutting ring little more, and then gently pry the Rock Valve
rearward a little more until it does. Rotate the ring
90° clockwise. (It doesn’t really matter which way
WARNING you rotate, but to keep from forgetting which way
Amputation/crushing hazard. Never work you went last time, Schwing recommends going
inside the hopper without disabling the clockwise each time.)
hydraulic system. 9. Be sure that the ring is centered in the Rock Valve.
W019.eps

Tighten the cover bolts slightly, if needed, to be


1. First, shut off the truck engine, and put the key in sure that the ring isn’t cocked one way or the other.
your pocket. 10. Be sure there is no debris between the back cover
2. Remove the 6-inch clamp between the tapered and the Rock Valve housing. If there is, clean it
bend and the 6-inch elbow (Figure 122). out. Tighten the cover bolts just enough to bring
3. Remove the wedge from the tapered bend, and pull the back plate up against the rock housing. Then
the tapered bend away from the 6-inch clamp. tighten each bolt equally, using a torque wrench.
Alternate which bolts you tighten, as you would
4. Loosen the tension nut as explained previously.
when tightening a wheel on a car. The torque
5. Loosen the seven cover bolts (Figure 122) two or specification for these bolts (M24 x 60, 8.8
three full turns, but do not remove the bolts. hardness) is 485 ft./lb. Replace the bolts once every
6. Push forward on the end of the Rock Valve slewing year.
cylinder. Because it has a single pivot point, it will 11. Replace the hopper grate. Bolt it into place.
push the Rock Valve backwards toward the
12. Tighten the tension nut according to the
loosened cover. If you meet resistance, do not force
instructions on Page 142. Tighten the keeper bolt.
it. After you have removed the hopper grate, you
can gently pry the Rock Valve backward from 13. Push the tapered bend closed, and install the
inside the hopper. wedge. Remember to install the hairpin.
7. Remove the hopper grate. 14. Install the 6-inch clamps and the hairpin.
8. From inside the hopper, tap the cutting ring
forward toward the spectacle plate. The ring should
pop loose. If it doesn’t, loosen the cover bolts a

144 Operation Manual - S 42 SXG revDate


Maintenance

• Lubricate mechanical moving parts with oil 5. Remove the dipstick plug (Figure 123).
or a WD-40 type of lubricant. This applies to The oil level should be visible on the dipstick
outrigger locking pins, hinges, valve handles, and should be near the full line. If needed, add
and other components. oil (90W gear lube). Do not replace the plug
• Once a week, check the bolt assembly that yet.
holds the tapered bend wedge. 6. Perform the steps listed in the following
procedure before replacing the pinion gear
cover.
Monthly Maintenance
• Clean the breather cap (Figure 123).
• Check the oil level in the boom slewing
1. Rinse both the breather and the dipstick
gearcase (Figure 123) by following these steps:
plug in cleaning solvent. In a pinch, brake
1. Be sure the machine is set up in a cleaner will work. Never use gasoline!
reasonably flat position.
2. Replace the dipstick plug, the breather cap,
2. Shut off the truck engine, and put the key and the pinion gear cover.
in your pocket.
3. Restart the unit. Slew the boom left and
3. Remove the boom slewing drive cover right several times, shut off the truck engine,
(Figure 123). Do not do this with the engine and put the key in your pocket. Then recheck
running because you will be exposing a pinch the oil.
point until the cover is replaced.
4. When oil level reaches the full line on the
4. Visually inspect the slewing pinion gear dipstick, replace the dipstick plug and pinion
(Figure 123) for wear. gear cover.

Cover removed for illustration only

Slewing pinion gear

Breather cap
Dipstick

slewdip.eps

Figure 123
Check gearcase fluid level

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 145
Maintenance

• Check the function of the mechanical


slewing brake system.

42bmslew.epsL

Brake system
pressure gauge

Multiple disk brake


system

Brake valve
manifold

Figure 124
Mechanical slewing brake system

The boom at rest is held by a multiple disk brake braking is accomplished by limiting how fast the oil
system (Figure 124), and stopping of the boom is can come out of the brake area. This is done with a
accomplished by hydraulic brake valves that are built throttle check valve. The throttle is preset at the factory
into the manifold shown in Figure 124. When the boom and should not be readjusted unless you first consult
is activated, pressure that turns the boom releases the the Schwing Service Department.
mechanical brake. When you are finished moving the Remember, if the reapplication of the brake is
boom, the mechanical brake must be reapplied slowly misadjusted, damage to the boom and the brakes
or damage could result to the brakes or the boom. Slow can occur!

146 Operation Manual - S 42 SXG revDate


Maintenance

• Check the mechanical brake reset time. the Schwing Service Department for advice on
1. Set up the unit as if pumping a boom job. how to proceed. This adjustment is critical. Do
Lift the boom far enough that it can be slewed not try to “wing” it.
back and forth without encountering any • Clean and repack the turret pinion gear and
obstacles or hazards. bolts.
2. With the engine running and the hydraulic 1. With the truck engine shut off, remove the
system engaged, stand with the remote box in a pinion gear cover to expose the Rollix ring
position where you can see the brake system gear (Figure 125).
pressure gauge (Figure 124).
NOTE!
3. Activate the boom slewing function either For the best maintenance of this gear,
left or right while watching the gauge. It remove the entire ring gear guard.
should go up to the top of the gauge as soon as
2. Clean the teeth of the gear with a thinning
you activate the function.
agent or cleaning solvent. Never use gasoline!
4. Let go of the boom function. The indicator
3. Apply fresh grease to the teeth. When
on the gauge should float down. If it takes
completed, replace the covers. Do not restart
more than 3 seconds or less than 1.5 seconds to
the unit until the covers are back in place.
float down, the throttle should be adjusted. If
the need for an adjustment is indicated, contact

Pinion gear

Rollix ring gear

slwpngr.eps

Figure 125
Clean and repack the Rollix slewing gear

WARNING
Explosion hazard. Never use gasoline or
diesel fuel as a cleaning solvent.
W017.eps

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 147
Maintenance

• Visually inspect the turret bolts once a


month (Figure 126).
42 turret bolts.epsL

Figure 126
Visually inspect the turret bolts for tightness.
(With boom in place, the top bolts must be
accessed through holes in turret.)

If you find any loose nuts or bolts, do not retighten


them! Instead, replace any bolt that is loose, as well as
the two bolts on each side of it.
Rules for installing new turret bolts:
1. If the bolt is black, it is Black Oxide. Tighten to
694 ft./lb.
2. If the bolt is silver, it is Dacromet/Geomet. Tighten
to 553 ft./lb.
3. Do not lubricate the new bolts when installing. Do
not use oil, Never Seize, grease, or Loc-tite on the
bolt.
NOTE!
It is important that you do not lubricate the
threads of the bolt or the washer when using
Dacromet/Geomet. If however, you are
forced to use Black Oxide, the washer
should be dipped in oil before installing it.
The process of oiling the washer will help
insure the proper torque.

148 Operation Manual - S 42 SXG revDate


Maintenance

• Check the fluid level of the distribution If your unit is equipped with a Hi-flo pump kit and a
gearcase (Figure 127). 4400 Stiebel gearbox (Figure 128) you will find an oil
Be sure the truck is on reasonably level ground. With check plug on the side of the spline flange between the
the truck engine off, and the key in your pocket, hydraulic pumps and the gear box. The reservoir holds
remove the oil check plug (Figure 127). The oil should 90 weight oil and can be filled through the breather on
be at the level of the bottom of the hole in the gear top of the spacer. There is, however, no oil drain plug
case. If oil is needed, add it by removing the breather on the spline.
and pouring in the oil through the top. Your unit may be • Check the mounting hardware of the
equipped with one of two Stiebel gear boxes, 4194, or subframe, the oil and water tanks, the delivery
4400. The gearcase uses 90W gear lube. pipeline, the pumpkit, the differential
• Check the oil level in the spline flange. cylinders, the material cylinders, and the
driveline hardware. Check for bolt tightness,
cracks, and other abnormalities.

Breather filter
filler spout Breather grbx-5-6.eps
Oil check plug

Oil Check Plug


4194 gearcase scan.eps

Drain plug Oil Drain Plug

Figure 127
Check fluid level of distribution gearcase Stiebel
box 4194 (left) or 4400 (right)

Spline flange breather

Figure 128
Oil check plug for spline flange cavity Oil check plug
(4400 gearcase) flange.eps

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 149
Maintenance

Setting Pressures 2. Activate the agitator. With the valve closed, the
agitator will not be able to turn, and the oil will be
The following pages provide the proper techniques for forced over the relief valve. At an idle (about 600
checking and setting hydraulic pressures of each RPM), 4.5 horsepower is being converted to heat.
system included on your unit.

Check all hydraulic pressures


Changes in pressures can indicate trouble in one or 
    agitoff2.eps

more components. The specifications for each circuit      
are shown on the hydraulic schematics found in the
Appendix of this manual. The hydraulic schematics are
the only documents in this manual that have been
updated specifically for your unit, by the serial number,
so in each of the following procedures you will be told 
to refer to the schematic for the pressure required.
Figure 129
If you wish to order a CD ROM which explains the
Agitator shutoff valve
pressure setting procedure for a specific model (all
pumpkits), call Schwing Spare Parts Department
and request the CD using the following part
numbers:
• 61/58 meter . . . . . . . . . . . . . . . . . . . . . . .30365860
3. When the oil temperature gauge shows 50˚C, open
• 52 meter. . . . . . . . . . . . . . . . . . . . . . . . . .30354732
the shutoff valve.
• 45/47 meter . . . . . . . . . . . . . . . . . . . . . . .30356770
• 42 meter. . . . . . . . . . . . . . . . . . . . . . . . . .30355485 Setting pressures on Hi-flo -5 pumpkits
• 39 meter. . . . . . . . . . . . . . . . . . . . . . . . . .30365861 To set the pressure of the main relief valve on Hi-flo
• 34 meter. . . . . . . . . . . . . . . . . . . . . . . . . .30356772 pumpkits, if your unit is twin circut, you must first
• 32 meter. . . . . . . . . . . . . . . . . . . . . . . . . .30355486 disable the soft switch circuit. Simply locate the ball
• 31 meter. . . . . . . . . . . . . . . . . . . . . . . . . .30365862 cock for the soft switch circuit (Figure 130) and close it
by rotating the handle 90 degrees.
Preheat the hydraulic oil
The quarter turn shutoff valve for the concrete pump
Pressure settings must be made with the oil at normal (Figure 130) will also need to be closed during this
operating temperatures (40°− 60° C). In the past we procedure.
could pressure out a function in the boom or outrigger
system to create heat, but load sensing systems no NOTE!
longer allow maximum oil flow to be forced over relief. Main system adjustments are preset at the
factory. The following procedure begins
Because of this the agitator circuit must be used to heat with adjustment of the main relief cartridge
the hydraulic oil. and pressure cutoff. If proper pressures can
To preheat the hydraulic oil: not be obtained through these steps, contact
the Schwing Service Department for specific
1. Locate the agitator shutoff valve (Figure 129) and instructions on the adjustment of flow,
close it. horsepower, beginning of stroke regulation,
and Q-min.
NOTE!
If your unit does not have a shutoff valve, Pressure setting procedure:
order one from the Schwing Spare Parts
Department using part number 10004680
(valve), and number 30303432 (tube).
Contact the Service Department for
installation instructions.

150 Operation Manual - S 42 SXG revDate


Maintenance

Gauge port
Soft switch
shutoff valve
00
02
97
.ep
s

Main relief valve

Concrete pump
hif
shutoff valve low
br
n.e
ps

Figure 130
Concrete pump and Soft switch shutoff valves

1. Be sure that the waterbox covers and guards are in with a 13mm wrench. Using a 4mm allen wrench,
place any time you will be working in the area turn the adjustment screw in (clockwise) one full
around the main control block. turn and tighten the jam nut. Restart the truck
2. Wear safety glasses when working around a engine.
concrete pump. 10. Adjust the engine RPM to maximum specification.
(See decal in truck cab)
NOTE!
It is vital that each adjustment screw be 11. Pressure out the system by activating the concrete
properly identified prior to making any pump forward switch on the rear panel. Using the
adjustment. All screw adjustments for the rear panel controls will allow you to read the
system relief must be made with the concrete pump main system pressure gauge, near
pumpkit in the neutral position and the e-stop manifold, from a safe distance.
adjustments for pressure cutoff must be
made with the engine shut off. NOTE!
3. Start the truck engine, and put the PTO in gear just Because you turned out the pressure relief
as you would to pump a job. cartridge in step 7, the system pressure
should read low at this time. If it does not
4. If you have not already closed the concrete pump and the gauge spikes to 320 bar or more,
shutoff valve (Figure 130) do so at this time. disengage the pump immediately. Turn the
5. Select “local” control with the “local/remote” relief cartridge out (counterclockwise)
more. For safety, it is important to adjust
switch and turn the electric stroke limiter knob the pressure up from below the specified
clockwise to maximum strokes per minute. target pressure rather than down from a
6. The main system control block pressure must be pressure which exceeds the target. Continue
set first to properly set the pressure cutoff on both this procedure until the main system
pressure gauge reads lower than the
pumps. Begin by backing off the jam nut of the specified target.
main relief cartridge (Figure 130) with a 9/16 inch
wrench. 12. To increase the pressure put the pump in the
neutral position and adjust the relief cartridge by
7. Using a 5/32 inch allen wrench, turn the turning it in (clockwise). When increasing the
adjustment screw out (counterclockwise) until you pressure, the adjustments should be made in
can feel no spring tension on the adjustment screw. quarter turn increments. If you make adjustments
8. Now, turn the screw back in (clockwise) two or to increase the pressure but the pressure does not
three full turns to give you a proper starting point come up, you are probably reading the pressure
and tighten the jam nut. cutoff of the pumps, if so proceed to the next step
9. Stop the truck engine and put the key in your otherwise skip to step 16.
pocket. Adjust the pressure cutoff screw (Figure
131) on each pump, by backing off the jam nut

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 151
Maintenance

13. Turn the relief cartridge adjustment screw back out until you achieve the desired pressure setting of
(counterclockwise) until you can no longer see a 350 bar (again, confirm the pressure specification
pressure drop and tighten the jam nut. with the hydraulic schematic).
14. Stop the truck engine, put the key in your pocket. 20. After pressure cutoff is set, return the pump to
15. Go to the pressure cutoff screw on both hydraulic neutral, bring engine RPM to idle, open the soft
pumps and back off the jam nut with a 13mm switch quarter turn valve, and either proceed to
wrench. Turn the adjustment screws in with a 4mm other pressure settings or take the transmission and
allen wrench one or two more turns, restart the PTO out of gear and shut off the truck.
engine and check the pressure again. Repeat this
procedure until the main system relief can be set to
the target pressure. 000336.eps

1 STROKE REGULATION 2 PRESSURE CUT OFF


16. When the proper main relief pressure is achieved,
3 HORSE POWER 4 Q-MIN
pressure cutoff can be set. Shut off the engine, put
the key in your pocket and install 0-600 bar gauges 2 2
with whip hoses to the “M1” gauge ports on the 1
1 3
bottom of the two hydraulic pumps (Figure 131). 3
4
You must be able to read both gauges 4
simultaneously to ensure that one pump is not
more dominant than the other.
M1 GAUGE PORT
NOTE! (BOTTOM OF EACH PUMP)
The gauges in the “M1” ports will read
considerably less than the cutoff pressure of
the pump. On a tandem A11VO 130 and
A11VO 130 pump combination, the gauges
should both read approximately 110 bar
when the unit is pressured out The actual Figure 131
cutoff pressure will be read on the concrete A11VO adjustment screws for Hi-flo -5
pump main system pressure gauge near the units 190/130
e-stop manifold.
17. Activate concrete pump forward to pressure out the
pump and read the pressure on the two gauges in
the “M1” ports.
18. Always stop the truck engine and put the key in Setting boom circuit pressures
your pocket before making any adjustment on the
hydraulic pump. If the cutoff on one pump is set NOTE!
higher than the other, that pump will be more Any time you set pressures for any circuit
dominant. The pressure gauge in the M1 port of the on any unit, the hydraulic oil should be at
normal operating temperature (40°–60° C).
dominant pump will however, read lower than the Instructions on heating the hydraulic oil are
other. To equalize the two pumps you must either found in the first step of this “checking
adjust the cutoff screw in (clockwise) to increase hydraulic pressures” segment.
the pressure of the pump showing the higher Read all of the instructions before beginning any
reading or adjust the cutoff screw of the dominant pressure settings. You will need an assistant for parts of
pump showing the lower reading out the procedure. You and any assistants should wear eye
(counterclockwise) to reduce the pressure. These protection when setting pressures.
adjustments must be made until the two gauges in
the M1 ports are reading approximately the same.
19. When you have achieved the same pressure on the
M1 port gauges, you can begin to adjust the
pressure cutoff screws in or out simultaneously

152 Operation Manual - S 42 SXG revDate


Maintenance

Load-sensing boom hydraulic controls to ensure that you have control when you need it. The
This unit is equipped with a load-sensing, proportional setting to maintain this minimum amount of oil is
boom hydraulic system. In a black-and-white system, called Q-min (pronounced “cue min”). To set the boom
the hydraulic pump puts out an unchanging amount of or outrigger hydraulic pressures on a load-sensing
oil, and speed control is done by restricting the oil to system, begin by setting ΔP and Q-min.
certain functions with orifices. In a load-sensing
system, the pump puts out more or less oil to respond
to the needs of the system. Generally, the pump puts
out enough oil to maintain 20 bar higher pressure at the WARNING
pump than the cylinders actually require. This 20 bar is
Entanglement hazard. Stop drive shafts
called delta P (ΔP). Additionally, we set the hydraulic before adjusting Delta P on A11VO pump.

W020.eps
pump so that it always puts out a small amount of oil,
even if no oil is needed for the system. This oil is used

pretension
only
33-35 bar

0-600 bar
gauge port
45bmcnbl.epsL

Figure 132
The 0–60 bar gauge port is located at the top of the boom control block, and the 0-600 bar
port is at the bottom.

Setting delta P pressure 3. Delta P is adjusted on the pressure regulator


Do not adjust ΔP or Q-min if your boom is running as (Figure 133, top) if your unit has an A7VO pump
you like it. The pressure setting procedure uses a or (Figure 133, bottom) if your unit has an A11VO
standard starting point and must be fine tuned from that boom pump. When all personnel are clear of the
point. The pressure was fine tuned at the factory and truck, restart the engine, engage the pumps, and
should not be adjusted unless absolutely necessary. leave the engine at an idle. ΔP pressure should read
17 bar, which is the standard starting point.
1. Start by turning off the engine and putting the key
in your pocket; then place a “Do Not Operate” sign 4. There are two adjustment screws on the pressure
on the windshield of the truck. regulator (Figure 133, top) for A7VO pumps. The
smaller screw is used in this procedure to adjust
2. Install a 0-100 bar gauge in the high pressure test ΔP. On the A11VO pumps there is only one ΔP
port at the bottom of the boom control block screw (Figure 133, bottom).
(Figure 132).
NOTE!
Do not activate any boom/outrigger
functions or release any e-stops with a low
pressure gauge attached to a high pressure
port.

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 153
Maintenance

5. If adjustment is required, loosen the jam nut, and


adjust the screw inward to increase pressure or
outward to decrease pressure until it is set at 20

pressreg.eps
bar. After achieving proper ΔP, tighten the jam nut Regulator pressure
adjustment
and bring the engine RPM up. If the pressure
gauge continues to read 20 bar, you are reading the T
true ΔP pressure and may move on to setting the Q- Adjustment for P pressure
min. If the pressure rises with the RPM, however, Delta-P
you may be reading the Q-min pressure instead of
true ΔP. If that happens, stop the engine, put the
key in your pocket, and place a “Do Not Operate”
sign on the windshield of the truck before
proceeding.

smdeltap.eps

Figure 133
Pressure regulator for A7VO boom pumps
(top) and A11VO pumps (bottom)

Q-min
Delta-P Pressure cut-off
adjustment screw

A7VX section min.top.eps

hifloreg.eps

Q max Q-min Q-max (bottom of pump)

Figure 134
Location of Q-min screw on the A7VO (left) and all adjustment screws of the A11VO (right)

6. Unscrew the Q-min screw (Figure 134) three full If pressure cannot be set correctly, there is a problem
turns. This step will help ensure that the pump either with the orifices in the base of the regulator or
produces only the amount of flow needed to with the regulator itself. Contact the Schwing Service
maintain ΔP pressure. Once all personnel are clear Department to determine how to continue.
of the truck, restart the engine, engage the pumps,
and recheck at an idle. Pressure should now read
17 bar. If it does not, go back and adjust ΔP until it
does.

154 Operation Manual - S 42 SXG revDate


Maintenance

If the boom does not run smoothly at 17 bar, you 1. If you unscrewed the Q-min screw as part of the ΔP
must fine tune the adjustment. Remove the gauge, and adjustment, begin by returning the screw to its
turn the ΔP adjustment screw until the boom is original position.
responsive and smooth. After adjusting, the gauge 2. All boom functions must be in neutral, and all
(reinstalled) must read between 14-25 bar. The emergency stop buttons should be up (not
electronics in the control system can also affect how engaged). Clear away all personnel, start the truck
the boom operates, so if ΔP adjustment does not seem engine, engage the pumps and bring engine RPM
to help, reset to 17 bar and check the electrical settings. to max. Read the pressure at the 0–600 bar main
Once electrical settings are verified, you could again boom gauge port (Figure 136) with a 0-100 bar
try to refine the boom action with the ΔP adjustment. gauge. Pressure should be at 30 bar. If no
NOTE! adjustment is needed, be sure the jam nut on the
Q-min screw is tight; then continue to set the rest
The pressure regulator (Figure 135) is of the boom and outrigger pressures. If adjustment
usually mounted on the inside of the
subframe, near the cab end of the is needed, continue to the next step.
differential cylinders. 3. Turn the Q-min screw (Figure 134) in to raise the
pressure. Turn it out to lower the pressure. Be sure
that you stop the drive shafts from turning each
time before making the adjustment. When pressure
is correct, tighten the jam nut on the adjustment
screw before continuing with the other procedures;
then recheck ΔP to make sure that it hasn’t
pressreg.eps

Regulator pressure changed during the Q-min adjustment.


adjustment
NOTE!
T
Adjustment for P pressure If you don’t have a 0-100 bar gauge you can
order one from Schwing Spare Parts
Department, part #
Figure 135 10004659.
Boom pressure regulator for units
with A7VO pumps

WARNING
Entanglement hazard. Stop drive shafts
before adjusting Q-min.
W009.eps

Setting Q-min
Check Q-min when the engine is at maximum specified
RPM. You must not adjust Q-min with the drive
shafts turning! Each time the Q-min screw must be
adjusted, the engine must be stopped or, at least, the
transmission must be taken out of gear so that the
drivelines stop turning.

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 155
Maintenance

Setting boom pressures mainrlf.eps

Now that ΔP and Q-min are set, you can remove the 0-
100 bar pressure gauge and proceed to check and
adjust the main boom pressures.
1. Loosen jam nut of the boom pressure relief
cartridge (Figure 136) with a 30mm open end
wrench.
2. Turn the adjustment cartridge clockwise all the #1 down side
way in with a 32mm wrench. relief cartridge
3. Loosen the jam nut on the pressure relief screw of
the regulator (Figure 135) or the pressure cut-off Main boom pressure
(Figure 134), and tighten the screw all the way relief cartridge
down.
4. Identify the main boom pressure relief cartridge on
the boom control block (Figure 137) and loosen the
jam nut. Then unscrew the adjustment two full
turns.
Figure 137
5. Take engine RPM to full throttle and activate boom Main boom pressure adjustment and
retract for any boom section except #1. piston side relief
6. Now adjust pressure, which is read at the main cartridge (32mm) out, or counter clockwise, until
boom gauge port, to the setting found on the you achieve the pressure shown on the schematic,
schematic by turning the boom pressure relief for the boom pressure relief cartridge. When the
cartridge in, or clockwise, using no more than 1/4 proper pressure is achieved, lock the jam nut.
turn increments.
9. The next pressure setting is the regulator pressure.
7. When desired pressure is achieved, lock down the Locate the regulator adjustment screw (Figure 134)
jam nut. or pressure cut-off screw (Figure 135). Back off the
jam nut, and turn the screw counterclockwise until
you achieve the pressure shown on the schematic;
0-600 bar then lock the jam nut.
gauge port 10. The final boom pressure setting is the #1 boom rod
0.e
ps side relief setting. This relief cartridge is in close
60
top
es
proximity to the main boom relief (Figure 137), so
be sure to locate the proper adjustment. This
procedure should be performed with the outriggers
extended and the boom unfolded over the cab.
Boom pressure
Disconnect all gauges from gauge ports prior to
relief cartridge
operating any boom or outrigger functions.
Bring section #1 all the way down until the
cylinder bottoms out. Install a 0-600 bar gauge in
the main boom gauge port of the e-stop manifold
(Figure 136), and activate boom #1 down. The
pressure should read the setting shown on the
Figure 136 schematic. If adjustment is required, back off the
Boom pressure relief cartridge jam nut and turn the relief cartridge in or out as
8. The next step is to return to the e-stop manifold required until the desired pressure is achieved; then
boom pressure relief cartridge (Figure 136) and lock down the jam nut.
back off the jam nut (30 mm). Turn the relief

156 Operation Manual - S 42 SXG revDate


Maintenance

Setting outrigger pressure 4. The pressure should read the bar value shown on
After the boom circuit is properly set, you can set the the hydraulic schematic. Adjust by loosening the
outrigger pressure. Find the relief cartridge jam nut with a 9/16” open end wrench and turning
located on the front of the passenger side outrigger the cartridge (Figure 138) in or out with 5/32 allen
control valve (Figure 138). wrench. When the proper pressure is achieved, let
go of the handle and release the outrigger enable
button.
WARNING testport.eps

Tipping hazard. Never set outrigger


pressures with the boom unfolded.
Pressure setting procedure requires REAR SLEW REAR JACKING FRONT JACKING FRONT EXTEND

30354359
retraction of an outrigger jacking

W026.eps
cylinder.

1. Attach 0-600 bar whip gauge to the gauge port


Relief
(Figure 138) below the outrigger valve bank. Cartridge
2. Push the outrigger enable button. Gauge Port

3. Activate an outrigger jacking cylinder to retract.


By retracting a fully retracted cylinder, the oil
coming from the pump has nowhere to go but over Figure 138
the relief valve. You cannot use an extension or Outrigger valve bank relief cartridge
slewing cylinder because they have secondary and gauge port
relief functions (nonadjustable) built into the valve.
While holding the handle to retract, read the
pressure gauge.

CONCRETE PUMP
FORWARD/REVERSE

AGITATOR

Relief valve
Gauge port

Figure 139
Agitator component location

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 157
Maintenance

Setting the agitator pressure


The agitator circuit has a maximum pressure shown on
the hydraulic schematic, which is limited by the relief Plugs Straight Fitting
cartridge (Figure 139) in the agitator hand valve. The
relief cartridge is located on the back side of the Figure 141
agitator manual control handle (Figure 139). The Approved hydraulic
cartridge is adjustable with just an 19mm open end dead plugs capplug.eps

wrench.
1. Plug the 0–600 bar whip gauge into the gauge port
(Figure 139) for checking or setting agitator Cap Nuts
pressure.
2. Locate the agitator shutoff (Figure 140) valve and 3. Increase the throttle to any speed above idle.
close it. If your unit does not have a shutoff valve, Activate the agitator valve handle in either forward
order one from the Schwing Spare Parts or reverse, and read the gauge. If it does not read
Department using part numbers 10004680 (valve) the specified pressure, adjustment is required. Turn
and 30303432 (tube). Contact the Service the entire valve body (Figure 139) in to increase
Department for installation instructions, or if you pressure or out to decrease pressure.
can’t wait for a shutoff valve, you will need to 4. When the pressure is set, deactivate the agitator by
remove one of the hoses from the agitator motor placing the manual control handle in the neutral
and plug the hose and open fitting with approved position.
hydraulic dead plugs (Figure 141).
5. Remove the whip gauge.
NOTE! 6. Reopen the shutoff valve or remove the dead plugs
Do not jam the paddles to force the oil over and reconnect the capped hydraulic line.
relief by stopping the movement of the
agitator.


    agitoff2.eps

     



Figure 140
Agitator shutoff valve

158 Operation Manual - S 42 SXG revDate


Maintenance

Cover removed for illustration only


Slewing pinion gear
mount screw

pinscrew.eps

Figure 142
Check the pinion gear mounting screw.

Cleaning oil cooler fins Change the oil for temperature reasons
Spray out the coils of the oil cooler with a high- Change hydraulic oil every six months if you live in a
velocity water nozzle or pressure washer. If you use a geographic location where seasonal temperature
pressure washer, be careful not to damage the electric changes are drastic. If you save the used oil in clean
motor or bend the cooler fins. barrels and properly store the barrels, you can reinstall
this oil when the weather changes back. You can use
the oil for a maximum of two six-month seasons.
Quarterly Maintenance
Caution! If you ignore proper storage procedures, the
Check the drive pinion and slewing joint oil will become contaminated and will cause damage to
1. With the truck engine turned off and the key in the machine if reused. Contact your hydraulic oil
your pocket, remove the pinion gear cover (Figure dealer to obtain clean barrels and proper storage
142). procedures. If you do not own a filter buggy for oil
2. Check the pinion gear mounting screw (Figure transfer, consider buying or renting one.
142). If it is loose, remove and clean it.
3. Apply Loc-tite or an equivalent primer to the
screw. When dry, apply Loc-tite 242 or equivalent.
4. Tighten the screw according to the torque chart in
the Appendix section of this manual.
5. Replace the pinion cover before restarting the unit.

Change the oil in the air compressor


If your unit is equipped with an optional air
compressor, the oil in that device should be changed
every three months.

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 159
Maintenance

Change oil in the distribution gearcase 2. Remove the breather filter and the drain plug
The oil in the distribution gearcase normally requires (Figure 143), and drain the old fluid into a drain
changing on an annual basis. The procedure is being pan.
shown in the Quarterly Maintenance section to remind 3. Clean the breather filter with cleaning solvent.
you that the oil should be changed for the first time Never use gasoline!
after a three month break-in period and annually 4. Rinse the case with clean hydraulic oil. Let the oil
thereafter. drain immediately out of the case. Dispose of this
Do this procedure when the oil is warm. When the oil oil; do not reuse it.
is cold, it does not drain as easily (Figure 143). 5. Replace the drain plug.
1. Park the truck in a level area. Place the “Do Not 6. Remove the full level plug or oil check plug
Operate” sticker on the window in front of the (Figure 143).
driver’s seat. Stop the engine, and put the key in 7. Refill through the filler spout (Figure 143) to the
your pocket. full level plug or oil check plug (Figure 143) with
90W gear lube. Replace the full level plug and the
breather filter.

Breather filter Fill plug


filler spout
Oil check plug Breather

Oil check plug


4194 gearcase scan.eps

Drain plug

Oil drain plug Gearcase.eps

Figure 143
Change distribution gearcase oil -Stiebel box 4194 (left) and 4400 (right)

Semiannual Maintenance Do not change oil when the temperature of the oil is
over 50˚C. Severe burns could result.
Change the oil in the boom slewing 1. Park the truck in a level area. Put the “Do Not
gearcase Operate” sticker on the window in front of the
Do this procedure (Figure 144) when the oil is warm. driver’s seat. Stop the engine, and put the key in
When the oil is cold, it does not drain easily, and it your pocket.
does not rinse dirt and contamination off the gears. You 2. Remove the boom slewing drive cover (Figure
must be sure, however, that the oil is not hot enough to 144). Do not do this with the engine running, as
burn you. you will be exposing a pinch point until the cover
is replaced.

160 Operation Manual - S 42 SXG revDate


Maintenance

3. Remove the breather filter and the dipstick/fill plug Test the dirty filter warning circuit
(Figure 144). Wash them both in solvent. Never All Vector units have two sensor switches to detect
use gasoline! dirty filters. One on the boom filter and one on the back
4. Remove one of the gearcase drain plugs (Figure of the oil cooler (Figure 145). Remove the connector
144), and let the old oil drain into a pan. plugs every 6 months. With the key switch in the “on”
5. Rinse the gear case with cleaning solvent or fresh position and the PTO selector knob in the “pumping”
hydraulic oil. Never use gasoline! Let it drain out mode, the fault warning horn should sound. If it does
immediately. Do not reuse this oil. not, contact Schwing Service Department
6. Replace the drain plug. for advice on how to proceed.
7. Fill the case to the proper line on the dipstick
(Figure 144). You will have to fill very slowly
because of the thickness of 90W gear lube.
8. Replace the breather filter, the dipstick/fill plug,
and the pinion gear cover.

boombrak.eps

Oil drain plug

Dirty filter warning switch

Cover removed for illustration only

Slewing pinion gear

filterswitch.eps

Breather cap
Dipstick

Figure 145
Dirty filter warning switches
shown in both locations
slewdip.eps

Figure 144
Change slewing gearcase oil

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 161
Maintenance

Annual Maintenance
Check the pre- charge of accumulators
Check the accumulator gas pre-charge as shown:
• 1st check-one week after first use
• 2nd check-three months after first use
• 3rd check-one year after first use
• 4th check and beyond-annually
If the accumulator requires charging, read all of the
instructions before beginning the job. Accumulators
must be charged only with dry nitrogen. Never use
compressed air or oxygen (Figure 146), as the
oxygen molecules will combine with the hydraulic oil
and lower the flash point of the oil to below room
temperature. You will create a major explosion by
using compressed air or oxygen to charge
accumulators. People have died using compressed air
or oxygen to charge accumulators. Use dry nitrogen,
not liquid nitrogen.

EXPLOSION CAUSED BY
WARNING
IMPROPER ACCUMULATOR
CHARGING CAN RESULT IN
DEATH OR SERIOUS INJURY!
* Follow the charging instructions exactly!
* Use ONLY dry nitrogen to charge the
accumulator!
* NEVER use oxygen or compressed air to
charge the accumulator! explosion warning.eps

Figure 146
Warning decal for accumulator charging

162 Operation Manual - S 42 SXG revDate


Maintenance

Tank Regulated High pressure gas


pressure pressure regulator is not
included with the
kit. These are
available from the
nitrogen supplier.

Regulator adjustment
Nitrogen bottle handle

100

1500

150
50
1000 2000
500 2500

PSI
bar 200
0

Hose
30341207
Charge valve assembly
30341201

BPL
Accumulator Charging Kit
HYDAC bladder
accumulator (Includes hose and charge valve assembly)
SCHWING PART NUMBER:
30338635 chargekit PN’s.eps

Figure 147
Accumulator charge kit for HYDAC bladder accumulators

Charging procedure 2. You must use a high-pressure regulator with the


The following steps are required for checking and nitrogen bottle. If it was not supplied with the
charging the accumulator. bottle, order one before proceeding with this job.
1. Before you begin, you will need a charging kit 3. Before beginning the charging procedure, stop the
(Figure 147). Do not attempt to charge the engine, and remove the key.
accumulators without one. You can order the NOTE!
charge valve assembly from Schwing ALWAYS Lock Out - Tag Out according to
using part number 30338635. There is also a kit the procedure recommended on page 139 of
available directly from Hydac. Hydac Corporation Maintenance before servicing the
can be reached. The Hydac part accumulator.
number is FPS 250 F 2.5 G4 K.

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 163
Maintenance

Pressure relief valve accuman1.eps

Manual bleed valve

ac
cu
m
ma
nif
old
.ep
s

Shutoff handle

Pressure Relief Cartridge


Electric dump valve
Manual bleed valve

Figure 148
Accumulator manifold bleed valves (Your unit should be equipped with one of the two
bleed valves shown above.)

4. Verify zero hydraulic pressure on the concrete 5. If there are multiple accumulators, charge one
pump’s accumulator gauge before beginning. The accumulator at a time. Leave the valve protection
accumulators should dump when the engine is caps (Figure 149) on the accumulators until you
stopped, but you still must verify it. If pressure actually begin the procedure.
remains, dump the accumulators using the manual 6. Remove the valve protection cap and the valve seal
bleed valve (Figure 148) on the manifold. cap from the accumulator that you will charge first.
(Figure 149)

Valve protection cap

Valve seal cap


Figure 149
Detail of accumulator
Valve stem
gas valve area O-ring

HYDAC bladder
accumulator
accum closeup

164 Operation Manual - S 42 SXG revDate


Maintenance

100

1500

150
50
1000 2000 Pressure
500 2500 gauge
PSI
bar 200 Valve body

0
Figure 150
Charge vavle assembly T-handle

Gas chuck

accum charge assy.eps


Swivel nut
Gas
valve stem

Bleed valve

7. On the charge valve assembly, locate the T-handle 8. On the charge valve assembly, close the bleed
of the gas chuck (Figure 150). Rotate it valve (Figure 151), and disconnect the hose from
counterclockwise (outward) completely before the gas valve stem. This step closes the charge
attaching the swivel nut to the accumulator gas valve stem to prevent the gas pressure from
valve stem. escaping out of the hose and ensures that the initial
pressure reading is accurate.

100

1500
150
50

1000 2000
500 2500

PSI
bar 200
0

Figure 151
Close bleed valve and
Remove hose
disconnect hoses
charge assy/bleed/hose.eps

Bleed valve

Close valve

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 165
Maintenance

9. Find the swivel nut (Figure 152) on the charge


.

valve assembly. Screw the swivel nut onto the


accumulator gas valve. Tighten to 10–15 in./lb.
10. After the swivel nut is attached, screw the T-handle
(Figure 150) in (clockwise) three (3) full turns.
This presses a pin into the gas valve and opens it.
Read the pressure on the charge valve assembly
gauge (Figure 153) before you attach the nitrogen
bottle to the charge valve assembly. The pressure
should read 100 bar (1450 PSI). If there is no
reading on the gauge, turn the T-handle in Spec. 100 bar (1450 PSI)
(clockwise) one more full turn.
100
NOTE!
1500

150
50
If the T-handle is turned in (clockwise) more 1000 2000

than 4 full turns from the full 500 2500

counterclockwise position, it may damage PSI


bar 200
the accumulator gas valve.

0
• If no adjustment is necessary, skip to step #18.
• If pressure is too high, skip to step #15.
• If pressure must be added, proceed to step #11.







 
 

251
>=H 


read gauge.eps

  Figure 153


Read nitrogen pressure
  
on gauge

 
 
    !"

Figure 152
Attach swivel nut to
accumulator gas valve

166 Operation Manual - S 42 SXG revDate


Maintenance

High-pressure
regulator
Nitrogen supply
valve

Regulated pressure
adjustment handle Higher
Figure 154 Nitrogen bottle
Make connections between Lower
nitrogen bottle and charge kit
100

1500

150
50
1000 2000
500 2500

PSI
bar 200

Bleed valve

chargekithookup

11. Be sure that the nitrogen bottle supply valve is 14. Adjust the regulator handle clockwise, raising the
firmly closed. Attach the high-pressure regulator to regulated pressure. The accumulator will begin to
the nitrogen bottle; then attach the hose to the high- fill. Continue filling until the charge kit gauge
pressure regulator. Finally, attach the other end of reads the desired pressure of 1450 PSI. Close the
the hose to the valve assembly gas valve stem, as nitrogen bottle supply valve.
shown in Figure 154. Do not open the nitrogen 15. If you overcharge the nitrogen pressure, proceed as
bottle supply valve yet. follows:
12. Turn the regulated pressure adjustment handle on • Close the nitrogen bottle supply valve.
the high-pressure regulator counterclockwise to its • Slowly open the bleed valve on the charge kit.
minimum setting. Close the bleed valve when the correct
13. Crack open the nitrogen bottle supply valve pressure is reached.
(Figure 155). You will get a reading on the high-
NOTE!
pressure gauge side of the regulator. Note that if
there is not at least 1450 PSI showing on the high Never let nitrogen out of the accumulator by
pressing the gas valve pin with a foreign
pressure regulator gauge at this time, you will not object. The high pressure may rupture the
be able to charge the nitrogen to the 1450 PSI valve seat!
specification. If that is the case, you will need a
16. Let the nitrogen sit in the accumulator for 10 to 15
new bottle of nitrogen before proceeding. If there
minutes. This allows the gas temperature to
is enough pressure in the nitrogen bottle to do the
stabilize. Recheck the pressure on the charge kit
job, proceed to step #14.
gauge.

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 167
Maintenance

MUST read at least 1450 PSI


Crack open
supply valve

Figure 155
When the supply valve is open, bottle
pressure shows on the high pressure gauge

Nitrogen Bottle
Cracksupply.eps

17. Add or release nitrogen until the pressure is •


Remove the charge kit.
correct. Be sure that the bleed valve is closed •
If you are finished with the charge kit, remove
before adding pressure and that the nitrogen bottle the hose and regulator.
supply valve is closed before releasing pressure. 19. Make a bubbly mixture from soap and water.
18. When the correct pressure is reached, proceed as Spread the mixture around the accumulator gas
follows: valve to check for gas leaks. Gas leaks will push
• Close the nitrogen bottle supply valve. the bubbles away from the area of the leak. If you
• Unscrew the T-handle on the charge kit find a leak, replace the accumulator or have it
(counterclockwise) until resistance is felt. This repaired by qualified personnel. Never repair an
will close the accumulator gas valve. accumulator yourself.
• Open the bleed valve, which releases the 20. Replace the gas valve seal cap (tighten to 22 ft./lb),
pressure in the hose, charge valve assembly, and hand-tighten the valve protection cap.
and regulator. 21. Repeat the procedure for any other accumulators.
• While holding the gas valve on the
accumulator, unscrew the charge kit swivel
nut.

EXPLOSION CAUSED BY
WARNING
IMPROPER ACCUMULATOR
CHARGING CAN RESULT IN
DEATH OR SERIOUS INJURY!
* Follow the charging instructions exactly!
* Use ONLY dry nitrogen to charge the
accumulator!
* NEVER use oxygen or compressed air to
charge the accumulator! explosion warning.eps

168 Operation Manual - S 42 SXG revDate


Maintenance

Change the hydraulic oil Change the corrosion inhibitors


If you have not changed your hydraulic oil because of To help protect against corrosion, Schwing is now
seasonal temperature changes, you will need to replace installing a stick-on corrosion inhibitor wherever there
the oil now for age reasons. The same filling rules that is an electronic circuit board. On the 45 SX there will
apply to adding hydraulic oil apply to filling the tank be one installed in the cable remote box as well as the
after draining and cleaning. To change the oil: radio remote and the Vector controller. The device is a
1. Shut off the truck engine, and put the key in your yellow, adhesive-backed sponge. It will require
pocket. replacement every year. The maintenance schedule is
detailed in the Maintenance section of this manual. To
2. For safety, the oil should be cool. Do not change
order corrosion inhibitors part #30346014, call the
oil that is above 120°F (50°C).
Schwing Spare Parts Department.
3. Drain the oil into a barrel or another receptacle.
The oil can be pumped out of the inspection cover
on the top of the tank or drained out of the drain Time-related Maintenance
cock or faucet on the bottom of the tank (Figure
156). The drain cock on the bottom of the tank is a Periodic - structural inspection
small port and will take much longer to drain the A complete structural inspection of the concrete pump,
tank than pumping it out. boom, and outrigger assembly should be performed at
the following intervals:
Figure 156
Drain cock on tank • The first five years - at least once per year
bottom • Five to ten years - every 6 months
drain cock
45 oil drain cock.epsL
• Ten years and older - every 500 working hours,
or at least once per year, whichever occurs first
4. After the oil is drained, clean the tank through the NOTE!
inspection covers using cleaning solvent and lint-
We, the manufacturer, would like to
free rags. Do not use gasoline! Remove all the silt emphasize that it is the owner’s
from the bottom of the tank. responsibility to insure that the boom
5. Close the drain if it is open. Refill the tank by inspections are completed and that the
pumping new oil out of the barrels with a filter cart. equipment is operated only under safe
conditions.
Remember! New oil is not clean enough to
install in your unit. If you do not filter the oil, you You may obtain a copy of inspection intervals and
may begin having trouble with pumps and valves procedures by calling the Schwing Germany Service
immediately or within the first few days of use. See Department.
the information at the beginning of this chapter for
specific information about hydraulic oils that are Unscheduled maintenance
approved for use in Schwing machines.
The amount and quality of service you get from your
6. Change the main system filter and the boom filters
unit varies according to the conditions to which the
before restarting the unit.
machine is subjected. Differences in concrete types and
pressure play a major role in the wear of machine
Clean the optional air compressor, if
components. Periodically, the rams and material
installed
cylinders must be changed.
If your unit is equipped with an optional air
compressor, the unit should be thoroughly cleaned Frequent inspections
annually. Spraying the fins to keep them free of debris
Frequent inspections should be performed by a
and grime will optimize the thermal cooling process.
designated person at daily to monthly intervals, and
This practice can help to keep the compressor running
should include observations prior to and during
efficiently for many years.
operation.

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 169
Maintenance

The designated person should determine whether b. proper operation of the adjusting nut, if so
conditions found during the inspection constitute a equipped;
hazard and whether a more detailed inspection is c. concrete preventing proper operation;
required. d. system compatibility.
4. Separately laid pipeline components for:
Frequent inspection of the boom and structural
a. sufficient wall thickness to withstand the
support system should include, as applicable:
maximum material pressure of the material
1. Safety devices, such as holding valves, guards and placement system, according to the
interlocks, for proper operation; manufacturers instructions.;
2. Boom controls for proper operation and b. dents, holes, or deformed ends;
engagement; c. the presence of old concrete inside the
3. Boom and outrigger hooks, straps, and latches for pipeline.
proper operation and engagement; 5. Cables or slings used to secure hanging system
components.
4. Hydraulic hoses for wear, rubbing and cracking;
6. Missing or damaged safety signs or operational
5. Hydraulic oil level;
labels.
6. Hydraulic oil leaks;
7. Remote control boxes and cables for proper
operation, exposed wires, broken controls, missing
control guards, or broken plugs;
8. Boom and outrigger structures for visible
deformations, cracks, and damage;
9. Boom and outrigger pins for visible wear, damage,
and missing hardware;
10. Tires for sufficient tread, proper inflation, cuts, and
loose lug nuts;
11. Proper loading of accessories to prevent loss while
traveling;
12. Proper lubrication of moving parts.
Frequent inspection of delivery system
components should include:
1. Boom Delivery system for:
a. minimum wall thickness to withstand the
maximum material pressure, according to the
manufacturer’s instructions;
b. dents or cracks;
c. missing locking pins;
d. leaking gaskets
2. Delivery system hoses for:
a. internal wear, according to the manufacturers
instructions;
b. separation of the ferrule from the hose;
c. bulges, kinks, soft spots, cuts, or abraded areas
which may indicate bad reinforcement;
d. presence of hardened concrete.
3. Couplings for:
a. cracked, broken, distorted, or missing
components;

170 Operation Manual - S 42 SXG revDate


Maintenance

Changing rams Place the local/remote/ram change


When you begin to see sand or pebbles in your water switch (#3 in Figure 157) in the ram
box at the end of the day, it is time to change the rams. vectorramchange.eps
change position.
This symbol is displayed in right center
of the display screen (Figure 157)
WARNING indicatiing that the machine is now in
ram change mode.
Crushing/amputation hazard. Disable the
hydraulic system before removing This symbol flashes in upper right corner
waterbox guards. STOP! of the screen when any E-stop on the

W007.eps
estop.eps
machine is pushed. Unlock all E-stops.
Avoid changing rams with the motor running; you are
inviting trouble when you do so. However, if you are This symbol flashes in the upper right
working alone and must get the ram changed in a hurry, corner when the system is ready for start-
Start up.
you may need to let the truck engine run. If so, take the Istart.eps

following precautions to avoid amputation of hands, Start up the controller with this switch
arms, or fingers. shown as #4 in (Figure 157).
• Do not use the remote for this procedure.
Unplug it and store it. Iswitch.eps
Starting is confirmed by a brief beep and
• The on-off switch for the concrete pump and this symbol is displayed in the upper
the manual handle for activating the concrete OK right corner (Figure 157).
pump are located in positions that make them
The ram change position disables both
impossible for you to activate while your
local (rear panel) and remote control, brings the engine
hands are in the waterbox. If, however, another
to idle, reduces the stroke limiter to minimum output,
person has access to these devices, the danger
and gives complete concrete pump control to the
of accidental activation increases. Avoid
concrete pump fwd/rev switch located at the ram
changing rams in this situation.
change station (Figure 158).
• The chances of accidental amputation are
6
greatly increased when more than one person 1
is near the switch. You also have fewer 5
distractions when you are alone. If someone
approaches you when you are changing
2
1
OK OFF

0 x1000 3
PTO 1500 rpm 62˚C

rams, stop working until the person leaves. Figure 157


Menu: [ENTER]=ON

2
Vector control HOME + HELP START
4

Ram change mode panel


CLEAR - ENTER QUIT
3
panelID.eps

32ramchange.eps

Figure 158
The “Ram change station” on the rear boom
cradle houses the concrete pump fwd/reverse
switch.

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 171
Maintenance

Grooves lined up
with ports - open Concrete pump
open shutoff valve

Blckgrvs.eps

closed Figure 159


Grooves at 90°
to ports - closed Concrete pump m
ns
ht
of
f.e
shutoff valve ps

Removing old rams the waterbox, leaving about one and one-half
1. Close the shutoff valve (Figure 159), also known as inches of travel. This will allow you to remove the
the ball cock or quarter-turn valve. This allows you spacer coupling (dog bone).
to control the direction of travel of the differential 000308.eps

cylinders.
2. Drain the waterbox. Remove the waterbox covers
(Figure 160) and the bolt-down grate. Retract the
driver side differential rod almost all the way into

Figure 160
Retract all but about 1 1/2 inches of the driver
side rod into the waterbox.

3. Push an emergency stop button. Stop the engine,


and put the key in your pocket.
4. A 55-mm open-end wrench and a 24–30-mm box
end wrench are supplied with your unit. You will
need them for this step. Put the 55-mm wrench on

172 Operation Manual - S 42 SXG revDate


Maintenance

the dog bone to prevent the assembly from turning. 6. Push an emergency stop button. Stop the engine,
You can rest the handle against the side of the and put the key in your pocket. Remove the dog
waterbox as shown in Figure 161. Unscrew the bone from the waterbox as shown in Figure 162.
four M20 bolts that hold the assembly together. 000310.eps

5. Be sure all body parts and tools are out of the


waterbox; then start the truck engine. Release the
emergency stop button, and finish retracting the
driver side rod into the waterbox. The dog bone
will fall out.
000309.eps

Figure 162
Remove the dog bone.

7. Start the engine. Release the emergency stop


button. Slowly extend the cylinder rod until it just
contacts the rubber ram flange. Be careful not to
Figure 161
drive the rubber ram into the material cylinder.
Remove the bolts from the dog bone.
NOTE!
If you accidentally knock the ram into the
material cylinder so far that you can’t reach
it, you will have to remove it by knocking it
out from the Rock Valve end of the unit.
Call Schwing Germany Service
for instructions on the removal procedure.
000311.eps

Figure 163
Removal bolt grooves on flanges

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 173
Maintenance

8. Push an emergency stop button. Stop the engine, Installing new rams
and put the key in your pocket. There is a groove in 1. Apply Loc-tite primer (or equivalent) to the M20
the ram flange that lines up with a groove in the bolts. Allow the primer to dry.
cylinder flange. An M12 x 45 bolt with nut will 2. While the primer is drying, apply a liberal coat of
drop into this groove and allow you to pull the ram clean grease to the new rams. There is no such
out (Figure 163). The fit should be snug, but there thing as too much grease here, because the excess
is no need to tighten the nut with tools. Note that, will be wiped off by the material cylinders during
for clarity, the ram flange and cylinder flange are installation.
shown outside the waterbox.
3. With the engine still stopped, hold the new ram up
9. Start the engine. Release the emergency stop to the cylinder flange. Line up the grooves, and
button, and slowly retract the cylinder rod (Figure drop your nut and bolt into place to hold the
164) until the ram is clear of the material cylinder. assembly together. Again, you should only tighten
10. Push an emergency stop button. Stop the engine, the nut finger-tight.
and put the key in your pocket. Remove the nut and 4. Start the engine. Release the emergency stop
bolt, and the ram will be free to come out of the button. Slowly extend the cylinder until the ram is
waterbox. installed in the material cylinder (Figure 165) but
11. Clean and inspect the bolts and cone washers, the the mounting flange is still exposed enough to
dog bone, and the cylinder flange. Replace any remove the nut and bolt.
damaged or worn parts with new ones. 5. Push an emergency stop button. Stop the engine,
and put the key in your pocket. Remove the nut and
bolt.

000313.eps

000312.eps

Figure 165
Figure 164 Slowly push the new ram into the
Slowly bring the ram into the waterbox. material cylinder

6. Start the engine. Release the emergency stop


button. Slowly retract the rod again until there is
room to install the dog bone.
7. Push an emergency stop button. Stop the engine,
and put the key in your pocket. Apply Loc-tite 242
or an equivalent to two of the M20 bolts. Place the
dog bone up against the flange of the new ram.
Install two of the M20 bolts (with Loc-tite) and the
cone washer sets. At this time, finger-tighten only.

174 Operation Manual - S 42 SXG revDate


Maintenance

NOTE! Changing material cylinders


It is important to install the dog bone The material cylinders eventually wear out. They are
against the new ram first, not the cylinder considered worn out when the inside diameter has
flange. This gives you an extra 6 to 8 inches
of safety margin when you extend the grown 3 millimeters beyond the specification for new.
cylinder to meet the dog bone. If you attach A unit with 8-inch (200 mm) material cylinders, for
to the cylinder flange first, chances are good example, is worn out when the inside diameter reaches
that you will accidentally knock the new 203 mm. A material cylinder with a 230 mm inside
ram into the material cylinder so far that diameter is worn out when the diameter reaches 233
you won’t be able to reach it.
mm, and so on. The end attached to the Rock Valve
8. Start the engine. Release the emergency stop usually wears out first, because it sees the most
button. Slowly move the cylinder down (Figure concrete. The waterbox end may be in like-new
166) to where its flange just makes contact with the condition, because that end never experiences concrete.
dog bone. Be careful not to go too far! For this reason, the material cylinders are designed to
9. Push an emergency stop button. Stop the engine, flip end for end. You can move the worn-out end to the
and put the key in your pocket. You may have to waterbox and the like-new end to the concrete valve for
rotate the dog bone slightly to align the bolt holes double the life. If you are going to do this, you have to
with the cylinder flange. When the bolt holes are catch the wear on the material cylinders before they get
aligned, coat the two remaining M20 bolts with too thin or break through in one or more spots. After
Loc-tite, and install them (including the cone that happens they cannot be flipped, because they are
washer sets). When all four bolts are started, too weak to hold the pressure forces at the waterbox
tighten the bolts to the torque specification for M20 end.
10.9 bolts (420 ft./lb). The procedure for changing and aligning the material
10. Repeat the previous steps for the passenger side cylinders is the subject of a service bulletin (G-102/
ram. 88).
11. Replace the bolt-down grate and waterbox covers.
000314.eps

Figure 166
Slowly move the cylinder to
meet the dog bone

12. Open the shutoff valve. The unit will not cycle
when this valve is closed.
Upon completion of your work in the water box, it is
important that you remember to deactivate the O/I
switch on the ram change operation panel, which will
give control back to the local/remote switch on the
main panel.

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 175
Maintenance

Setting Vector Controller-Teach Mode 1. Go to the Vector controller and select ‘local’
control, but do not activate the reset “I” switch.
NOTE!
Setting the parameters in “Teach Mode” 2. Open the front cover and insert the “Teach Key”
should only be done by persons with a into the connector shown in Figure 168.
complete understanding of the Vector 3. The display window on the front cover should now
control system. be showing you the screen shown in Figure 167.
Teach mode offers the user the opportunity to teach the
main controller how he or she would prefer to have the
boom respond to the remote control joystick Restore parameters
movements by setting parameters for minimum and
maximum response times of each boom movement.
to factory setting OK
MIN is the amount of signal it takes to start boom
movement, and MAX is the signal required to make the
no yes
boom manual control handle travel all the way to the [CLEAR] [ENTER]
mechanical stop. Setting these parameters requires
setting up the unit and unfolding the boom. Be certain
that the boom has room to move safely during this Teach Mode E C
vectorrestore.eps
procedure.
Figure 167
NOTE! Vector display window for restoring
When the unit is in teach mode, the concrete to factory settings
pump and agitator are disabled to prevent
the operator from accidentally trying to
pump while the teach mode key is installed.
4. Push the ‘ENTER’ button to select yes. The
controller will then restore the parameters to the
values set in the Schwing Test Department. After
about 10 seconds, the system will reset itself.
WARNING NOTE!
When the system restart screen appears
Improper setup causes job site accidents: after setting the parameters, allow the
• Look for power lines before unfolding controller time to complete the process
• Be sure of unit's stability before performing any other system
W024.eps

functions in order to prevent losing your


stored information.
5. Select the ‘Remote’ mode, and activate the reset
“I” switch on the remote box.
Heat the oil first
6. Operate each function of the boom to see if it is
When setting the boom parameters the hydraulic oil now responding the way you prefer. If it is, no
temperature must be at least 50˚ C and the engine RPM further action is required.
should be increased to normal operating speed.
NOTE!
Check original factory settings The boom operates normally while in teach
mode, so the key can be left in while testing
When setting parameters, you will need take your each boom function.
remote control with you and go to the main controller.
7. If the boom is still not performing as you prefer, it
If your boom parameters have been changed and you will be necessary to continue with setting each
would like to have them revert to where they were parameter individually by completing the steps that
originally, you can perform a simple procedure to follow.
restore the original factory settings.

176 Operation Manual - S 42 SXG revDate


Maintenance

Setting parameters the teach mode. Switch the local/remote


1. Place the controller in ‘Remote’ mode and activate switch to the ‘remote’ position, and activate
the “I” switch on the remote box.
the “I” switch on the remote box.
2. Open the front cover of the Vector controller, and 4. If the display again asks the question “Restore the
plug in the hardware “Teach Key” to the connector parameters to factory setting?”, press the
shown in Figure 168. “CLEAR” button to say no.
5. If you pushed the “CLEAR” button to answer no to
Vector Teach Key the question, the display window will show you the
Connector screen in Figure 170. This chart shows you RPM,
oil temperature, a picture of a boom cylinder, and
six different boom options. The far left column is
where the boom slewing adjustment will show,
while columns A through E represent each boom
section (A=1, B=2, C=3, D=4, and E=5 if you have
a five section boom).

1760 rpm 52 ˚C
OK
A B C D E
Teach
connectorlocation.eps mode!
Figure 168
Location of “Teach key” connector
Teach Mode
3. The display window on the controller cover will teachfunctionscreen.eps

show that the unit is in ‘Teach’ mode and the “I” in Figure 170
the upper right hand corner will be flashing, which Teach mode parameter screen
indicates that you need to activate the reset “I”
switch to start the “Teach mode” process (Figure 6. You are now ready to teach the controller what
169). parameters you prefer. We’ll use boom #1 as an
example. Before you activate the function to be
adjusted, you must decide which parameter you
1 2 want to adjust (MIN or MAX). The selection is
Start made with the “Rabbit/Off/Snail” switch. Choose
‘Rabbit’ for MAX or ‘Snail’ for MIN. So to set the
Teach #1 boom MIN, you must first place the switch to
0 x1000 3 mode! the ‘Snail’ position (Figure 171).
NA 1760 U/min 52˚C

Menu: [ENTER]=ON
teachmode.eps
snailspeed.eps

Figure 169
Teach mode screen Figure 171
Choose ‘Snail’ speed to set MIN
NOTE!
If the unit is in local control when the teach
key is inserted, the display will tell you that
you must change to remote control to enter

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 177
Maintenance

7. Start by holding down the “I” switch on the remote 9. If the boom is not moving, you should increase the
box while you activate the right hand joystick. percentage to this function by activating the
throttle switch to the “+” position (Figure 174).
Each time you tap the switch the duty cycle
percentage will increase by 1%.

activate"I".eps

vectorthrtlpicto.eps
Figure 172
Activate “I” switch and hold
NOTE!
Boom movement is not proportional in Figure 174
“Teach mode”, so the joystick can be moved Throttle switch on remote box
all the way to extend or half way; it doesn’t
matter as long as the boom function is
activated.
8. When the joystick is activated and the “I” switch is
still being held down, the display will show a bar
graph like the one shown in Figure 173, at which
time the “I” switch can be released. The joystick,
10. When the boom begins to move and you are
however, must remain activated, or the screen will
satisfied that the percentage of MIN is where you
revert to the one shown in Figure 170 and you will
need it to be, you will be required to push up on the
need to start over at the previous step. The
horn switch (Figure 172) to store the number. If
percentage shown on the graph indicates the duty
you release the joystick before beeping the horn,
cycle of this particular function. A reading of 45%
the percentage will revert to where it was when you
indicates that the duty cycle is on 45% of the time
began. After you store the information for “#1
and off 55%.
boom extend MIN”, the screen will display a single
mark in the “A” column as shown in Figure 175.

1760 rpm 52 ˚C
OK
A
15
45 %
50
Teach
mode!
1760 rpm

A B C
52 ˚C

D E
OK
Teach
45 mode!
Teach Mode
minparameterscreen.eps

Figure 173 Teach Mode


extendstored.eps
#1 boom extend MIN screen
Figure 175
Boom #1 extend MIN stored

178 Operation Manual - S 42 SXG revDate


Maintenance

11. If you felt that the boom took off too fast when the
joystick was activated and the percentage needs to
be decreased, tap the throttle switch (Figure 174)
to the “-” position until the boom responds as you
like, and store with the horn button as explained in
the previous step before releasing the joystick.
12. You should now activate the #1 boom joystick to
the retract position and adjust the percentage the
same way you did for the extend position. After
storing the parameter with the horn switch, the

s
V.ep
vlvR
display should look like Figure 176.

xbm
42s
1760 rpm 52 ˚C
OK Figure 178
A B C D E
Teach Manual boom control handles
mode!
14. Activate the “I” switch on the remote box, and hold
it down. Move the right hand joystick to the extend
Teach Mode position.
minretractstored.eps

Figure 176 NOTE!


Boom #1 retract MIN stored Boom movement is not proportional in
“Teach mode”, so the joystick can be moved
all the way to extend or half way; it doesn’t
13. You now have the option of continuing on to set the matter as long as the boom function is
MIN on the other boom sections or moving the activated.
Rabbit/Snail switch to the ‘rabbit’ position (Figure 15. When the joystick is activated (Figure 178) and the
177) and set the MAX for boom #1 as follows.: “I” switch is still being held down, the display will
show a bar graph like the one shown in Figure 179,
at which time the “I” switch can be released. The
joystick, however, must remain activated or the
rabbitspeed.eps
screen will revert to the one shown in Figure 176,
and you will need to start over at the previous step.
Figure 177
Rabbit speed
1760 rpm 52 ˚C
OK
Setting the MAX parameters requires
opening the hydraulic enclosure to gain
NOTE! A
60
80 %
95
Teach
mode!
access to the boom hand valve (Figure 178).
This procedure applies to all units except 80
the 45/47 meter units, which have no visible
hand valve handles to view. The MAX Teach Mode
parameter on those units must be set by maxparameterscreen.eps

checking the boom times found in the Figure 179


Specification section of the operation
manual and operating each boom section to MAX parameter screen
monitor those times.

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 179
Maintenance

16. The handle on the boom valve should now have 17. Now activate the “I” switch again, and move the
moved to the extend position. Grab the handle, and right hand joystick to the retract position. Follow
pull or push it in the same direction it has already the same procedure, adjusting the manual control
moved. If the handle will not move any further, it handle to the mechanical stop on the opposite side.
has reached the mechanical stop. If you feel it is When the adjustment is complete and you have
solidly against the stop and should be backed off stored the information by sounding the horn,
slightly, tap the throttle switch to the “-” position release the joystick, and the display window should
until the pressure is relieved from the mechanical look like the one in Figure 181.
stop. If, on the other hand, the handle moves freely
and is not in contact with the mechanical stop, tap 1760 rpm 52 ˚C
the throttle switch to the “+” position until the
handle comes in light contact with the stop. When
OK
you feel that the handle is properly adjusted,
A B C D E
Teach
activate the horn button to store the parameter and
mode!
release the joystick. The display should now look
like the one in Figure 180.
NOTE! Teach Mode
With the apitech hand valve, it is necessary maxretractstored.eps

to have pulsation in the handle after MAX


parameter is set. If pulsation stops, the Figure 181
MAX is too high. Boom #1 MAX retract stored
18. The procedure is the same for all functions, so
1760 rpm 52 ˚C activate the “I” switch and move to the next
OK function until you have completed all parameter
settings. Any time you have entered information
A B C D E and then change the position of the local/remote
Teach
switch, the controller will first ask if you want to
mode! store the new parameters (Figure 182).

Teach Mode

Figure 180
Boom #1 MAX extend stored
maxextendstored.eps

Store new parameters ?

no yes
?
[CLEAR] [ENTER]

Teach Mode E C
Storenew.eps

Figure 182
Window for storing new parameters

180 Operation Manual - S 42 SXG revDate


Maintenance

19. If you answer ‘yes’, the system will restart and seconds, and when completed the display
store the new parameters (Figure 183). If you will again show the screen below (Figure
answer no, the window will ask if you want to 184).
restore to the original factory settings. If you
answer ‘no’ to that question, the system will
remain unchanged.
1 2
Start

SYSTEM MESSAGE 0 x1000 3


!!! Attention !!! NA 1760 U/min 52˚C

Parameter changed Menu: [ENTER]=ON


vectornormal.eps
by Terminal !
MAIN Board will
Figure 184
restart automatically !
Vector normal operation screen
rebootscreen.eps

Figure 183
System restart screen will appear when the
local/remote switch is moved

NOTE!
When the system restart screen appears
after setting the parameters, allow the
controller time to complete the process
before performing any other system
functions in order to prevent losing your
stored information. The restart takes only

speedy:opmanuals:42SX vector:42SXG:42SXGmaintenance.fm
Operation Manual - S 42 SXG 181
Maintenance

NOTES

182 Operation Manual - S 42 SXG revDate


Appendix

WARNING

on
Do not stand
hopper grates.

S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR

PERFORMING ANY SERVICE:


Gasoline or Diesel Engines
1. Stop the engine.

2. Remove the key, place it


in your pocket, and put
a "DO NOT OPERATE"
tag on the switch.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.

2. Lock out the power


source according to an
approved lockout-tagout
program.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.

42SXside.eps

APPENDIX
Hydraulic Oil Viscosity Chart .................................................................. 184
Torque Specifications for Metric Bolts..................................................... 185
Recommended Emergency Hose Kit...................................................... 189
Fitting Wrench Sizes ............................................................................... 189
Grease Zerk Locations-Boom................................................................. 191
Bearing Clearance Specifications........................................................... 192
Maintenance Checklist............................................................................ 193
Weld-on Ends / Coupling Comparison.................................................... 194
Output Charts ......................................................................................... 195
Using a Nomograph................................................................................ 202
Minimum Pipe Wall Thickness ................................................................ 210
Pictograms.............................................................................................. 211
Glossary of Terms................................................................................... 212
List of Lubricants and Nitrogen............................................................... 217
Hydraulic Schematic—Boom Circuit (1 of 2) .......................................... 221
Hydraulic Schematic—Boom Circuit (2 of 2) .......................................... 223
Hydraulic Schematic—Concrete Pump .................................................. 225
Output Chart ........................................................................................... 227
Nomograph ............................................................................................. 229

Operation Manual - S 42 SXG


Appendix

Appendix • The cold start limit represents the coldest


temperature at which the oil is thin enough to
This section contains the technical information for flow into the hydraulic pumps. If it were any
your machine and its systems. This information is colder, the pumps would not be able to suck in
correct for your machine when it leaves the factory, but the oil (cavitation).
it may need to be updated from time to time. • The minimum permissible viscosity represents
the warmest temperature at which the oil will
NOTE! still be thick enough to provide lubrication and
The electric schematic for 42 SX units is a sealing. If it’s warmer, the components will
separate book, and is included with each have metal-to-metal contact (thermal
machine.
breakdown).
• The optimum operating viscosity is the range
Hydraulic Oil Viscosity Chart of oil thickness at which the oil works best
The illustration below shows the relationship between (thin enough to flow easily, yet thick enough to
the oil temperature and its viscosity. As you can see, protect the system components).
the oil gets thicker when the temperature is low and An example of how to read a chart for VG-46 oil is
thinner as the temperature rises. given in the chart below. The chart shows the cold start
limit as –8°C (18°F) and the minimum permissible
viscosity as 90°C (194°F). The optimum range is 50°–
76°C.

Temperature of Hydraulic Oil


(°C) -40° -30° -20° -10° 0° 10° 20° 30° 40° 50° 60° 70° 80° 90° 100° 110° 120°
Cold Start Limit
(very thick oil)
Water freezes

Water boils
VG
VG 2
VG 2
VG 6
VG 8
2
3
4
6
10
0

Optimum
Operating
Viscosity
temp chart.eps

Minimum permissible
viscosity
(°C) -40° -30° -20° -10° 0° 10° 20° 30° 40° 50° 60° 70° 80° 90° 100° 110° 120°
(°F) -40° -22° -4° 14° 32° 50° 68° 86° 104° 122° 140° 158° 176° 194° 212° 230° 248°
°C = degrees Celsius
°F = degrees Fahrenheit

184 Operation Manual - S 42 SXG revDate


Appendix

Torque Specifications for Metric must be torqued to within 6% of the requirement. For
example, a bolt to be torqued to a 200 pound
Bolts requirement must be within the range of 208–192 foot
The following charts show the tightening torques pounds for a dial scale torque wrench.
specified for the bolts used on Schwing equipment. The Schwing equipment uses two different types of bolts;
charts are to be followed unless a different torque one has a black finish and the other has a Dacromet/
specification is indicated for a particular procedure. Geomet finish.
A torque wrench must be calibrated to within 1% of its Torque specifications are very important for proper
indicated value throughout its range. Bolts must be machine function. For more information on this
torqued to within 4% of the requirement if the wrench subject, refer to the section on bolt tightening in the
has a dial scale. If no dial scale is present, the bolts Maintenance section of this manual.

Black Screw and Nuts Torque Specifications


Wrench size For Metric NORMAL Thread
= 13 mm
8.8 10.9 12.9
Wrench Hardness Hardness Hardness
Bolt Size Size (mm) ft-lb (N-m) ft-lb (N-m) ft-lb (N-m)
M6x1 10 7 (10.5) 11 (15.5) 12 (18)
Example M 8 x 1.25 13 17 (23) 24 (32) 29 (39)
M 10 x 1.5 17 33 (44) 48 (65) 56 (76)
M 12 x 1.75 19 56 (77) 83 (113) 96 (131)
M 14 x 2 22 90 (122) 133 (180) 156 (212)
Dia =
8 mm M 16 x 2 24 139 (189) 206 (279) 242 (329)
M 18 x 2.5 27 199 (270) 286 (387) 332 (450)
M 20 x 2.5 30 282 (383) 405 (549) 472 (639)
M 22 x 2.5 32 385 (522) 551 (747) 644 (873)
Pitch =
1.25 mm M 24 x 3 36 485 (657) 697 (945) 810 (1098)
M 27 x 3 41 731 (990) 1030 (1395) 1196 (1620)
M 30 x 3.5 46 963 (1305) 1395 (1890) 1627 (2205)
M 33 x 3.5 50 1328 (1800) 1860 (2520) 2192 (2970)
M 36 x 4 55 1660 (2250) 2391 (3240) 2790 (3780)
M 39 x 4 60 2192 (2970) 3122 (4230) 3653 (4950)
Bolt torque-course.eps

Note: This chart does not apply to slewing bearings or hydraulic cylinders.
Conversion: 1 N-m = 0.738 ft-lb; 1 ft-lb = 1.355 N-m. Revised 11/96

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 185
Appendix

Black Screw and Nuts Torque Specifications


For Metric FINE Thread
8.8 10.9 12.9
Wrench Hardness Hardness Hardness
Bolt Size Size (mm) ft-lb (N-m) ft-lb (N-m) ft-lb (N-m)

+!.  ! /,-0 ,( / $0  /-0


+  . ,$  ( /-'0 $ /(!0 ( /!0
+ , . ,$ ' (, /!-0 ' /,,0 ( /--0
+ , . $ ' $' /!0 !( /0  /-0
+ - . $ ,, '( / 0 - /'-0 (' /, 0
+ ( . $ ,- -' /, 0 ,' /,'0 ,$' / $0
+ ! . $ , ,,( / (0 ,, /- 0 ' /$ 0
+ , . $  $ /-,!0 -$, /(,0 $,$ /0
+ ,, . $ , - , /$!$0 ( /!,!0 (' /'-$0
+ ,- . , ( $  /,0 (- / $0 !' /,$0
+ , . , - (- / $0 '( /-!$0 ,'$ /$$0
+ ., -( '( /-!$0 $( /,$0 !, /,-$0
+ ., $ -( /'!0 ,$' /,'0 , ' / ,-0
+ (. $$ ' /,- 0 ,$,- / -,0 ,'!' /-$0
+ '. ( , ,$ / $0 , /-$0 !$, /$,,0
%)  *" 

 
  
not  
   
    


     ! "#  "   $$  %
 &'(

186 Operation Manual - S 42 SXG revDate


Appendix

Wrench Size
= 13 mm
DACROMET/GEOMET 500a Torque Specifications
For Metric NORMAL Thread
8.8 10.9 12.9
Wrench Hardness Hardness Hardness
Bolt Size Size (mm) ft-lb (N-m)b ft-lb (N-m) ft-lb (N-m)
Example M 8 x 1.25 13 13 (18) 20 (27) 23 (32)
M 10 x 1.5 17 27 (36) 39 (53) 46 (62)
M 12 x 1.75 19 46 (62) 66 (90) 80 (108)
M 14 x 2 22 73 (99) 106 (144) 126 (171)
Dia =
8 mm M 16 x 2 24 113 (153) 166 (225) 193 (261)
M 18 x 2.5 27 163 (221) 229 (311) 269 (365)
M 20 x 2.5 30 227 (308) 325 (441) 379 (513)
M 22 x 2.5 32 312 (423) 438 (594) 518 (702)
Pitch =
1.25 mm M 24 x 3 36 392 (531) 559 (758) 651 (882)
M 27 x 3 41 578 (783) 830 (1125) 963 (1305)
M 30 x 3.5 46 797 (1080) 1129 (1530) 1295 (1755)
Bolt torque-courseDACRO.eps

Note: This chart does not apply to slewing bearings or hydraulic cylinders.
a. DACROMET/GEOMET 500 means coated with Teflon and silver colored.
b. Conversion: 1 Nm = .738 ft-lb.

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 187
Appendix

DACROMET/GEOMET 500 a Torque Specifications


For Metric FINE Thread
8.8 8.8 12.9
Wrench Hardness Hardness Hardness
Bolt Size Size (mm) ft-lb (N-m)b ft-lb (N-m) ft-lb (N-m)
M8x1 13 15 (20) 21 (29) 25 (33)
M 10 x 1.00 17 29 (40) 43 (58) 50 (68)
M 10 x 1.25 17 28 (38) 41 (56) 48 (65)
M 12 x 1.25 19 50 (68) 73 (99) 86 (117)
M 12 x 1.5 19 48 (65) 70 (95) 83 (113)
M 14 x 1.5 22 80 (108) 116 (158) 133 (180)
M 16 x 1.5 24 120 (162) 176 (239) 206 (279)
M 18 x 1.5 27 179 (243) 256 (347) 299 (405)
M 20 x 1.5 30 249 (338) 352 (477) 412 (558)
M 22 x 1.5 32 339 (459) 478 (648) 559 (758)
M 24 x 2 36 443 (587) 598 (810) 697 (945)
M 27 x 2 41 611 (828) 863 (1170) 1030 (1395)
M 30 x 2 46 863 (1170) 1244 (1685) 1428 (1935)
Bolt torque-fineDACRO.eps

Note: This chart does not apply to slewing bearings or hydraulic cylinders.
a. DACROMET/GEOMET 500 means coated with Teflon and silver colored
b. Conversion: 1 Nm = .739 ft lb.

188 Operation Manual - S 42 SXG revDate


Appendix

Recommended Emergency
Hose Kit
Schwing recommends that you carry one of each of the
following hoses on the unit in case you blow a hose on
the job. Each size listed represents the longest hose of
each diameter that is installed on the unit at the factory.
Keep the insides of the hoses clean until they are
needed by capping the ends and using tape to hold the
cap in place. Dirt introduced into your hydraulic
system through the installation of a hose that was not
kept clean will cause a variety of problems in the
operation of the unit.
45 6 hose lengths

Diameter Length Part Number


8 6400mm 30314105
13 6400mm 30314106
16 1350mm 10049948
20 1000mm 10049959
25 2100mm 30347677
32 1100mm 10000230

Fitting Wrench Sizes


This chart is provided as an aid to selecting the proper
wrench to hold or tighten the hydraulic fittings on
Schwing equipment. Sizes may change, so use this
chart only as a guide.
Straight fittings

Metric Wrench Sizes Nearest American Wrench Sizes


Fitting or
Tube Size Cap Nut Coupling Body Cap Nut Coupling Body
(mm) (mm) (mm) (in.) (in.)
8 17 17 11/16 11/16

12 22 19 7/8 3/4

16 30 27 1 3/16 1 1/16
20 36 32 1 7/16 1 1/4
25 46 41 1 13/16 1 5/8
30 50 46 2 1 13/16
38 60 55 2 3/8 1 13/16
new fitting wrench size.eps

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 189
Appendix

Banjo fittings

End Cap Separate from Stem


Metric Wrench Sizes Nearest American Wrench Sizes
Fitting or Cap Nut Coupling Body End Cap Cap Nut Coupling Body End Cap
Tube Size (mm) (mm) (mm) (mm) (in.) (in.)

8 mm 17 22 19 11/16 7/8 3/4

12 / R1/4 in. 22 22 19 7/8 7/8 3/4

12 / R3/8 in. 22 27 22 7/8 1 1/16 7/8

12 / R1/2 in. 22 30 24 7/8 1 3/16 15/16

16 mm 30 32 27 1 3/16 1 1/4 1 1/16


20 mm 36 41 32 1 7/16 1 5/8 1 1/4
25 mm 46 50 41 1 13/16 2 1 5/8
30 mm 50 60 50 2 2 3/8 2
38 mm 60 70 55 2 3/8 2 13/16 2 3/16
new banjo fitting size.eps

End Cap Part of Stem


12 / R3/8 in. 22 24 22 7/8 15/16 7/8

16 mm 30 30 27 1 3/16 1 3/16 1 1/16


25 mm 46 46 41 1 13/16 1 13/16 1 5/8
38 mm 60 65 55 2 3/8 2 9/16 2 3/16

190 Operation Manual - S 42 SXG revDate


Appendix

Grease Zerk Locations-Boom


The following diagram illustrates the locations of the
boom grease points. If your unit is not equipped with
autogreaser, count the zerks as you are greasing them
so you don’t miss any. There are 31 points on the boom
and turret. The feeders for the auto- greasing system
are also shown.
#1 & 2 FEEDER
12 GREASE POINTS

1 + 1 1 + 1
1 + 1

1 + 1 1 BO
O
M
#2
KVM 42
1
1

1
1 + 1
#1

1
OM

#2 & 3 FEEDER
BO

10 GREASE POINTS
1 + 1 1 1 + 1
1 1
1
TURRET FEEDER 1
12 GREASE POINTS
1 1 + 1
4
M#

1 + 1
BOO

1
1 #3
2 + 2 M
B OO
2 hollow pins,
2 grease points on each
1 + 1 1
#3 & 4 FEEDER
1 + 1 11 GREASE POINTS

2 + 2 1 + 1
One grease point on each 42 greasing locations42.eps
side of each of the two pins KEY
Identifies which autolube feeder
} 4 is connected to the grease point
The number inside tells how many
To Rock
1 2 1 grease points are at the location
#1-#2
valve feeder Signifies that the grease point is not
1
Primary #3-#4 greased by any autolube system
feeder
Signifies that there is a grease point
Turret/#2-#3 1 + 1 1 + 1 on each side of the boom

If you did not order an autolube system, ignore


the outside shape. The number will still tell you
how many grease zerks you’ll find on the bearing.

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 191
192
Appendix

.072
(hollow pin)

42 bearing clrnce.eps
.039 .039
.054
.054 .039 .039
.059 .035 .035
.059 .035
.054
.029
Bearing Clearance Specifications

.054 .035
.114
(hollow pin) .044

.044 BEARING CLEARANCES

Operation Manual - S 42 SXG


ROLLIX KVM 42 (LW)
The following diagram gives the specifications for the allowable gaps in pins and bores.

NOTE! ALL MEASUREMENTS ARE IN INCHES, AND REPRESENT MAXIMUM ALLOWABLE CLEARANCES.
Contact the Schwing service department if you have any questions.

revDate
Appendix

Maintenance Checklist
The following are the normal recommended maintenance schedules after the break-in period is completed.

SCHEDULED MAINTENANCE UNITS OF FREQUENCY*

Item D W M Q SA A page/

Changing your hydraulic oil filters When dirty filter lamp comes on ..............................135
Changing boom oil filter When you change main return filter.........................135
Changing high pressure water filter When you change main return filter.........................135
Check truck fluid levels X ............................................. ................................141
Bleed moisture from air tanks X ..............................................................................141
Check truck tires X ..............................................................................141
Check hydraulic fluid X ..............................................................................141
Bleed moisture from hydraulic tank X ..............................................................................141
Check differential cylinder rod packings X ..............................................................................142
Inspect bolts on Rock Valve and rams X ..............................................................................142
Grease rock and agitator bearings X ..............................................................................142
Grease boom bearings and hollow pin X ..............................................................................142
Fill auto greaser reservoir X ..............................................................................142
Inspect for damage and leaks X ..............................................................................142
Check if maintenance is due X ..............................................................................142
Grease the boom zerks ......... X.....................................................................142
Check pipe wall thickness ......... X.....................................................................142
Check oil in optional air compressor ......... X.....................................................................143
Check Rock Valve tension nut ......... X.....................................................................143
Inspect cutting ring and rotate, if needed ......... X.....................................................................143
Lubricate mechanical moving parts ......... X.....................................................................145
Check tapered bend wedge bolt ......... X.....................................................................145
Check boom slewing gearcase level ......... .........X...........................................................145
Clean slewing gearcase breather ......... .........X...........................................................145
Check function of mech. boom brake ......... .........X...........................................................146
Clean and repack the Rollix gear ......... .........X...........................................................147
Check turret bolts for tightness ......... .........X...........................................................148
Check fluid in distribution gearcase ......... .........X...........................................................149
Check unit mounting hardware ......... .........X...........................................................149
Check hydraulic pressures ......... .........X...........................................................150
Clean the oil cooler fins ......... .........X...........................................................159
Check drive pinion bolts ................... .........X .................................................159
Change oil in optional compressor ................... .........X .................................................159
Change oil for temperature reasons ................... .................. X .......................................159
Change oil in distribution gearcase ................... .........Δ ...... ..........X............................ .160
Change oil in boom slewing gearcase ............................. ........ X....... ................................160
Test the dirty filter warning circuit ................... .................. X .......................................161
Change oil for age reasons ...................................... ......... X..............................162
Complete cleaning of optional compressor ...................................... ......... X..............................162
Inspect boom, outriggers, and tower Changes with unit age .............................................162
Change corrosion inhibitors ...................................... ......... X..............................162

*D = daily, W = weekly, M = monthly, Q = quarterly, SA = semi annually, A = annually,


Δ = Break-in period

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 193
Appendix

Weld-on Ends / Coupling Comparison


Shown is a comparison among commonly used
ends/couplings. No two ends shown can be joined
without the use of an adapter pipe or a special
adapter clamp. Clamps and pipe strength must also
be considered when determining proper system
requirements. The ratios shown in the text below
represent the safety factor from burst : working Male / Female
pressures. O-Ring
(shown with clamp)
1. Male / female o-ring type couplings have the
highest pressure rating of the ends commonly used
for concrete pumping. They can withstand 4350 PSI
@ a 2:1 safety factor. They are self aligning and
waterproof when used with o-rings in good condi-
tion. These are typically not used on booms because
of their weight. Pipes equipped with this style cou-
pling cannot be swapped end-for-end.

2. Heavy-Duty couplings are designed for pressures Heavy Duty


up to 2250 PSI @ 2:1. They have 20% more contact
area than metric couplings and a tapered face that
draws the pipe sections together during assembly.
Both the ends and clamps weigh more than metric
style and, therefore, should not be used on booms
without consulting the manufacturer.

3. Metric couplings are designed for pressures up to


1400 PSI @ 2:1. They have 85% more contact area
Metric
than grooved couplings. The face is flat and will not
draw pipe together. Although they have a raised
edge, they are not compatible with Heavy Duty cou-
plings unless a special clamp or an adapter pipe is
used to change from one style to the other. Metric 0.15"
connections are standard equipment on booms
because of the weight savings compared with other
styles.

4. Grooved couplings (lip height of 0.15” or less) Grooved


are designed for pressures only up to 750 PSI @ (Victaulic)
2:1. The recessed groove is hard to clean when
changing pipe on a job. The weld-on end fails
before the pipe, because the groove is cut into the
pipe thickness, making it the weakest spot. Grooved weldends4.eps

couplings are not recommended for concrete pump-


ing applications.

NOTE: All pressure ratings listed refer to 5 inch (125mm) diameters


in like-new condition. Other pressures would apply to other sizes.

194 Operation Manual - S 42 SXG revDate


Appendix

Output Charts • maximum strokes per minute of your pumpkit


model,
The hydraulic pumps that drive your concrete pump are • maximum output (in liters per minute, L/min)
horsepower controlled. That means that when pressure of your hydraulic pumps,
rises past a certain point (known as the breakpoint), the
• output that can be expected at various pumping
pumps change their displacement per revolution,
pressures,
resulting in less flow and fewer strokes per minute. The
reason for this is so the pumps will not stall your • condition of your hydraulic pumps when used
engine by drawing too much horsepower. Output charts in conjunction with a flowmeter, and
show the horsepower curve (in kilowatts, or Kw) of the • breakpoint of your hydraulic system.
concrete pump hydraulic circuit. From them, you can An explanation of an output chart is shown on the
determine the: following pages, followed by some examples of chart
• maximum concrete pressure of the pumpkit usage. The output chart of the pumpkit shipped with
model, this manual is shown later.
• maximum output (in cubic yards per hour) of
the pumpkit model,

CONCRETE CONCRETE
BPL 1200 HDR-23 PRESSURE PRESSURE
Pumpkit model (PSI) (BAR) Concrete
2000 138
PERFORMANCE CHARACTERISTICS OF pressure is
PISTON SIDE

THE AXIAL PISTON HYDRAULIC PUMP 1900 131


ROD SIDE

1800 124
shown here.
(bar)

(bar)

PUMP SPEED
2100 RPM
1700 117 Max. pressure
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110 is shown for
350
PISTON SIDE
1500 103
both piston
1400 97
Hydraulic oil and rod side
300 Piston side 1300 1285 88.6 90
pressure shown configurations
breakpoint 1200 83

here, ranging from 250


1100 76
OIL PRESSURE (BAR)

zero to the relief 1000 70


ROD SIDE 900 62
valve setting. 200 350
Rod side 800 55
300 758 52
breakpoint 700 48
150 250
600 41 Concrete
200 500 34 output is
100
150 400 28 shown here,
300 21
50
100 with max
200 14
50 7
shown for both
The breakpoint 100
piston and rod
specification is breakpoint 0 13 26 39 52 65 105 118 131 144 157 170 183 196
78 92
178 bar
103 170.5 side
listed here. CONCRETE OUTPUT (cu yd / h)
configurations.
26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
Hydraulic liters per 50 100 150 200 250 300 350 400 (liter / min.)

minute, and the PISTON 5 10


15.5
15 20 25 30 NUMBER OF STROKES Information
SIDE (stroke / min.)
corresponding OIL VOLUME about the
100 200 300 400 500 (liter / min.)
strokes per minute, pumpkit and
for both piston and Differential Hydraulic Cylinder
Bore dia. / Rod dia. x Stroke length
Material Cylinders
Bore dia. x Stroke length
Hydraulic Pumps
Type / KW
hydraulic
rod side. 125 mm / 80 mm x 2000 mm 230mm x 2000 mm 2 x A7VO-107
pumps is
2 x 66KW
output chart explain.eps shown here.
Slewing cylinder 80 / 45 x 185

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 195
Appendix

Using the chart the 220 bar oil pressure marking on the rod side scale
Example 1—Checking flow at a given pressure (Item A in the example below). Draw a line straight
Your unit is configured on the rod side (standard from across the page until you intersect with the horsepower
the factory). You notice that your machine is not getting curve (Item B). Next, draw a straight line down from
as many strokes per minute as you are used to seeing. the intersection point until you pass through the rod
You count the strokes and see that you are getting side number of strokes scale, and read the strokes per
about 21 1/2 per minute. You check your pressure gauge minute. At 220 bar you should be getting a little more
and see that the hydraulic oil pressure is at 220 bar. To than 21 strokes per minute. Your unit is fine.
determine whether your unit is acting normally, locate

CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
output chart use.eps
2000 138
PERFORMANCE CHARACTERISTICS OF
PISTON SIDE

THE AXIAL PISTON HYDRAULIC PUMP 1900 131


ROD SIDE

1800 124
(bar)

(bar)

PUMP SPEED
2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110

350 1500 103


PISTON SIDE
1400 97
B. Draw a line STRAIGHT 1300 1285
300 88.6 90
across the page until you
contact the horsepower 1200 83
A. Find 220 bar curve of the rodside. Then 1100 76
250 on the rod side oil draw a line straight down
OIL PRESSURE (BAR)

pressure scale. from the intersection point. 1000 70

350 ROD SIDE 900 62


200
800 55
300 758 52
700 48
150 250
600 41
200
EXAMPLE 1 500 34
100
150 400 28
300 the line leaves
C. Where 21 the
100 graph tells you how 14 many
50 200
yards/hour you can expect
50
(in this100case, about 7138).
Where the line crosses the
breakpoint 0 13 number
26 39 52 65 78 92 105 118 131 144 157 170 183 196 of strokes scale tells
178 bar 103 170.5 you how many strokes per
minute you can expect (in
CONCRETE OUTPUT (cu yd / h)
this case, a little over 21).
26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
15.5
PISTON 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
100 200 300 400 500 (liter / min.)

196 Operation Manual - S 42 SXG revDate


Appendix

Example 2—Checking your hydraulic pumps of even a few RPM will give you a bad
To determine whether your pumps are still in good reading. Check the RPM of the drive shaft with
working condition, use the output chart and a flow a digital tachometer if one is available.
meter. Test one pump at a time, multiply the readings • Know how to use your flowmeter. Read the
by 2, and chart the result. You must multiply the instructions that came with it, and remember
readings, because the chart is based on the output of that a flowmeter must be calibrated
two pumps but we are only testing one at a time. periodically.
To test your pumps: • Make two copies of the output chart so you
• Be sure you are using the chart that applies to don’t ruin your original. You need one chart for
your unit. each pump tested.
• Select the proper gear for pumping (found on Read the flow at 0 bar, 100 bar, 150 or 200 bar, 250 bar,
the information plate mounted in the cab). and 300 bar. Also, document the breakpoint. The
• Set the pump speed (input drive shaft) RPM. breakpoint is where the flow drops off rapidly. You will
Pump speed information is found on line 16 of be able to notice it on the flowmeter. If you think it
the Delivery Inspection Report which arrived would be helpful, copy the chart below. Check which
with your unit when it was new. A difference reading you used (150 or 200 bar). The breakpoint will
be very close to either 150 or 200 bar, so it is not
necessary to take both readings. The breakpoint
specification is shown on each output chart.

Breakpoint 1st Pump 2nd Pump


specification Liters/min Total Liters/min Total
(read on meter) (for plotting) (read on meter) (for plotting)
0 bar x2 x2

100 bar x2 x2

breakpoint x2 x2
breakpoint
150 or 200 bar x2 x2

250 bar x2 x2

300 bar x2 x2
checking output form

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 197
Appendix

As an example, we’ll assume that we have just taken


the following readings:

Breakpoint 1st Pump 2nd Pump


specification Liters/min Total Liters/min Total
(read on meter) (for plotting) (read on meter) (for plotting)
178 0 bar 199 x2 398 x2

100 bar 196 x2 392 x2


178 breakpoint 194 x2 388 x2
breakpoint
150 or 200 bar 169 x2 338 x2

250 bar 138 x2 276 x2

Check output form-fill1


300 bar 117 x2 234 x2

Now plot the readings on the output chart. Take a clean


output chart and proceed as follows:
• Lay a straight edge horizontally across the
page, at the pressure point you are plotting.
Draw a light line across the chart. In the
example below, we use the rod side scales and
curve (you could use the piston side scale and
curve instead if your unit is configured for
piston side pumping). The ruler is shown ready
to draw a line at 250 bar hydraulic pressure.
• Turn the ruler sideways, and draw a light line
up the page from the liters/minute reading you
took at that pressure (remember to multiply the
reading by 2). In our example, we measured
276 liters at 250 bar.
• Put a dot at the point where the two lines
intersect.

198 Operation Manual - S 42 SXG revDate


Appendix

• Do the same thing with each pressure reading.


You should end up with six dots.

CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
1checking output.eps
2000 138
PERFORMANCE CHARACTERISTICS OF
PISTON SIDE

THE AXIAL PISTON HYDRAULIC PUMP 1900 131


ROD SIDE

1800 124
(bar)

(bar)

PUMP SPEED
2100 RPM
1700 117
HYDRAULIC RELIEF VALVE IS SET AT
300 BAR MAX. PRESSURE (4350 PSI). 1600 110

350 1500 103


PISTON SIDE
1400 97

300 1300 1285 88.6 90


1200 83
1100 76
250
OIL PRESSURE (BAR)

1000 70

350 ROD SIDE 900 62


200
800 55
300 758 52
700 48
150 250
600 41
1
200 2 3 4 5 6 7 8 9 10 11
500 34
100
150 400 28
300 21
100
50 200 14
50 7
100

breakpoint 0 13 26 39 52 65 78 92
105 118 131 144 157 170 183 196
178 bar 103 170.5
CONCRETE OUTPUT (cu yd / h)

26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
15.5
PISTON 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
100 200 300 400 500 (liter / min.)

• Connect the dots. If your plotted line you have done the test incorrectly or are using
reasonably matches the specification plot on the wrong chart. In our example, the pump is
the chart, the pump is fine. If your line is to the okay. (See the plot that follows.)
lower left of the specification plot, the pump is
getting weak. If your line is to the upper right,

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 199
Appendix

CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
2checking output.eps
1200 83
ROD SIDE

300 bar
(bar)

1100 76
1000 70

350 ROD SIDE 250 bar 900 62


Breakpoint 800 55
300 758 52
700 48
OIL PRESSURE (BAR)

250
600 41
200 500 34

150 200 bar 400 28


300 21
100 100 bar
50
OK 0 bar
200 14

7
100

breakpoint 0 13 26 39 52 65 78105 118 131 144 157 170 183 196


92
178 bar 170.5
CONCRETE OUTPUT (cu yd / h)

26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
(234) (276) (338) (388) (398)
(392)

Piston side scales have been removed for clarity.

Check the second pump. Hook up the flowmeter just as


when you checked the first pump. Again, be sure that
you have the correct speed, gear, chart, and so on. This
time our example will have worse results.

Breakpoint 1st Pump 2nd Pump


specification Liters/min Total Liters/min Total
(read on meter) (for plotting) (read on meter) (for plotting)
178 0 bar 199 x2 398 195 x2 390
100 bar 196 x2 392 183 x2 366
178 breakpoint 194 x2 388 178 166 x2 332
breakpoint
150 or 200 bar 169 x2 338 137 x2 274
250 bar 138 x2 276 102 x2 204
Check output form-fill2
300 bar 117 x2 234 69 x2 138

200 Operation Manual - S 42 SXG revDate


Appendix

Again, plot the results on a clean copy of the flowchart.


As we plot this pump, we can see that the dots are
moving quite a bit to the inside of the flow specification
(see below).

CONCRETE CONCRETE
PRESSURE PRESSURE
(PSI) (BAR)
3checking output.eps
1200 83
ROD SIDE

300 bar
(bar)

1100 76
1000 70

350 ROD SIDE 250 bar 900 62


Breakpoint 800 55
300 758 52
700 48
OIL PRESSURE (BAR)

250
600 41
200 500 34
400 28
150 200 bar
300 21
100 100 bar
50
WEAK 0 bar
200

100
14

breakpoint 0 13 26 39 52 65 105 118 131 144 157 170 183 196


78 92
178 bar 170.5
CONCRETE OUTPUT (cu yd / h)

26
ROD 5 10 15 20 25 30 NUMBER OF STROKES
SIDE (stroke / min.)
OIL VOLUME
50 100 150 200 250 300 350 400 (liter / min.)
(138) (204) (274) (332) (366)(390)

Note: Piston side scales have been removed for clarity.

When you connect the dots, the line is completely If the plotted curve matches the specification plot for a
below the specifications. This pump is very weak and while but the breakpoint is too high or too low, it is
will completely stop pumping oil soon. You may notice possible to make an adjustment. Contact Schwing
high heat with this unit if you are pumping at high oil Service Department for the procedure.
pressures. There are many different possible pump kits and power
NOTE! settings for this unit. If you accidentally destroy your
Never try to make up for this weak pump by original output chart, please have your serial number
increasing the speed of the engine. If the handy when you call to get a replacement. Also, please
pump turns faster than specification, it will advise us if you have changed differential cylinders,
not be able to draw oil as fast as it is turning material cylinders, or hydraulic pumps, because you
(“cavitation”), and immediate failure could may need a different output chart than the one that was
result.
originally shipped with the unit.

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 201
Appendix

Using a Nomograph power rating (in Kw) is shown for the engine or electric
motor. With a truck-mounted pump that uses a PTO
from the truck engine, the power rating reflects the
General information
power output of the hydraulic pumps only. (All the
If you have read the original Schwing power from the truck engine is normally not available
publication Nomographs—A Guide to Usage, you will to the concrete pump and should not be used for power
notice several changes in this document. Because not calculations.) If you know the required output for the
all of the power from the truck engine can be used for job, the nomograph will help you calculate the required
the concrete pump, the TK number of the engine has no pressure. If you know the output and pressure, you can
meaning. Therefore, this section about using calculate the power requirement.
nomographs is being adapted especially for boom The nomograph was developed by extensive trial-and-
pumps. We can still figure out the TK of the job to do, error testing and has proven to be accurate to ±10% in
but the suitability of the pump has to be determined in nearly all pumping applications. The original
a different manner. To make the pump numbers and job nomographs used “spread measure” of fresh concrete
numbers match, we will use a “Power Factor Number,” instead of slump, and the two are not directly
which takes into account the power of the hydraulic interchangeable. Some approximations are used in
pumps instead of the engine and is easy to use with translating the charts from spread measure to slump,
cubic yards per hour and PSI instead of cubic meters but the ±10% accuracy still applies. In all cases, it is
per hour and bar. assumed that you will receive fresh, high-quality
Concrete pumps are limited in what jobs they can do concrete on your job and that the concrete will be
by three factors: plastic enough to flow into the material cylinders. If
1. the amount of power available, you know that the concrete will be hard to feed into the
cylinders, you should adjust the output requirement to
2. the maximum concrete output available, and
compensate for incomplete filling. For example, if you
3. the maximum concrete pressure available. will need 50 cubic yards per hour into the form but the
To estimate the power a pump requires to complete a concrete is so stiff that it will fill the cylinders only
particular job and to determine which pump is 80%, you should multiply the required output by 1.25
appropriate, a nomograph is used. (1÷80%).
With a concrete pump that is driven by its own prime The nomograph is divided into four quadrants (Figure
mover, such as a trailer-mounted concrete pump or a 185).
truck-mounted pump with a separate drive engine, the

TK number does not apply to truck mounted units.


(72600) Pipeline diameter in inches
Curve shown is the Power Factor number (PF).
200
42 boom-small-no blocks-eps

Q in yd3/hr.

Upper Upper right quadrant


addleft quadrant
For vertical placing, 180
1.105 PSI per foot
of level difference. 160
6" 5" 4.5"
140
4"
120 116
Rodside
100

80
Pistonside 67
60

40

Figure 185 132 KW 20


3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
Quadrants P in PSI 1566 870

100

200

2"
Lower left quadrant Lower right quadrant300
400
2.5"

500

600

3"
4" 5" 6" Pumpkit Model: 120/80 x 1600:200 3000 2500 2000 1800 1500 1200 1000 800
Slump of fresh concrete in inches Power: 132 KW Proportional value of pipeline in feet

202 Operation Manual - S 42 SXG revDate


Appendix

The upper left quadrant is the beginning and end point To use the nomograph, you begin at output required
of the graph, and it shows maximum output, pressure, and move clockwise until you encounter the lines that
and power for a specific machine. The upper right represent your job situation. Each time you meet the
quadrant accounts for the relationship between line that applies, you make a 90° turn until you come to
concrete output and pipeline diameters. The lower right a point on the bottom of the upper left quadrant that
quadrant accounts for the resistance to flow of the shows pressure required (Figure 186).
entire pipeline system. The lower left quadrant
accounts for the pumpability of the concrete.

TK number does not apply to truck mounted units.


(72600) Pipeline diameter in inches
Curve shown is the Power Factor number (PF).
200
boom-small-no blocks-eps

Q in yd3/hr.
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
6" 5" 4.5"
140
4"
120 116
Rod side
100

80
Piston side 67
60

40

132 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI 1566 870

100

200

2"
300

400
2.5"

500

600

3"
4" 5" 6" Pumpkit Model: 120/80 x 1600:200 3000 2500 2000 1800 1500 1200 1000 800
Slump of fresh concrete in inches Power: 132 KW Proportional value of pipeline in feet

Figure 186
Moving around a nomograph

To illustrate the use of a nomograph, we will use a Boom pipe, elbows, and deck system:
hypothetical job situation with the following • 13 ft of 5-in. rubber hose
specifications: • 144 ft of 5-in. steel pipe (on the boom and
1. We will need an average output of 75 cubic yards pump deck)
per hour, but we will be pumping only 75% of the • 5.25 ft of 6–to–5-in. reducer (on the pump)
time. The rest of the time will be spent moving • 4 5-in. 45° elbows, radius 250 mm
hose, removing pipe lengths, waiting for concrete
• 11 5-in. 90° elbows, radius 250 mm
trucks, and taking care of miscellaneous jobs. This
means that when we are actually pumping, we will • 2 6-in. 90° elbows, radius 250 mm
need an output rate of 75 ÷.75 = 100 yd3/hr. 4. We will specify a slump of 5-6 in. and use the 5-in.
line on the chart.
2. We will use 5-in.-diameter pipeline.
5. In addition, when we add the pressure for the
3. We will need the following pipeline lengths:
vertical run, we will have to add 1.1 times 70 ft =
Separately laid pipeline: 77 PSI.
• 40 ft of 5-in. rubber hose All of these criteria will be explained in detail as we go
• 150 ft of 5-in. horizontal steel pipe through the individual quadrants.

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 203
Appendix

The quadrants
1. The upper left quadrant describes the power
curve of a given hydraulic pump Kw rating and the
maximum output and maximum pressure of a
particular model of concrete pump (Figure 187).

Power factor
number
TK number does not apply to truck mounted units. (replaces TK)
Curve shown is Power Factor number (PF). 72600
200
boom-upper left quad-eps

Q in yd3/hr.
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160

140

Rod Side 120

Power curve 100


Maximum output and
80
maximum pressure
Piston Side
60 of a specific unit
Kw rating 40
132 KW
20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI

Figure 187
Upper left quadrant

Any concrete pump selected for a job must meet three efficiency factors figured in. When using an
technical parameters: Americanized nomograph (pressure in PSI and flow in
• the power factor number of the pump must be cubic yards per hour), the pressure multiplied by the
equal to or greater than the power factor output must always be less than or equal to the PF. For
number of the job, example, if you needed 50 cubic yards per hour and
• the maximum output required by the job must determined that this will require 750 PSI, you can
be available from the pump, and multiply 50 by 750, which equals 37,500. Any pump
you select must have a PF of 37,500 or greater. If you
• the maximum pressure required by the job
are using a nomograph that has been converted to
must be available from the pump.
metric units of measure (pressure in bar and output in
It is important to notice the pump maximum pressure cubic meters per hour), you can still multiply the
and maximum output, even if the power factor number pressure by the output, but you must multiply the
of the pump is larger than the job requires. These answer by the conversion factor between metric and
parameters are decided during the design stage of the English units of measure to get the PF. The conversion
unit and cannot be adjusted on the job. If the unit is factor for cubic yards to cubic meters and for bar to PSI
able to go from rod side to piston side, maximum is 18.966. For all practical purposes, you can use 19.
pressure and output can be exchanged—that is, you can For example, if you need 50 cubic meters per hour and
decrease one while increasing the other the same determine that your job setup will require 65 bar, you
amount. can multiply 50 by 65, which equals 3250. Multiply
The power factor number (PF) replaces the TK this by 19, and you find that your PF requirement is
number on a truck-mounted unit. It is the Kw 61,750. Again, any pump you select for the job in this
multiplied by a constant (550) that has several example should have a PF of 61,750 or greater.

204 Operation Manual - S 42 SXG revDate


Appendix

The maximum output (abbreviated as max Q) is the pipeline and forms a slippery layer on which
determined by the size of the hydraulic pumps, the the bulk of the concrete slides. While it is true that
number of strokes per minute, and the size of the a 6-inch pipeline has 49 percent more surface area
differential and material cylinders. The unit is usually to coat than a 4-inch pipeline, the volume of
designed so maximum output can be achieved only at concrete that can move on the layer is increased by
less than maximum pressure. 125 percent, which results in lower velocity of the
Maximum pressure (abbreviated as max P) is concrete (in feet per second), lower friction, and,
determined by the size of the differential and material therefore, lower pressure. A pump that may not be
cylinders and the setting of the main relief valve. To be capable of completing a difficult job through 4- or
sure that the unit will handle the job, be careful to 5-inch pipe may be able to do it easily through 6-
notice max P and max Q. Here is an example of why inch pipe. Experience has taught us that 5-inch is
that is important: You contract to pump a job that the optimum pipeline size for lengthy vertical
requires only 20 yards per hour, but you calculate that runs, such as those found on high-rise buildings. It
you will need 2100 PSI pressure. The PF of this job is is large enough for most aggregate but small
42,000 (20 x 2100). The pump shown in Figure 187 enough that you minimize the amount of concrete
has a TK of 72,600, so there is enough power available. that slides back into the hopper when the concrete
However, the maximum pressure available from the valve cycles, which we call backwash. You must
pump is only 1570 PSI. This pump would not do the also consider the people at the point of placement.
job. Very few hose handlers, if any, can move 6-inch
hose on a slab all day. There is no provision in the
2. Follow the chart in a straight line from required
nomograph for mixing pipeline sizes. For example,
output into the upper right quadrant until you
if you will be reducing from 5-inch to 4-inch pipe,
come to the size of the pipeline that you will use. A
you should calculate the chart as if you were using
good rule of thumb for sizing pipeline is to use the
4-inch pipe for the entire distance. This will not be
largest diameter pipeline that you can. It takes less
completely accurate, but you will be safe in your
force to move concrete through a 6-inch pipeline
pressure calculation. In our example, we use 5-inch
than, for example, a 4-inch pipeline. When
pipeline (Figure 188).
pressure is exerted on concrete in a pipeline, a
paste of water and cement fines coats the inside of
Pipeline diameter in inches
Q in yd3/hr.

6" 5" 4.5"

4"

Make a 90° turn when


you intersect with the
pipeline diameter that
applies to your job.

uppr rght quad-eps

Figure 188
Upper right quadrant—Pipeline diameter

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 205
Appendix

When the output line intersects the pipeline diameter • each 90° bend with a radius of 1 meter (long
that corresponds to your job, draw a line straight down sweep) = 10 feet
into the lower right quadrant, as shown in Figure 188. • each 30° or 45° bend with a radius of 1 meter
3. The lower right quadrant refers to the or 250 mm = 3 feet
proportional value of your pipeline. It is a way of • each section of rubber hose causes three times
taking into account not only the length of the as much resistance as the same length of steel
pipeline, but also the number of bends, the pipe (e.g., 12 ft of rubber hose has the same
increased resistance of flow in rubber hose, and resistance as 36 ft of pipeline)
other factors. It is more a measure of the resistance • Figure all horizontal and vertical distances
to flow than a measure of length. In calculating the equally. The increased pressure required to
proportional value of your pipeline, always apply push concrete vertically is accounted for by
the following criteria: adding pressure, not distance. An example
• each 90° bend with a radius of 250 mm (boom pipeline is shown below (Figure 189).
elbow) = 3.5 feet
boom 4 nomo.eps

40 ft.
hose
150 ft. pipe

70 ft.
level
difference

elbow - 90°, r = 250 mm...3.5 feet


elbow - 90°, r = 1 meter...10 feet
elbow - 30° or 45°, r = 250mm or 1 meter...3 feet

NOTE!
Proportional value of the 42 boom and deck pipe system is 260 feet.
This value includes elbows, reducer, and tip hose.

Example: You must go 150 feet out through the deck and boom pipe, including the tip hose, then
through 40 feet of rubber hose. Calculate the proportional value as follows:
all boom system = 260 feet (includes a 12-ft long, 5-in. tip hose)
15 10-foot pipe sections = 150 feet
40 x 3 = 120 feet (for the rubber hose)
Total = 530 feet.
Round down to 500 feet to make it easy to use the chart (Figure 190).

Figure 189
Calculating proportional values

206 Operation Manual - S 42 SXG revDate


Appendix

Once you have calculated the proportional value of intersection, make a 90° turn clockwise into the lower
your pipeline, extend your line down from the upper left quadrant. As noted previously, we are using 500
right quadrant until it intersects with the line that feet as our proportional value (Figure 190).
represents your pipeline. When you reach the
lwr rght quad-eps

100

200

300

400
Make a 90° turn when
you intersect with the
500
proportional value that
applies to your job.
600

3000 2500 2000 1800 1500 1200 1000 800


Proportional value of pipeline in feet
Figure 190
Lower right quadrant-—Proportional value of pipeline
4. The lower left quadrant refers to the pumpability quadrant until it intersects with the 5-inch slump
of the concrete. If the concrete specifications allow line; then make a 90° turn clockwise. This will lead
a range in slump (for example 5–6 in.), always use you back into the upper left quadrant (Figure 191)
the lower end to be safe. In our example, we use 5- through the pressure scale.
inch slump. Extend the line from the lower right

3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI

Figure 191 2"


Lower left quadrant—
Pumpability of the
concrete 2.5" Make a 90° turn when
you intersect with the
slump that applies to
your job.

3" lwr left quad-eps


4" 5" 6"
Slump of fresh concrete in inches

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 207
Appendix

As you can see by the chart in Figure 191, we are PF = (627 x 100)
reentering the upper left quadrant through the pressure PF = 62,700
scale at about 550 PSI. Remember, we now have to add
The unit must have a PF over 62,700, and it must be
the head pressure for our vertical rise. At 1.1 PSI per
able to pump 100 yd3/hr and 627 PSI simultaneously.
foot of level difference and our 70-foot vertical run, we
Look at the pump shown in our sample nomograph
must now add 1.1 x 70 = 77 PSI to the 550 PSI from
(Figure 192).
the chart.
• Can the unit pump at 627 PSI? Yes
550 PSI + 77 PSI = 627 PSI
• Can the unit pump 100 yd3/hr? Yes
NOTE!
• Can the unit pump both simultaneously? No!
When calculating the head pressure from
vertical runs, it doesn’t matter if the This unit will not do the job.
pipeline runs straight up and down or if it The engine is a little too small. The intersection of 100
runs uphill at an angle. Only the level yards3/hr and 627 PSI has been plotted for visual
difference in feet is needed for the pressure representation, but you can see immediately that the PF
calculation. If the pipeline is running
downhill, the operator will need special of the job (62,700) is bigger than the PF of the unit
knowledge, but you don’t need to add any (56,650). The curved black line represents the PF of the
head pressure to the nomograph. unit. If the unit is going to be able to handle the job, the
The nomograph is now complete. The PF of our job intersection of pressure and yd3/hr will be to the right
can be calculated like this: and down from the curved line. Anything to the left or
above the line is beyond the power of the hydraulic
PF = PSI x yd3/hr
pumps. If we could order this same unit with the pumps
We need a unit that is capable of 627 PSI and 100 yd3/ set to a higher Kw, the PF of the higher Kw unit would
hr. The PF of this job is: be 72,600, which would be sufficient.

56,650

Power factor number (PF)


English to Metric Conversion Factor is PF ÷ 18.966
upper left quad-eps
200
Q in. yd3/hr.

For vertical placing, 180


add 1.105 PSI per foot
of level difference. 160

140
Example Job
Working power (in kW)

120

100

80

60

40

103 KW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
P in PSI

Figure 192
Is this unit sufficient for the job?

208 Operation Manual - S 42 SXG revDate


Appendix

Plotting the intersection of our hypothetical job again, • Pump the top of the building at 85 yd3/hr
you can see that it falls within the power zone of the
instead of 100 yd3/hr.
hydraulic pumps with a higher Kw (Figure 193).
• Pump the top of the building at a 6-inch slump
Bearing in mind that the nomograph should only be instead of 5-inch. (This would still be within
considered accurate to within ±10 percent, you should specifications.)
always calculate conservatively, and allow for the
• Remove some of the rubber hose at the end of
graph tolerance. In the case of the pump in Figure 193,
the horizontal run. Normally, with job
we should still be safe even if the pressure required
circumstances that did not require a substantial
were 10% greater (690 PSI).What if you already own
vertical run, you could also use 6-inch instead
the pump shown in Figure 192? Is there anything that
of 5-inch-diameter pipeline. But in our
can be done to the job specifications to make the unit
example, the entire vertical run was made with
with the less powerful pumps work? You could use the
the boom. The boom can never support 6-inch
smaller PF unit shown in Figure 192 if you can get
pipeline.
permission to do any of the following things:

72,600
Power Factor number (PF)
English to Metric Conversion factor is PF ÷ 18.966
200

Q (in yd3/hr)
For vertical placing, 180
add 1.105 PSI per foot
of level difference. 160
Working power (in kW)

140

120

100

Example Job 80

60

40

132 kW 20
3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
up lft 132Kw Qwad 2000R-eps
P (in PSI)

Figure 193
Same model pump with larger Kw hydraulic pumps

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 209
Appendix

Minimum Pipe Wall Thickness


Minimum Pipe Wall Thickness As a Function of Pressure
11 gauge 9 gauge 7 gauge 3/16” SCHEDULE 40
(1/4 wall)
300

D
4200 290

ED
ATE

m
D
EAT

te
ATE
TRE
280

ys
4000

“s
T TR

TRE

ED

4.4
EAT
270

AT

m
A

AT

ste
RE
4“ H
” HE
)

HE
3800

TED
m

TT

sy
260
5m

4.4

em


EA
4.9

4.0
EA
2
(1

st
m

H
250 ste

TR

sy
3600

”&
m

6“
te sy

8“
AT
ys

4.8
5“

4.
240 )s

HE
e
3400 ug

5“
230 ga m
, 11 ste
3200 220 ,9 sy
“ (7 6“
210 4.9
3000
200
2800
190
2600 180
MATERIAL PRESSURE

170
2400
160
2200 150
2000 140
130
1800
120
1600 110
100
1400

pipewallvsPress2.eps
90
1200 80
1000 70
60
800
50
600 40

400 30
20
0.120”

0.150”

0.177”
0.188”

0.250”

200
10
0 0
PSI BAR
0 .050" .100" .150" .200" .250" .300" .350"
.025" .075" .125" .175" .225" .275" .325" .375"

.heat treated .standard PIPE WALL THICKNESS

1. This chart assumes a safety factor of 2:1. Higher safety factors may be required in some circumstances.
2. Wear reduces wall thickness. Thickness must be checked on a regular basis.
3. Pressures may be limited even more by clamp style or pipe end used.
4. The chart is based on 62,000 PSI tensile strength. Heat-treated calculations are based on 120,000 PSI tensile strength.
5. The chart is for pressure calculations ONLY. There is no allowance for mechanical forces other than pressure, and thicker
walls may be needed for mechanical strength because of support or restraint considerations.
6. The chart does not take into account metal fatigue caused by pressure cycles.
Note! This chart is intended as a guide for concrete pumping applications and is subject to the notes,
assumptions, and conditions listed above. Any other use of this chart is not recommended.
This chart does not apply to double-wall pipe. Double wall pipe can be checked by inspecting the inside of the pipe. If the insert is intact, the pipe is
okay. If the insert is worn through, the pipe must be replaced. Contact your pipe supplier for the pressure capacity of your double-wall pipe.

210 Operation Manual - S 42 SXG revDate


Appendix

Pictograms
Shown below are the pictograms used on Schwing
pumps and their accessories, along with a brief
description of each.

REMOTE CONTROL BOX

Boom #1 (main) Boom #2 Boom #2 speed control Boom #3 Boom #4 (tip) Boom slewing
slow
medium
extend retract extend retract fast extend retract extend retract clockwise counter-
(CW) clockwise
(CCW)
Remote box ON / OFF Truck engine ON / OFF Engine throttle Electric vibrator Concrete pump
off Decrease off On reverse
on Increase Off
automatic
(Not functional on 45 SX) On forward

Stroke limiter (concrete pump) Radio on/off


Agitator Horn
Decrease strokes/min.
Increase strokes/min.

OMNEX REMOTE BOXES ONLY


Remote box power Box-to-truck communications Emergency stop status

Boom hose/HP water switch OPERATOR'S PANEL Agitator Engine throttle


(unrelated optional items)
Decrease
boom tip High pressure
hose release water pump Increase

Electric vibrator Water pump / Compressor Concrete pump Truck engine ON / OFF
Manual ON Water pump ON On reverse off

Off Off Off on

Automatic ON Compressor ON On forward (Not functional on 45 SX)

Stroke limiter (concrete pump) Cab collision warning


Local / Remote Panel lamps
Local control Decrease strokes/min. off
on= #1 boom disabled
Remote control Increase strokes/min. off= #1 boom enabled on

OUTRIGGERS
4552pcto.eps

Extend (DS front) Extend (PS front) Slewing (DS rear) Slewing (PS rear) Jacking

Extend Retract Extend Retract Slewing open Slewing closed Slewing open Slewing closed extend (down) retract (up)

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 211
Appendix

Glossary of Terms certification, each relating to a different category


of pump. For an operator to become certified, he
The following list defines some terms used in this or she must pass tests regarding operation,
manual. setup, and cleanout for each category of pump;
They must also pass the safety rules test
Agitator common to all certification categories, meet the
A device set in the concrete hopper to keep experience requirements set forth for each
concrete moving, which prevents it from setting. category, and maintain a safe and clean driving
It is typically a rotating shaft to which several
record. Certified operators are considered
paddles have been mounted. See also: Hopper
qualified operators in their categories. See also:
Grate
Expert, Qualified Operator
AWS D1.1 Certified Welder
The code for structural welding with steel, as As it relates to concrete pumping and this safety
defined by the Welding Society. manual, a Certified Welder is a person who has
Sections 3, 5, and paragraph 9.25 of section 9 applied for, taken, and passed the
apply. See also: Certified Welder and EN 287-1 Welding Society (AWS) or the European Normal
Black and White (EN) test for structural steel welding. Anyone
If a boom is black and white it means that the welding on a concrete pump placing boom,
speed of the boom is not proportional to the outrigger, tower, or other device must be certified
movement of the joystick. Speed can only be to AWS D1.1 sections 3, 5, and paragraph 9.25
controlled by feathering of the joystick. of section 9 and/or EN287-1/PREN288-3.
Blanking Plate Concrete Pressure
Also known as a blanking plug or end cap. Its The force per square area that is exerted on the
purpose is to prevent material from falling out of concrete. The concrete pressure is always a ratio
the delivery system (typically the end hose) when in direct proportion to the hydraulic oil pressure
moving a full boom over personnel or property. on the concrete pump circuit. See also: Maximum
Pressure
Blockage
If the pump is pushing and concrete fails to come Conductors
out at the point of discharge, a blockage is the Materials that conduct electricity. Copper, silver,
cause. The causes of blockages are detailed in aluminum, gold, steel, and water are considered
section 6.18 of this manual. Blockages can good conductors of electricity. Air, fiberglass,
create dangerous situations by causing high rubber, ceramics, and glass are considered poor
concrete pressure combined with the sometimes conductors. All of these conductors have a
uncoordinated efforts of untrained workers to resistance to the flow of electricity, which is
remedy the problem. measured in terms of ohms per linear foot. As
voltage increases, more current flows through
Bulk Density the same resistance. With high-voltage electric
The mass of a substance per volume. For wires—8000 volts, for example—even poor
example, 1 cubic foot of air weighs much less conductors carry enough current through your
than 1 cubic foot of water. One cubic foot of body to ground to kill you. (As little as 35
lightweight concrete weighs less than 1 cubic milliamps can cause cardiac arrest.) Some
foot of steel-entrained concrete. We could say conductors, such as air, resist electricity very
that steel-entrained concrete has a higher bulk well, but if the voltage gets high enough, current
density than lightweight concrete. All calculations will flow. (Lightning is a good example of this.)
for the operation manuals and specifications of See also: Electrocution
concrete pumps are based upon 150 pounds per
cubic foot, which is the approximate mass of Decibels
hard rock (normal) concrete. A measurement of volume equal to one tenth of
a bel, abbreviated dB. As it applies to concrete
Certified Operator pumps, it is a measurement of the sound
An operator who has been issued a certification
pressure level one meter away from a noise
card by the Concrete Pumping
source. Because constant exposure to loud
Association. There are several classes of
sound can cause permanent hearing loss, OSHA

212 Operation Manual - S 42 SXG revDate


Appendix

has developed guidelines for time limits on Go Devil


exposure to sound at different volumes. The A plug made from a rubber composite, usually
chart is in section 6.13 of the Safety Manual. with several fins that expand to seal when
Drive Engine pressure is applied. Go devils are intended to be
The primary source of power for a hydraulic inserted in a steel delivery pipeline and pushed
system. Typically, the word engine denotes an with water or compressed air for the purpose of
internal combustion device, whereas the word cleaning the pipe. Not to be used with rubber
motor denotes an electrical device. See also: hose or short sections of pipe. See also: Sponge
Prime Mover Ball

Electrocution Guide
Made by combining the words “electric” + An assistant brought in to help with backing up a
“execution.” It means “death by electricity.” See truck or trailer or with other circumstances in
also: Conductors which the driver cannot see enough to ensure
safety. See also: Spotter
EN 287-1 / PREN 288-3
The code for structural welding with steel as High Voltage
defined by the European Norm. See also: For the purposes of this manual, any current over
Certified Welder 120 volts AC is considered high voltage. In the
United States, electrically driven concrete pumps
Expert normally operate the motors at 480 volts AC
As used in this manual, an expert is defined as a (high voltage) and the controls at 24 volts DC
person who, on the basis of specialized training (low voltage). With electric wires in residential or
and experience, has developed a high degree of industrial areas, the voltage is approximately
knowledge and skill in the areas of concrete 8000 volts to ground or 13,800 volts from phase
pumps, concrete pumping, cleanout procedures, to phase (distribution voltage). When dealing
generally accepted engineering norms, and with electric wires that are mounted high above
safety regulations to the extent of being able to the ground on steel towers, the voltage ranges
evaluate equipment and processes as they relate from 100,000 to 1,000,000 volts (transmission
to job safety. Experts demonstrate their voltage).
knowledge and abilities by passing the
certification testing and experience requirements Hopper Grate
of the Concrete Pumping Association. A meshwork typically made from steel bars and
Other experts may include master mechanics placed over the concrete hopper. It serves to
and after-sales service technicians of the keep human body parts away from the agitator
manufacturer. See also: Certified Operator (when left in its proper position) and to keep
large foreign objects from falling into the hopper,
Fast Switch which could cause blockages if they were
A secondary hydraulic circuit added to single- pumped. The hopper grate must be secured in
circuit machines to disable the stroke limiter position in order to be effective.
during the switch of the Rock Valve cylinder,
thereby making the Rock Valve switch quickly. Jacking the Outriggers
This circuit is not needed or available on twin- Adjustment of the outriggers in the vertical
circuit machines. direction. With boom-mounted concrete pumps,
you should strive to make the adjustments so
Foreign Material that the unit sits within 3° of level.
Material that was never intended to be pumped
but ends up in the concrete hopper. Examples of Licensed Electrician
foreign material include small animals, hammers, A qualified electrician licensed by the state,
ready-mix truck fins, unmixed clumps of cement, county, or municipality where the connections
hardened concrete that breaks away from ready- are to be made. In some locations, electricians
mix truck fins, and soft drink cans. Many of these are not required to be licensed, but the work
items can create a blockage if they are pumped should still be completed by a competent
through the system. professional. Under no circumstances should
high-voltage connections be made by a concrete
pump operator or related personnel.

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 213
Appendix

Maintenance OSHA
All procedures for servicing, inspection, and Occupational Safety and Health Administration.
repair of concrete pumps and related equipment A branch of the U. S. federal government that
and devices. Maintenance and inspection are deals with job safety. It establishes and enforces
methods of maintaining the desired state of the safety regulations for industry and business. One
equipment. Repair is the method of restoring the of the areas over which it has authority is
desired state of the equipment. construction job sites and workshops.
Maximum Pressure Personal Protective Apparel
When talking about a hydraulic system, Things you can wear to protect yourself from
maximum pressure refers to the highest pressure potential dangers in a concrete placing
that can be achieved with the settings of the environment. Examples are:
circuit relief valves. When discussing concrete • snug-fitting work clothes
output, maximum pressure refers to the pressure • steel-toed work boots
that will be developed if the hydraulic system • lime-resistant gloves
pressure reaches the relief valve setting. • safety glasses
Concrete pressure is always the force at which • ear muffs or ear plugs
the differential cylinders are moving, divided by • rubber boots for when you have to stand in
the cross-sectional area of the concrete cylinder. concrete
Maximum concrete pressure, then, is developed • hard hat
when the differential cylinders are moving with
Point of Discharge
maximum force, which is determined by the
The location on the machine from which concrete
hydraulic system relief valve setting. During
is expelled from a delivery system. This can be
normal pumping, the resistance of moving the
the point of placement (the actual form that is
concrete through the pipe or boom creates the
being filled with concrete) or the cleanout area
pressure needed by the pump and is well under
after completion of a job.
the maximum pressure. See Also: Concrete
Pressure Pour
Used by the concrete pumping industry and in
Minimum Safety Distance
this manual as a noun. It is the specific job for the
In this manual, the term “minimum safety
pump during any given time period, e.g. “We’ll
distance” refers to the closest distance that you
grab lunch right after the pour.”
are allowed to approach an object or electrical
wires while leaving room for errors in human Prime Mover
judgment or machine malfunction. The distance The primary power source for a hydraulic
from electrical wires in the United States is 17 system. The term “prime mover” denotes neither
feet, as recommended by the Concrete an internal combustion engine nor an electric
Pumping Association. This distance may have motor.
other values in different countries.
Proportional
Murphy’s Law Proportional movement means the speed that a
An old adage that says: “Anything that can go boom or outrigger travels is proportional to the
wrong, will go wrong, and at the worst possible amount of movement on the control handle
moment.” (joystick or outrigger handle).
Operational Area PTO
The area around a working piece of equipment (Power Take Off) A switchable output from the
or point of discharge where dangers can be transmission or an intermediate gearcase. On a
encountered because of the nature of the concrete pump, the PTO is used to divert the
machinery or process in use. For safety reasons, power from the engine and drive train to turn the
do not allow unauthorized presence in the hydraulic pumps.
operational area.

214 Operation Manual - S 42 SXG revDate


Appendix

Qualified Operator Separate Pipeline


An individual who meets all the following A pipeline, other than the placing boom pipeline,
qualifications: that is laid between the concrete pump and the
• reached the age of 18 point of discharge.
• is physically and mentally capable
Shutoff Valve
• has been trained in the proper operation
In hydraulics: a valve with the ability to stop the
and maintenance of the pump and placing
flow or pressure of hydraulic oil. Must be able to
boom, if applicable
withstand the maximum pressure of the hydraulic
• has demonstrated his or her capabilities to
circuit that it controls. In concrete: A manually or
the hiring company with respect to the
hydraulically operated valve that prevents the
operation and maintenance of the pump
flow of concrete in either direction. Some
and placing boom
concrete shutoff valves also have the ability to
• can be expected to perform assigned
divert the flow of concrete to a different pipeline:
duties in a reliable manner
to a discharge point for cleanout for example.
Qualified Personnel The shutoff valve must be able to withstand the
A generic term used to describe people who are maximum pressure on the concrete of which the
qualified to do work in their area of application. pump is capable.
For example, having your boom repairs
Single Circuit
inspected by “qualified personnel” before use
The plumbing method used for the pumpkit in
refers to inspection by a certified welder or
which both the differential cylinders and the Rock
certified welding inspector. Having repairs to
Valve cylinder are moved by the main hydraulic
your hydraulic system done by “qualified
pumps. Single-circuit machines are not equipped
personnel” would refer to repairs made by
with an accumulator.
qualified workshop personnel.
Soft Switch
Qualified Workshop Personnel
A secondary hydraulic circuit added to twin-
An individual who meets all of the following
circuit machines to account for the oil coming
qualifications:
from the main hydraulic pumps while the Rock
• has reached the age of 18 years
Valve is being switched by the oil from the
• is physically and mentally capable
accumulator.
• has been trained in proper repair, mainte-
nance, and inspection procedures plus the Soil Pressure
pertinent safety rules for concrete pumps The force per square area that is exerted on the
and related equipment ground by the outrigger legs. The amount of
• has demonstrated their capabilities to their pressure that the soil will support varies with the
company with regard to the procedures composition and compaction of the soil. To
and rules discussed above determine the stability of the soil, see the chart in
• can be expected to perform assigned section 5.16 of this manual.
duties in a reliable manner
Sponge Ball
Rock Jam A medium to hard, spherical sponge used to
A specific type of blockage caused when the clean the inside of delivery pipelines. See Also:
cement and fines of the concrete are not present Go Devil
in sufficient quantity to fully coat the larger
Spotter
aggregates and the walls of the delivery system.
A spotter is a person who stands at a vantage
In these cases, the rock (larger aggregates of the
point where he or she can see both the point of
mix) form a wedge inside the pipe. Resistance to
discharge and the pump operator. The spotter
movement then becomes overpowering and the
uses two-way radios or hand signals to direct the
concrete stops. Increasing pressure to try to
operator to operate the unit as required by the
remove the wedge only results in forcing more of
job circumstances. A spotter can be anyone who
the finest particles past the rocks, compounding
is familiar with the safety rules for the pump and
the problem. In some cases, the wedge can be
workers and is equipped with a radio or knows
broken up by alternately pumping in forward and
the appropriate hand signals. A spotter is needed
then reverse. See also: Blockage

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 215
Appendix

whenever the operator cannot safely see the Unauthorized


point of placement or the distance between the Without authority, without permission. Examples:
unit and an unsafe area. See Also: Guide Unauthorized operation of the boom could be
Sucking Back operation by a passing teenager. Unauthorized
The act of putting the concrete pump into the repairs to the boom could be repairs made
reverse mode for any of several reasons. Some without the manufacturer’s permission.
examples of reasons to suck back: Unintentional Movement
• To relieve pressure in the delivery system Movement of the pump, boom, or related
before opening when a blockage has equipment without a specific, intentional
occurred. command by the operator. An example of an
• To clean the boom with a sponge ball upon unintentional movement is if an operator fell
completion of the pour. while walking with the remote control box and
• To remove concrete from the boom for the accidentally hit a joystick, which caused a boom
purpose of folding the boom for moving. movement. Unintentional movement can be
Thrust Block avoided by disabling the hydraulic system with
Also known as a “dead man.” This is a large block the emergency stop devices when the unit is not
of poured concrete, usually with one or more in immediate use.
sweep elbows cast inside, placed at the bottom Vertical Run
of a vertical run for the purpose of supporting the Sections of concrete delivery pipeline that run in
weight of the vertical run and for lateral an up and down direction. Vertical runs have very
stabilization of the pipeline. It stabilizes and specific procedures and rules for installation,
supports the vertical run by virtue of its support, cleaning, and inspection. Concrete
enormous mass (normally one cubic yard or pumping personnel should, therefore, have
larger). specific training in these procedures and rules
Towing Vehicle before attempting to use them in a job setting.
In this manual, the term “towing vehicle” applies Water Jet
only to trailer- mounted concrete pumps. It is the The stream of water that comes out the end of a
vehicle you use to tow the trailer on the road, water hose or pressure washer. The water jet is
jobsite, or in the yard. The size and condition of the only part of the water system that needs to
the towing vehicle are extremely important in go into the hopper, concrete valve, or waterbox
these applications. See the safety rules for cleaning.
regarding this subject in section 4 of the Safety
Manual.
Transport Position
“Transport Position” refers to the position of the
boom during transport. For transport, the boom
is completely folded and lowered into the rests,
and the boom straps are secured. When stowing
in the traveling position because of a
thunderstorm, however, the boom straps need
not be secured, if no travel is imminent.
Twin Circuit
The plumbing method used for the pumpkit in
which the differential cylinders are moved by the
main hydraulic pumps but the Rock Valve is
moved by the oil stored in an accumulator.

216 Operation Manual - S 42 SXG revDate


Appendix

Additional Reading Material


This is a partial list of the books that have been written on the subject of concrete pumping. Omission of any
relevant books was done so unintentionally.
• Pumping Concrete and Concrete Pumps, Karl Ernst v. Eckardstein. F. W. Schwing GmbH, 1983.
• Pumping Concrete—Techniques and Applications, Robert Allen Crepas. Aberdeen Group, 1991.
• Nomographs—A Guide to Usage, Robert Edwards. Schwing America, Inc., 1992.

List of Lubricants and Nitrogen


This list describes the materials that were installed in your concrete pump unit when it left the factory. Other
brands of lubricants and their usage are described in the following lists.

Hydraulic oil Texaco Rando 46

Gearcase oil HD 80w-90

Truck fluid levels See owners manual for your specific truck

Compressor oil Mobil Rarus 427 or 429

Grease for
Optimoly Paste White T - 250 grams
spline and couplers

Grease for autogreaser EP2/NLGI No. 2

Dry nitrogen Any brand of dry nitrogen is suitable for


recharging accumulators
Rack and pinion grease Lithium base, NLGI No. 2, with a minimum
for 28 meter and smaller booms 3% molybdenum disulfide
000566.eps

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 217
Appendix

Hydraulic Oils
ISO viscosity VG 32 = winter in northern US and Canada
ISO viscosity VG 46 = summer in northern US and Canada
ISO viscosity VG 68 = tropical areas, desert summers, indoor uses .

Brand Viscosity / DIN quality designation


VG 32 / HLP VG 46 / HLP VG 68 / HLP
Texaco Rando HD* HD 32 HD 46 HD 68
Texaco Rando HDZ** HDZ 32 HDZ 46 HDZ 68
Mobil DTE DTE 24 DTE 25 DTE 26
Shell Tellus 32 46 68
Aral Vitam GF 32 GF 46 GF 68
BP - Energol HLP 32 HLP 46 HLP 68
Esso - Nuto H 32 H 46 H 68
Total - Azolla ZS 32 ZS 46 ZS 68
Wintershall - Wiolan HS 32 HS 46 HS 68
* Rando HD 46 is installed in new machines at the Schwing Factory - standard
** Rando HDZ is available for installation in new machines from the Schwing Factory - optional

The following table shows the characteristics of Rando HD 46. You may use this information for
comparison with other brands.
ISO Viscosity Viscosity Flash Pour Foam, Seq II
Viscosity cST @ cST @ Viscosity Gravity point point ml foam @ 0/10
Class 40 C 100 C Index API F F minutes
VG 32 30.1 5.3 106 30.7 385 -25 20/0
VG 46 46.2 6.9 105 29.3 425 -20 20/0
VG 68 65.5 8.7 103 28.6 445 -20 20/0

Some oil manufacturers offer vegetable-based hydraulic oils, which are considered environmentally
friendly (the additive packages are not inert, however). These vegetable-based oils must NEVER be
mixed with mineral-based oils. A complete flush of the hydraulic system must be performed when
changing to this type of fluid. See the list below for a sample of the available oils and viscosities.

Vegetable Based Hydraulic Oils


Brand Viscosity Information
Texaco Biostar Hydraulic 32 Considered equivalent to ISO VG 32 viscosity
Texaco Biostar Hydraulic 46 Considered equivalent to ISO VG 46 viscosity
Mobil EAL 224-H Considered equivalent to ISO VG 36 viscosity
Shell Naturelle HF-M Considered equivalent to ISO VG 42 viscosity OM14

218 Operation Manual - S 42 SXG revDate


Appendix

Gearcase Oils
A) for distribution gearcases

Brand Viscosity / DIN quality designation


VG 220 / CLP
Texaco Meropa 220
Mobil Mobilgear 630
Shell Omala Oil 220
Aral Degol BG 220, Degol BMB 220
BP Energol GR-XP 220
Esso Spartan - EP 220
Wintershall Wiolan - IT 220

B) for motor vehicle gearcases

Brand Viscosity / Mil-L quality designation


90 (85w-90) / 2105 B
Texaco Geartex EP-C
Mobil Mobilube HD
Shell Spirax HD, Spirax MB
Aral Gearbox Oil HYP
BP Energear Hypo 90, Hypogear 90 EP
Esso Gear Oil GX-D, Gear Oil GX
Wintershall Wiolan Hypoid Gearbox Oil 90

The order of the list is meaningless. Any oil that meets the DIN quality designation and ISO
viscosity specification may be used.
The lubricants listed above are suitable for continuous ambient (outside) temperatures of -10 C (14
F) to +40 C (104 F). For conditions outside of this range, contact the oil manufacturer for
recommendations.
Viscosity class 220 roughly corresponds to SAE 90.

Compressor Oils
Use VG 100 oil when ambient (outside) temperature is 0 to 10 C (32 to 50 F).
Use VG 150 oil when ambient temperature is above 10 C (50 F).

Brand ISO Viscosity / DIN quality designation


VG 100 / VDL VG 150 / VDL
Texaco Compressor Oil - EP 100 Compressor Oil - EP 150
Mobil Rarus 427 Rarus 429
Shell Corena - H 100 Corena - H 150
Aral Motanol - HE 100 Motanol - HE 150
BP Energol - RC 100 Energol - RC 150
Wintershall
OM15

Wiolan - CD 100 Wiolan - CD 150

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 219
Appendix

Grease

A) For filling the automatic greasers

Brand Viscosity / DIN quality designation


EP 2 / CLP
Texaco Starplex 2
Mobil Mobilgrease HP
Shell Alvania EP - 2

Shell Alvania is installed in new machines at the Schwing factory.


Any equivalent grease may be used.

B) For all other bearings

Brand Viscosity / Pressure rating


2 / EP
Texaco Multifak EP-2
Mobil Mobilith AW 2
Shell Alvania grease R 2
Aral HLP 2
BP Energrease LS2
Esso Multipurpose grease Beacon 2
Optimal Olitsta longtime 3 EP

The order of the list is meaningless. Any grease that meets the quality designation and viscosity
specification may be used.
OM19A

220 Operation Manual - S 42 SXG revDate


Appendix

Hydraulic Schematic—Boom Circuit (1 of 2)

Remove this page and install correct


schematic for the unit being shipped.

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 221
Appendix

Remove this page and install correct


schematic for the unit being shipped.

222 Operation Manual - S 42 SXG revDate


Appendix

Hydraulic Schematic—Boom Circuit (2 of 2)

Remove this page and install correct


schematic for the unit being shipped.

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 223
Appendix

224 Operation Manual - S 42 SXG revDate


Appendix

Hydraulic Schematic—Concrete Pump

Remove this page and install correct


schematic for the unit being shipped.

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 225
Appendix

Remove this page and install correct


schematic for the unit being shipped.

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 226
Appendix

Output Chart

Remove this page and install the correct


output chart for the unit being shipped.

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 227
Appendix

228 Operation Manual - S 42 SXG revDate


Appendix

Nomograph

Remove this page and install the correct


output chart for the unit being shipped.

speedy:opmanuals:42SX vector:42SXG:42SXG appndx


Operation Manual - S 42 SXG 229
Appendix

230 Operation Manual - S 42 SXG revDate


Alphabetical Index

WARNING

on
Do not stand
hopper grates.

S 42 SX SAFETY INSTRUCTIONS
BEFORE REMOVING HOPPER GRATE OR

PERFORMING ANY SERVICE:


Gasoline or Diesel Engines
1. Stop the engine.

2. Remove the key, place it


in your pocket, and put
a "DO NOT OPERATE"
tag on the switch.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.
Electric Motors
1. Stop the electric motor.

2. Lock out the power


source according to an
approved lockout-tagout
program.

3. Check accumulator
circuit pressure gauge
(if so equipped) to verify
zero system pressure.

42SXside.eps

ALPHABETICAL INDEX

Operation Manual - S 42 SXG


Alphabetical Index

A moving over people . . . . . . . . . 107


accessories operation of joysicks . . . . . . . . . 57
checklist for driving . . . . . . . . . .83 pipeline
checklist for pumping . . . . . . . . .83 inspection . . . . . . . . . . . 98
supplied in tool box . . . . . . . . . .72 wall thickness chart . . . . . . . . 210
vibrator . . . . . . . . . . . . . . 112 positioning for slurry expulsion . . . . 100
accident releasing the tip hose . . . . . . . . . 97
traffic . . . . . . . . . . . . . . .86 setting up . . . . . . . . . . . . . 96
accumulator sucking sponge ball back . . . . . . . 115
charging . . . . . . . . . . . . . 162 tie-down strap . . . . . . . . . . . 96
safety . . . . . . . . . . . . . . .39 vertical strength . . . . . . . . . . . 109
additional reading material list . . . . . . 217 boom bounce . . . . . . . . . . . . . 110
agitator bearings, greasing . . . . . . . . 102 boom specifications . . . . . . . . . . 20
alignment arrows, location . . . . . . . . .79 boom times . . . . . . . . . . . . . . 24
appendix by-pass key switch . . . . . . . . . . . 30
additional reading material . . . . . . 217
bearing clearance specifications . . . . 192 C
fitting/wrench sizes . . . . . . . . . 189 cable remote box
glossary of terms . . . . . . . . . . 212 led status messages . . . . . . . . . 60
grease zerk location drawing . . . . . 191 calculating the outrigger load . . . . . . . 88
hydraulic oil viscosity chart . . . . . . 184 caution . . . . . . . . . . . . . . . . 12
minimum pipe wall thickness chart . . . 210 changing lanes (driving) . . . . . . . . . 86
nomograph . . . . . . . . . . . . 229 charging the accumulator . . . . . . . . 162
output chart . . . . . . . . . . 195, 227 clamps
pictogram list . . . . . . . . . . . 211 inspection . . . . . . . . . . . . . 98
recommended emergency hose kit . . . 189 mating dissimilar ends . . . . . . . . 100
scheduled maintenance checklist . . . . 193 washing . . . . . . . . . . . . . . 109
torque specifications . . . . . . . . 185 cleanout . . . . . . . . . . . . . . . 114
using nomographs . . . . . . . . . 202 boom . . . . . . . . . . . . . 114, 115
arrive on time . . . . . . . . . . . . . .82 concrete valve . . . . . . . . . . . 121
hopper and valve housing . . . . . . . 118
B moving before cleanout . . . . . . . 116
backing up (driving) . . . . . . . . . . .86 reduction pieces . . . . . . . . . . 122
batteries removing hardened material . . . . . . 120
disposal of . . . . . . . . . . . . 132 rock valve . . . . . . . . . . . . . 121
blockages . . . . . . . . . . . . . . 113 sponge ball
causes, see safety manual locating . . . . . . . . . . 115, 119
reversing the pump . . . . . . . . . 113 sucking back . . . . . . . . . . 115
book holder wetting . . . . . . . . . . . . 114
location . . . . . . . . . . . . . . .33 water supply . . . . . . . . . . . . 114
boom waterbox . . . . . . . . . . . . . 122
cleaning . . . . . . . . . . . . . 114 cold weather pumping . . . . . . . . 110, 127
hanging extra pipe and hose . . . . .99, 100 minimum operating temperature . . . . 129
holding valves . . . . . . . . . . 32, 63 preheating
manual controls . . . . . . . . . . .68 boom pipeline . . . . . . . . . . 128
moving near forms . . . . . . . . . 111 hydraulic oil . . . . . . . . . . 129

232 Operation Manual - S 42 SXG revDate


Alphabetical Index

time constraints . . . . . . . . . . 110 location . . . . . . . . . . . . . . 33


component identification cribbing pads . . . . . . . . . . . . . 91
alignment arrows . . . . . . . . . . 79 cylinder
drivers side outrigger controls . . . . . 67 boom . . . . . . . . . . . . . . 32, 63
duvac ii voltage converter . . . . . . 76 differential . . . . . . . . . . . . . 42
fuel reservoir . . . . . . . . . . . 74 rock valve slewing . . . . . . . . . 41
hydraulic oil reservoir . . . . . . . . 77
manual boom controls . . . . . . . . 68 D
passenger side outrigger controls . . . . 66 danger . . . . . . . . . . . . . . . . 12
quick index pocket . . . . . . . . . 76 decal location guide and warning labels . . . 29
remote control cable receptacle . . . . 75 delays during the pour . . . . . . . . . . 111
supplied accessories . . . . . . . . . 72 diagrams
toolbox compartments . . . . . . . . 72 differential cylinder . . . . . . . . . 42
warning horns . . . . . . . . . . . 80 nomograph . . . . . . . . . . . . 229
water tank . . . . . . . . . . . . . 72 one to one rule . . . . . . . . . . . 88
waterbox . . . . . . . . . . . . . 78 output chart . . . . . . . . . . . . 227
concrete proportional analog and digital . . . . . 55
freezing . . . . . . . . . . . . . 110 s1and s2 valve . . . . . . . . . . . 41
inspecting before dumping . . . . . . 106 switching valve . . . . . . . . . . . 42
minimum hopper level . . . . . . . . 109 differential cylinder diagram explanation . . 42
time constraints . . . . . . . . . . 110 digital control system
who can add water . . . . . . . . . 106 explanation . . . . . . . . . . . . 55
concrete pump disabling
circuit . . . . . . . . . . . . . . 37 the entire machine in an emergency . . . 130
hi-flo pumpkit components . . . . . . 38 distribution gearcase . . . . . . . . . . 43
setting main relief pressure . . . . . . 150 driving
concrete pump specifications . . . . . . . 18 backing up . . . . . . . . . . . . . 86
concrete shut-off valve changing lanes . . . . . . . . . . . 86
optional . . . . . . . . . . . . . 53 license requirements . . . . . . . . . 86
options box . . . . . . . . . . . . 54 safety rules . . . . . . . . . . . . 86
control box (cable remote) see also, safety manual
led status messages . . . . . . . . . 60 towing the unit . . . . . . . . . . . 86
control box (radio remote) dump valve bypass
led status messages . . . . . . . . . 59 switch location . . . . . . . . . . . 62
control panel use of . . . . . . . . . . . . . . . 131
functions . . . . . . . . . . . . . 58 dump valve location . . . . . . . . . . 62
controls duvac ii voltage converter . . . . . . . . 76
boom, manual . . . . . . . . . . . 68
control indication devices . . . . . . 56
outrigger operation . . . . . . . . . 90 E
couplings electrical system
grooved type . . . . . . . . . . . . 194 note- schematic is a separate book
heavy-duty type . . . . . . . . . . 194 emergency
male/female o-ring type . . . . . . . 194 hose kit . . . . . . . . . . . . . . 189
metric type . . . . . . . . . . . . 194 procedures . . . . . . . . . . . . . 130
victaulic type . . . . . . . . . . . 194 emergency stop
co-worker safety rules dump valve location . . . . . . . . . 62

speedy:opmanuals:42SX vector:42SXG:42SXGIOM.fm
Operation Manual - S 42 SXG 233
Alphabetical Index

manifold . . . . . . . . . . . . . .62 hydraulically unlockable check valve, see h.e.r.


switch location . . . . . . . . . . . .61
equipment pre-checks . . . . . . . . . .85 I
e-stop manifold override . . . . . . . . .31 id tags
if missing . . . . . . . . . . . . . 16
F main location . . . . . . . . . . . . 15
falling concrete hazard inspection
prevention . . . . . . . . . . . . 111 boom pipeline . . . . . . . . . . . 98
fitting/wrench size chart . . . . . . . . . 189 frequently performed . . . . . . . . 169
frequent inspection tip hose . . . . . . . . . . . . . . 98
to be performed . . . . . . . . . . 169 introduction
fuel tank . . . . . . . . . . . . . . . .74 manufacturer’s statement . . . . . . . 12
function diagram model number nomenclature . . . . . 14
phase a . . . . . . . . . . . . . . .44
phase b . . . . . . . . . . . . . . .47 J
phase c . . . . . . . . . . . . . . .48 jacking outriggers . . . . . . . . . . 92, 95
phase d . . . . . . . . . . . . . . .51 joystick movement explained . . . . . . . 57
fuses . . . . . . . . . . . . . . . . .63

L
G
laborers and oilers, safety rules . . . . . . 100
glossary of terms, alphabetical . . . . . . 212
laminated book container . . . . . . . . 33
greasing
license required to drive . . . . . . . . . 86
agitator bearings . . . . . . . . . . 102
list of lubricants and nitrogen . . . . . . . 217
boom zerk location chart . . . . . . . 191
local/remote switch
list of lubricants . . . . . . . . . . 217
vector controller . . . . . . . . . . 90
rock valve . . . . . . . . . . . . . 102
location
concrete shut-off valve . . . . . . . . 54
H options box . . . . . . . . . . . . 54
h.e.r. valve (holding valve) . . . . . . 32, 63 lock out - tag out
hi-flo pumpkit procedure . . . . . . . . . . . . . 139
components . . . . . . . . . . . . .38 lubrication . . . . . . . . . . . . . . 104
hi-flo pumpkit components . . . . . . . .38 boom pipe . . . . . . . . . . . . . 100
hopper quantity of slurry needed . . . . . . . 104
cleanout . . . . . . . . . . . . . 118 slickline . . . . . . . . . . . . 100, 104
removing hardened material . . . . . 120 slurry . . . . . . . . . . . . . . . 107
spraying with kleen kote . . . . . . . 103 with commercial lubricant . . . . . . 104
horn, warning . . . . . . . . . . . . . .80 with portland cement . . . . . . . . 104
hose shut-off with ready mix grout . . . . . . . . . 104
use . . . . . . . . . . . . . . . 111 without slurry . . . . . . . . . . . 104
how to reach us . . . . . . . . . . . . .13
hurry up cleanout . . . . . . . . . . . 124 M
hydraulic components . . . . . . . . . .38 machine
hydraulic pump drive, distribution gearcase . .43 selection . . . . . . . . . . . . . 82
hydraulic system maintenance
pressure specifications . . . . . . . . .22 filtration

234 Operation Manual - S 42 SXG revDate


Alphabetical Index

general information . . . . . . . 134 N


specific information . . . . . . . 134 nomographs . . . . . . . . . . . . . . 202
when to change filters . . . . . . 135
general maintenance tips
adjusting relief valves . . . . . . 138
O
removing safety devices . . . . . . 138 office hours, service . . . . . . . . . . 13
greasing . . . . . . . . . . . . . 102 oil cooler, cleaning the fins . . . . . . . . 159
hoses, pipes and fittings oilers and laborers, safety rules . . . . . . 100
general information . . . . . . . 136 omnex
specific information . . . . . . . 137 control box . . . . . . . . . . . . 56
hydraulic oil one to one rule . . . . . . . . . . . . . 88
general information . . . . . . . 135 operation
specific information . . . . . . . 136 cleaning the hopper . . . . . . . . . 118
when to change oil . . . . . . . . 136 emergency procedures . . . . . . . . 130
preventive maintenance other things you need to know . . . . . 132
annual maintenance . . . . . . . 169 preparing for the ready-mix trucks . . . 100
daily maintenance . . . . . . . . 141 preperation . . . . . . . . . . . . 82
monthly maintenance . . . . . . . 145 pumping the job . . . . . . . . . . 106
quarterly maintenance . . . . . . 159 rear control panel . . . . . . . . . . 58
scheduled maintenance checklist 140, 193 special pumping situations . . . . . . 124
semi-annual maintenance . . . . . 160 unit setup . . . . . . . . . . . . . 87
time related-time changes . . . . . 169 optional
weekly maintenance . . . . . . . 142 concrete shut-off valve . . . . . . . . 53
record keeping . . . . . . . . . . . 134 options box
torque specifications . . . . . . . . 138 concrete shut-off valve . . . . . . . . 54
unscheduled maintenance . . . . . . 169 output chart
changing material cylinders . . . . 175 checking your hydraulic pumps . . . . 197
changing rams . . . . . . . . . 171 explanation . . . . . . . . . . . . 195
makeup pipe outriggers
id tag for . . . . . . . . . . . . . 16 activating the hydraulics . . . . . . . 89
reason for . . . . . . . . . . . . . 16 control valves . . . . . . . . . . . 90
manual adjustment extension . . . . . . . . . . . . . 91
stroke limiter . . . . . . . . . . . 108 jacking . . . . . . . . . . . 91, 92, 93
manual controls maximum load . . . . . . . . . . . 89
boom . . . . . . . . . . . . . . 68 setting . . . . . . . . . . . . . . 88
material cylinders shortrigging . . . . . . . . . . . . 94
size explained . . . . . . . . . . . 14 soil bearing capacities . . . . . . . . 88
minimum temperature stabilization . . . . . . . . . . . . 95
boom operation . . . . . . . . . . 129 use of cribbing pads . . . . . . . . . 91
model number override
explained . . . . . . . . . . . . . 14 e-stop manifold . . . . . . . . . . . 31
pump and boom . . . . . . . . . . 14 overview
pumpkit . . . . . . . . . . . . . 14 alignment arrows . . . . . . . . . . 79
model number nomenclature . . . . . . . 14 boom hydraulic pump . . . . . . . . 43
moving with a full boom . . . . . . . . 107 concrete pumpkit . . . . . . . . . . 37
duvac ii voltage converter . . . . . . . 76
fuses . . . . . . . . . . . . . . . 63

speedy:opmanuals:42SX vector:42SXG:42SXGIOM.fm
Operation Manual - S 42 SXG 235
Alphabetical Index

holding valves . . . . . . . . . . . .63 pumping the job . . . . . . . . . . . . 106


hydraulic oil reservoir . . . . . . . . .77 pumpkit
hydraulic pump drive . . . . . . . . .43 explanation (overview) . . . . . . . . 37
pressure relief valves . . . . . . . . .61 model number explanation . . . . . . 14
rock valve slewing cylinder diagrams . . .41
safety devices . . . . . . . . . . . .61 Q
warning horn . . . . . . . . . . . .80 quick index
warning labels . . . . . . . . . . 29, 63 location . . . . . . . . . . . . . 33, 76
waterbox . . . . . . . . . . . . . .78

R
P
radio
parts, see spare parts
loss of remote signal . . . . . . . . . 132
personal protective equipment . . . . .84, 101
ram changing . . . . . . . . . . . . . 171
pictograms . . . . . . . . . . . . . . 211
ready-mix drivers
pinch valve
pointing out warning horn . . . . . . . 109
concrete shut-off . . . . . . . . . . .53
safety rules . . . . . . . . . . . . 100
pipe
reassembling the unit . . . . . . . . . . 123
makeup . . . . . . . . . . . . . . .16
reducers, remove for cleaning . . . . . . . 114
pipe ends, dissimilar . . . . . . . . . . 100
releasing the tip hose . . . . . . . . . . 97
pipeline, see slickline
remote box
placing crew, safety rules . . . . . . . . 100
led status messages . . . . . . . . . 59
pre-checks
loss of signal . . . . . . . . . . . . 132
importance of . . . . . . . . . . . .82
omnex . . . . . . . . . . . . . . 56
on pump . . . . . . . . . . . . . .85
remote control, cable receptacle . . . . . . 75
preheating the boom pipeline . . . . . . . 128
reordering
preparation
documentation . . . . . . . . . . . 132
for pumping . . . . . . . . . . . . .82
warning labels . . . . . . . . . . . 132
prechecks . . . . . . . . . . . .85
reservoir
rock valve . . . . . . . . . . . 102
fuel . . . . . . . . . . . . . . . 74
selecting a set-up location . . . . . .87
hydraulic oil . . . . . . . . . . . . 77
spraying the hopper . . . . . . . 103
water . . . . . . . . . . . . . . . 72
for travel
rock valve
after cleanout . . . . . . . . . . 124
cleaning . . . . . . . . . . . . . . 121
boom tie-down strap . . . . . . . .96
grease . . . . . . . . . . . . . . 102
pressure relief valves . . . . . . . . . . .61
preparation for concrete . . . . . . . 102
pressure setting
slewing cylinder diagrams . . . . . . 41
agitator . . . . . . . . . . . . . . 158
boom circuit . . . . . . . . . . . . 152
boom control block . . . . . . . . . 156 S
boom redundant relief . . . . . . . . 156 s valve diagram explanation . . . . . . . 41
delta p . . . . . . . . . . . . . . 153 safety
main concrete pump . . . . . . . . . 150 arranging for a spotter . . . . . . . . 101
outrigger . . . . . . . . . . . . . 157 blockages . . . . . . . . . . . . . 113
q-min . . . . . . . . . . . . . . 155 devices . . . . . . . . . . . . . . 61
pressure specifications agitator shut-off . . . . . . . . . 61
hydraulic . . . . . . . . . . . . . .22 blanking plug . . . . . . . . . . 107

236 Operation Manual - S 42 SXG revDate


Alphabetical Index

bypassing the dump valve . . . . . 130 stabilization . . . . . . . . . . . . 95


emergency stop switch . . . . . . 61 shipping the unit, loading by
fuses . . . . . . . . . . . . . 63 crane . . . . . . . . . . . . . . . 87
holding valves (h.e.r.) . . . . . . 63 ramp . . . . . . . . . . . . . . . 86
pressure relief valves . . . . . . . 61 shortrigging . . . . . . . . . . . . . . 94
removal for maintenance . . . . . 138 signals
warning labels . . . . . . . . 29, 63 acpa standard hand signals . . . . . . 106
disabling the entire machine . . . . . 130 who can give . . . . . . . . . . . . 106
driving . . . . . . . . . . . . . . 86 slickline
backing up . . . . . . . . . . . 86 inspection . . . . . . . . . . . . . 98
changing lanes . . . . . . . . . 86 lubrication . . . . . . . . . . . . . 100
towing the unit . . . . . . . . . 86 mating dissimilar ends . . . . . . . . 100
minimum hopper level . . . . . . . . 109 minimum wall thickness chart . . . . . 210
moving a boom near forms . . . . . . 111 pumping from the boom . . . . . 100, 109
moving a full boom over people . . . . 107 washing . . . . . . . . . . . . . . 109
personal protective devices . . . . . . 84 slurry
procedures before mixing . . . . . . . . . . . 101
lock out - tag out . . . . . . . . 139 boom or slickline . . . . . . . . . . 100
rules for oilers and laborers . . . . . . 100 choices . . . . . . . . . . . . . . 101
rules for the placing crew . . . . . . . 100 if it plugs . . . . . . . . . . . . . 107
shortrigging dangers . . . . . . . . . 94 pumping . . . . . . . . . . . . . 107
spotters . . . . . . . . . . . . . . 109 soil
testing unit stability . . . . . . . . . 98 types . . . . . . . . . . . . . . . 88
safety guard locations . . . . . . . . . 63 weight bearing capacity . . . . . . . 88
safety manual spare parts
quick index location . . . . . . . . 33, 76 hours . . . . . . . . . . . . . . . 13
selection telephone numbers . . . . . . . . . 18
correct pump for a job . . . . . . . . 82 special pumping situations . . . . . . . . 124
set-up location . . . . . . . . . . . 87 cold weather pumping . . . . . . . . 127
serial number moving the pump during the pour . . . . 125
this unit . . . . . . . . . . . . . 13 specifications
service assembled unit . . . . . . . . . . . 21
telephone numbers . . . . . . . . . 13 bearing clearances . . . . . . . . . . 192
service department . . . . . . . . . . . 13 boom times . . . . . . . . . . . . 24
setting paramaters hydraulic oil reservoir capacity . . . . . 77
vector controller . . . . . . . . . . 175 outriggers . . . . . . . . . . . . . 21
setting pressures . . . . . . . . . . . . 150 pressure of hydraulic circuits . . . . . 22
main concrete pump . . . . . . . . . 150 times of boom sections . . . . . . . . 24
set-up . . . . . . . . . . . . . . . . 87 torque . . . . . . . . . . . . 138, 185
outriggers . . . . . . . . . . . . . 88 water reservoir capacity . . . . . . . 72
activating the hydraulics . . . . . 89 speed control . . . . . . . . . . . . . 108
control valves . . . . . . . . . . 90 by engine rpm . . . . . . . . . . . 108
extension and jacking . . . . . . . 91 by stroke limiter . . . . . . . . . . 108
jacking . . . . . . . . . . . 92, 93 by transmission . . . . . . . . . . . 108
maximum load . . . . . . . . . 89 sponge ball
shortrigging . . . . . . . . . . 94 finding during cleanout . . . . . . . . 119
pumping to slickline . . . . . . . 100, 109 sucking back . . . . . . . . . . 114, 115

speedy:opmanuals:42SX vector:42SXG:42SXGIOM.fm
Operation Manual - S 42 SXG 237
Alphabetical Index

wetting . . . . . . . . . . . . . . 114 W
spotter . . . . . . . . . . . . . . 101, 109 warning . . . . . . . . . . . . . . . 12
stability of the unit . . . . . . . . . . . .98 warning horn
stroke limiter instructions . . . . . . . . . . . . 109
manual adjustment . . . . . . . . . 108 location . . . . . . . . . . . . . . 80
switch, emergency stop . . . . . . . . . .71 warning labels
locations . . . . . . . . . . . . . .61 decal location guide . . . . . . . . . 29
switching valve diagram . . . . . . . . .42 reorder . . . . . . . . . . . . . . 63
waterbox
T cleaning . . . . . . . . . . . . . . 122
tank filling . . . . . . . . . . . . . . . 101
fuel . . . . . . . . . . . . . . . .74 keeping it full . . . . . . . . . . . 112
hydraulic oil . . . . . . . . . . . . .77 safety . . . . . . . . . . . . . . . 78
water . . . . . . . . . . . . . . . .72
teach mode Z
vector controller zerks
setting parameters . . . . . . . . 175 agitator . . . . . . . . . . . . . . 102
time constraints . . . . . . . . . . . . 110 boom . . . . . . . . . . . . . . . 191
tip hose rock valve . . . . . . . . . . . . . 102
inspecting . . . . . . . . . . . . . .98
removal for cleaning . . . . . . . . 114
towing the unit (driving) . . . . . . . . .86
troubleshooting
checking your hydraulic pumps . . . . 197
loss of boom and outriggers . . . . . . 130
loss of electricity . . . . . . . . . . 130
time constraints . . . . . . . . . . 110

U
unfolding the boom . . . . . . . . . . .96
unit setup, location . . . . . . . . . . . .87
unlocking the tip hose . . . . . . . . . .97

V
valve . . . . . . . . . . . . . . . . .42
vector control
controls and indication devices . . . . .56
explanation . . . . . . . . . . . 52, 55
rear panel operation . . . . . . . . . .58
vector controller
local/remote switch . . . . . . . . . .90
teach mode . . . . . . . . . . . . 175
voltage converter, duvac ii . . . . . . . . .76

238 Operation Manual - S 42 SXG revDate

You might also like